Masood Textile Mills: Standing Out with Vertical Integration
In a world where transparency and sustainability are paramount, Masood Textile Mills, Ltd. (MTM) puts these issues front and center. Hailing from Pakistan, MTM has redefined textile manufacturing with its total vertical integration, setting it apart from both local and global textile players.
Masood’s commitment to state-of-the-art vertical integration begins at the root of supply chain—raw material sourcing. The company starts with the purest Pakistani cotton, cultivated with an overriding goal of sustainability and traceability. This attention to the source of raw materials ensures that every garment produced can be meticulously traced through the innovative “Cotton Source Tracking” system. The system allows customers to trace the cotton’s origins, precisely pinpointing its country of origin and the specific regions of cultivation. Moreover, it provides customers with a detailed specifications sheet, offering comprehensive insights into the precise attributes of the cotton used while creating the products.
More from Sourcing Journal
The company also boasts cutting-edge ring-spinning mills equipped with 63,000 spindles to produce quality yarn. These facilities showcase the company’s capability to produce 34,000 kilograms (kgs) of mélange yarn—yarn produced with various combinations of raw white and dyed cotton or fibers—daily.
Masood’s extensive array of state-of-the-art knitting machines, including circular and flat knitting equipment, highlights the company’s production capacity of 100,000 kgs daily. These machines collectively contribute to creating a wide range of high-quality, innovative, textured and sustainable fabrics, offering adaptability and versatility in product development.
Revolving around a vertically integrated structure, the company’s advanced, multi-dynamic dyeing and processing facilities can process 120,000 kgs of fabric daily, capable of handling various materials, including cotton, polyester and other synthetic fabrics.
Within its integrated ecosystem, Masood boasts in-house facilities for a diverse range of printing techniques, including rotary, digital and screen printing with a capacity of over 100,000 garments each day. These advanced printing technologies not only reflect the company’s commitment to versatility, but also enable the creation of products with exceptional quality and unparalleled precision.
At the core of Masood’s vertically integrated operations lies its vibrant apparel division, home to multiple sewing facilities, each tailored to meet the unique needs of the company’s diverse clientele. With a wealth of top-tier sewing machines and a highly skilled workforce, these facilities craft an extensive range of product categories with various styles in sportswear, activewear, loungewear, sleepwear, base layers and more. These high-tech, high-capacity production facilities deliver 5 million value-added garments every month.
Masood’s strong global presence is credited to its strategically established product development centers and design houses across various continents, where top-tier designers and product developers collaborate closely with clients to create innovative and tailored solutions. Moreover, these designers curate specialized catalogs that align with the latest seasonal trends. This proactive approach enables Masood to stay at the forefront of the ever-evolving fashion landscape, offering clients products that resonate with the contemporary style preferences of each season and region.
Hence, Masood’s operations span the entire production spectrum, ensuring that the path from raw materials to the finished garment is meticulously crafted, managed and controlled under one roof. This seamless vertical integration empowers Masood with unparalleled advantages, ensuring unwavering quality control, limitless customization, peak efficiency and a steadfast commitment to sustainability and traceability.
Quality assurance in every stitch
For Masood, quality is knitted into every thread and stitch. A dedicated team of quality experts rigorously supervises every facet of production, guaranteeing persistent adherence to the company’s brand-standardized protocols. These protocols are consistently upheld, from the earliest stages of sourcing raw materials to the final stitch in the production process. In this holistic approach, fabric testing laboratories operate around the clock, conducting rigorous tests to guarantee that only the highest-quality products make their way to customers.
MTM’s devotion to quality has garnered international recognition, with certifications like ISO 9001 serving as a testament to the company’s steadfast commitment to upholding the highest international quality management standards. What sets Masood apart is the integration of efficient systems, key performance indicators, radio-frequency identification (RFID) and enterprise resource planning (ERP) tools. These tools further exemplify MTM’s dedication to operational excellence.
This precise quality control process is underpinned by Masood’s vertically integrated operations, which maintain meticulous quality control throughout. In traditional fashion manufacturing, each stage of production, such as spinning, dyeing, knitting and sewing, may involve multiple entities, each with its own standard and quality checks.
In stark contrast, Masood’s vertically integrated structure provides direct oversight at every step of the process. This unified approach fosters cohesive communication and quality control, with concerns or necessary adjustments swiftly implemented without the need for prolonged negotiations between separate entities.
The efficiency of Masood’s vertically integrated textile manufacturing serves as a wellspring of competitive advantage and customer satisfaction. Reduced lead times are tailored to today’s dynamic fashion landscape, where trends evolve rapidly, and customers seek timely access to the latest styles. This operational excellence further underlines Masood’s reputation as an industry leader committed to unwavering quality, customer satisfaction and delivering products that exceed expectations.
Setting new standards with sustainability
In an era where sustainability is an undeniable ethical necessity, Masood shows unyielding dedication to environmentally responsible practices. These endeavors signify the company’s dedication to both eco-conscious manufacturing and sustainable sourcing, ultimately ensuring a brighter future for our planet.
One of the central tenets of Masood’s sustainability mission has been adopting cleaner and more environmentally friendly alternatives for process heating. By transitioning to low-carbon fuels, Masood has markedly diminished its carbon footprint while maintaining efficient heating processes. The company’s use of carbon-neutral biomass fuels, such as corn cobs, rice husks and mustard stock, exemplifies a pioneering approach toward reducing emissions and conserving energy resources. This step is not merely an industry requirement, but a testament to Masood’s deep-seated sense of responsibility toward the environment.
Rather than letting heat go to waste, the company has harnessed this surplus energy and repurposed it for valuable applications. This initiative showcases Masood’s resourceful thinking and environmental stewardship, marking it a leader in sustainable textile production.
Furthermore, Masood is at the vanguard of environmental responsibility, vigorously shifting toward biofuels for maximum energy conservation. This forward-thinking approach not only underscores the company’s dedication to sustainability but also paves the way for future energy-saving practices within the industry.
Co-creations
MTM excels in the conventional role of a manufacturer, thriving on collaborative innovation. The company actively engages in co-creations with brand teams and clients, embarking on a mutual journey to conceptualize and craft novel products. This partnership ensures a seamless integration of customer preferences, market trends and brand identities into every creation, resulting in products that resonate with end-users.
Masood’s commitment to innovation is manifest in its Product Development Center, strategically based in Shenzhen, China, serving as a crucible for creativity and forward-thinking. Here, an adept team harnesses avant-garde tools like Browzwear—software that scans and reads fabric properties to show how garment drapes on the body—to envision and breathe life into the products of the future. This fervent emphasis on co-creation and relentless innovation distinguishes MTM as a dynamic, customer-centric force in the textile industry.
As Masood forges ahead, it lays the groundwork for a sustainable and conscientious future, not solely within the textile sector, but for the larger global society.
This article was written by Ali Yaqoob, general manager/head of corporate HR & communications at Masood Textile Mills Limited.
To learn more about Masood Textile Mills Limited, click here.
