UNIVERSITY OF DAR ES SALAAM

COLLEGE OF ENGINEERING AND TECHNOLOGY (CoET)

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING

TX 499: FINAL YEAR PROJECT

PROJECT TITTLE: ASSESSMENT OF TEXTILE ENVIRONMENT AND SAFETY

CONDITION AT FRIENDISHIP TANZANIA-CHINATEXTILE MILLS

PROJECT NUMBER (TX16-15-4)

YEAR OF STUDY (2015/2016)

STUDENT NAME: MWAISANILA, LAURENT

REG NO: 2012-04-02042

DEGREE PROGRAMME: BSC. IN TEXTILE DESIGN AND TECHNOLOGY

SUPERVISOR: DR. M.H. MRANGO

i

ABSTRACT

This project is about assessment of textile environment and check if they meet the standard

regulation required for health and safety. For that comparative study it comprises the following

parameters dust and flying particles such as fibres, noise and chemicals. That will be tested

practically by using litmus paper, sound level meter, dust level meter. It includes the general

introduction of manual observation versus instrument testing of those parameters

The collected information will be used make recommendations to the management of each plant

concerning possible implementations healthy and safety of textile industries in Tanzania. Such as

the controlling of dust, noise and chemical that have direct effects to the workers and to the

surrounding environment

Occupational safety and health administration (OSHA) is a cross-disciplinary area and it is

concerned with guarding the safety, health and welfare of people who are engaged in work or

employment.

Health is associated to the physical conditions of both mind and body, of all people at the workplace

including the workers, contractors and visitors, and their protection from harm in the form of injury

or disease.

Safety is related to the physical condition at the worksite and applies to a state where the risk of

harm and damage has been removed or reduced to a tolerable level. And the protection of

environment is comprised of usually two types. First is the internal environment at the workplace

and it is related to overall condition in the workplace. Second are the harmful conditions which are

present in the external environment outside the workplace (Towlson 2003).

ii

ACKNOWLEDGEMENT

First and foremost, praise to the almighty GOD who gave me opportunity to do this project for his

guidance, support, encourage and strengthen me in each and every step of this project. I would

like to thank Department of Mechanical and Industrial Engineering for giving me this chance to

conduct the project concerning assessment of textile environment basing on the standards of dust,

noise and chemical to sort out its effects to the workers.

Secondly, I thank my supervisor Dr. M.H.Mrango for his valuable advices; assistance in proof-

reading the project and availability in orientating me when things could not break through are highly

appreciated.

I would also like to thank Dr. M. Lughano for giving me an opportunity of using their instrument

sound level meter and MicroDustPRO and his assistant for assisting me during project parameters

measurement dust and noise at Friendship Tanzania-China Textile mills. And thanks to FTC textile

mills for giving an opportunity to conduct the project at their company

Lastly, I present my attitude to all individuals that have unconditionally assisted me in any way to

achieve this project and Dr.M.H.Mrango with his panel for their advice and suggestions.

Finally, but not the least I appreciate the support given to me by my family who spent a lot of time

to give me courage and advise.

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TABLE OF CONTENTS

ABSTRACT ......................................................................................................................................................... i

ACKNOWLEDGEMENT ..................................................................................................................................... ii

TABLE OF CONTENTS ...................................................................................................................................... iii

LIST OF TABLES ............................................................................................................................................... vi

List of figures ................................................................................................................................................. vii

1. CHAPTER ONE ............................................................................................................................................. 1

1.0 INTRODUCTION ......................................................................................................................................... 1

1.1 Background of the project .................................................................................................................... 1

1.2 Problem statement. .............................................................................................................................. 1

1.3 Project objectives .................................................................................................................................. 2

1.3.1 Main objective ............................................................................................................................... 2

1.3.2 Specific objective ........................................................................................................................... 2

1.4 Study questions ..................................................................................................................................... 2

1.5 Significant of the project ....................................................................................................................... 3

1.6 Scope of the project .............................................................................................................................. 3

2. CHAPTER ..................................................................................................................................................... 4

2.0. LITERATURE REVIEW ................................................................................................................................ 4

2.1 Ginning and Spinning process ............................................................................................................... 4

2.1.1 Cotton mixing ................................................................................................................................. 5

2.1.2 Blow room ...................................................................................................................................... 5

2.1.3 Carding ........................................................................................................................................... 6

2.1.4 Draw frame .................................................................................................................................... 7

2.1.5 Roving frame or simplex. ............................................................................................................... 8

2.1.6 Ring frame ...................................................................................................................................... 8

2.1.7 Winding machine or Auto corner................................................................................................... 9

2.2. Fabric production ............................................................................................................................. 9

2.2.1Warping ......................................................................................................................................... 10

2.2.2 Sizing ............................................................................................................................................ 10

2.2.3 Drawing in .................................................................................................................................... 11

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2.2.4 Tying in or knotting ...................................................................................................................... 11

2.2.5 Weaving process .......................................................................................................................... 11

2.3 Finishing process ................................................................................................................................. 12

2.3.1 Singeing ........................................................................................................................................ 12

2.3.2 Desizing ........................................................................................................................................ 12

2.3.3 Scouring........................................................................................................................................ 12

2.3.4 Bleaching ...................................................................................................................................... 13

2.3.5 Mercerization ............................................................................................................................... 13

2.3.6 Dyeing and printing process......................................................................................................... 14

2.3.7 Finishing. ...................................................................................................................................... 15

2.3.8 Instruments used to measure noise, dust and flying particles, and chemicals ........................... 15

3. CHAPTER ................................................................................................................................................... 23

3.0 METHODOLOGY ...................................................................................................................................... 23

3.1 Literature review ................................................................................................................................. 23

3.2 Research survey .................................................................................................................................. 23

3.3 Industrial testing ................................................................................................................................. 24

3.3.1 Noise level .................................................................................................................................... 24

3.4. Dust and flying fibers emission measure ........................................................................................... 32

3.4.1. MicroDust PRO ............................................................................................................................ 32

3.4.2. DATA COLLECTED ........................................................................................................................ 33

TBS (Tanzania Bureau of Standard), IFC (INTERNATIONAL FINANCE CORPORATION), WHO (WORLD

HEALTH ORGANIZATION) ...................................................................................................................... 38

3.5. Chemical measure .............................................................................................................................. 38

3.5.1 After risk assessment, the following actions should be taken to eliminate or control the

identified risks: ..................................................................................................................................... 38

3.5.2 Operation procedure on how to use pH meter ........................................................................... 39

3.5.3 pH Meter Calibration ................................................................................................................... 39

3.5.4 DATA COLLECTED ......................................................................................................................... 41

4. CHAPTER ................................................................................................................................................... 42

4.0 RESULTS AND DISCUSSION ...................................................................................................................... 42

4.1 Sound level meter ............................................................................................................................... 42

4.1.2 Spinning section analysis ............................................................................................................. 42

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4.1.3 Weaving section analysis ............................................................................................................. 43

4.1.3 Processing section ........................................................................................................................ 43

4.2. Dust level ............................................................................................................................................ 44

4.2.1. MicroDustPRO ............................................................................................................................. 44

4.2.2. SPINNING SECTION ANALYSIS ..................................................................................................... 45

4.3. WEAVING SECTION ANALYSIS ........................................................................................................ 46

4.4. PROCESSING SECTION ANALYSIS ....................................................................................................... 48

4.5 Chemical discharged to the environment ........................................................................................... 51

4.5.1 METTLER TOLEDO ........................................................................................................................ 51

5. CHAPTER FIVE............................................................................................................................................ 52

5.0 CONCLUSION AND RECOMMANDATION ................................................................................................ 52

5.1 CONCLUSION ....................................................................................................................................... 52

5.2 RECOMMENDATIONS.......................................................................................................................... 52

References .................................................................................................................................................... 54

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LIST OF TABLES

Table 1:Weaving Noise level data ................................................................................................................ 26

Table 2: Finishing weaving Noise level data ................................................................................................ 26

Table 3: Spinning noise level data ................................................................................................................ 27

Table 4: Blowroomg Noise level data........................................................................................................... 27

Table 5: Carding Noise level data ................................................................................................................. 27

Table 6: Ring frame Noise level data ............................................................................................................ 28

Table 7: Cone winder Noise level data ........................................................................................................ 28

Table 8: Pin winder Noise level data ............................................................................................................ 29

Table 9: Warping Noise level data ................................................................................................................ 29

Table 10: Sizing Noise level data ................................................................................................................. 29

Table 11: Mixing Noise level data ................................................................................................................ 30

Table 12: Processing Noise level data .......................................................................................................... 30

Table 13: Processing 1Noise level data ........................................................................................................ 30

Table 14: Printing Noise level data ............................................................................................................... 31

Table 15: Bleaching Noise level data ........................................................................................................... 31

Table 16: Dust data collected ........................................................................................................................ 33

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List of figures

Figure 1.cotton mixing .................................................................................................................................... 5

Figure 2. blow room and plucker .................................................................................................................... 6

Figure 3.Carding process ................................................................................................................................ 7

Figure 4:Draw fame ........................................................................................................................................ 7

Figure 5:Roving frame .................................................................................................................................... 8

Figure 6: Winding process .............................................................................................................................. 9

Figure 7:noise measuring instruments .......................................................................................................... 18

Figure 8: Noise effects .................................................................................................................................. 21

Figure 9: Sample room .................................................................................................................................. 24

Figure 10. MicroDustPRO ............................................................................................................................ 32

Figure 11: METTLER TOLEDO .................................................................................................................. 39

Figure 12. Spinning section noise level data graph....................................................................................... 42

Figure 13: Weaving noise level graph .......................................................................................................... 43

Figure 14: : Processing section noise level data............................................................................................ 44

Figure 15: Spinning reception dust level graph ............................................................................................ 45

Figure 16: Blowroom dust level graph ......................................................................................................... 45

Figure 17: Carding dust level graph .............................................................................................................. 46

Figure 18: Ring frame dust level graph ........................................................................................................ 46

Figure 19: Winding machine dust level graph .............................................................................................. 47

Figure 20: Warping dust level graph............................................................................................................. 48

Figure 21: sizing dust level graph ................................................................................................................. 48

Figure 22: Bleaching dust level graph .......................................................................................................... 49

Figure 23: Printing dust level graph .............................................................................................................. 49

Figure 24: Finishing process dust level graph .............................................................................................. 50

Figure 25: Inspection and packing dust level graph...................................................................................... 50

Figure 26: METTLER TOLEDO .................................................................................................................. 51

1

1. CHAPTER ONE

1.0 INTRODUCTION

1.1 Background of the project

Environmental and human health and safety assessment is the initial stage of Environmental

management system. To improve the quality of life it is a necessity for any textile industries to do

careful assessment both before and during operation. Environmental Health and Safety focuses on

exchange of exchange of know-how regarding health-safety-and safety environmental aspects of a

material; - promotion of good working practices, such as post use material collection for recycling.

