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THE

TEXTILE MAGAZINE

Contents
6 Editorial

INDUSTRY NEWS
12

8
KARL MAYER plan to set up production facility in India

Yarn export incentivization scheme restored

IT SOLUTIONS
20 OCM India implements Datatex ERP solution in just 4 months

WEAVING
60 Growing Indian appreciation for Stublis new technologies

30 COVER STORY

WELSPUN
targets $2 billion turnover by 2020

84
RICHARD HOUGHs
all-out effort at Asian market expansion

CORPORATE
14 22 28 28 67
2

Raymonds quarterly PAT moves up four-fold at Rs. 57 cr. Sutlej net surges 82% Aditya Birla Nuvo registers all-round growth Marked increase in Grasims VSF sales DyStars holistic approach towards sustainability

THE TEXTILE MAGAZINE FEBRUARY 2014

Contents

92

JEANOLOGIAs
SPINNING
16 26 68 74

lead in sustainable technology for garment finishing

64
SAVIO fares well in 2013

Rieters innovation & expansion strategy of 2012 pays Trtzschlers 10,000th card delivered to Arisht Spg. MOHLER bags huge export orders for OHTCs Prosino targets sale of 500,000 rings in India by 2015

PROCESSING
63 InspirOn meet on stenter role, a big success

JOINT VENTURE
70 LEEDs total environment management solutions

TESTING
78 USTER device for cotton testing

ENERGY EFFICIENCY
80 Sustained textile industry drive to enhance energy efficiency

100
DHL Supply Chain
to invest more for expanding Indian operations

TECHNOLOGY
86 ColorDry water-free dyeing system at NIKEs Taiwan 88 Grundfos solar pumps help tackle worsening power crisis

PRODUCT LAUNCH
90 Mahindra Powerols new range of diesel generators

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THE TEXTILE MAGAZINE FEBRUARY 2014

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THE

TEXTILE MAGAZINE

Publishers Gopali & Co., Quanta Zen Building, No.38, Thomas Road, 2nd Street, Off. South Boag Road, T.Nagar, Chennai-600017. Ph.: 24330979, 42024951. Fax: 044-24332413 Email: textile.magazine@gmail.com textile_magazine@rediffmail.com Website: www.indiantextilemagazine.in Founder M. Rajagopalan Mentor Rajagopalan Kalidasan Managing Editor & Publisher R. Natarajan (Cell: 9381062161 (R) 24343475) Assistant Editor K.N. Ananthanarayanan (Cell: 9003053132) Associate Editor Rajeswari Prasad Executive Editor & General Manager K. Gopalakrishnan (Cell: 9840897542) N. Balasubramanian (Cell: 9840597082) Email: balanatarajan.gopali@gmail.com Online & Digital Media Lakshmi Natarajan (Cell: 9884544953) Email: lakshmidotnatarajan@gmail.com Marketing G. Mohan N. Ananthan Designer E. Marimuthu Photographer M. Sathya Mumbai AR. Balasubramanian G 102, Shrinagar Co.Op. Housing Society, P.L. Lokande Marg, Chembur (West), Mumbai - 400 089. Ph.: 022-25252377. Cell: 9323711291. Email: r.balagopali@gmail.com Coimbatore Ganesh Kalidasan Flat No.A1-42, TVH Ekanta No.5/179, Masakalipalayam Road Uppilipalayam, Coimbatore 641 015. Cell: 97909 26388 Email: ganesh.kalidas@gmail.com Bangalore J. Saravanam 17/1-1, 2nd Floor, G No. 13th Street, Jogupalya, Ulsoor, Bangalore - 560 008. Cell: 9880974765 Email: saravanam_j@yahoo.co.in Member INS / AINEC / IFSMAN
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The views presented herein are those of the authors. They are not necessarily the views of the editor. All rights reserved. Neither this publication nor any part of it may be reproduced in any form or by any means, nor may it be printed, photocopied or stored on microfilm without the written permission of the publisher.

