Dewan Farooque Spinning Mills Ltd.Ring-spun and COM4® yarns from a single source

Dewan

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Dewan Abdul Baqi, CEO of Dewan Farooque Spinning Mills Ltd.

DEWAN MUSHTAQ GROUP – HISTORY OF SUSTAINABLESUCCESSESThe history of the Dewan Mushtaq Group dates back to 1916 when Dewan Mohammad and his son Dewan Mushtaq ven-tured into the garment business in East Punjab and moved further with the set up of a trading company in Karachi Sindh two years later. This trading company was involved in import-ing commodities and merchandize with a distribution network across the sub-continent. In 1947 the Dewan family, under the dynamic leadership of Dewan Mushtaq Ahmad, set up their headquarters in Karachi, Pakistan, for their trading business and soon became a renowned trading house dealing in sugar, tea and garments known for their commitment, integrity and fair dealings. Over the next three decades transformation took place and the Dewan Mushtaq Group, moving along the value chain, became a leading and emphatic industrial group besides maintaining their traditional trading business.

The Dewan Mushtaq Group is now one of the largest industrial and trading conglomerates of Pakistan committed to national development and social uplift with diversifi ed business portfo-lios including cotton textiles, polyester and acrylic fi bers, sug-ar, automobiles, cement, oil and gas exploration, retailing and trade. The Group employs over 12 000 permanent employees

A fl ying startDEWAN FAROOQUE SPINNING MILLS LTD.

and has a gross sales turnover of US $ 750 million and com-bined assets in excess of US $ 500 million. Twelve Group com-panies are listed on the Karachi Stock Exchange with a total capitalization exceeding US $ 300 million. Believing in good manufacturing practices and emerging technology as the path to success, the Group companies are ISO certifi ed with the lat-est enterprise resource planning software SAP implemented in 2006, bringing them in line with global organizations adopting the latest ICT and MIS trends and advancements.

DEWAN FAROOQUE SPINNING MILLS – ON THE WAY TO THE TOPDewan Farooque Spinning Mills (DFSML), a group concern of the Dewan Mushtaq Group was incorporated in January 2004 and is the group’s fourth textile venture with top-of-the-line equipment and a logical response to ever-changing market de-mands, competitiveness in the quality segment together with global demands for high-quality yarn and effi cient pricing. Tak-ing advantage of Pakistan’s growing textile economy and with investments in quality DFSML is carving a niche in this emerg-ing scenario. Within the fi rst year of operation the company was able to export its production to many countries includ-ing USA, Europe and the Far East. In the fi rst year of commer-cial production DFSML exported yarn worth US $ 15 million to world leading end-users, besides maintaining links with quality conscious domestic consumers.

DFSML with a capacity of 28 800 spindles and 295 employees, produces 3,4 million kilograms of yarn annually, consisting ex-clusively of 100% combed cotton ring-spun and compact yarns, using the latest ComforSpin process, for woven and knitted fab-rics in the medium to fi ne yarn count range (ring spun yarn in Ne 30 – Ne 80, COM4® in Ne 40 – Ne 100). DFSML, the pioneer in Pakistan utilizing the G 33 ring spinning technology, also in-vests in the Rieter Core Yarn System. Convincing features, e.g. stepless drive for the elastic fi lament, simultaneous travers-ing of elastane and roving and optical sensors enable DFSML to produce high quality core yarn within a wide yarn count range. 60% of the complete yarn output is exported primarily for use in high-quality shirting fabrics, 40% is sold on the domestic market to leading bed linen and home textile manufacturers.

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THE BASIS FOR SUCCESSDFSML takes deliberate, innovative and strategic steps to en-sure its quality consistency at highest level all along the value chain. The exclusive use of fi rst class cotton as raw material, state-of-the-art processing equipments, quality assurance at each level and well-trained personnel provide a fi rm foundation for fulfi lling the requirements of quality-conscious local and for-eign customers. DFSML is strategically positioning itself to be certifi ed in coming years with ISO 9000, ISO 14000, SA 8000, OEKO TEX, etc. This will further enhance their cutting edge po-sition in the local and global markets.

