GOOD MANUFACTURING PRACTICES (GMP) FOR TEXTILE WET PROCESSING

Vijay Shirole

Senior Scientific Officer – I

Technical Service Department, BTRA Mumbai

Abstract

Good manufacturing practices (GMP) for textile wet processing industries are a set of guidelines and regulations that aim to ensure the consistent and safe production of textiles. These guidelines cover areas such as worker safety, environmental protection, product quality, etc., and are designed to minimise the risk of contamination and defects in the finished products. 

Keywords

GMP, Compliance, Guidelines, Regulations, Standardisation, Set of guidelines, Standard Operating Procedure, Good Practices, Work Instruction, Etc.,

Citation

Introduction

Good Manufacturing Practices (GMPs) for wet processes carried out in the textile industry involve a set of guidelines and regulations that are designed to ensure that products are consistently produced and controlled according to quality standards.

Implementing GMP can help to improve compliance, Productivity, Safety, Work culture, Quality, and customer trust. It also minimizes waste and maintains the integrity of the fabric. Overall, it protects both companies and the consumer from negative events.

What is GMP

Good Manufacturing Practices or GMP is a system that consists of processes, procedures, and documentation that ensures manufacturing products, such as fabric, Garments, etc., are consistently produced and controlled according to set quality standards. 

This includes strict control of the manufacturing process, such as proper sanitation and cleanliness, accurate record keeping, and regular testing of products. 

Benefits of GMP 

Adherence to GMP guidelines can help textile manufacturers improve their operations, reduce costs, and produce high-quality products that meet the needs and expectations of their customers. GMP is beneficial to the textile industry in several ways:

• Compliance with regulations: By adhering to GMP guidelines, textile manufacturers can ensure that their products meet the relevant regulatory requirements. This can help avoid fines and other penalties for non-compliance.
• Consistent quality: GMP standards help ensure that products are consistently manufactured to a high level of quality, reducing the risk of defects and product recalls. This can help build customer trust and loyalty.
• Increased efficiency: GMP guidelines often include recommendations for optimizing manufacturing processes, reducing waste, and improving productivity. By implementing these best practices, textile manufacturers can reduce costs and increase profitability.
• Improved safety: GMP standards include measures to ensure that products are safe for consumers to use. This can include testing for harmful substances, implementing safety protocols, and providing appropriate labeling and instructions for use.

Importance of GMP

GMPs examine and cover every aspect of the manufacturing process to guard against any risks that can be catastrophic for products. Some of the areas that can influence the safety and quality of products are as addressed below,

• Quality Control

• Compliance

• Production efficiency

• Consumers trust

• Environmental protection

• Sanitation and hygiene of facility, equipment, and staff

• Storage and handling of chemicals

• Maintenance and calibration of equipment

• Record keeping of all production activities

• Training of staff

The goal of GMPs is to minimise the risk of product contamination and ensure that the textiles produced meet the desired quality standards. We further go into detail on these major aspects.

1. Total Quality Management (TQM)

Quality control is a critical aspect of Good Manufacturing Practices (GMPs) in the textile wet processing industry. 

Here are some specific ways in which quality control is implemented in the textile wet processing industry:

• Establishing and maintaining written standard operating procedures (SOPs) for all processes and activities that affect the quality of the products.
• Regular testing and inspection of raw materials, intermediate products, and finished products to ensure that they meet the desired quality standards.
• Implementation of a system for identifying and traceability of products and raw materials.
• Implementation of a system for handling and investigating customer complaints and non-conformities.
• Keeping accurate records of all production, testing, and quality control activities, and reviewing these records regularly to identify any trends or issues that may need to be addressed.
• Regularly conducting internal audits and inspections to ensure compliance with GMP guidelines and regulations.
• Establishing and maintaining a quality management system (QMS) that includes a system for continuous improvement and regularly reviewing it for effectiveness.

2. Compliance:                                          

     Compliance with Good Manufacturing Practices (GMPs) in the textile wet processing industry is essential to ensure that products are consistently produced and controlled according to quality standards and regulations. Textile industries are subject to a range of compliance regulations, including:

• Environmental Compliance: This includes regulations related to water and air pollution, waste management, and energy conservation.
• Labour Compliance: This involves adhering to laws and regulations related to worker rights, health and safety, and fair labor practices.
• Product Safety Compliance: This refers to ensuring that textile products meet safety standards, such as those related to flammability, lead content, and labeling requirements.
• Import/Export Compliance: This involves meeting the regulatory requirements of importing and exporting goods, including customs, tariffs, and quotas.
• Ethical Compliance: This involves ensuring that textile production processes are ethical and do not involve forced or child labor.
• Intellectual Property Compliance: This refers to adhering to laws and regulations related to trademarks, patents, and copyrights in the textile industry.
• Quality Compliance: This involves meeting quality standards for textile products, including specifications for fiber content, construction, and finish.

