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Textile industry

The document provides information about Pakistan's textile industry. It discusses the history and development of the textile industry in Pakistan from its beginnings in the 1950s to the present day. Key points include: - Textiles are Pakistan's largest industrial sector and main export earner, contributing over 50% of total exports. - The industry has grown significantly since the 1950s and now includes over 400 textile units employing millions of workers. - Pakistan has a dynamic textile industry due to its abundant cotton crops and cheap labor. The industry produces goods for major global brands. - Major textile hubs include Faisalabad, known as the "Manchester of Pakistan" for its large number of power loom

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TEXTILE INDUSTRY PREPARED BY: GHULAM MUSTAFA SSE-CHEMISTRY GHSS ISLAMIA, JHANG.
WHAT IS TEXTILE INDUSTRY • Textile is a term that comes from “textilis” which is a Latin word, that means “woven fabric”. • The textile industry is the industry which involves the sections like research, design, development, manufacturing and distribution of textiles, fabrics and clothing.
HISTORICAL BACKGROUND There are some indications that weaving was already known in the Palaeolithic. An indistinct textile impression has been found at Pavlov, Moravia. Neolithic textiles were found in pile dwellings excavations in Switzerland and at El Fayum, Egypt at a site which dates to about 5000 BC. Old Basket Oldest Needle Oldest Fibre Oldest Loom Oldest Fibre Shoes
MODREN TRENDS IN INDUSTRY IN ERA OF 1600- 1799 • 1600 - The Modern Spinning Wheel was Made. • 1738 - Lewis Paul invented Draw Roller. • 1764 - James Hargreaves made Spinning Jenny. • 1765 - James made Stocking Frame. • 1767 - John Kay invented Spinning Frame. • 1779 - Samuel Crompton made Spinning Mule. • 1784 - Edmund Cartwright invented Power Loom. • 1791 - The Englishman Dawson made Warp Knitting Machine. • 1794 - EliWhitney made Cotton Gin.
19th Century Developments Modern Spinning Wheel The First Latch Needle 1813 – William Improved the Power Loom 1842 – John First Sewing Machine Circular Knitting Machine 1889 – Northrop First Automatic Bobbin Changing Weaving Loom 1892 – Cross, Bevan & Beadle invent Viscose 1881 – Pierre Tubular Pipe Compound Needle
20th Century Developments 1920 - Geroge Developed Looms 1910 – Spiers Invented the circular bed purl knitting machine 1953 – DuPont produced First commercial polyester fibre 1949 – Heinrich discovered the sewing- knitting technique 1954 – Fibre reactive dye invented 1963 – Open-end spinning developed in Czechoslovakia.
21ST CENTURY REPORT AND ANALYSIS ON TEXTILE COUNTRY EXPORT Bangladesh 85.90% Macau 84.40% Cambodia 72.50% Pakistan 72.10% El Salvador 60.20% Mauritius 56.60% Sri Lanka 54.30% Dominican Republic 50.90% Nepal 48.70% Tunisia 42.40% • According to the reports, Bangladesh had been the country exporting textile products and earning most of their economy as compared to other countries like pakistan. • In 2002, textiles and apparel manufacturing accounted for $400 billion in global exports. •
• Here is the report of export of textile and clothing and its earning in $ millions. WORLDWIDE 1990 2000 2004 2005 2006 2007 2008 WORLDCLOTHI NG 10435 4 15729 5 19554 1 20265 7 220367 240364 250198 TEXTILE 10812 9 19772 2 26056 9 27680 2 309142 345830 361888 • The clothing trade is growing at a faster rate. • The Textile & Clothing trade has increased; from US$ 212 Billion in 1990 to US $ 612.1 Billion in 2008. 400000 350000 300000 250000 200000 150000 100000 50000 0 345830 309142 260569 276802 197722 108129 Year 0 1990 2000 2004 2005 2006 2007 2008 361888
PAKISTAN TEXTILE INDUSTRY • Pakistan has a dynamic, vigorous and export oriented textile industry that has an overwhelming impact on economy. Textile is the largest industrial sector and generates the country’s highest export earnings of about 58%. It also provides the bulk of employment (39%) to largely underutilized workforce, and contributes with 8.5% to GDP. Nearly all the world-renowned brands are manufactured in Pakistan which keeps with high standard of international quality and competitiveness.
• At present, there are 1,221 ginning units, 442 spinning units, 124 large spinning units and 425 small units which produce textile. • The Pakistan’s textile sector, in 2011, has registered an impressive growth of 38 percent. This was expected after European Union’s (EU) grant of duty free access to 75 products from Pakistan and out of which 65 are textile products. The EU facility is initially for two years, extendable for third year after which Pakistan would quality for Generalized System of Preferences (GSP) plus status to export duty free to EU as per revised criteria. Main markets of Pakistani textile are USA, EU, and Gulf region, UK, Hong Kong, Japan, Korea and Saudi Arabia. • Pakistan is the 4th largest producer of cotton with the third largest spinning capacity in Asia after China and India and contributes 5% to the global spinning capacity.
HISTORYOF TEXTILE INDUSTRYIN PAKISTAN Valika textile mill was established in 1953 In 1960’s ,180 units of textile in Karachi and Punjab In 1970, there were 113 textile units , 2605 spindles and 30 thousand looms CEC was established after separation of east Pakistan PIDC was established in 1950’s Textile exports rose to $10.5 billion by 2007 Textile exports in 1999 were $5.2 billion In 1996, there were 440 textile units
TOP PLAYERS IN PAKISTAN • Chenab Limited • Fateh Textile Mills • The National Silk & Rayon Mills Limited • GulAhmed Textile Mills Limited • Husein Industeries Limited • Kohinoor Textile Mills Limited • Nishat Mills Limited • Safa Textiles Limited • The Crescent Textile Mills Limited • Fazal Textile Mills Limited
Current Status of Textile Industry in Pakistan Textile sector developed in a rapid rate in Pakistan. Thanks to abundance of basic inputs like cotton, and cheap and skilled labor. Here are some briefs about the industry’s current status. Table-01-Textile Setups in Pakistan Installed Capacity Textile units 464 Spindles 10,965,000 Looms 1,716,300 (Million Sq. Mtrs.)
