Colony Group is one of the leading and oldest Textile Manufacturing group in Pakistan. The 1st industrial venture of the group was in cotton ginning sector back in 1881. Gradually the group diversified in to flour milling in the early 1900s. First textile spinning plant was put up in 1946 under the name of Colony Textile Mills Limited. The Group further ventured in to Banking, Insurance, Cement, and Power Generation & Distribution. By 1952 Colony Textile Mills Limited was a composite textile plant with a 120,000 spindles, 1,500 looms, and fabric finishing capacity in excess of 150,000 meters per day. Nationalization of 1972 took most of the business away, leaving Textile and Insurance in the Group. Presently, there are two companies in the group, namely, Colony Textile Mills Limited (CTM) with about 195,000 Spindles, and Colony Industries (Pvt.) Limited (CIL), consisting of 35,000 Spindles and 418 Air Jet Looms.
Width | Looms| |
190cm| 180| 176 Cam +12 Dobby + 12 Crank (20 Looms with Batchers)| 210cm| 24| 24 Cam Looms (4 Looms with Batchers)|
280cm| 26| 20 Cam + 6 Dobby|
340cm| 188| 174 Cam + 14 Dobby|
CIL is a very strong and only group that has 418 Looms in same place. This helps in fulfilment of large orders at high speed. If the looms are installed at different locations large orders cannot be processed because of factors like communication barrier and increased cost of transportation etc. Another unique thing CIL has is the Automatic Drawing in machine. When order of new quality is received it needs to be designed for the loom to work on. If manually this process is done the time required to feed the new design in the loom would be around 16 hours. The time CIL takes to do the same task is just 2 hours with better efficiency. This automated machine is only available at CIL and increases order fulfilment speed. The power requirement for the setup of 418 looms, compressor fleets and other support functions is 8MW. The cost of power i.e. electricity is reduced to a greater extent by manufacturing through its own power generation system which produces 10MW through Natural gas. Moreover for an uninterrupted supply of electricity CIL has its own grid station. Similarly CIL’s own compressors fleet decreases the cost of raw material i.e. compressed air which prevents the machinery from heating up and maintain humidity and temperatures. Capacity
Capacity or the production of looms greatly depends upon the quality of fabric. If fabric is of high quality production will be less. The reason behind this is high quality fabric uses fine threads. Production also depends upon the number of threads used in manufacturing. 6 million meters per month approx production has been recorded by CIL. Initially there were 120 looms at CIL. Capacity addition was done in March 2005 and 154 looms were added. Capacity addition for the 2nd time was done at the end of 3rd quarter by adding 144 looms making production capacity of 6.0 million meters fabric per month. Core Services and Value Added Services
The core service of CIL is grey fabric manufacturing. They don’t provide internal information of accounts, operations etc. to external people. However they provide samples to their clients which are sales support. Field support is also not easy in this weaving business but they do rectify the error within the specified time. Fail Safing techniques
Automated motion sensors
Automated motion sensors stop the process of creeling, sizing and weaving whenever a thread breaks down or any error appears in the process. This prevents errors from increasing.
Online Inspection System
Online Inspection system is a manual system by which errors can be checked by mills manager. The data is fed to the system by operators and is evaluated by mills manager for removal of errors.
During Production Checks
Technicians and operators are responsible for checking and removing the...