Company Profile & Sustainability Efforts 2018/2019 - www.sharabati-denim.com
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Company Profile &
Sustainability Efforts
2018/2019
info@sharabati-denim.com
www.sharabati-denim.com
Index
1. About us ............................................ 4
A message from our Chairman .............. 4
What we do ............................................ 5
Milestones .............................................. 6
Company structure ................................. 7
Markets ................................................... 7
2. Delivering optimal performance...... 8
Products .................................................. 8
Processes ................................................ 9
Customer service .................................... 10
Delivery .................................................. 10
3. Sustainability ..................................... 12
Our commitment to the environment .... 12
TADWEER: closing the loop on production waste ... 16
Compliance ............................................ 18
4. Social responsibility .......................... 19
Caring for our employees and
communities............................................ 19
3
1. About us
1.1. A message from our 1.2. What we do Year Location Total Capacity
Chairman Sharabati Denim is one of the largest
integrated textile manufacturers in the 1978 Syria 1 million metres
Heritage, innovation and transformation
are the core values that lay at the heart of Middle East, Egypt and Turkey, producing
Sharabati Denim, which was established in 100 million running meters of fabric annually. 1984 Syria 2.5 million metres
1978 in Aleppo, the industrial city of Syria.
We oversee the entire process of denim and
1989 Syria 5 million metres
I owe the company’s success and flat fabric production, from sourcing high
international presence to our performance quality raw materials to producing yarn,
infrastructure and dedicated team. Our finished denim and flat fabrics. As a family- 1992 Syria 10 million metres
development and transformation plan have owned business, we promote a supportive,
enabled us to become a world leader in the inclusive working environment and prioritize Syria
1998 18 million metres
production of denim and gabardine. our 3,790 employees’ health and safety. Egypt
Syria
The robust tracking and reporting systems We have successfully expanded over the 2004 33 million metres
Egypt
at Sharabati Denim continue to achieve years, nearly doubling our production every
unfaltering commitment to quality and seven years, and now operate factories in 2017 Egypt 55 million metres
customer service. Sadat City, Egypt, and Kadirli, Turkey. With
sales offices in Germany, Italy, Turkey, Egypt, Egypt
Tunisia and Morocco, we serve customers 2018 100 million metres
At Sharabati Denim, we take social and Turkey
environmental sustainability seriously. We worldwide.
strive to maintain a high level of corporate
responsibility, which enables the longevity of
100Million
our business for future generations.
Sincerely,
Mohammed Sabbagh Sharabati, Chairman meters of running
fabric/year
4 5
1. About us
1.3. Milestone 1.4. Company structure
Year Milestone Product Egypt Turkey
Headquarters and factory - export sales Factory
Sabbagh Sharabati founded by
1978 Flat fabric - Corduroy
Mohamad Sabbagh Sharabati in Aleppo Syria
Alroubaia Textile Co. Fourtex JNR Mensucat Tekstil
1984 First denim line in Syria Denim - Flat fabric - Corduroy
Sales Offices
1989 Expansions in Syria Denim - Flat fabric - Corduroy
With warehouses
- Egypt (Cairo)
1992 Expansions in Syria Denim - Flat fabric - Corduroy - Turkey (Istanbul)
- Morocco (Casablanca/Tanja)
- Tunisia (Sousse)
1998 Foundation of Alroubaia Textile Co. Fourtex Egypt Denim - Flat fabric - Corduroy
2004 First flat fabric line in Egypt Denim - Flat fabric - Corduroy Without warehouses
- Italy
- Germany
2005 First international sales office in Turkey Denim - Flat fabric - Corduroy
2011 Major expansion in Egypt Denim - Flat fabric
1.5. Markets
Sales office in Tunisia
2014 Denim - Flat fabric Sharabati Denim is strategically located
Sales office in Germany
at both the south and north of the
Mediterranean. This means we are uniquely
2014 Creation of Sharabati Denim Brand Denim - Flat fabric
placed to serve local and international
textiles and apparel markets. Today, from
2015 Sales office in Morocco Denim - Flat fabric Egypt headquarters and our base in Turkey,
we export our products to more than 100 top
2016 Foundation of JNR Mensucat in Turkey Denim - Flat fabric
fashion brands in 27 countries, in particular to
Europe, North Africa and the Far East.
