INTRODUCTION

Cleaner Production Institute (CPI) is a not-for-profit and non-governmental

organization registered under Societies Registration Act of 1860. The institute aims to
promote and execute environmental development projects in the industrial sectors of
Pakistan and conduct research in areas concerning to environmental technology.

CPI has initiated the Programme for Industrial Sustainable Development (PISD) on
July 01, 2007 with technical assistance from the Royal Netherlands Embassy (RNE) to
help Pakistani industry stay competitive. The programme essentially upholds the need of
internalizing environment and energy costs into an economic process. Sector specific
cleaner technology and energy efficiency projects are the components of PISD. Textile
processing is one of the four major industrial sectors- together with leather, pulp & paper
and sugar - on which the programme will continue to focus during the first three years of
its operation.

TEXTILE PROCESSING INDUSTRY OF PAKISTAN

The textile sector, with more than 700 industrial units currently running, is the most
important industrial sector of Pakistan. Textile and its made-ups account for over 60% of
the country’s total exports, besides catering to the local market demands. In year 2005-
06, the sector contributed 8.5% to the Gross Domestic Product and employed 38% of
total manufacturing labor force of the country. But of late, the sector has been struggling
to compete with Chinese, Indian and Bangladeshi products that are eating into its market
share, primarily because of lower prices. Textile exports fell 9.11 percent year-on-year to
$3.23 billion in the first four months of the 2006/07 fiscal year. Besides other remedial
measures to stay competitive, improvement in resource use efficiency and better
environmental performance can contribute significantly in supporting the Pakistani
textile processing industry.

MAJOR ENVIRONMENTAL & ENERGY CONCERNS

Wastewater

Textile processing consumes extensive water particularly in the washing steps. Water
consumption figure varies from 70-400 liters per kg of finished fabric, very high
compared to the optimum figure of 70-100. Major factors responsible for this huge water
consumption are the unawareness regarding water conservation measures, old and
inefficient machines, lack of monitoring and measurement aptitude etc. High water
consumption leads to excessive chemical and energy usage, while a major part of this
water is discharged as untreated wastewater posing environmental and health hazards.

Excessive Biochemical Oxygen Demand (BOD5) and Chemical Oxygen Demand (COD)
is the major issue of textile effluent, along with high concentrations of Total Dissolved
Solids (TDS), Total Suspended Solids (TSS), Copper and Chromium.

Air Emissions

Air pollution of mild to medium intensity is caused via both point and diffused sources.
Point air emissions sources are steam and therm oil boilers, diesel and gas generators, gas
based stenters etc. Major air pollutants include COx, SOx, NOx and PM. Diffused air

CLEANER TECHNOLOGY PROJECT FOR TEXTILE SECTOR (CTPT) Page 1 of 5

emission sources are the chemical stores, color kitchen and processing areas. These
sources generate Volatile Organic Compounds (VOC), besides other pollutants.

Solid Waste

Major solid waste streams are the rejected fabric, empty chemical and lubricant
containers, polythene bags and cardboard cartons of dyes and pigments, discarded
machine parts, oily rags, screen cuttings, expired chemicals, packing material etc. Some
part of this stream is reused and recycled. Proper collection, segregation and disposal
system for solid waste does not exist in most cases.

Health Risks

Exposure to particulates and VOC, high noise levels and hot working environment are
major health irritants in a textile processing unit. Excessive exposure to particulates may
cause eye soreness, asthma, and other respiratory diseases. VOC fumes are severely
hazardous to health. Working in hot environment may also result into heat stroke,
fainting and heat rashes among workers. Excessive noise in the occupational areas can
cause permanent hearing loss, dull senses and increase accident rates. Chemical
containers are not provided with the secondary containment due to which spills and leaks
badly affect soil and occupational areas.

Energy Losses

Various forms of energy are extensively used in a typical textile processing unit, with
thermal energy being the most critical. Thermal energy losses occur mainly due to steam
leakages, improper machine maintenance, malfunctioning of steam traps, uncovering of
hot pipelines and surfaces, wastage of hot cooling water, conventional washing sequence
instead of countercurrent in the machines, no recovery of heat from the hot wastewater
and flue gases streams, wastage of steam condensate etc.

PISD

Cleaner production technologies have gained good reputation and success over the years
in Pakistani industry under various projects aiming to help industrial units improve their
environmental performance without compromising on profit margins.

More recently, the energy efficient technologies have also gained significance due to the
heavy cost of electrical and thermal energy. Substantial savings could be made annually
by conserving energy alone through adopting energy- efficient processes and practices.
There has been a growing interest over the recent years amongst textile processing units
to benefit from energy efficient solutions.

