Forging a Sustainable Future: Masood Textile Mills’ Exemplary Vertical Integration

SJ Studio
·10 min read

This is the first article in an 11-part series from Masood Textiles. It was written by Muhammad Surfraz Gill, corporate HR and communications at Masood Textile Mills Limited.

Amidst a global push for transparency and sustainability, Masood Textile Mills, Ltd. (MTM) takes the lead in the textile manufacturing sector. With its origins in Faisalabad, Pakistan, MTM has revolutionized the industry through its unwavering dedication to total vertical integration, distinguishing itself both in the local landscape and on the global front.

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Rooted in Ethical Sourcing: The Foundation of Excellence

Masood’s journey commences at the very roots of the supply chain, placing meticulous emphasis on raw material sourcing. The company begins with the selection of the purest Pakistani cotton, cultivated with a predominant focus on sustainability and traceability. Through the innovative “Cotton Source Tracking” system, customers gain the ability to trace the cotton’s origins, ensuring a transparent supply chain. Moreover, this system provides customers with a comprehensive specifications sheet, offering detailed insights into the precise attributes of the cotton used in each product. This commitment to sustainable sourcing not only ensures the quality of MTM’s products but also signifies a significant step toward a more sustainable and ethical fashion industry.

Spinning Excellence: Crafting Quality Yarn for Superior Fabrics

Masood boasts state-of-the-art ring-spinning mills equipped with an impressive 63,000 spindles, showcasing the company’s prowess in producing 34,000 kilograms of mélange yarn daily. This intricate process involves various combinations of raw white and dyed cotton or fibers, resulting in the creation of quality yarn that forms the very foundation of MTM’s fabric excellence.

The emphasis on quality at the yarn stage sets the tone for the entire manufacturing process. This meticulous approach ensures that every garment produced by Masood is not just a piece of clothing but a testament to the company’s commitment to excellence.

Innovative Knitting: Crafting Versatile and Sustainable Fabrics

Masood showcases an impressive range of cutting-edge knitting machines, encompassing both circular and flat knitting equipment. These advanced machines highlight the company’s substantial daily production capacity, reaching an impressive 100,000 kilograms. Together, these machines play a pivotal role in crafting a diverse array of high-quality, innovative, and sustainable fabrics, exemplifying Masood’s commitment to adaptability and versatility in product development.

Central to Masood’s operations is a steadfast dedication to innovation in fabric creation. The company strategically invests in state-of-the-art knitting technology, ensuring not only operational efficiency but also the capability to generate a broad spectrum of fabrics. This proactive approach positions Masood at the forefront of meeting the dynamic demands of the fashion industry, where evolving trends and diverse preferences require a versatile and forward-thinking approach to fabric development.

Dyeing and Processing: A Symphony of Colors with a Touch of Green

Within its vertically integrated structure, Masood excels in dyeing and processing with facilities capable of processing 120,000 kilograms of fabric daily. This not only accommodates various materials, including cotton and polyester but also reflects MTM’s commitment to sustainability through energy-efficient processes.

The integration of sustainable practices in the dyeing and processing stage is a testament to Masood’s holistic approach to environmental responsibility. By reducing energy consumption and adopting eco-friendly processes, the company sets new standards for sustainable textile manufacturing.

Precision in Printing: A Fusion of Technology and Craftsmanship

Masood’s in-house facilities for diverse printing techniques, including rotary, digital, and screen printing, underline the company’s commitment to versatility. With a capacity of over 100,000 garments each day, these advanced printing technologies enable the creation of products with exceptional quality and unparalleled precision.

Precision in printing is not just a technical necessity for Masood but a creative expression. The ability to bring intricate designs to life on fabrics showcases the company’s dedication to craftsmanship and attention to detail.

Crafting Excellence: The Heartbeat of Masood’s Operations

At the core of Masood’s vertically integrated operations lies its vibrant apparel division. Multiple sewing facilities, tailored to meet the unique needs of diverse clientele, deliver a stunning array of products. With top-tier sewing machines and a highly skilled workforce, these facilities craft 5 million value-added garments every month.

The apparel division is the heartbeat of Masood’s operations. By combining state-of-the-art technology with skilled craftsmanship, the company ensures that each garment not only meets but exceeds the expectations of its clientele.

Global Innovation Centers: Staying Ahead of Trends with a Global Vision

Masood’s robust international footprint is attributed to the deliberate establishment of product development centers and design houses strategically positioned across different continents. Within these hubs, elite designers and product developers engage in close collaboration with clients, crafting bespoke and inventive solutions. These creative minds curate specialized catalogs meticulously aligned with the latest seasonal trends, positioning MTM at the forefront of the continually evolving fashion panorama.

The global innovation centers represent a strategic investment aimed at maintaining relevance in the industry. By remaining attuned to international trends, Masood ensures that its products transcend mere fashionability, standing at the vanguard of trends and fulfilling the preferences of a diverse global clientele. This forward-thinking approach not only solidifies Masood’s position as a trendsetter but also underscores its commitment to anticipating and meeting the dynamic demands of the global fashion landscape.

Fabricating Excellence: MTM’s Endeavor for Perfection

At Masood, a commitment to quality is intricately woven into every aspect of the production process. The dedicated team of quality experts rigorously oversees every stage, ensuring steadfast adherence to the brand-standardized protocols. These protocols, diligently followed from the initial phases of raw material sourcing to the final stitch in production, reflect MTM’s holistic approach to maintaining unparalleled quality. Operating round the clock, the fabric testing laboratories conduct rigorous tests to guarantee that only the highest-quality products reach the customers.

