Kohinoor Textile Mills enters into
digital printing market with the successful
installation of SPGPrints JAVELIN® printer
Mr. Muhammad Usman Zafar, General
Manager Processing, Kohinoor Textile Mills
The first wider width JAVELIN® has been sold to Kohinoor
Textile Mills belonging to Kohinoor Group including Maple Leaf
Cement. Pakistan Textile Journal is pleased to present an
exclusive interview with Mr. Usman Zafar, General Manager
Processing who has been associated with Kohinoor for more than
Please tell us why have you decided
to acquire JAVELIN® by SPGPrints?
This is the first machine to be used for wider width home
textiles applications for our own exports. The decision was made
after extensive research and visits to fashion houses in Europe.
I believe this technology has given us the edge to meet our
customers’ strict requirements of quality.
We have focused on sustainability. In making any decision
there are a few parameters: Sustainability of the environment,
people and the organisation. These are the factors we have taken
into consideration while planning and designing this project.
This printer uses a very small amount of water as it is
recycled. We need a very small quantity of water for cleaning
the blankets. There are no ink vapours in the room because of
its specially designed ink missed suction bars and unique
capping cleaning and wiping systems.
I visited a lot of European manufacturers before finalizing
JAVELIN® with Mr Taufeeq Segal. We took the decision after
evaluating so many factors. The factors that I already have
explained to you, include sustainability and reliability. But we
have to see how the machine is robust, so you can make
deliveries with confidence and you can also commit the exact
delivery timelines to the customers. If the machine does not
support you, and you have an order, but you will be unable to
deliver it to the customers. Therefore, the reliability is the
most important thing while deciding the selection of the
The technology at the moment is at the developing phase and
there is a rapid change in this market segment. The designers
now want what they have created, also due to the fact there are
some limitations on the rotary, such as only 16 or 24 colours,
but the digital has no limitations, so whatever you want you to
create, you can implement that design in digital.
This new technology will stimulate our imagination. Whatever
you can imagine you can translate into reality because everybody
wants to see their imagination and design in real form. As I
mentioned earlier, with the rotary machine, we have so many
limitations like colour and repeats, etc. and we basically get
stuck, as we cannot see what we think, imagine and design
actually, so ultimately we have to make some compromises.
The designs are becoming tougher day by day the design, as
compared to what we printed in 2010, 2011and 2012. In 2018,
every design comes from the customer or the designer and they
want the digital look on the rotary. So that’s why we have
invested a lot of money on our engraving section, also we are
producing designs that are very close to the digital but with
What is your philosophy for
People do not consider the environment for digital machines.
Instead of using the conventional air conditioning system, which
may create a conducive environment for the bacteria to grow due
to condensing humidity, we have installed the first HVAC system
that creates non-condensing humidity to avoid growth of
bacteria. We have also coated the supply and return ducts with
We are working with leading brands such as Ted Baker, Lacoste
and others. This machine is the most reliable as proven by the
rigorous and intensive tests we have conducted since it was
commissioned on 22nd July 2018. When the same tests are repeated
today, the heads are found to be in exactly the same condition
as at the time of commissioning with no nozzle blockage. Even
after the machine was closed down for five days due to Muharram
it did not need any cleaning and started immediately smoothly
reflecting on the reliability of the technology.
Mr. Adnan Khurshid of SPGPrints Pakistan Pvt. Ltd.
with Mr. Aslam Khan,
Mr. Usman Zafar and Mr. Ansar ul Haque.
Please tell us about quality and the
efficiency of JAVELIN® in detail?
This machine has a very fine blending of the colours with
impeccable grey scale as the droplet size is very fine, up to 2
picolitres. This is indeed the most challenging aspect in
digital printing, thanks to the high technology, sharp lines and
fine geometrical designs are perfectly rendered. We are
extremely satisfied with the performance of the machine.