Breakup of Textile Units installed across Pakistan Areas Textile Units Punjab 316 Sindh 116 Khyber Pakhtunkhwa 17 Baluchistan 9 Azad Kashmir 6 Total 464 Although there are number of organized or non-organized setups of textile in Lahore, Karachi, Sialkot, and other main cities, Faisalabad is Pakistan’s textile centre, even called the Manchester of Asia. There are about 60,000 powers loom factories in Faisalabad, and the city accounts for half of all textiles in Pakistan. .
Ancillary Textile Industry The ancillary textile industry includes cotton spinning, cotton cloth, cotton yarn, cotton fabric, fabric processing, home textiles, towels, hosiery and knitwear, and readymade garments. These components are being produced both in organized large-scale as well as in unorganized cottage/small and medium units. Production July-Mar (2011-2012 ) Mill Sector 764.480 (Million Sq. Mtrs.) Non Mill Sector 5,971.650 (Million Sq. Mtrs.) Total 6,736.130 (Million Sq. Mtrs.) Cloth Exports Quantity 1,294.863 (Million Sq. Mtrs.) Value 1,716.300 (Million US $) Table-02: Production and Exports of Clothing sector
Annual production Cotton 26 % Polyester 30 % Cotton 63 % Polyester 51% Viscose 7 % Viscose Others 16 % 5% Others 2% Pakistan Global
Technical Technical Textile 7 % Textile 14 % Textile Growth Home Textile 17 % Home Apparel Textile 58% 28% Apparel 76 % Pakistan Global
RAW MATERIALS COTTO N JUTE SYNTHETIC FIBRES FILAMENT YARN ARTIFICIAL SILK WOOL DYE S
• Cotton: Cotton spinning is perhaps the most important segment in the Pakistan textile industry with 521 units installed and operational. • Synthetic fibres: Within synthetic fibres, nylon, polyester, acrylic, and polyolefin dominate the market. There are currently five major producers of synthetic fibres in Pakistan, with a total capacity of 636,000 tons per annum. • Filament yarn: Three types of filament yarn are produced in Pakistan. These are acetate rayon yarn, polyester filament yarn, and nylon filament yarn. There are currently about 6 units in the country. • Artificial Silk: This fibre resembles silk but costs less to produce. There are about 90,000 looms in the country located mainly in Karachi, Faisalabad, Gujranwala, and Jalalpur Jattan, as well as some in FATA. • Wool: The main products manufactured from wool include woolen yarn, acrylic yarn, fabrics, shawls, blankets, and carpets. • Jute: Jute sakes and hessian cloth are primarily used for packing agricultural products such as grain and rice. The production of jute products was approximately 100,000 tons in 2009-10.
Cotton Growing Area In Pakistan cotton grown in canal irrigated areas of Punjab and Sindh provinces. In Punjab province, the Multan division ranks at the top, so far as the production of cotton is concerned, beside this Bahawalpur, Dera Ghazi Khan, Faisalabad, Sargodha, Lahore, Gujranwala and Rawalpindi divisions have the serial number according to production. In these areas American medium staple cotton is grown, and a small quantity of native qualities of cotton is allowed to grow for domestic use.
Investment Opportunities Pakistan is the 4th largest cotton producer and 3rd largest cotton consumer. This sector has been Pakistan’s main export driver for the last 50 years, and there has been investment of $ 7.5 billion over the last 10 years. Pakistan has a liberal investment policy and gives equal treatment to local and foreign investors. All economic sectors are open to foreign investors and foreign equity up to 100% is allowed. No Government permissions are required and remittance of capital, profits, royalty, technical & franchise fee is also permitted. Import of raw material for export manufacturing is zero- rated.
Incentives: Textile sector of Pakistan always gets a preferential treatment from Government of Pakistan because its importance to the Pakistani economy. • Textile manufacturers are encouraged to invest in new and modern machineries as currently there are no custom duties and taxes on the import of textile machinery. • There is Research and Development (R &D) rebate of 6% on export of textile products. • The Ministry of Textile Industry has also approved the Technology Up- gradation Fund (TUF) to improve and enhance the output capacity of the industrial units across the country. Small-scale units making investment up to 105,000 3 USD (10 million Pak. Rupee) would be provided 20% discount on loan, as the government would bear 20% loan shares of the units fulfilling the set standards.
Textile City: Pakistani Government has planned an industrial zone specifically dedicated to the textile processing and related industry known as “Textile City” Comprising of a total area of 1250 acres, the estate is located near Port Qasim Karachi, 6 km from the National Highway. Pakistan Textile City will offer the textile processing industry the desired state-of-the-art environment to achieve cost effective high productivity. The facility will provide uninterrupted power, clean and continuous water supply, natural gas, effluent treatment and efficient transportation systems. Services will be streamlined as a one window operation and managed in a highly efficient and professional manner. Textile City’s location at Port Qasim, a modern port, will facilitate import/export processing and transportation.
Future Outlook • Future Outlook of the textile industry in Pakistan seems bright as lots of opportunities are available in the wake of rising world demand for textiles. • The rise in demand is estimated at around 2.5 per cent per annum. This increasing demand itself is a great opportunity for the fourth biggest cotton producer of the world. There are number of other factors which can contribute to the growth of industry, for instance, the ban on cotton import from India has been lifted and spinning Industry would be allowed to import cotton from India.
