Customer Success Story from SAPPHIRE | SUNTECH Textile Machinery

SUNTECH & SAPPHIRE TEXTILE MILLS
Automated Material Storage Solutions Realize Smart Management of Warp Beams

SAPPHIRE TEXTILE MILLS was established in Pakistan in 1970. It is a factory integrating weaving, dyeing, finishing, and garment home textile finished products, with a monthly output of 4,500 tons of yarn and 7,000,000 meters of woven fabrics. The group's business has expanded to industries such as dairy, power generation, and retail. SAPPHIRE TEXTILE MILLS also always adheres to its commitment to innovation, design, and excellent service. In 2021, in cooperation with SUNTECH, it purchased automated material storage solutions, which greatly saved factory space, increased storage capacity, and realized intelligent management of warp beams.
SUNTECH & SAPPHIRE TEXTILE MILLS
Automated Material Storage Solutions Realize Samrt Management of Warp Beams

SAPPHIRE TEXTILE MILLS was established in Pakistan in 1970. It is a factory integrating weaving, dyeing, finishing, and garment home textile finished products, with a monthly output of 4,500 tons of yarn and 7,000,000 meters of woven fabrics. The group's business has expanded to industries such as dairy, power generation, and retail. SAPPHIRE TEXTILE MILLS also always adheres to its commitment to innovation, design, and excellent service. In 2021, in cooperation with SUNTECH, it purchased automated material storage solutions, which greatly saved factory space, increased storage capacity, and realized intelligent management of warp beams.

Background

Founded in 1970, SAPPHIRE has grown to become one of Pakistan’s largest integrated textile manufacturers and exporters, operating a vertically integrated production complex spanning weaving, spinning, dyeing, finishing, and finished product manufacturing. With cutting-edge technology imported from Europe, Japan, and the United States, the company leverages locally sourced premium cotton, complemented by imported specialty fibers, to create end-to-end textile solutions in its factories in Pakistan – from yarn production to finished fabrics. Serving renowned apparel manufacturers in Asia, Europe, Australia, and North America, SAPPHIRE has built synergistic partnerships with global fashion brands with over 50 years of technical expertise and full-range manufacturing capabilities. The company’s “Made in Pakistan” commitment ensures complete supply chain control while maintaining international quality standards.

At present, SAPPHIRE's products cover yarn, gray woven fabrics, dyed and finished fabrics, denim, knitwear, home textiles, work clothes and casual wear, denim clothing, etc. Committed to minimizing environmental impact and creating a more sustainable future by using natural, recycled, and regenerated fibers.
During its digital transformation journey, SAPPHIRE identified key challenges in warp beam storage management, limited warehouse space limiting production scalability, inefficient manual handling of warp beams, lack of real-time inventory tracking leading to production delays, and risk of physical damage during material handling. In 2021, following an extensive market assessment, SAPPHIRE partnered with SUNTECH to implement beam stackers.

Honored Customer Journey

Founded in 1970, SAPPHIRE is a leading company in Pakistan's textile industry, integrating spinning, weaving, dyeing, finishing, and finished products with internationally advanced technology and equipment. SAPPHIRE's products are exported to Asia, Europe, Australia and North America, and have established long-term and stable cooperative relations with many internationally renowned clothing manufacturers. SUNTECH tailored an automated material storage solution-warp beam warehouse for SAPPHIRE based on its actual needs. This solution effectively solved SAPPHIRE's space bottleneck problem, significantly expanded storage capacity, and realized intelligent management of warp beams, greatly improving storage efficiency.

SUNTECH always puts customer satisfaction first and has upgraded the VIP system for customers. We regard SAPPHIRE as one of the most valuable customers and provide it with more intimate and comprehensive services. From the entire life cycle of the equipment to local services, SUNTECH provides strong support for SAPPHIRE to ensure smooth and efficient production operations. Through cooperation with SUNTECH, SAPPHIRE has successfully solved the warehousing problem and achieved intelligent upgrades. The precise positioning and rapid access to the warp beams have greatly improved management efficiency..

Challenges & Why SUNTECH

Business Challenges

As one of the largest textile product manufacturers and exporters in Pakistan, SAPPHIRE has won the favor of many international brands such as COTTON USA and Fire Trade with its high quality and professional attitude. However, with the changes in production needs, SAPPHIRE is also facing production difficulties. Their warp beam management has become a bottleneck, limited storage space has caused production delays, and precious materials are at risk of damage in crowded warehouses. This problem has seriously affected SAPPHIRE's production efficiency and high time and labor costs, greatly damaging its interests and affecting SAPPHIRE's market competitiveness.
Product Requirements

To solve the problems of insufficient storage space and low efficiency in storing and retrieving warp beams, SAPPHIRE urgently needs to adopt more advanced storage methods to improve efficiency and optimize spatial layout. In SAPPHIRE's production process, traditional warp beam storage relies on manpower and has chaotic management. Improper protection can easily cause warp beam wear and occupy a large space. SAPPHIRE hopes to shorten the storage and retrieval time of warp beams, optimize spatial layout, save space, and save costs by introducing advanced automation equipment.
Why SUNTECH

SAPPHIRE chose to cooperate with SUNTECH because of SUNTECH's expertise and experience in textile machinery and equipment as well as its localized services. The customized automatic storage solution provided by SUNTECH helps save factory space and achieve intelligent management. The equipment is fully automated and has multiple safety guarantees, which can improve the efficiency of warp beam storage and retrieval and achieve safe storage. In addition, SUNTECH's service team can provide SAPPHIRE with timely and professional services, and the localized service team ensures that the equipment is always in the best operating condition. This cooperation not only solves the problems of insufficient space and difficult management, but also greatly improves efficiency and saves manpower and operating costs.

SUNTECH Solutions to Help Out

Automated Material Storage Solutions

In the communication with SAPPHIRE, we learned that they faced problems such as small storage capacity and limited space in the warp beam storage link. There were also problems such as high labor consumption, poor packaging effect, and low efficiency. The previous warp beam management became a bottleneck, and limited storage space led to production delays, while precious materials were at risk of damage in crowded warehouses. In addition, the storage and retrieval links required a lot of manual operations, which were labor-intensive and prone to errors, increasing production costs. The automated material storage solution provided by SUNTECH utilized vertical space, greatly increased storage capacity, and safely reduced safety risks.

This beam stacker uses high-strength hanging chains, which increase the load-bearing capacity by 6 times. At the same time, the automatic chain is synchronized with the photoelectric detection function, which is safer and more stable to use. In addition, anti-collision alarms are installed to ensure safe spacing and safety fences are equipped to ensure personnel safety. SAPPHIRE has realized intelligent management of warp beams by investing in this beam stacker and connecting it to the ERP system. It has successfully solved problems such as insufficient storage space and low efficiency, saved 6 times the space, operated stably, and was smaller, more efficient, and labor-saving.

Reviews from SAPPHIRE TEXTILE MILLS

SAPPHIRE TEXTILE MILLS expressed their gratitude to SUNTECH and its partners for their invaluable support

The beam stacker from SUNTECH works perfectly, both in terms of quality and service. It's also allowed us to achieve smart management of warp beams, which is really important to us.

-- Mr. Shahzad Khalil

(General manager)

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