Setcore Spinning: Premier League Spinning

Egypt-based Setcore Spinning specializes in long-staple cotton, fine-count yarn production.

Jürg Rupp, Executive Editor

E gypt is known for its long tradition in textiles, and is even more well-known for high-quality long-staple cotton. Setcore Spinning SAE is an Egypt-based spinner that is transforming long-staple cotton into some of the finest yarn counts one can imagine.

The city of Alexandria, Egypt, is probably one of the most famous ancient cities, and known for its historic library. Not far away from this ancient city lies Borg El Arab, a modern city with an industrial park built in the 1990s. This is where the Setcore Group is located. Because of its proximity to the Mediterranean Sea, the climate is perfect for growing cotton and operating a spinning mill. There is a saying that Alexandria gets some rain every day.

The Setcore Group

The Setcore Group was founded in 1972, at a time when Egypt was opening its borders, but its origins go back to the 19th century. Like many European textile companies, it began as a leather tannery. From 1972 over the next 20 years, the company diversified into different business areas, also dealing with oil, sugar and grains. When cotton trade was liberalized in 1995, Setcore totally changed the focus of its business and concentrated on oil and textiles. The company has became one of the largest exporters of Egyptian cotton by forming its subsidiary company Nassco Trading SAE Nassco not only grows cotton, but also gins and sells cotton around the world.


Spinning

With this successful cotton business in mind, Setcore explored new fields for added-value selling of its cotton. In 2003, Setcore Spinning SAE was founded to produce first-class long-staple cotton yarn from its own high-grade cotton. During a recent visit to Alexandria, Textile World Asia had the opportunity to interview Yassine Zaied, general manager, Setcore Spinning.

“Since we started our cotton business in 2003, it was our intention to serve the top class,” Zaied said. “Today we are working with 55,000 spindles. We are operating with an efficiency of 97 percent and use mainly Egyptian cotton and some Pima. Our yarn program is divided into three categories: Ne 50/1 up to 100/1, Ne 120 up to 170/1 and Ne 190/1, 210/1 and 240/1 single and plied yarns. Through the years, we have established an exceptional relationship with our customers. You have to be fast to be successful. Today, we provide 24-hour service; require no letter of credit; and deliver to our customers with open payment.”

This open customer relationship Setcore has with its customers requires a special policy.  “We have high quality standards, as you can see in our spinning mill,” Zaied explained. “We want proximity to the customers and high production efficiency. We have our own training center, and one person is responsible for four spinning frames only. The safety is controlled every day vigorously.”

The values of Setcore are based on the following company philosophy: high quality standards, closeness to the customer and production efficiency. To keep everything under control, Setcore owns its cotton ginning plant.


Modern Equipment, Modern Education

A walk through the spinning mill is astonishing. Every corner is very clean and functional. Remarkable is the attitude of the personnel: everyone is very open, ready to answer any question with a smile. A look into the cans full of cotton waste shows that this waste of long-staple cotton could be used for any low or medium range of cotton yarns. Top European equipment produces top-class yarn. From opening to spinning, Rieter machinery is at work, including 12 ring-spinning frames with 1,200 spindles each, 24 compact-spinning machines with 1,200 spindles each, and 12 compact-spinning machines with 1,008 spindles each. For yarn winding, Setcore uses Schlafhorst Autoconer 5 machines as well as Saurer Compact Twisters from Volkmann.

Setcore invested a lot of money to be able to produce its power in an environmentally friendly manner using natural gas. Investments are not only made in machinery, but also in human resources. According to Zaied, human power is the most precious asset at Setcore.

“We are working with the integrated management system Oracle,” Zaied said. “You may wonder, but we only hire people who didn’t work in any other textile company. We even apply IQ tests before engaging new people. The reason for all this is quite simple, however, very logical: we want to implement our own company philosophy to employees without a biased mind. This helps a lot to maintain the quality of our products. All our personnel enjoy a six-month training course. We are working three shifts per day, 365 days a year without any break and without any problem. Our employees are working 5 days a week and can live in company houses.”


Market

Setcore is exporting 100 percent of its cotton yarn. The main target groups are the top labels in 25 countries around the world. Setcore was the first textile company outside Europe to receive Öko-Tex Standard 1000 certification. To be even more competitive, the company plans to develop a so-called Egyptian Textile Cluster.

“Borg El Arab is near the port of Alexandria and is an excellent place for exports to Europe, where most of our customers are based,” Zaied said. “There are 1.2 million square meters of land provided by the government to build this center of excellence. I’m convinced that all interested partners will succeed with this plan, which enjoys the great support of the government of Egypt. It is also known that some European weavers are planning to build up their own weaving plant in this future center. This new center will bring the Egyptian textile industry a major push to new success.”

