Dewan

Dewan Farooque Spinning Mills Ltd.

Ring-spun and COM4 yarns from a single source

Rieter . Dewan

DEWAN FAROOQUE SPINNING MILLS LTD.

Dewan Abdul Baqi, CEO of

Dewan Farooque Spinning
Mills Ltd.

A ying start

DEWAN MUSHTAQ GROUP HISTORY OF SUSTAINABLE

SUCCESSES

The history of the Dewan Mushtaq Group dates back to 1916

when Dewan Mohammad and his son Dewan Mushtaq ventured 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 importing 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 diversied business portfolios including cotton textiles, polyester and acrylic bers, sugar, automobiles, cement, oil and gas exploration, retailing and
trade. The Group employs over 12 000 permanent employees

and has a gross sales turnover of US $ 750 million and combined assets in excess of US $ 500 million. Twelve Group companies 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 certied with the latest 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 TOP

Dewan Farooque Spinning Mills (DFSML), a group concern of

the Dewan Mushtaq Group was incorporated in January 2004
and is the groups fourth textile venture with top-of-the-line
equipment and a logical response to ever-changing market demands, competitiveness in the quality segment together with
global demands for high-quality yarn and ecient pricing. Taking advantage of Pakistans growing textile economy and with
investments in quality DFSML is carving a niche in this emerging scenario. Within the rst year of operation the company
was able to export its production to many countries including USA, Europe and the Far East. In the rst year of commercial 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 exclusively of 100% combed cotton ring-spun and compact yarns,
using the latest ComforSpin process, for woven and knitted fabrics in the medium to 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 invests in the Rieter Core Yarn System. Convincing features, e.g.
stepless drive for the elastic lament, simultaneous traversing 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.

Rieter . Dewan

STRATEGY AND POSITIONING

DFSMLs place in the spinning market

THE BASIS FOR SUCCESS

DFSML takes deliberate, innovative and strategic steps to ensure its quality consistency at highest level all along the value
chain. The exclusive use of rst class cotton as raw material,
state-of-the-art processing equipments, quality assurance at
each level and well-trained personnel provide a rm foundation
for fullling the requirements of quality-conscious local and foreign customers. DFSML is strategically positioning itself to be
certied in coming years with ISO 9000, ISO 14000, SA 8000,
OEKO TEX, etc. This will further enhance their cutting edge position in the local and global markets.
DFSML OPTING FOR RIETER

Rieter as systems supplier oered the competitive solution for

DFSML business strategy and plan covering technology expectations, eciency measurements and back-up supports. Following 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
customers
Coordinated sub-processes
Automation solution based on protability analyses that are
tailored precisely to customers needs
Worldwide service, spare parts deliveries and support by experienced technology specialist
Partnership throughout the decision-making process up to the
production phase
A single contact address for all the customers concerns
MARKET LEADERSHIP IN QUALITY YARNS

DFSML is committed to continuous quality improvement and

product development. As a manufacturer of COM4 yarns it
benets from Rieters 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 investing systematically in equipment for producing yarn specialties
such as COM4core compact core-spun yarn. Rieter provides
DFSML with advice and assistance in implementing its projects.

Rieter . Dewan

BLOWROOM AND CARDS

Perfect process start

COORDINATED PROCESSES

The quality of spun yarns depends on both the raw material

used and the appropriate processing. DFSMLs goal is to maintain a high degree of exibility in the spinning process with dened, consistent quality standards, and thus be able to respond
exibly to customers requirements.
CONVINCING BLOWROOM CONCEPT

Two universal Rieter blowroom lines on which various types

of cotton are processed provide the starting point for this.
Starting with bale opening on the UNIoc A 11, gentle and efcient opening and cleaning of the bers are guaranteed. Optimum cleaning eciency and ber conservation can be set at
the push of a button in two cleaning stages on the UNIclean
B 11 and the UNIex B 60 in accordance with the ber being
fed in. The Vision Shield reliably detects and removes foreign
bers.
EXTENDED CLOTHING SERVICE LIFE WITH IGS

DFSML places its condence 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 consistently high quality.
MACHINERY INSTALLED:

