Introduction:

My name is Hassan Raza. I am student of BS Mechanical Engineering from UET Lahore.

Previously, I passed my intermediate exam with 89% marks under the supervision of
“Punjab College, Faisalabad” as well as I passed my matriculation with 86.7% marks from
“The Educators Al-Qadir campus”, Faisalabad. Moreover, I am also familiar with MS Word,
MS Power Point, MS Excel, AutoCAD and Solid works. Due to the importance of exposure
of practical work, PEC requires that every student must go to any industry for at least six
weeks and analysis how technical knowledge can be used in industry. That’s why I
searched it and got it. I tried my best to collect the valuable information and its relevant
facts and this report is also result of my internship with Crescent Textile Mill Faisalabad.

Crescent Textile Mills is a Faisalabad based textile unit. The foundation stone of The
Crescent Textile Mills was Laid by Mr. Muhammad Shafi on May 01, 1950. His leadership
qualities make Crescent Textile Mill able to start their products in international market. In
1956 Crestex started to export most of its products to USA, Japan, Europe, Middle East.
In 1958, Crescent Textile Mills was converted into a public limited company. After the
death of Muhammad Shafi, Muhammad Anwar and Muhammad Nasir shafi took over the
charge of the Crestex. Also, the enormous contribution of of Mr. Muhammad anwar
towards textile industry has been acknowledge by Pakistan Federation of chambers of
commerce and industry in the form of most prestigious award “Business of the year” in
1987-1988, 1993-1994, 1994-1995. And Now Crescent Textile Mills has seven
independent complete units of spinning, one separate unit of towel & one complete unit
of garments. Crescent Textile Mills has one of the largest textile-processing units with a
capacity of 2.5 million meters fabric monthly. CTM exports more than 80% of its products
and remaining they sell in the local market. Crescent Textile Mills is playing a vital role in
the development of Pakistan specially by earning a huge foreign exchange through
exports.
The electricity consumed by Crescent Textile Mills is produced by its own power station
located within the boundary of Crescent Textile Mills. All spinning, weaving, towel,
processing and garment units are located within the same boundary. The total no of
employees is more than 5000 from which 2000 employees are staff and on permanent
basis. Factory runs complete 24hrs a day.

Main products of CTM are yarn, Gray-cloth, bed sheet, fabric etc.
It sells two types of Yarns One is Cotton Yarn and other one is Poly-cotton Yarn.
Also, it sells different Fabric products such as Printed Fabric, Dyed Fabric, Bleached fabric.
Workplace learning:
In Crestex, I take training related to Mechanical Engineering. In this regard, I visited 4
main sections of the factory, which are as below:
 Power Generation plant
 Boiler house and Water Treatment plant
 Mechanical Workshops
 Compressors and chiller house

Man:
A proper training should be given to the employees and the workers to enhance their
skills to increase their productivity and ultimately of the company. All the duties and
responsibilities of the employees and the workers are clearly defined. Crestex employees
enjoy a better workplace environment than other industries. All the employees (from
workers to managers) are very co-operative. Their working schedules are well defined
and they obey the schedule. They have a fixed break for lunch and Prayer of Zohar from
1:00 to 2:00. This rest of an hour increase the workability of worker and refresh them for
rest of time.
In Power Generation section, I met Engr. Azhar Iqbal, Engr. Mr. Ali Akbar and Mr.
Munir Ahmad.
In Boiler house & Water treatment plant, I met Engr. Muhammad Zafar, Engr.
Muhammad Khalid and Engr. Muhammad Ashraf.
In Compressor & chiller house, I met Engr. Muhammad Iqbal and Mr. Muhammad
Sohaib Anwar.
In Mechanical Workshops, I met Engr. Hassan Sarfraz, Engr. Ali Hussain, Mr.
Muhammad Mansoor, Mr. Nazir, Mr. Abdul Wahid, Mr. Abdul Qayyum, Mr.
Khalid Ali.

Method:
In Power Generation section, Electricity is produced by burning fuel (HFO, Diesel &
Gas) in 4 stroke IC engines. Fuel is burnt in the IC engines, which rotate the crankshaft
and crankshaft is coupled with the alternator dynamo. In alternator, which dynamo is
rotated, there is a variable electric flux produced, this cause to production of EMF across
the terminals of stator coil.
In Power Generation plant, there are 8 engines in power generation plant, from which 3
are working. The specifications of engines are as follow:
Sr. Company Name Power Capacity Fuel Status
No.
1 Wartisla 1.5 MW Diesel Stand by
2 Wartisla 1.5 MW Diesel Stand by
3 Wartisla 1.5 MW Diesel Stand by
4 Wartisla 6.0 MW Gas Working
5 Wartisla 6.0 MW Gas Working
6 Wartisla 4.0 MW Diesel + HFO Stand by
7 Wartisla 4.0 MW Diesel + HFO + Gas Working
8 Wartisla 1.5 MW Diesel Off
Table 1: Specifications of IC Engines in Power Generation Plant of Crescent Textile Mills.