• In keeping with its resolute determination to realize its vision, the textile industry of Pakistan is striving to improve its performance. For this reason Industry is re-investing its earnings in productive assets. There is strong possibility that textile export of Pakistan might reach $ 25 billion in near future with an investment of $ 2 billion per annum, resulting in creation of job opportunities for one million people.
PROCESSES IN TEXTILE MANUFACTURING
Textile manufacturing begins with the production or harvesting of raw fibre. After collecting the fibre from resources following steps should adopted. 5 Garments 4 Complete Fabric3 Raw Fabric2 Yarn1 Raw Material Spinning: Weaving & Knitting: Ginning: Dying and Finishing Strings of fibers are produced from raw materials to manufacture yarn. Raw Fibers is prepared by separating impurities by cotton balls. Garment Processing: Yarn is further woven into raw fabric. : Further after dying and finishing, Finish fabric is produced. Different articles including readymade are processed from finished Fabric.
YARN FABRICATION Yarn fabrication is the process, which converts raw fibre into yarn or thread. V V V V A MODEL OF YARNMANUFATURING PROCESS
STEPS FOR YARN MANUFATURING CLEANIN G OPENING /BLENDI NG RAW FIBRE CARDING COMBING DRAWING SPINNING YARN
OPENING /BLENDING Raw material (cotton and synthetic) are received in compact bales. Opening is the first operation required to carried out to open material from highly pressed cotton/synthetic bales. A textile machine of blending
CLEANING Cotton fibre must be cleaned to remove foreign matter such as plant parts, seed hulls, dirt etc. from the fibres. CARDING The blow room only opens the row material to flock whereas the card opens the flock into individual fibres. Complete diagram of carding process • The working elements are taker- in, main cylinder, card top and doffing cylinder. • The working elements are equipped with saw-tooth wires.
COMBING Combing process serves to improve the raw material in production ofmedium, medium to fine and fineyarns. The combing machine, whose use is optional, to improve the yarn quality, is located in the spinning process between the drawing frame and the flyer. Its goal is achieved by combing out the shorter fibres, thus increasing the effective fibre length. Animated process of combing
DRAWING The task of drawing process is to improve evenness over short, medium and especially long term level by straightening and paralyzing the fibre. In addition to this it also for blending of different fibres (Blending of Polyester / Cotton, Polyester / Viscose, Polyester / Wool etc.) Animated diagram of drawing machine process
SPINNING In this process rove is fed to drafting arrangement, which further attenuate to spin into final yarn. The delivered stand of fine fibre from the drafting arrangement, is strengthe- ned by inserting twist in it. This twist is generated by the spindle, which rotate at a higher speed. Spinner rollers are attached with looms
PROCESS OF SPINNING MACHINE
MAN MADE FIBERS Manmade fibres are often shipped as staple (similar in length to natural fibres), which is ready for spinning, or as filament yarn, which may be used directly or following further shaping or texturizing. The three main methods of fibre manufacture. •WET SPINNING •DRY SPINNING •MELT SPINNING Roller of man made fiber
FABRIC PRODUCTION Fabric production, the second step, involves weaving, knitting, tufting and non-woven. Tufting and non-woven are used in the fabric manufacturing but not as widely as weaving and knitting.
WEAVING Weaving is the most common method used for producing fabrics. The process is carried out of two sets of threads, which interlaces lengthwise yarns (warp yarns) with width wise ones (weft or filling yarns). To prevent the warp yarns from braking during weaving, the warp threads are coated with a size before weaving, to increase their tensile strength and smoothness. Natural starches are the most commonly used sizes, although compounds such as polyvinyl alcohol (PVA), resins, alkali-soluble cellulose derivatives and gelatine glue have been used. The sizing compound is dried on the threads and remains a part of the cloth until it is removed in the subsequent processes.
A MODLE OF WEAVING A lady doing weaving of fibre with the weaver machine
KNITTING In knitting fabric is formed through interlocking series of yarn loops. Rows of stitches are formed so that each row hangs on the row behind it, usually using sophisticated, high-speed machinery.
TUFTING Tufting is the process of inserting additional yarns into fabric to create a pile fabric. The substrate fabric can range from a thin backing to heavy burlap-type material and may be woven, knitted, or web. An industrial machine of tufting
Textile wet processing •Textile wet processing is the process that use in any finishing treatment. Where, this process is applied on textile in form of liquid with involves some for chemical action on the textile. •Examples: bleaching, printing, dyeing and printing.
In textile wet processing it can be divided into three process, that are preparation process, coloration process and finishing process. Singeing: Singeing is the process is removing the hairs of fabrics or fibers. In singeing process, we use three technique to applied it. Such as, gas flame technique. At the end of this process, we will find, that the fabrics is smoother than before and the fabrics wettability is increase.
Desizing: Desizing is the process or removing the starch or size the covering the warp yarn using enzyme. Oxidizing agent, or other chemicals. There are three types of technique in desizing and four method of desizing that has been used in wet processing.
Scouring: Scouring is a chemical washing process carried out on cotton fabric to remove natural wax and non-fibrous impurities (e.g. the remains of seed fragments) from the fibers and any added soiling or dirt. Scouring is usually carried in iron vessels called kiers. The fabric is boiled in an alkali, which forms a soap with free fatty acids (saponification). The three main processes involved in the scouring are saponification, emulsification and detergency. The main chemical reagent used in the cotton scouring is sodium hydroxide which converts saponifiable fats and oils into soaps, dissolves mineral matter and converts pectose and pectin into their soluble salts. Another scouring chemical is detergent which is an emulsifying agent and removes dust and dirt particles from the fabric.
