Internship Report

Sultan Ali
BSc. Textile Engineering
Session 2011-2015

National Textile University Faisalabad

This report includes the throughout learning in all processes and challenges faced in
wet processing analysis of working environment in crescent textile mills
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Introduction
Countless thanks to almighty Allah, the lord of the whole universe and the greatest force behind
my success in my life. I also pay my heartily to Hazrat Muhammad (SAW) whose whole life is
marvel and model of any person belonging to any walk of life.
My name is Sultan Ali and I am student of BE Textile from National Textile University
Faisalabad. My major studies or technical field is Textile Wet Processing.
Being aware of the importance of practical training, the NTU requires every student to go through
training for practical purpose as trainee.
The internship program is to broaden the vision of practical experiences with theoretical
knowledge as it increases ones capabilities to handle problems at various stages and the ability of
decision. I tried my best to collect the valuable information and its relevant facts. This report is
the result of my internship with Crescent Textile Mill Faisalabad.
Crescent Textile Mills is a Faisalabad based textile unit. The company was listed at stock
exchange in 1951. Crescent Textile Mills is engaged in the business of textile manufacturing of
spinning, weaving, dyeing, bleaching, printing, made ups and otherwise dealing in yarn and
fabrics.
Now Crescent Textile Mills has seven independent complete units of spinning, one separate unit
of towel & one complete unit of garments. Crescent Textile Mills has one of the largest textileprocessing units with a capacity of 2.5 million meters fabric monthly. CTM exports more
than 80% of its products and remaining they sell in the local market. Main products of CTM are
yarn; Gray-cloth, bed sheet and fabric etc.
The main products of CTM are as follow:
Yarn products:

Two types of yarn products

Cotton Yarn
Poly-cotton Yarn
Fabric products:

Printed Fabric
Dyed Fabric
Bleached fabric or white
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Workplace learning
Man:

A proper training should be given to the employees and the workers to enhance their skills to
increase their productivity and ultimately of the company. All the duties and responsibilities of the
employees and the workers should be clearly defined. Salary package of employees/ worker are
not satisfactory thats why they are not taking interest to work honestly. By giving fixed break
time to employee for rest, company can get better output from employee. The company should
adopt an efficient appraisal system and give rewards to the employees who have done well. The
number of workers or employees is less and doing extra work other than their field, which cause
delay in time and company may not complete its order before the time of completion.
Method:

The methods can be classified as chemical treatment (wet) methods and physical treatment (dry)
methods. Chemical treatment methods are most often used in actual practice. Because of the large
amount of energy involved and the high consumption of water and consequently increase of
pollution, these techniques are costly and not eco-friendly. In addition, these processes treat the
fabric in bulk, something which is unnecessary and may adversely affect over all product
performance. In woven case there are two methods one is continuous and other is exhaust process.
The continuous process is most important and difficult to control but it gives better results and
less time consuming. The sample of dyeing or printing fabric should be prepared in the laboratory
to match the shade with standard sample for save the time in shade matching and recipe
preparing.
Machines should be installed in such a way that fabric, come out from one machine and feed to
the next machine. In this way we can save the time and increase the production. Skip that process
which is not play any impotent roll to finalize the process. Preparation of bleaching, dyeing and
printing chemicals should be careful and chemical tanks should be part away to one another
otherwise it can cause serious injury if reaction between them takes place. There should be proper
maintenance of machines to get better results.
Material

First of all the machines installed should not much old that they gives technical problems every
time. Raw material should be clean and less soil. The quality of fabric depends on raw material.
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Chemicals apply on fabric depends on quality of fabric and raw material of fabric. If we purchase
good quality dyes and chemicals it consumes less, will easy to apply on fabrics and give better
results. Avoid to use expire chemicals these can harmful for human health and also give variations
in shade matching and may also damage the fabric. The materials and chemicals used in wet
processing may recycle in order to decrease the cost and keep the environment clean. The polluted
water should be retreated and used for next process to save the water resources.

Environment

Environmental considerations are now becoming vital factors during the selection of consumer
goods including textiles all over the world. However due to increased awareness of the polluting
nature of textiles effluents, social pressures are increasing on textile processing units.
Due to very high temperature in processing unit, it is very difficult to work in hot and moist
environment therefore there should be proper ventilation system. It is very important for the
ergonomics of workers.
Exhaust fans should be place above the machine/steamer to reduce the heat. There should be air
suction system to reduce the lint particles and fluff in grey department, which cause breath
problem for workers.
The waste gases and waste water should be retreated to keep environment clean save the sources.
The textile chemical processing plays an important role in controlling the pollution load for
environment. Because the textile industry has long recognized that, for a large number of process
and applications, the surface properties are a key aspect of the product and often need to be quite
different from those of the fabric bulk.