The efficiency of IC engines is boosted up by use of turbocharger, which supply

compressed air with appropriate pressure and volume to the engine.
The hot exhaust gases are used to generate steam after leaving the engine in the boilers
which are located outside the engine room. Hot exhaust gases generate about 5-7 tones
steam per hour.
In Boiler House and Water treatment plant, there are 2 RO plant (one of 35 cubic
meter per hour and other one with a capacity of 70 cubic meter per hour), 4 filtration
plants, 3 water softening plants and 2 boilers with a capacity of 15 tones per hour steam
production each. One oil heater is also available in this section. One boiler is in working
condition and other one is stand by. One boiler is dual fuel (HFO + Gas fired) and other
one is coal fired boiler.
In Compressor & chiller house, there are 5 compressors (3 small screw type
compressors and 2 main impeller type compressors) and 3 chillers.
In compressors, air is sucked from the atmosphere and filtered by 3 microns. This air is
sucked in the first stage of compressor, which compressed the air and temperature is
raised up (~150oC). The hot compressed air is then passed through intercooler, where
its temperature becomes low (~40oC), then this air passes through second stage and
intercooler and in similar way through third stage and then it reaches at a pressure of 7
bar. This pressurized air is then sent to storage tank and then after drying, it is sent to
concerned department for its application in various machines.
In chillers, there are three cooling towers of capacity of 750 tone per hour each. Which
helps to operate Centrifugal Chiller, whose capacity is 560 tone per hour. it is mainly
consist of Compressor and Evaporator. It can cool water up to 10 C. This cool water is
used in Spinning Unit in the production of supreme Quality Yarn.
In Mechanical workshops, there are five section.
In carpentry shop, wood is used to make different thing like Switch Boards.
In foundry shop, different part is casted. First, mold of the part is prepared by green
sand, then the mold is hardened by heating and then molten metal is poured in the mold
cavity to get required casted part. This casted part is then machine to get actual sizes.
In machine shop, there are numerous lathe machine, 2 universal milling machine, 2
shaper machines and one planer machine. These machines are used to cut the additional
material from the casted workpiece and made its sizes perfect. The cutting tool in this
shop are of HSS, Tipped tool.
In machine shop also there is a separate section of fabrication where workers can repair
gears and produce different structures.
Fifth section in Machine shop is Welding and Cutting section in this section workers
bend sheets in different shapes and weld them. In this section we are using two types of
welding one is Electric arc welding which is used mostly for Thick and Ferrous materials
and second one is gas welding which is used for thin and non-Ferrous materials. In gas
welding we mostly use mixture of Acetylene and oxygen as a fuel.

Material:
For power generation plant, raw material is the fuel of IC engine which consists of Diesel,
HFO and Natural Gas. And great amount of water is also used to moderate the
temperature of IC engines.
Ground water is used as raw material in BH & WTP along with fuel. Ground water is first
filtered and then purify by RO process and then feed to boiler or where it needs.
In mechanical workshops, different metals like SS, GI, MS and cast iron is used to make
different machine elements.
Also in Colling towers and water treatment plant different type of chemicals are used to
avoid scaling and algae etc

Environment:
Environmental considerations are now becoming vital factors during the selection of
consumer goods including textiles all over the world. However due to increased
awareness of the polluting nature of textiles effluents, social pressures are increasing on
textile processing units.
Due to very high temperature in processing unit, it is very difficult to work in hot and
moist environment therefore there should be proper ventilation system. It is very
important for the ergonomics of workers.
Exhaust fans should be place above the machine/steamer to reduce the heat. There
should be air suction system to reduce the lint particles and fluff in grey department,
which cause breath problem for workers.
The waste gases and waste water should be retreated to keep environment clean save
the sources. The textile chemical processing plays an important role in controlling the
pollution load for environment. Because the textile industry has long recognized that, for
a large number of process and applications, the surface properties are a key aspect of
the product and often need to be quite different from those of the fabric bulk.