Bleaching: It improves whiteness by removing natural coloration and remaining trace impurities from the cotton; the degree of bleaching necessary is determined by the required whiteness and absorbency. Cotton being a vegetable fiber will be bleached using an oxidizing agent, such as dilute sodium hypochlorite or dilute hydrogen peroxide. If the fabric is to be dyed a deep shade, then lower levels of bleaching are acceptable. However, for white bed sheets and medical applications, the highest levels of whiteness and absorbency are essential. Reductive bleaching is also carried out, using sodium hydrosulphite. Fibers like polyamide, polyacrylics and polyacetates can be bleached using reductive bleaching technology. After scouring and bleaching, optical brightening agents (OBA), are applied to make the textile material appear more white. These OBAs are available in different tints such as blue, violet and red.
Mercerizing process Mercerizing is the process to improve the luster, hand and other properties of cotton by using strong caustic alkaline solution. In this process, it can be divided into three uses that are dyeing printing, finishing and it also has been used in final appearance in general. Beside that, in this process has some type of mercerizing. Slack mercerizing is the example of type of mercerizing.
DYEING PROCESS: Dyeing is the process of give color to fibers, yarn, or fabrics by using natural or synthetic dye. In this process it have involving three principle process, that are retardation, migration and diffusion which all this are chemical process. There are many type of dyeing that using in textile wet processing such as cross dyeing, union dyeing and gel dyeing. All of then has there own process to make the dyeing process smoothly and produce a good quality of dyeing. Cross Dyeing: Cross dyeing is “a method of dyeing blend or combination fabrics to two or more shades by the use of dyes with different affinities for the different fibers”. The cross dyeing process can be used to create heather effects, and plaid, check, or striped fabrics.
Union Dyeing: Union dyeing is "a method of dyeing a fabric containing two or more types of fibers or yarns to the same shade so as to achieve the appearance of a solid coloured fabric". Fabrics can be dyed using a single or multiple step process. Union dyeing is used to dye solid coloured blends and combination fabrics commonly used for apparel and home furnishings Gel Dyeing: Passing a wet-spun fiber that is in the gel state (not yet at full crystallinity or orientation) through a dye bath containing dye with affinity for the fiber. This process provides good accessibility of the dye sites.
ACIDIC DYES An acid dye is a dye that is typically applied to a textile at low pH. Mainly used on wool, silk and polyamide fibers. They give very bright colors, whose fastness ranges from very poor (allowing colors to run) to very good. Acid red 88 is an acid dye used to produce red woolen yarns
BASIC DYE Basic dyes are water soluble cationic dyes. These dyes consist of amino groups (trialkyl amines , dialkyl amines ) and are usually aniline dyes. Basic dyes produce bright shades on textile materials e.g., Methylene Blue .
DIRECT DYE: Direct dye, also called Substantive Dye, any of a class of colored, water- soluble compounds that have an affinity for fiber and are taken up directly, such as the benzidine derivatives.
DISPERSE DYE Disperse dye is one kind of organic substances which is free of ionizing group. Disperse dyes are less soluble in water and used for dyeing synthetic textile materials.
DISADVANTAGES AND HAZARD EFFECT OF DYES
PRINTING Printing is a process by which coloured patterns are produced on the fabric. Unlike dyeing, it is usually only carried out on prepared fabric where it is applied to specific areas to achieve a planned design. The color is applied to the fabric and then treated with steam, heat or chemicals to fix the color on the fabric. Fig- A man printed the logo on T-shirt by using dye
GARMENT MANUFACTURING The finished cloths are fabricated into a variety of apparel and household industrial products. The simpler of these products, such as bags, sheets, towels, blanket, and draperies often produced by the textile mills themselves, but apparel or more complex house-wares are usually fabricated by cutting trades. Fig-27- Animated picture of single machine
FACTORSAFFECTING TEXTILE INDUSTRY • PROBLEMS FACED BY INDUSTRY • CLIMATIC CONDITION • TRAINING • EDUCATION
PROBLEMS FACED BY THE INDUSTRY • Lack Of ResearchAnd Development In Cotton Sector • Lack of Modernize equipment • Finance bill to burden industry further • Increasing cost of production • Internal issues Pose a Larger Threat for Pakistan’s Textile Industry. • Energy crisis • Lack of new investment
CLIMATIC CONDITION: Although Pakistan has the ideal climatic conditions for the growth of cotton providing a factor advantage to the textile industry, but it is also quite vulnerable to pesticides that can lower the yield per hector. The textile sector is largely dependent on the supply of raw material of the agricultural sector and hence whatever happens to the agricultural sector like floods will adversely affect the textile industry rendering it even more vulnerable to environmental conditions.
TRAINING: Limited availability of trained technical staff to maintain and run machinery at full efficiency is a constraint upon the development of Pakistan’s textile industry. This shortfall is partly due to a lack of technical education facilities. Some of the developments in the textile industry include: Advances in ring spinning, Computerized dyeing and finishing, computer-aided designing , manufacturing and developing retailing links. Hence, all these demand new and greater skills and Pakistan lacks it.
EDUCATION • Education is essential for the development of the textile industry. Even if the basic factors are present, unless value-addition is not done on them, they will not be productive enough. • Even if there is not enough production a country could still manage through research and development. • Survey shows that technical manpower need in the industry is 12,750 grads. But up to 2003 the available graduates were 7,950.
THREATS: • Pakistan is facing new competitors in textile sector such as Bangladesh, Vietnam and Turkey. Though we cannot avoid competition but we can always stay ahead of them by reforming our strategies and educating our entrepreneurs so as to move one step forward in every aspect. • As the quota system is ruled out by WTO, there is a threat by the Chinese and Indian manufacturers to gain most of the market share. We have high costs, low labor productivity and inefficient production processes.

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Textile industry

  • 1.
    TEXTILE INDUSTRY PREPARED BY:GHULAM MUSTAFA SSE-CHEMISTRY GHSS ISLAMIA, JHANG.