Here are some specific ways in which compliance is implemented in the textile wet processing industry:

• Ensuring that the facility, equipment, and staff meet the required standards for sanitation, hygiene, and safety.
• Implementing a system for identifying and traceability of products and raw materials.
• Keeping accurate records of all production, testing, and quality control activities and reviewing these records regularly to identify any trends or issues that may need to be addressed.
• Establishing and maintaining a quality management system (QMS) that includes a system for continuous improvement and regularly reviewing it for effectiveness.
• Maintaining proper documentation and records to demonstrate compliance with the regulatory bodies during inspections.
• Ensuring that all necessary licenses, permits, and certifications required by the local regulations and industry standards are up to date.
• Keeping track of the regulatory updates and changes in the industry and adapting accordingly.

3. Production Efficiency:

Here are some specific ways in which production efficiency is implemented in the textile wet processing industry:

• Utilizing advanced technology and equipment that are designed to improve production efficiency and reduce costs.
• Implementing a system for monitoring and controlling production processes, such as Statistical Process Control (SPC) and Total Quality Management (TQM).
• Establishing and maintaining written standard operating procedures (SOPs) for all processes and activities that affect the efficiency of production.
• Implementing a system for identifying and resolving production bottlenecks and delays.
• Implementing a system for employee training, development, and performance management to ensure that staff members are skilled and motivated to improve production efficiency.
• Establishing and maintaining a preventive maintenance program for equipment and facilities to reduce downtime and improve equipment efficiency.
• Implementing a system for monitoring and controlling inventory levels to ensure that raw materials, intermediate products, and finished products are available when needed.
• Implementing a system for continuous improvement and regularly reviewing it for effectiveness.

4. Consumer trust:

Consumer trust helps to ensure that customers have confidence in the quality, safety, and compliance of textile products. Here are some specific ways in which consumer trust is implemented in the textile wet processing industry:  

• Communicating transparently about the production processes and the materials used in the production of textile products.
• Providing accurate and detailed information about the textile products, including the materials used, the manufacturing process, and the certifications and standards that the products meet.
• Implementing a system for handling and investigating customer complaints and non-conformities.
• Maintaining certifications such as Oeko-Tex, Global Organic Textile Standard (GOTS), and other relevant certifications that demonstrate compliance with industry standards and regulations.
• Maintaining a robust quality management system (QMS) that includes a system for continuous improvement and regularly reviewing it for effectiveness.
• Implementing strict measures to ensure that the products are safe, free from contamination, and meet the desired quality standards.
• Building a reputation of trust and reliability among customers and suppliers, by consistently meeting or exceeding expectations.

5. Environmental Protection:

Environmental protection helps to ensure that textile products are produced in an environmentally responsible manner. Here are some specific ways in which environmental protection is implemented in the textile wet processing industry:

• Implementing a system for reducing energy consumption, such as using energy-efficient equipment and implementing energy-saving practices.
• Implementing a system for reducing water consumption, such as recycling and reusing water, and implementing water-saving practices.
• Implementing a system for reducing waste, such as recycling and reusing materials, and implementing waste reduction practices.
• Implementing a system for reducing chemical usage and disposal, such as using non-toxic or less toxic chemicals and implementing chemical management practices.
• Implementing a system for monitoring and controlling emissions, such as air and water emissions, and implementing emission reduction practices.
• Implementing a system for monitoring and controlling environmental performance, such as conducting regular environmental audits and implementing a system for continuous improvement.
• Implementing a system for complying with relevant environmental laws, regulations, and industry standards.
• Implementing sustainable practices like the use of organic cotton, sustainable dyes, and low-impact production techniques.