Uptrend in cotton output


Cotton production during the 2013-14 season has been estimated by the Cotton Advisory Board, Indian Cotton Federation and the Cotton Association of India at 376 lakh bales. Further, market arrivals of 13.3 million bales of cotton as of December 31, 2013, have been officially confirmed against 10.4 million bales in the corresponding period of last season. This consensus of views among official agencies on the estimated cotton production is in striking contrast to the usual trend witnessed in the last few years, with the Government as well as the official agencies coming out with R. Natarajan, conflicting ideas about the expected seasonal Managing Editor & Publisher cotton output, the crop yield and the exact quantum available for local consumption and for export. This invariably led to nagging uncertainties related to the cotton economy and to the Government failure to announce a clear-cut and predictable cotton and yarn supply policy. The higher output and market arrivals so far this year are quite conducive for a speedier recovery of the textile sector. Equally significant is the proposed launch of the Rs. 50-crore Tamil Nadu Cotton Cultivation Mission as envisaged in the State budget for 2014-15. This has come as a big relief for the textile sector in the southern region, particularly in Coimbatore, the so-called Manchester of India where a vast majority of the States 1,948 spinning mills are located. Under the Mission, an additional 3.70 lakh acres will be brought under cotton cultivation in the current year. This will be gradually expanded to six lakh acres in the next five years. The main objective here is to maximise production to the extent possible to enable the huge number of mills in the State to meet their annual requirement of 110 lakh bales. The State Government move is expected to considerably improve cotton supply not only in the southern region but all over India. Meanwhile, the core group set up by the All-India Federation of Co-Operative Spinning Mills to study the general problems facing the textile industry, particularly the co-operative sector, and work out a viable strategy for an early solution has been termed timely. The core group would study, among other things, the measures to be initiated by the co-operative sector, with particular reference to spinning, for improving its operational and financial performance. The move would positively help intensify the Textile Ministry drive for industry rehabilitation by launching a series of promotional measures since last one year.

THE TEXTILE MAGAZINE FEBRUARY 2014

COVER STORY

KARL MAYER plan to set up production facility in India


For KARL MAYER, the new year began with a high-level visit by the Indian Textiles Minister, Dr. K.S. Rao, and his team on January 9. He took advantage of his visit to Heimtextil in Frankfurt to make a short trip to nearby Obertshausen for visiting the KARL MAYER plant there.
Dr. Rao and his team were received by Mr. Arno Grtner, Managing Director, and Mr. Oliver Mathews, the Head of Sales of the Warp Knitting Business Unit, Mr. Bastian Fritsch and Mr. Peter Obrist, Sales Managers of the company, and representatives of the local agent, A.T.E.

Mr. Fritz P. Mayer, member of KARL MAYERs Supervisory Board

THE TEXTILE MAGAZINE FEBRUARY 2014

COVER STORY

Impressed by the modern production processes at KARL MAYER, Dr. Rao said that the machines were of the highest technical calibre, and the companys innovative products were extremely important for the development of the Indian textile industry. Expressing his interest in the possibilities of encouraging traditional medium-sized, familyrun companies to invest in India, he said this traditional approach really motivated KARL MAYER to become very active in India. As part of its strategy of manufacturing close to its markets, KARL MAYER has been run10

ning its own service subsidiary in Mumbai since 2009. The service

operations are being expanded on a regular basis.

KARL MAYER - LIBA integration in progress


As announced earlier, KARL MAYER has acquired majority ownership of LIBAMaschinenfabrikGmbH. Integration of the two worldwide leading companies in areas of development, manufacturing and delivery of warp knitting and technical textile machinery has been implemented ac-

cording to plan. As a member of the KARL MAYER Group from now on

LIBAMaschinenfabrik will be incorporated under the name KARL MAYER LIBATex-

THE TEXTILE MAGAZINE FEBRUARY 2014

tilmaschinenfabrik GmbH. In addition, the processes that started at the end of last year to work out Best of Both Worlds solutions for products, processes and concepts are progressing well. In the middle of this year, this project will be finalized. In the meantime the business of both parties in terms of products and market approach will be unchanged. All important tasks

will be completed as before. Following completion of the Best of Both Worlds projects full integration of LIBA into the KARL MAYER business unit structure will start. This should be finalized at the end of 2015. Customers will then benefit from a strong partner with a unified approach and optimized products and solutions.