DFSML OPTING FOR RIETERRieter as systems supplier off ered the competitive solution for DFSML business strategy and plan covering technology expec-tations, effi ciency measurements and back-up supports. Follow-ing were some of the decisive factors of DFSML choosing Rieter technology:

Expertise of proven and innovative technologies that are continuously being developed further in cooperation with customersCoordinated sub-processesAutomation solution based on profi tability analyses that are tailored precisely to customers’ needsWorldwide service, spare parts deliveries and support by ex-perienced technology specialistPartnership throughout the decision-making process up to the production phaseA single contact address for all the customer’s concerns

MARKET LEADERSHIP IN QUALITY YARNSDFSML is committed to continuous quality improvement and product development. As a manufacturer of COM4® yarns it benefi ts from Rieter’s marketing activities. DFSML sells its ring spun yarns under the Avant Garde brand. It also aims to cover the yarn count range from Ne 7 – Ne 170 so that it can continue to satisfy demanding customer requirements. It is also invest-ing systematically in equipment for producing yarn specialties such as COM4®core compact core-spun yarn. Rieter provides DFSML with advice and assistance in implementing its projects.

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DFSML‘s place in the spinning marketSTRATEGY AND POSITIONING

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Perfect process startBLOWROOM AND CARDS

COORDINATED PROCESSESThe quality of spun yarns depends on both the raw material used and the appropriate processing. DFSML‘s goal is to main-tain a high degree of fl exibility in the spinning process with de-fi ned, consistent quality standards, and thus be able to respond fl exibly to customers‘ requirements.

CONVINCING BLOWROOM CONCEPTTwo universal Rieter blowroom lines on which various types of cotton are processed provide the starting point for this. Starting with bale opening on the UNIfl oc A 11, gentle and ef-fi cient opening and cleaning of the fi bers are guaranteed. Op-timum cleaning effi ciency and fi ber conservation can be set at the push of a button in two cleaning stages on the UNIclean B 11 and the UNIfl ex B 60 in accordance with the fi ber being fed in. The Vision Shield reliably detects and removes foreign fi bers.

EXTENDED CLOTHING SERVICE LIFE WITH IGSDFSML places its confi dence in proven C 51 card technology, equipped with the IGS classic integrated grinding system for card clothing. Cylinder clothing is automatically sharpened during production and thus produces card slivers of consistent-ly high quality.

MACHINERY INSTALLED:1 UNIfl oc A 11 automatic bale opener 1 UNIclean B 11 pre-cleaner 2 UNImix B 70 blenders 2 UNIfl ex B 60 fi ne cleaners 16 C 51 Hi-Per cardsJossi TVS „The Vision Shield“ foreign material detector

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Optimum sliver qualityCOMBING AND DRAWFRAMES

PROVEN DRAWFRAME-UNILAP PROCESSAfter passing though the SB-D 15 preliminary drawframes, the slivers are formed into homogeneous laps on the UNIlap E 32. The features of this preparatory process are a broad range of application, high production performance and excellent quality consistency. DFSML benefi ts from lap weights of up to 25 kg, good uniformity along the entire lap length and production speeds of up to 120 m/min.

EFFICIENT COMBING OPERATION Rieter‘s lead in the world market for combing is based on years of development and optimization of the process by C•A•P•D+ (Computer Aided Process Development). This provides the basis for top-quality results in combination with high produc-tion volumes. The E 65 combers at DFSML impress with up to 450 nips/min with superior running behavior. The use of appropriate technology components enables them to be opti-mized for any raw material.

PERFECT DRAWFRAME RESULTS The combed slivers are doubled, drawn and leveled on the RSB-D 35 autoleveler drawframes. The reliable digital leveling system with high-precision scanning dependably equalizes piecings and other fl uctuations in sliver weight and ensures outstanding long-term count consistency. High operator-friend-liness and easy batch changeover support the fl exible use of the drawframes. Centralized setting of the drafting system, automatic fi lter cleaning, centralized lubrication and the SLIVERprofessional expert system for fault analysis and prod-uct management are functions that guarantee a high degree of machine availability and operating reliability.

MACHINERY INSTALLED:3 SB-D 15 preliminary drawframes2 UNIlap E 32SERVOtrolley E 6/4-L semi-automatic transport system10 E 65 combers4 RSB-D 35 autoleveler drawframes

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RING SPINNING MACHINE – PROVEN AND INNOVATIVERing spinning machines from Rieter have impressed with their reliability and high fl exibility for many years, and produce ring-spun yarns economically. DFSML manufactures its quality yarn on 12 G 33 ring spinning machines and 12 K 44 ComforSpin machines, each with 1 200 spindles. DFSML was the fi rst yarn spinner in Pakistan to install Rieter ring spinning machines with this number of spindles.

Both types of machine are based on the same model. One of their many impressive features is the SERVOgrip doffi ng proc-ess without underwinding, which is unique to date. This results in substantial yarn savings, reduced fi ber fl y and signifi cantly less cleaning eff ort. The machines at DFSML are equipped with a transfer unit to the winder. The cops are transferred fully automatically from the doff er to the SERVOdisc conveyor belt and transported to the winder. The G 33 and K 44 impress with doffi ng times of approx. 1 min. 40 sec. and maximum doffi ng reliability.

