Fatullah Dyeing & Calendering Mills Ltd. is one of the forerunner dyeing factories in Bangladesh – serving the dyeing sector with its unparalleled support for the last three decades.
Fatullah Dyeing & Calendering Mills Ltd. sets an unparalleled benchmark in ensuring sustainability and innovation. The company recently applied for the LEED certification and wants to set an example by achieving a gold rating as a dyeing factory.
Fatullah Dyeing specializes in making high-quality fabrics and serving their customer with on-time fabric delivery at the best price are the main reason for the success of the company. It specializes in making knit fabrics in the form of 100% Cotton, 100% Polyester, Spandex Cotton and Polyester, PC, CVC, Viscose, and all kinds of washes too.
Also to bring innovation in the textile and apparel industry, Fatullah Dyeing joined Textile Today Innovation Hub as a ‘Textile Today Associates’.
Recently Minhazul Hoque, Director, Fatullah Dyeing & Calendering Mills Ltd. shared their vision and future aspects with Textile Today.
Textile Today: Please share with us the journey of Fatullah Dyeing & Calendering Mills Ltd. What is the company’s recent business status?
Minhazul Hoque: Fatullah Dyeing & Calendering Mills Ltd. has been contributing to the RMG sector for around 35 years. As a second-generation entrepreneur, I joined the family business back in 2013 after finishing my studies. The journey was a challenging one and at the same time gave me an opportunity. I had to learn from scratch – as I graduated with an accounting background.
Although I joined Fatullah Dyeing, I started educating myself from knitting – as Fatullah Group has a composite facility. Then I worked on the dyeing floor and in the lab to learn the various processes involved. Later I worked in the process development, financial department to get accustomed to it holistically.
This transformation of mine was not a smooth journey, but with a clear dedication and passion, I made myself at ease with the whole process. And for the new and fresh textile graduates, the process is the same. You have to be passionate enough to learn daily and eventually with time – then you will be able to take a leadership role.
At Fatullah Dyeing, we are ensuring innovation in every aspect possible and daily. We believe that we have a long journey ahead on the road to sustainability and innovation.
Textile Today: What are the innovations Fatullah Dyeing & Calendering Mills Ltd is offering for the textile industry?
Minhazul Hoque: Innovation in textile dyeing takes place in two areas. One is in fabric development and another is in technical innovation.
In technical innovation in dyeing the first and foremost thing is water. Less water consumption creates a positive domino effect in the whole process. Less chemical usage, less power consumption, more batch efficiency, all in all – overall impact in factory overhead cost.
An efficient dyeing machine plays a critical role to ensure less water consumption innovation. Fatullah Dyeing is giving utmost importance to reducing water consumption in terms of machinery. We discussed with our dyeing machine suppliers regarding machine construction. They provided us such machinery which requires less water to run the pump. Also, the same level of efficiency in every nozzle.
Most of the machinery of Fatullah Dyeing has a water flow meter which is giving us an approximate idea of water consumption.
We are proud that in Fatullah Dyeing, we have successfully implemented most of these innovations. As a result since 2015, we have significantly reduced water consumption in Fatullah Dyeing & Calendering Mills Ltd. which is one of our biggest achievements.
In terms of fabric development, Fatullah Dyeing is working with various new types of fabric to implement product diversification. Usually, in Bangladesh knit garments are mostly produced. To develop out-of-the-box apparel fabric and products needs a strong R&D team.
At the moment, from innovative knitting construction to different types of innovative dyeing – Fatullah Dyeing is researching the scopes of these innovative product developments.
Textile Today: As a knit composite factory how is Fatullah Dyeing & Calendering Mills Ltd forecasting the future of the knit market? How are you getting prepared to grab the new market opportunities?
Minhazul Hoque: Although globally the COVID-19 is still a real threat, I think that Bangladesh’s knit export prospect is bright. As there are available orders in the market and our existing customers are giving us more orders.
Also, I want to elaborate here that, we will grab new market opportunities. Despite the pandemic, globally apparel consumption is growing steadily.
As a result, we are planning to increase our dyeing and sewing capacity soon to cater to the growing demands.
One crucial aspect here is sticking to the sustainable profit margin. As retailers are pushing us to squeeze the apparel price sighting the pandemic and the economic crisis their part of the world is going through, on the hind side we also have to keep in mind that the raw material price has increased enormously during this period, instability in the cotton market globally and the global logistic chain hampered by the pandemic resulted in the hike in prices. So it is very important for the apparel manufacturers to stick to their fair prices for the betterment of their factory and also for the industry as a whole.
Textile Today: As you have already mentioned raw materials prices are drastically increasing. How is it impacting the overall textile and apparel industry? To what extent is your factory being affected by it?
Minhazul Hoque: Cotton and yarn price increase plays an immediate component and it is a global factor. Fashion buyers are aware and accept that to some extent. On the other hand, in the case of dyes and chemical price hikes, buyers are less acquainted and hence do not provide a fair price. The dyes and chemical market are volatile over the last two years and we cannot adjust or predetermine the unpredictable dyeing cost.
In my opinion, if the textile factories need to build 3 to 4 months of storage capacity – then it will to some extent cushion the impact.
But the permanent solution is to develop dyes and chemical manufacturing plants locally. And it requires government and other stakeholders’ initiative and interests. Unless we develop that, our storage capacity will give us the extra mileage – be it cotton, yarn, or dyes and chemical.
I will say the pandemic has taught us a lot of vital lessons regarding survival. Instead of being reactive, we have to be proactive. And I think 2022 is a transition year for us to implement the lessons we have learned in the last two years.
Textile Today: Fatullah Dyeing recently joined Textile Today Innovation Hub. Kindly share with us your experience and outcome of this collaboration.
Minhazul Hoque: I am honored to be a part of the ‘Textile Today Innovation Hub.’ Fatullah Dyeing achieved a great result in the lab to bulk RFT project in knit dyeing. As a leading dyeing factory in Bangladesh, I can say that every dyeing factory in the country does R&D and does continuous development with the lab to bulk process. But with our long experience, we have seen that it was not possible to achieve the expected outcome.
Thanks to Textile Today Innovation Hub, through a joint collaboration we pointed out all the areas and worked on it on a daily basis for almost three months for a successful outcome and hence we have achieved the desired result in the lab to bulk RFT in knit dyeing.
During the process, we observed that light shade color becomes lighter and dark shade color becomes darker in lab to bulk. So, our team hand in hand with Textile Today started working in the lab at first to achieve accurate RFT results in bulk.
It was a great pleasure to work with Textile Today Innovation hub and achieve a positive outcome in our project which will help us and the industry as a whole.
I will urge Textile Today to highlight this great innovation case study in the industry. So that other dyeing factories can achieve a similar outcomes.
Partnering with Textile Today Innovation Hub will surely assist Fatullah Dyeing and Calendering Mills Ltd. decide on the best sustainable solution for their industry.