Sustainable Pakistan
ABOUT Al Makkah Apparel
Over the period of merely a decade,Al Makkah Apparel has swiftly climbed the ladder of success. Having started off with less than twenty workers in 2010, ten years down the line they now have a team of over 1000
employees. In June 2016,they relocated to the north of Faisalabad, a textile production hub that is designed for sustainable growth over the coming years. The new purpose-built factory premises span over 200,000
square feet. With 700 stitching machines at the plant, they are able to produce 2500 units of jackets and 6000 units of knits per day.
Al Makkah Apparel’s mission is to produce world-class apparel in a state-of-the-art working environment. This mission is supported by a thoughtful lay-out that allows the factory to develop further capacities in
manufacturing and absolute numbers while maintaining a high standard of compliance and safety for the workers. Integrity, respect and excellence are Al Makkah Apparel’s guiding values, which are confirmed and
embraced bytheir workers andstrongly influence every decision the company makes.The factory conducts training and qualifying sessions for their workers and management staff on a regular basis. This includes
internal and external sessions on environmental management, grievance management and change management, among others. What is more, the company conducts regular trainings on fire fighting and first aid.
In order to demonstrate the company’s commitment to occupational health and safety practices, a dedicated compliance team works to support and consistently improve the working environment for all employees
across the production facilities. The team ensures that all working practices are fully compliant with local, national and international laws and meet all required standards.Today,Al Makkah Apparel is BSCI,
SMETA and OEKO-TEX 100 certified while the team keeps committing to building capacities in all aspects of compliance and sustainability.
Al Makkah currently manufactures and supplies a variety of fashion and functional jackets to the international market. They are working on a number of innovative fabrics with a motivated team of engineers
to fulfil their customers’ requirements. Their capabilities and their commitment put them in a top position as one of the few internationally competitive manufacturers ofhigh-quality fashion jackets.
Visit partner website: www.makkahapparel.com
ABOUT Crescent Bahuman
Crescent Bahuman (CBL) was the first vertically integrated denim facility of the country. It was inaugurated in 1995 and has a sustainability and commitment
story tracing back to the very beginning. Unlike many other factories, CBL is unique in its location. Based approximately two hours outside of the major textile
hub Lahore, CBL funded its current location based on a meticulous evaluation of developable locations.
Among their first steps before establishing the plant was raising the groundwater level in the area. A planted forest enabled this finally allowing for the
establishment of the CBL campus. What used to be a remote and rural area has become a textile city around the CBL campus including schools, housing facilities,
medical installations, shops and of course the integrated manufacturing area.
In the beginning of its story CBL was jointly owned by Crescent Group and Greenwood Mills. However, it has been solely owned by the Crescent Group since 2001
being responsible for the development it has taken over the last 20 years.
CBL has successfully established a stimulating environment that fosters a culture of growth and development of all their employees which is supporting their
claim of high quality and responsible fashion. Their workers are their most valuable resource and they thus encourage policies that would enhance their skills
and continuously develop their capacities.
At the same time CBL has established themselves as a company considerate and aware about their environment and their responsibility as one of the market leaders
in Pakistan. This includes fulfilling challenging certifications, the establishment and implementation of sustainable and advanced solutions within their machine
park as well as the awareness and improvement in terms of energy and water consumption.
Today CBL provides Denim fashion for more than 10 million customers per year globally. They have adopted eco-friendly practices in order to make their production
sustainable. In the year 2015 they introduced Environmental Impact Measuring for the purpose of quantifying sustainable apparels. Next to their commitment towards
sustainable manufacturing CBL prides itself in its community engagement and continues to thrive within its surroundings.
CBL is committed to providing their customers with the best possible experience. It is ensured that all the needs are catered to and all their requirements
are fulfilled. CBL promises a unique experience and assures to live up to all expectations.
Visit partner website: www.crescentbahuman.com
ABOUT Crescent Textile Mills
Crescent Textile Mills is one of the leading manufacturers for yarns and home textiles in Pakistan and an essential part of Sustainable Pakistan.
CTM is located in Faisalabad, and is therefore part of the largest textile cluster in Pakistan as well as the largest textile city in Pakistan, often referred to as
the Manchester of Pakistan. Faisalabad, and therefore CTM, are contributing a significant share towards Pakistan’s overall export economy but plays a major role
on the local market as well.
Crescent Textile Mills is a state of the art vertically integrated textile manufacturing company known for its world-class textile development. Incepted
in 1950 they have ever since been engaged in the advanced manufacturing of Yarns, Greige/Processed Fabrics, Home Textiles, and Institutional Garments.
Crestex has a long-standing history in driving innovation. New products and product ranges go hand in hand with ongoing and dedicated R&D activities preparing
the company for ongoing change and maintaining its relevance to the market. Throughout the years they have participated as leaders in the change happening within
the market but also its materials.
CTM has a strong commitment towards sustainability. This is reflected in their long-lasting participation in various GIZ projects, their local contributions
towards community development as well as their dedication towards Research and Development. These activities have made CTM one of the leading authorities on
the development and utilisation of recycled materials. Materials they are providing to various companies within Pakistan.
Today CTM is globally known for their quality, sustainability, and reliability.
Visit partner website: www.crescenttextile.com
ABOUT DADA ENTERPRISE
Dada enterprise is located in a designated industrial zone spread over an area of 25 acres. The company competes globally by adopting the most creative techniques
and practices to produce the best quality goods. Their teams in Pakistan and Italy come up with out of the box ideas. With their state of the art equipment they
successfully yield the most unique products.Furthermore, Sustainable and environment friendly raw materials and practices are ensured.
