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Pre auditing of textile industry based on operational permits and controls including energy
audits, financial audits, EMS audits and regulatory compliance audits as these are to be carried
on the basis of the operating processes and procedures being performed in the industry like
knitting, dyeing, cutting, finishing etc., as highlighting them in process mapping and flow
diagram for the inputs, processes and outputs being generated including finance cost analysis in
the transformation process. Technical audits will be done for the instruments and machinery used
in the industry. As well as the Energy efficiency measures and environmental friendly techniques
will be suggested in on-site auditing on the basis of walk around audit and pre-audit of the
concerned industry.
Chapter 1
Introduction
1.1 Objectives of Audit
To identify the environmental impacts (Air emissions, Wastewater, Noise & Solid
Waste) of activities, products and services
To access the risks the industry is causing and is confronting with.
To suggest improvements in the system based on the areas lacking technological or
environmental controls.
1.2 Scope
SCOPE
all the concerned data of the industry. A detailed work plan for collection of specific information;
resource persons and their responsibilities, the time schedules and requirement of the logistics
are arranged.
1.3.3 Data Collection
In this step, detailed information about the industry was collected in accordance with the audit
checklist, as discussed in the preceding step. Initially, the data available with the industry was
collected and reviewed. Later, the audit team conducts detailed field visits in the industry.
1.3.4 Data Analysis
The audit data was examined and compared with the standard practices being exercised. Detailed
analyses are conducted to conclude audit findings.
1.3.5 Recommendations
Recommendations were made on the basis of findings of data analysis. The main focus of the
recommendations was the implementation of the energy management practices keeping in view
the process and working environment improvements.
1.3.6 Limitations
All the base line data collection activities were performed with the high level of care and skill
with mutual coordination by the industry management or employees. It was assumed that the
information provided was accurate, factual, and the team accepts no responsibility for any
deficiency, misstatements, or inaccuracies contained in the report as a result of omission or
misrepresentation of any person interviewed or contacted.
The condition and energy consumption, solid liquid and gaseous waste and workers health and
safety practices of the site may change with the passage of time, so the information relate to the
specific conditions and are based upon information that exists at the time of the data collection of
the industry and conclusions of the results.
1.3.7 Draft Report
Initially, a draft audit report of findings and recommendations was prepared and submitted to the
industry owner. An audit debriefing session was organized to present the findings and
recommendations of the audit to the industry management to get their point of views.
1.3.8 Final Report
After incorporating the comments from the client on the draft report, a final report was prepared
and submitted to the client.
1.4 Background
The textile Combined Fabric is one of the upright structured knitwear installations that are
involved in major production yield and all kinds of export of knit garments since 1994. We have
production facilities that accommodate fabric knitting to the last packing stage of fabric.as being
one of the structured knitwear textiles being a composite knitwear company; it competes with the
delivery of better and quality goods as the competitor for others. It is a medium sized industry.
The high level equipment theme of combined fabrics originated from Europe and japan. Among
them are six color Auto-stripers by Orizio (Italy), Soft Flow dyeing machines by Obermeir
(Germany), computerized lock-stitch, buttoning and bartak by Juki (Japan), nine colour
embroidery machine by Barudan (Japan) and much more. We can ship goods within 40-60 days
(depending upon style) from receipt of purchase order.
Combines clientele includes renowned International brands i.e., Levis, Duck Head, Calvin
Klein, Chaps, Munsingwear, IZOD, Starter, Host Apparel, Golf Classic, Arrow, Block
Sportswear, Principle for Kids & Men, King Size, CSA, Cadre Athletic, Big Time Player, Camp
David, Cheyenne River, Penguin from USA, Kiabi from France, Russell from UK and many
more. We can produce up to 45,000 dozens garments a month in different styles. Our exports
for year 2012 were above US $ 22 Million.
