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M52GED ENVIRONMENTAL ENERGY MANAGEMENT
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ENVIRONMENTAL MANAGEMENT FACULTY OF
BUSSINESS, ENVIRONMENT AND SOCIETY
M52GED
ENVIRONMENTAL ENERGY MANAGEMENT STUDENT NAME- Mr. SHAIK ABDUL WAHAB
Student ID- 3928736
Module Head- Mr. I Duckers
COVENTRY UNIVERSITY, 2011-12
Submission date- 1ST December 2011
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Contents M52GED ......................................................................................................................................................... 1
ENVIRONMENTAL ENERGY MANAGEMENT .................................................................................................. 1
Module Head- Mr. I Duckers ......................................................................................................................... 1
COVENTRY UNIVERSITY, 2011-12 .................................................................................................................. 1
Submission date- 1ST December 2011 ........................................................................................................... 1
SuperNova Fashion Limited ........................................................................................................................... 3
Manufacturers and Exporters of Quality Clothing Worldwide ..................................................................... 3
INTRODUCTION ............................................................................................................................................. 3
PRODUCTS ................................................................................................................................................. 4
COMPANY PROFILE ........................................................................................................................................ 5
RAW MATERIALS ........................................................................................................................................... 6
MANUFACTURING ......................................................................................................................................... 6
Sewing ....................................................................................................................................................... 6
A. Industrial Sewing ......................................................................................................................... 7
B. Pre sewing functions ................................................................................................................... 7
C. Fabric Edges to be sewn .............................................................................................................. 7
D. Planning of sewing process ......................................................................................................... 7
E. Identification of seam lines ......................................................................................................... 7
Significant aspects of sewing .............................................................................................................. 8
Fabric Painting (Only for special orders) ................................................................................................... 8
Printing Process ......................................................................................................................................... 8
MACHINERY ................................................................................................................................................... 8
MAN POWER REQUIREMENT AND ANNUAL LABOUR COST ......................................................................... 8
ENVIRONMENTAL ISSUES .............................................................................................................................. 9
LEGISLATION .................................................................................................................................................. 9
NEW PROPOSITIONS .................................................................................................................................... 10
CONCLUSION ............................................................................................................................................... 14
REFERENCES ................................................................................................................................................ 14
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SuperNova Fashion Limited
Manufacturers and Exporters of Quality Clothing Worldwide
INTRODUCTION
SuperNova Fashion was constituted by Mr. Eashwaran (founder and adviser) who has sound
background and 20 years of experience in Textiles and was formed in the year 1999, since there
we have grown from a small company to one of the best company in India, after his retirement
from appex management now the next generation take the seat of the concern.
WHY US?
We have marked a distinguished position for ourselves in this competitive market
by providing finest quality products as per the latest fashion trends. Our products are widely
recognized for its quality, cut and designs inputs.
We are ahead of our competitors due to following features:
* Quality standards
* Competitive prices
* Innovation
* On time delivery
* Expert product solutions
* Highly skilled professionals
* Stock holding and management upon request
* Short time deliveries
* Handling minimum quantities
* Vertical manufacturers
* Eco friendly suppliers, processes, products
* Skin friendly products Okeo Tex certified vendors
* Organic certified vendors GOTS, OE100
* Complaint factories WRAP, SA 8000.
OUR SERVICES
Sampling Development and R&D - The samples are made to clients specifications
and our innovative creation based on fashion trend in the global market.
Price Negotiation - Competitiveness, Transparency.
Vendor selection / Order placement - Choosing the vendors according to the
product specification and order placement accordingly.
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Order follow up - Periodic production status, Right from laboratory test with
international accredited lab and quality control at various stages from fabric
to Final Random Inspection.
Logistics and Shipment follow up - Ensuring correct shipping documents and
prior approval from the clients before and post shipment ensuring trouble free delivery.
Buyer & Seller meet - Planning and organizing the buyers visit to any our factories.
Buyers will be taken to vendors and their factories in order to make
personal assessment about the vendor.
Market information and Fashion trend - Periodical market information such as
competitor activities, socio-political activities, industrial problems,
currency fluctuations etc., will be informed to the clients.
Personalized Follow Up - Frequent visiting across the globe to have a personal
encounter with the Company's long list of clients ensures instantaneous updating
of fashion, trends, developments and consolidation clubbed with expansion.