The most distinctive quality of the company is their attention to detail. Their in-house team of 1000 employees bring in innovative ideas and provide a vast variety
of leather ranging from deer, sheep and goat skins to cow hides. Moreover, they have an in-house processing system. It starts from the very first step of collection
to the final step of packing of finished product. Their raw material comes from all over the country and worldwide. All the processes of tanning, dyeing, processing
and packing are conducted at the same location. Strict measures are taken for maintaining their high standards of quality.
Dada Enterprise pride themselves in their customer service. Their customer is always their priority and it is ensured that all the requirements are fulfilled. The
customers are involved in every step of the way. It is ensured that the products are made in complete accordance to the instructions. The company has a stellar
record of satisfied customers.
Next to their priced in their customer service, Dada is committed to work within a clean and safe environment. Dada is focussing not only on their occupational
health and safety performance; they are furthermore committed to manufacture their goods in the most sustainable way possible. As a tannery this includes a
meticulous screening and effort towards their chemical performance and their water consumption as well as their waste management.
A performance well enough to be among the first LWG certified tanneries in Pakistan, the first ever, to achieve the LWG gold standard certificate. They work
relentlessly to constantly bringing in more sustainable and more efficient solutions to their everyday challenges. Among others this includes the installation
of advanced water treatment facilities as well as their onsite energy production.
The company works to come up with unique ideas, pay attention to every detail and serve their stakeholders in the best possible way. They like to keep up with
the latest trends and the changing demands of all of their stakeholders. With their services and their commitment, Dada enterprises is a valuable and fully
transparent member of our supply chain within the project.
Visit partner website: www.dada.com.pk
ABOUT Firhaaj Footwear (Pvt.) Ltd
Firhaaj Footwear (Pvt.) Ltd. is part of the Umer Group of Industries. It is a family business established in the year 1989. Its vision is to be the most admired
company in Pakistan. Their mission is to improve the quality of the lives of everyone involved in the production and consumption of their goods. The company prides
itself in it’s out of the box thinking and unique practices. Their vision is strongly influenced by the values of honesty, empowerment, alignment and trustworthiness
as pillars of support. The plant is equipped with fully automatic and modern footwear machinery from Italy. They are also the only ones preparing Hush puppies
products with a license in Pakistan.
Firhaaj Footwear is known for its transparent supply chain and its unique workmanship. All their suppliers are government registered. Moreover, it is ensured that
the suppliers have the capacity as well as the willingness to innovate and keep up with the changing trends and with this attitude represent a strong partner within
Sustainable Pakistan.
In order to ensure environmental compliance all of their leather suppliers are certified through the Leather Working Group. Moreover, their efficient production
processes minimise wastes and recycle the inevitable waste products. Limited water is used in leather tanning. The waste water is reprocessed and reused. Sludge
is converted to fertilizers and sold in the market. Firhaaj Footwear has also taken a step in the direction of a greener leather option. Samples of products using
cactus leather are in the sampling stage and are being modelled at exhibitions. Furthermore, the company is also moving towards reliance on solar energy. Their 50%
of energy requirements is currently being met by solar panels and it is planned to extend it to 100% by the end of 2020.
Furthermore, the quality and consistency of their products are maintained as a result of the trainings conducted for all their workers in their training school.
Focus is given on their skills enhancement and capacity development. As the level of skills increases, their salaries are increased as well.
Firhaaj Footwear is known for its commitment and its strong quality measures. They have an R&D department dedicated towards product development and work closely
with their customers to facilitate and influence new trends. They also take assistance from design studios in Italy and China in ensuring that the current trends
are followed.
Their workers are more than satisfied by the work environment and to many it is like their home.
Visit partner website: Firhaaj Footwear (Pvt.) Ltd.
BACKGROUND
Intermarket is a family-run business. Its prime objective was and is to provide a livelihood to people. It was founded on the belief that
the right kind of environment is crucial for growth. The aim of the company was to train their staff and workers towards their capacity building
and skill enhancement. They strived to foster a culture cultivated by ethical values. As they entered the sock industry, which was heavily
influenced by a sustainable business culture,they always wanted to run their business on merit and professional grounds. Located near central
Lahore, their current location was established in 1998 and has been there ever since.
SUSTAINABILITY
Awareness needs to be spread on both ends, the manufacturers side as well as the consumers side. Consumers should also be taught and encouraged to
demand more environment friendly products. This needs to be reflected in their products choices.
The company has kept up with the changing requirements of the world. Be it compliance to labour standards, ensuring security against terrorism or
sustainability. The company has worked towards saving water and energy conservation while at the same time experimenting with sustainable and
innovative materials. Solutions it can today offer to its customers.
Through significant investments over the last years, the usage of water has reached almost zero with a controlled pollution load. Instead of going
through the whole washing process, Intermarket is working with solutions making the last washing steps unnecessary. But it’s not just water that
has been the at the centre of the attention. Intermarkets’ sustainability team performs regular maintenance checks and consecutively issues utility
reduction targets. In combination with a lean management, investments Intermarket has improved their environmental and business performance
significantly over the course of the years following their credo – sustainable growth for sustainable products.
INNOVATION
Intermarket has worked with CSI on restructuring and carefully improving their chemical inventory and production materials focussing on blue sign
approved chemicals to minimise the environmental impact of their organisation. Additionally, to inhouse solutions Intermarket has put a focus on
sourcing more innovative and sustainable materials. This allows them today to offer a range of products made from biopolymers instead of
petroleum-based polymers turning out to be a suitable addition to their organic and BCI cottons yarns. Further more, Intermarket is working on
developing solutions with recycled materials, environmentally friendly treatments and washing free solutions.
Today Intermarket is a reliable and committed partner within Sustainable Pakistan being able to manufacture high quality and highly functional
products according to their customers requirement while at the same time offering a story. A success story of a small manufacturer that has built
its companies success on the understanding that change must come from within and that responsibility must be owned by those bearing it.
