Nishat Mills: The "Ceiling" of Pakistan's Textile Industry

Nishat Mills Limited, established in 1951, is the flagship enterprise of the Nishat Group — a conglomerate with total assets of approximately 4 trillion rupees, 9 listed companies, and over 54,000 employees directly on its payroll.

Nishat Mills itself employs 24,767 people, generates annual revenue of $745 million, and operates 303,048 spindles, 10,320 rotors, and 959 Toyota air-jet looms — with fully integrated operations spanning spinning, weaving, dyeing, and garment manufacturing.

It is the first textile company in Pakistan to join the bluesign® system — meaning its chemical management, emission control, and worker safety standards are held to the most rigorous global benchmarks. It is also one of the few Pakistani manufacturers that has set science-based carbon reduction targets through the Science Based Targets initiative (SBTi) ： reducing Scope 1 and 2 emissions by 69.3% and Scope 3 emissions by 27.5% by 2031.

For a company like this, a supplier is not just "good enough" — every link in the chain must match its standards.

2020: First Contact, A Long Preliminary Planning Phase

In 2020, we first engaged with Nishat Mills' waste cotton recycling project team.

Nishat Mills' procurement process is not a simple three-step "inquiry-quote-order." Its preliminary planning is exceptionally rigorous, divided into three stages：

Stage 1: Waste Composition Analysis. Each of Nishat Mills' plants generates different types of waste — spinning produces cotton yarn waste, comber noil, and card fly; weaving produces fabric scraps, denim offcuts, and braided tape; dyeing produces pigment-contaminated fiber waste. Our technical team sampled and analyzed each waste stream individually, determining tailored opening and cleaning solutions for each type.

Stage 2: Process Solution Design. Based on the waste composition and the customer's target capacity, we designed complete line layouts — including equipment selection, line configuration, dust collection system setup, and voltage specification customization. Nishat Mills does not accept "generic solutions" — it requires independent technical designs for each plant.

Stage 3: Technical Review and Bidding. Nishat Mills assembled a multi-department review team covering production, technical, quality, and procurement, comparing the proposals, specifications, and operational data of multiple suppliers. In the end, our solution passed every round of review.

From first contact to formal contract signing, the process took over eight months.

The First Line: From Planning to Execution — Delivery Was Just the Beginning

In 2021, Nishat Mills placed its first order with us. The equipment was installed, commissioned, and put into operation — then Nishat Mills did one thing： it observed for an entire year.

What it needed to confirm was not whether the machine "could run" — it was whether it could run consistently. Double shifts every day, waste coming in daily, fiber going out daily, quality stable, production uninterrupted.

We established a regular communication mechanism with Nishat Mills' waste cotton recycling team and assisted them in developing operational procedures and daily maintenance protocols. Any parameter fluctuations during operation were met with immediate technical support.

One year later, Nishat Mills' conclusion was： You can continue supplying.

Three Plants, All Chose Us

Nishat Mills operates multiple manufacturing units across Pakistan — from spinning to weaving to dyeing — each with different waste types, processing requirements, and workshop conditions.

Yet its choice was the same： waste cotton recycling lines at all three plants, all from Morinte.

This means our equipment had to satisfy three different sets of working conditions simultaneously：

Different waste compositions — spinning waste, weaving offcuts, dyeing fiber waste

Different workshop conditions — space constraints, power configurations, operator practices

One unified standard — fiber quality must remain consistent, regardless of which plant it comes from

Our technical team independently completed on-site surveys, layout designs, and installation and commissioning for each plant.

Product Quality: Why Nishat Mills Chose Us

Equipment Stability

The opening machine is the first gateway of the entire waste cotton recycling line — if it stops, the whole line stops. Our licker-in rollers are dynamically balanced twice to a precision grade of G6.3； bearings are standard SKF/FAG； frames are constructed from heavy-gauge steel plates, welded as a single unit and stress-relieved through annealing. As Nishat Mills' production supervisor told us： "After your equipment was installed, we didn't need to watch it every day to keep it running."

