Adil Ghani – Nishat Mills – greatly satisfied with the innovative, versatile, and precise inspection technology. TESTA Group is a technological innovator in the textile sector, always at the forefront in the search for absolute quality and in identifying extraordinary solutions to ordinary problems. They guarantee high-quality products, in components and materials, as well as in innovation and work philosophy.

SuperTestaRossa can save up to 3-4% of the fabric with optimized inspection in comparison to traditional manual inspection machines. With SuperTestaRossa automation, less human handling, and human error occur, resulting in higher A-grade fabrics. Along with this, the labor used in the process is also greatly reduced which is also a big cost-cutting.

For 50 years, TESTA Group has been designing and manufacturing inspection, cutting, and packaging machinery for the fabric and knitwear industry, technical articles, and non-woven fabrics. They highly value and analyze the specific needs of each customer which allows them to create machines that are much more than a serial number. To know more about how Nishat Mills is benefiting from the purchase of the SuperTestaRossa and in the quest for finding answers on how this technology makes a difference in the productivity and inspection process of the dyeing house, TEXtalks International interviewed Adil Ghani, Technical Director, Nishat Dyeing and Finishing Mills Lahore.

TEXtalks: Would you like to give a brief introduction about Nishat Mills?
Adil Ghani: Nishat Mills already being a familiar and well-known entity in the industry, requires no formal introduction. However, for the formality, Nishat Dyeing and Finishing Mills is an export-oriented apparel dyeing house that is always on the go to invest in the latest technologies, systems, and equipment that not only enhance the quality of the fabric but also provide a solution that has lesser impact on our environment. As impacts on the environment are alarming and this problem is staring everyone in the eye, sustainability is our priority and the only way to move forward. Minimum wastage paired with top-notch quality is an undeniable combination and exactly what our customers expect from us.

TEXtalks: When did you install the auto-cutting system SuperTestaRossa and how many machines are working in Nishat Mills as of now?
Adil Ghani: Working was commenced on this project in 2014 to improve the inspection and cutting process. With technology advancing one step every day, SuperTestaRossa was an innovative concept that needed to be introduced in Pakistan. After a thorough evaluation, the decision of purchasing this equipment as a prototype was made leading to successful installation and a running span of three years. Ultimately in 2018, after observing and learning how this system functions, we finally bought two machines. After the mapping is complete which is the inspection of fabric without cutting the fabric, optimization is done which is then followed by automatic cutting on the SuperTestaRossa.

TEXtalks: What are the benefits of the SuperTestaRossa in terms of saving, especially fabrics?
Adil Ghani: SuperTestaRossa not only reduced our wastage but at the same time helped us achieve efficiency. We have saved an average of 0.6% wastage which means 250 000 to 300 000 meters of fabric are saved annually. Financially, by the end of this year, we will be able to recover our costs, hence it is safe to say that the return on investment has been brilliant.

TEXtalks: As labor is becoming increasingly expensive, to what extent has SuperTestaRossa contributed to replacing it using this automation?
Adil Ghani: At Nishat, almost 180,000 meters of fabric need to be inspected every day which occupied 21 inspection machines and in consequence required increased labor. However, after installing the SuperTestaRossa, the exact process was done with 11 machines. As compared to manual machines, this auto-cutting machine can handle heavy rolls which are difficult to manage by human force. Pakistan is in dire need of qualified and technical labor which is in extreme shortage. By using this technology, labor usage has been reduced significantly by an estimated value of 80 workers, which is a big cost saving with this automation.

TEXtalks: How efficient is SuperTestaRossa and what is its payback period?
Adil Ghani: SuperTestaRossa is an efficient technology and through our calculation, the payback period of this system was 4 years. However, it is now obvious by examining the results that the return on our investment will be no more than three and a half years. The pandemic period, as we all are well aware was nothing less than a tricky puzzle that led to us not operating at full capacity. But now that it is over, we are hopeful again and bouncing back with full force.

TEXtalks: What was the response of international buyers after reviewing this system’s functioning?
Adil Ghani: When our buyers saw the system functioning, they were satisfied and confident in the quality and labeling of the fabric that we offered. The inspection process is important for our buyers and the SuperTestaRossa offers them the exact assurity that they require for the inspection of fabric properly.

TEXtalks: What is the feedback from the buyers of Nishtat Mills for the fabric inspected on SuperTestaRossa?
Adil Ghani: The feedback has been so far so good and there have been no inspection problems. We are hopeful and confident that it will remain this way.

TEXtalks: How was your experience with the after-sales service from TESTA Group?
Adil Ghani: All new projects are destined to face challenges and obstacles, however, at Nishat, our vision and mission only have one way to deal with challenges, which is, to conquer them. There were differences of opinion but at the end of the day, we solved them all and I think TESTA Group with its local representative, Rahman Brothers, is doing a great job as an after-sale service provider.

TEXtalks: In your opinion, how beneficial is the SuperTestaRossa for Pakistani mills?
Adil Ghani: Well, this question is really important for the Pakistani textile industry and one that needs to be asked quite frequently. It is crucial to understand that innovative technology and systems are the crux of every mill that should aim to reduce wastage which will consequently reduce financial costs. I would recommend it to others in the industry as there is no substitute for innovative technology.