According to C. Stephan, Environmental Health and Safety management has two general objectives

Prevention of incidents or accidents that might result from abnormal operating conditions.

Reduction of adverse effects that result from normal operating conditions

For examples, fire, explosion, and release of harmful substances into the environment 0r the

workplace or area must be prevented. Also action must be taken to reduce a company’s

environmental impact under normal operating conditions like reducing the company’s carbon

footprint and to prevent workers from developing work related diseases.

Occupational safety and health administration (OSHA) is a cross-disciplinary area and it is

concerned with guarding the safety, health and welfare of people who are engaged in work or

employment.

Health is associated to the physical conditions of both mind and body, of all people at the workplace

including the workers, contractors and visitors, and their protection from harm in the form of injury

or disease. Safety is related to the physical condition at the worksite and applies to a state where the

risk of harm and damage has been removed or reduced to a tolerable level. And the protection of

environment is comprised of usually two types. First is the internal environment at the workplace

and it is related to overall condition in the workplace. Second are the harmful conditions which are

present in the external environment outside the workplace (Towlson 2003).

1.2 Problem statement.

During twentieth century textile industry focused its energies and resources on product and process

innovations. As a result, phenomenal improvement in product quality was observed. Unfortunately,

little attention was paid to the consequences that the introduction of new chemicals and new

processes might have no ecological balance of the environment and working condition to the

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workers. Thus, by dumping chemical effluents and non-biodegradable material the eco-balance of

nature was disturbed slowly. Textile industry is highly dust, noise flying fibers, water intensive and

major user of toxic chemicals that cause textile industries to be major contributors of environmental

pollution. Textile processes include four stages of production that may include yarn formation,

fabric formation, wet processing, and textile fabrication.

There are numerous non health and safety (H&S) issues associated with the textile industry. These

include: chemical exposure from the processing and dyeing of materials; exposure to cotton and

other organic dusts, which can affect the throat and lungs; musculoskeletal stresses; noise exposure,

which can lead to hearing loss; temperature and ventilation, which can lead to fatigue and

dehydration of temperatures are too high; and working hours and breaks, including access to food,

drinks and bathroom facilities.

1.3 Project objectives

1.3.1 Main objective

To assess textile environment effects and safety condition at Friendship Tanzania - China textile

mills.

1.3.2 Specific objective

To assess amount of dust emitted in spinning, weaving, and process and compare it with the

standard.

To measure the level noise in spinning process and weaving process and compare it with

the standard.

To assess the pH level from textile finishing process and compared with the standard needed

to discharge to the environment.

1.4 Study questions

What measure should be taken to ensure good working environment in textile industries?

What measure should be taken to minimize noise in spinning and weaving process?

What the prevention measures should be taken to minimize dusts and flying particles?

What measure should be taken to minimize dyeing chemicals or pigment for printing that

harm the environment?

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1.5 Significant of the project

This project mainly deals on comparative study on good working environment and the use of good

fabric production process that will consider the health and safety of workers like no or less dust

emission in spinning, weaving/knitting and finishing process that have less or no harm to the

environment. The analysis will focus on the key quality working environment to workers which

will be obtained from the research observation such as interview, questionnaire, and oral interview.

It will also concentrate on determining the ways which will help to improve the good working

environment and methods that emit less dust, noise and chemical those are harmless to the

environment by providing the information to textile mills through email

1.6 Scope of the project

This project provides the actual health and safe working environment in textile industries in

Tanzania and problems associated with working in in non-supportive environment to workers. The

assessment will sort out some of the physical hazards, mechanical hazards, ergonomically hazards,

chemical hazards, physiological hazards as well as suggesting the healthier and safety working

condition for textile industrial workers in Tanzania. The project will have importance to textile

industries of healthier and safety environment improve wellbeing of people working in our

industries by giving the training before they start working, giving them education about safety and

health environment like they must have protective shoes garment and goggles.

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2. CHAPTER

2.0. LITERATURE REVIEW

The hazards happening in the Textile industries are Mechanical Hazards, physical hazards, chemical

hazards, Ergonomic hazards and physiological hazards. Exposure of cotton disease called

Byssinosis. The Symptoms are chest tightness, breaking problem, asthma and irritation in the

Respiratory track. The study tells about the accumulation of workers, improper condition of the

machine, ergonomic problem faced by the worker, dust problems, poor lighting, ventilation and

unaware of personal protective equipment not given Occupational Health and Safety in these

industries. Education is the fundamental right that helps the Growth of nation; education helps the

workers to get knowledge about medical rights, legal and social behavior. Most of people are

uneducated most of them do not know about Occupational Health Safety at workplace. To control

the noise level in the company premises and outside the company necessary action must be taken

and to maintain the quality and production, the consideration safety and health environment of

worker or wellbeing of workers is essential. (Ahmad HO et al.,2001).

The Main cause of noise problem in the weaving and spinning industry is due to the poor design,

overload and old machinery. In industries noise is a big problem that affects the human peace and

increase the stress. The musculoskeletal disorders are caused by continuous work, lifting high

weight, doing job without appropriate procedures. (Tiwari Meenaxi et al.,2012).

2.1 Ginning and Spinning process

The cotton in a machine which is used to separate the cotton fiber from the seeds and the cotton

send to the textile for making yarn. The one of main Hazard in ginning industry is fire, the causes

of fire happens in the Ginning Industry Are Electrical, Manmade Behavior, spark from the Machine

and stored Raw cotton in sunlight and other causes. The hazards happening in the Textile industries

are Mechanical Hazards, physical hazards, chemical hazards, Ergonomic hazards and physiological

hazards. Spinning is the major part of textile industry where fibers are converted into yarns that are

necessary for fabric production and threads. Dusts, noise and flying fibers are the main hazards

occur often in spinning department in textile industries. Also fire hazards in the spinning mills are

more compare to other sectors of textile industry because the raw material cotton exposed to the

fire easily. In spinning major hazard is cotton dust causes many health problems to the workers.

Spinning have the following processes blow room, carding, draw frame, roving frame, roving

frame, ring frame, cone winding.

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2.1.1 Cotton mixing

Figure 1.cotton mixing

Mixing is the term used for the arrangement of various cotton varieties or various grades of same

variety to get a product having all the characteristics of different varieties of cotton. The objectives

of mixing are; Financial reasons that’s why cheaper cotton and cotton waste is mixed with the

upgraded cotton to get better results. For better processing performance of cotton fibers in carding

and roving formation through control of nep level and variation. It also effects on the working

efficiency of ring frame because better mixing results in the form of less variation in yarn count.

Like in spinning it also effect the efficiency of machines used for weaving functions and operations

because fine yarn results in the form of uniform fabric. It also has a contribution in dyeing and

finishing processes. By using different combinations of fibers having different fiber properties

fulfill the requirements of given end use for the spun yarn or the woven fabric to improve physical

properties of cotton such as tensile and tear strength, elasticity, abrasion and shrinkage resistance.

The problem is the environmental condition of doing mixing of cotton in textile industries for the

workers is not supportive because they are doing it by hand, without having the nose mask,

protective garments that approved to worn in doing such kind of the job, goggles, cap or hat that

make them easily to breath the dust air, air moving fibres.

2.1.2 Blow room

A blow room is a section of a yarn production(spinning) factory where opening, cleaning, mixing

and blending of fibres are done to enhance yarn quality. The blow room consists of a number of

machines used on succession to open and clean cotton fibres. Blow room consists of the following

processes that ensure intensive cleaning. Automatic plucker, autoblender with condenser, step

cleaner, unclean B11, multimixer, dustex, pin beater with condenser, scutcher.

6

Blow room is the first department in the spinning process. Raw cotton contains a number of different

impurities which called as “Trash”. These types of impurities are present in cotton such as sand,

soil, dust, whole seed, broken seed coats, undeveloped seeds and broken fragments.

The extraction of dust and trash is reliant on the quantity of fiber individualization, which can be

obtained from the processing of fibers. Most of the impurities are removed in this department while

other ones are removed in next department. About 40% to 70% trash is removed in blow-room

section. The removal of those impurities such as sand soil, micro dust, and flying fibers cause health

risk to workers such as skin diseases, induced hearing loss due to high noise and byssinosis because

of breathing dust and fiber flying and make unsafe working condition to the workers.

Figure 2. blow room and plucker

2.1.3 Carding

Carding involves the disentangling, cleaning and mixing of fibres to produce a sliver suitable for

subsequent processes. The blow room process opens the compressed bales of cotton into small tufts

and also removes 75% trash present in the cotton. Still the cotton has to be opened to individual

fibre state and it must be free of impurities and trash, Elimination of impurities present in cotton

that were not extracted in the previous cleaning departments, removal of the short fibers, opening

of fibers to individual state, disentangling of the neps, fiber blending, fiber orientation, and sliver

formation. up to the maximum possible extent so, the fibre-to-fibre opening and complete removal

of trash is carried out on the card machine. It is therefore rightly said that “Half Carded, Half Spun”

and “Well Carded Well Spun” because it is the process of carding which plays a very important

role in the spinning process and is called as the Heart of Spinning. Also in carding show that there

is intensive cleaning of cotton fiber which means there is micro dust removal, removal of short and

immature cotton fibres this show that the working environment is the same as in blow room and

7

have the same problem that cause unsafe working environment and create health risk to workers

such as skin diseases, induced hearing loss due to high noise and byssinosis because of breathing

dust and fiber flying and make unsafe working condition to the workers.

2.1.4 Draw frame

Draw Frame is a machine on which drawing is done. In this section sliver from card department,

is again processed. For this purpose, two types of passages are done to that sliver with the help of

breaker and finisher drawings. The reason behind these two passages is to make sliver more

uniform, even, dust removal and parallelization of cotton fibers. It contributes less than 5 percent

to the production cost of the yarn but its influence on the yarn quality is enormous. (W. Klein,

1987).

Figure 3.Carding process

Figure 4:Draw fame

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2.1.5 Roving frame or simplex.

