Masood Textile Mills LTD

Fabric Division
Unit # 3

Project Report
(Insights and Observations from an Internship at Masood Textile Mills Ltd.)
Submitted by:
Muhammad Hassan
Department of Textile Engineering
UET Lahore Faisalabad Campus

1|Page
Table of Content
1. Introduction………….……………………………………………………………… 03
1.1 History……………………………………………………………………… 03
1.2 Vision…….………………………………………………………………… 03
1.3 Mission……………………………………………………………………... 03
1.4 Organization Values………………………………………………………... 04
1.5 Infrastructure……………………………………………………………….. 04
2. Visited Process……………………………………………………………………… 04
2.1 Pre-treatment……………………………………………………………….. 04
2.1.1 Scouring……………………………………………………….. 04
2.1.2 Bleaching………………………………………………………. 05
2.2 Dyeing…………………………………………………………………….... 05
2.3 Post Treatment………………………………………….………………..…. 06
2.4 Quality Control……………………………………….……..……………… 06
2.5 Environmental Consideration………………………………………………. 06
2.6 Dyeing Machines…………………………………………………………… 06
2.7 Flow chart for cotton……………………………………………………….. 07
2.8 Flow chart for polyester………………………...………………………….. 07
3. Parameters…………………………………………………………………………. 08
3.1 pH………………………………………………….……………………….. 08
3.2 Redox Potential…………………………………….………………………. 08
4. Departmental Organogram………………………………….……………………… 08
4.1 Management Hierarchy in MTM……………………………………….. 09
5. Areas of Improvement……………………………………………………………… 10

2|Page
 Assignment

1. Introduction of Masood Textile Mills

Ch. Nazir Ahmed who was the founder established Masood Textile mills limited in 1984 and
now Ch. Shahid nazir is the chief executive. The Masood textile mill is established under the
company ordinance 1984. The company has latest equipment and machinery to serve globally.
The company has modern computerized networking system. All the Accounting and finance
relating work is carried out through computer. The company has capability in fabric, ginning
spinning, knitting laundry and apparel manufacturing. The company’s apparel division, which
is producing high quality garments, is situated at Sargodha road, near singed cinema,
Faisalabad. But its registered office has shifted to canal road Faisalabad. The company
implements the quality system and had awarded ISO 9002 certificate. The company maintains
quality standard at all levels to establish consistency and efficiency. The company is exporting
its products to U.S.A.U.K. and Germany

1.1 History

Masood Textile mills were incorporated in 1984 with 4 spinning mills. It is a public limited
company with its registered office at Faisalabad and listed in all stock exchanges of Pakistan.
It is vertically integrated textile unit. It has its own spinning, knitting, processing and stitching
units. Initially it was engaged only in spinning. But in 1993 company changed its strategy in
adding up most process and disposed off three spinning units. In 1995 company made its own
garments units with only 35 stitching machines but today it has about 1000 stitching machines
of different brands. All credit of this success goes to visionary personality of Mr. Shahid Nazir,
the Chief Executive of the company. They strive to lead in creating, developing and
manufacturing of knitted apparel products right from basic to highly fashioned garments thus
responding to emerging trends in the industry. They translate conceptual ideas of our customers
into reality and shape them through our technical bent and professional acumen. The team here
strongly believes that Customer satisfaction is the essence of business today. MTM has the
technology with expertise, products with knowledge and most importantly the right mindset to
achieve total customer satisfaction

1.2 Vision Statement

• A leading producer of textile products by producing the highest quality of products and
services to its customers.
• To strive for excellence through commitment, integrity, honesty and team work.
• Highly ethical company and be repeated corporate citizen to continue playing due role
in the social and environmental sectors of the company.
• To develop and extremely motivated and professional trained work force, which would
drive growth through innovation and renovation.
• Sustained growth in earning in real terms.

1.3 Mission Statement

Our mission is to be a dynamic, profitable and growth oriented company by providing good
return on investment to its shareholders and investors, quality products to its customers, a

3|Page
secured and friendly environment place of work to its employees and to project Pakistan’s
image in the international market.

1.4 Organizations Values

• Trust
• Integrity
• Respect

1.5 Infrastructure

2. Visited processes
We visit the unit of dyeing and examined different processes of dyeing on knitted fabric of
cotton, polyester and their blend.
2.1 Pre-treatment:

Before dying, the fabric undergoes pre-treatment to prepare it for the dyeing process. This
typically includes:

• Scouring
• Bleaching

2.1.1 Scouring

Scouring is a preparatory treatment of certain textile materials. Scouring removes soluble and
insoluble impurities found in textiles as natural, added and adventitious impurities: for
example, oils, waxes, fats, vegetable matter, as well as dirt.

Objectives of Scouring

• Remove non-color impurities

• Increase fabric absorbency

4|Page
Chemicals

We tend to used scourzyme L for scouring method (NaOH), Detergent, Sequestering Agent,
Wetting Agent/Non-ionic surfactants, Reactive dyes, Soda ash, Glauber salt chemical are use
additionally.

2.1.2 Bleaching

Bleaching is the process of decolorization of raw textile material by removing inherent and/or
acquired coloring components from the fiber. It provides a base whiteness to the textile material
which could be further whitened with the help of optical brighteners or dyed | printed depending
on the desired end use.