2017 Sales office in Italy Denim - Flat fabric
2018 Expansions in Egypt Denim - Flat fabric
27
Sharabati Denim exports fabrics to 127 top fashion
brands in 27 countries.
6 7
2. Delivering Optimal Performance
Delivering optimal product and sustainability 2.1. Products 2.2. Processes
performance is in Sharabati Denim’s DNA.
We offer outstanding reliability and flexibility
to our customers from start to finish. We 2.1.1 High quality raw materials 2.2.1 State-of-the-art technology
continue to respond rapidly to evolving Our strategic location allows us to source We harness the latest technology and best
customer requirements, offering efficient and high quality raw cotton from Africa, Greece practices to ensure flexibility, high levels
timely delivery. and the United States. In particular, we have of accuracy and quality at every level of
achieved the Egyptian Cotton Trade Mark production: spinning, weaving, dyeing and
Certification, which enables us to produce finishing. We continuously evaluate our
superior fabrics made of 100% Egyptian progress, optimize our processes and invest
cotton - the highest quality cotton in in state-of-the-art technology.
the world. Products made from Egyptian
Cotton1 are known to be softer, finer and 2.2.2 Quality control
more durable than any other cotton products
We use world-leading fiber quality control
worldwide.
technologies in our spinning mills, such as
USTER systems. We also use the American
2.1.2 A wide range of fabrics
Society for Testing and Materials (ASTM) and
In 2018, our production was divided into 60% American Association of Textile Chemists
denim and 40% flat fabric. Our fabric weights and Colorists (AATCC) standard methods
range from 3.5 oz./y² to 14.5 oz./y². of testing fibers and fabrics to measure and
evaluate performance characteristics
The beginning of 2019 brought a new life to
our product range. At the Munich Fabric Start
2019 fair, we introduced for the first time a set 2.2.3 Research and development
of concepts for our fabrics. These concepts
Our expert R&D and sales teams work with
gave our denim and flat fabrics meaning and
leading brands to keep pace with evolving
provided a fresh and integrated platform to
fashion and style trends, holding regular
market our fabrics to our customers.
customer meetings and participating in joint
product development projects. We also stay
Fabric types by informed of the latest trends by participating
Materials in key international fairs such as the Kingpins
appearance*
Show Amsterdam, Kingpins Show New York,
Denim 100% cotton, stretch Selvedge, vintage,
fabrics (comfort, power, su- blended, strip, fancy, Premier Vision Istanbul, Munich Fabric Start,
per and hyper stretch) crossage and printed. Bangladesh Denim Expo and Maroc in Mode.
and bi-stretch. Our collections are designed twice a year and
Flat 100% cotton, stretch Dyed, bull denim, showcased worldwide.
fabrics (comfort, power, su- blended, strip, fancy
per and hyper stretch) and printed. Our flat
and bi-stretch. fabrics are deliv-
ered either dyed or
prepared for dyeing
(PFD).
* Selvedge, printed, blend and strip are produced soon
1
Cotton Egypt Association (CEA)
https://www.cottonegyptassociation.com
8 9
2. Delivering Optimal Performance
2.2.4 In-house innovation lab Sharabati Denim is an early adopter of
State-of-
Through this platform hosted in our factories
in Egypt, we create incubators for future
product development collaborations with
leading denim brands. Our laboratory
the-art
comprises a stitching unit, laundry unit,
showroom and working booths (dedicated
workspaces for each partner brand). Working
with experienced washing experts from the
world, we develop wash concepts that reflect
our customer’s overall desired look and feel technology
for the upcoming season.
2.3. Customer Service
Our flexible system allows us to manipulate
the order of production to create new fabrics
when handling special requests with rapid
delivery dates. Moreover, we offer an in-
house laundry service.