PRODUCTS
Mens wear - Shirts, Boxer shorts, Pull on/Constructed waistband Shorts and pants, Trousers,
Jeans, Vest Jackets, T-shirts, Jackets (Quilted/Lined), Vests, Over t-shirts, Zipper/Button polo,
Mock neck, Crew neck, Tank top,
Boxer shorts, Intimates, Bath robes, Track suits
Womens wear - Shirts, vests, Skirts, Quilted skirts, Double layer Shorts,
Pull on pant, Capri, Bias jumper, Romper, Jump suits, Trousers, Jeans, Scarf
Mock neck, Crop tops, Basic T-shirts, Poloshirt, Skirts, dresses, Shorts, Pull on pants, Scarf,
Pinafore gowns, Pyjama sets, Pants, Capri, Intimates, Bath robes, Tank top, Track suits,
Sweatshirts, Night wears, Bikini wear, Shoulder cover
Kids wear - Shirts, Shorts & Pants, Jump suits, Capri, T-shirt, Shorts, Dresses, Jumpsuits,
Intimates
Infant wear - Romper, Body-suit, T-shirt, Intimates
Home Textiles - Napkins, Towels, Bed covers, Pillow covers, Bed sheets, Curtains, Table
cloths, Placemats
FABRICS
Woven fabrics - Poplin, Drill, Denim, Dobbies, Flunnel, Suitings, Satin, Voile, Canvas,
Jacquards, Yarn dyed check & Stripes, Corduroy
Knitted fabrics - Single jersey, double Jersey, Interlock, Single rib, Double rib
Derby rib, Flatback rib, Airtex, Pique, Honeycombed, Waffle, Fleece, Pointel, Velour, Terry,
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Polar fleece, Jaquards, Herringbone, Flat knit, Feeder strippers,
Auto & Engineered Stripes
Contents - Cotton, Polyester, Modal, Bamboo, Viscose, Linen, Hemp, Rayon
Polyamide, Organic Cotton, all with lycra & without lycra and combination blends of all above.
SuperNova Fashion Ltd will always try to pursue good workmanship. With over 10 years of
experience in the competitive textile industry, our proficiency as an apparel manufacturer allows
us to provide our customers with clothing that is the absolute top class in quality and durability.
Our certain range of clothes is hand-made by our finest tailors for a personal touch.
The company employs a 100 odd people from all races on various categories such as skilled,
highly-skilled, salesmen, cashiers, drivers, storekeepers and so on. The company factory is
located in the outskirts of Tirupur (TeOnline), India
Our unit is divided into 4 sections. Sections A consists of machineries required for the
production, finishing and packaging process, consumes more amount of energy compared to the
other three sectors. Sections B contains of a canteen, rest rooms for both male and female and
a small lounge for relaxation and recreation. Section C contains office rooms and medical
amenities. Section D consists of a midsized go down for the purpose of storage for raw materials
and the finished products along with the waste yarn that are to be recycled and is a part of an
old warehouse. All the infrastructures in the respective sectors have fire exists in case of
mishap.
COMPANY PROFILE
BASIC INFORMATION
OWNERSHIP & CAPITAL
Year Established: 1999
TRADE & MARKET
Main Markets: 1. North America 2.Eastern Europe
Company Name: SuperNova Fashion Ltd
Business Type: Manufacture, export and Wholesale
Product/Service (We Sell):
Mens Wear, Women’s wear, Kid’s wear etc.
Product/Service (We Buy):
Mentioned below in detail
Number of Employees: 103 People (Permanent and temporary, contracted)
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3.Africa 4.South America 5.Northern Europe 6.Southern Europe
Total Annual Sales Volume: INR 400 Million to INR 600 Million
Export Percentage: 91% - 100%
FACTORY INFORMATION
Contract Manufacturing: OEM Service Offered, Design Service Offered, Buyer Label Offered
RAW MATERIALS
We import high quality yarn, threads, zippers and buttons from India and Bangladesh. In all we
have 12 registered vendors for raw materials. We procure mostly polyester and cotton yarn.
The price of the raw materials would be estimated upon the type of order we get. If it is a large
order, the raw materials we purchase is about 15 Million Rupees (inclusive of taxes, labour
charges, handling and transportation).
