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Noman Terry Towel Mills Limited (NTTML) is the largest integrated hundred percent export oriented terry towel manufacturer in Bangladesh. It is one of the sister concerns of Noman Group. Since its inception in 2012, NTTML has accomplished many achievements that never before encountered in the textile industry of Bangladesh. Its 85 metric ton production capacity per day generates more than 80 million US dollar annual revenue. With over 20 percent growth rate NTML has become an icon in terry towel production and one of the market leaders of the world.
Noman Group has a successful experience in producing yarns, fabrics and garments. Its home textiles add a new dimension to the group as well as to the economy of Bangladesh. The company is experimenting new material innovation and technology adaptation for diversifying terry towel products into value added item.
Recently Textile Today team has visited the factory and met with the dynamic young entrepreneur Mr. Abdullah Mohammad Talha, Deputy Managing Director of Noman Group and Managing Director of NTTML. Today’s ‘Factory Tales’ is about the beginning, current endeavor and future planning of NTTML.
Motivation of establishment
Noman group is the largest vertically integrated textile group in Bangladesh since 1968. With more than 1 billion US dollars revenue, its export amount is the highest compared to any other companies in Bangladesh. While asked Mr. Talha about the motivation of establishing the terry towel industry he said, “We already have very good experience and reputation in marketing and manufacturing fashion products, fabrics, yarns in both cotton and synthetic form. We also have setup home textile factory long ago. Actually home textiles are the combination of bed textiles, kitchen textiles and bath textiles. Our honorable Chairman inspired in producing diversified products. Therefore, we started terry towel production both for bath and kitchen. Now we have completed home textile package for customers.”
“In towel products we are the first one to bring H& M and IKEA in Bangladesh. H& M started their home textile with Zaber & Zubair and towel business with Noman Terry Towel,” Mr. Talha continued.
Contribution of NTTML
According to Bangladesh Terry Towel and Linen Manufacturers and Exporters Association (BTTLMEA), total home textile export of Bangladesh is about 1500 million USD. Among them terry towel export is close to 250 million USD. Noman Terry Towel contributes around 80 million USD currently and it has employed more than 8500 people.
Factory Inside
NTTML started construction in 2007, finished in 2010. However, they did not get gas supply for two years. Therefore, it started production in April 2012 with around 600-core taka primary investment. Furthermore, 200-core taka was invested later. Total area of the factory is 1 lakh 10 thousand square meters with 30% open area. With three dyeing and three weaving shades, there are 15 shades in total. NTTML has top to bottom setup including yarn dyeing, weaving, fabric dyeing, sewing and finishing. Yarn is sourced from the mother Noman Group’s spinning division.
Machines
NTML believes in “Quality First, Production Must”. To produce right product in right time it uses sufficient amount of modern machineries.
Weaving
Number of Weaving machines = 346,
Including Air Jet, Rapier, Projectile, Jacquard and Dobby
Weaving Production = 85 tons per day
Dyeing
Number of Fabric Dyeing Machines= 23,
Company: Sclavos
Dyeing Capacity= 8o tons per day
Number of Yarn Dyeing Machines= 42,
Company: THIES (Germany)
Dyeing Capacity= 25 tons per day
Sewing
Number of Machines: 9000
Capacity= 85 tons
Products
NTTML has a large variety of products both basic and fancy items including Institutional Towel, Home Towel, Kitchen Towel, Bath Robe, Bath Mate, Beach Towel, Bibs, Hooded Towel, Zero Twist Towel, Bed Spreads etc.
The factory has specialties in velour towel, printed towel, jacquard towel, dobby towel, zero twist towel and embroidery towel and they have plan to introduce bamboo towel from Bangladesh in the future.
Value addition
Towel is a basic product and it often not changes with the trend and time. About 70% of towel consumption is institutional white towel and rest of 20%-30% products is fashion oriented and changes with trend. Mostly cotton is used as raw material. NTTML introduced Viscose, Tencel , Layocell, Modal, Solucell and Jutton into material list.
“We are very focus in product diversification. Our R& D team has much potential to bring innovation in product. We are adapting new technology, innovating material and improving continuously through R& D,” Mr. Talha Told.
He farther continued, “We want to support the R& D and innovation for product development and challenging future trend, but it needs specialized lab. It is very essential specialized lab full of modern machines and talent people to make Bangladesh an innovation hub. It is not possible for me alone to support the R& D platform. The government should come forward and make a policy regarding this. This R& D setup needs to be commercialized for investment.”