2.4. Delivery
With a large supply of diverse raw materials,
a significant production capacity and 40
years of experience, we offer timely repeated
fabric delivery from both production sites
(Egypt, Turkey). Additionally, we can serve
our customers with warehouses strategically
located in Morocco and Tunisia. Moreover,
by providing Movement Certificates, our
customers can benefit from trade terms such
as COMESA agreement, Agadir agreement,
Euro-Med, EUR.1, Form A and an Arab
League Certificate of Origin. Additionally, we
offer air freight delivery options.
10 11
3. Sustainability
3.1. Our commitment to the means we produce zero effluents during the 3.1.2 Optimizing our use of
environment process and save water. electricity
In 2019, we began trials for a denim dyeing
At Sharabati Denim, we have a We use electricity through our production
chemical that is used in multiple dyeing
longstanding commitment to environmental facilities. We are making energy savings by
processes. This chemical can have the effect
sustainability, and are among the leaders adding modern energy-saving machines
of waterless dyeing in one process, and zero
of the sustainability movement in the and taking steps to save energy in our office
water discharge in another. Our trials have
Mediterranean region. We focus on the buildings.
been successful and the chemical is under
areas where we stand to make the greatest
development to be extended to most of our
difference: conserving water and improving Energy saving at our headquarters and
production.
wastewater quality, optimizing our use of factory offices
energy, and managing chemicals responsibly. We have modified the air conditioning
Treating wastewater effectively
We also place an increasing focus on system at our head offices in Egypt to
At our flagship factory in Egypt, we conduct
sustainable raw materials, recycling and operate more efficiently and provide
effluent purification in wastewater treatment
closed loop manufacturing. We adhere to good quality, sufficiently humid indoor air,
plants through a biological process. In 2011,
international standards on health and safety, promoting a healthy working environment.
we established a biological treatment plant
quality, chemicals and sustainable materials Additionally, we have replaced conventional
for our expanding production sites with a
(please see Compliance). Additionally, we air conditioning systems with evaporative
daily capacity of 1,000 cubic meters per day.
comply with national and local environmental coolers (desert coolers). Evaporative coolers
The characteristics of the biologically treated
regulations. use less energy while operating when
water discharged into the public wastewater
compared to typical air conditioning units
system are within legal limits. The resulting
3.1.1 Conserving water and and produce very low CO2 emissions.
sludge (biological effluent treatment) is
improving water quality Saving electricity in spinning mills, we select
delivered to a specialized government
our spinning machines primarily based on
Saving water in denim dyeing and finishing agency for further treatment. Similarly, solid
energy-saving criteria. Over the past two
We have steadily decreased the volume and liquid wastes are pre-treated before
years in Egypt, we have made the following
of water we use in denim dyeing, nearly being delivered to the government for
savings, while extending our spinning mills:
halving our water consumption between further treatment. In addition to our internal
2010 and 2018. To achieve this, we added daily monitoring, regular measurements are
Saving electricity in spinning mills
multiple rope dyeing lines that use less also conducted in independent laboratories.
We select our spinning machines primarily
water for washing. In 2018, we also reached based on energy-saving criteria. Over the
a considerable saving of water in our Caustic Recovery Plant (CRP)
past two years in Egypt, we have made
denim finishing processes by updating and Our CRP recovers up to 75% of the
extensive energy savings, while extending
automating our existing dyeing lines. used caustic soda from the mercerizing
our spinning mills.
wastewaters. This unit allows us to reuse
Innovations in waterless dyeing and zero the caustic soda in our production, instead
Reducing heating requirements in denim
water discharge of discharging it (and treating it with
dyeing
To conserve water and reduce our use of chemicals) and reduces the waste load on
We used cold dyes (with a dyeing
chemicals, we are exploring best practice in our wastewater treatment plant. Additionally,
temperature of between 40 and 50°C) to
waterless dyeing. In 2017, we began using we use the heat released through the
save electricity and water in the laundry
dyes based on the chemistry of solubilized exchangers to heat industrial water. We also
washing process. To save energy in the
sulphur dyes. This new range of sustainable recapture the water evaporated from the CRP
denim dyeing process, we reuse condensate
dyes is affinity-free and sulphide-free, and and reuse it in the mercerizing machine.
return water and opt for cold dyes that
suitable for the Global Organic Textile require less heating in the dyeing process.
