INDUS INSTITUTE OF HIGHER EDUCATION.

M.B.A – IV (EVENING)

• SUBJECT : BUSINESS RESEARCH

SUBMITTED TO: MR.

PROJECT:

RESEARCH PROPOSAL
Proposal to study on Steam consumption

• SUBMITTED BY:

ZAHOOR AHMAD.

TABLE OF CONTENTS
Acknowledgment .............................................................................. .1
Executive summary................................................................................2
Problem statement ...................................................... 3
Project goals.....................................................................................4
Project time line.............................................................................5
Motivation....................................................................5
Back ground..............................................................................................6
Introduction of Liberty Textile
mills...........................................................................................6
Types of energy used in textile
industry..............................................................................................8
Progress in relative
field...............................................................................................10
Importance of
Boiler.......................................................................................13
Identification of problems and its
justification...........................................................................14
Research method.....................................................................................15

INDUS INSTITUTE OF HIGHER EDUCATION

 PROJECT PROPOSAL

ACKNOWLEDGEMENT:
“The hardest steel goes through the hottest furnace”

The same was the case with us. We faced many problems when we started the work

on Report. There was no any information about our research. But, we are greatly

thankful to Al Mighty Allah for enable us to get successfully through our

Responsibilities.

Very warm and special tanks to our respected teacher “Mr.Rana Tariq”

We also thank to

DYEING HOUSE MANAGER “BABAR KHAN”

ALL DYEING MANAGERS

ALL SENIOR MACHINE CHEMIST

And all whole technician of “LIBERTY TEXTILE MILLS”.

Who gives us a lot of information and pay full attention? And give real dedication

and devotion kindly for us.

Sir we thank full yours ability of extracting the very best out of us. For your

Patience and perseverance, and also for acknowledgement the efforts made by us

during the whole semester.

Thank you sir, God Bless You

INDUS INSTITUTE OF HIGHER EDUCATION

 PROJECT PROPOSAL

EXECUTIVE SUMMARY

INDUS INSTITUTE OF HIGHER EDUCATION

 PROJECT PROPOSAL

Problem Statement

The purpose of this proposal is to outline the need for a project that analyze the

Use of steam in textile industry. This project will seek answer the following

Question.

• What is the use of steam in textile?

• How can we reduce the steam consumption during process?

• Is this step can able to cut down the cost of production?

INDUS INSTITUTE OF HIGHER EDUCATION

 PROJECT PROPOSAL

PROJECT GOALS

The result of this project will be suggest to reduce the production cost by reducing

Consumption of steam by use of better steam management and technology.

INDUS INSTITUTE OF HIGHER EDUCATION

 PROJECT PROPOSAL

PROJECT TIME LINE

The project will be completed according following schedule,

Initial research complete 2nd Class

Follow up research 3rd Class

Interviews/Questioner Completed 4th To 8th Class

Analysis of date completed 9th and 10th Class

Final report draft 11t Class

Final presentation submit 12th Class

INDUS INSTITUTE OF HIGHER EDUCATION

 PROJECT PROPOSAL

MOTIVATION:
Textile industry has a lion share in export of Pakistan, and these days in industry in

Troubles Because of high energy charges, in addition shortage of electricity , gas,

and water have depend the problem. Exports are also suffering due to high

Production cost then other competitor’s countries.

As we know that steam is one of the main source of dyeing and printing process and

Generate by gas and water through boiler.

 INDUS INSTITUTE OF HIGHER EDUCATION

PROJECT PROPOSAL

BACK GROUND:

This conservation of energy is an essential step we can all take towards overcoming

the mounting problem of the world wide energy crises and environment

degradation.

In particular, developing countries are interested to increase their awareness on the

inefficient power generation and energy usage in their countries. However, usually

only limited information sources on the rational use of energy are available,\.The

know-how on modern energy saving and conservation technologies should ,

therefore , be disseminated to governments and industrial managers, as well as to

Engineers and operators at the plant level in developing countries. It is particularly

important that they acquire practical knowledge of the currently available energy

conservation technologies and techniques.

 INDUS INSTITUTE OF HIGHER EDUCATION

PROJECT PROPOSAL

INTRODUCTION OF LIBERTY TEXTILE MILLS

Liberty Mills Limited, located in the industrial heart of Karachi, Pakistan,

was established in 1964. From humble beginning it is today one of the

largest textile processing and production unit in Karachi, Pakistan with a

production capacity of about 500,000 square meters of fabric per day. The

whole production is exported directly and indirectly to customers which

include vendors of internationally recognized brands, departmental stores

and mail order firms.

Liberty Mills Limited is an ISO 9001:2000, OE 100 and OEKO TEX Standard

100 Certified companies. Upgrading the quality of our products and

services, personnel, equipment and infrastructure is an ongoing feature of

our operation.

INDUS INSTITUTE OF HIGHER EDUCATION

 PROJECT PROPOSAL

TYPES OF ENERGY USED IN THE TEXTILE INDUSTRY

In general , energy in the textile industry is mostly used in the forms of

electricity, as a common power source for machinery, cooling and

temperature control system , lighting office equipment , etc; oil as a fuel for

boilers which generate steam; liquefied petroleum gas; coal ; and city gas.