High-quality ring-spun yarnsSPINNING MACHINERY

RING-SPUN YARN OR COM4® YARNThe option of producing ring-spun or compact yarns enables DFSML to respond fl exibly to customers‘ requirements, e.g. for bulkier ring-spun yarns with good fabric cover as weft yarn for weaving or as knitting yarn, or for COM4® yarns with high yarn tenacity and low hairiness for warp yarns. The quality lead of COM4® yarns is recognized and accepted in the marketplace. The main distinguishing features of compact yarns are reduced hairi-ness and higher tenacity. Fabrics produced from them display improved elongation, strength and uniformity values. End-users are aware of lower abrasion and extended capability of use.

MACHINERY INSTALLED6 roving frames with automatic doff ers and overhead cleaners, 128 spindles each12 G 33 ring spinning machines, 1 200 spindles each (14 400 spindles in all) 12 K 44 ComforSpin machines, 1 200 spindles each (14 400 spindles in all) Machines equipped with SPIDERweb and link to winders24 ORION L winders from Savio with twin splicers

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PRODUCTION AND QUALITY DATA FROM SPIDERWEBDFSML appreciates the fact that Rieter, as a systems supplier, off ers a modern mill monitoring and production data system, namely SPIDERweb. Dewan Baqi rates SPIDERweb as the most advanced system available for recording data from the individ-ual process stages, displaying them graphically and analyzing them at a glance. This data transparency and the optimized fl ow of information means that very short response times are pos-sible. These are essential for detecting and correcting quality variances quickly so that the spinning mill continues to operate trouble-free. SPIDERweb supplies clear information as a basis for reliable decision-making.

QUALITY ASSURANCE IN THE SPINNING PROCESSDFSML is committed to systematic quality monitoring during the spinning process. Quality assurance measures start by ensuring constant climatic conditions during production by means of a Luwa air-conditioning system. Foreign fi bers are detected and removed in the early stages of the spinning process by the TVS. DFSML maintains a fully equipped laboratory with testing in-struments from Uster Technologies in order to manufacture competitive products in optimum quality.

QUALITY ASSURANCE AFTER SPINNING The yarns are transferred fully automatically from the spinning machines to the winders, thus preventing confusion or damage resulting from manual handling. DFSML is the fi rst spinning mill in Pakistan to remove polypropylene particles and other impu-rities at each winding position by means of Uster Quantum II yarn clearers. Pallets with a wide variety of package sizes and also yarn packages on creel trolleys can be conditioned and / or steamed in the cube-shaped Xorella CONTEXXOR© system. The stabilized yarns are less inclined to twist or snarl during weaving and knitting, and the correct moisture of the material reduces susceptibility to yarn breaks. This is an important pre-condition for economical downstream processing of the yarns.

DFSML, established to attain a leading position in the high quality yarn market, is well equipped for the future with its Rieter spinning installation and modern auxiliary equipment.

Successful fi nishQUALITY MONITORING AND QUALITY ASSURANCE

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USASpartanburg

TURKEYIstanbul

CHINAShanghaiBeijingChangzhouUrumqiJinanWuhanHong Kong

TAIWANTaipei

INDIANew Delhi CoimbatoreMumbaiChandigarh

CZECH REPUBLICÚstí nad OrlicíŽamberk

FRANCEMontbonnot

SWITZERLANDWinterthur

GERMANYIngolstadt

Grossostheim

PAKISTANDewan

BRAZILSão Paulo

Dewan Farooque Spg. Mills Ltd. Head Offi ce8th Floor, Block-A,Finance & Trade Centre, Shahrah-e-FaisalPK - Karachi 75250T +92 21 111 364 111F +92 21 563 0883

DFSML Mill Location54 km, Lahore Multan RoadPhool Nagar ByPass,District Kasur, Pakistan.T +92-4943-512538F+ 92-4943-512539dfsml@dewangroup.com.pk www.dfsml.com

Rieter Machine Works Ltd.Klosterstrasse 20CH-8406 WinterthurT +41 52 208 71 71F +41 52 202 83 20sales.sys@rieter.com

The data and illustrations in this brochure and on the cor-responding data carrier refer to the date of printing. Rieter reserves the right to make any necessary changes at any time and without special notice. Rieter systems and Rieter innovations are protected by patents.

1943en-BAAH-43-Printed in CZ