Quality and innovation are at the heart of everything we do
Fazal Group is one of the oldest and largest textile groups in Pakistan, with operations in cotton ginning, yarn spinning, greige woven fabric manufacturing and towel production. The Group produces over 156 million kg of top-quality yarn annually for a range of textile customers, following strict testing standards on automated spinning plants, equipped with the latest European machines. Speaking to Fibre2Fashion, Director Abdullah Amir Fazal talks about the advantages of vertically-integrated manufacturing, sustainability, innovation and more.
What challenges do textile companies face today in balancing sustainability with cost-efficiency, and how can these be mitigated?
Balancing sustainability with cost-efficiency is undoubtedly a complex challenge. On one hand, there is a fear that adopting greener practices might increase production costs. However, at Ahmed Fine Textile Mills (a Fazal Group company), we have discovered that strategic investments in sustainability yield long-term savings while also building trust with customers. Over the years, initiatives that were initially costly have now paid off in the form of improved unit economics and better environmental outcomes. The key is adopting an integrated approach where innovation drives both sustainability and cost-efficiency.
How is the textile industry in Pakistan adapting to the global trend of digitalisation and smart manufacturing, especially in traditional sectors like weaving and spinning?
The Pakistani textile industry is gradually embracing digital transformation, driven by the desire to remain globally competitive. At Ahmed Fine Textile Mills, we have implemented real-time monitoring systems for power quality and steam usage. This digitisation not only enhances operational efficiency but also ensures optimal energy utilisation. For example, we have installed monitors on our looms to track efficiencies and speeds, which can be accessed from anywhere in the world. I recall a time when we had thousands of workers in our spinning mills, but today, thanks to smart manufacturing and automation, we operate with just a few hundred.
We are also adopting predictive maintenance practices to minimise downtime and reduce waste. As more companies realise the tangible benefits of digital solutions, the industry is progressively moving towards a smarter and more sustainable future.
With the rise of eco-conscious consumers, what steps should textile manufacturers take to incorporate more sustainable practices and materials into their production?
Eco-conscious consumers are reshaping our industry, creating a sense of urgency for manufacturers to prioritise sustainability. At Ahmed Fine Textile Mills, our approach is multi-faceted. We have transitioned to using eco-friendly materials such as recycled cotton, hemp, and Tencel. Additionally, our closed-loop water systems, including a Reverse Osmosis (RO) plant, help conserve water significantly. To stay ahead, manufacturers should also consider building green infrastructure—like our facility, which features XPS insulation, double-glazed windows, and advanced air filtration systems to enhance energy efficiency and indoor air quality. These initiatives resonate with eco-aware consumers and reinforce a brand’s commitment to sustainability. I am proud to say that we are the only LEED-certified towel manufacturing facility in Pakistan.
What role does government policy play in supporting or hindering the growth of the textile industry in Pakistan, particularly regarding exports and sustainability?
Government policies play a critical role in shaping the textile industry’s future, and often, there is a mixture of hope and apprehension about how these policies evolve. Supportive measures— such as incentives for adopting renewable energy or streamlined export regulations—can significantly empower companies to grow sustainably. However, inconsistent or unclear policies can stifle innovation. We believe that strategic partnerships between the government and private sector are crucial. If the government prioritises policies that encourage environmental responsibility—such as offering tax breaks for green investments—the textile industry can thrive while remaining globally competitive.
How do you see the future of synthetic vs. natural fibres in textile manufacturing, and what might this mean for the industry in the next decade?
The future will likely be a balance between advanced synthetic and natural fibres. With growing concerns about climate change, natural fibres like organic cotton and bamboo will gain popularity, especially among environmentally conscious consumers. However, innovation in synthetic fibres— particularly recycled and biodegradable options—will remain relevant. At Fazal Group, we are committed to staying ahead by exploring and investing in fibre innovations that align with both consumer preferences and environmental goals. Over the next decade, the industry will likely face resource scarcity and increasing demand for high-performance, sustainable alternatives, necessitating a thoughtful, balanced approach.
Fazal Group has a diverse portfolio, from ginning to spinning, weaving, and towel production. How does this vertical integration enhance your operational efficiency and product quality?
Our vertical integration is a key strength, providing us with unity and efficiency across the entire production process—from ginning to the final towel. This approach ensures impeccable quality control and allows us to be more adaptable to client needs. It also enables us to implement sustainable practices, like waste heat recovery and energy-efficient air systems, across all our facilities. Additionally, vertical integration reduces costs and streamlines logistics, ensuring timely delivery of high-quality, eco-friendly products. Beyond this, it gives us the flexibility to conduct R&D, exploring different fibres and techniques to innovate further.