6. Sanitation and hygiene of the facility, equipment, and staff

Proper sanitation and hygiene of the facility, equipment, and staff is an important aspect of Good Manufacturing Practices (GMPs) for textile wet processing industries. This includes:

• Regular cleaning and disinfection of the facility, equipment, and work areas to prevent the build-up of dirt, dust, and other contaminants.
• Adequate ventilation and air filtration systems to maintain a clean and safe work environment.
• Proper sanitation and hygiene are essential to prevent product contamination and ensure the safety of the staff. It also helps to maintain the quality of the final product and ensures that the facility is operating in a compliant and efficient way.
• Implementation of strict hygiene rules, such as prohibiting eating or smoking in the production areas.
• Regular pest control measures prevent the presence of pests that could contaminate the products.
• Proper waste management, such as separating and disposing of hazardous and non-hazardous waste properly.
• Establishing procedures for cleaning, sanitizing, and maintaining equipment and facilities.
• Regular inspections and audits of the facility, equipment, and staff to ensure compliance with GMP guidelines.
• The water quality should be regularly tested and monitored to ensure that it meets the required specifications for the specific process.
• Water used in textile wet processing should be stored in appropriate tanks or reservoirs and should be kept separate from other types of water (e.g., drinking water, wastewater).
• It is also important to have an emergency plan in case of water contamination or interruption of the water supply
• Proper documentation should be maintained of the water treatment and monitoring process.

7. Storage and handling of chemicals

Proper storage and handling of chemicals help to prevent chemical accidents, protect the health and safety of the staff, and prevent product contamination. It also helps to ensure that the facility is operating in compliance with local regulations and industry standards.

Here are some specific ways in which storage and handling are implemented in the textile wet processing industry:

• Chemicals should be stored in a designated area, away from heat sources, and with appropriate ventilation.
• Chemicals should be labeled with their proper name, hazard information, and handling instructions.
• Chemicals should be stored in their original containers, and should not be transferred to other containers unless it is necessary.
• Hazardous chemicals should be stored in compliance with local regulations, such as keeping flammable chemicals away from heat sources and providing appropriate fire protection.
• Chemicals should be kept in their original containers with their original labels and stored in a secure, dry, and well-ventilated area.
• Only authorized personnel should handle chemicals, and they should be trained on the proper handling and storage procedures.
• Personal protective equipment (PPE) should be used when handling chemicals and emergency procedures should be in place in case of chemical spills or releases.

8. Maintenance and calibration of equipment

Regular maintenance and calibration of equipment help to prevent equipment breakdowns and to ensure that the equipment is operating safely and efficiently. It also helps to prevent product contamination and to ensure that the facility is operating in compliance with local regulations and industry standards.

It also helps to prolong the life of the equipment and reduces the cost of repairs and replacements

• Equipment should be regularly inspected, cleaned, and maintained to ensure that it is in good working condition and operating at optimal efficiency.
• Preventive maintenance schedules should be established, and equipment should be serviced and repaired as needed.
• Critical equipment should be inspected and calibrated regularly to ensure that it is operating within the manufacturer’s specifications.
• Proper documentation should be kept of all maintenance and calibration activities, including the date, the equipment or process involved, and the results.
• Equipment operators should be trained to identify and report any equipment malfunctions or problems.
• A preventive maintenance program should be in place and records of all maintenance activities should be kept.

9. Record keeping of all production, testing, and quality control activities

 Accurate record-keeping of all production, testing, and quality control activities is an important aspect of Good Manufacturing Practices (GMPs) for textile wet processing industries.

• Detailed records should be kept of all production, testing, and quality control activities, including the date, the product or process involved, the results, and any corrective actions taken.
• Records should be legible, accurate, and complete, and should be easily accessible for review and inspection.
• Records should be kept for a specified period, as required by local regulations or industry standards.
• Records should be stored in a secure location to prevent unauthorized access or alteration.
• A system should be in place for the review and approval of records.
• Quality control records should be maintained for each batch or lot of products processed and for each batch of raw materials used.

10. Training of staff

Training of staff on Good Manufacturing Practices (GMPs) guidelines and procedures is an important aspect of textile wet processing industries.

• All staff members who are involved in the production, testing, and quality control of textile products should be trained on the GMP guidelines and procedures that are relevant to their job responsibilities.
• Training should include the proper handling and storage of chemicals, equipment operation, sanitation and hygiene, and emergency procedures.
• Training should be provided regularly and should be updated as necessary to reflect any changes in GMP guidelines or procedures.
• A record of training should be kept and updated regularly, including the date of the training, the staff members who were trained, and the topics covered.
• Training should also include the proper use of personal protective equipment, emergency response procedures, and the proper disposal of hazardous waste.
• All employees should be trained and knowledgeable in the GMP procedures of the company and the industry.
• Proper training of the staff ensures that they are aware of the GMP guidelines and procedures and that they understand the importance of following these guidelines to ensure the safety, quality, and compliance of the products. It also helps to prevent product contamination and to ensure that the facility is operating in compliance with local regulations and industry standards.