The ink delivery system is very fine for this machine, the
geometrical designs require very sharp images and fine lines are
the biggest challenges for the digital sector. This is due to
the fact the line normally breaks, so with the digital machine,
you can print geometrical designs so easily. Another factor is
head technology and because of the smaller droplet size and
there is no difference of side centre side in the geometrical
design which is the hardest and the biggest challenges in
The challenge in the geometrical designs not to have a side
centre side deviation. We can see the future of this technology
in Pakistan, and even if you also meticulously evaluate the
JAVELIN than you can see the future of this machine in Pakistan.
We can say there is a huge potential of this machine in the
digital market, which means that the digital has improved the
printing quality as against rotary, because many designers gave
us the designs, that we could not print on rotary, but we have
to print with 36 colours designs, our staff has to make the
changes in such a way that the basic theme of the design does
not change. Basically, this increases a lot of load on the CAD
design section and although, we have very creative people, so at
times we change the design and submit it to the customer.
However, thanks to the SPG technology, we have two SPGPrints’
smartLEX machines. We believe that with the help of this
technology, we also have a rotary as the backup in the engraving
section, and therefore, with SPGPrints’ smartLEX machine with
the engraver, we can achieve high quality. We have to consider
this new machine, as they have enabled us to print very sharp
images of very good quality even on the rotary. So we do not
focus on the meter of the fabric produced, but we focus on the
I don’t ask my team that how many meters you produce, I asked
them how much better is the quality of the fabric printing, what
is your rejection level what is your second choice today.
I always like to evaluate the print the quality, instead of a
number of the metres printed on a machine. If you ask for the
rejection rate, the machine operators will work on quality and
will produce excellent results. We also focus on the quality of
chemicals and auxiliaries. We are using branded auxiliaries.
We do not use the other substandard things, for example, we
use the thickeners from SNF (France) for the last twelve years.
SNF has developed a broad range of thickeners for pigment,
disperse and reactive printing. These products make it possible
to print very fine details and allow for improved colour yield.
The range is accompanied by fixatives, anti-migration agents and
dispersants. Even so, many companies have tried to replace our
choice thickeners, but they had failed because whatever results
we are getting from SNF, we cannot get from any other
We are producing digital prints on lawn fabrics. The lawn is
a lightweight article of ladies fashion and we are working on a
single width, because if you move from one position to other, it
takes the 20s to bring back the carriage to get the printed
section of 120 inches and if you are printing the 40 inches, it
may take 40s, so the production level will remain the same.
The control of the carriage is the most important thing, and
that should run only on the required width. This machine enables
the carriage to be moved only on the portion of the width
adjusted by the customer. So that’s why we believe we can
replicate the same meterage what the people are doing by
printing the double web or triple web. If you print thee webs
you need to have three people to monitor and how you can we
monitor the piece which is in the centre. you can’t stand on top
of the centre point. So we print one because we don’t need the
quantity we need the quality to be produced on the machine and
believe in the lowest rejection level.
SPGPrints JAVELIN® in operation at Kohinoor Textile
What is the basic philosophy of
The basic philosophy of Kohinoor is the quality of our work.
When we are getting the good price from the customers, we should
also strive to offer the agreed quality fabrics as per our
For example, why do we have this HVAC system? We have
invested a lot of money in this system and in my opinion, people
do not bother to invest in climate control systems. However, for
us, it is an essential part to control the climate issues in
We have installed double panelled insulated glass windows
with a sealed space in between that is filled with Argon gas to
slow the transfer of heat through the window. There is no
outside atmosphere interference with the inside atmosphere.
We have placed the machine inside the polythene panel rooms
not inside a bricked wall or any cemented structure and have
invested a huge amount on this feature. Humidity inside can
fluctuate from 48% to 58% depending upon the kind of the fabric.
We have to print viscose as well as cotton and many other
things, so for all the things, one perimeter is not necessary.
There was a time when we produced 4.5 million meters and now
for the past six years we are producing 1.2 to 1.5 million
meters and in this way, we have to change the whole structure of
the company. Because we don’t produce things that don’t give us
any gross profit. We are working with leading brands such as
Lacoste, Ted Baker, Calvin Klien and Laura Ashley.
This is our philosophy and approach that enables us to be
successful. This is the same thing that big players have
survived with all these difficulties. They never compromise on