SWOT Analysis
Strength

Crescent Textile Mills is using imported machinery

Crescent textiles has strong market popularity all over Pakistan.
The customer of crescent textiles mills requires outstanding results of end product, their desires
are fulfills with the help of highly efficient management methods.
Capital cost of crescent textile is very high. Advanced and high productive machinery is one of
the main feature this industry (Kuster Bleaching, Manfort thermex thermosole dying
machine). It means financial condition of crescent textiles is very strong.
It has competent and responsible staff working for the progress of the company.
It has automated system of production.
Environment of mill is very coziness and friendly.
It has certificate of ISO 9002 (International Organization for Standardization).
It has a wide range of products in Yarn manufacturing, dying, printing and garments
manufacturing
Its design studio is equipped with latest technology.
It has given a large quota for exports in international market.
Weaknesses:

There is no well arrangement of training of workers mostly they learn from their experience and
from their officers. This results in wastage of time and production.
Wastage is very high especially in spinning sector
Waste material produce hurdles in production planning. there is no proper arrangement to sale
waste cotton and waste yarn
Some time delivery lattes due to lack of production planning
There is no job commitment among the employees.
Annual turn out of crescent textile is higher than other industries. Reason is that salary is not
satisfied and long time increment in salary.
There is no proper criteria for performance appraisal thats why staff in not motivated
Crescent textile is lack of measurement to motivate the workers to attain higher production for
example no transportation, facility of cheap mess.

There is no proper treatment with the waste water drainage after usage in textile wet processing
(Dying, Printing, Finishing)
Opportunities

As Crescent Textile Mills internationally ISO-9002 certified company so it has a chance to

increase & expand business all over the world.
Crescent textiles manufacture high quality products demand of its products are very high
internationally.
Govt. of Pakistan is providing discount facilities to crescent textiles
Long term loans are easily available
Company can expand its operations easily
Anti dumping duties in European market are overdrawn, so the chance is to increase the export as
compared to last years.
Devaluation of rupee made Pakistani export more acceptable to the foreign buyers. There is a
chance to compete better now.
Govts pre import-export policy for cotton is also in favor of Crescent Textile Mills.
Threats

Due to energy crises in Pakistan most of the forgoing investors invests in India and Bangladesh
this situation is very difficult for Crescent textile mills.
It has been seen that many other groups in Pakistan have entered in competition with Crescent
Textile Mills. If they will not be competed well, there is a chance that they can get share of export
from foreign buyers.
South Africa is thinking about to impose the anti-dumping duties on Pakistan textile exports. If it
is imposed, a reasonable export share and big market may be lost.
There is no proper attention towards Russian market. Crescent Textile Mills can get big orders
from Russia. If attention will not be given towards this side there is a chance that any other
competitor can introduce its products in Russia and this market can be lost.
High inflation rates and energy crises are hinder in competing the Indian and Bangladesh yarn at
international level.
In off-season of cotton production cotton is import from western countries so the fluctuation in
value of dollar effects the production.
Due to economic crises of eastern countries, so many sales lost during last few years, but now
these countries are again on the road of progress. If the previous customers are not properly
attended, they may be last forever.

Brief on Opportunities
Impacts of removal of anti dumping on textile industry of Pakistan

Textile is one of the most heavily protected sectors in developed countries. A new form of trade
restriction. Protectionism is still common place in textiles, tariffs remain high and progress in
eliminating import quotas has been slow. In fact, protectionism is on the rise in a new guise: antidumping cases against Asian countries are multiplying in the US, EU and around the world.
Pakistani textiles (yarn, unbleached grey cotton fabric and bed-linen) exports are being
increasingly subjected to the initiation of anti-dumping investigations, which creates uncertainty
and depresses business sentiment.
Investigation periods are quite lengthy and the legal costs of defending against these cases are
enormous. These result in a great loss of time that could be better spent in a productive manner.
This phenomenon is a matter of great concern because it has created a damaging impact on the
normal growth of trade. In fact, by merely initiating an anti-dumping case against exporting
country's manufacturers, or even just threatening to do so, developed countries producers can
cause extensive disruption to the market for an extended period of time. At the end of the day,
whether dumping and injury are proven may no longer matter for some Asian manufacturers, who
could be driven out of the market simply as a result of the case being initiated.
Anti-dumping measures are not only legal, they are also very flexible. Only some firms in an
industry need complain for an investigation to be launched. It can be directed at specific firms and
countries, and they can be hit with differing duties. The most important aspect about ADD is that
these duties can be presented not as protection but as compensation against unfair competition.
In theory, anti-dumping measures are intended to restore fairness to the market by ensuring that
foreign-made goods are sold at a fair price. In practice, however, they can undermine all
competition from a particular country, without regard to whether specific manufacturers are
dumping their goods.
The likely replacement of quota with anti-dumping actions to protect US and EU textiles
industries will have significant implications for Pakistani textile exporters and manufacturers.
Anti-dumping actions means anti-dumping duties, which must be paid in addition to regular
duties. Also, participating in a complex anti-dumping investigation is a considerably expensive
and time-consuming undertaking. Pakistani textiles manufacturers and exporters whose products
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are being targeted have to collect and organize an enormous amount of data related to their
domestic costs, sales and prepare for a complicated review process.