SWOT Analysis:
Strength:
Main strength of any industry is its Laboure. If they are loyal to company, company can
work well otherwise it becomes a challenge for that firm. Without loyal workers a
company can never be flourished and alhamdullilah crescent has loyal Laboure. They
have potential to face the challenges. Crestex gain their loyalty by his positive attitude.
It treats them like a family. It pays them on time which force workers to work with loyalty
and also worker of Crestex are as old as Crestex only because of its Family like treatment.
Second most important factor that effects any company is source of Electricity. Electricity
provided by government of Pakistan is very costly due to internal issues of Pakistan that’s
why most of the companies have their own power generation system like Crestex. It has
eight power full engines it can generate more then enough energy. It has backup engines.
It can use three means of power.
 Power from Furnace oil
 Power from Natural Gas
 Power from FESCO
Means if he founds that cost of HFO is high then they have backup Engines he can use
Engines which can use Natural Gas as a fuel and if they found both the means costly,
they can use power supply of FESCO. In short, they have many means to maintain the
cost of their products.
Also, Crestex have latest machines that’s why it can produce fine qualities yarns and other
items such as bad sheets, Fabric etc. Due to this specialty, Crestex becomes the name of
quality in Pakistan and outside the Pakistan.

Weakness:
In Crestex, you can observe that after Shifting of power loams most of engines of Power
generation, boilers of Boiler House, lath Machines on Machine Shop, Cooling Towers of
Chiller house and Compressors of Compressor house are on stand by conditions which is
strength of Crestex that it has extra power but due their stand by condition Crestex has
to supply energy to them. Crestex need to use Heat exchangers to Maintain their
temperature which increase the cost of their product which is hazards for Crestex because
day by day saturation in international market is increasing and if your product cost is
more you can’t get enough margin from products.
There is no well arrangement of training of workers mostly they learn from their
experience and from their officers. This results in wastage of time and production.
Some of workers in Crestex thinks that they are competent and they are not rewarded
according to their skill they also think their pay is not according to their work. They think
that their heads are not competent.

Opportunities:
As, I mentioned above that crescent has capacity to generate extra power which can
becomes opportunity for Crescent Textile Mills because now it can install more machines
in spinning and blowing room in short it can only increase its production without spending
money on accessories, he has to buy only necessary production machines.

Crestex is internationally ISO-9002 certified company so it has a chance to increase &

expand business all over the world.

Crestex has experienced workers and also its machines in processing room and spinning
room are latest which helps him to generate supreme quality products

Anti-dumping duties in European market are overdrawn, so the chance is to increase the
export as compared to last years.

Devaluation of rupee made Pakistani export more acceptable to the foreign buyers. There
is a chance to compete better now.
Threats:
Crestex has main problem is that all its workers are as old as Crescent and also they are
loyal and experienced but they are know grown old and they are about to retire and if at
once Crestex lost most of its experienced workers definitely it will effect its production
because new worker are not as much train.

It has been seen that many other groups in Pakistan have entered in competition with
Crescent Textile Mills. If they will not be competed well, there is a chance that they can
get share of export from foreign buyers.

Crescent textile mill has its own power house to fulfil the needs of energy. In power
house energy is produced by heavy generator. They are operated by fuel like HFO,
Natural gas and Diesel oil. Fuel prices are increasing day by day. Which creates a serious
problem for Crestex to maintain its production cost
Due to energy crises in Pakistan most of the forgoing investors invests in India and
Bangladesh and in this situation, it is very difficult for Crescent textile mills to install more
loams in processing room.
In Chiller room, condition of cooling tower is worse. There are three chillers but only one
is functional which is also not able to work well. If Crestex doesn’t take any action on this
problem, soon it has to face the Consequence

Suggestions:
As, I mentioned in weakness section that machines in Crestex are more then his need
and also, he has to spent money to maintained them and also, they have to operate other
machines to maintain them in stand by condition. According to my opinion Crestex think
to sold these extra machines and also some times cost of HFO increases and sometimes
Nature Gas becomes the cause of increasing the cost of their product they have to think
about shifting of Power generation system from generators to solar panels they are less
complicated and Crestex have to Spent less funds to maintain them and it requires no
fuel to operate which becomes the cause of increment in margins of products.
Second Weakness that I discussed is unawareness of workers which can be resolve by
arranging seminars in Crestex. These seminars can create awareness about their
responsibilities in workers. We have to pay them according to their duties. If you give
them permanently fix pay it makes them un -responsible they starts to think that they
will get pay whether they serve Crestex or not.