The world's first eco-friendly fabric and apparel manufacturing zone, called MAS Fabric Park (MFP), started operation in Thulhiriya, Sri Lanka in late October.
Previously known as Kabool Lanka textile manufacturing zone, the facility was idle for a number of years before it was handed over by the government to an intimate apparel maker in the country, MAS Holdings, which later upgraded the facility with US$25 million and renamed it as the MAS Fabric Park.
The first project at the renovated fabric park is US$30 million Dogifa, a joint venture between the Spanish-based Dogi International owning brands of Dogi, Penn and EFA, and MAS Holdings. It will be the first high-quality warp knit operation in South Asia catering to the increased demand for warp knit fabrics in the region driven by the growth in intimate apparel, swimwear and sportswear markets.
Next step: eco-friendly bras production
Another project underway at the fabric park is MAS Intimates Thurulie, a green intimate apparel manufacturing facility to make bras exclusively for Marks & Spencer (M&S). M&S will support the development of the factory by providing advice on sustainable construction through its experience in store development and the creation of its "green" stores in the UK. It will also sponsor the costs of architecture design.
A zero-emission green factory will be built in Sri Lanka. |
This zero-emission green factory will have a total floor area of 110,000 square foot with a US$5 million investment. It will be specifically designed for MAS Operating System (MOS), the lean manufacturing methodology developed by MAS for the apparel industry based on the principles of the Toyota Production System, making it the first lean and green apparel manufacturing facility in Sri Lanka.
Being operational by March 2008 with a combined workforce of 550, the new facility is expected to operate at full capacity with 1,300 people in employment by 2010. It is also expected to deliver more than 50% and 40% savings on water and electricity respectively in comparison to a standard factory, through the use of renewable energy sources on site, including solar-electric, solar-thermal, wind, and methane through sewerage treatment. LED based task lights will be adopted to minimize energy consumption. Rainwater harvesting is also planned for the full roof area.
Moreover, the facility will be surrounded by green belts as part of a comprehensive bio-diversity plan. Incentives will be offered to management and employees to promote the use of bicycles and reduce fuel consumption. Further training on environmental sustainability will be provided for employees and the community.
Notably, eco-friendly construction material including Forest Stewardship Council (FSC) certified wood and cement-stabilized-earth bricks will be used for construction.
The project will be independently certified by the US Green Building Council's (USGBC) Leadership in Energy and Environmental Design (LEED) Green Building Rating System.
According to the MAS Holdings, the entire MAS Fabric Park project consists of three components: the industrial park as a business hub, the MAS Institute of Management Technology (MIMT) for training and IT development, and a platform that deals with the needs of workers employed in the park. For the benefits of labor, the fabric park will also provide accommodation for employees within the park in the form of dormitories and villas with healthcare and sports facilities.
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