On the occasion, Mr. Grtner explained that India has been an important sales region for the warp preparation machines produced at Obertshausen for some time. Since 2010, demand for new warp knitting machines manufactured by KARL MAYER has increased considerably. The Managing Director went on to say that this development has made India an important growth market for the textile machinery manufacturing company. This positive

development has also encouraged it to consider setting up its own production centre in India. Preliminary work on the project is currently underway. As an important contribution to the continuing process of modernisation in the Indian textile sector, KARL MAYERs discussion partners expresed happiness over the offer of special incentives such as the Technology Upgrading Fund Scheme put in place by the Indian Textile Ministry. w 11

THE TEXTILE MAGAZINE FEBRUARY 2014

INDUSTRY NEWS

Yarn export incentivization scheme restored


The Government has restored the benefit of the Incremental Exports Incentivization Scheme (IEIS) for cotton yarn. This will certainly go a long way in increasing exports of cotton yarn and would contribute towards achievement of the overall exports target for cotton textiles, said Mr. Manikam Ramaswami, Chairman, Cotton Textiles Export Promotion Council (Texprocil). According to him, this will also strengthen the confidence of the exporting community with regard to the stability of policy provisions, which is crucial for taking long-term perspectives while negotiating export orders. IEIS which extends a two per cent duty credit scrip on incremental exports achieved during 2013-14 as compared to 2012-13 was withdrawn on exports of Mr. Manikam Ramaswami, cotton yarn in September last. Since then, Texprocil has been relentlessly representTexprocil Chairman ing to the Government for its restoration. The Government has also increased the all-industry rates of duty drawback on knitted cotton fabrics with a lycra content of five per cent and more based on representations from Texprocil. This will increase exports of lycra-based fabrics whose share in the total world trade in textiles is increasing significantly, said Mr. Ramaswami, who also expressed his confidence that India will soon play a major role in exporting lycra-based fabrics. He has profusely thanked the Department of Revenue and the Ministry of Textiles for accepting the Texprocil proposals and implementing them. w

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THE TEXTILE MAGAZINE FEBRUARY 2014

CORPORATE

Raymonds quarterly PAT moves up four-fold at Rs. 57 crores

aymond Ltd.s consolidated net sales for the quarter ended December 31, 2013, moved up by 15 per cent to Rs. 1,207 crores and consolidated PAT jumped up by 343 per cent to Rs. 57 crores. The textile segments consolidated sales for the quarter witnessed an increase of eight per cent at Rs. 543 crores on the back of higher realization in the domestic and export segments. The apparel segment net sales stood at Rs. 250 crores, an increase of 15 per cent on y-o-y basis. The retail stores count as at December 31, 2013, stood at 955 across all formats, including 41 stores in the Middle East and the SAARC region covering over 1.8 million square feet of retail space. During the quarter, like to like sales growth blended across all formats were flat. Secondary sales through the retail channel grew by five per cent. The garmenting segment net sales grew by

45 per cent to Rs. 104 crores during the quarter. EBITDA rose by 54 per cent to Rs. 15 crores. The cotton shirting fabric business grew by seven per cent to Rs. 86 crores. However, EBITDA for the quarter was impacted due to higher input costs and lower exports. The denim business witnessed eight per cent sales growth during the quarter and stood at Rs. 235 crores backed by higher realisation in the domestic as well as export segments. EBITDA was impacted due to higher input cost. Sales in the tools & hardware segment grew by 15 per cent to Rs. 110 crores, led by both domestic and export markets. EBITDA grew by 90 per cent to Rs. 11 crores. Sales in the auto component segment grew by 13 per cent to Rs. 56 crores led by both domestic and export markets, and EBITDA improved by 65 per cent to Rs. 7 crores. Announcing the results, Mr. Gautam Hari

Mr. Gautam Hari Singhania, Chairman & MD, Raymond Ltd.

Singhania, Chairman & Managing Director, Raymond Ltd., said: We have ended the third quarter on a positive note, despite subdued discretionary spend witnessed in the month of December 2013. Our focus on profitability through margin expansion across key business segments of the Group has led to a strong bottom line growth in the current quarter as well as

for the period till date. Going forward, while factors like inflation and interest rates will continue to play a role in the consumer discretionary space, we are confident that our long-term sustainable initiatives in Brands, Retail, Supply Chain Management and Operational Efficiency will enable Raymond to surge ahead. w

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THE TEXTILE MAGAZINE FEBRUARY 2014

SPINNING

RIETERs
R
ieter recorded a pleasing trend in business in 2013. The improvement in its market

innovation & expansion strategy of 2012 pays


Big spurt both in order intake and sales

position enabled the company to post significant growth in both order intake and sales. Order intake of 1,259.4 million CHF was 50 per cent higher. Sales totalled 1,035.3 million CHF, representing an increase of 17 per cent.
Mr. Erwin Stoller, Executive Chairman, Rieter