Standard and BLUESIGN certification
(obtained by our supplier). Importantly, this
12 13
3. Sustainability
45%
Saving electricity in denim finishing Improving wastewater quality through
In 2017, we added a continuous finishing efficient sizing
We have steadily decreased the
line for denim to our existing lines. This By adopting an innovative sizing method
eco-line offers a more controllable process,
volume of water we use in denim in our factories, we saved 22% of sizing
less steam, less electricity, lower water
dyeing, nearly halving our water materials in 2018. Sizing solutions can be run
use between 2010 and 2018
consumption and lower costs. reduction in water use at lower temperatures, saving electricity as
in denim dyeing well as creating a safer and more comfortable
3.1.3 Managing chemicals work environment for the machine operator.
responsibly This method also allows us to reduce the
chemicals and water needed in the desizing
Chemicals are used throughout garment
process, which in turn improves the quality of
and textile production to dye fabrics and
our wastewater.
give them performance characteristics. In
addition to complying with regulations and
Switching to safer substances for desizing
producing OEKO-TEX certified fabrics, we
Since 2017, and until today, we further
are reducing our use of chemicals by using
improved the sustainability of this process by
more sustainable dyes and re-engineering
completely switching from enzymatic (non-
dyeing processes and installing chemicals
soluble starch) to non-enzymatic (soluble
recovery and water treatment units.
starch) desizing. We also modified our
desizing method, achieving considerable
Reducing chemical use with pre-reduced
savings in desizing materials in 2017 - 2018.
liquid indigo
We were among the early adopters of the
Reusing yarn carriers
pre-reduced liquid indigo in 2005. This
Our integrated production allows us to reuse
dyeing method reduces our direct chemical
durable yarn carriers for spun yarns. Cones
use and is safer for our employees, who
and separators used in the transportation of
avoid handling the chemicals previously
our spun yarns to our weaving department
used in the powder indigo dyeing. Using
are reused several hundred times. By using
pre-reduced liquid indigo in 2017 - 2018,
carriers made of durable materials instead of
we avoided using considerable amounts of
paper, we save 580 tonnes of paper annually
chemicals, compared to powder indigo:
in our spinning mills in Egypt:
• 550 tonnes of paper are saved per year for
• 58.8% less sodium hydrosulphite
using durable cones.
• 54% less sodium hydroxide
• 30 tonnes of paper are saved per year for
• 19.4% fewer wetting agents
using durable separators.
• 62.5% less dispersing agent
• 22.5% less sequestering agent
Recycling e-waste and promoting
rechargeable batteries
Opting for more sustainable sulphur dyes
We collaborated with RecycloBekia to recycle
In 2016, we started replacing the reducing
our electronic waste and remove any data
agent within the sulphur dyeing process
from end-of-live machines in a safe and
with a more sustainable reducing agent. In
sustainable way. To protect the environment
2018, we decreased the consumption of the
and save costs, we also use rechargeable
reducing agent by 50% by replacing it with
batteries to replace all types of single-use
dextrose.
batteries.
14 15
3. Sustainability
3.2.4 Sustainable knowledge and manage energy. We used multiple
transfer techniques including wind catchers, solar
screens, self-shading, a solar chimney and
Building on our 40 years of experience
3.2. TADWEER: Closing the in continuous innovation for quality and
multiple alterations to move light deeper into
loop on production waste sustainability, we will leverage the knowledge
the workplace and control natural ventilation.