S. No Types of Raw materials Units Quantity
1 Yarn
Cotton
Polyester
Nylon
Tonnes Tonnes Tonnes
75 54 14
2 Buttons
Round
Trouser
Jeans
Special
Pcs 16million 4.5 million 3 million 500,000 average Or as per order
3 Zippers
Trousers
Jeans
Pcs 2.2 million 3 million
4 Threads-all colours Tonnes 12
Table 1- Raw Materials
MANUFACTURING
Sewing The basic process of sewing involves fastening of leather, fabrics, furs with the help of
needle and threads. Sewing is one of the important processes in apparel making. Industrial
sewing machines do most of industrial sewing. The cut pieces of a garment are mostly tacked,
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or stitched temporarily at the initial stage. The complex parts of the machine then pierces thread
through the layers of the cloth, interlocking the thread.
A. Industrial Sewing
Looks to be a simple process, industrial sewing is quite complex involving many
preparations and mathematical calculations for the correct seam quality. Quality sewing
also depends on the sound technical knowledge that goes into designing pattern and
making. Flat sheets of fabric having holes and slits into it can curve and fold in three-
dimensional shapes in very complex ways that require a high level of skill and experience
to manipulate into a smooth, wrinkle-free design.
B. Pre- sewing functions
Before the actual task of sewing begins, there are certain other tasks that have to be
taken care of which can be termed as fabric handling functions ply separation, placing
the fabric on working table, guiding the fabric towards sewing needle and tension control
of fabric during the sewing process. While ply separation, stacks of fabric plies are
sequentially positioned with the help of some feeding apparatus in an unloading position.
The topmost ply in such a stack is individually and sequentially separated from the stack.
In the process, an edge of the separated fabric is presented between the jaws of a
gripping device. A proximity switch checks the space between the gripper jaws. When
this spacing confirms that only one fabric ply is in place between the jaws, the single ply
is transferred over the receiving end of a conveyor for further processing.
C. Fabric Edges to be sewn
Two basic types of stitches- one is that are for joining two parts of cloth together and the
other one is done for decorative purposes. Sometimes, both types of stitching have to be
done for eg, a pocket has to be joined on three sides with the apparel as well as it may
be given some decorative stitches too. At what points and which type of stitching has to
be done- all such information is stored digitally on automated devices through CAD and
properly sewn.
D. Planning of sewing process
Sequence of seams to be stitched is checked before you start sewing. Which part will be
joined first, what stitches will follow one another, etc. are decided. However, some
stitches have to be necessarily done before or after another stitch. Like mentioned
above, the decorative stitches must be done first followed by the joining stitches
E. Identification of seam lines
Sewing process is performed on seam lines situated inside the fabric edges, some mm
inside the fabric's outer line. For the straight lines, the seam line is found by transferring
the outer lines inside the fabrics and the intersection of these lines makes the vertices of
the seam line. Hence, seam line is parallel to the outer edge and the distance between
the two has to be determined as it is different for different parts of the cloth. Seam
allowance is the area between the edge of the fabric and the line of stitching. It is usually
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1.5 cm away from the edge of the fabric. Seam allowance is usually 2.5 cm or more for
standard home dressmaking. Industry seam allowances vary but they are usually 0.6 cm.
Significant aspects of sewing
There are certain aspects that have to be carefully considered while the sewing process as they
are very crucial for high quality sewing.
Thread tension and consumption
Presser- foot displacement and compressing force
Needle penetration force measurement
Fabric Painting (Only for special orders) Different fabrics such as apparel fabrics or home furnishing fabrics can be crafted beautifully
using fabric painting. This technique can also be used for decorating denim jeans, shirts, skirts,
t-shirts and jackets.
Printing Process The Dyes used for printing mostly include vat, reactive, naphthol and disperse colours which
have good fastness properties. The pigments, which are not truly dyes, are also used
extensively for printing. These colours are fixed to the fibre through resins that are very resistant
to laundering or dry-cleaning. Pigments are among the fastest known colours and are effective
for light to medium shades. If used for applying dark colours, they may crock or rub off. Cheap
prints are made from basic colours mixed with tartar emetic and tannic acid but they are not
acceptable in today’s market.