Through significant investments over the last years, the usage of water has reached almost zero with a controlled pollution load. Instead of going
through the whole washing process, Intermarket is working with solutions making the last washing steps unnecessary. But it’s not just water that
has been the at the centre of the attention. Intermarkets’ sustainability team performs regular maintenance checks and consecutively issues utility
reduction targets. In combination with a lean management, investments Intermarket has improved their environmental and business performance
significantly over the course of the years following their credo – sustainable growth for sustainable products.
INNOVATION
Intermarket has worked with CSI on restructuring and carefully improving their chemical inventory and production materials focussing on blue sign
approved chemicals to minimise the environmental impact of their organisation. Additionally, to inhouse solutions Intermarket has put a focus on
sourcing more innovative and sustainable materials. This allows them today to offer a range of products made from biopolymers instead of
petroleum-based polymers turning out to be a suitable addition to their organic and BCI cottons yarns. Further more, Intermarket is working on
developing solutions with recycled materials, environmentally friendly treatments and washing free solutions.
Today Intermarket is a reliable and committed partner within Sustainable Pakistan being able to manufacture high quality and highly functional
products according to their customers requirement while at the same time offering a story. A success story of a small manufacturer that has built
its companies success on the understanding that change must come from within and that responsibility must be owned by those bearing it.
ABOUT KAY & EMMS
Kay & Emms is a vertically integrated factory offering all processes from knitting to packag-ing. The company possesses state-of-the-art facilities for yarn
production, knitting, dyeing, rotary and panel printing, finishing, cutting, stitching, embroidery, wet garment processes and packing. They are also capable of
making special and sophisticated fashion stitches, special finishes and using advanced fibres for their yarn and garment production.
Founder and chairman Sharif Tariq established the company in 1990. Within just 25 years, Kay & Emms has grown into a globally competitive and respected supplier of
high quality, responsible knit clothing that enjoys credibility and is active in the world’s largest mar-kets.Thanks to Kay & Emms commitment to ensure high quality
production in every process, the company supplies many well-known US-American and European brands and retailers.
The factory’s production capabilities include many special fibres for enhanced functionality and sustainability and a huge variety of special fabric constructions
in the knitting department. Their dye stuff is compliant with standards like OEKOTEX and REACH. The finishing section offers a wide selection of versatile finishes.
Besides takingcustomer requests, Kay & Emms also creates own rotary printing designs that are produced to the highest standard with the latest machinery.
The stitching section is equipped with highly skilled personnel to make any type of clothing – from basics to high fashion, for men’s, women’s and kid’s collections.
Kay & Emms’ efforts to minimise its impact on the environment and society can be seen in investments in the most environmentally-friendly and efficient machinery,
installation of an Effluent Treatment Plant and software-based KPI monitoring to ensure any potential issue is addresses swiftly and to identify opportunities for
optimisation. The company has acquired a range of certifications, such as WRAP, Fair Labour Association, C-TPAT and many more, with more in progress. Besides that,
the Kay & Emms support schools and a medical centre generously and offers employee welfare schemes.
Visit partner website: www.bestoftheknits.com
ABOUT KLASH
Klash was established in Oldham in 1990. In the year 2003 they became part of the textile industry of Pakistan. Today Klash employs over 9000 employees mainly from
Faisalabad. Local roots are important for the company allowing for a strong integration into the local community.
They are considered to be one of the largest and most sophisticated knitted garments manufacturer with ‘caring for the society’ as their core value. They are a
vertically integrated knitted garment manufacturer giant. They have the capacity of producing 2.3 million kg garments of vast range and design every month. Their
fine quality fabric is the hallmark of their state-of-the-art machinery equipment, which is manned by highly skilled workers. Knowledge they preserve, knowledge
they value and knowledge they provide to new generations of workers or managers.
Through rigorous training and capacity development of their employees, each member of the merchandise is exceptionally professional and possesses the required
expertise to cater to the needs of the customers. The company is trained to provide customer satisfaction through quality products and timely delivery of goods.
The company takes its social responsibility very seriously. They have a recycling system in place, which ensures that the majority of its waste (process and
non-process related) is efficiently recycled and reused. Moreover, they have the certifications of ISO 9002, ISO 14001 and Organic Content Standard amongst others.
Furthermore, the company sponsors schools to provide free education to children as well as a park to encourage healthy outdoor activities. They have installed clean
drinking plants all over the city.
Their commitment towards sustainability, their commitment towards social responsibility as well as their commitment towards manufacturing high quality knitwear
make Klash an ideal partner for Sustainable Pakistan.
Visit partner website: www.klashpvt.com
ABOUT NISHAT CHUNIAN GROUPS (NCG)
Nishat Chunian Group (NCG) is a vertically integrated manufacturer of yarn, fabrics and home textiles for the Asian and European market. NCG has eight spinning mills
that can produce up to 85,000 tons of greige ring-spun yarn (Ne 2/1 – Ne 135/1) annually. These yarns can be made from a wise selection of available cottons, such
as BCI or GOTS certified cotton. The group’s weaving division has a capacity of 54 million meters per year. It offers a wide range of complex and intricate weaves
and designs, such as high strength fabrics, fire retardant fabrics, cut resistant fabrics, industrial fabrics and many more. Moreover, they can weave various fancy
or ethnic fabrics, for instance Silk, Tencel ® and fabrics from different natural fibres. Dyeing and printing capacity reaches 35 million meters annually, just as
stitching capacity. Application of NCG products range from bedding, upholstery, apparel and garments, stretch fabrics, etc. for use at home or as institutional
textiles.