Future sustainable building initiatives at
Our strategic business unit, TADWEER, we develop through TADWEER to promote
TADWEER will encompass the installation of
established in 2018, is among the first of its further circular and sustainable practices
solar water heaters and the use of recycled
kind in the region. At TADWEER, we primarily across our business.
grey water for toilet flushing and irrigation.
recycle fabric and cotton waste generated
through the spinning, weaving, finishing 3.2.5 Towards sustainable building
and sampling processes, closing the loop certification
on fabric waste. We are also planning to TADWEER’s main office building was
integrate post-consumer waster as secondary designed to stimulate natural ventilation
raw material. Our state-of-the-art recycling and promote daylight in order to save
plant has the capacity to recycle 8,000
tonnes of waste material annually to produce
yarns and non-wovens.
3.2.1 Vertically integrated
production
TADWEER is vertically integrated with our
production lines providing Sharabati Denim
with an ongoing supply of recycled fibers for
our fabrics, and allowing us to create our own
raw materials from waste.
3.2.2 Closing the loop
Sharabati Denim will direct all waste from
spinning, weaving, finishing and sampling
processes to TADWEER, closing the loop on
our own production process.
3.2.3 Quality without compromise
Our pioneering closed loop initiative
will further support our goal to provide
customers with high quality products that
comply with international standards for
quality and sustainability. We can adapt the
recycling process to produce diverse types of
raw materials, depending on our customers’
fabric requirements, continuing to deliver on
our commitment to be a reliable and flexible
partner.
16 17
3. Sustainability 4. Social Responsibility
3.3. Compliance Cotton is grown in 23 countries worldwide. By 4.1.2 Promoting employee
2030, BCI aims to have reached 5m farmers wellbeing
producing 8.2m metric tonnes of Better
3.3.1 Quality We have created high quality
Cotton annually.
accommodation for workers comprising 27
ISO 9001:2015 This international quality GOTS: Gaining GOTS certification apartment buildings. The 376 housing units
management system confirms that we provide demonstrates the organic status of textiles cover approximately 34,000 m2. We provide
products that meet customer and applicable to consumers. It considers everything from accommodation suitable for families, couples
statutory and regulatory requirements, and we raw materials to manufacturing (such as and singles, offering affordable payment
take steps to enhance customer satisfaction wastewater treatment and labour standards) plans over the long term. Additionally,
through managing our system effectively and to labelling. This is very important in light of residents have access to multiple services,
continuously improving our practices. the growing importance of transparency in including a three-story shopping mall
the garment industry. The Standard can be totaling 2,400 m2, enabling them to adopt
applied to textiles made from at least 70% a low carbon emission, sustainable lifestyle
3.3.2 Health and safety certified organic natural fibres. by purchasing fresh food and drink without
BS OHSAS 18001 This BSI Group GRS: We have achieved Global Recycled travelling long distances by car.
Occupational Health and Safety Management Standard certification for our Egypt plants,
Certification is an international standard 4.1.3 Workplace health, well-being
which can be applied to fabrics that are at a
providing a framework to manage workplace minimum of 20% recycled yarn. Our Tadweer and safety
health and safety risks. Implementing this plant regenerates recycled fibers and yarns Workplace health, wellbeing and safety our
standard further confirms our commitment to from pre-consumer and post-consumer hard mills are equipped with advanced systems
our employee’s health and safety. waste, which are then re-used in our fabric for air filtration and conditioning. These
production. systems serve a dual function in terms of
COTTON MADE IN AFRICA: This initiative guaranteeing a clean and healthy working
3.3.3 Chemical management environment for the workforce in addition to
has set itself the goal since 2005 to
STANDARD 100 by OEKO-TEX®: The sustainably improve the living conditions of improving the performance of the machines
STANDARD 100 by OEKO-TEX® is a globally cotton farmers in Sub-Saharan Africa. The and therefore the quality of the product.
recognised, independent textiles testing and initiative is based on the principle of helping Our head office employees and factory
certification system. The fabrics we produce people to help themselves through trade: 4.1. Caring for our workers in Egypt enjoy free, nutritious
with OEKO-TEX® labelling confirm to our meals prepared daily on-site from a variety
African smallholders learn about efficient and employees and communities
customers that we have tested our fabrics for environmentally friendly cultivation methods of locally purchased fresh ingredients.
