Muhammad Zia Ur Rehman. Sr. MM Unit No.

3 & 5

 Industrial Advisory Board Meeting at BZU 09th Oct 2019

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Agenda of Meeting
 Objectives and Challenges Faced by Spinning Industry---------------03
 Raw Material (Cotton)-----------------------------------------------------04
 Raw Material (Synthetic and Regenerated Fibers)----------------05~06
 Machinery-------------------------------------------------------------------07
 Power (Electric)--------------------------------------------------------08~11
 Men (Managers, Workers)---------------------------------------------12~13
 Summary Regarding Objectives and Challenges ----------------------14
 Scheme of Studies-----------------------------------------------------15~17
 Summary Regarding Theoretical Scheme of Studies-----------------18
 Summary Regarding Practical Scheme of Studies---------------------19

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Objectives and Challenges Faced by Spinning Industry

 To Produce a product competitive to other Market Share Holders

Following things will be helpful in making our product competitive
 Raw Material
 Machinery
 Power (Electric)
 Men (Workers, Managers)

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Raw Material (Cotton)
 India and China are main competitors in textile spinning. They both have very good
cotton available considering majority of the cotton parameters.
 India has variety of cotton and they export comparatively low quality Shankar to other
countries like Pakistan
 Good quality cotton (almost same level as Pima and Giza) being used in house to
produce good quality fine yarns.
 Chinese cotton is also very good in quality and they don’t export their cotton now. All
fine counts being produced by their cotton.
 When Pakistan will import US or Egyptian cotton to produce finer counts, then of
coarse they need more efforts and more output to become competitive.
 Pakistani cotton has very good dye ability. If we have good length and strength of
cotton fiber in addition to maturity, we can get extra advantage.
 We must have more cotton research institutes. At the moment we find only few
institutes like Central Cotton Research Institute Multan. Still research based cottons
are not in bulk production.
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Raw Material (Synthetic and Regenerated Fibers)

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Raw Material (Synthetic and Regenerated Fibers)
 Demand of Synthetic and Regenerated fibers has been increasing day by day
while there is no major increase in consumption of cotton.
 Major increase is in Polyester and consumption of increased from 5 million
tons to 50 million tons in last 30 years.
 In Polyester sector we have good manufacturers like Ibrahim, ICI and Rupali.
 Regenerated cellulosic fibers is an alternate of cotton and its demand is
increasing day by day. In last 10 years its demand has increased almost 8
million tons and it seems that in coming days, demand of regenerated
cellulosic fiber will further increase.
 We must have Regenerated fibers manufacturers in Pakistan. We have to
import all these fibers to produce yarn and fabric.

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Machinery
 China has wide range of all spinning machinery and they use their own machinery in
spinning to produce all kind of yarns. This surely gives huge benefit in capital
investment.
 India is also manufacturing almost all kind of spinning machinery at the moment. They
have very effective planning regarding modern technology. They invite all the
machinery manufacturers to install their machinery manufacturing plants. After few
years all the technology transfers to their country. Earlier they have Rieter technology
and recently Toyota Plants have been shifted there as well. These are two major
spinning machinery manufacturers.
 After having their own machinery manufacturing units, they have complete range of
spare parts, whereas in Pakistan we have to import parts as well after machinery which
increases our production cost.
 We must try to convince major machinery manufacturers to install their manufacturing
plants here in Pakistan so that technology can be transferred in few years. This will
help us in making us competitive.
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Power (Electric)

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Power (Electric)
 Electric cost in yarn manufacturing is second to Raw material cost in any
spinning mills
 It is normally 12-20% of total cost of production depending on yarn count.
 Normally we consume 3.25-3.75 KWH/Kg of ring spun yarn for 30/1.
 Though recent rates of electricity for textile sector are not more than our
competitors but huge investment in raw material and machinery forces us to
reduce our electric cost as much as possible.
 As we all know, our cost of producing electricity at the moment is high in
Pakistan. With increase in Gas and oil prices, it will be difficult for textile
sector to survive if government gave no support.
 We must keep on working on all the aspects of saving electric cost to be
competitive and one of the neglected sector in spinning is Air conditioning
system.