Nishat Chunian started as a spinning mill 30 years ago and has since then rapidly diversified to become one of the top textile producers in Pakistan. The Group now
consists of four companies, two of which are power generation companies, one incorporated company in the USA for supplies to the international retail market, and
the original Nishat Chunian Limited (NCL) textile company. Thanks to the two power generation companies, NCG produces 195.722 MWh of net output, which guarantees
uninterrupted power supply to production facilities.
Nishat Chunian Group continuously strives for excellence in the textile and power sectors.The Group uses the latest, most updated versions of machinery and technology
in their facilities. It has implemented a Management Information System that links all processes to increase productivity and efficiency. The in-house spinning
department is used to regularly experiment for product enhancement and development. The Group values competence and innovation in its employees and products,
which is why it sees itself as an equal opportunity employer. Nearly 60% of the senior management is comprised of women. NCG invests in its employees by arranging
regular trainings and providing benefits for better work-life balance.
Corporate Social Responsibility is a crucial part of NCG’s long-term strategy. GOTS, Oeko-Tex “Made in Green” and ISO 9001 are only some of NCG’s many compliance
certificates. On site, a Caustic Recovery Plant has been set up to recycle caustic soda used for fabric processing. This way, water pollution and energy use are
reduced. Moreover, a Water Effluent Plant has been installed at the dyeing and printing site that recycles contaminated wastewater. To give back to the community,
NCG has established a High School for employee’s children and the general public that offers subsidised quality education. Besides that, NCG support the
construction of a not-for-profit hospital as the largest donor.
Visit partner website: www.nishat.net
ABOUT H. Nizam Din & Sons Pvt Ltd
H. Nizam Din & Sons Pvt Ltd. is a family-run business established in 1869. With their experience of over 150 years they have earned themselves an enviable reputation
as innovative creators of cost-effective and diversified products. Their vision is to definetheir place in the global fashion industry and effectively contribute to
the protective clothing market.
They are a diverse player in the global textile industry and have customers in over 100 countries. They believe in investing in
modern technology, which produces goods efficiently, on time and cost-effectively. Nizam’s research and development team works tirelessly to keep up with the
latest demands of the consumers. The four pillars of quality, design, innovation and functionality uphold the establishment.
It is a vertically integrated business model thus has the opportunity to manage the entire process of product development. Nizam has state of the art facilities and
an amazing team of experts working for them. The factory adheres to sustainable and ethical practices in order to have a greener production process. Nizam strives
to become a niche producer of woven garments while at the same time focusing on producing goods sustainably.
By implementing sustainable practices it is ensuresthat the environmental carbon impact during the process of product development is minimised. However, this is
done without compromising on the design, quality or comfort of the products. Their collections are driven by understanding the latest trends in consumer preferences,
newly accessible materials, embellishments, modern technology and equipment and changes in the customer’s product requirements to keep them ahead of their
competition.
Visit partner website: www.nizamapparel.com
ABOUT NOOR FATIMA FABRICS
Noor Fatima Fabrics produces high-quality fabrics, bed linen and kitchen accessories. Their fabrics are made from 100% cotton, flannel, polyester, or from various
blends and compositions. Noor Fatima offers excellent products in a variety of weaves and designs, as well as many special finishes, such as fire retardant,
water repellent, anti-allergic finishes etc.
Noor Fatima is a vertically integrated company that does every step from weaving to dispatch on-site. The company possesses warping and sizing facilities for quality
assurance. Its pre-treatment and bleaching department has a capacity of 150,000 meters of fabric per day. The dyeing facility dyes up to 40,000 meters every day.
In the printing section, Noor Fatima has rotary, panel and digital printing technology at its disposal. Besides that, it has in-house CAD, engraving and a
centralised cutting department. Special wadding plants and computerized quilting machines create extra soft and relaxing fabric for domestic use. Finished
products are packaged on-site and dispatched in a timely manner.To assure uninterrupted power supply, Noor Fatima has an integrated power generation plant
using natural gas and alternatives to continuously supply the factory.
Noor Fatima follows a strict Quality Assurance Management system, with an on-site processing lab and by table checking every single piece in the stitching
department. Moreover, the company takes its social and environmental responsibilities to heart. It is a strong supporter of local hospitals, schools and
foundations for the betterment of society. Noor Fatima also provides hands-on support by building plant nurseries and installing water filter and chillers
in public places and institutions.
Noor Fatima Fabrics invests in its continuous development and possesses a vast number of compliance certifications such asSEDEX, BSCI, ISO 9001:2008,
ISO 14001:2004, C-TPAT and many more. It has achieved Oeko-Tex Standard 100 for Made Ups and Processing, Bleaching, Dying & Printing, including for
glitter printing. Their Personal Protective Equipment is recognised by the EU with an EU Declaration of Conformity.
Visit partner website: www.noorfatima.com
Saad Textile Mills is a family-owned towel manufacturer that directly supplies international retailers, such
as Carrefour, La Redoute and
Primark.Their products include bath towels and robes, utility and hospitality towels. Apart from working with a variety of specialised yarns, they can create
various textures, edges, wefts and dyes.
To ensure quality, they maintain in-house laboratories, independent quality teams and long-term partnerships with spinning mills. The testing laboratories continuously
assess raw materials and fabric and test every roll used for stitching. To guarantee consistent, on-time delivery, Saad is operating a diversified in-house energy back-up
support system.
By using only the latest, most efficient machines for the various manufacturing processes, Saad reaches monthly production capacities of 500 tons of weaving
and processing, 1.8 million units towel stitching and 46,800 units of bathrobe stitching. The company has planned several expansions in the coming two years to improve
efficiency, capacities and quality.