A roving is continuous, slightly twisted strand which needs to be further draft and twisted to form

a yarn. The roving frame performs three operations which are twisting, drafting, and winding. But

“Roving frame is known as necessary evil”. The problem is that this machine has many

complications, creating faults which have no solution, increasing production costs, its finished

product is sensitive while using in winding and unwinding operations. Then, why this machine is

still in use?

It has two reasons:

1. As far as the structure of drawing sliver is concerned it is thick and hairy and creates fly during

working. Draft needed to convert this thick sliver into a yarn is 300 to 500 so, it is not possible for

ring machines to make a yarn on this single drafting system that fulfill all the demands.

2. Presentation of feed material to the ring spinning department and draft can signify the worst

conceivable mode of transportation. (Merrill 1959)

As one of the reasons stated that there is flying hairy cotton or fibers during working that makes

workers uncomfortable working conditions during machine operation and makes workers to be

easily attacked with diseases caused by cotton known as byssinoss, breathing air that contain too

much dust and noise to some extent.

Figure 5:Roving frame

2.1.6 Ring frame

The ring spinning frame consists of the drafting system, the spindle, the yarn guide and the ring rail.

The rings are built in the ring rail. The yarn guide, the ring and the spindle share the same vertical

9

axis. The yarn from the roving passes through the drafting system, where it is reduced to a lower

linear density. The roving is gradually reduced as it progresses from the back to the front roller. The

task of ring spinning frame is drafting; the purpose of drafting is to get the desired thickness.

Twisting The twist has its own importance for inserting the strength in the yarn because twist

interlocks the fibers with one another. Package formation at the end the yarn is wound on small

packages (ring bobbins) and stores it for further processes. Also as in roving frame, ring frame has

too much flying fibres, micro dust that cause uncomfortable working environment to the workers

which is not safety and healthier.

2.1.7 Winding machine or Auto corner

The basic function of winding machine is the transfer of yarn from smaller packages (ring bobbins)

to bigger package (cone), which is suitable for transport and for further processing. In winding

machine, the yarn passes from the supply bobbin through the tension device, a slub remove, a

tension bracket, over a package lever and finally on the take up package. Task of the winding

process are extracting yarn faults, manufacturing of large yarn packages such as cones, cheese

having sufficient yarn length on it, to remove yarn faults, to improve the quality of yarn, in some

cases during winding process, waxes are also applied to the yarn to reduce the abrasion and friction

resistance the yarn softer. In winding machine also there are flying fibers, noise pollution, micro

dust that create unhealthier and unsafe working condition to the workers.

Figure 6: Winding process

2.2. Fabric production

Levels of dust cotton are decreased, since cotton already has also been cleaned. However, high

concentration of dust appears in weavings and knitting process. Fabric production or weaving

10

means the making of fabric by yarn, which is made by the interlacement of warp and weft yarn on

the loo m. These yarns are vertically interlaced. There are different processes involved for making

the fabric like warping, sizing, weaving and folding. These processes are dependent on each other.

Warp beams are transferred to the sizing process where these beams are sized by different chemicals

to give strength to yarn and then, these sized beams are attached in looms for making the fabric.

After this, fabric is sent to the folding department where fabric is folded and inspected to check the

faults. Before weaving process there are process such as warping, sizing, drawing in, and tying in

2.2.1Warping

The objective of warping process is to make the weavers beam for the weaving machine because it

is impossible that to place the hundreds of cones in front of weaving loom to provide the warp

threads. Types of warping are direct warping, sectional warping. Direct warping when several

beams with same beam length are prepared then direct warping is used. In this process the proper

winding takes place, the available threads from the creel are wound on the beam. After this all

available beams are unwound on the weaver’s beam. Sectional warping in this system several

sections are wound in the sequence which parallel to each other on a drum. This type of warping is

cost effective for short and striped warp and fancy pattern.

2.2.2 Sizing

The yarns are unwound from the warp beam and put through the slashing or sizing bath containing

either starch based or synthetic based starches (PVA) depending upon the fibre content of warp

yarns. The sized yarns are again wound on a final warp beam which can be readily used in the

loom. The purpose sizing or slashing process are to reduce the yarn hairiness that would interfere

with the weaving process, to protect the yarn from various yarn to yarn and yarn to loom abrasion,

to increase the strength of the yarn. And the goal of sizing process is to reduce the warp breakage

during weaving. Warp breakage is either caused by low strength yarn or through high tension. The

ingredients used in sizing in sizing recipe are adhesives, lubricants, additives, water like polyvinyl

alcohol, sodium carboxymethyl cellulose, and the parameter which are controlled in the size box

are level of sizing solution, temperature, size liquor concentration, squeeze roller pressure, and yarn

speed. The workers in sizing process face the problems of high temperature that exceed normal

temperature, some of effective chemicals in sizing such as polyvinyl alcohol, carboxymethyl

cellulose that have negative impacts like eye irritating, skin irritating

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2.2.3 Drawing in

This process consists of threading through each drop wire, heald wire and reed dent depending on

style and size of machine. This operation is carried out manually and now a day’s automatic drawing

machines are available. But most of textile industries in Tanzania use manual operation that cause

workers to be tired during working time, cause pain to the back bone.

2.2.4 Tying in or knotting

When the fabric is mass produced and weaver beam is about to finish then, new weaver beam is

placed on the loom having same ends, each end is tied to its corresponding end of loom. This process

is carried out through knotting machine. So the problems mostly occurred during drawing in are

omitted to some extent.

2.2.5 Weaving process

Weaving is the interlacement of warp and weft yarn. The machine which is used for this process is

called loom; both yarns are interlaced at right angle, warp yarn is working in vertical direction while

weft yarn is inserting in horizontal direction. Many types of looms are available for fabric

production and are being used in different companies which are shuttle loom, projectile loom, rapier

loom, rapier loom, water jet loom, air jet loom and multiphase. The problem in weaving process

are high noise especially in shuttle loom, lifting of high weight beams high level flying fibres, high

level of micro dust that affects the health of workers and safety of workers.

2.2.5.1 Knitting process

Knitting is the method of fabric construction in which the yarn is formed into loops which are

connected together. Knitted fabrics are constructed by using hooked needles to interlock one or

more sets of yarns through a set of loops and is performed using either weft or warp process. Knitted

structure comprises the following plain knitted structure, rib knitted structure, interlock knitted

structure, purl knitted stricture. The most tiresome process in knitting is creeling of wound cone

from spinning to the knitting machine. The problems associated in knitting are micro dust, little

noise, change of cam when new design is needed. This problem creates unhealthier and unsafe

working condition to the workers. To reduce such kind of problem is to do waxing of yarn after

winding so as to reduce flying fibres, and micro dust in knitting.

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2.3 Finishing process

All woven and knitted fabrics contain impurities that have to be removed prior to dyeing or printing.

These impurities may be those present in natural cellulosic fibres, examples cotton waxes and

natural colouring matter, or those added to facilitate spinning, weaving or knitting, such as warp

sizes or lubricants. The removal of these impurities is called fabric preparation and includes the use

of various processes: These processes are singeing, desizing, scouring, bleaching and mercerizing.

2.3.1 Singeing

Fabrics containing cotton or viscose staple yarns show protruding fibre ends at the fabric surface.

These disturb the surface appearance of the woven fabric and in dyeing produce an effect known as

frosting. It is therefore necessary to remove the surface fibres by passing the fabric through a gas

flame, a process known as singeing. In the standard process, the fabric is passed rapidly over a row

of gas flames at high speed (50-300 m/min). High temperature is the necessary conditions in

singeing process whereby protruding fiber in the fabric are removed by burning. The process of

burning requires high heat that affects the working environment of workers. Workers may get heat

stress which is the net heat load to which worker may exposed from the combined contributions of

metabolic heat, environment factors such as air temperature, humidity, air movement, and radiant

heat, and the clothing requirements.

2.3.2 Desizing

Desizing is the process of removing the size applied during weaving. A size is a gelatinous film-

forming substance, in solution or dispersion, applied normally to warps but sometimes to wefts,

generally before weaving to protect the yarns from abrasion and to strengthen them. Chemical used

in sizing poly (vinyl) alcohol, polyacrylates or polyacrylamides. These chemicals are removed by

other chemicals such as hydrochloric acid, enzyme. The stability and activity of enzymes depend

on many factors, including pH, temperature, and the presence of activators (examples metal ions)

and wetting agents. In desizing there are chemicals, temperature, that have some effect to the health

and affect the safety of workers and also there is strong smell that affect the breathing of workers

during working time.

2.3.3 Scouring

Scouring is a treatment with alkali that removes or destroys cotton waxes, coloured impurities and

other non-cellulosic substances, such as pectic cell wall material and fragments of leaf and seed

coat that are present as impurities in cotton fibres. And the mechanisms of scouring are

13

saponification and emulsification scouring process. This leads to more absorbent fibres with greatly

enhanced wettability characteristics. Scouring is usually carried out with sodium hydroxide but the

addition of other alkalis (trisodium phosphate, sodium silicates and tetrasodium pyrophosphate),

caustic soda, surfactant, detergent, chelating agents, sodium silicate, soda ash and solvents. The

purposes of scouring in fabric preparation are; - to increase hydrophilicity, impurity free

fabric/yarns: fat and waxes, pectic substances and proteins, absorbency (without physical and

mechanical damage) for uniform printing, dyeing and finishing, clean material (use of alkali),

prepare the fabric for subsequent processes, removal of non-cellulosic material. As in mercerization

the temperature and chemical used in scouring is non-friendly to human health and safety hence

create dangerous environment if workers don’t wear protective garment and mostly of Tanzania

textile industries does not consider the health and safety to its workers.

2.3.4 Bleaching

Bleaching is the removal of unwanted colour from the textile fibres and typically involves the use

of one of the main bleaching agents namely sodium hypochlorite, calcium hypochlorite, sodium

chlorite, and hydrogen peroxide. Bleaching process includes three main steps namely saturating the

fabric with the bleaching agent and other necessary chemicals, raising temperature to the

recommended level for the particular textile and maintaining that temperature for necessary

duration, and thoroughly washing and drying the fabric. Prior to bleaching, most of the impurities

present in cotton material are removed by pressure boil under alkaline conditions. Hydrogen

peroxide bleaching is also performed under alkaline conditions and as a result may be combined

with scouring process. Hydrogen peroxide is ecofriendly and it is carried out at pH 10.5-11 and

temperature 80-850C for 4 hours conventionally in the presence of sodium silicate as a stabilizer.