Objectives of Bleaching

• Increase Whiteness
• Increase absorbency

Chemicals

• Hydrogen per oxide

• Wetting agent
• Sequesting agent
• Caustic flakes
• Perchlorethylene
• Felosan RG-N

2.2 Dyeing

A dyeing process is the interaction between a dye and a fibre, as well as the movement of dye
into the internal part of the fibre. Generally, a dyeing process involves adsorption (transfer of
dyes from the aqueous solution onto the fibre surface) and diffusion (dyes diffused into the
fibre). There are two methods to dye the fabric first is exhaust and second is continues. But we
examined only exhaust method.

Dyes Used

There are two types of dyes which are used to dye the cotton and polyester in this industry.

Reactive Dyes: Commonly used for cotton fabrics, these dyes form a covalent bond with the
fabric, ensuring good color fastness.

Disperse Dyes: Used for synthetic fibers like polyester. They are dispersed in water and then
dye the fabric through diffusion.

Mechanism

The activated dye molecules form covalent bonds with the hydroxyl groups (in cellulosic
fibers) or amino groups (in protein fibers) on the fiber molecules. This reaction typically
involves nucleophilic substitution or addition reactions.

5|Page
Two process are done during dyeing. First is exhaustion and second is fixation. Exhaustion is
done by dozing of sodium chloride and fixation is done by dosing of sodium carbonate. Sodium
chloride creates positive layer on fabric then use sodium carbonate for the fixation of dye.

2.3 Post-treatment

After dyeing, fabrics undergo various post-treatment processes to ensure color fastness and
quality:

Washing: Removing excess dye and chemicals.

Soaping: Enhancing color fastness by removing any unfixed dyes.

Fixation: Using chemical agents to fix the dye onto the fabric.

2.4 Quality Control

Throughout the dyeing process, quality control measures are in place to ensure that the fabrics
meet the desired specifications:

Color Matching: Ensuring the dyed fabric matches the required color standards.

2.5 Environmental Consideration

Masood Textile Mills, like many modern textile companies, likely places a strong emphasis on
sustainable practices:

Effluent Treatment: Treating wastewater to remove harmful chemicals before discharge.

Eco-friendly Dyes: Using dyes that have a lower environmental impact.

Water Recycling: Implementing systems to recycle water used in the dyeing process.

2.6 Dyeing machine

Machines which are used in this industry are follow as:

Machines name Capacity

T 51 1500kg

T 48 2000kg

T 31 1000kg

T 144 1000kg

T 143 1000kg

6|Page
 T 142 1000kg

T 49 2000kg

T 108 1000kg

2.7 Flow chart of cotton dyeing

De oiling

Semi-bleaching

Acid neutral

Reactive dyeing

Wash off

2.8 Flow chart of polyester cotton dyeing:

Disperse dyeing for PC

Reduction clearer

7|Page
 Acid neutral

Reactive dyeing

Wash off

3. parameters

3.1 pH Control

The pH of the dye bath can significantly affect the dyeing mechanism. For instance, acidic
conditions are required for acid dyes to bond with protein fibers, while alkaline conditions are
necessary for reactive dyes to form covalent bonds with cellulosic fibers. This is measured by
pH meter.

3.2 Redox potential

Redox potential is a measure of the tendency of a chemical species to acquire electrons from
or lose electrons to an electrode and thereby be reduced or oxidised respectively. Redox
potential is expressed in volts (V)

4. Departmental organogram:
An organogram is a graphical representation of an organisation's structure. It's used to show
hierarchical relationships between managers and the people who report to them, as well as
departments. An organogram is a useful tool for organisations to both visualise reporting
relationships and communicate employees’ names, skills, and contact information. The term
"organogram" is used most often in the UK and is synonymous with "org chart."

8|Page
4.1 Management Hierarchy in MTM
They may categorize into top, middle and lower management as follows:
Top Management

Middle Management

Managers

Lower management

Supervisors

Helpers Foramens Operators

9|Page
The organigram shows each position in the company, who they report to, and where they fit
into the scheme of the hierarchy. As a tool, new employees can use this information to help
them learn their coworkers' positions, understand their own position better, and get
acclimatized with the people on their teams.

5. Areas of improvement
Sustainability
Invest in energy-efficient machinery and processes to reduce energy consumption and lower
operational costs.
Real-time Monitoring
Utilize IoT and other digital tools for real-time monitoring and control of dyeing processes.
Skill Enhancement
Provide ongoing training for employees on new dyeing technologies, techniques, and best
practices.
Recycling and Reuse
Implement systems for recycling and reusing dye baths and other materials where possible.
Partnerships
Collaborate with universities, research institutions, and industry experts to stay updated with
the latest advancements in dyeing technology.
Feedback Mechanism
Establish a feedback mechanism to capture customer feedback and continuously improve the
dyeing process.
References:

1. ^ Iqbal Qureshi, Zafar (June 26, 2005). "Performance Challenges at Masood Textile
Mills". Asian Case Research Journal. 09 (01): 61–
81. doi:10.1142/S0218927505000587 – via CrossRef.
2. ^ Correspondent, Our (December 15, 2014). "Foreign interest: Chinese company
acquires 24.3% of Masood Textile Mills". The Express Tribune.

3. Ibidapo, T. A. (1992). Application of redox potentials in the selection of reducing

agents for vat dyes. Chemical Engineering, 49, 73–78.

10 | P a g e