Saad is actively improving its sustainability by integrating various environmentally friendly systems and technologies into their processes. They possess various
certifications, like BCI, ISO9001, BSCI and Oeko-Tex® and more. If you are looking for a highly reliable supplier of premium towels, Saad Textile Mills will meet
your requirements.
Visit partner website: www.saadtextile.com
SUMMARY
Since Samad Group started as a rubber-based adhesive business in 1948, the group has expanded its production to inflatable products, technical textiles and soccer
balls. In 2013, Samad built up vertically integrated denim production and recently begun to produce fashion wear. Samad has a strong company culture that values
teamwork and ownership. After the firm joined the GIZ Labour Standards Programme, a change management team was set up. Samad was able to improve its corporate
sustainability and efficiency by introducing lean management principles. Its ambition is to grow into a national and international industry leader by applying
lean management principles, human resource development, Quality Management Systems and Management Information Systems.
CSR AND COMPLIANCE
Corporate responsibility is important to Samad Apparel, which joined the GIZ Labour Standards Programme (LSP) in 2016. The activities conducted by GIZ showed Samad
Apparel that change is possible, and things can be done in a different way. The Dialogue for Compliance is based on the assumption that improvements in labour
conditions correlate with increases in productivity. Following this approach, Change Management Teams (CMT) were composed by representatives of workers and management
to jointly identify and solve problems in the workplace.
Thanks to the collaborative approach and the lean management principles (6S, Kaizen) introduced by GIZ, Samad Apparel improved significantly on several KPIs in
stitching: i) the response time to the customer was reduced by 50%; ii) the throughput time plummeted by 86%; iii) work in process declined by 91%; and iv) the
overall production cost per piece was reduced by 26%. Cleaner production practices introduced in the washing department provided significant savings in some key
areas: thanks to new processes implemented, the consumption of water nearly halved (-47%). The Overall Equipment Effectiveness (OEE) significantly improved (31%),
as did quality and cost. Equipment failure was brought down, inducing less rework and rejected goods.
The methodologies introduced by the GIZ programme and followed up by an external consultant have made Samad Apparel more competitive and sustainable. Prior
to GIZ interventions, workers were believed to only respond to pressure. However, those who were trained for the newly established finishing model line were
transferred from a piece-rate to a salary basis, which proved to be highly effective: the finishing model line turned out to be 10-12% more productive than the
conventional lines.
Everyone at Samad Apparel is delighted about the positive impact the GIZ programme had on both labour rights and business. The management is already planning to
expand the methodologies to the entire factory.
Visit partner website: www.samadapparel.com
ABOUT Sarena Textiles
Sarena Textiles started operating in 2001 as a sister company of Sefam (Pvt) Ltd. and Ali Group of Industries. It is a vertically integrated company specialised in
weaving, dyeing, finishing and manufacturing woven, non-denim fabric and apparel. With 35 retail shops at the time, Sarena realised that it required in-house
production in order to become more flexible in the amount, frequency, and variety of new products launches. As the capacity of initially 2.5 million meters of
fabric per month soon fell short of meeting the expanding demand, Sarena addedbleaching, dyeing, finishing, printing, weaving, yarn dyeing, andapparel facilities.
The annual production capacity has now reached 100 million meters of fabric and 3 million garments. Currently, Sarena Textiles is exporting 80-90% to garment and
fabric producers in the UK, Germany, Sri Lanka and Bangladesh, and others. The main product in apparel is fire-, insect- and water-resistantworkwear for armed
forces in Pakistan and the UK. The factory has a strong focus on workwear and function wear. Their customers include brands and retailers, but also public
institutions such as local and international relief and emergency service providers. Their durable fabrics are an essential part of the supply chain for various
customers in Pakistan manufacturing for the European market already. Their modern mindset, transparent approach to factory management and compliance make them a
reliable partner for their many happy customers!
Inrecent years, Sarena has increasingly focussed on compliance and sustainability in order to meet the challenging requirements that increasingly impact
the market. It is their vision to become the national benchmark for a sustainable, green work environment and socially responsible manufacturing in the
textile industry. This attitude is not only shared through their values and thrive for excellence, but also through their actions. For more thanfour years,
Sarena has participated in various projects focussing on their sustainable performance.
CSR and Compliance
Sarena Textiles joined the GIZ programme ‘Water Efficiency in the Textile Industry’ (WETI) in 2016 and was part of a supplier development programme that was
subsidised by the German Investment and Development Company (DEG) and implemented by Consulting Service International (CSI).
Throughout the course of the project, a number of achievements were reached. Among others, the company succeeded to reduce its overall water consumption by almost
50% - partially through new manufacturing techniques, partially through new machines they installed. Additionally, they invested a huge amount of time raising
awareness and building capacities among their management teams as well as workforce. Additionally, Sarena is committed to increasing the workers’ overall
satisfaction as well as occupational health and safety (OHS) performance. Workerare trained on a regular basis to deal with OHS challenges, while, wherever
possible, engineering and other controls are implemented to protect the workers from hazards.
Apart from the efforts in social compliance, Sarena has conducted a number of activities that were aimed to improve environmental performance. Embedded in a
multi-stakeholder improvement process that consisted of the German Ministry of Economic Development and Cooperation (BMZ), GIZ and CSI, Sarena has continuously
established good practices that eventually led to the STeP by OEKO-TEX®certification in 2019. Besides their international commitment towards sustainability and
compliance, Sarena is locally involved in charity projects, supporting two public schools and the plantation of trees.
Visit partner website: www.sarenapk.com
ABOUT SHAFITEXCEL LIMITED
ShafiTexcel Ltd. is a family business, which started off as a weaving unit in 2004, eventually turning into a vertically integrated textile unit by making the addition of a Yarn dyeing unit in the year 2009 along with a fabric-finishing unit in 2014. In 2018 ShafiTexcel decided to step out of Pakistan’s comfort zone by establishing a modern and compliant stitching unit and manufacture high quality shirts, a product new to the market. Their vision is strongly influenced by the idea to expand their market, build confidence in buyers and thus bring more customers to Pakistan and its thriving textile industry.