However, sodium silicate is not ecofriendly and also imparts harshness to cotton material.

Bleaching with hydrogen peroxide requires a large amount of steam, there by adding to the fuel

cost. Thus, the temperature in bleaching process is too high and make uncomfortable environment

to the worker due to high steam required during bleaching. And the use of corrosive chemical like

hydrogen peroxide is not safe for human although it is ecofriendly bleaching chemical.

2.3.5 Mercerization

Mercerization is the treatment with strongly alkaline solutions to improve fibre lustre, tensile

strength and dye uptake. The invention based on treatment of cotton fabrics with strong caustic soda

(NaOH) solution, without tension, to improve colour yield. It can be carried out either on yarn or

on woven or knitted fabric. And these are done to improved lustre, improved tensile strength,

14

improved dimensional stability, improved dye uptake, improved coverage of immature cotton.

Although mercerization has great importance but have some effects to workers such as working in

the environment containing strong alkali like caustic soda and other supportive chemicals is very

dangerous to workers especially when they don’t have protective garment to chemicals, strong smell

due availability of some starch and affect to the working environment of workers

2.3.6 Dyeing and printing process

Dye: A soluble colorant that attaches in molecular form to the fibres, as opposed to a pigment,

which exists as much large particles that are attached to the fibre with a binder. Dyeing: Colouring

fibres, yarns and fabrics using dyes.

Dyes can be divided into three classes based on their method of application. Fiber reactive dyes

react with functional groups in the fibers. This class includes acid, basic, reactive, direct and

mordant dyes. Reactive dyes are anionic dyes that form covalent bonds with the hydroxyl groups

in the cellulose. Acid dyes contain sulfonic groups.

These dyes are rarely used in cotton dyeing, but are commonly used on nylon and wool. They attach

to organic fibers under acidic conditions. Direct dyes are often used in cotton dyeing. They are

applied to the yam under neutral conditions. Mordant dyes are acid dyes which are reacted with a

metal salt prior to dyeing. The second class of dyes needs chemical reaction before application. Vat

dyes are soluble in their reduced form. They are made insoluble by oxidation after they are applied

to organic fibers. Sulfur dyes are also made insoluble through oxidation. The third dye class is

special dyes such as disperse, solvent, and natural dyes and pigments. Disperse dyes are water

insoluble and are used for most synthetic fibers. They contain anthraquinone or azo groups. Solvent

dyes have an improved solubility in solvents. Pigments are set to the fabric by an adhesive. Dyes

most commonly applied to cotton are reactive and direct dyes. Cotton/polyester goods are dyed

using reactive or direct dyes for the cotton portion of the fabric and disperse dyes for the polyester.

(Needles, 1986)

Printing; print applied to the fabric by using pigments. Pigments are coloured, organic or inorganic

solid powder, and usually are insoluble. They are not affected physically or chemically in the

substrate in which they are incorporated. They do not penetrate the fibre but are affixed to the

surface of the fabric by means of synthetic resins which are cured after application to make them

insoluble.

Pigment printing pastes (print pastes) contain a thickening agent, a binder and, if necessary, other

auxiliaries such as, ingredients found in most paste formulations include the following: dyes or

15

pigments, thickeners, sequestering agents, dispersing or suspending agents (surfactants), water-

retaining agents (humectants), defoamers, fixing agents, plasticizers, catalysts, and hand modifiers.

After applying the print paste, the fabric is dried and then the pigment is normally fixed with hot

air.

The application of color to the fabrics involves the use of color that contains chemicals that have

direct reaction with the fibers and those chemicals contains basic and acidic nature that have great

effect to the workers and create uncomfortable working environment to the workers especially when

the workers does wearing protective tools like gloves, protective garment, caps, goggles.

2.3.7 Finishing.

Finishing operations change the properties of the fabric or yarn. They can increase the softness,

luster, and durability of textiles. Finishing can also improve the water repelling and flame resistant

properties of the fabric. The characteristics of textiles can be altered by physical techniques (dry

finishing processes) or by application of chemicals (wet finishing processes). Luster can be added

by both physical and chemical methods. Characteristics like flame or water repellency can only be

obtained by wet finishing. (Needles, 1986)

The application of finishes to the fabrics involves the use of finishes that contains chemicals that

have direct reaction with the fibers and those chemicals contains basic and acidic nature that have

great effect to the workers and create uncomfortable working environment to the workers especially

when the workers does wearing protective tools like gloves, protective garment, caps, goggles.

2.3.8 Instruments used to measure noise, dust and flying particles, and chemicals

2.3.8.1 Measure of noise

Noise levels are measured using a noise meter. This is an electronic device that is easy to use by

following simple instructions that come with the meter. Noise can be measured by using a noise

meter initially to get an indication of noise levels or to carry out a more detailed noise survey.

Alternatively, you can get an external noise surveyor to carry out a noise survey. While measuring

noise using a meter is straightforward, interpreting the results of measurement in accordance with

the regulations can be quite technical and may require external expert assistance

Exposure to high levels of noise, either continuously or as a sudden loud bang from equipment such

as Textile operated machines such as operated loom, spinning machines, can have a number of

physiological and psychological effects on employees, including tinnitus and stress. If exposed to

16

high noise levels over long periods of time, permanent loss of hearing can occur. High noise levels

can also interfere with communications in the workplace, leading to an increased risk of accidents.

2.3.8.1.2 Noise unit and noise level required

Noise is measured in units known as decibels (dB). Noise can be measured both as an average level

over a day or as a maximum instantaneous level. These terms are described as follows:

The daily noise exposure level is the average exposure level over an eight-hour day and is expressed

as LEX,8hdB(A).

Peak sound pressure is the maximum value of the noise pressure and is expressed as peak dB (C).

As a rough guide, if it is difficult to hear a normal conversation at a distance of two meters from the

person speaking, it is likely that the noise level in the area is above 80 dB (A)

These are the daily noise exposure levels or peak sound pressure levels, which if exceeded for any

employee require specified actions to be taken by the employer to reduce risk. The exposure action

values do not take account of any attenuation or reduction in noise exposure provided by hearing

protection. There are two action values: (According to WHO & TBS)

Lower exposure action values:

LEX,8h=80 dB (A)

Ppeak =135 dB (C)

Upper exposure action values:

LEX,8h=85 dB (A)

Ppeak =137dB (C)

The exposure limit of noise level

This is the level of daily noise exposure or peak sound pressure that must not be exceeded for any

employee. In determining an employee’s effective exposure, you may take account of the

attenuation provided by hearing protection worn by the employee. Exposure limits values:

LEX,8h=87 dB (A)

Ppeak =140 dB (C)

Measure to be taken when the noise level is above the required lower exposure action value of

80 dB (A) You must reduce noise exposure and make an audiometric screening test available to

employees

Measure to be taken when the noise level is above the upper exposure action value of 85 dB (A)

You must design and implement a programme to reduce noise exposure. Mandatory warning signs

must be displayed, and hearing protectors must be available and must be worn. A hearing check,

including audiometric screening test, must be made available to employees. And the measurement

17

of noise must be repeated at appropriate intervals especially if there is any significant change in

work patterns or equipment. The measurements must reflect the actual amount of noise the

employee is exposed to over the working day. Measurements can either be taken using the

appropriate equipment in the workplace used by the employee or by using instruments attached to

the employee.

2.8.3.2 Measure of dust level

Dust can be defined in practical terms as any particle from a few nanometers (nm) to a few

micrometers (μm) in diameter that can become suspended in the atmosphere. According to the

British Standard code (BS 6069-2)1 dust is defined as a solid particulate matter (PM) 1–75 μm in

diameter. According to the International Standardization Organization (ISO 4225 - ISO, 1994),

"Dust: small solid particles, conventionally taken as those particles below 75 µm in diameter, which

settle out under their own weight but which may remain suspended for some time". According to

the "Glossary of Atmospheric Chemistry Terms" (IUPAC, 1990), "Dust: Small, dry, solid particles

projected into the air by natural forces, such as wind, volcanic eruption, and by mechanical or man-

made processes such as crushing, grinding, milling, drilling, demolition, shoveling, conveying,

screening, bagging, and sweeping. Dust particles are usually in the size range from about 1 to 100

µm in diameter, and they settle slowly under the influence of gravity.". Dust may cause health and

nuisance effects, depending on the concentration and size of the particles and exposure time. Health

effects associated with exposure to elevated dust levels include coughing, sneezing, wheezing and

increased breathlessness. Nuisance effects include short-term reduction invisibility, textile

industries and soiling of washing. Dust is considered a nuisance when the amount settling out in a

given time (deposited dust), or the amount of dust in the air (total suspended particles, TSP), exceeds

a certain level.

Examples of the types of dust found in the work environment include:

Mineral dusts, such as those containing free crystalline silica (example as quartz), coal and

cement dusts;

Metallic dusts, such as lead, cadmium, nickel, and beryllium dusts;

Other chemical dusts, examples, many bulk chemicals and pesticides:

Organic and vegetable dusts, such as flour, wood, cotton and tea dusts, pollens;

biohazards, such as viable particles, moulds and spores

Dusts are generated not only by work processes, but may also occur naturally, examples pollens,

volcanic ashes, and sandstorms.

18

Figure 7:noise measuring instruments

2.8.3.3 Chemical measure

Textiles include very broad categories of articles and are used in a way that both consumers and the

environment are directly or indirectly exposed to their chemical content. Large quantities of

chemical substances are used in the manufacture of textiles, from processing of fibres and raw

materials to the final touch of the finished article.

The chemical substances used in the manufacture of textiles can be categorized into functional (or

effect) chemical substances, auxiliary chemical substances and chemical substances not

intentionally added. Functional (effect) chemical substances

Functional/effect chemical substances are added to the textile to contribute to the design or give the

final article certain properties, examples colourants stabilizers, flame retardants, water repellence,

anti-shrink agent, and crease resistant agents. These substances are therefore intended to remain in

the final article and are expected to be present at certain concentrations in order to achieve the

desirable function

Auxiliary chemical substances, also known as process chemical substances, are necessary to make

textile processes work, but they do not provide any desired properties to the final article and are

therefore not meant to remain in the finished textiles. Some examples of auxiliary chemical

substances are: Organic solvents, Surfactants, Softeners, Salts, Acids and bases, Biocides as

preservatives in the process or during storage and transport.