Effects of nuclear power as source of energy

The advantages and disadvantages of nuclear energy have made this energy source one of the
most controversial on the market today. Despite potential drawbacks and the controversy that
surrounds it, nuclear energy does have a few advantages over some other methods of energy
production.
Advantages:
Expense

Less uranium is needed to produce the same amount of energy as coal or oil, which lowers the
cost of producing the same amount of energy. Uranium is also less expensive to procure and
transport, which further lowers the cost.
Reliability

When a nuclear power plant is functioning properly, it can run uninterrupted for up to 540 days.
This results in fewer brownouts or other power interruptions. The running of the plant is also not
contingent of weather or foreign suppliers, which makes it more stable than other forms of energy.
No Greenhouse Gases

While nuclear energy does have some emissions, the plant itself does not give off greenhouse
gasses. Studies have shown that what life-cycle emissions that the plants do give off are on par
with renewable energy sources such as wind power. This lack of greenhouse gases can be very
attractive to some consumers.
Disadvantages:
Raw Material

Uranium is used in the process of fission because it's a naturally unstable element. This means
that special precautions must be taken during the mining, transporting and storing of the uranium,
as well as the storing of any waste product to prevent it from giving off harmful levels of
radiation.
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Water Pollutant

Nuclear fission chambers are cooled by water. This water is then turned into steam, which is used
to power the turbines. When the water cools enough to change back into liquid form, it is pumped
outside into nearby wetlands. While measures are taken to ensure that no radiation is being
pumped into the environment, other heavy metals and pollutants can make their way out of the
chamber. The immense heat given off by this water can also be damaging to
eco systems located nearby the reactor.
Waste

When the uranium has finished splitting, the resulting radioactive byproducts
need to be removed. While recycling efforts of this waste product have been
undertaken in recent years, the storage of the byproduct could lead to
contamination through leaks or containment failures.
Leaks

Nuclear reactors are built with several safety systems designed to contain the
radiation given off in the fission process. When these safety systems are
properly installed and maintained, they function adequately. When they are
not maintained, have structural flaws or were improperly installed, a nuclear
reactor could release harmful amounts of radiation into the environment
during the process of regular use. If a containment field were to rupture
suddenly, the resulting leak of radiation could be catastrophic.

Suggestions
In this competitive age there is also a competition to get the resources. Careful usage of resources
not only responsible for success but also profitable In production. Only the required amount of
chemicals and equipments should be use to save the resources and in order to get more profit. By
adopting fair usage policy, company may save energy, fuel, gas and steam. The computer
Technology should also be used in decision making as well as in storing and feeding the data.
Well trained and educated persons are very useful for production. There should be a proper
system to train the workers. In this regards company should establish a skill development
departments in corresponding section (wet processing, garment manufacturing and yarn
manufacturing) for both newly and existing workers to increase workforce. Turkey would like to
arrange experts for imparting training to Pakistani workers in a bid to meet the needs of textile units,
especially those engaged in export of their products to European countries.

The management should be aware or latest trends in market place and make the market survey
time to time to get more and latest information about the market factors like the price of raw
materials and demands of products.
As the world has become a global village, the management should have the latest knowledge and
informations about the world because now a little change in any corner of the world can affect
your business. The top management should give the autonomy and the flexibility to every
manager to make decisions according to the situation at any time and in the absence of the top
managers.
The company should make it possible to deliver the goods to the buyers at the agreed time. The
company should adopt an efficient appraisal system and give rewards to the employees who have
done well. The management should recruit right persons for the right job. The management
should be able to assess the problems before its occurring so that they are able to find the ways of
their solution. The management should hire multi-skilled workers to get economy of scale. The
company should emphasize on its personnel department immediately on emergency basis.

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Conclusion
A lot of experience in Crescent Textile Mills was attain after a long period of study in Textile
education. During my internship I came to know that how the different activities take place, what
are the procedures.
Over all crescent textile mills making progress according to needs of modern age. Using high
productive machinery to compete with others. Managers if each department is well educated,
having lot of experience and problem solver. The management is professionally qualified and
experienced.
The Crescent Textile Mills should motivate their employees by providing different basic facilities
like transportation, mess facility and allowance. Attractive salary packages are sources of their
motivation
Outstanding quality products (yarn and cloth) are produced in Crescent Textile Mills. The demand
of Crescent Textile Mills products is increasing with the passage of time. The company should
expand its capacity as soon as possible to satisfy the demands of their customers.

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