A Monforts Montex stenter has been installed as part of an expansion programme, by Portugal’s Malhas Sonix following its takeover, to meet added production in new vertical integration. Malhas Sonix renown since 1966 for its knitwear confectionary, weaving and dyeing for shirts, t-shirts and own brand underwear was recently taken over by the Portuguese Diastêxtil Group. A confectionary and knitting company Diastêxtil was seeking to diversify with more vertical integration to provide quicker response times for its customers and guaranteed quality control.

Diastêxtil had been formed in 1984 by its president Mrs Conceição Dias and operated as a subcontractor until 1989. Continued investment in new equipment saw production increase to 20,000 pieces / week in 1994 and almost double between 2000 – 2005 to 4.5 million pieces / year.

“Sonix offered us a dyeing and finishing house that we didn’t have before, plus the improved margins production offered an attractive option” said co-owner and husband Mr João Alberto. “We also wanted to offer a complete weaving, dyeing, knitting and garment confectionary production, without depending on others, making us more flexible” added Mrs Conceição Dias.

Almost immediately, the need was recognised for a second stenter to provide increased capacity at the Barcelos-based operation, in the heart of Portugal’s knitted textiles centre.

A new gas fired Monforts Montex 6500 stenter was ordered through the local representative Hitzemann & Sampaio. “I wanted the best machine on the market offering improved quality and increased capacity, providing the latest developments, such as the Monformatic automatic fixation feature” said João Alberto adding, “Plus of course the significant energy savings available, including the exhaust heat recovery system.”

“We have since recognised the benefits of running the larger batches on the new Montex as it can run at faster speeds and provides energy savings” confirmed Mrs Conceição Dias.

The Montex is used for fabric widths of between 1.4 – 2.1 m and fabric weights of 100 – 360 g / m² in 100% cotton, polyester, viscous and polyamides mixes.

The Monforts stenter has been installed in a new 1350 m² warehouse and finishing facility alongside Sonix’s existing production units.

The Diastêxtil Group also includes a weaving company, Modelmalhas plus a factory in Tunisia where dyed and cut fabrics are shipped from Portugal to the confectionary operation before being shipped to the UK. Other export markets include Germany and the Netherlands.

All three operations in the group produce 800,000 pieces / month with Sonix producing almost 200,000 pieces. Almost 70% of this production passes through Monforts Montex at least once and twice for thermofixation of fabrics with lycra mixes.

Before the Monforts stenter was installed, capacity had been just 4 t / day, today it has increased to 9 t / day.