  • 2.
    WHAT IS TEXTILE INDUSTRY •Textile is a term that comes from “textilis” which is a Latin word, that means “woven fabric”. • The textile industry is the industry which involves the sections like research, design, development, manufacturing and distribution of textiles, fabrics and clothing.
  • 3.
    HISTORICAL BACKGROUND There aresome indications that weaving was already known in the Palaeolithic. An indistinct textile impression has been found at Pavlov, Moravia. Neolithic textiles were found in pile dwellings excavations in Switzerland and at El Fayum, Egypt at a site which dates to about 5000 BC. Old Basket Oldest Needle Oldest Fibre Oldest Loom Oldest Fibre Shoes
  • 4.
    MODREN TRENDS ININDUSTRY IN ERA OF 1600- 1799 • 1600 - The Modern Spinning Wheel was Made. • 1738 - Lewis Paul invented Draw Roller. • 1764 - James Hargreaves made Spinning Jenny. • 1765 - James made Stocking Frame. • 1767 - John Kay invented Spinning Frame. • 1779 - Samuel Crompton made Spinning Mule. • 1784 - Edmund Cartwright invented Power Loom. • 1791 - The Englishman Dawson made Warp Knitting Machine. • 1794 - EliWhitney made Cotton Gin.
  • 5.
    19th Century Developments Modern Spinning Wheel TheFirst Latch Needle 1813 – William Improved the Power Loom 1842 – John First Sewing Machine Circular Knitting Machine 1889 – Northrop First Automatic Bobbin Changing Weaving Loom 1892 – Cross, Bevan & Beadle invent Viscose 1881 – Pierre Tubular Pipe Compound Needle
  • 6.
    20th Century Developments 1920 - Geroge Developed Looms 1910– Spiers Invented the circular bed purl knitting machine 1953 – DuPont produced First commercial polyester fibre 1949 – Heinrich discovered the sewing- knitting technique 1954 – Fibre reactive dye invented 1963 – Open-end spinning developed in Czechoslovakia.
  • 7.
    21ST CENTURY REPORTAND ANALYSIS ON TEXTILE COUNTRY EXPORT Bangladesh 85.90% Macau 84.40% Cambodia 72.50% Pakistan 72.10% El Salvador 60.20% Mauritius 56.60% Sri Lanka 54.30% Dominican Republic 50.90% Nepal 48.70% Tunisia 42.40% • According to the reports, Bangladesh had been the country exporting textile products and earning most of their economy as compared to other countries like pakistan. • In 2002, textiles and apparel manufacturing accounted for $400 billion in global exports. •
  • 8.
    • Here isthe report of export of textile and clothing and its earning in $ millions. WORLDWIDE 1990 2000 2004 2005 2006 2007 2008 WORLDCLOTHI NG 10435 4 15729 5 19554 1 20265 7 220367 240364 250198 TEXTILE 10812 9 19772 2 26056 9 27680 2 309142 345830 361888 • The clothing trade is growing at a faster rate. • The Textile & Clothing trade has increased; from US$ 212 Billion in 1990 to US $ 612.1 Billion in 2008. 400000 350000 300000 250000 200000 150000 100000 50000 0 345830 309142 260569 276802 197722 108129 Year 0 1990 2000 2004 2005 2006 2007 2008 361888
  • 9.
    PAKISTAN TEXTILE INDUSTRY •Pakistan has a dynamic, vigorous and export oriented textile industry that has an overwhelming impact on economy. Textile is the largest industrial sector and generates the country’s highest export earnings of about 58%. It also provides the bulk of employment (39%) to largely underutilized workforce, and contributes with 8.5% to GDP. Nearly all the world-renowned brands are manufactured in Pakistan which keeps with high standard of international quality and competitiveness.
  • 10.
    • At present,there are 1,221 ginning units, 442 spinning units, 124 large spinning units and 425 small units which produce textile. • The Pakistan’s textile sector, in 2011, has registered an impressive growth of 38 percent. This was expected after European Union’s (EU) grant of duty free access to 75 products from Pakistan and out of which 65 are textile products. The EU facility is initially for two years, extendable for third year after which Pakistan would quality for Generalized System of Preferences (GSP) plus status to export duty free to EU as per revised criteria. Main markets of Pakistani textile are USA, EU, and Gulf region, UK, Hong Kong, Japan, Korea and Saudi Arabia. • Pakistan is the 4th largest producer of cotton with the third largest spinning capacity in Asia after China and India and contributes 5% to the global spinning capacity.
  • 11.
    HISTORYOF TEXTILE INDUSTRYIN PAKISTAN Valika textile mill was establishedin 1953 In 1960’s ,180 units of textile in Karachi and Punjab In 1970, there were 113 textile units , 2605 spindles and 30 thousand looms CEC was established after separation of east Pakistan PIDC was established in 1950’s Textile exports rose to $10.5 billion by 2007 Textile exports in 1999 were $5.2 billion In 1996, there were 440 textile units
  • 12.
    TOP PLAYERS INPAKISTAN • Chenab Limited • Fateh Textile Mills • The National Silk & Rayon Mills Limited • GulAhmed Textile Mills Limited • Husein Industeries Limited • Kohinoor Textile Mills Limited • Nishat Mills Limited • Safa Textiles Limited • The Crescent Textile Mills Limited • Fazal Textile Mills Limited
  • 13.
    Current Status ofTextile Industry in Pakistan Textile sector developed in a rapid rate in Pakistan. Thanks to abundance of basic inputs like cotton, and cheap and skilled labor. Here are some briefs about the industry’s current status. Table-01-Textile Setups in Pakistan Installed Capacity Textile units 464 Spindles 10,965,000 Looms 1,716,300 (Million Sq. Mtrs.)
  • 14.