Chemical substances that are not intended to remain in the finished article, such as contaminants

and degradation products, have no function in neither the textile production process nor in the

finished textiles. Unintended chemical substances which remain in the final article often have a

relatively low concentration, compared with the concentrations of functional chemical substances,

19

but may sometimes be of concern for human health and the environment. Some examples of

unintended chemical substances are: Formaldehyde released from certain reactive resins,

polyaromatic hydrocarbons (PAH) impurities in pyrolysed products such as Carbon Black,

arylamines derived from certain azo dyestuffs and pigments, toxic metals (heavy metals) due to

impurities from the raw material.

Environmental exposure of chemical substances from textile industries mainly occurs due to

leaching via laundering, via chemical substances from textile wet processing, and from textile

waste. There is a release to wastewater during washing of textiles. Substances emitted from the

textiles reach the wastewater treatment plants and if they are poorly degradable they will be released

with the treated wastewater effluents or end up in the sludge. Humans might indirectly be exposed

to chemical substances via the environment.

Environmental risks associated with chemical substances in textiles are mainly expected to occur

in the aquatic compartment. Other sources including evaporation of chemical substances from

textiles and consumer treatment of finished textiles, such as home-dying, water resistant

impregnation or bleaching may also result in environmental exposure.

2.8.3.4 The effects of dust, noise, and chemical to the health of the workers and the environment

2.8.3.4.1The effects of dust

Cotton is a natural fiber used in the production of cloth. When cotton is being processed, it emits

fine cotton dust particles into the air. These particles are breathed into the lungs by the person

working with the fiber. Sometimes the person can have an allergic reaction which is similar to an

asthma attack. This allergic reaction causes the small airways in the lungs to contract so air cannot

quickly leave the lungs. Any air that is already in the lungs at the time of the attack has to force its

way out of the body through narrowed lung passages which in turn produces wheezing sounds that

are common during asthma attacks. Even if a person working with cotton does not display any

allergic reactions, there is scientific evidence that people who are exposed to cotton dust may

develop a permanent decrease in their breathing ability. This cotton dust related disease is known

as Brown Lung or byssinosis, and affects thousands of people in the textile industry who are

exposed to large quantity of dust.

In addition to lung problems caused by dust, textile workers who work with dyes or finishers can

develop skin allergies or rashes known as dermatitis. Finishing agents such as formaldehyde used

in permanent press materials can cause allergic reactions that affect the respiratory system. Also,

textile workers who are regular smokers working with dusts or finishing agents are at a higher risk

20

of developing lung and heart problems. The risk multiplies with the amount of exposure. The duty

of the employer becomes even greater in making sure that workers are not exposed to large

quantities of foreign substances such as cotton dust or chemicals

Particles small enough to stay airborne may be inhaled through the nose (nasal route) or the mouth

(oral route). The probability of inhalation depends on particle aerodynamic diameter, air movement

round the body, and breathing rate. The inhaled particles may then either be deposited or exhaled

again, depending on a whole range of physiological and particle-related factors. The five deposition

mechanisms are sedimentation, inertial impaction, diffusion (significant only for very small

particles < 0.5 mm), interception, and electrostatic deposition. Sedimentation and impaction are the

most important mechanisms in relation to inhaled airborne dust, and these processes are governed

by particle aerodynamic diameter. There are big differences between individuals in the amount

deposited in different regions (Lippmann, 1977)

The largest inhaled particles, with aerodynamic diameter greater than about 30 mm, are deposited

in the airways of the head that is the air passages between the point of entry at the lips or nares and

the larynx. During nasal breathing, particles are deposited in the nose by filtration by the nasal hairs

and impaction where the airflow changes direction. Retention after deposition is helped by mucus,

which lines the nose. In most cases, the nasal route is a more efficient particle filter than the oral,

especially at low and moderate flow rates. Thus, people who normally breathe part or all of the time

through the mouth may be expected to have more particles reaching the lung and depositing there

than those who breathe entirely through the nose. During exertion, the flow resistance of the nasal

passages causes a shift to mouth breathing in almost all people. Other factors influencing the

deposition and retention of particles include cigarette smoking and lung disease.

Fibres behave differently from other particles in their penetration into the lungs. It is striking that

fine fibres even as long as 100 mm have been found in the pulmonary spaces of the respiratory

system. This is explained by the fact that the aerodynamic diameter of a fibre, which governs its

ability to penetrate into the lung, is primarily a function of its diameter and not its length (Cox,

1970).

Wherever the particles are deposited, either in the head or in the lung, they have the potential to

cause harm either locally or subsequently elsewhere in the body. Particles that remain for a long

time have increased potential to cause disease. This is why inhaled particles are important in relation

to environmental evaluation and control.

In order to ensure efficient and safe process design (the preferable approach), or to effectively

modify a certain process or operation to decrease dust exposure, many factors must be considered;

inputs from aerosol sciences and engineering (Vincent, 1995; Faye and Otten, 1984) are essential.

21

Success can often only be achieved through teamwork involving occupational hygienists,

production personnel, engineers, aerosol technology specialists and other professional.

2.8.3.4.2. The effects of noise.

Noise is defined as any undesirable human or machine created noise which disturbs the activities

or balance of human or animal life. The noise problem generally consists of three inter-related

elements- the source, the receiver, and transmission path. This transmission path is usually the

atmosphere through which the sound is propagated, but can include the structural material of any

building containing the receiver. The noise level in decibel is measured with an instrument called

sound level meter.

The effects of noise are hearing loss loud noise damages fine hair cell in the ear. The vibration of

these hair cells is responsible for hearing of sound. Since our body cannot replace the damaged hair

cells. Permanent hearing loss is caused by long term exposure to loud noise.

Figure 8: Noise effects

Physiological effect like breathing difficulty, the rise in blood pressure, migraine, headaches,

constriction of blood vessel and even a health attack.

Human performance the working humans will be affected as they will lose their concentration.

Nervous system it causes pain ringing in ears, feeling of tiredness, thereby effecting functioning of

human system.

Sleeplessness it affects the sleeping thereby inducing the people to become restless and lose

concentration and presence of mind during their activities.

22

Control of noise; - noise is not only a nuisance but a serious environmental problems and a health

hazard to like all other pollution, noise is needed to be controlled. Noise can be controlled by taking

the following measures.

Control at receiver’s end for people working in noisy areas ear protection aids like ear plugs, muffs,

noise helmets, headphones should be provided it reduces occupation exposure.

Controlling at source; - this is only possible if working method is improved like shifting from shuttle

loom weaving machine to the shuttle less weaving example air jet weaving machine, projectile

weaving machine, water jet weaving machine. Design new machine to replace the noise ones,

proper lubrication, and better maintenance of machines. Installing noisy machine with sound

absorbing materials.

Sound insulation; - a sound insulation can be achieved by constructing windows with more than

one panes of glass and filling the gap with sound absorbing material. Acoustical tiles, perforated

plywood, can be fixed on wall, ceiling, and floors to reduce noise.

2.8.3.4.3 The effects of chemicals

In recent years increased attention has been given to the chemicals which are contained in textile

products (Munn, 2011), as well as exposure of textile industry workers to hazardous chemicals and

environmental effects in the countries of production (Stenborg, 2013). There is a need for more

knowledge and also practical tools that can be used to reduce the exposure of people and nature to

harmful chemicals. The use of quantitative measurement tools such as life cycle assessment (LCA)

(ISO, 2006a) for evaluation of chemicals is today not widespread in the textile industry. So the

concept of sustainable use of chemicals where employed in textile industries to reduce the effects

of chemicals in wet processing.

Sustainability has been generally defined in the Brundtland Commission Report: "Sustainable

development is development that meets the needs of the present without compromising the ability

of future generations to meet their own needs"

The presence of hazardous substances in textiles, including azo dyes of direct and acid application

type, should be further investigated. Substances that may cause severe health effects should be

avoided in articles with direct and prolonged skin contact. Since the knowledge on the chemical

content of textiles in general is poor there may be hazardous substances present in the textile articles

causing exposure of humans and the environment. To assess the chemical risks related to the use of

textile articles it is necessary to have comprehensive information about the identity of the substances

and their hazardous properties

23

3. CHAPTER

3.0 METHODOLOGY

The instrument used for the measurement of those parameters obtained from Tanzania industrial

research and development organization (TIRDO) and the testing conducted at Tanzania- China

friendship Textile Company.

Tanzania Industrial Research and Development Organization (TIRDO) is a multi-disciplinary

research and development organization established by an Act of Parliament No. 5 of 1979 and it

became operational on 1st April, 1979. Its mandate is to assist the industrial sector of Tanzania by

providing technical expertise and support services to upgrade their technology base. As well as

carrying out applied research, for the development of suitable technologies, and value addition to

indigenous resources through industrial processing.

Tanzania-China Friendship Textile Co. Ltd (FTC) is a Joint Venture Company between Changzhou

State owned Textile Assets Operation Company of Changzhou, China and the Government of the

United Republic of Tanzania.

FTC was incorporated on 2nd October 1996. FTC is a fully integrated Textile Mill, with Spinning,

Weaving and Processing. The mill has (19,800) Spindles, 1108 Shuttle Looms and two processing

Lines with the capacity of producing over 30 million meters of fabric per year.

The production is supervised by joint Management of the Chinese experts and Tanzanian Trained

and experienced Textile Technologists.

3.1 Literature review

Data collection through studying. To complete and to achieve the objectives of this project the

relevant and technical information was collected through journals, brochures, books and website to

get the latest information without depending only at information provided at conferences,

workshops or in magazines

3.2 Research survey

Direct observation at the organization (Tanzania-China Friendship Company) through visiting

company and studying existing technology, by studying and assessing the amount of dust and flying

particles emitted, level of noise during production processes, and chemical released from wet

processing. Through interview, by asking questions to machine operators and manager.

24

3.3 Industrial testing

Data will be collected through industrial testing. Industrial experiment procedure will comprise the

following parameters

The sample room showing how the data was collected by using sound level meter and

MicroDustPRO, M-stand for machine and position stand for movement one point to another on how

data was taken from one point to another.

Figure 9: Sample room

3.3.1 Noise level

3.3.2.1Sound level meter

The electrical signal from the transducer is fed to the pre-amplifier of the sound level meter and, if

needed, a weighted filter over a specified range of frequencies. Further amplification prepares the

signal either for output to other instruments such as a tape recorder or for rectification and direct

reading on the meter.