Rieter had a backlog of orders in hand of some 765 million CHF at the end of 2013. This will ensure a high capacity utilization until well into 2014. After a subdued start to the year, the market for short-staple fiber ma16

chinery and components gained momentum in the course of 2013. Spinning mills margins continued to develop favorably, and this stimulated customers willingness to invest. This positive trend was broad-based in regional terms and apparent in a

large number of national markets. Following a strong initial six months, demand stabilized in the second half of the year, but remained at a pleasingly high level. The positive trend in order intake and sales in 2013 underlines that

Rieter is on the right track with the innovation and expansion strategy it has been implementing since 2012. Demand for Rieters offering, expanded by major product launches, has been very good in both the traditional and

THE TEXTILE MAGAZINE FEBRUARY 2014

SPINNING
due to large raw material inventories and growing difficulties with financing investment projects. Healthy demand for Rieter products nevertheless continued throughout the year in a number of Asian countries, such as Pakistan, Uzbekistan, South Korea, Bangladesh, Indonesia and Vietnam. Spinning mills in the US are renewing capacity as the industry benefits from a competitive cost structure. Business here developed briskly in the second half in particular, and

new markets. Rieter has further developed its already strong market position with the implementation of the large-scale investment program in 2012-2013 aimed at further growth and focusing on expansion in Asia, innovation and process improvements. With its product range centering on specific markets and its new plants, the company is ideally positioned with a worldwide operating network. Spinning mills in all major markets are increasingly placing their confidence in machinery and components which enable a high degree of automation to be achieved in conjunction with higher productivity and yarn quality with lower energy consumption. As the sole global supplier of integrated 18

systems for all four spinning processes, Rieter can optimize the entire spinning operation in line with customers specific needs. This is a crucial and lasting competitive advantage. In the year under review, new orders received by Rieter increased by 50 per cent to 1,259.4 million CHF. After developing especially vigorously in the first half of 2013, order intake slowed slightly in the second six months, but still remained above the long-term average. This trend was especially true in Turkey where demand had been particularly strong with the support of Government development schemes. Rieter booked new big orders in China, especially in the first six months, thanks to the

further expansion of its local presence. However, investments by Chinese spinning mills waned towards the year-end

THE TEXTILE MAGAZINE FEBRUARY 2014

Rieter secured substantial orders for rotor spinning machines. Orders received in India rose in the second half, albeit still at a modest level. Rieter posted an increase in order intake at both Business Groups, with the striking momentum in the first six months being attributable especially to orders for complete installations from Spun Yarn Systems. Compared to 2012, Spun Yarn Systems (the machinery business) posted a 56

per cent increase in new orders to 1,084.3 million CHF. At Premium Textile Components (the components business),

Encouraging sales trend


The sales trend at Rieter in 2013 was also very good. The figure of 1,035.3 million CHF was 17 per cent higher than a year earlier. All regions recorded increases, with only Europe posting slightly lower sales. Expanded and modernized manufacturing capacity enabled Rieter to process orders promptly and post a 17 per cent increase in sales in the

order intake increased by 21 per cent in 2013 to 175.1 million CHF. Rieter had a backlog of orders in hand of some 765 million CHF at the end of 2013, which will ensure high utilization until well into 2014 compared to some 550 million CHF on December 31, 2012.

second half of the year compared with the first six months. Spun Yarn Systems reported sales of 857.8 million CHF in 2013, equivalent to an increase of 18 per cent compared with the previous year. Premium Textile Components posted a 10 per cent increase in sales to third parties to a figure of 177.5 million CHF. The margins earned in the machinery business in the second half of the year were better than expected and above the average of the existing orders in hand. With this improvement in operating profitability and volume growth, Rieter foresees net profit of around 3.5 per cent of sales for the 2013 financial year. w 19

THE TEXTILE MAGAZINE FEBRUARY 2014

IT SOLUTIONS

OCM India implements Datatex ERP solution in just 4 months


OCM India Ltd., is a leading mens apparel fabric retailer offering quality suiting fabrics in all wool and innovative wool blends with multiple fibers. Located at Amritsar, the company has its vertically integrated fabric plant with production facilities for converting wool tops into finished fabrics through dyeing, spinning, weaving and finishing processes. Early last year OCM selected the NOW ERP solution from Datatex to be implemented by Infinite Computer Solutions, Bangalore. Work related to its implementation started on June 01, 2013, and completed on October 1. Infinite deployed functional consultants specifically from the worsted industry for this high-technology project, while OCM deployed a full-time core team comprising functional leads from all departments. The project implementation covered Datatex NOW across the functionalities of database, sales, planning, manufacturing/production, purchase/materials, costing, quality management, plant & maintenance, warehouse management, external order management, HRMS & payroll with integration to SAP FICO. Datatex is the worlds leading provider of ERP solutions for the textile industry, with over 400 customers in 42 countries. The Datatex NOW suite, with all the required textile application functions, is a web-based system using state-of-theart J2EE Java standards. w