    Breakup of TextileUnits installed across Pakistan Areas Textile Units Punjab 316 Sindh 116 Khyber Pakhtunkhwa 17 Baluchistan 9 Azad Kashmir 6 Total 464 Although there are number of organized or non-organized setups of textile in Lahore, Karachi, Sialkot, and other main cities, Faisalabad is Pakistan’s textile centre, even called the Manchester of Asia. There are about 60,000 powers loom factories in Faisalabad, and the city accounts for half of all textiles in Pakistan. .
  • 15.
    Ancillary Textile Industry Theancillary textile industry includes cotton spinning, cotton cloth, cotton yarn, cotton fabric, fabric processing, home textiles, towels, hosiery and knitwear, and readymade garments. These components are being produced both in organized large-scale as well as in unorganized cottage/small and medium units. Production July-Mar (2011-2012 ) Mill Sector 764.480 (Million Sq. Mtrs.) Non Mill Sector 5,971.650 (Million Sq. Mtrs.) Total 6,736.130 (Million Sq. Mtrs.) Cloth Exports Quantity 1,294.863 (Million Sq. Mtrs.) Value 1,716.300 (Million US $) Table-02: Production and Exports of Clothing sector
  • 16.
    Annual production Cotton 26 % Polyester30 % Cotton 63 % Polyester 51% Viscose 7 % Viscose Others 16 % 5% Others 2% Pakistan Global
  • 17.
    Technical Technical Textile7 % Textile 14 % Textile Growth Home Textile 17 % Home Apparel Textile 58% 28% Apparel 76 % Pakistan Global
  • 18.
  • 19.
    • Cotton: Cottonspinning is perhaps the most important segment in the Pakistan textile industry with 521 units installed and operational. • Synthetic fibres: Within synthetic fibres, nylon, polyester, acrylic, and polyolefin dominate the market. There are currently five major producers of synthetic fibres in Pakistan, with a total capacity of 636,000 tons per annum. • Filament yarn: Three types of filament yarn are produced in Pakistan. These are acetate rayon yarn, polyester filament yarn, and nylon filament yarn. There are currently about 6 units in the country. • Artificial Silk: This fibre resembles silk but costs less to produce. There are about 90,000 looms in the country located mainly in Karachi, Faisalabad, Gujranwala, and Jalalpur Jattan, as well as some in FATA. • Wool: The main products manufactured from wool include woolen yarn, acrylic yarn, fabrics, shawls, blankets, and carpets. • Jute: Jute sakes and hessian cloth are primarily used for packing agricultural products such as grain and rice. The production of jute products was approximately 100,000 tons in 2009-10.
  • 20.
    Cotton Growing Area InPakistan cotton grown in canal irrigated areas of Punjab and Sindh provinces. In Punjab province, the Multan division ranks at the top, so far as the production of cotton is concerned, beside this Bahawalpur, Dera Ghazi Khan, Faisalabad, Sargodha, Lahore, Gujranwala and Rawalpindi divisions have the serial number according to production. In these areas American medium staple cotton is grown, and a small quantity of native qualities of cotton is allowed to grow for domestic use.
  • 21.
    Investment Opportunities Pakistan isthe 4th largest cotton producer and 3rd largest cotton consumer. This sector has been Pakistan’s main export driver for the last 50 years, and there has been investment of $ 7.5 billion over the last 10 years. Pakistan has a liberal investment policy and gives equal treatment to local and foreign investors. All economic sectors are open to foreign investors and foreign equity up to 100% is allowed. No Government permissions are required and remittance of capital, profits, royalty, technical & franchise fee is also permitted. Import of raw material for export manufacturing is zero- rated.
  • 22.
    Incentives: Textile sector ofPakistan always gets a preferential treatment from Government of Pakistan because its importance to the Pakistani economy. • Textile manufacturers are encouraged to invest in new and modern machineries as currently there are no custom duties and taxes on the import of textile machinery. • There is Research and Development (R &D) rebate of 6% on export of textile products. • The Ministry of Textile Industry has also approved the Technology Up- gradation Fund (TUF) to improve and enhance the output capacity of the industrial units across the country. Small-scale units making investment up to 105,000 3 USD (10 million Pak. Rupee) would be provided 20% discount on loan, as the government would bear 20% loan shares of the units fulfilling the set standards.
  • 23.
    Textile City: PakistaniGovernment has planned an industrial zone specifically dedicated to the textile processing and related industry known as “Textile City” Comprising of a total area of 1250 acres, the estate is located near Port Qasim Karachi, 6 km from the National Highway. Pakistan Textile City will offer the textile processing industry the desired state-of-the-art environment to achieve cost effective high productivity. The facility will provide uninterrupted power, clean and continuous water supply, natural gas, effluent treatment and efficient transportation systems. Services will be streamlined as a one window operation and managed in a highly efficient and professional manner. Textile City’s location at Port Qasim, a modern port, will facilitate import/export processing and transportation.
  • 24.
    Future Outlook • FutureOutlook of the textile industry in Pakistan seems bright as lots of opportunities are available in the wake of rising world demand for textiles. • The rise in demand is estimated at around 2.5 per cent per annum. This increasing demand itself is a great opportunity for the fourth biggest cotton producer of the world. There are number of other factors which can contribute to the growth of industry, for instance, the ban on cotton import from India has been lifted and spinning Industry would be allowed to import cotton from India.
  • 25.
    • In keepingwith its resolute determination to realize its vision, the textile industry of Pakistan is striving to improve its performance. For this reason Industry is re-investing its earnings in productive assets. There is strong possibility that textile export of Pakistan might reach $ 25 billion in near future with an investment of $ 2 billion per annum, resulting in creation of job opportunities for one million people.
  • 26.
    PROCESSES IN TEXTILEMANUFACTURING
  • 27.