The rectifier gives the RMS (Root Mean Square) value of the signal. The RMS signal is then

exponentially averaged using a time constant of 0.1s ("FAST") or 1 s ("SLOW") and the result is

25

displayed digitally or on an analog meter. In some cases, the sound level meter does not include a

logarithmic converter. The scale on the indicating device is then exponential so that the linear signal

may be read in decibels.

The use of sound level meter

This section describes how to use physically the instrument in order to correctly measure the noise

level existing at the point where the microphone is placed. The following steps must be taken

successively:

1. Batteries must be checked before use and during long measuring sessions.

2. A wind shield must be used if the air velocity is noticeable. It should anyway be used all the time

as a dust shield.

3. The microphone should be well oriented.

4. All intruding objects such as the body of the sound level meter (SLM) or the operator itself will

degrade the frequency response of the microphone at high frequencies and directivity effects will

appear at much smaller frequencies. Therefore, the SLM should be, whenever possible, installed on

a stable and sturdy tripod equipped with resilient blocks to isolate the sound level meter from

vibration and consequent spurious readings. The operator should beat a reasonable distance (2-3 m)

behind the sound level meter. Extension cables should be used if possible when measurements are

to be made in a restricted area

When the instrument makes it possible, an extension rod should be used for the microphone.

For walk-through surveys, the SLM should be held well away from the body.

5. The SLM must be calibrated before any measuring session using a calibrator. If the temperature

of the instrument is significantly different from the ambient temperature where it will be used, it

should be first warmed up before calibration and use. The calibration must be checked at the end of

the session. If the instrument is not calibrated anymore, the data might have to be discarded and the

reasons for this calibration change should be investigated as this might indicate an important

malfunctioning of the instrument.

6. Nowadays, it is much more advantageous to use an integrating sound level meter to determine

the Low equivalent exposure, over a representative period of time T than to use a simple SLM on

fast or slow giving an instantaneous value

26

3.3.2.2 DATA COLLECTED

Table 1:Weaving Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Weaving

1 96 96.2 96.6 96.5 96.3

85.0

2 96.2 96.1 96.6 96.5 96.4

3 97.5 97.2 98.1 97.2 97.5

4 96.2 97.3 96.4 96.5 96.6

5 95.8 97.2 96.7 96.1 96.5

6 95.2 96.5 95.8 95.7 95.8

7 97.4 97.6 97.5 97.6 97.5

8 95.9 96.1 95.5 95.4 95.7

9 94.3 94.7 94.4 94.8 94.6

10 94.2 93.8 94.2 93.8 94.0

11 94.4 94.8 93.6 94.1 94.2

12 93.9 95.1 94.3 95.1 94.6

MEAN VALUE 95.8

Table 2: Finishing weaving Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Finishing

weaving

1 79.4 79.6 78.7 79.9 79.4

85.0

2 72.1 72.2 73.7 74.1 73.0

3 70.4 70.3 70.9 69.5 70.3

4 69.9 69.7 70.7 71.7 70.5

5 73.6 74.6 73.1 72.5 73.5

MEAN VALUE 73.3

27

Table 3: Spinning noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Spinning

1 45.7 47.6 47.8 45.5 46.7

85.0

2 45.5 47.2 49.8 52.1 48.7

3 46.3 53.1 48.9 46.6 48.7

4 48.3 48.7 49.2 51.2 49.4

5 53.2 55.1 55.9 51.1 53.8

MEAN VALUE 49.4

Table 4: Blowroomg Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Blow room

1 88.1 87.9 88.6 88.2 88.2

85.0 2 86.3 85.3 85.9 85.5 85.8

3 82.3 81.9 82.2 81.5 82.0

MEAN VALUE 85.3

Table 5: Carding Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Carding

1 83.6 83.5 83.2 83.7 83.5

85.0

2 82.6 83.1 82.7 82.8 82.8

3 84.2 83.2 84.2 83.4 83.8

4 84.5 84.6 84.3 84.4 84.5

5 82.3 82.3 82.6 84.2 82.9

6 86.3 85.3 85.1 85.5 85.6

28

7 81.6 81.8 80.9 80.8 81.3

8 82.3 77.2 77.6 78.6 78.9

9 86.6 86.8 87.3 86.5 86.8

MEAN VALUE 83.3

Table 6: Ring frame Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Ring Frame

1 90.2 89.1 90.4 90.1 90.0

85.0

2 92.2 91.7 91.9 92.3 92.0

3 92.3 92.1 92.1 91.9 92.1

4 93.4 92.6 92.2 93.2 92.9

5 93.1 92.1 92.2 92.5 92.5

6 90.2 89.3 90.3 89.2 89.8

7 90.1 89.3 90.2 89.6 89.8

8 92.5 93.3 92.4 93.2 92.9

9 93.3 92.5 93.1 92.7 92.9

MEAN VALUE 91.6

Table 7: Cone winder Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Cone winder

1 83.5 83.4 83.5 83.2 83.4

85.0

2 83.6 84.2 84.6 83.5 84.0

3 84.5 84 83.8 84.3 84.2

4 84.1 83.6 83.6 83.5 83.7

5 82.2 82.7 82.6 82.2 82.4

MEAN VALUE 83.5

29

Table 8: Pin winder Noise level data

Location Point

0.2 TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Pin winder 1 83.1 83.2 82.9 82.4 82.9

85.0 2 82.1 81.9 81.8 82.1 82.0

MEAN VALUE 82.4

Table 9: Warping Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Warping

1 74.3 73.2 73.6 72.2 73.3

85.0

2 78.8 71.4 71.5 71.7 73.4

3 80.2 79.4 80.5 79.7 80.0

4 68.7 68.4 68.2 68.2 68.4

5 84.5 86 83.2 84.3 84.5

MEAN VALUE 75.9

Table 10: Sizing Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Sizing

1 81.4 82.2 81.9 80.2 81.4

85.0 2 76.5 76.2 75.9 75.6 76.1

3 81.9 82.1 82.3 82.5 82.2

MEAN VALUE 79.9

30

Table 11: Mixing Noise level data

Location Point

0.2 TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Mixing 1 63.2 62.7 63.4 63.3 63.2 85.0

MEAN VALUE 63.2

Table 12: Processing Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Processing

Finishing

1 77.6 76.9 77.1 77.2 77.2

85.0

2 79.6 79.5 78.7 78.6 79.1

3 76.8 76.9 76.5 76.2 76.6

4 81.6 82.8 83.2 82.5 82.5

5 77.4 76.4 76.6 77.4 77.0

MEAN VALUE 78.5

Table 13: Processing 1Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Processing

finishing 1

1 76.3 77.5 76.5 77.4 76.9

85.0

2 78.4 79.2 78.4 79.4 78.9

3 79.2 79.8 79.2 78.5 79.2

4 74.9 75.2 75.2 74.9 75.1

5 78.4 78.6 77.7 78.2 78.2

MEAN VALUE 77.6

31

Table 14: Printing Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Printing

1 83.1 83.3 83.2 83.6 83.3

85.0

2 81.9 81.7 85.4 84.2 83.3

3 85.7 85.1 83.1 81.9 84.0

4 84.5 81.2 83.1 81.9 82.7

5 79.5 79.7 79.6 82 80.2

MEAN VALUE 82.7

Table 15: Bleaching Noise level data

Location Point

NOISE LEVELS (dBA) TBS

LIMIT-

EMDC 6

(1733) P2

Reading

1

Reading

2

Reading

3

Reading

4 Average

Bleaching

1 80.3 80.2 80.5 80.0 80.3

85.0

2 73.8 73.5 73.6 74.3 73.8

3 79.6 79.5 80.2 79.2 79.6

4 75.4 75.3 75.7 75.6 75.5

MEAN VALUE 77.3

32

3.4. Dust and flying fibers emission measure

3.4.1. MicroDust PRO

The MicrodustPRO from Casella United States of America (USA) is a portable, real time monitor

for assessing the concentration of suspended particulate matter, and is probably the most versatile

instrument available with the ability to measure from 1µg/m3 to 2500 mg/m3. It is the only handheld

real-time dust monitor on the market capable of graphically presenting variations in dust

concentration on a real time scrolling graph – no longer is it necessary to wait to analyze results on

a PC

Figure 10. MicroDustPRO

Wide range from 1µgm-3 to 2500 mgm-3 in single meter

Data-logger with >15,700 readings

Detachable probe TSP, PM10, PM2.5 or respirable measurements

Firmware calibration and zero in the field 4 user defined calibration routines available for

differing dust types

Alkaline or rechargeable batteries or mains power

32bit WinDustPro PC software as standard

33

3.4.2. DATA COLLECTED

Table 16: Dust data collected

Location Point Total Suspended Particulates, TSP (mg/m3) MAXIMUM LIMIT*

TBS

LIMITS

(TZS845:20

05)

IFC (2007)

and WHO

AQG

(2006)