The combined fabrics are aware of its social accountability towards the society and giving its
best towards the direction in making this world a better place to live. As per the responsibility of
management it forbids the child abuse and works towards children welfare agency the topical
regulations are followed for both labor and environment. We believe in teamwork toward
achieving the high quality. The certification is by wrap (Worldwide responsible apparel
production) and the dealing is with both the factors that are social and the environmental
compliance certification. The Company is registered with SMART (Self-monitoring and
reporting tool for the companies who voluntarily try for the betterment of environment) that is
part of Environment protection department of Pakistan for our effluent treatment plant. . Also
registered with the EPA approved lab for complete environment monitoring
1.5 Hierarchical Management
Chief Executive Officer) CEO
Managing director
General Manager (GM)
Departmental Managers (more than 1)
Human Resource Manager (HR) & Administration
Internal Auditor
External Auditor (Levis Auditing Team)
Firefighting team
1.6 The Product
All sorts of knit garments in 100% Cotton & Cotton/Polyester blends. Active wear, Casual wear
& Fashion wear for Men, Boys, Women, Girls, Kids & Big & Tall. T-shirts, sweatshirts, polos,
shorts, pajamas from most basic styles to multi-color jacquards, vertical / horizontal stripes,
Yarn-dyed, pigment print, pieced, body size and much more.
Implemented Laws
1.7 Compliance
Combined fabrics are in compliance with standard of quality i.e., ISO 9001:2000 and with the
standard of environment i.e., ISO 14001:2004. And the company got compliance certificate from
2009 to 2011. In addition company is also showing compliance with Integrated Management
System IMS 18000.
1.8 Quality Policy
Their objective is to produce best possible product through a quality management system, for the
entire satisfaction of the buyer.
CHAPTER 2
Organizational Structure
2.1 Company Introduction
Combined Fabrics Pvt.Ltd , is a project of Combined Dyeing & Finishing Industry, is a garment
manufacturing and export unit established in 1994. With a strong fabric sourcing and processing
facilities backing, the company specializes in manufacturing T-Shirts for National and
International Customers.
2.2 Location and Surroundings
Combined Fabrics Pvt. Ltd is located near children hospital on Ferozepur road. Industry is
surrounded by many other textile industries. The company's mailing address is:
Combined Fabrics (PVT.) LTD
22 - Km Ferozepur Road, off 1.5 Km Bulhar Road Rohi Nallah Lahore PAKISTAN
Tel: +92-42-35272621
Fax:+92-42-35965232
Machine Name
Machine Quantity
Processing Machines
1
2
3
Sewing Machines
Commercial Fabric Cutters
Industrial Exhaust Fans
300
10
24
4
5
7
8
9
10
11
Boilers
Stain Blower
Steam Electric Iron
Stain Wash Gun
Spinners
Washing Machines
Generators
6
6
12
2
6
8
3
Service Machines
1
Air cooler
2
Cooling Systems
3
Tube lights/ Energy Savers
4
Ceiling Fans
5
Bracket Fans
Source: Field visit & Management of Combined Fabrics
4
26
600
206
10
AUDIT PLAN
Audit Team
1. Khadija Asad
2. Namra Hayat
3. Sidra Ahmed
PRE-AUDIT ACTIVITIES
Adopted Approach: Waste Audit
Production Process Selection: Knitted garments (T-shirts)
Production line: T-Shirts
Target Areas for Auditing:
Verification of Documents
Waste Generation
Wastewater Generation
CHAPTER 3
Production Process and Utilities
Audit Team
1.
Khadija Asad
2.
Namra Hayat
3.
Sidrah Ahmed
Pre-Audit Activities
Adopted Approach: Waste Audit
Production Process Selection: Knitted garments (T-shirts)
Production line: T-Shirts
Target Areas for Auditing:
Verification of Documents
Waste Generation
Wastewater Generation
Sources of Noise Pollution
Components of Hazardous Waste Generation
Sources of Air Emissions
Material Balance
Risk Assessment
3.1 Raw Material
There are thousands of raw materials used in the combined fabrics. The major raw materials used
in Combined Fabrics Pvt. Ltd are yarn, synthetic colors, threads etc. The knitted fabric being
used is also of different qualities such as interlock and single jersey depending upon the demand
of the consumer.
3.2 Process Chemicals
In different processes, there is application of range of chemicals. The usage of these synthetic
chemicals depends upon the
Nature of raw material
Fabric
Inspection
QualityCheck
No
Sent to supplier
Yes
Energy
Paper
Solid waste
(fabric trimmings)
Cutting
Inspection
Quality Check
No
Wasted
Yes
Energy
Thread
Cardboard
Thread
Cardboard pieces
Cloth Trimmings
Stitching
Inspection
Quality Check
Water
Detergent
Soap
Energy
Yes
No
Wasted
Washing
Wasted colours
Addition of colours
chemicals
Dyeing
Carton
Tags
Plastic bags
Tapes
Pressing
Packaging
Solid waste
(cardboard, plastic)
Dispatch
1 kg of
Fabric
150 Liters
Water
Detergent 0.5
kg
Natural gas
0.1756 m3
Steam 1.5
Kg
0.3 kg of
Solid waste
CHAPTER 4
Environmental Issues and Monitoring
Product/piece
4.1 General Conditions
130 liters of
waste water
4.1.1 Structure
The facility was made up of bricks and cement which was divided into many sections. Each
section was separated by wooden doors. The stitching and dyeing section was maintained at a
satisfactory level. The packaging area is also proper but somehow it is congested with wasted
plastic bags and cardboard.