    Textile manufacturing beginswith the production or harvesting of raw fibre. After collecting the fibre from resources following steps should adopted. 5 Garments 4 Complete Fabric3 Raw Fabric2 Yarn1 Raw Material Spinning: Weaving & Knitting: Ginning: Dying and Finishing Strings of fibers are produced from raw materials to manufacture yarn. Raw Fibers is prepared by separating impurities by cotton balls. Garment Processing: Yarn is further woven into raw fabric. : Further after dying and finishing, Finish fabric is produced. Different articles including readymade are processed from finished Fabric.
  • 28.
    YARN FABRICATION Yarn fabricationis the process, which converts raw fibre into yarn or thread. V V V V A MODEL OF YARNMANUFATURING PROCESS
  • 29.
    STEPS FOR YARNMANUFATURING CLEANIN G OPENING /BLENDI NG RAW FIBRE CARDING COMBING DRAWING SPINNING YARN
  • 30.
    OPENING /BLENDING Raw material(cotton and synthetic) are received in compact bales. Opening is the first operation required to carried out to open material from highly pressed cotton/synthetic bales. A textile machine of blending
  • 31.
    CLEANING Cotton fibre mustbe cleaned to remove foreign matter such as plant parts, seed hulls, dirt etc. from the fibres. CARDING The blow room only opens the row material to flock whereas the card opens the flock into individual fibres. Complete diagram of carding process • The working elements are taker- in, main cylinder, card top and doffing cylinder. • The working elements are equipped with saw-tooth wires.
  • 32.
    COMBING Combing process servesto improve the raw material in production ofmedium, medium to fine and fineyarns. The combing machine, whose use is optional, to improve the yarn quality, is located in the spinning process between the drawing frame and the flyer. Its goal is achieved by combing out the shorter fibres, thus increasing the effective fibre length. Animated process of combing
  • 33.
    DRAWING The task ofdrawing process is to improve evenness over short, medium and especially long term level by straightening and paralyzing the fibre. In addition to this it also for blending of different fibres (Blending of Polyester / Cotton, Polyester / Viscose, Polyester / Wool etc.) Animated diagram of drawing machine process
  • 34.
    SPINNING In this processrove is fed to drafting arrangement, which further attenuate to spin into final yarn. The delivered stand of fine fibre from the drafting arrangement, is strengthe- ned by inserting twist in it. This twist is generated by the spindle, which rotate at a higher speed. Spinner rollers are attached with looms
  • 35.
  • 36.
    MAN MADE FIBERS Manmadefibres are often shipped as staple (similar in length to natural fibres), which is ready for spinning, or as filament yarn, which may be used directly or following further shaping or texturizing. The three main methods of fibre manufacture. •WET SPINNING •DRY SPINNING •MELT SPINNING Roller of man made fiber
  • 37.
    FABRIC PRODUCTION Fabric production,the second step, involves weaving, knitting, tufting and non-woven. Tufting and non-woven are used in the fabric manufacturing but not as widely as weaving and knitting.
  • 38.
    WEAVING Weaving is themost common method used for producing fabrics. The process is carried out of two sets of threads, which interlaces lengthwise yarns (warp yarns) with width wise ones (weft or filling yarns). To prevent the warp yarns from braking during weaving, the warp threads are coated with a size before weaving, to increase their tensile strength and smoothness. Natural starches are the most commonly used sizes, although compounds such as polyvinyl alcohol (PVA), resins, alkali-soluble cellulose derivatives and gelatine glue have been used. The sizing compound is dried on the threads and remains a part of the cloth until it is removed in the subsequent processes.
  • 39.
    A MODLE OFWEAVING A lady doing weaving of fibre with the weaver machine
  • 40.
    KNITTING In knitting fabricis formed through interlocking series of yarn loops. Rows of stitches are formed so that each row hangs on the row behind it, usually using sophisticated, high-speed machinery.
  • 41.
    TUFTING Tufting is theprocess of inserting additional yarns into fabric to create a pile fabric. The substrate fabric can range from a thin backing to heavy burlap-type material and may be woven, knitted, or web. An industrial machine of tufting
  • 42.
    Textile wet processing •Textilewet processing is the process that use in any finishing treatment. Where, this process is applied on textile in form of liquid with involves some for chemical action on the textile. •Examples: bleaching, printing, dyeing and printing.
  • 43.
    In textile wetprocessing it can be divided into three process, that are preparation process, coloration process and finishing process. Singeing: Singeing is the process is removing the hairs of fabrics or fibers. In singeing process, we use three technique to applied it. Such as, gas flame technique. At the end of this process, we will find, that the fabrics is smoother than before and the fabrics wettability is increase.
  • 44.
    Desizing: Desizing is theprocess or removing the starch or size the covering the warp yarn using enzyme. Oxidizing agent, or other chemicals. There are three types of technique in desizing and four method of desizing that has been used in wet processing.
  • 45.
    Scouring: Scouring is achemical washing process carried out on cotton fabric to remove natural wax and non-fibrous impurities (e.g. the remains of seed fragments) from the fibers and any added soiling or dirt. Scouring is usually carried in iron vessels called kiers. The fabric is boiled in an alkali, which forms a soap with free fatty acids (saponification). The three main processes involved in the scouring are saponification, emulsification and detergency. The main chemical reagent used in the cotton scouring is sodium hydroxide which converts saponifiable fats and oils into soaps, dissolves mineral matter and converts pectose and pectin into their soluble salts. Another scouring chemical is detergent which is an emulsifying agent and removes dust and dirt particles from the fabric.
  • 46.
