Analysis of Energy Consumption Patterns and Conservation Opportunities in a Textile Mill in Kaduna State

Energy costs constitute one of the largest and most controllable operating expenses for textile manufacturing enterprises in Nigeria, where grid electricity is costly, unreliable, and frequently supplemented by expensive diesel generation. This study analyses energy consumption patterns across all production utilities in a large-scale textile mill in Kaduna State and identifies actionable conservation measures. An energy audit was conducted following the procedures of ISO 50002, covering electrical distribution panels, spinning and weaving machines, air compressors, lighting systems, and steam boilers. Energy consumption data were collected over a 12-month period from utility bills, sub-meter readings, and direct measurement of key equipment. Specific energy consumption indices were computed by production unit and compared against published benchmarks for the textile sector. The audit identified that compressed air generation, steam boilers, and lighting together accounted for 71 percent of total site energy consumption. Energy loss analysis revealed that compressed air system leaks alone accounted for estimated wastage equivalent to 18 percent of compressor energy input. Boiler efficiency was measured at 74 percent, below the recommended 82 to 85 percent range for the fuel type used. A prioritised conservation action plan with estimated energy and cost savings was developed, projecting annual savings of approximately 22 percent of the current energy bill through combined corrective measures. Keywords: energy audit, textile mill, energy conservation, compressed air, Kaduna State.