Table 1 compares the energy consumption shares of various specialized

technical fields and it can be seen that energy consumption is relatively

high in the fields of dyeing and finishing ,fiber production , spinning,

weaving and clothing manufacturing.

INDUS INSTITUTE OF HIGHER EDUCATION

PROJECT PROPOSAL
 Specialized Technical Shar
Fuel Electricity Total
Field e

32,55
Fiber production 21,498 54,049 21.0%
1

Spinning 3,224 44,262 47,480 18.4

Twisting 219 1,660 1,879 0.7

Textured-yam production 120 1,543 1,663 0.6

Weaving 4,467 24,848 29,315 11.4

Knitting 4,059 11,709 15,858 6.1

37,66
Dyeing 28,412 66,073 25.0
1

Clothing manufacturing 8,240 15,420 23,660 9.2

Others 5,959 12,000 17,959 7.0

96,50 257,94
Total 161,442 100.0
0 2

Note: Calculated from the Tabulated Industrial Statistics (Industry Volume)

INDUS INSTITUTE OF HIGHER EDUCATION

 PROJECT PROPOSAL

In 90’s UNIDO organized a Regional Meeting on Energy

Consumption as well as an Export Group Meeting on Energy Conservation in small

and medium scale industries for Asian countries. During these meetings , it was

Brought out that, for some energy intensive industries , saving up to 10% could be

Achieved through basic housekeeping improvements,

Such as auditing and energy management. The rational use energy calls for a broad

Application of energy conservation technologies in the various industrial sector

Where energy is wasted. One of these energy intensive industrial sectors to be

Consider to improve efficiency through the introduction of modern energy

Conservation technologies is the textile industry.

“In the textile industry, appreciable amount of energy could be saved or conserved

By regulating the temperature in the steam pipes , adjusting the air/fuel ratio in the

boilers, and installing heat exchangers using warm waste water.”

Currently, UNIDO, with the financial support of Japanese Government, is carrying

out a regional programmed on the promotion and application of energy saving

Technologies in selected Asian developing countries. This program aims at

adopting

these innovative energy conservation technologies, to the conditions of develop

countries. In this programmed, we are considering that the transfer of these

technologies could be achieved throgh

INDUS INSTITUTE OF HIGHER EDUCATION

 PROJECT PROPOSAL

A: Conducting surveys of energy usage and efficiency at the plant level.

B: Preparing manual on energy management and energy conservation / saving

Technologies, based on the findings of the above surveys;

C: Presenting and discussing the manual at seminars held for government

officials, Representatives of industries, plant managers and engineers;

D: Disseminating the manuals to other developing countries for their proper

utilization and application by the industrial sector.

INDUS INSTITUTE OF HIGHER EDUCATION

PROJECT PROPOSAL
IMPORTANCE OF BOILER
As we know steam generate by boiler. Water, gas and electricity are the main raw

material of steam. If boiler is working efficiently there raw material use in very

Uncomely than generation of steam and if boiler is not work effecienlly their steam

Generation process become costly because heavy amount of gas and electricity use

During this process and amount of steam generate very pour. So, role of boiler and

Selection of boiler play a very important role in conservation of energy.

INDUS INSTITUTE OF HIGHER EDUCATION

 PROJECT PROPOSAL

PROBLEM IDENTIFICATION

During visit of “LIBERTY TEXTILE MILL” we discover that steam waist on

Following ways;

PROBLEM:

1: Steam lines are not in proper ways.

JUSTIFICATION:

If we re-arrange the steam lines we can reduce the wastage of steam.

PROBLEM:

2: High neglected attitude of machine staff concern steam line leakage.

JUSTIFICATION:

If machine staff inform about leakages it will be control.

PROBLEM:

3: Mechanical and electrical staff attitude also seems be very negative.

JUSTIFICATION:

Maintenance staff works with loyalty. It can be helpful to minimize the leakage.

INDUS INSTITUTE OF HIGHER EDUCATION

PROJECT PROPOSAL
PROBLEM:

4: Sensor and actuating valve often not working properly.

JUSTIFICATION:

Sensor and actuating valve should be monitor because it control over all steam

consumption.

PROBLEM:

5: Fabric moisture is less than required moisture.

JUSTIFICATION:

We can reduce steam consumption, if we put dryer temperature according

fabric.

PROBLEM:

6: Water chamber temperature also more than required temperature.

JUSTIFICATION:

We can also reduce steam consumption by putting water chamber temperature

according manually.

INDUS INSTITUTE OF HIGHER EDUCATION

PROJECT PROPOSAL
RESEARCH METHOD
We did our research by filling questionnaire to the employees of “LIBERTY

TEXTILES MILLS” (Dyeing unit) .We categories our questionnaire sample in 3

Categories. The Question mode of questionnaire is investigative.

1: TOP LEVEL MANAGEMENT

We get filled 7 questionnaire sample by dyeing house manager , dyeing manager,

And assistant dyeing managers.

2: MIDDLE LEVEL MANAGEMENT

We get filled 17 questionnaire sample by supervisor and senior machine chemist.