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THE TEXTILE MAGAZINE FEBRUARY 2014

CORPORATE

SUTLEJ net surges 82%


Big yarn capacity hike in progress
31, 2012, to Rs. 1,399 crores, marking an increase of 12 per cent. EBITDA is Rs. 236 crores as compared to Rs. 174 crores, showing a growth of 36 per cent. Strong operational and financial performance of the company was due mainly to improved profitability on the back of operational and financial efficiency, better realizations and higher production of units resulting in revenue expansion, margin progression on the back of improved cost efficiencies and profitability enhancement on account of lower interest outgo and improved cost management. STILs spinning capacity is being expanded by 30,672 spindles, resulting in higher production of value-added yarns at a project cost of Rs. 175 crores. Expansion is on schedule, and commercial production is likely to commence in the third quarter of 2015. Further, modernization-cum-upgradation of the existing projects will result in substantial cost reduction. In line with the company philosophy of rewarding its shareholders, it allotted bonus shares in the ratio 1:2 in June 2013. Commenting on the results, Mr. C.S. Nopany, STIL Chairman, said: Our strategy to focus on manufacturing

Mr. C.S. Nopany, STIL Chairman

S
22

utlej Textiles and Industries Ltd. (STIL), a leading manufacturer of value-added synthetic, cotton and blended yarns, fabrics and home furnishings, recorded a net profit of Rs. 111 crores during the nine months of the year

ended December 31, 2013, as against Rs. 61 crores generated during the corresponding period last year, registering a growth of 82 per cent. Its revenue expanded from Rs. 1,248 crores garnered in the nine months ended December

THE TEXTILE MAGAZINE FEBRUARY 2014

CORPORATE
export performance in 2009-10, (up 77 per cent over the preceding financial year), Gold Trophy from SRTEPC for best performance in export of fabrics to focused Latin American countries in 2011-12 and the Silver Trophy, also from SRTEPC, for the second best export performance in the spun yarn category

niche products in the yarn category, namely, specialty & value added yarns, is reflected in the sustained improvement in operational and financial performance even in a protracted slowdown prevailing in the macro environment. Our constant endeavour towards maintaining a high degree of cost efficiencies has also enabled us to soften the impact of cyclicality associated with the business. Favorable domestic and international factors in general have aided the sector by keeping the raw material prices steady during the period. In addition, our innovative R&D enables us to broaden our sourcing capabilities, thus strengthening our ability to mitigate volatile raw material prices over the years. While the econo24

my at present continues to reel under pressure, we are optimistic that the companys current implementation of capacity addition and modernization will further consolidate its position within the industry and enable us to deliver healthy financial performance going forward. Incorporated in 2005, Sutlej, an ISO 9001:2008-certified

company, excels in all stages of textile production, with its versatile facilities being vertically integrated, from spinning and weaving to dyeing and finishing to making home textile furnishing. The company has also been a recipient of numerous prestigious awards, the latest ones being the Niryat Shree Gold Trophy Award in October 2012 for its

in 2011-12. STIL has its global footprint with presence across Australia, Argentina, Bangladesh, Canada, China, Egypt, England, France, Germany, Greece, Hong Kong, Indonesia, Pakistan, Panama, Philippines, Sri Lanka, Turkey, the US, the UAE and Vietnam. w

THE TEXTILE MAGAZINE FEBRUARY 2014

SPINNING

TRTZSCHLERs 10,000th card


delivered to Arisht Spinning Mills

he Trtzschler Group and A.T.E. together reached a new milestone with the recent delivery of the 10,000th Trtzschler card in India. The card was delivered to Arisht Spinning Mills of the Vardhman Group. It was also a happy coincidence that, with the delivery of the card, the total number of cards in the Vardhman Group has reached 502, probably the highest number of cards purchased by any single company in the world. This group probably has all models of Trtzschler cards like DK 760, DK 803, DK 903, TC 03, TC 5 and TC 11. A special function was held at the Arisht unit in Baddi to commemorate this unique occasion. It was attended by Mr. S.P . Oswal, Chairman and Managing Director of Vardhman, Mr. Heinrich Trtzschler and Mr. J.P . Bhatt from Truetzschler, and Mr. Anuj Bhagwati, Mr. G.V. Aras and Mr. Sunil Bhatnagar from A.T.E.