MTM’s dedication to quality has earned international recognition, with certifications such as ISO 9001 serving as a testament to the unwavering commitment to upholding the highest global quality management standards. What truly distinguishes Masood is the seamless integration of efficient systems, key performance indicators, radio-frequency identification (RFID), and enterprise resource planning (ERP) tools. These sophisticated tools further exemplify MTM’s dedication to operational excellence.

This precise quality control process is bolstered by Masood’s vertically integrated operations, ensuring meticulous quality oversight at every stage. In traditional fashion manufacturing, disparate entities at each production stage may have their own standards and quality checks. In contrast, Masood’s vertically integrated structure provides direct oversight throughout the process. This unified approach facilitates cohesive communication and quality control, enabling swift implementation of adjustments without prolonged negotiations between separate entities.

The efficiency of Masood’s vertically integrated textile manufacturing not only serves as a wellspring of competitive advantage but also contributes to customer satisfaction. Tailored reduced lead times align with today’s dynamic fashion landscape, where trends evolve rapidly, and customers seek timely access to the latest styles. This operational excellence underscores Masood’s reputation as an industry leader, steadfastly committed to unwavering quality, customer satisfaction, and delivering products that consistently exceed expectations.

Sustainability at the Core: Nurturing The Planet

In an era where sustainability is an essential ethical imperative, Masood Textile Mills has fully embraced eco-friendly practices. These initiatives underscore the company’s commitment to both environmentally conscious manufacturing and sustainable sourcing, laying the foundation for a more sustainable future for the planet.

At the core of Masood’s sustainability mission is the adoption of cleaner and environmentally friendly alternatives for process heating. Transitioning to low-carbon fuels, Masood has significantly reduced its carbon footprint while ensuring the efficiency of heating processes. The company’s utilization of carbon-neutral biomass fuels, such as corn cobs, rice husks, and mustard stock, exemplifies an innovative approach to lowering emissions and conserving energy resources. This step goes beyond industry requirements, reflecting Masood’s profound sense of responsibility toward environmental preservation.

Rather than allowing excess heat to go to waste, Masood has ingeniously harnessed this surplus energy and repurposed it for valuable applications. This initiative highlights Masood’s resourceful thinking and commitment to environmental stewardship, positioning it as a leader in sustainable textile production.

Furthermore, Masood is at the forefront of environmental responsibility, actively transitioning toward biofuels to maximize energy conservation. This forward-thinking approach not only underscores the company’s dedication to sustainability but also sets the stage for future energy-saving practices within the industry. Masood’s proactive stance in environmental conservation reflects its commitment to being a trailblazer in sustainable textile manufacturing.

Innovation in Supply Chain

Masood Textile Mills’ pursuit of innovation extends deep into its supply chain, particularly in the realm of raw material selection and fabric development. The company’s innovation journey begins with the careful curation of fibers, allowing it to craft distinctive melanges, fancy yarns, and injection slubs. This meticulous selection process enables the creation of textiles that not only meet the highest standards but also bear the mark of innovation. Beyond fibers, Masood’s dedication to innovation shines through in its fabric selection, from hosiery to Jacquard. This diverse range of materials showcases the company’s flexibility in catering to a multitude of customer needs and fashion preferences. Moreover, Masood’s innovative spirit is further reflected in its exploration of new materials through the ingenious mixing of various raw components. This dynamic approach to material development ensures that the company remains at the forefront of the textile industry, offering its customers products that are both cutting-edge and of the utmost quality.

Exceeding Expectations: Masood’s MTM Elegance

MTM redefines personalized clothing with its Made to Measure (MTM) services, striking an elegant balance between off-the-rack and bespoke fashion. MTM clothing stands out for its personalized approach, committed to crafting each garment according to the unique specifications and preferences of the wearer. What truly sets Masood apart is its unwavering dedication to exceptional customer experiences. The company goes above and beyond, guiding clients toward the best choices and tailoring personalized solutions.

Masood’s customer-centric approach offers an unparalleled degree of customization, allowing clients to tailor garments precisely to their requirements. From fabric selection to style, fit, and embellishments, every detail is customizable, enabling customers to bring their unique vision to life. This commitment is not just theoretical; it’s validated by the success stories of countless satisfied customers. Masood’s ability to transform a customer’s vision into a tangible, high-quality product has earned the company a reputation for exceeding expectations and maintaining a competitive edge in the market.

Collaborative Innovation

MTM goes beyond the traditional role of a manufacturer, excelling in collaborative innovation and co-creations. The company actively participates in co-creations with brand teams and clients, embarking on a shared journey to conceptualize and craft innovative products. This strategic partnership ensures the seamless integration of customer preferences, market trends, and brand identities into every creation, resulting in products that deeply resonate with end-users.

Masood’s unwavering commitment to innovation is epitomized by its Product Development Center, strategically located in Shenzhen, China. Functioning as a crucible for creativity and forward-thinking, this center is the nucleus where an adept team utilizes avant-garde tools such as Browzwear—a cutting-edge software that scans and interprets fabric properties, demonstrating how a garment drapes on the body. Through this visionary approach, Masood breathes life into the products of the future.

The company’s fervent emphasis on co-creation and relentless innovation sets MTM apart as a dynamic, customer-centric force in the textile industry.

To learn more about Masood Textile Mills Limited, click here.