At AGI Denim, we are unlocking the power of data to transform the denim supply chain. AGI is proud to add the first LEED-certified Spinning Unit in the country after already being one of Pakistan’s highest-ranked LEED GOLD certified facilities. LEED is a rating system that provides a framework for creating healthy, highly efficient, and cost-saving green buildings.
Our state-of-the-art new LEED-certified spinning facility will produce 60,000 Kg of yarn daily. In addition, in keeping with our zero-waste focus, we will also install an automated shredding unit in the second half of 2022 that will convert post-consumer waste into a recycled fiber. This will replace a portion of the conventional cotton in our spinning process. Our multi-year, forward-thinking investment plan includes a cutting-edge denim facility for dyeing, weaving, and finishing as well, powered in part by renewable energy.
Using a set of intelligent, connected technologies that merge the real and the digital, AGI Denim’s Smart factory transforms how we do business. Industry 4.0 allows AGI to stay resource-efficient whilst maximizing value and output with the power of data.
Inaugurating the first LEED-certified Spinning unit in Pakistan
The brand-new Spinning unit features automation at different levels of yarn manufacturing, creating increased efficiency and better yarn quality throughout the supply chain. There is complete automation from the blow room to the carding process and an automated contamination sorter separating impurities from the cotton.
A fire detection system from Argus (American best in class) is installed at the spinning mill. In case of a fire, it will automatically detect and help extinguish it immediately. An automatic data control system aggregates all machine data in one area (T-DATA central control room). The new Autoconer machines identify and automatically remedy faults to ensure more uniform yarn. The Industrial Recycled Waste System (IRW) recycles all spinning mill waste and upcycles it into yarn making.
Each spindle has a unique quality monitoring system called Sentinel by Uster Technologies, Switzerland, which helps us achieve our zero-defect goal.
Weaving Unit (OPTIMAX – I)
The brilliant performance and sustainability focus of the Picanol Optimax – I weaving machine allows us to thrive in today’s world of Industry 4.0, which is connected, digital, and sustainable.
The Prewinder Switch-Off (PSO) system ensures the machine carries on weaving automatically even if a filling break occurs on the weft bobbin. The Bluebox electronic system gathers data and makes it accessible for the teams to make the production even more efficient.
Finishing Unit (BLUETEX FINISHING) – by CIBITEX
At AGI, we use Bluetex finishing machinery that guarantees the highest quality and standard of denim. The finishing of denim fabric plays an essential role in fabric properties such as appearance, softness, and residual fabric shrinkage.
The production and controls on the Bluetex machines are fully automated, supervising all the production data for machine settings. The line includes the weft-skewing process and pre-drying before sanforizing, which guarantees fabrics with dimensional stability complying with the highest international standards of lab controls.
Waste Water Treatment
AGI set the goal to release zero liquid discharge into the environment and a reduction in overall water consumption by 2025. We have invested in water treatment and recycling plants designed to reuse wastewater in the manufacturing process. The plants are designed to meet the British Standard Guidelines and European Standard Guidelines for releasing wastewater into the sea. Our long-term goal is to recycle almost all of our daily water consumption through reverse osmosis plants. We are currently constructing a wastewater ETP and recycling plant to achieve this goal.
At AGI, we truly believe in investing in the best denim manufacturing processes to ensure a greener, brighter tomorrow.