4.1.2 Air Emissions
Air emissions from the industry were observed to be from generators and boilers. They were
actually the point sources air emissions. Table 4.1 shows the sources of air pollution in industry.
Table 4.1 Sources of Air pollution in Industry
Source
Generators
Mechanism
Fuel Combustion
Pollutants
References
NO, NO2, CO, CO2, (Wierzbicka et al.)
volatile
organic
compounds (including
aldehydes,
benzene,
toluene) and polycyclic
aromatic hydrocarbons
(PAHs)
PM, NOx and CO
(Yu et al.)
Boilers
Fuel combustion
4.1.3 Solid Waste
Combined Fabrics processing unit produces variety of solid wastes cardboard, plastic bags,
polythene bags, trimmings of fabric, rejected fabric. The facility the solid wastes was segregated
and fabric and cardboard wastes are to vendors at a fixed price per kg. Sources and Types of
waste (solid) are given in the table
Table 4.3 Sources of solid waste
Sr No
Process
Solid Waste
1
Cutting
Fabric trimmings, rejected fabric
2
Stitching
Threads, small pieces of fabric
3
Finishing
Tags, paper, threads
4
Packaging
Cardboard, plastic bags
4.1.4 Waste Water
The main sources of waste water are from washing, bleaching and dyeing. Dyeing discharges
various synthetic chemicals such as azo dyes etc.in the wastewater the wastewater is drained into
the treatment section and after the biological and chemical treatment it is drained into the main
drain of industrial area. Waste water sampling was done and then after it, its laboratory analysis
was done. Laboratory results showed that all the parameters of the waste water were within the
acceptable limits.
4.1.5 Other Audit Findings:
The reviewed documents were updated and compiled recently and were saved in an
adequate place.
As these documents met the targets, so these were signed and dated and remarked.
Recommendation and their effective implementation from previous audit reports in the
factory were checked. This fabric industry had implemented cleaner production
technology and chemical treatment of water.
Figure: 4.1 ETP Plan
According to OSHA:
Workers are equipped with helmets and they were wearing those helmets.
There is no illuminous hazard as light system is properly designed.
Heat hazard was present in the singeing process. This is the process in which flame is
used to eliminate the fluff from the surface of grey cloth.
Noise level was above the acceptable limits by OSHA but they were wearing ear muffs
and their annual test was done.
In dying facility, firefighting system is situated to control the hazard of fire from burning
process.
First aid and fire safety facilities are also provided by the management.
PPE were also being provided by the factory in the almost every section in order to
protect employees from exposure to any substances or activity.
Caution signs were displayed in the concerned section.
An effective job was done by Compliance department as they were giving instructions to
employees in order to do their specific task in safe & effective manner.
Good housekeeping was observed during the several visits.
Workers' trainings were conducted regarding emergency situations on monthly basis.
CHAPTER 5
Environmental Issues and Recommendations
Table 5.1 gives detailed recommendations of the issues
Issues
Recommendations
1- Water Usage and Waste Water
The water consumptions in washing - Water conservation and process standardization
section high
- Reduction in hydraulic load of the mill
- Reduction in the volume of wastewater to be
treated
- Record daily water consumption from turbine
- Establish unit water consumption to reduce
water usage at the steps where possible
2. Solid Waste Disposal
Solid waste generation is not a problem
in the industry. Paper, cardboard and
fabric waste is segregated and sold to
vendors.
3. Air Emissions
The air pollutants are released from
different boiler and diesel generators
include COx, SOx, NOx and particulate
matters.
4.Noise Pollution
Noise generation from generators and It is Recommended that the management should
machines
conduct :
- Regular maintenance of generator, including
replacement and repair of noisy, worn and loose parts
- Proper lubrication and oiling of moving parts,
especially, motors, gears, pulleys and pumps
References