ShafiTexcel Ltd. is the leading producer of yarn dyed fabrics and formal as well casual shirts for both men and women. Their speciality is indigo yarn dyed shirts. Today they offer a variety of products like flannel shirts, printed, striped and checked shirts. Next to their high quality Shafi benefits of its in-house fabric manufacturing hence the factory does not have to rely on fabric imports reducing the lead time for their manufacturing significantly. Today they are usually offering around 30-35 days from order to shipping. Additionally, having yarn dyeing and fabric manufacturing under one roof provides ShafiTexcel with a high degree of control over their quality and production.
The factory has the ability to work on different fabric blends of nylon and cotton, viscosis, BCI/Organic cotton, recycled cotton and retrieve polyester. Their streamlined production processes allow for a high degree of waste control. Further more, with their own water treatment plant on site, they manage to reduce the environmental impact of their production on an on-going basis while at the same time maintaining the highest level of product and manufacturing quality.
In regards to sustainability, the company is closely monitoring its Energy, Water, Chemical and CO2 footprint. All the waste that is generated in terms of threads, fibre or plastic is recycled either in-house or by a third party. Steps are taken to recover heat from wastewater as well which reduces the requirement of steam leading to improved emissions and a reduced energy consumption.
As ShafiTexcel Ltd. is the sole shirt manufacturer in Pakistan they train their staff possessing basic skills from scratch. Unlike denim, fabric for shirts is much lighter and thus difficult to handle. Therefore, the workers are trained in producing value-added and specialised products.
Moreover, ShafiTexcel Ltd. is valuing its workforce. According to their corporate values the workers are given excellent working conditions, financial assistance in case of emergencies as well as capacity development and skill enhancement opportunities.
Visit partner website: www.shafitexcel.com
SUMMARY
Softwood Textiles supplies a wide range of textile products to the European market. In 2011, it opened its own manufacturing plant in Lahore and
since then grew to a company of 490 employees. Softwood strives for excellence and aims to gain a
competitive edge by utilising Pakistan’s raw materials. Its vision is to learn, develop and implement best-management
practices that serve common welfare and achieve excellence by investing in their human resources. After entering the Dialogue for
Compliance and introducing lean management principles, efficiency increased and employee’s upward mobility opportunities were created. A Change Management Team was established to identify and solve problems relating to occupational health and safety and improve working conditions. Softwood Textiles has embarked on a path of sustainable growth by joining more programmes and investing in their dedicated employees.
CSR AND COMPLIANCE
Softwood Factory operates two production lines, both of which have applied the Dialogue for Compliance and linked it with lean management principles. Effective
helper, was enabled to double her monthly piece-rate based salary to nearly 30,000 PKR, thanks to the more efficiently organised production setup. Other machine
production planning was instrumental to increasing efficiency levels and thus productivity. One female stitching operator, who joined Softwood two years ago as a
operators have been promoted to supervisor positions. In addition to productivity increases and individual upward social mobility, the company understood the
importance of ensuring occupational safety and health by establishing appropriate the asian management systems. The 6S methodology was implemented to improve housekeeping
and safety standards. Change Management Teams (CMT) composed of management and wide representatives were established to identify and solve problems jointly.
Workers were encouraged to be forthcoming with suggestions and ideas to improve the conditions of their workplace. The CMTs took responsibility to identify hazards,
come up with adequate corrective measures and arrange safety trainings that managed to reduce accident rates and increase the motivation of the workers.
The inclusion of the workers in decision-making contributed considerably to an improved performance in occupational safety and health. Moreover, social security
benefits (e.g. EOBI) extended to the workers have been paid with increased loyalty as overall absenteeism has been reduced.
Softwood Textiles also participated in an environmental and resource management programme initiated by GIZ. Operations are being continued on own account.
Currently, all possibilities are being tested to modify washing processes and reduce the consumption of chemicals and waters. As GIZ programmes resulted
in widely positive impacts, Softwood continued to develop own solutions and set up several committees (e.g. workers’ management, safety, canteen management) that
aimed to ensure a safe and healthy workplace. The company remains true to its principle of continuous learning and strongly supports upskilling initiatives.
Female staff and workers have been hired to increase the proportion of female employees and promote gender equality. Trainees have been sent abroad to enjoy
better education and engage in more effective training formats, while staff members have been taking language courses (French) to better communicate with their
customers in their daily tasks. Softwood Textiles has embarked on a path of sustainable growth and is determined to continue.
Visit partner website: www.softwoodtextiles.com
SUMMARY
Vision Technologies is one of Pakistan’s leading makers of footballs, handballs, volleyballs, rugby balls and futsal. The companyset out as a sporting ball
manufacturer in rented facilities in 2000 and shifted to its current location at the outskirts of Sialkot in 2004. Other sporting goods likegoalkeeper gloves
were integrated in the product range two years ago.
Vision employs a workforce of more than 1,600 at their facilities in Sialkot, most of them in manufacturing. The factory runs its operation with a production
capacity of 15,000 balls and 1,000 pairs of gloves per day. At the moment, Vision reaches 12,000 balls and 400-500 gloves per day.
Vision prides itself on serving quality and excellency by producing sporting balls in different technologies. Depending on the use, balls are sewn by hand,
machine stitched or were developed applying other technologies like thermobond, hybrid, fusion tech, and lamination to enhance accuracy. All sporting goods
are made of high-quality material and meet internationally recognised standards.