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 Rated Electric Load of a 50000 Spindles Spinning Unit

S.No. Department Manufacturer Machine No. of KW/MC Total %age

Frames

1 AC+ Filter+ Pneumafil Collection Luwa   1 1995 2371 24

2 Compressors+Conditioning+Lighting     4 75 594 6

3 Colony     1 200 200 2

RX 300 1824
4 Ring Toyota
Spindles
27 147.5 3983 41

5 Auto Cone Q Pro 50 sp   27 24.85 671 7

6 Blow Room+ Card Rieter   8 42 637.5 7

Trutzschler+
7 Back Process
Marzoli
  23 15.3 1223 13

Total KW 9679

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 Ring contributes to 41% of total load of spinning unit. However, all modern
machinery manufacturers have taken all the measures to reduce power. Ring is
the key of yarn production so there we can try limited experiment to save
power.
Second major department in power consumption in spinning units consists of
AC and Filter. We, as spinner, are lagging behind in this area. We must focus
on AC and filter as there remains potential of optimization.

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Men (Managers, Workers)
 This is something important to understand that our labor cost per person is
not very high as compared to our competitors but if we consider over all
wages of a similar kind of project, then our cost is high.
 In China, wages are 240 USD/Worker as compared to 140 USD/Worker
(including incentives) in Pakistan. However total cost of wages for same
number of spindles is almost 70-75% of wages cost in Pakistan.
 Our work force is always hesitant towards innovation and modernization
whereas our competitors adopt those immediately to reduce their labor cost.
 We, being Mangers of textiles, must pay attention to enhance positive
attitude in our workers which can be done by training of supervisors+ workers
and boosting their morals by certain incentives. Modernization of technology
and positive competition among workers by motivation of managers will help
a lot.

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Here is some old data of Labor Cost. Even with Less labor cost, we are paying
extra wages for same number of spindles.

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Summary Regarding Objectives and Challenges

 We must put our efforts to enhance cotton research and farmers should have
some incentives in cultivating new varieties of Cotton.
 Production of Regenerated cellulosic fibers should be encouraged
 We should try to convince major machinery manufacturers to install their
plants in Pakistan. Government and Industrial funded projects for new
innovation in machinery should be planned.
 We should try to reduce our electric cost as much as possible
 Modernization should be adopted without wasting time and work fore should
be trained to boost their positive attitude towards their work.

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Scheme of Studies
 Considering the challenges faced by Textile industry in recent times, there
can be following additions in Scheme of Studies
 Students should have little bit more knowledge about Synthetic and
Regenerated fibers. In 2nd and 3rd Semester, Textile Raw Materials can cover
this. It will be much better if students are assigned some research based
activities about these fibers in 6th Semester along with high performance
fibers.
 Important features of latest machinery of specialized field must be included
in scheme of studies. This can be added in 7th Semester along with Technical
writing.
 Composite Materials should be included along with Mechanical Engineering
Fundamentals in 3rd Semester. This will help students a lot in understanding
the proper use of materials in addition to cost cutting in the form of capital
cost and running cost. Industrial training also necessary along with this.
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Scheme of Studies
 Textile Engineers must have complete grip over basics of electric, electronics.
We mostly lack in this field. For this our students must know the followings
 How to read basic electric drawings
 Electric tools
 Basic electric equipments
 Basic electronics
Complete Industrial training is necessary in this regard. We can include this in
4th Semester along with Electrical and Electronic engineering Fundamentals. It
seems that this subject should prevail over two semesters at least.
 In 8th Semester we must include Air Engineering of Textiles in detail. This can
be enhanced in Textile Engineering Utilities and Services. Final year project
must have some part of Textile Air Engineering research.

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Scheme of Studies
 Unnecessary theoretical work should be reduced and it should be replaced
with Practical work.
 We must increase the frequency of visits to industry for traings/ seminars and
learning about modern technology.
 Students should participate in government and industrial funded projects
along with their faculty for innovation in machinery.

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Summary Regarding Theoretical Scheme of Studies
 In 2nd and 3rd Semester, Textile Raw Material should cover more synthetic and
Regenerated cellulosic fibers
 In 7th Semester, along with technical writing, special features of modern
machinery in respective field should be included
 Composite Materials should be included along with Mechanical Engineering
Fundamentals in 3rd Semester.
 Try to increase credit hours of Electrical and Electronic Fundamentals
considering its importance in recent times.
 In 8th Semester, knowledge of Air Engineering of Textiles should be enhanced.
 Try to reduce un necessary theoretical work.

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Summary Regarding Practical Scheme of Studies
 In 3rd Semester, Industrial training regarding Composites Material should be
included.
 In 4th or 5th Semester, Industrial training regarding Electric and Electronics
should be considered.
 In 7th Semester along with Final Year Project I, important features of latest
machinery should be essential part of Project.
 In 8th Semester along with Final Year Project II, Air Engineering of Textiles
must be focused.

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