Considering this, Cleaner Production Institute (CPI) has started the Programme for
Industrial Sustainable Development (PISD). Cleaner Technology Project for Textile
Processing Industry (CTPT) is a component project of PISD. CTPT intends to
provide free of cost technical services to textile processing units in implementing energy
efficient and environment friendly technologies.

CLEANER TECHNOLOGY PROJECT FOR TEXTILE SECTOR (CTPT) Page 2 of 5

CLEANER TECHNOLOGY PROJECT FOR TEXTILE SECTOR (CTPT)

In view of the present situation and as an effort to approach the textile processing sector
with better solutions to the growing environmental, social and energy related problems,
Programme for Industrial Sustainable Development has included CLEANER
TECHNOLOGY PROJECT FOR TEXTILE PROCESSING INDUSTRY
(CTPT) as one of its component projects. All Pakistan Textile Processing Mills
Association (APTPMA) is collaborating with CPI to implement CTPT which focuses on
cleaner production technology, energy efficiency, wastewater treatment, environmental
management system and corporate social responsibility.

PROJECT SERVICES

Following are the major activities and outputs of the project:

1. Dissemination and Communication

o Seminars, Workshops, Brochures, Posters, Leaflets and Website for raising awareness about
cleaner and energy efficient technologies.
2. Training and Human Resource Development
o Training of industry personnel on Cleaner Production Technologies, Energy Efficiency,
Wastewater Treatment Technologies, Environmental Management System and ISO 14001
Certification.
3. Cleaner Technologies and Energy Efficiency
o Integrated environmental and energy audits and action plans.
o Implementation of Cleaner Production Technologies.
o Implementation of Energy Efficient Technologies.
o Environment and energy reports.
4. Wastewater Treatment Plants
o Designing and implementation of Wastewater Treatment Plants.
5. Environmental Management System and Certification
o Development of EMS manual.
o Implementation of EMS.
o ISO 14001 Certification.
6. Corporate Social Responsibility (CSR)
o CSR Reports of selected industrial units.
7. Cleaner Production and Energy Efficient Technologies and WWTP
Performance Reports
o Performance Reports for various Technology Interventions

PROJECT BENEFITS

A variety of multi-faceted benefits are expected from the implementation of the project,
including:

o Implementation of cleaner production, energy efficient technologies and

environmental management system.
o Increased awareness on environmental and energy issues among industrial personnel.
o Effective and trained workforce on cleaner technologies, energy efficiency,
environmental engineering, occupational health and safety, environmental
management systems, corporate social responsibility etc.

CLEANER TECHNOLOGY PROJECT FOR TEXTILE SECTOR (CTPT) Page 3 of 5

o Improved competitiveness and business image through resource conservation and
environmental compliance.
o Effective institutional coordination between industrial associations and Government
agencies for dovetailing environmental issues into national industrial policies.
o Improved work force productivity through better occupational health and safety
conditions.
o Improved relations and links of the industry with R&D institutions, certification and
legal bodies, vendors and other stakeholders.

PROJECT TEAM

Dedicated teams of CPI professionals and experts are placed in the three regions of
Lahore, Faisalabad and Karachi to provide technical assistance available under the
project to partner industrial units. Each region has a separate project team comprising of
engineers (mechanical, chemical, environmental and electrical) and EMS specialists.

All the teams are working under the supervision of a National Programme Coordinator
and two Programme Managers, one in Karachi and Lahore each. The project team also
has valuable support from separate Dissemination & Communication team in carrying
out different activities and events. Besides, expatriate professionals and local consultants
in pertinent areas are also hired to assist the project teams in various tasks.

WHO CAN JOIN CTPT?

The industrial units meeting the following criteria are eligible to benefit from the services
available under the project:

1. Are members of APTPMA or are willing to become so.

2. Show verifiable interest in mobilizing human and capital investments for successful
implementation of solutions suggested by the project team.

3. Are nominees of the steering committee of APTPMA

Once nominated, the unit may reach us at the contact details given overleaf.


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CONTACT DETAILS:

Lahore: Plot # 18, Perfect SITE, 22 km Ferozepur Road

near Masjid-e-Ibrahim, Lahore
Tel: 042-5273741-46, Fax: 042-5273750

Karachi: Plot # 39& 41 C, Third Floor, Principal House, 22nd Commercial Street,
Off Khayaban-e-Ittehad, Phase-II, Extension, DHA, Karachi
Tel: 021-5893341-42, Fax: 021-5893340

Faisalabad: 371-A, Gulistan Colony #2, Near Millat Chowk., Faisalabad

Tel: 041-8581816, Fax: 041-8581295

URL: www.pisd.com.pk, www.cpi-pak.com.pk

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