We believe that in textiles, Quality means
“ Best Raw Material”, “State of the
art Machinery” & “ Highly Trained and
Skilled Human Resources”.
The Quality Management at our Mills believes in implementation
of all three.
Souring of Raw Materials
The Market environment today has become increasingly
competitive with the consumer becoming more Quality
conscious. Therefore, besides sophistication in terms
of speed and technology of machinery, it is very important
for a mill to know all the important properties of the
Fiber. In the case of Raw Cotton, especially, it is
necessary to know Fiber properties of each and every
bale and to understand how the fiber properties interact
with the processing conditions to determine the Yarn
quality and the performance of the process itself.
Raw Cotton Fiber characteristics vary from field to
field. This variation is due to genetic and environmental
factors such as harvesting and ginning conditions. Therefore,
our Raw Cotton selectors choose Raw cotton based on
its Physical characteristics, Length of Fibre, Trash
Percentage, Micronaire, Pressley and Colour grade. The
quality monitoring starts at the cotton procurement
stage. Only cotton which meets all the required characteristics
We also Import Raw Cotton from America, Australia,
Egypt, West Africa, C.I.S. China depending on the type
of yarn to be produced as per the customer’s requirement.
Processing ( Machinery & and Professional Human
“NO SUBSITITE OF BEST QUALITY” is the reality
we believe in, and we strive to service our customers
at every stage according to that belief by adopting
the following procedure:
- We carry out mixing of the cotton in three shifts,
round the clock. Trained and expert workers open bales,
which are laid down properly by trained labourers
after the bales have been tested by the quality department.
All the important parameters of fiber are tested to
keep the mixing even throughout the season.
- Our Blow room line consists of Trutzschler machines.
To keep the yarn free from contamination we employed
persons on the feed lattice for manually picking out
contaminants. Fiber growth, neps and waste extraction
is monitored throughout the blow room line using most
modern testing equipment, including AFIS.
We use different Origin of Cotton such as US PIMA,
EGYPTIAN GIZA, Chinese, among others. Unlike these growths,
Pakistani Cotton has some inherent contamination and
we use the following procedures to minimize the contamination
presence in yarn:
- We have manual Contamination Picking System at
our Blow Room level so that maximum quantity of foreign
Matters can be removed at the early stages.
- LOPTEX CONTAMINATION SORTER: Our blow rooms are
equipped with Two Loptex Sorters in one line to remove
the remaining contamination before it reaches the
Carding stage. The Loptex Sorters can detect and remove
visible contamination of upto 1 square centimeter
- All Autoconers are equipped with Loepfe Yarn Master
Spectra, which further controls and eliminates the
contamination in the yarn.
- The card machines have a chute feed system and
consist of Trutzschler DK 903, Crosrol MK5D and Rieter
C51 equipped with Auto-levelers. Waste percentage,
Card U% and wrapping is carried out daily to check
the performance of the Cards. The maintenance cycle
of Card machine is monitored using AFIS N module.
Every individual card is tested for neps fortnightly
using spin test technique along with continuous checking
of neps with the help of AFIS-nep module to keep the
neps under control.
- The Toyoda drawings are used as breaker for cotton
carded yarn. Card U% and Sliver Wrapping is checked
for each machine daily to ensure proper working of
machine within our quality parameters.
- The Automatic Unilap machines are used to feed
the E62 Rieter combers. All combers are checked throughout
the day for sliver wrapping and a weekly cycle of
checking of waste percentage is carried out to ensure
proper removal of short fibers. The extracted waste
is also checked on the AFIS to ensure that the Noil
percentage is sufficient. Neps are again monitored
during combing process with the help of AFIS. Spin
tests are also carried out keeping in view that every
comber must be checked at-least once a month.
- Our Auto leveler Rieter D35 and Trutzschler HSR1000
Finisher Drawings are equipped with Sliver Quality
Monitoring System. It allows 24 hour on-line checking
and detection of faults that could cause Drawing Sliver
to deviate from it’s required mean. Additionally
Uster Tester-4 is used to test evenness of sliver
daily for each machine.
- Toyoda FL-16 and FL100 Simplex machines are used
to convert sliver into roving of our required parameters.
Evenness of roving is checked for every machine daily
by using wrapping drums and Uster Tester-4. The Uster
standards are strictly followed through out the back
process to produce high quality roving.
- Our Ring department consists of Toyoda RX240 and
Chinese EJM 128A with SKF-225 German drafting system.
Every individual count spun on our Ring machines is
checked daily for count, twist / inch, strength and
evenness using Uster Autosorter, Zweigle Twist Tester,
Uster Tensorapid and Uster Tester-3 and 4 respectively.
We practice to keep all quality parameters of yarn
within Uster Statistics category of 5%. Some individual
values may exceeds to Uster category of 12% but they
are always monitored, and we try to keep it within
Uster category of 5%.
- Yarn from Ring department is converted onto required
package using Schlafhorst-238, 338, Savio Espero and
Savio Orion winders. The Schlafhorst machines are
equipped with Loepfe Yarn master 930 Plus and Uster
Quantum clearer. On-line classimat is performed on
Savio Espero to check the yarn parameters daily for
each individual count. The contamination clearance
is also carried out on these machines to produce “contamination-controlled”
By employing the above stringent measures we try and
keep the quality of our products consistent.