March/April 2008

 

Setcore Spinning 纺纱厂: 纺纱业的超级联赛企业

埃及纺织业的历史源远流长，出产的高档长绒棉尤其闻名。当地企业Setcore Spinning SAE，自然地也就在生产长绒棉的业务上，转型至生产最优质的细支纱。

埃及亚历山大市，是史上有名的古迹城市，向以历史图书馆闻名于世。离此不远的，是现代 化的Borg El Arab市。Borg El Arab于1990年兴建工业园，而Setcore 集团的厂址便位于 工业园内。由于当地邻近地中海，气候极适宜种植棉花及营运纺纱业务。俗语也说，亚历 山大市每日一雨。

Setcore集团

Setcore集团于1972年成立，当时正值埃及开放边境之际；不过集团的历史可追溯至十九世 纪。与不少欧洲纺织企业一样，集团以皮革制造起家。1 972年成立后的20年内，集团不断 扩展业务，生意遍及油、糖及谷物等范畴。埃及于1995年开放棉花贸易后，Setcore的业务 全面转型至以油及纺织为主。集团之后，并晋身为埃及具规模的棉花外销企业。不 单种植 棉花，同 时亦从事轧棉及于国际市场销售棉花。




纺纱业务

在棉花业务有所成之后，Setcore 进一步拓展增值棉花的商机。集团于2003年成立 Setcore Spinning SAE，采用集团种植的优质棉花，生产一流的长绒棉纱。《亚洲纺织世 界》的代表最近前往亚历山大市，并借机访问了Setcore Spinning总经理Yassine Zaied。

"我们自于2003年开展棉花业务以来，便一直以提供最优质的产品为目标。" Zaied表示： "我们现时拥有55000部锭子，以97%的效率进行生产。我们采用的原材料主要为埃及棉及 少量Pima棉。厂房的纱线生产业务共分3个级别：Ne 50/1 至100/1、Ne 120 至170/1 及Ne 190/1，以及210/1和240/1 的单纱与合股线。经营多年，我 们早与客户建立了紧密的 合作关系。只有迅速响应市场的需要才能取得成功，我们现时为客户提供24小时服务、毋 须客户提供信用状，而且不必收到订金才送货。"

Setcore 能与客户建立如此良好的关系，全赖集团的特殊措施：“由纺纱厂可见，我们具备 卓越的生产标准。"Zaied 解释说："我们锐意拉近与客户的距离，并致力保持高度的生产 效率。集 团设有内部培训中心，每名员工只需负责4部纺纱机。此外，我们对厂房日常安全 的要求极为严格。"

Setcore 的企业宗旨，是优质生产、靠近客户、生产效率。为确保贯彻集团的企 旨，Setcore 更特别设置轧棉厂。



现代化设施、现代化培训

到Setcore 的纺纱厂一行，你必会大感惊讶。厂房内每个角落均整洁非常，且各有用途。 工作人员的表现也令人刮目相看：态度亲切，面 带笑容地积极响应各项询问。向盛满棉花 废料的筒子一看，更 可看到不少其实是可以用于生产中、低档棉纱的长绒棉废料。厂房内 确切地反映了一流欧洲设备生产一流纱线的情况。由开棉至纺纱等流程，Setcore 均采用 立达的设备，包 括12部各具1200个锭子的环锭纺纱机、 24 部各具1200个锭子的微型纺纱 机，以及12 部具有1008个锭子的微型纺纱机。络纱方面，S etcore选用Schlafhorst Autoconer 5型号设备及 Volkmann 的Saurer 微型捻线机。

Setcore 在环保设备上，亦投放了大量投资，以采用天然气进行生产。此外，集团更致力在 人力资源方面作出投资。Zaied 表示，人力是Setcore 最宝贵的资产。

"我们采用Oracle的综合管理系统，"Zaied说："集团只会聘请从未在其它纺织厂工作的员 工，这你或会感到奇怪。我们甚至对人选进行智力测试，才决定聘用与否。原因非常简 单，却 甚为合理：我们希望对行业一无概念的新人灌输企业的宗旨，这对我们维系产品的水 平大有作用。集团所有员工均需接受6个月的训练课程；厂房每日3班运作，全年无休，但运 作却相当畅顺。员工每星期5天工作，可 住在公司的房子里。"




市场概况

Setcore 的棉纱产品全部用于外销，销售对象为全球25个国家的领先品牌。此 外，Setcore 亦是欧洲以外首个取得Oko-Tex 1000 标准的纺织企业。集团致力提高竞争 力，更 计划发展一项名为“埃及纺织群”(Egyptian Textile Cluster) 的项目。

"我们的客户以欧洲企业为主，Borg El Arab毗邻亚历山大港，是输出货物往欧洲的上佳地 点。"Zaied表示："政府为行业提供了120万平方米土地，以建立纺织中心。项目获得埃及 政府的大力支持，我深信所有参与者均会透过项目取得成果。此外，据闻已有欧洲织造商 计划在未来的纺织中心设立织造厂。纺织中心的计划将把埃及的纺织业推向另一高峰。"

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