Polyester

The manufacturing operations are divided into three plants located within the same premises, at 38th K.M. Faisalabad – Sheikhupura Road, Faisalabad and are spread over an area of more than 100 acres of freehold land with a capacity to produce 390,600 tons per annum of Polyester Staple Fibre (PSF) or it can also alternatively produce Polyester Chips. The salient features of these Plants are as under.

Engineering and Technology

Polyester Plants (Plant – I, II, III) are based on the engineering and technology supplied by (Lurgi GmbH) now known as Air Liquide Global E&C Solutions Germany GmbH who are market leaders in the polyester polymer capacities supplied worldwide representing more than 50% share in the world market. These plants are equipped with Provox plus Distributed Control System (DCS) using SRX process controllers providing a foundation for real time, efficient and accurate control and monitoring of the process of entire plant through Computer Integrated Manufacturing (CIM). The Provox plus data provides access to historical process data for monitoring and analyzing process conditions. Intelligent alarming techniques help enhanced operator control capability to evaluate changing conditions and to respond quickly to any process changes. The plants have one to one redundancy starting from process control units upto all Input/Output modules enabling smooth and consistent operations.

The polyester plants are also equipped with bulk PTA container charging facility having a storage capacity of 600 containers ensuring dust free PTA charging to polycondensation resulting in low wastage and improved quality of finished product.

Along with complete technology transfer, the plants have been supplied and installed as a turnkey project by (Lurgi GmbH) now known as Air Liquide Global E&C Solutions Germany GmbH. The designed capacities of the plants, consumption of raw materials, utilities and quality of finished product are all guaranteed by the plant supplier.

Polyester Plant - I

Initiated in 1994 and operational since December 1996, Plant-I has a capacity to produce 200 tons/day of PSF in two lines of 100 tons/day each. Based on 24 hours/day operations of the polycondensation and spinning plant and on 20 hours/day operations of fibre lines, the installed annual manufacturing capacity of the plant is 70,000 tons of PSF.

Polyester Plant - II

This Plant has a single polymer line of 410 tons/day and three spinning and staple fibre processing lines, each having a capacity of 132 ton/day. The installed annual manufacturing capacity of the plant is 138,600 tons of PSF per annum. The plant started its trial run production in June 2002 and commercial production was started in October 2002.

Polyester Plant – III

This Plant has a single polymer line of 650 tons/day and four spinning and staple fibre processing lines, each having a capacity of 130 ton/day. The installed annual manufacturing capacity of the plant is 182,000 tons of PSF per annum. The plant started its trial run production in February 2013 and commercial production was started in April 2013.

Product Range

The polyester fibre Division of the company produces wide range of the PSF of different lusters and varieties including semi dull, bright, optical bright, anti pilling, flame retardant and trlobal with cut length of 32, 38, 44, 51 and 64 mm and fineness of 0.8, 1.0, 1.2, 1.5, 1.7, 2.0, 3.0 and 6.0 denier. The project is the first in Pakistan to start the production of dyed fibre and hollow fibre in siloconised and non-siliconised varieties.

Product specification