    Bleaching: It improves whitenessby removing natural coloration and remaining trace impurities from the cotton; the degree of bleaching necessary is determined by the required whiteness and absorbency. Cotton being a vegetable fiber will be bleached using an oxidizing agent, such as dilute sodium hypochlorite or dilute hydrogen peroxide. If the fabric is to be dyed a deep shade, then lower levels of bleaching are acceptable. However, for white bed sheets and medical applications, the highest levels of whiteness and absorbency are essential. Reductive bleaching is also carried out, using sodium hydrosulphite. Fibers like polyamide, polyacrylics and polyacetates can be bleached using reductive bleaching technology. After scouring and bleaching, optical brightening agents (OBA), are applied to make the textile material appear more white. These OBAs are available in different tints such as blue, violet and red.
  • 47.
    Mercerizing process Mercerizing isthe process to improve the luster, hand and other properties of cotton by using strong caustic alkaline solution. In this process, it can be divided into three uses that are dyeing printing, finishing and it also has been used in final appearance in general. Beside that, in this process has some type of mercerizing. Slack mercerizing is the example of type of mercerizing.
  • 48.
    DYEING PROCESS: Dyeing isthe process of give color to fibers, yarn, or fabrics by using natural or synthetic dye. In this process it have involving three principle process, that are retardation, migration and diffusion which all this are chemical process. There are many type of dyeing that using in textile wet processing such as cross dyeing, union dyeing and gel dyeing. All of then has there own process to make the dyeing process smoothly and produce a good quality of dyeing. Cross Dyeing: Cross dyeing is “a method of dyeing blend or combination fabrics to two or more shades by the use of dyes with different affinities for the different fibers”. The cross dyeing process can be used to create heather effects, and plaid, check, or striped fabrics.
  • 49.
    Union Dyeing: Union dyeingis "a method of dyeing a fabric containing two or more types of fibers or yarns to the same shade so as to achieve the appearance of a solid coloured fabric". Fabrics can be dyed using a single or multiple step process. Union dyeing is used to dye solid coloured blends and combination fabrics commonly used for apparel and home furnishings Gel Dyeing: Passing a wet-spun fiber that is in the gel state (not yet at full crystallinity or orientation) through a dye bath containing dye with affinity for the fiber. This process provides good accessibility of the dye sites.
  • 50.
    ACIDIC DYES An aciddye is a dye that is typically applied to a textile at low pH. Mainly used on wool, silk and polyamide fibers. They give very bright colors, whose fastness ranges from very poor (allowing colors to run) to very good. Acid red 88 is an acid dye used to produce red woolen yarns
  • 51.
    BASIC DYE Basic dyesare water soluble cationic dyes. These dyes consist of amino groups (trialkyl amines , dialkyl amines ) and are usually aniline dyes. Basic dyes produce bright shades on textile materials e.g., Methylene Blue .
  • 52.
    DIRECT DYE: Direct dye,also called Substantive Dye, any of a class of colored, water- soluble compounds that have an affinity for fiber and are taken up directly, such as the benzidine derivatives.
  • 53.
    DISPERSE DYE Disperse dyeis one kind of organic substances which is free of ionizing group. Disperse dyes are less soluble in water and used for dyeing synthetic textile materials.
  • 54.
  • 55.
    PRINTING Printing is aprocess by which coloured patterns are produced on the fabric. Unlike dyeing, it is usually only carried out on prepared fabric where it is applied to specific areas to achieve a planned design. The color is applied to the fabric and then treated with steam, heat or chemicals to fix the color on the fabric. Fig- A man printed the logo on T-shirt by using dye
  • 56.
    GARMENT MANUFACTURING The finishedcloths are fabricated into a variety of apparel and household industrial products. The simpler of these products, such as bags, sheets, towels, blanket, and draperies often produced by the textile mills themselves, but apparel or more complex house-wares are usually fabricated by cutting trades. Fig-27- Animated picture of single machine
  • 57.
    FACTORSAFFECTING TEXTILE INDUSTRY •PROBLEMS FACED BY INDUSTRY • CLIMATIC CONDITION • TRAINING • EDUCATION
  • 58.
    PROBLEMS FACED BYTHE INDUSTRY • Lack Of ResearchAnd Development In Cotton Sector • Lack of Modernize equipment • Finance bill to burden industry further • Increasing cost of production • Internal issues Pose a Larger Threat for Pakistan’s Textile Industry. • Energy crisis • Lack of new investment
  • 59.
    CLIMATIC CONDITION: Although Pakistanhas the ideal climatic conditions for the growth of cotton providing a factor advantage to the textile industry, but it is also quite vulnerable to pesticides that can lower the yield per hector. The textile sector is largely dependent on the supply of raw material of the agricultural sector and hence whatever happens to the agricultural sector like floods will adversely affect the textile industry rendering it even more vulnerable to environmental conditions.
  • 60.
    TRAINING: Limited availability oftrained technical staff to maintain and run machinery at full efficiency is a constraint upon the development of Pakistan’s textile industry. This shortfall is partly due to a lack of technical education facilities. Some of the developments in the textile industry include: Advances in ring spinning, Computerized dyeing and finishing, computer-aided designing , manufacturing and developing retailing links. Hence, all these demand new and greater skills and Pakistan lacks it.
  • 61.
    EDUCATION • Education isessential for the development of the textile industry. Even if the basic factors are present, unless value-addition is not done on them, they will not be productive enough. • Even if there is not enough production a country could still manage through research and development. • Survey shows that technical manpower need in the industry is 12,750 grads. But up to 2003 the available graduates were 7,950.
  • 62.
    THREATS: • Pakistan isfacing new competitors in textile sector such as Bangladesh, Vietnam and Turkey. Though we cannot avoid competition but we can always stay ahead of them by reforming our strategies and educating our entrepreneurs so as to move one step forward in every aspect. • As the quota system is ruled out by WTO, there is a threat by the Chinese and Indian manufacturers to gain most of the market share. We have high costs, low labor productivity and inefficient production processes.