Waving Value Readin

g 1

Readin

g 2

Readin

g 3

Mean

Value

0.230mg/m3 0.230mg/m3

1 Average 0.001 0.001 0.002 0.001

Maximum 0.002 0.003 0.004 0.003

2 Average 0.002 0.002 0.005 0.003

Maximum 0.004 0.004 0.005 0.004

3 Average 0.003 0.003 0.003 0.003

Maximum 0.004 0.005 0.004 0.004

4 Average 0.003 0.002 0.004 0.003

Maximum 0.004 0.005 0.005 0.005

5 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

6 Average 0.003 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

7 Average 0.004 0.005 0.005 0.005

Maximum 0.006 0.006 0.006 0.006

8 Average 0.003 0.004 0.003 0.003

Maximum 0.004 0.005 0.005 0.005

9 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

10 Average 0.004 0.004 0.004 0.004

Maximum 0.008 0.005 0.005 0.006

11 Average 0.006 0.005 0.005 0.005

Maximum 0.01 0.007 0.007 0.008

12 Average 0.005 0.004 0.005 0.005

Maximum 0.006 0.006 0.006 0.006

1 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

34

Finishin

g

Waving

2 Average 0.004 0.004 0.006 0.005

Maximum 0.005 0.005 0.09 0.033

3 Average 0.005 0.005 0.005 0.005

Maximum 0.007 0.007 0.007 0.007

4 Average 0.005 0.005 0.005 0.005

Maximum 0.008 0.01 0.008 0.009

5 Average 0.004 0.004 0.006 0.005

Maximum 0.005 0.008 0.008 0.007

Spinning

Cotton

receptio

n

1 Average 0.003 0.002 0.003 0.003

Maximum 0.004 0.004 0.004 0.004

2 Average 0.003 0.003 0.003 0.003

Maximum 0.004 0.004 0.004 0.004

3 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

4 Average 0.003 0.003 0.003 0.003

Maximum 0.004 0.004 0.004 0.004

5 Average 0.003 0.003 0.003 0.003

Maximum 0.004 0.004 0.004 0.004

Blow

room

1 Average 0.005 0.005 0.006 0.005

Maximum 0.007 0.008 0.007 0.007

2 Average 0.006 0.008 0.008 0.007

Maximum 0.010 0.010 0.010 0.010

3 Average 0.009 0.009 0.010 0.009

Maximum 0.020 0.020 0.050 0.030

Carding 1 Average 0.120 0.110 0.120 0.117

Maximum 0.210 0.210 0.210 0.210

2 Average 0.120 0.120 0.120 0.120

Maximum 0.190 0.200 0.200 0.197

3 Average 0.150 0.150 0.150 0.150

Maximum 0.210 0.200 0.210 0.207

4 Average 0.180 0.180 0.160 0.173

Maximum 0.240 0.220 0.210 0.223

5 Average 0.160 0.160 0.160 0.160

Maximum 0.210 0.220 0.220 0.217

6 Average 0.170 0.170 0.170 0.170

35

Maximum 0.200 0.210 0.210 0.207

7 Average 0.160 0.160 0.160 0.160

Maximum 0.220 0.220 0.220 0.220

8 Average 0.190 0.190 0.190 0.190

Maximum 0.230 0.230 0.240 0.233

9 Average 0.170 0.170 0.170 0.170

Maximum 0.220 0.220 0.220 0.220

Ring

frame

1 Average 0.250 0.250 0.250 0.250

Maximum 0.350 0.320 0.321 0.330

2 Average 0.231 0.230 0.230 0.230

Maximum 0.262 0.240 0.240 0.247

3 Average 0.300 0.310 0.310 0.307

Maximum 0.450 0.450 0.450 0.450

4 Average 0.260 0.260 0.260 0.260

Maximum 0.320 0.320 0.321 0.320

5 Average 0.250 0.250 0.250 0.250

Maximum 0.290 0.280 0.290 0.287

6 Average 0.240 0.240 0.240 0.240

Maximum 0.270 0.270 0.270 0.270

7 Average 0.250 0.250 0.250 0.250

Maximum 0.320 0.310 0.310 0.313

8 Average 0.220 0.210 0.210 0.213

Maximum 0.240 0.240 0.240 0.240

9 Average 0.220 0.220 0.220 0.220

Maximum 0.230 0.240 0.240 0.237

Cone

winder

1 Average 0.210 0.210 0.210 0.210

Maximum 0.250 0.250 0.250 0.250

2 Average 0.210 0.220 0.220 0.217

Maximum 0.260 0.260 0.260 0.260

3 Average 0.220 0.220 0.220 0.220

Maximum 0.300 0.290 0.290 0.293

4 Average 0.230 0.230 0.230 0.230

Maximum 0.310 0.320 0.310 0.313

5 Average 0.210 0.210 0.210 0.210

Maximum 0.290 0.290 0.290 0.290

36

Pin

winder

1 Average 0.090 0.090 0.090 0.090

Maximum 0.020 0.022 0.022 0.021

2 Average 0.100 0.100 0.100 0.100

Maximum 0.210 0.210 0.210 0.210

Warping 1 Average 0.190 0.190 0.190 0.190

Maximum 0.220 0.220 0.220 0.220

2 Average 0.200 0.200 0.200 0.200

Maximum 0.230 0.230 0.230 0.230

3 Average 0.200 0.200 0.200 0.200

Maximum 0.230 0.230 0.230 0.230

4 Average 0.200 0.190 0.200 0.197

Maximum 0.220 0.220 0.220 0.220

5 Average 0.210 0.210 0.210 0.210

Maximum 0.240 0.240 0.240 0.240

Sizing 1 Average 0.004 0.004 0.004 0.004

Maximum 0.006 0.006 0.006 0.006

2 Average 0.005 0.005 0.005 0.005

Maximum 0.006 0.006 0.006 0.006

3 Average 0.005 0.005 0.005 0.005

Maximum 0.006 0.006 0.006 0.006

Mixing 1 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

Processi

ng-

Finishin

g

1 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

2 Average 0.005 0.005 0.005 0.005

Maximum 0.006 0.006 0.006 0.006

3 Average 0.005 0.005 0.005 0.005

Maximum 0.006 0.006 0.006 0.006

4 Average 0.005 0.005 0.005 0.005

Maximum 0.006 0.006 0.006 0.006

5 Average 0.005 0.005 0.005 0.005

Maximum 0.006 0.006 0.007 0.006

Processi

ng-

1 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

2 Average 0.004 0.004 0.004 0.004

37

Finishin

g1

Maximum 0.005 0.005 0.005 0.005

3 Average 0.005 0.005 0.004 0.005

Maximum 0.006 0.007 0.007 0.007

4 Average 0.005 0.005 0.005 0.005

Maximum 0.006 0.006 0.006 0.006

5 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

Printing 1 Average 0.004 0.005 0.005 0.005

Maximum 0.006 0.006 0.006 0.006

2 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

3 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

4 Average 0.005 0.005 0.005 0.005

Maximum 0.007 0.007 0.006 0.007

5 Average 0.005 0.005 0.005 0.005

Maximum 0.007 0.007 0.007 0.007

Bleachin

g

1 Average 0.004 0.004 0.004 0.004

Maximum 0.006 0.006 0.006 0.006

2 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

3 Average 0.005 0.005 0.005 0.005

Maximum 0.007 0.007 0.007 0.007

4 Average 0.005 0.005 0.005 0.005

Maximum 0.007 0.007 0.007 0.007

Inspectio

n and

Packing

1 Average 0.004 0.005 0.004 0.004

Maximum 0.007 0.006 0.006 0.006

2 Average 0.005 0.005 0.006 0.005

Maximum 0.007 0.007 0.007 0.007

3 Average 0.004 0.004 0.006 0.005

Maximum 0.005 0.007 0.007 0.006

4 Average 0.005 0.004 0.005 0.005

Maximum 0.006 0.006 0.006 0.006

5 Average 0.004 0.004 0.004 0.004

Maximum 0.005 0.005 0.005 0.005

38

TBS (Tanzania Bureau of Standard), IFC (International Finance Corporation), WHO (World Health

Organization)

3.5. Chemical measure

Chemical are measured evaluating risk assessment of chemicals from textile industries especially

from finishing processes.

Risk assessment is a process to evaluate what chemicals or processes would cause harm at work in

terms of frequency of exposure, likelihood and consequence. Based on the assessment results,

suitable safety measures could be developed to reduce the risks.

Risk assessment should be performed by competent persons with suitable experience and training

on the concerned work activities. They should have knowledge on the nature and hazardous

properties of the reactants and products/by-products as well as the characteristics of the physical

and chemical changes at each stage of the process and the required safe practices.

Identification of hazards

It is the process of identifying all hazardous chemicals used or may be present, and the hazardous

chemical processes conducted in the workplace. The operating procedure of each chemical process

is examined for the critical steps where potential hazards exist.

Determination of risks

This is the process of making an objective evaluation of the risks associated with each hazard

assuming that planned or existing controls are in place, and considering the effectiveness of the

controls and the consequences of their failure. Also, it is necessary to decide if the risks are

tolerable. The risks associated with a chemical process should be re-assessed whenever there is any

change to the operating procedure, such as change in the scale of the process, change in the

reactants, change in operating temperature, or when safer procedures or improved control measures

become reasonably practicable.

3.5.1 After risk assessment, the following actions should be taken to eliminate or control the

identified risks:

Development of safety procedures and risk control measures;

Implementation and maintenance of safety procedures and risk control measures; and

Review of safety procedures and risk control measures.

39

To measure the level of chemical is by using litmus paper in order to know the level of chemical to

emit to the environment from water treatment plant.

And the use pH meter to obtain the exact value of acidity and basicity of the chemicals so as to

remove the danger that could be caused by the chemicals present in wet processing department

3.5.2 Operation procedure on how to use pH meter

The pH of a solution is simply the measurement of the acidity or alkalinity of a solution. Pure water

is neutral - pH of 7. Acids range in pH from 0 - 7 with 0 being the strongest and alkalines range

from 7-14 with 14 being the strongest. The more "extreme" the pH the more corrosive the solution.

The pH of a solution in relation to the pretreatment of metal is critical. For example, the pH of the

cleaning stage must be within a specified range in order for the removal of certain soils to take

place. Too mild a solution will not clean the product.

3.5.3 pH Meter Calibration

A pH meter electrode needs to be calibrated regularly. It is recommended that you do this at least

once a day before you start measuring. The calibration is necessary to adjust the slope and offset of

an electrode to their true values for the measuring system in question. (METTLER TOLEDO)

Figure 11: METTLER TOLEDO

Calibration Points for pH meters

40

Since an electrode is characterized by both its zero point and its slope, it is advisable to do a

minimum of a two-point calibration for reliable measurements and better precision.

When measurements are performed over a large range of pH values it is recommended that one

takes at least 3 calibration points. Most pH meters can do 3–5 point calibrations. It is important to

note that one should only measure samples within the chosen region of calibration.

How to successfully calibrate your pH Meter

Switch on the pH meter and select the correct buffer group or buffer values for the

calibration.

Set the meter to manual temperature correction if no temperature probe is attached.

Select the correct temperature for the buffers if no automatic temperature correction is done.

Prepare the buffer solutions intended for calibration by pouring a sufficient amount of the

solutions into clean beakers.

Make sure that the buffer solutions are used in the correct order for the calibration unless

the pH meter has auto-buffer recognition

Take the electrode out of its holder and visually inspect it to see if there are any obvious

problems with the electrode. Make sure that you have opened the electrolyte filling hole to

ensure that there is no pressure build up or reduction in the electrode and to ensure that the

electrolyte can slowly flow into the sample.

Rinse the electrode with distilled or deionized water.

Take the first buffer solution, stir gently and immerse the electrode.

Press the calibration (or equivalent) button on the pH meter.

Wait until the measurement is stable. METTLER TOLEDO instruments have automatic

endpoint algorithms which freeze the measurement automatically as soon as the value is

stable.

Take the electrode out of the buffer solution and rinse it.

Take the second buffer solution, stir gently and immerse the electrode.

Press the calibration (or equivalent) button on the pH meter.

Wait until the measurement has reached an endpoint.

Take the electrode out of the buffer solution and rinse it.