Sustainability is a core focus for Fazal Group. Could you share more about your recycling initiatives, particularly with GRS-certified polyester and pre- and post-consumer waste processing?
Sustainability is at the heart of everything we do. We are proud of our Global Recycled Standard (GRS) certification, which underscores our commitment to using recycled materials. We have invested in advanced shredding and recycling systems that convert both pre- and post-consumer textile waste into reusable fibres. These fibres are spun into high-quality yarns for our terry towels. This approach not only helps reduce landfill waste but also demonstrates our commitment to circular production. Our customers can take pride in knowing that every recycled towel they use is a testament to responsible and innovative manufacturing.
You said that your towel production facility is Pakistan’s first LEED-certified building. What steps did Fazal Group take to achieve this certification, and what benefits do you foresee?
Achieving LEED certification is a monumental accomplishment and reflects our commitment to environmental excellence. We have installed 2.7 MW of solar panels, adopted biomass steam boilers, and implemented advanced energy and water management systems, including heat recovery and effluent treatment plants. Our building also features XPS insulation and double-glazed windows to optimise energy efficiency. This certification not only reduces our carbon footprint but also enhances our status as a global leader in sustainable manufacturing. We expect significant benefits, including reduced operational costs, a healthier workplace environment, and an enhanced reputation among eco-conscious consumers.
How does the presence of an effluent treatment plant in your operations contribute to sustainable practices, and how does it impact the communities around your facilities?
Our effluent treatment plant (ETP), with a capacity of 1,200 cubic metres per day, plays a vital role in our sustainability strategy. It treats and recycles wastewater, significantly reducing our reliance on freshwater. This initiative has a direct, positive impact on local communities, as it helps prevent pollution of nearby water sources and supports agricultural irrigation. The ETP reflects our commitment to environmental stewardship and fosters trust and goodwill with our neighbours. Our long-term goal is to create a fully closed-loop water system, ensuring no discharge and reusing treated water in our processes.
Given Fazal Group’s extensive weaving capacities, what unique advantages do the Karl Mayer and Picanol air jet looms provide in terms of productivity and quality?
Our Karl Mayer and Picanol air jet looms are crucial to our weaving operations, offering exceptional precision, speed, and efficiency. These state-of-the-art machines enable us to meet global demand with top-tier quality while also allowing us to produce complex designs, such as Dobby and Jacquard patterns, for premium markets. Additionally, they are energy-efficient, aligning perfectly with our goal of minimising resource consumption. This technological investment reinforces our reputation for excellence and provides our global clientele with a sense of reliability and authority.
In terms of energy, you utilise solar power and gas-fired generators. How much of your energy demand is met by these renewable sources, and what future plans do you have for increasing renewable energy usage?
Currently, our renewable energy efforts are led by our 2.7 MW solar system, which we plan to expand by an additional 2.4 MW. This expansion will further offset our carbon emissions and reduce our reliance on conventional energy sources. In addition, we are exploring the use of electric vehicles and installing EV chargers at our facilities to promote sustainable transportation. Our long-term vision is to achieve energy independence by increasing our use of renewable energy, driven by our commitment to environmental responsibility and the desire to protect the planet for future generations.
Fazal Group’s mission emphasises continuous improvement. Could you elaborate on some recent innovations or improvements that have significantly impacted your production processes?
Continuous improvement is a cornerstone of our operations. Recently, we have installed energy-efficient LED lighting across our facilities and upgraded our air conditioning systems to use R-32 refrigerant, which reduces greenhouse gas emissions. Our heat recovery systems have been instrumental in conserving energy by repurposing hot drain water back into our processes. We have also implemented advanced air filtration systems to ensure a safe and healthy indoor environment for our employees. These advancements not only improve efficiency but also underscore our commitment to sustainability and worker well-being.
How does Fazal Group ensure consistent quality and innovation in its yarn products, given the diverse range of materials you use, from organic cotton to synthetic fibres?
Quality and innovation are at the heart of everything we do. We maintain stringent quality control at every stage of production, from raw material sourcing to final yarn production. Our state-of-the-art testing laboratories ensure that our yarns meet or exceed industry standards, regardless of the fibre type. We also continuously invest in R&D, exploring new fibre blends and sustainable materials. This commitment to quality and innovation builds trust with our clients and helps us stay ahead in an increasingly competitive global market.
