“Investment in Goller Mercerizing
machine has reduced our energy costs by 40%”
Mr. Avais Waris, Vice
President Operations, Crescent Textile Mills (Crestex).
How has been your experience with
Goller? Are you satisfied with your investment and what
advantages does this machine provides?
Our experience with Goller mercerizing is very good. Goller
represents the best of European textile technology. Despite
being more expensive than Chinese or other countries, European
machines are very sturdy and longer lasting with a life span of
15 to 20 years.
Yes, we are pretty much satisfied with the mercerizing plant
from Goller. Previously we had a machine from China and we had
serious quality issues with the production. For example, if we
go above 300 thread counts there were issues of creasing and
higher energy consumption in terms of water, electricity, and
steam. So after installing the new Goller machine, we reduced
our variable cost by around 40%. The maximum benefit we get
from the machine is in the steam that is the most expensive
utility in processing. We have been consuming around 7,500
tonnes of steam in a month and now it has shown a reduction of
20 to 25% with this new machine. This amounts to about 20
million Rupees (140,000 US$) savings per month.
We are also now in the process of buying new digital printing
machines, some special effects machines, like the bulk
production in sampling.
What is your total capacity?
Our total capacity is 3.6 million meters a month. This is not
very huge, as our emphasis is on the highest quality rather than
quantities. As a matter of fact, we know that it is not
possible for us to work with price sensitive customers because
of our higher quality and the subsequent higher price. So most
of the mass retailers are very price sensitive. And then it’s no
fun to produce millions of meters and earning nothing out of it.
So the stores and brands such as Debenhams, Dunelm, Tchibo that
are our major customers.
In Pakistan we are probably the leaders in implementation of
DETOX, we are now in a process of achieving their last step that
is the progressive step. We have already achieved their first
two steps. For that we are working for all the Crescent
Customers, we had some meetings had some workshops, we attended
on behalf of our suppliers.
What kind of technical textiles do
We started working on technical textiles since last two years
and within those two years, we had a major breakthrough in the
automobile sector for producing highly specialised fabrics for
seat covers for a US-based company. Since that was a special
product, it took us 7 to 8 months to develop it as per the
specifications of our customer. We started from a special fiber
used in those seat covers with together with FDA approved clay.
Even after driving for hours the driver won’t feel fatigued
sitting on that special seat cover. It is our first project in
technical textiles as it takes a long time and extensive
research to produce such product. However our philosophy is that
If you want to be the leader you will have to think out of the
box. We are now working with the best partners in the world, who
expect quality from us and with them we are developing new
Have you been satisfied with the
services of Al-Ameen Trading Corporation?
The machines may be very good but the real test is when a
problem may occur and how quickly and effectively it is
addressed. We have long term and continued relations with Al-Ameen
Trading Corporation and Goller. We bought the first machine from
them in 1988 and the machine is still running to our
In your opinion, what are the new
directions of the textile industry?
Adaptability is very important nowadays. If you don’t adapt
fast to the new situations you will be no more. You will have
to learn and adapt. For that, you will have to spend first on
human resources & then on the machines.
Crescent is probably one of the highest spending companies in
human training. We attend a large number of exhibitions
throughout the world for the training purposes and for seeking
knowledge. Besides the technical training, there are regular
training sessions at all levels such as management training,
leadership training, pressure management, time management and
more. Crescent is probably one the best companies to invest in
the human resources.
What about the hands-on training?
We do not induct any people or any helper, who does not know
the basic concepts. We do not allow any person to work with the
machine until we give him a basic one-week in-house training.
Then there are operators’ training, supervisors’ training and
management training. We keep on spending on our human resources
and then on the machines and technology.
How would you describe the key to the success of Crescent
Group as you are among the oldest and the best performing
textile groups in country.
The key to success is a positive attitude and the clarity of
the goals. There is no ambiguity and right from the CEO to the
helper, all of them know what their vision is, what our goals
are and how to achieve them.
All things are very clearly defined, written out and
available with everybody. And at every level, we also know what
our targets are. We all have our agreed targets that are not
imposed upon us. Last, but not least is the intent at every
level. We think human resources as not our expense but as an
invaluable asset. That's the reason some people are working with
us in the footsteps of their fathers and grandfathers who have
devotedly worked with the company.
We certainly have some issues like power and for that, we
have our own power generation unit working to meet our energy
requirements. Any surplus energy that the system generates goes
into the main grid of WAPDA contributing towards meeting the
shortage of energy. We have got 110,000 spindles, 130 looms,
and 400 stitching machines, and we convert 1.8 million meters
stitched every month. We produce more than a million meter in
our own weaving mill. In the future, we are planning to have
some machines for automatic cutting and sewing.
In Pakistan domestic market where do
you find yourself in future?
We are a country of more than 200 million people so there is
a huge market for textiles. In the world, if any country has
more than 50 million population it is least bothered with
exporting if they are good with their finances. And if you are
not good with the finances then there is a huge untapped market
for export. Moving towards the technical textiles was a choice
previously, but this is not the choice now. If you do not
diversify do you will not exist anymore. Similarly cotton was
previously 80% of the total textiles and now globally cotton is
just a small fraction of the total textile trade. Since the
fibers are manmade and are regenerated, the entire textile
supply has shifted and you can’t keep your eyes closed. I
believe Crescent is well poised to meet the challenges of the
Crescent Textile Mills Limited
Crescent Textile Mills (Crestex) was founded in 1950. It is a
vertically integrated composite textile unit engaged in supreme
quality manufacturing of yarn, greige/processed fabrics, home
textile and institutional garments. For more than sixty years
since its inception, the name of Crestex is known for its
quality, innovation and reliability all over the world.
Being a socially responsible corporate entity Crestex is an
equal opportunity employer, with nearly 5,000 employees
consisting of workmen, staff and executives. The company
strictly adheres to its policy of non-hiring of children and
reserves a special place for candidates with physical
limitations. Crestex encourages female candidates and these
inductions spread from worker to senior management level.
Crescent takes pride in their CSR activities which include:
Go green initiatives (carbon neutralization, Water treatment,
waste management & Paper recycling), housing community services,
power generation for industrial & community use, state of the
art schooling system, philanthropy, welfare support to needy
families and TCF (The Citizens Foundation School).