Mr. S.P. Oswal, Chairman & MD, Vardhman, and Mr. Heinrich Trtzschler, Managing Partner, Trtzschler

In his welcome address at the function, Mr. Oswal said the Vardhman Group is the first organization in India to cross the one millionspindle mark. Over the years Trtzschler has brought new technologies to the Indian shores through its joint venture. Mr. Trtzschler thanked Mr. Oswal for giving his company the first opportunity in 1994 in

the VMT project and for its continued support for the last 20 years. With the launch of the Trtzschler comber in India, the operation between the two groups would strengthen further. Mr. Trtzschler also handed over to Mr. Oswal a specially-made replica of the TC 5 card and a golden card for crossing the 500-number mark by the group.

In his address, Mr. Anuj Bhagwati, A.T.E. Managing Director, said that the succss of Vardhman, Trtzschler and A.T.E. is based on their commitment to customers, and what is of special significance is that Trtzschler is celebrating its 125th year, A.T.E. its 75th year and Vardhman its 50th year. w

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THE TEXTILE MAGAZINE FEBRUARY 2014

CORPORATE

ADITYA BIRLA NUVO


For the quarter ended December 31, 2013, the Fashion & Lifestyle business of Aditya Birla Nuvo rose by 12 per cent to Rs. 1,558 crores and EBITDA by 41 per cent to Rs. 192 crores. It expanded its retail presence to 1,670 exclusive brand outlets/ stores, spanning nationwide across 4.11 million sq. feet. Madura posted allround growth in top line, margins and free cash flows. During the quarter, its revenue grew by 23 per cent to Rs. 855 crores and EBITDA doubled to Rs. 116 crores, led by growth in the wholesale channel, retail stores expansion and four per cent like-to-like retail stores sales growth. Madura added 276 stores and generated free cash flows of about Rs. 250 crores during the nine months ended December 31, 2013. Pantaloons is in the investment phase and is strengthening its retail presence, brand positioning and merchandise to increase the sales 28

Marked increase in
sales
Grasim Industries Viscose Staple Fibre (VSF) business has recorded volume growth, supported by increased capacity at Harihar. Production increased by four per cent over the last years. Sales volume at 97,049 MT was up by 24 per cent, led by better performance in both domestic and exports markets. The company was able to maintain the realisations despite the sharp fall in international prices, supported by the rupee depreciation. The input costs have gone up with the increase in pulp prices, coupled with rupee depreciation. The performance of the pulp JVs was affected on account of planned maintenance shutdowns. The anti-dumping duty levied in China impacted realisations and the volumes of pulp sold in China. The VSF project of 120,000 TPA at Vilayat is expected to go on stream in a phased manner from the fourth quarter. The commissioning of major projects by the company will help improve volume and profitability. w

registers all-round growth Grasims VSF

Mr. Kumar Mangalam Birla, Chairman

volume. It has launched nine new Pantaloons stores and one factory outlet during the nine months. To strengthen its market leadership, Jaya Shree has expanded the annual linen yarn capacity from 2,300 to 3,400 tonnes and the linen fabric capacity from 7.3 to 10.1 million metres. The revenue from the manufacturing businesses at Rs. 1,109 crores and EBITDA at Rs. 118 crores are lower by 19 per cent mainly on account of the discontinuance of trading in imported P&K fertilisers, which has also led to rationalisation of capital employed through reduction in the outstanding subsidy. The Rayon Business recorded its highest-ever quarterly earnings. The new superfine yarn unit, currently operating at full capacity, will help in enhancing the product quality and range. w

THE TEXTILE MAGAZINE FEBRUARY 2014

COVER STORY

Targets $2 billion turnover by 2020


Anjar, a small sleepy town in the hinterlands of Gujarat, is now a buzzling city. Till 2004 it was just barren lands with not much industrial development. It was in 2004 that Welspun decided to set up a large-scale manufacturing unit for its textile and steel business. Today, Anjar can be called the Welspun City. This is the best example of what an industrial project initiated by a responsible corporate can do the economy around it, providing employment opportunities and livelihood to thousands of families.
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THE TEXTILE MAGAZINE FEBRUARY 2014

Welspun, one of the worlds leading home textile manufacturers, has unveiled the companys vision for 2020. Welvision 2020, an iconic event, was recently organised at Anjar which was attended by suppliers and partners from all over the world. Many in the industry felt that this was the first time that an event of this magnitude has been organised in the history of the Indian textile industry. Mr. S.S. Aich, Director, Welspun India Ltd. (WIL), and his team had put together an event comparable to global standards and conducted in a most professional manner.