Vision is a Fairtrade certified producer of footballs and has been closely working with a customer base spread over the globe, with partners in Europe
(France, Germany), Japan, Korea, Australia, USA, and South America.
Vision Technologiesconstantly challenges itself to become one of the leading ethical manufacturers of sporting goods securing a competitive edge in technology
and craftsmanship. The sporting ball manufacturer believes in continuously improving its system by investing in people and technology. Opportunities like trainings
provided to young workers and professionals are believed to generate long-term returnsfor the company and its workforce.
Vision joined the GIZ Labour Standards Programme (LSP) in 2017 and has been determined to improve labour standards ever since. Thanks to the Change Management Teams
(CMT) that consist of worker and management representatives to developchallenges and solutions jointly, Vision has adopted a pro-active view of managing change that
can benefit business. TheCMT workshops organised by GIZ LSP introduced into the process, whileGIZ consultancy was employed to take advantage of the positive
relationship between labour conditions and productivity.
The sporting goods manufacturer from Sialkot is also part of Vision Zero, a programme funded by GIZ with the objective to prevent accidents and occupational
diseases by strengthening safety, health, and well-being. One of the main benefits for Vision has been to learn how to conduct risk assessments effectively.
The third CSR project Vision partners with GIZ is the Communities of Practices (CoP), which serves as a peer-learning platform to share best practices, challenges,
and advice with manufacturers from different industries. CoP has been a valuable resource for the Vision team to exchange on compliance challenges and learn from
other manufacturers.
Sustainable Pakistan is the most recent project initiated by GIZ and provides another platform where Vision meets with manufacturers from different industries to
learn about compliance and sustainable growth. Vision participates in comprehensive assessment and qualification programmes to provide key personnel with the
knowledge required to systematically implement sustainable practices in its supply chain, thereby strengthening the company’s competitiveness.
Visit partner website: www.vision.com.pk
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Karl Borgschulze
Managing Director
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Miriam Oehler
Director
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Lukas Rebentisch
Director
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Saniya Nasir
Communications Manager
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Max Gilgenmann
Consultant
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Hayley Kiesthardt-Wong
Consultant
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Simone Charlet
Consultant
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Joseph Strasser
Consultant
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Nasim Ahmend Mazumder
Consultant
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Assadul Hassan
Consultant
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Raymond Rozario
Consultant
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Zubair Bandukda
Consultant
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Areeb Sattar
Consultant
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Nouman Ayyaz
Consultant
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Romina Kochius
Project Leader
Romina Kochius is a textile enthusiast by birth and expert by training. She has spent several years in Ethiopia, working on economic development for textile trades. Since 2014 she has lived in Lahore, Pakistan, where she manages a project on labour standards and environmental good practices in the textile and garment industry for Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ). In the context of the project activities, she and her team support home textiles, denim and knitwear producers, manufacturers of shoes as well as football producers in enhancing their compliance with labour and environmental standards. Using a unique change management technique, their productivity is boosted, too. Another area of her work is the support to state institutions to fulfil their role as a regulator. -
Mr. Muhammad Ubaid
Consultant
Muhammad Ubaid is seasoned, result oriented, dedicated and technically skilled professional with versatile management & administrative skillset having 13+ years of diverse experience, including 10 years of managerial/leadership experience of implementing the private sector development projects of national and international development cooperation. He has a vast experience of all pillars of project management with a special interest in organizational development, change management and quality management. Since 2016, he is managing the private sector development component in a project on labour standards and environmental good practices in the textile and garment industry for Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ). -
Mr. Raza Abbas
Consultant
In span of a decade, Raza has earned trust with leading national / international public and private institutions, organizations and associations created impact, visibility, employee engagement. He has earned acknowledgment from diverse employers and partners as a result oriented, friendly, responsible, trust-worthy, flexible and compassionate team member demonstrating sustained commitment and excellence. Within the project Mr. Abbas is responsible Initiated organizational change through behaviour communication change, customized corporate training programs, institutional career development reforms, strategic development, engaging employees and inspiring countless employees in workshops and seminars. Mr. Raza Abbas holds a dual degree in Business Administration & Communication from the University of Arizona representing a modern take on the development and implementation of development programs
Labour Standards Program (LSP)
The GIZ has been active in Pakistan for a number of years with various projects. The Labour Standard Program of the GIZ has been, among others, one of the
significant projects implemented on our way to sustainable Pakistan.
The challenge
The textile and garment sector, with its large clusters in Punjab, is Pakistan’s most important branch of the manufacturing industry. Some 15 million people
(around 25% of the workforce) are employed in this sector. The working conditions have poor workplace safety, low wages and lack co-determination at company
level as well as a lack of dialogue between management, workers and state institutions.
The provincial labour administration’s responsibilities include labour inspection, occupational health and safety, medical care & rehabilitation and compensation.
However, it is hardly effective despite its large workforce. The reasons include close nexus of political and business stakeholders, weak state structures and under
financing. The interaction among the state institutions and authorities is insufficient for their effective role. The private sector does not perceive incentives
for compliance with labour standards and lacks access to advisory services.
Objective
The Project aims at improving the framework conditions for the implementation of labour standards in Punjab. For the implementation phase the GIZ has chosen
partner factories within the Textile and Garment, the shoe as well as the sports articles cluster in Lahore, Faisalabad and Sialkot.
Key elements being capacity development of state institutions and fostering better cooperation among the relevant institutions. It also supports the dialogue
between state, private sector and civil society and promotes incentives and advises companies on improving labour standards.
Approach
An effective labour inspectorate contributes to decent work in the long-term and thus enhances income opportunities and living conditions. However, the labour
inspectorate can only produce impact if it combines monitoring functions with advisory services and highlights incentives for compliance with labour standards.