Fiber Quality

Nishat Mills spins yarn for global brands, with clear threshold requirements for fiber length and impurity content. Our gentle opening technology — featuring a carding plate opening structure — removes impurities while maximizing fiber length retention, ensuring consistent recycled fiber quality and high spinning pass rates. Internal testing data from Nishat Mills shows that after processing with our equipment, recycled fiber length retention and impurity rates consistently meet their spinning standards.

Controllable Energy Consumption

Our equipment features variable frequency drive — low speed for light materials to save energy, high speed for heavy materials to maintain efficiency. Motors are selected at IE3 energy efficiency class. Nishat Mills conducts regular energy monitoring, and our equipment has consistently operated within expected parameters.

After-Sales Service: From Installation to Long-Term Support

Preliminary: Planning and Execution — No Rush

From our first contact in 2020 to the formal signing of the first line in 2021, we accompanied Nishat Mills through every stage of preliminary planning. Three things we did most thoroughly：

• On-Site Survey – Our technical team visited each plant, measuring workshop dimensions, verifying power configurations, and assessing waste storage areas — every detail was cross-checked multiple times before we finalized the plan, ensuring precise alignment with site conditions

• Customized Solutions – Based on waste composition and capacity requirements, we independently designed layouts for each line. No two sets of drawings were identical across the three plants

• Complete Line Delivery – From opening, cleaning to baling, everything was designed, manufactured, and commissioned by us — no patchwork of components, but a fully matched integrated solution

Mid-Term: Installation, Commissioning and Training — We Stay Until It Runs

During the installation of the first line, our engineers worked with the Nishat Mills team to develop the installation plan, guiding hoisting, cabling, electrical connections, and piping. Once the equipment was in place, we commissioned each unit individually, then coordinated the entire line. We ran continuous trial runs with Nishat Mills' actual waste materials until the line produced recycled fiber that met their quality standards.

After installation, our engineers remained on-site at Nishat Mills for 7 days, providing systematic training for operators：

• Start-up and shut-down sequences — correct procedures to prevent misoperation damage

• Daily maintenance — lubrication points, cleaning schedules, inspection items

• Fault identification — unusual noises, vibration, temperature rise — catching problems early before minor issues escalate

• Basic repairs — changing card clothing, adjusting gaps, clearing jams — small tasks operators can handle without waiting for an engineer

Long-Term: After-Sales Support — No Downtime Waiting

Equipment delivery is not the end of the relationship — it's the beginning of a long-term partnership：

• Local Teams – We have installation and maintenance teams in Pakistan. When Nishat Mills' lines encounter issues, they don't need to wait for us to fly in from China

• Spare Parts Supply – Critical wear parts (card clothing, bearings, belts, blades) are stocked both at our Shandong headquarters and in our Pakistan warehouse. When Nishat Mills places an order, parts are dispatched within 48 hours from the nearest location

• Regular Follow-Ups – At month 1, month 3, month 6 after commissioning, and every 6 months thereafter, we proactively reach out to confirm operating metrics, remind maintenance schedules, and collect feedback

• Warranty Commitment – 1-year full machine warranty. Any component failure due to design, material, or manufacturing defects — replaced free of charge, shipping on us

• Long-Term Parts Availability – We guarantee spare parts supply for at least 10 years after equipment discontinuation. Nishat Mills never needs to worry about parts availability

To this day, not a single Nishat Mills line has ever been shut down waiting for parts or an engineer.

Why Did All Three Plants Choose the Same Supplier？

The reasons are straightforward.

Nishat Mills has tried other suppliers. But in the end, all three plants standardized on Morinte equipment. Because：

• Unified Lines – One brand, one standard. Common spare parts, consistent operation, simplified maintenance

• Unified Quality – Recycled fiber quality is consistent across all three plants — no need for spinning processes to constantly readjust

• Unified Service – We cover all sites. One call, one team, one standard

Not one plant, but three. Not one machine, but a complete recycling system.

From our first contact in 2020 to the first line's completion in 2021, and today to full coverage across three plants — Nishat Mills' waste cotton recycling has been entrusted entirely to Morinte.