MAS Holdings achieves many new firsts

By Rashika Fazali

MAS Holdings is set to invest US$ 70 million on a fully-automated manufacturing plant, spread out over 200,000 sq feet, making it the largest manufacturing plant in the region. This plant will employ over 1,000 workers and is expected to be completed by end 2013.

With another first under its belt, MAS Fabric Park (MFP) recently received ISO 14001 certification for Environmental Management Systems (EMSs), becoming the first fabric privately-operated industrial free zone in Sri Lanka to receive this certification.

At a media briefing held at MFP, Thulhiriya MFP Director Misver Deane stated: “Our journey was not easy. There were many plants that needed to be aligned. Sustainable initiative goes hand in hand with linear manufacturing management system. It took us one and half years to get to where we are today. We believe in going slow to go fast.”

In complying with the ISO 14001 standards, MFP had to undergo extensive changes and close inspections. MFP Hydro and Environment Manager Harsha Deraniyagala who initiated the certification noted the six objectives: saving energy and water usage, legal compliance, building safe and sustainable centres, reduction of fossil fuel usage, energy recovery, and sustaining the ISO 14001 standard.

ISO 14001 certification initiatives

When it comes to saving energy, Deraniyagala told the Daily FT that MFP alone, minus the other entities, uses 80,000 kWh per month.

With the sustainable initiative in place, he acknowledged that today they save 2,000 kWh per month. However, he explained that the entire park energy consumption is about four million kWh per month.

He also noted that they process 300 tons of sludge wastage per year and this wastage is carefully used and disposed of with the proper equipment and care. He explained that before they built their own processors to get rid of wastage, the wastage was sent to Holcim for disposal.

Speaking about general solid waste, he explained that it was being used and processed at its own Eco Centre in collaboration with Green Keepers Ltd., where they reuse and recycle waste materials into usable materials.

Green Keepers Managing Director Edward Fernando stated that MFP had produced 110,000 kg of waste since its inception in April 2012, which is 100% reused and recycled. The MFP Eco Centre reuses materials such as clothing, cardboard, and polythene.

One issue Sri Lanka is trying to solve is lowering its fossil fuel usage and hopefully eliminating its usage by 2030. MFP has already taken measures to eliminate fossil fuel, thus far saving usage by 19%, stated Deraniyagala.

He added that they have taken measures to become more sustainable by ensuring sustainable solving of biomass, reduction of internal causes for global warming, and recovering energy from waste.

Last year they invested in a biomass powered boiler to provide steam to its customers within the park, thus saving MFP spending on heavy furnace oil. Deraniyagala noted that they produce 75 tons of steam per day with the use of sawdust and wood. However it has been noted that MFP can produce up to 140 to 150 tons of steam per day.

MFP has its own water supply where it takes water from the river, treats it through its water treatment centre, and supplies it to the entire park. Deraniyagala explained that they can process up to nine million litres of water per day. However, they currently process only three million litres of water per day.

They have other projects in helping them sustain and use materials carefully. One is a unique rainwater harvesting model and the other is developing a series of green buildings which consume less energy, less water, and improve air quality.

World’s first eco-friendly garment factory

MAS Intimates has built the world’s first purposely built eco-friendly factory, Thurulie, at MFP which consumes 40% less energy and 50% less water. Thurulie received the highest rated certification, the LEED Platinum Green Building Certification awarded by LEED (Platinum) established by the US Green Building Council and verified by the Green Building Certification Institute (GBCI).

This unique green factory is solely powered by renewable sources and carbon-neutral sources. It uses natural lighting, solar power, renewable electricity, and waste water management, in addition to eco-friendly material like eco bricks and consists of a green roof with an adaptation of ‘evaporate cooling’.

This garment factory has also been built to support disabled people. Deraniyagala noted that there are around 30 to 40 disabled people working at Thurulie.

Thurulie achieved 22 of 23 points for water efficiency, site sustainability and innovation. Deraniyagala asserted that around US$ 10 million was spent on building such an eco-friendly building.

MFP is also home to the LEED Gold rated Linea Apparel Innovation and Training Centre (AITC) which was established to support the Nike (AITC) that provides apparel training and education.

MAS Fabric Park

MFP lies across 165 acres of land with eight housing entities involved in fabric manufacturing, sewing solutions, fabric printing, and supply chain management, offering their investors multiple services.

MFP has also additional services like employee accommodation, training facilities, and ISO 22000 industrial catering, dining and clubhouse facilities, sports ground, gymnasium, swimming pool, and adventure activities.

Pix by Daminda Harsha Perera