For a third calibration point, repeat steps above and end the calibration procedure on the pH

meter by pressing the appropriate button.

Take the electrode out of the buffer solution, rinse it and store it in its holder.

41

* Always rinse probes off with deionized water after using.

Quality: Never rinse the probe with tap water

3.5.4 DATA COLLECTED

The measurement for pH value from the discharged water from wet processing and sizing to the

environment from Friendship Tanzania-China textile mills was 11.77 which shows that they didn’t

take any measurement to meet the standard which are 6.5 – 8.5 to be discharged to the environment.

42

4. CHAPTER

4.0 RESULTS AND DISCUSSION

4.1 Sound level meter

Through the use of sound level meter to measure the noise level in different sections was too high

in some department, moderate in some department, and too low in some department. As a standard

of noise level a worker should receive in a day for 8 hours is 85dB in Tanzania.

4.1.2 Spinning section analysis

The results show that people working in blow room store working at low level of noise which has

no effects workers, people working in carding, draw frame, cone and pin winding working at a

moderate and acceptable level of noise in Tanzania, and people working in blow room, roving

frame, and ring frame are working at very high noise level which is too risky to workers.

The line crossing the graph indicate maximum and minimum level of noise. When the graph line is

above the crossed line means exceed the required standard and below the crossed line means it is

within the standard. As shown in figure 12.

Figure 12. Spinning section noise level data graph

0

10

20

30

40

50

60

70

80

90

100

reception blowroom carding draw frame rovingframe

ring frame conewinding

pin winding

dB

A

Spinning section noise level

43

4.1.3 Weaving section analysis

As a standard of noise level a worker should receive in a day for 8 hours is 85dB in Tanzania. The

results show that people working in sizing mixing room working at low level of noise which has no

effects to workers, people working in warping, sizing, and finishing working at a moderate and

acceptable level of noise in Tanzania, and people working in weaving (shuttle loom) are working

at very high noise level which is too risky to workers since it exceeds the standard a worker should

receive per day

The line crossing the graph indicate maximum and minimum level of noise. When the graph line is

above the crossed line means exceed the required standard and below the crossed line means it is

within the standard. As shown in figure 13.

Figure 13: Weaving noise level graph

4.1.3 Processing section

As a standard of noise level a worker should receive in a day for 8 hours is 85dB in Tanzania. The

results show that people working in processing department in all sub-sections they are working in

a moderate noise level conditions and acceptable level of noise in Tanzania. As shown in the figure

below

0

20

40

60

80

100

120

warping mixing sizing weaving finishing

dB

A

Weaving noise level

44

4.2. Dust level

4.2.1. MicroDustPRO

The analysis show that workers in ring frame and cone winding inhale the air that exceed the

standard which is 0.230mg/m3 for occupational thoracic inhalable air quality. Through the use of

MicroDustPro to measure the dust level in different sections was too high in some department,

moderate in some department, and too low in some department. As a standard of dust level a worker

should receive in a day for 8 hours is 0.230mg/m3 in Tanzania. The results show that people working

in other department than ring frame and cone winding store working at low level of dust which has

no effects workers, people working in carding, draw frame, cone and pin winding working at a

moderate and acceptable level of dust in Tanzania, and people working in cone winding, roving

frame, and ring frame are working at very high dust level which is too risky to workers.

72

74

76

78

80

82

84

86

Bleaching finishing 1 finishing 2 printing

dB

AProcessing noise level

Figure 14: : Processing section noise level data

45

4.2.2. SPINNING SECTION ANALYSIS

Some graphs are indicated with the crossing line. The line crossing the graph indicate maximum

and minimum level of noise. When the graph line is above the crossed line means exceed shown in

figure 17 and 18 the required standard and below the crossed line means it is within the standard as

shown in figure 15 and 16

Figure 15: Spinning reception dust level graph

Figure 16: Blowroom dust level graph

0.001

0.01

0.1

1

1 2 3 4 5

mg/

m3

Position

Spinning reception dust level

Average Maximum Standard

0.001

0.010

0.100

1.000

1 2 3

mg/

m3

Position

Blowroom dust level

Average Maximum Standard

46

Figure 17: Carding dust level graph

4.3. WEAVING SECTION ANALYSIS

According to the measurement of dust level by using MicroDustPRO not all workers in weaving

section are inhaling within the standardized level of occupational a worker should inhale during

working time (TBS limits TZS 845; 2005 and IFC & WHO AQG 2006). Since workers in winding

machine are working in unfavorable condition which exceed the standard and in warping the level

0.000

0.050

0.100

0.150

0.200

0.250

1 2 3 4 5 6 7 8 9

mg/

m3

Position

Carding dust level

Average Maximum Standard

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

0.5

1 2 3 4 5 6 7 8 9

mg/

m3

Position

Ring frame dust level

Average Maximum standard

Figure 18: Ring frame dust level graph

47

of dust is fluctuating due to stoppage of warping machine that cause the dust level decrease as

shown in figure 19 and 20 which indicated by the standard line.

And in mixing and sizing room the level of dust was favorable to workers since the machine does

not generate too much dust and mostly uses water that reduces the flying particles by trapping it.

As shown in figure 21.

Figure 19: Winding machine dust level graph

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

1 2 3 4 5 6 7

mg/

m3

Position

Winding machine dust level

Average Maximum Standard

48

Figure 20: Warping dust level graph

Figure 21: sizing dust level graph

4.4. PROCESSING SECTION ANALYSIS

Generally, workers in wet processing are working in low level of dust since with the use of

MicroDustPRO the results showed that the level of dust was below the standard that worker should

inhale below 0.230mg/m3 (TBS limit TZS 845:2005 and IFC & WHO AQG 2006) which is the

0

0.05

0.1

0.15

0.2

0.25

0.3

1 2 3 4 5

mg/

m3

Position

Warping dust level

Average Maximum Standard

0.001

0.01

0.1

1

1 2 3 4

mg/

m3

Position

Sizing dust level

Average Maximum Standard

49

standard during working and not maximum of 10mg/m3 for 8 hours. The naming of the process

during measurement was given according to the naming of the room that comprise the number of

machine. Instrument should be held at the height of 1.2 meter during measurement since many

workers’ height is ranging in that position

Figure 22: Bleaching dust level graph

Figure 23: Printing dust level graph

0.001

0.01

0.1

1

1 2 3 4

mg/

m3

Position

Bleaching dust level

Average Maximum Standard

0.001

0.01

0.1

1

1 2 3 4 5

mg/

m3

Position

Printing dust level

Average Maximum Standard

50

Figure 24: Finishing process dust level graph

Figure 25: Inspection and packing dust level graph

0.001

0.01

0.1

1

1 2 3 4 5 6 7 8 9 10

mg/

m3

Position

Finishing process dust level

Average Maximum Standard

0.001

0.01

0.1

1

1 2 3 4 5

mg/

m3

Position

Inspection and packing

Average Maximum Standard

51

4.5 Chemical discharged to the environment

4.5.1 METTLER TOLEDO

The standard certified by Tanzania Standard of Bureau (TBS) is 6.5 - 8.5 pH to be discharged by

chemical industries to the environment. But Friendship Tanzania-China (FTC) textile mills

discharge alkalines of 11.77 pH to the environment which is not allowed and it need to be controlled

so as to continue production with considering the environmental management as well.

Figure 26: METTLER TOLEDO

52

5. CHAPTER FIVE

5.0 CONCLUSION AND RECOMMANDATION

5.1 CONCLUSION

Textile also is a chemically intensive industry, and therefore, the waste water from textile

processing contains processing bath residues from preparation, dyeing, finishing, and other

operations. These residues can cause damage if not properly treated before discharge to the

environment. At the end of the present work and through the field work in textile mills, the

followings are often predominating, typically they are: Low level of technology, Poor knowledge

of textile chemicals and their hazards, Unspecialized workers, Protective measures are neglected,

Lack of modernization, Poor environmental performance, there are high risks from occupational

and environmental exposure, No sufficient waste water treatment.

Through the use of Sound Level Meter, MicroDustPRO capsule and METTLER TOLEDO pH

meter we see that there is some section within textile industries workers are working in conducive

environment for their health and safety mater and in some section seems that workers are working

in unfavorable environment that need to be checked and managed so as to create favorable

environmental condition to them. Sound level meter used show that people working in weaving

(shuttle) loom, ring frame spinning, and roving frame spinning. Are working in unfavorable

condition in terms of noise level which exceed the standard (85 dBA). And MicroDustPRO show

that people working in ring-frame, and winding section are working in unfavorable condition in

terms of dust or total suspended particles (TSP). And the pH meter show that Friendship Tanzania-

China (FTC) Textile Mills discharge untreated effluent from processing and sizing section that

affect the environment. Through the use of the mentioned instruments if the industrial testing will

have been conducted by accredited institution like Tanzania industries Research Development

Organization (TIRDO) and National Environment Management Council (NEMC) to measure the

level of noise and dust receive by worker per day will at least help to make a good working

environment to the workers

5.2 RECOMMENDATIONS

Systematic safety and health inspection of the workplaces, which plays a key role in the control of

workplace safety and health hazards, has to be planned, organized and conducted. Such inspection

can help to ensure that the workplace complies with all relevant safety and health legislation,

standards and Code of Practice. Effective occupational safety and health inspection programs are

53

one of the most important preventive measures that can be taken to ensure a good safety and health-

working environment. After inspection, an inspection report would then be prepared listing down

the problematic or hazardous areas, the recommended corrective and preventive actions and its

priority or urgency of the actions which need to be taken. The following should be done so as to

ensure the safety and health of the workers

The companies should employ environmental specialist and health and safety specialist so

as to ensure that companies operate at standard inserted in all aspects to ensure safety of

workers, the chemical from wet processing discharged to the environment are at the required

level.

Health and safety consideration of the worker should be the first thing to consider by textile

industries in terms of noise workers working in high noise section should wear ear plug-in

so as to minimize or reduce the effect that could be caused like loss of hearing

In terms of dust and flying particles workers should wear nose mask so as to reduce or

eliminate total suspended particles that can be inhalable and affect workers.

Chemical discharged to the environment should be treated so as to meet the standard that

required when exposed to the environment so that will not affect the living.

Based on the information and experience gained through this project here are other

recommendations to considered most: Raise environmental awareness, Establishment of the cleaner

production center for monitoring all industries, Apply the environmental management system,

Improvement of the working conditions, Doing environmental impact assessment for the present

mills and projects, Capacity building.

54

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