09.01.2018 - 12.01.2018 — Hall: 10.1 Stand: C 52
Owners are the Dogar Family who started the manufacturing business 25 years ago.
Rustam are manufacturers and exporters of terry towels and bathrobes. The factory is fully integrated on 15 Acres of land and employs 1,500 staff. The production includes weaving, dyeing and making up, including embroidery facilities.
The factory is working to be WRAP approved and eventually to be SEDEX approved as well.
The factory has a needle policy and a metal detector.
The product range consists of: Plain Dyed towels, Yarn Dyed towels, Printed towels, Embroidered towels, Velour towels and bathrobes and all terry accessories.
Besides the regular virgin cotton ring spun carded yarns Rustam produces towels and robes from a wide range of other fibres such as: Combed cotton, Egyptian cotton, Non twist cotton, Modal and other viscose, bamboo, hemp.
The factory has 4 main departments. Weaving, Dying, Stitching and Packing.
24 new Vamatex looms with dobby and 12 new Vamatex looms with Staublies double jacquard have recently been installed. Besides that there are 185 power looms in the factory with a total production of 15,000kg grey terry cloth per day.
All dyes used are reactive dyes, or on special instructions Indigo dyes are used. In house test equipment monitors the colourfastness is available including a Wash Wheel for testing to CO6a2s standards.
The dyeing facility has a complete range of Softlow machines resulting 16,000 kilo per day dyeing capacity. Colour matching is controlled by a fully computerised lab.
In the factory there is a yarn dying equipment for 2,500kg per day.
Finishing is done with finishing agents to obtain Hydrophilic finish with a soft touch.
Stitching & quality:
We have fully automatic length stitching machines and every piece is checked before going for final packing. Prior to shipment an AQL2.5 is normally carried out unless the customer specifies differently.
Normally the goods are snake loaded at the factory into sea containers 10 days before the vessel sailing date (to allow transit time and waiting time at the port).
The factory employs separate staff who are based outside the factory to perform the AQL tests. This team reports on a weekly bases the production status to the relevant customers, they prepare each order and obtain all required confirmations from the customers before confirming to the factory to proceed with the next step of the production. As a result, for the last six months all orders are shipped ex Karachi port are within one week of the target ship date and no claims related to quality issues have been raised.
The US market accounts for 30% of the business and the EU just over 55% with the remainder being exported to the Middle East.
15% to the total business being is for jacquard terry beach towels to Spain, France and Italy.
40% is mainly domestic towels for retail in departmental stores and supermarket chains in France, Germany, UK and Ireland either direct or via importers.
Rustam is making an effort to improve the over all standards of their products with a view to attract more higher quality conscious customers. Besides installing better quality machines the factory is working to improve the general efficiency, reduce the CO2 footprint and reduce the waste emissions.