Product finishes
NTTML has extensive range of towel finishing technology. They provide below finish to the towel:
- Bleach resistant
- Cosmetic care
- Anti-bacterial
- Bleach fast
- Quick dry
- Soil Release
- Air reach treatment
- Hydrophilic
- Denim wash
- Anti-pilling
- Fragrance finish
- Temperature regulator finish
- Hybrid finish
- Stone wash
- Anti-static
- Shrink-resistance
Sustainability
Sustainability is an integral part of the overall objective of Noman Group. NTTML has kept sustainability in the heart of its business strategy for reducing environmental, social and economic impact. NTTML targeted to reduce its carbon footprint into a minimum level within 2020. The factory ensured 100 % super energy saving LED light that reduced its energy consumption at lower level. The company running a pilot project of 220 KW solar panel, which will be able to reduce 292 tons of CO2 emission per year.
NTTML strives to minimize its environment impact through one of the nation’s biggest biological ETP plant by Panta Rei. The capacity of the plant is 6000 m3/day.
The factory is sustainable throughout its supply chain. All the cotton it sourced is 99% BCI cotton. The company also uses EGYPTIAN, SUPIMA, CMIA cotton. Its dyeing and finishing process consuming as less as much water that minimized to 40 liter of water per kg throughout its full production cycle. It also has condensed recovery plant, heat recovery plant and hot water recovery plant that enable the boiler to generate steam by minimum energy consumption. NTTML has installed flow meter in its water and steam supply pipe. It also uses water efficient tab and water gun that ensures less water wastage.
“We are planning to install zero liquid discharge systems and trying to get out of fossil fuel,” Mr. Talha told. The factory also has recycling project. Its paper waste is recycled into new paper sheet and sent to accessories division to make cartoon.
“ETP sludge needs very careful attention for disposal and further use. Sludge could be used in making brick and could be used as clinker in cement plant. However, there is no policy in sludge management from the government. We need immediate direction from government to make use of sludge for better environment,” Mr. Talha said.
Compliance
The company has achieved all the necessary certification including WRAP, BSCI, GOTS, ISO 9000, OE, OEKOTEX 100, C-TPAT, SEDEX (for responsible supply chain).
NTTML keeps employees at the heart of its community engagement programs, they have introduced ‘Better Wage Initiatives’. In addition to that, they have organized Fair Trade and allow timely salary disbursement through ATM cards to all employees. The factory has fair price shop and hygienic dining facility for all employees. It also has accommodation facility for plant workers.
The company believes in women empowerment and its 80% garments workforces are female. It allows maternity leaves and day care center for infants. It does not allow child labor. The Management is very concern about the well-being of team members and it has invested heavily on Occupational Health and Safety Assessment Certification OHSAS 18001. It has also in-house Medical Facility.
The company has ISO 27001 certification for better information security management, ISO 28001 for supply chain security and safety management, ISO 9001 for quality management and shipment tracking system. “We started construction according to building code. We also rectify these code and conduct for better result. We are also working with Accord and Alliance,” Said Mr. Talha.
Factory runs training activities for skill developments of workers. Currently SEIP project and company DMD himself monitor the training closely. “We regularly train our workers and management stuffs. Through the training our manpower efficiency increased at least 10%,” Mr. Talha added.
ERP
NTTML is playing market leadership role since its beginning. Recently the company starts using
ORACLE for ERP solution. “Oracle is a good ERP system and marketing tool. It allows the company to become process oriented rather than people oriented. I can integrate my process with technology and access one stop information. We are adapting the positive changes continuously,” Mr. Talha explained.
Plan for future
NTTML is the pioneer in towel production and marketing. It is constantly striving and creating new example by its calculative and detail oriented future plan. The company has set target to generate 120 million US dollars revenue this year. The Deputy Managing Director indicates his future plan, “We are trying to get out from cotton dependency, working in material development. We are also working for becoming circular, get rid of fossil fuel in future. We are adapting technology and have planned to setup automation into production to become process oriented rather than people oriented.”
Another plan of the company is to achieve in-house lab accreditation that will minimize third party dependency in testing. The company is very much ambitious to remain years ahead in innovation and implementation. “We are not only working to satisfy customer, but also for delight and loyal customer,” Mr. Talha Told.
India, Pakistan and China are the main competitor for exporting terry towel. They get competitive advantage as they have their own raw materials like cotton and chemical. These countries get their government support and subsidies also. Expressing hope Mr. Talha said to the Textile Today reporter that if our government offers minimum10 percent incentive in towel exporting and develop port facility, Bangladesh would grow much better in Terry Towel sector.
