Debut for Monforts Thermex 5500 with
Econtrol® process in Pakistan
reactive dyeing process on a new Monforts Thermex 5500
continuous dyeing system with an Econtrol® unit at Pakistan’s
Nishat Mills is thought to be the first in Pakistan.
Pakistan’s Nishat Mills has taken delivery of a new,
purpose-ordered, Monforts Thermex 5500 continuous dyeing
process with an Econtrol® process system to introduce, it is
thought, the country’s first continuous reactive dyeing line.
According to Nishat MillsTechnical Director, Hafeez-ur-Rehman
Siddique, the company had recognised that the combination of
Thermex 5500 and Econtrol® was proving extremely popular in
India but the concept was new for Pakistan.
“There had to be a reason for its success. Although at this
point we are still learning and evaluating as it has only been a
few months since its installation.
Mr. Hafeez-ur-Rehman Siddiqui,
Technical Director, Nishat Mills Ltd.
“We are looking to meet our target of at least a million
metres per month but our decision to acquire the Thermex system
was not only to increase production, but also to enhance quality
“We also bought the Econtrol system to help us reduce the
cost of production by reducing water consumption and controlling
pollution as well,” he added.
Nishat Mills Ltd
Nishat Mills Ltd was established in 1951 and is considered to
be the flagship company of the Nishat Group. The company’s
dyeing and finishing plant, based in Lahore, initially processed
“Today,” said Hafeez-ur-Rehman Siddiqui, “we are working in
three different sectors; home textiles, linen and bottom wear.”
In addition to shirting, poplins, lawn fabrics and home
textiles, the facility is also equipped to handle heavy weight
fabrics such as twills, canvas and bottom wear in addition to
stretch fabrics in a variety of high density woven fabrics.
The company’s fabric dyeing plant in Lahore was already
equipped with Monforts stentering, sanforizing and other
equipment, which have been complemented by the new Thermex and
Continuous reactive dyeing
The Thermex 5500 continuous dyeing system along with the
Econtrol® was ordered through local representative Al Ameen
“Since we had already been relying on Monforts technology
dyeing, l felt that we should consider changing to continuous
dyeing for bottom wear, narrow width dyeing – which accounts
for 70% of our total dyeing capacity.
“Furthermore, with our Monforts experience we did not want to
deviate from our existing range and configurations.
“We evaluated the various advantages of the Econtrol® process
to meet our specific quality parameters in processing bottom
wear, narrow width, woven fabrics.
The main advantage of the Econtrol® process, in addition to
the energy savings, for Nishat, was the improved fabric
specifications of dyed materials with, for example, rubbing and
light fastness, when compared with other processes, according to
He went on to explain, “We expect better quality and fabric
specifications, and are currently running 100% cotton.
“An impressive feature of the Thermex continuous dyeing with
Econtrol® is its energy savings,” he explained elaborating
further, “The cost of utilities in Pakistan is very high; almost
equal to the total cost of dyes and chemical consumption.
“The continuous process Econtrol® is not only energy
efficient but also offers ecological advantages of continuous
finishing with a minimum use of chemicals.
“It is great that we can finish our fabrics with excellent
light and washing fastness.
“Installing the Monforts Thermex 5500 with Econtrol® was the
right decision for us and will greatly contribute to meeting our
target of 1 million metres of fabric per month,” he concluded.
The fully automatic processing unit is ideal for companies
such as Nishat, who strive for continuous quality management and
low operating costs.
The Thermex 5500 range is the modern solution for the
continuous dyeing and finishing, which is economical for dyeing
both large and small batches.
The machine is also operationally reliable incorporating
latest air flow technology and innovative process engineering.
High-speed batch changing is possible thanks to automatic
cleaning and Teflon-coated rollers.
Thermex 5500 offers uniform air flow, temperature and fabric
The air circulation fans in each Thermex unit are arranged
symmetrically and designed to provide the perfect match for the
various heating systems used in the processes of drying,
thermosoling and curing.
Another important aspect is the fact that the lint filters
can be removed from outside the machine for cleaning without
Before the air supplied by the two fans enters the jets, it
passes through a flow junction chamber. The controlled removal
of the waste air takes place through an exhaust duct leading out
of the treatment chamber.
The circulation air is always uniformly heated no matter what
the heating system employed. The heating chamber extends along
the entire width of the machine.
The top transport rollers are driven via friction clutches -
a drive system which keeps the fabric tension constant even when
it undergoes dimensional change during drying or heat-setting.
Another feature of Thermex 5500 is the process control
sensors. These sensors measure high moisture, liquor pick-up and
distribution, processing temperature, residual moisture check,
fabric temperature, air velocity and humidity of circulating
With two spinning units and an existing Monforts yarn dyeing
operation in Faisalabad, a weaving unit in Sheikhupura and
weaving, fabric dyeing and finishing, stitching and garment
making-up operations in Lahore, Nishat has grown over the years
to become one of the biggest vertically-integrated textile
operations in the country.
The company is now achieving export sales of over US$400
million a year.
The fabric processing plant has the capacity to process over
10 million m of fabric monthly and has been purpose-designed to
handle heavy weight fabrics such as twills, canvas and poplins,
in addition to stretch fabrics in all high density weaves.
Nishat’s operations are also equipped with extremely
efficient, captive co-generation, power plants to meet in-house
energy requirements at all of its spinning, weaving, processing,
stitching and apparel units.
It has been a satisfied Monforts customer since starting in
house dyeing operations in 1989; following its formation in