Doing so requires structurally improved cooperation between different departments and levels of the labour administration. The project focuses on improved
cooperation in the areas of inspection, prevention, rehabilitation and compensation. Furthermore, an intertwining of inspections and industrial safety management
systems is also planned.
The project’s capacity development strategy comprises of capacity development for individuals, organisations and networks. By encouraging dialogue cooperation
and networking among state, private sector and civil society is improved. In addition, by providing organisational development opportunitiesto the institutions
of the Labour& Human Resource Department (L&HRD)the labour inspectors can be professionally trained. In addition, the programme supports selected textile and
garment companies with organisational development measures to enhance productivity. Individual capacity development measures include training for experts in the
area of occupational health and safety, training of labour inspectors and training of multipliers, such as trainers, organisational advisors and companies’
managerial staff. This area has a special focus on gender aspects.
Capacity development for labour inspections
This field of activity has a focus on the Department where there are selected subordinate authorities and four selected district labour offices. The basis for
this is an improved definition of the duties and requirements performed by labour inspectors. The labour inspectors from the four districts undergo further training.
The unit will receive various capacity development measures in order to expand the services and advisory measures of the Saeed Ahmed Awan Centre for the Improvement
of Working Conditions and Environment (SAA-CIWCE). The Punjab Employees Social Security Institution (PESSI) receives capacity development to improve diagnostic
skills for occupational diseases. The capacities of textile and garment producers in the development and management of industrial safety are being strengthened
through initiatives like training of safety officers.
Increase Department ́s organisational capacity:
This includes improving the organisational capacity of the L&HRD to foster the industry’s compliance with labour standards, with a focus on strengthening
cooperation and coordination between various units within the Department on aspects of occupational safety and health. In particular, units entrusted with
the social security of employees (e.g. PESSI) are involved in joint activities, for example data collection and evaluation on occupational accidents in order
to provide information regarding areas requiring greater prevention. Thefirst step would be to link the departments of inspection, prevention, rehabilitation
and compensation and encourage information-sharing practices.
The project addresses the setup of joint processes and procedures that include the exchange of information, coordination, planning and provision of services by
the relevant institutions of the L&HRD in the field of health and safety at the workplace. This requires the integration of PESSI into project, since itworks on
rehabilitation and compensation for work accidents. A joint strategy for change can lead to reduced treatment & compensation costs thus improving labour standards
while simultaneously increasing profits. Moreover, it is important to support the L&HRDon the development and monitoring of KPIs to observe progress and impacts
regarding the provision of services.
This coordinated effort aims to increase the ownership of the various actors for the overall process. The participants will learn about the experiences of other
countries in the field of labour inspection and learn about different models for the design of effective labour inspection systems. The importance of preventive
measures in the area of occupational safety and health is illustrated using practical examples from the production sector.
Support for private sector actors
This field of activity aims to help private sector achieve compliance with labour standards, while simultaneously boosting productivity. It enables partner
companies to use dialogue-based methods in their companies as instruments for change in their managements that strive to both boost productivity and improve
labour standards.
The concept of Dialogue for Compliance is a platform where people from different departments and hierarchal positions come together. Theypromoteproblem-solving
skills and enhance cooperation.It mainly focuses on the communication between the management and factory workers.
To this end, joint workshops, training courses, coaching sessions and ongoing process support are carried out. Here too, the different needs of female and male
workers, identified by conducting company audits, are taken into account. This could involve training courses for women to qualify them for higher quality jobs
or communication courses to strengthen their negotiation position in workers’ councils. This methodological approach highlights the aspect of the interrelationship
between improved labour standards and the boost in productivity and in turn, the mutual benefits for both the management and the workers. The new practices are
implemented as models in various subsectors (e.g. spinning mills, weaving mills and manufacturers of knitted goods, dye works and sewing rooms) and different
types of companies (e.g. original equipment manufacturers or suppliers, medium sized companies or large companies) in order to incorporate the incentive-oriented
Dialogue for Compliance in the value chain.
A focus is on adapting the Dialogue for Compliance to informal economies & home-based workers. The results of the interventions of selected companies are
compiled as business cases in the form of cost-benefit analyses. These are also used to create materials that can in turn be used by labour inspectors or
SAA-CIWCE, for example, to increase the acceptance of labour standards. Furthermore, local multipliers are qualified for the use of the Dialogue for
Compliance, in order to scale up its dissemination in the industry. The aim is to enable local institutions to offer the dialogue-based method autonomously
as a service demanded by companies. This can be considered as one of the sustainable exit strategies of the project.
Water Efficiency in the Textile Industry (WETI)
The objective of the Water Efficiency in the Textile Industry project revolved around the capacity development of the relevant government institutions and to provide
advisory services to the textile industry. This was done by highlighting the potential economic benefits, which companies can reap by implementing water efficiency
measures. These practices lead to efficient use of water resources, which enhance their resilience to climate-induced water scarcity.
The GIZ conducted the project on the grounds of dialogue and knowledge sharing. The aim was to emphasise on the profits yielded from investments in efficient
water-saving techniques.
A learning culture in the selected companies was established by conducting trainings and by providing mentoring services. The company staff worked on collectively
identifying the challenges and establishing targets leading to solutions.
Another integral facet of the project was to assist the government in defining measures to enhance water efficiency in the textile and garment industry. Dialogue
played a pivotal role here as well as all the stakeholders that included the private sector companies and the governmental institutions collaborated together with
a common objective. GIZ supported all partners in establishing a solid cooperation system that catalysed the implementation of the action plan developed on a
provincial level.
GIZ worked on supporting the development of good practices for efficient use of water and water-water disposal. Tools like capacity development, dialogue and
networking and e-learning systems were utilized for achieving the purpose.
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