1 UNIoc A 11 automatic bale opener

1 UNIclean B 11 pre-cleaner
2 UNImix B 70 blenders
2 UNIex B 60 ne cleaners
16 C 51 Hi-Per cards
Jossi TVS The Vision Shield foreign material detector

Rieter . Dewan

COMBING AND DRAWFRAMES

Optimum sliver quality

PROVEN DRAWFRAME-UNILAP PROCESS

After 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 benets 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

Rieters lead in the world market for combing is based on years

of development and optimization of the process by CAPD+
(Computer Aided Process Development). This provides the
basis for top-quality results in combination with high production 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 optimized 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 uctuations in sliver weight and ensures
outstanding long-term count consistency. High operator-friendliness and easy batch changeover support the exible use of
the drawframes. Centralized setting of the drafting system,
automatic lter cleaning, centralized lubrication and the
SLIVERprofessional expert system for fault analysis and product management are functions that guarantee a high degree
of machine availability and operating reliability.
MACHINERY INSTALLED:

3 SB-D 15 preliminary drawframes

2 UNIlap E 32
SERVOtrolley E 6/4-L semi-automatic transport system
10 E 65 combers
4 RSB-D 35 autoleveler drawframes

Rieter . Dewan

SPINNING MACHINERY

High-quality ring-spun yarns

RING SPINNING MACHINE PROVEN AND INNOVATIVE

RING-SPUN YARN OR COM4 YARN

Ring spinning machines from Rieter have impressed with their

reliability and high exibility for many years, and produce ringspun 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 rst yarn
spinner in Pakistan to install Rieter ring spinning machines
with this number of spindles.

The option of producing ring-spun or compact yarns enables

DFSML to respond 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 hairiness 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.

Both types of machine are based on the same model. One of

their many impressive features is the SERVOgrip dong process without underwinding, which is unique to date. This results
in substantial yarn savings, reduced ber y and signicantly
less cleaning eort. The machines at DFSML are equipped with
a transfer unit to the winder. The cops are transferred fully
automatically from the doer to the SERVOdisc conveyor belt
and transported to the winder. The G 33 and K 44 impress with
dong times of approx. 1 min. 40 sec. and maximum dong
reliability.

MACHINERY INSTALLED

6 roving frames with automatic doers and overhead

cleaners, 128 spindles each
12 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 winders
24 ORION L winders from Savio with twin splicers

Rieter . Dewan

QUALITY MONITORING AND QUALITY ASSURANCE

Successful nish

PRODUCTION AND QUALITY DATA FROM SPIDERWEB

DFSML appreciates the fact that Rieter, as a systems supplier,

oers 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 individual process stages, displaying them graphically and analyzing
them at a glance. This data transparency and the optimized ow
of information means that very short response times are possible. 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 PROCESS

DFSML 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 bers are detected and
removed in the early stages of the spinning process by the TVS.
DFSML maintains a fully equipped laboratory with testing instruments 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 rst spinning mill
in Pakistan to remove polypropylene particles and other impurities 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 precondition 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.

GERMANY
Ingolstadt
Grossostheim

CZECH REPUBLIC
st nad Orlic
amberk

SWITZERLAND
Winterthur

CHINA
Shanghai
Beijing
Changzhou
Urumqi
Jinan
Wuhan
Hong Kong

FRANCE
Montbonnot

USA
Spartanburg

TAIWAN
Taipei
TURKEY
Istanbul

BRAZIL
So Paulo

Dewan Farooque Spg. Mills Ltd.

Head Oce
8th Floor, Block-A,
Finance & Trade Centre,
Shahrah-e-Faisal
PK - Karachi 75250
T +92 21 111 364 111
F +92 21 563 0883

www.rieter.com

INDIA
New Delhi
Coimbatore
Mumbai
Chandigarh

PAKISTAN
Dewan

DFSML Mill Location

54 km, Lahore Multan Road
Phool Nagar ByPass,
District Kasur, Pakistan.
T +92-4943-512538
F+ 92-4943-512539
dfsml@dewangroup.com.pk
www.dfsml.com

Rieter Machine Works Ltd.

Klosterstrasse 20
CH-8406 Winterthur
T +41 52 208 71 71
F +41 52 202 83 20
sales.sys@rieter.com

The data and illustrations in this brochure and on the corresponding 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