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Mills Stories Mills Stories

Tailor-made solutions

TESTA Group

SuperTestaRossa

Adil Ghani. Technical Director. Nishat Dyeing and Finishing Mills
TESTA Group is a technological innovator in the Minimum wastage paired with top-notch quality is a
Adil Ghani - Nishat Mills - greatly textile sector, always at the forefront in the search for combination that is undeniable and exactly what our
absolute quality and in identifying extraordinary
customers expect from us.
satisfied with the innovative, versatile, solutions to ordinary problems. They guarantee TEXtalks: When did you install the auto-cutting system
high-quality products, in components and materials,
as well as in innovation and work philosophy.
SuperTestaRossa and how many machines are working
and precise inspection technology For 50 years, TESTA Group has been designing and in Nishat Mills as of now?
Adil Ghani: Working was commenced on this project
manufacturing inspection, cutting, and packaging in 2014 to improve the inspection and cutting
SuperTestaRossa can save up to 3-4% of the fabric with machinery for the fabric and knitwear industry, process. With technology advancing one step every
technical articles, and non-woven fabrics. They highly
day, SuperTestaRossa was an innovative concept
optimized inspection in comparison to traditional manual value and analyze the specific needs of each that needed to be introduced in Pakistan. After a
thorough evaluation, the decision of purchasing this
customer which allows them to create machines that
inspection machines. With SuperTestaRossa automation, are much more than a serial number. To know more equipment as a prototype was made leading to
successful installation and a running span of three
about how Nishat Mills is benefiting from the
less human handling and human error occur, resulting in purchase of the SuperTestaRossa and in the quest years. Ultimately in 2018, after observing and
for finding answers on how this technology makes a
learning how this system functions, we finally bought
higher A-grade fabrics. difference in the productivity and inspection process two machines. After the mapping is complete which
is basically the inspection of fabric without cutting the
of the dyeing house, TEXtalks International
interviewed Adil Ghani, Technical Director, Nishat fabric, optimization is done which is then followed by replacing it using this automation? TEXtalks: How efficient is SuperTestaRossa and what
Along with this, the labor used in the process is also Dyeing and Finishing Mills Lahore. automatic cutting on the SuperTestaRossa. Adil Ghani: At Nishat, almost 180,000 meters of fabric is its payback period?
Adil Ghani: SuperTestaRossa is an efficient
need to be inspected every day which occupied 21
greatly reduced which is also a big cost-cutting. TEXtalks: Would you like to give a brief introduction TEXtalks: What are the benefits of the inspection machines and in consequence required technology and through our calculation, the payback
about Nishat Mills?
SuperTestaRossa in terms of saving, especially
Adil Ghani: Nishat Mills already being a familiar and fabrics? increased labor. After installing the SuperTestaRossa, period of this system was 4 years. However, it is now
well-known entity in the industry, requires no formal Adil Ghani: SuperTestaRossa not only reduced our the exact process was done with 11 machines. obvious by examining the results that the return on
introduction. However, for the formality, Nishat Dyeing wastage but at the same time helped us achieve our investment will be no more than three and a half
and Finishing Mills is an export-oriented apparel efficiency. We have saved average of 0.6% wastage As compared to manual machines, this auto-cutting years. The pandemic period, as we all are well aware
dyeing house that is always on the go to invest in the which means 250,000 to 300,000 meters of fabric are machine can handle heavy rolls which are difficult to was nothing less than a tricky puzzle that led to us
latest technologies, systems, and equipment that not saved annually. Financially, by the end of this year, we manage by human force. Pakistan is in dire need of not operating at full capacity. But now that it is over,
only enhance the quality of the fabric but also provide will be able to recover our costs, hence it is safe to qualified and technical labor which is in extreme we are hopeful again and bouncing back with full
a solution that has lesser impact on our environment. say that the return on investment has been brilliant. shortage. By using this technology, labor usage has force.
As impacts on the environment are alarming and this been reduced significantly by an estimated value of
problem is staring everyone in the eye, sustainability TEXtalks: As labor is becoming increasingly expensive, 80 workers, which is a big cost saving with this TEXtalks: What was the response of international
is our priority and the only way to move forward. to what extent has SuperTestaRossa contributed to automation. buyers after reviewing this system's functioning?
May/June 2023 May/June 2023