3: LOWER LEVEL MANAGEMENT

We get filled 16 questionnaire sample by machine chemist and assistant machine

Chemist.
Question -1

Ever the company study on the wasta

Management Level

Top Management

Middle Management
Lower Management
Total
Question -3

Management is satisfied with the des

Management Level

Top Management

Middle Management
Lower Management
Total
Question - 4

Ever you realized that company need

in use

Management Level

Top Management

Middle Management
Lower Management
Total
Question -5

If company studded on it so, manage

Management Level

Top Management

Middle Management
Lower Management
Total
Question - 6

Have the system is implemented

Management Level

Top Management

Middle Management
Lower Management
Total
Question - 7

Interest of company to improve boil

Management Level

Top Management

Middle Management
Lower Management
Total
Question - 8

Trend of management about trainin

Management Level

Top Management

Middle Management
Lower Management
Total
Question - 9

Management supplies of related mate

on steam

Management Level

Top Management

Middle Management
Lower Management

Total
 Question - 10

Machine staff is informed about less

Management Level

Top Management

Middle Management
Lower Management

Total
Question -11
Logbook/history data is maintaining for individual machine on daily basis and it is shared
with all concerned.

All the Some Never No Idea

Management Level Time Time
Top Management 7

Middle Management 7 10
Lower Management 4 12

Total 18 22
 25

20

15

10

0
A ll th e T im e S o m e T im e Ne v e r No Id e a

CONCLUSION: 45% says all the time, while 53% says some time

Question -12
Appraisal or punishment system to staff is existing and implementing

All the Some Never No Idea

Management Level Time Time
Top Management 7

Middle Management 1 16
Lower Management 16

Total 1 39
 45

40

35

30

25

20

15

10

0
A ll th e T im e S o m e T im e Ne v e r N o Id e a

CONCLUSION:97% employees says never know while only 2.5% says all the time.

Question -13
Company staff having technical skills
 All the Some Never No Idea
Management Level Time Time
Top Management 7

Middle Management 12 5
Lower Management 10 4 1

Total 29 9 1

35

30

25

20

15

10

0
A ll th e T im e S o m e T im e Ne ve r N o Id e a
CONCLUSION: 72.5% all the time while 22.5% are some times.

Question -14
Machine staffs are aware about the moisture required for different fabric on
different process.

All the Some Never No Idea

Management Level Time Time
Top Management 5 2

Middle Management 7 10
Lower Management 4 7 3 2

Total 16 19 3 2
 20

18
16

14
12
10

8
6

4
2
0
A ll th e T im e S o m e T im e Ne v e r N o Id e a

CONCLUSION:40% says all the time,47.5% says some time,7.5%says never and
5%don’t know.

Question -15

Machine staffs are aware about the temperature of different areas of machine
required for different process.

All the Some Never No Idea

Management Level Time Time
Top Management 7

Middle Management 17
Lower Management 15 1

Total 39 1
 45

40

35

30

25

20

15

10

0
A ll th e T im e S o m e T im e Ne v e r N o Id e a

CONCLUSION:97.5%employees agree to alla the time while 2.5% say never

Question -16

Existing staff is capable to handle the issues and complaints about the steam
leakages.
 All the Some Never No Idea
Management Level Time Time
Top Management 7

Middle Management 17
Lower Management 15 1

Total 39 1

45

40

35

30

25

20

15

10

0
A ll th e T im e S o m e T im e Ne ve r N o Id e a

CONCLUSION: 97.5% employees agree to all the time and 2.5% says never.
Question -17

Response of machine staff if any error is formed in parameters.

All the Some Never No Idea

Management Level Time Time
Top Management 7

Middle Management 4 13
Lower Management 6 10

Total 10 30
 35

30

25

20

15

10

0
A ll th e T im e S o m e T im e Ne v e r N o Id e a

CONCLUSION:25% employee agree to all the time , while 75% says some time.

Question -18

Yours efforts are apprized by the management for the process

All the Some Never No Idea

Management Level Time Time
Top Management 4 2 1

Middle Management 1 6 10
Lower Management 2 14

Total 5 10 25
 30

25

20

15

10

0
A ll th e T im e S o m e T im e Ne ve r N o Id e a

CONCLUSION:12.5% says all the time , 25% says some time while 62.5% agree to
never.

Question -19

Supervisor’s trend for feed book of employee/machine staff how they are
performing towards achieving the result expected
 All the Some Never No Idea
Management Level Time Time
Top Management 3 3 1

Middle Management 2 14 1
Lower Management 1 9 6 3

Total 6 26 8 3

30

25

20

15

10

0
A ll th e T im e S o m e T im e Ne ve r N o Id e a

CONCLUSION:15%employee agree all the time , 65% say to some time while 20%
says to never.
Question -20

They monitor the safety valves

All the Some Never No Idea

Management Level Time Time
Top Management 7

Middle Management 10 7
Lower Management 2 1 13

Total 19 1 20
 30

25

20

15

10

0
A ll th e T im e S o m e T im e Ne v e r N o Id e a

CONCLUSION: 47.5% employee agree to all the time 50% don’t know while 2.5%
says never.