MACHINERY
S.NO LIST OF MACHINARY QTY
1 Sewing Machine 20
2 Embroidery machine 1
3 Cutting machine for garments 1
4 Industrial Sewing machine 1
5 Household sewing machine 10
6 Ironing machine 10
7 Steam Press 5
8 Hemming Machines 2
9 Denim Sewing Machines 3
MAN POWER REQUIREMENT AND ANNUAL LABOUR COST
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S.NO Description Req. No.
Annual Salary (INR)
1 Plant Manager 1 350,500
2 Production and Technical manager
1 350,500
3 Finance and administrative manager
1 245,500
4 Commercial manager 1 200,000
5 Chemist 2 200,000
6 Executive secretary 1 200,000
7 Production supervisors 3 200,000
8 Mechanic 3 200 per day
9 Electrician 3 200 per day
10 Skilled operators 25 180,000
11 Unskilled workers 55 150,000
12 Accountant 2 180,000
13 Purchaser 1 200,000
14 Sales man 3 500 per day
15 Cashier 1 180,000
Table 2-Manpower Required
Any additional worker employed at per day basis.
ENVIRONMENTAL ISSUES
Environmental issues during the operational phase of textile manufacturing primarily include the
following:
· Hazardous materials management- Dyes and paints.
· Wastewater- Chemical water but drained properly.
· Emissions to air- Vapours of paint and dyes
· Energy consumption- View to minimise working more shifts during daytime.
· Solid and liquid waste- waste extra cloth sold as cleaning
LEGISLATION
The Health and Safety at Work Part 8.
The Safety Representatives and Safety Committees Regulations 1977
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The Management of Health & Safety Regulations 1992 amended 1999
The Health & Safety (Consultation with Employees) Regulations (HSCEC) 1996
The Information and Consultation with Employees Regulations 2004. (house)
Contract Law
Employer will ensure the employees’ health, safety and welfare.
Inspecting the workplace.
Investigating potential hazards.
Investigating reportable accidents, cases of diseases or ill health and dangerous
occurrences. It is good practice to investigate all accidents that occur in the workplace.
Besides this there is the common laws and regulations.
NEW PROPOSITIONS
The propositions made from 2006-2011 to mitigate the amount spent, environmental
issues.
YEAR 2006
Economic/Environmental
Driving force
Strategy Yearly
accomplishments
Future plans
Climatic change and the
increase in utilisation
cost
Improved
energy
efficiency will
achieve the
target of
reducing
Group
energy
consumption
by 19% from
that of the
2006
calendar
year by
2011.
Accomplishment of
46% reduction in
energy
consumption with
mitigation of utility
price increase and
daytime machinery
operation.
Solar panels
installation
could be
possible.
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Management and
corporate social
responsibility auditing
ISO
9001:2005
accreditation
of site.
Site now
accredited to ISO
9001:2005 with
mature
management
Achieve
EMAS
accreditation
within 2
years.
Noise and air emission The odours
from the site
should not
impact the
boundaries
beyond the
site.
Reduction of
complaints is
achieved by
proper techniques
of abatement,
mitigating, odour,
emission, noise
with upgraded
treatment
processes.
Upgraded
odour control
and wet
scrubbing
plant with bio
filters. Sound
proofing
sewing unit.
Land fill availability and
costs
This can be
achieved by
avoiding
waste
creation and
there by
employing
the beneficial
technique of
reuse.
Another
method is to
not keep
excess stock.
Composting or
beneficial
application
account for 80% of
biodegradable
waste. The sale of
by-products has
also replaced
landfill.
Shaving
reduced and
alternate
application of
waste
recovery in
case of more
waste and
thereby
increasing
profit by 6%.
Table 3-New Propositions-2006
YEAR 2007
Taking into account the environmental drivers such as climatic changes and utility costs we aim
to start using renewable sources of energy. This is achieved by generating thermal energy from
the waste. This will tremendously reduce gas purchase and also lessen waste disposal. Both the
compliance and feasibility trials are successfully completed. The risk assessment is planned with
the detailed design of the application process and the methods on how to achieve it with
minimum cost.