Welcoming the guests, Mr. Aich said: Innovation has always been Welspuns forte and a major driving force to emerge as a key home textile player in the global arena. This conclave is Welspuns attempt to further develop knowledge and understand the emerging textile technologies and applications that will shape the future of the textile industry. Part of the $3.5 billion Welspun Group, WIL is one of the top three home textile manufacturers in the world and the largest home textile company in Asia. With a distribution network

Mr. B.K. Goenka, Chairman, Welspun Group

THE TEXTILE MAGAZINE FEBRUARY 2014

31

COVER STORY
in 32 countries and manufacturing facilities in India, it is the largest exporter of home textile products from India. Supplier to 14 of top 30 global retailers, the company has marquee clients like Wal-Mart, J C Penny, Macys, to name a few. Last year, the company was rated the No.1 home textile company in the US. This is a remarkable achievement as the US is one of the biggest and most competitive markets. Over the last several years, Welspun has achieved global manufacturing scale with integrated facilities and a diversified product portfolio, making itself a one-stop shop for home textiles. The extensive product mix has enabled the company to reach out to a larger consumer base. The technological superiority, along with its full-fledged Design Studio, has enabled Welspun to deliver world class quality products with a wide range to meet the rising consumer needs. Further, the companys efforts to bring the textile business under a single umbrella have already started yielding results. Its vision to become a fully 32
THE TEXTILE MAGAZINE FEBRUARY 2014

Mr. Rajesh R. Mandawewala, Managing Director, Welspun India Ltd.

COVER STORY
integrated player will further improve performance and enable it to consolidate itas position as one of the top home textile suppliers globally. Mr. Rajesh R. Mandawewala, Managing Director, Welspun Group, delivered one of the best and most inspirational extempore speeches witnessed in recent years. He started saying: Change is the only constant. Everything in this world changes around us and has an impact on one business after the

other. Those who failed to recognise the change are no more present in the competition. In the early 90s, most of the big businesses in the developed economies failed

to see that the world was ready to offshore manufacturing of textiles to the east, particularly to the Asian countries. At that time, we did not find anyone to partner us in

our decision to expand our business. This is the when our chairman, Mr. B.K. Goenka, decided to set up our own plant at Vapi in Gujarat in 1993. Due to the good efforts

A.T.E.s strong and successful partnership


A.T.E. has been having a strong and successful relationship with Welspun for more than two decades. Due to its strong presence across the textile value chain A.T.E. has been fortunate to be invited to participate in almost all the projects of Welspun. It partnered with the group in its first spinning project at Vapi in 1993. A.T.E. supplied Truetzschler spinning preparatory equipment, Zinser spinning machinery and Volkmann twisting machines from Germany, followed by its participation in further expansion of the plant in spinning, weaving and processing. At Welspuns Anjar plant, it supplied spinning machinery from its European principals and processing equipment from Monforts, Osthoff, Stork, etc. It also supplied the warp preparation of Karl Mayer at both the plants. Mr. G.V. Aras, Director, A.T.E. Recently, as Welspun expanded the carpet and rug manufacturing facility at Vapi, A.T.E. provided it with Cobble tufting machines and Zimmer chromo jet digital printing and coating equipment. It also facilitated availability of Truetzschler nonwovens for its nonwovens project at Anjar. While dealing with Welspun all these years, A.T.E. experienced sheer professionalism at all levels. Especially due to the vision and clear business focus of Mr. B.K. Goenka, Chairman, Welspun Group, ably supported by his team, the group could take bigger strides in home textiles and take advantage of the emerging opportunities in the global markets. A.T.E. is hopeful that it will continue to partner with the Welspun Group in all its future endeavours as an able technology partner. Welspun also benefits from the knowledge of A.T.E.s vast pool of technical people having domain knowledge in different verticals of textile processes.
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Archroma helps Welspun focus on sustainability and innovation


