Production Expansion & Automation Roadmap
At Ashraf & Sons, our commitment to excellence drives us to continually enhance both capacity and capability. In partnership with leading Canadian and German equipment manufacturers, we’re rolling out a suite of highly automated production lines—set to be fully operational by July 2026. This strategic investment will elevate output consistency, reduce lead times, and maintain our reputation for premium quality.
Key Automation Installations
• Dual Automatic Fabric-Processing Plants
Two end-to-end systems that handle everything from unwinding and inspection to automated cutting—ensuring precision nesting and minimal material waste.
• Duvet Cover Set Assembly Lines (Two)
Each line integrates programmable stitching stations with inline inspection cameras to guarantee perfect seams and color consistency across every set.
• Flat Sheet Manufacturing Units (Two)
High-speed looms coupled with digital pattern programmers will deliver flat and fitted sheets in a spectrum of thread counts, all with sub-1% tolerance on dimensions.
• Fitted Sheet Fabricators (Two)
Specialized machinery for elastic edge application and corner reinforcement, streamlining what was once a multi-step manual process.
• Pillowcase Production Cells (Two)
Automated folding, edge-stitching, and label-attachment stations designed for swift changeovers between sizes and fabric weights.
• Press, Fold & Pack Lines (Four)
Integrated steam-press tunnels, robotic folding arms, and intelligent packaging robots will handle up to 500 units per hour—uniformly folded, wrapped, and pallet-ready.
Timeline & Impact
• Q3 2025:
Finalize procurement of all weaving, processing, and packaging equipment; begin reconfiguration of the Nooriabad facility.
• Q4 2025:
Install and commission Canadian cutting looms and German stitching platforms, alongside initial dyeing/printing cells.
• Q1 2026:
Roll out comprehensive staff training on the new MES interfaces, maintenance protocols, and safety standards.
By July 2026: Have all six specialized production lines and four packaging cells fully operational, on track for our July 1, 2026 home-textile launch.