YEAR 2008
Economic/
Environmental
Strategies Yearly
accomplishments
Future plans
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Driving force
Climatic change
and the increase in
utilisation cost
Improved energy
efficiency will
achieve the target
of reducing Group
energy consumption
by 10%.
Reduced Carbon
Dioxide Emissions
and improved
efficiency through
application of radiant
heating, variable
speed drive
installations, reduced
water temperatures.
Continued efficiency
gains especially heat
recovery systems,
application of
variable speed
drives, boiler
decentralisation and
radiant heating
applications.
Auditing
management and
corporate social
responsibility
ISO 14001:2007
accreditation of site.
All sites are now
accredited to
ISO14001:2007 with
optimise
management
system.
Reduce risk to
forthcoming
environmental
liability legislation.
Seek business case
for EMAS
accreditation.
Storage systems Proper storage of
fuels, waste and
raw materials pre
production and post
production.
Raw materials used
for production are
stored efficiently
under cool dry
containers. The
products produced
are packed and
sealed and finally
stored onsite for
transport two times a
week.
This ensures a
proper management
system and low
vulnerability towards
laws and also
improves the
aesthetics of the site
windows.
Table 4-New Propositions-2008
YEAR 2009
Economic or
Environmental
Driving force
Strategized
objective
Yearly
achievements
Futuristic action or
anticipated
deviation
Climatic change
and the increase
in utilisation cost
Improved energy
efficiency will
achieve the target of
reducing Group
energy consumption
by 10% in the year
2008.
Reduced Carbon
Dioxide Emissions
and improved
efficiency through
application of
radiant heating,
variable speed
Continued efficiency
gains especially heat
recovery systems,
application of
variable speed
drives, boiler
decentralisation and
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drive installations. radiant heating
applications.
Land fill
availability and
costs
Avoid landfill by
avoiding waste
creation, employing
beneficial reuse and
recycling.
The reduction of
shavings by
precision splitting
and sale of
trimmings.
Registered and
compliant to
Packaging
Obligations.
Minimise landfill.
Thermal Energy
Plant with direct
waste heat recovery.
Sale of all
recyclables remains
a target
Table 5- New Propositions-2009
YEAR 2010
Concentration on yield improvement, along with the strategies;
SuperNova Fashion Ltd area yield improvement programmes improve company performance by
maximising the quality. View to keep the value of the business high, best quality yarn
manufacturers across the world especially in India. Sewing operation facilities need to remain
focused on maximising company performance.
SuperNova Fashion Ltd Yield Improvement Programmes offer a low risk strategy to improve
profitability in a very short time frame. Area gains of 4% to 8% or more are achievable,
depending on the type of clothes produced and the degree of comprehensive perception and
control of existing products and process. The programmes are carried out systematically in
collaboration with the operational team. A key element of the success rate is training labour,
concentrating on using raw materials economically, maintaining quality standards, maintaining
and improving output rates. As well as significant area gains, the programmes also contribute to
easier production management and enhanced competitive advantage.
YEAR 2011
The money saved from the profit, low energy consumption, low waste strategy year by year from
2006 to 2010 is used to increase the buying of raw materials in order to supply too many other
customers in 2010 and also to build up an efficient pre treatment facility for water discharge. The
effluent and the contaminated water are directed into the water treatment system thereby
cleaning the discharge making it contaminant free and reusing that for industry purposes.
Accreditation of clean water act and clean air act of 2010 and also ISO 14001:2010 adhering to
the legislation is prioritized and all employees of all positions are knowledgeable of the laws and
regulations of the company along with its policies and work towards a better futures.
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CONCLUSION
SuperNova Fashions Ltd has undergone major changes in its policies accordingly so that the
environmental impacts are reduced thereby increasing the profit by employing new techniques.
The company has prioritized the effective strategies such as the reduction energy over
consumption, water treatment facilities to mitigate environmental problems and also has
invested a lot in saving energy keeping in mind the depletion of natural resources. We also have
a new 5 year plan in place and if we act accordingly we hope to maximise our profits by 8-18%.
REFERENCES
house, E. p. (n.d.). Retrieved from http://www.edym.com/en/
Safety, H. a. (n.d.). Retrieved from http://www.hse.gov.uk/textiles/audit/part8.htm
TeOnline. (n.d.). Retrieved from http://www.teonline.com/knowledge-centre/textile-
processes.html