harmful chemicals. through agricultural training provided by The menus include a variety of recipes to
experts. At the same time, the initiative promote healthy diets. Our central kitchen
4.1.1 Employee training
establishes an international alliance of textile and bakery distribute around 1,500 meals a
3.3.4 Sustainable materials companies which purchase the Cotton made
We are committed to providing our day in our factories in Egypt. All meals are
employees with the highest standards of prepared in accordance with international
BETTER COTTON INITIATIVE (BCI): in Africa raw material and pay a licensing fee
training in multiple fields, in order to help hygiene rules and served in 11 canteens in
Through the Better Cotton Standard to use the seal. The proceeds from licensing
them stay up to date with the latest spinning, Fourtex, Egypt.
System, BCI aims to take sustainable cotton fees, in following with the workings of a social
weaving and dyeing/finishing knowledge, We have well-equipped medical offices
mainstream by helping farmers to cultivate business, are reinvested in the project regions
and further promote their language and providing first aid and pharmacy services
cotton in a way that is better for people, the of Sub-Saharan Africa.
computer skills. In 2017 and 2018, more than to our employees. Our employees in Egypt
environment and their livelihoods. Better
one hundred employees in our factories in also have access to a subsidized, fully
Egypt benefited from English classes given functional, on-site gym and we support our
by a professor from the American University local communities both economically and via
of Cairo. educational and health initiatives.
18 194. Social Responsibility
4.1.4 Promoting textile education
We collaborate with higher local educational
institutions specialized in textile education.
This cooperation includes welcoming
students to visit our factories and discover
our running machines. In 2016 and 2017,
we hosted 88 students. We also offer in-mill
internships for university students specializing
in textiles. In 2017, we received 10 students.
Additionally, we provide key institutions with
educational tools. For example, in 2016,
Sharabati Denim donated one loom to the
University of Menoufia in order to establish a
new textile department.
4.1.5 Sharing safety best practice
We offer free training for neighboring
factories in work safety standards. In 2016,
95 workers benefited from this activity,
in cooperation with local and national
authorities and the International Labour
Organization.
4.1.6 Supporting our employees’
families
We support our employees’ families by
facilitating access to healthy food, health
clubs, and scholarships and educational
financial aid. Contributing to our local
economy In Egypt, we run an initiative called
‘Proudly made in Egypt’, which aims to
introduce consumers to Egyptian products
that adhere to high quality standards,
replacing imported goods.
20 21Egypt
Headquarters & Factory (Export Sales)
Alroubaia Textile Co. Fourtex
3rd Industrial Zone Extension
El-Sadat City
P.O. Box: 148
t: +20 482659023/24
Sales Office
19 Dr El Mahroky St.
Salah Salem St. – after Air Force House
Heliopolis
Cairo
t: +20 222901530
Turkey
Factory
JNR Mensucat Tekstil Sanayi Ve Ticareet A.Ş.
Yusuf İzzettin Köyü Mahallesi
Kadirli Organize Sanayi Bölgesi 2.Etap
2.Kisim
Kadirli
t: +90 328 717 00 04
Sales Office
JNR Mensucat Tekstil Sanayi Ve Ticareet A.Ş.
Merkez Mah. Sanayi Cad. No.5
Bahcelievler - Yenibosna
Istanbul
t: +90 212 637 64 21
Germany
Sales Office
Tunisia SGS Textilhandels GmbH
Sales Office and Warehouse Adolf-Kolping – Strasse 39
Zi Sidi Abdelhamid Holzkirchen
Sousse Bavaria
P.O. Box: 4003 P.O. Box: 83607
Morocco Italy
Sales Office and Warehouse Sales Office
Bd AL Qods, N° 115 Via Pasubio, N° 5
Etg 1 Appartement 12, San Lazzaro di Savena (BO)
Casablanca Bologna
P.O. Box: 20460 P.O. Box: 40068You can also read