DEPARTMENT-WISE GOOD MANUFACTURING PRACTICES:

Good manufacturing practices (GMP) in textile wet processing industries are essential to ensure the quality and safety of the finished products. Here are some department-wise key practices:

Pre-treatment Department:

• Ensure that the incoming fabric is inspected for defects, damage, and contamination before processing.
• Clean the fabric before processing to remove dirt, dust, and other contaminants.
• Maintain the required temperature and humidity levels in the processing area to ensure the proper performance of the chemicals.
• Use proper personal protective equipment (PPE) such as gloves, goggles, and masks when handling chemicals.

Dyeing Department:

• Follow the standard dyeing recipe and ensure that the correct amount of chemicals are used.
• Maintain the required temperature and pH levels for dyeing.
• Ensure that the dyeing machines are clean and free from contamination.
• Avoid cross-contamination by separating dyeing machines for different colors.
• Clean and maintain the dyeing machines regularly.

Printing Department:

Here are some GMPs that can be applied specifically to the printing department in the textile wet processing industry:

• Ensure that the printing paste is prepared as per the standard recipe.
• Keep the printing machines clean and free from contamination.
• Avoid cross-contamination by using separate screens and machines for different colors.
• Use proper PPE when handling printing paste and chemicals.
• Clean and maintain the printing machines regularly.

Finishing Department:

Here are some GMPs that should be observed in the finishing department of textile wet processing industries:

• Follow the standard recipe for finishing chemicals and ensure that the correct amount is used.
• Maintain the required temperature and humidity levels in the processing area.
• Keep the finishing machines clean and free from contamination.
• Use proper PPE when handling finishing chemicals.
• Clean and maintain the finishing machines regularly.

Overall, it is essential to ensure that all the workers in the textile wet processing industries are trained in GMP and follow the guidelines to maintain the quality of the finished product, minimize the risk of contamination, and ensure their safety.

Steps in GMP audit:

Preparation: Gather information about the company and the products being manufactured, review company policies and procedures, and create an audit plan.

Site Arrival: Meet with key personnel, confirm audit scope and objectives, and review the audit schedule.

Document Review: Review and assess the quality management system documentation, including standard operating procedures and records.

Plant Tour: Observe the manufacturing process, including raw material handling, production operations, and final product inspection.

Employee Interviews: Interview employees to assess their understanding of company policies and procedures and to gather information about any potential quality concerns.

Data Analysis: Analyse production and quality data to determine trends and identify areas for improvement.

Report Preparation: Prepare a comprehensive report detailing the findings and recommendations, including any non-conformities identified during the audit.

Exit Meeting: Discuss the audit findings with key personnel, obtain their feedback, and agree on a timeline for implementing recommended improvements.

Follow-up: Follow up on recommended improvements to ensure they are implemented and effective.

Note: The specifics of the audit process may vary depending on the company’s policies, procedures, and the type of audit being performed

Points to remember

Good Manufacturing Practices (GMP) in the textile wet processing industry can be implemented as follows:

1. Employee training: Regular training on GMP, hygiene, and safety for all employees, including management and front-line workers, should be provided.
2. Facility design and maintenance: Ensure that the facility is designed to prevent contamination and is regularly maintained, cleaned, and sanitized.
3. Equipment and utensils: Regular maintenance of equipment and utensils to prevent contamination and ensure they are in good working order.
4. Raw materials control: Control over the sourcing and storage of raw materials, including regular monitoring and testing of materials.
5. Production process control: Control over the production process, including monitoring of critical control points, documentation, and record-keeping.
6. Quality control: Establish a quality control program that includes testing, inspection, and monitoring of finished products.
7. Hazard analysis and critical control points (HACCP): Implement a HACCP program to identify potential food safety hazards and implement preventive controls to minimize or eliminate those hazards.
8. Documentation and record-keeping: Maintaining accurate and complete records of all processes and activities, including raw materials, production processes, finished products, and employee training.

By implementing these GMP principles, textile wet processing industries can ensure the production of safe and high-quality products that meet customer and regulatory requirements.

The Bombay Textile Research Association (BTRA) is conducting a Good Manufacturing Audit (GMP) audit in the textile industries for their continual improvement. The industries which want to avail of this service can furthermore contact with Technical Service Department of BTRA, Mumbai. The email id for communication is  tsd@btraindia.com and info@btraindia.com.