ABSTRACT

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

1. Scope of the Industry

2. Scope of our Study

Production best possible product

through a quality management system
for the entire satisfaction of the buyer

Pre auditing of the textile industry and the

processes:
1. Dying
2. Dying Finishing
3. Waste Audit

1.3 Audit Methodology

Following steps were adopted to carry out audit in Combined Fabrics Pvt. (Ltd.).
1.3.1 Orientation Session
This marks initiation of the task by the consulting team, to brief the audit scope, its objective and
data collection methodology to the industry management and resource persons. This activity
aimed at achieving a common ground of understanding of various issues of the study and
achieving coordination among the consultants and the client for efficient execution of work.
1.3.2 Data Acquisition Plan
Subsequent to the concept clarification and understanding obtained in the preceding step, a
detailed data acquisition plan was developed which comprises of a detailed checklist to collect

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

Factory Act 1934

Payment of wage Act 1933

Apparatus ship 1963

Standing order 1968

International Relations (IR) Act 2010

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

E-mail: marketing@Combined Fabricsl.com

2.3 Facility Layout

The General Manager office was located on the right side of the industry on the ground floor.
Stitching, washing, finishing, pressing and packaging sections were situated in the middle of
industry. Commercial exhaust fans and small sized steam boilers (to provide steam to electrical
steam iron) were installed in the facility.
2.4 Processing and Service Machinery
Different types of machinery and equipment were utilized to accomplish different processes in
Combined Fabrics. Table 2.1 shows the names and numbers of machines.
Table 2.1 Machine name and quantity
Sr
No.

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

2.5 Facility Layout

The General Manager office was located on the right side of the industry on the ground floor.
Stitching, washing, finishing, pressing and packaging sections were situated in the middle of
industry. Commercial exhaust fans and small sized steam boilers (to provide steam to electrical
steam iron) were installed in the facility.

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

Sources of Noise Pollution

Components of Hazardous Waste Generation
Sources of Air Emissions
Material Balance
Risk Assessment
Occupational Safety & Health Administration (OSHA)

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

 Desired characteristics of the finished product

Process chain being employed by the manager
3.3 Utilities
In combined fabrics, the most consumed utility is water which is consumed as process water and
boiler water. Natural gas is used as fuel for boilers, generators and for printing ovens but in
winters due to shortage of natural gas wood and other fuel sources are used. Moreover, electricity
is also used for running various machineries and for overall lightening system of the area.
Table 3.1 Utility Consumptions
Sr
Utility
Consumption per piece of product
No.
1
Electricity (kWh)
17.35
2
Natural Gas (m3)
0.1756
3
Steam (kg)
0.5
4
Water (Liter)
150
Source: Field visit & Management of Combined Fabrics

3.4 Process Description

Raw yarn is converted into a textile finished product with the aid of various processes.
Dyeing
Dyeing is the process of divulging color to the raw fabric with the aid of coloring agents which
are either water soluble or insoluble. Figure ---shows the complete dyeing process.
Applications of Softeners
After dyeing, softeners are applied to the fabric to improve its luster and also to improve the feel
of the fabric.
Heat Treatment
After this, heat treatment is done in order to control the width, length and weight of the
processed fabric.
Fabric Cutting
In next step fabric cutting take place through machines.
Fabric Stitching
After cutting, fabric is pressed and then it goes for the stitching process and finally it is pressed
again.
Finished Product Packing
Last step includes the packing of finished product which is T shirt.

3.5 Process Mapping

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

Wastewater (BOD, COD,

TDS, TSS)

Washing
Wasted colours
Addition of colours
chemicals

Dyeing

Air emission from boiler

(COx NOx, Sox)
Energy
Steam

Carton
Tags
Plastic bags
Tapes

Pressing

Packaging

Solid waste
(cardboard, plastic)

Dispatch

3.6 Material Balance

0.6 Kg
Product

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.

- Plastic waste should be compacted at source so that

more and more waste could be dumped at the
container

- It is Recommended that the management should

conduct quarterly monitoring of air emissions of:
Steam boilers
Diesel based generators
This monitoring is also required for the EMS (ISO
14001) and Environmental Protection Agency (EPA)
also requires its report from the industry.
- If possible scrubbers should be installed

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

- For generator, process isolation should be

considered
5.Occupational Health and Safety
It is Recommended that the management should
conduct:
Improved working environment
Safety and Work Instructions
Use of Safety guard on machine parts
Installation of Machine guards

References