Archroma is extremely proud to have been associated with Welspun for the past 15 years. Archroma specializes in colours and performance technologies and is committed to fostering sustainability and innovation in the textile industry. This is why companies such as Welspun turn to it in their own quest for more innovative and eco-friendly textile products. Welspun has introduced impressive high-end towels and bed sheets in a very competitive market. It has earned special reputation as a highly innovative company dedicated to meeting the highest quality standards. Archroma provides process solutions to Welspun which aim Mr. Rainer ROESCH, Business Operation Leader Textile Specialties at improving the environmental profile of its own production process with no compromise on efficiency, for the pre-treatment and finishing of terry towels and home textiles. It also provides high fastness dyes and optical brightener agents. Archroma is a natural partner for the development of carpets and technical textiles. Thanks to its experience in these applications and a full range of products and services, it is in a position to work closely with Welspuns experts from the very beginning of new projects, starting from product development. The company has built an excellent partnership with Welspun over the years with its trustful and open relations resulting in many successful developments. It is to be a supplier to, and partner of Welspun, and is keen on taking up new developments and challenges together.
of my colleagues, who are in the organisation since its inception, we are today the largest producers and sellers of towels in the world. Unveiling the Vision for 2020, Mr. Rajesh said: We are targeting a turnover of $2 billion by 2020. Our first target is to achieve a turnover of $1 billion by 2016 from the current level of around $700 million. We want to be the worlds No.1 manufacturer of home textiles. Most of the $700 36
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million turnover that the company does in textiles comes from home textiles segment. The company is investing Rs. 2,500 crores over the next three years to further increase the capacity across the entire manufacturing value chain from spinning to finishing. All these investments will propel the companys future growth to achieve the vision it has set for itself. Welspun is well set to achieve the 2016 target through the existing expansion and business growth. The challenge will be to double the turnover from $1 billion to $2 billion by

Mr. S.S. Aich, Director, Welspun India Ltd.

Picanol weaving Welspun success story


Picanols association with Welspun started with the supply of its new generation Summum airjet machines last year. Its experience in working with Welspun has been enriching, to say the least. Welspuns sincere, co-operative and methodical approach has resulted in achieving top class performance of Picanols new gen machines which are in use at the Anjar plant producing top quality bed sheeting fabrics. Picanol started its Indian operations in 2008 with the sole purpose of being closer to its customers and providing them with best of service. It has a local team of trained technicians who take care of the erection and commissioning of the new machines and aftersales service. Picanol has a fully-equipped electronic prints repair station in New Delhi where all the prints are repaired locally. The company technicians attend to customer complaints immediately so as to avert losses. Picanol has a full range of weaving machines which can cover the wide range of fabrics which Welspun is venturing into. Its machines are suitable for bed sheeting, terry towel as well as technical applications such as automotive textiles. Picanol believes that it can offer complete solution to Welspun and be one of its key partners in its journey to achieve its Vision 2020.
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Saurers high-end solutions


Saurer has been supplying high-end machinery to Welspun for the past 30 years. Its co-operation with the group started with winders, followed by ring spinning lines and later on with rotor spinning frames. Saurer is proud to be associated with a company like Welspun which has a clear vision and is very well managed by a professional team. The products manufactured by it are of the highest quality and cater also to markets like Japan, the US and the UK. Saurer and Welspun have a very cordial business relationship based on mutual interest. Welspun runs about 20,000 Zinser ring spindles, 4,000 ACO open end spindles and 4,500 winder positions from Saurer Schlafhorst. Saurer service stations in India are located in close proximity to its Mr. Daniel Lippuner, CEO, Saurer customers. Its service engineers respond immediately to customer requests and take regular visits to them for periodic checks and technological support. Saurer has supplied Welspun with its latest model in rotor spinning, ACO 8, which offers high productivity. On the ring spinning side Saurer is the leading provider of solutions, from roving to winding for all yarn applications. Rising wages and quality demand are making automation a must in the production process. The Schlafhorst product range offers automation, from roving frame up to the winder, to bring clear benefits to customers. Welspun is also running the latest version of the Schlafhorst winding machine ACX 5 linked to the ring spinning frames. Both ACO 8 and ACX 5 are state-of-art technology making Welspun excellently positioned for 2020.
2020. The big question is whether the home textile segment alone could help achieve this ambitious target. The company realises the need for expanding its domestic distribution network, entering new product segments and resort to diversification to achieve the vision. Accordingly, in 2013 Welspun invested in manufacturing car40 pets and identified this as an important growth segment with an initial investment of Rs. 250 crores. The next important segment which the company is actively exploring is technical textiles, particularly in nonwovens, like wipes, automotive textiles and a few other products. This is still in the initial stage of development. Based on the products developed and the market potential and acceptance, it will decide on the way forward for this business. Welspun is also focussing on expanding its distribution footprint in India. The domestic business currently contributes three-five per cent of the total business, and this is expected to increase to 20 per cent by 2016. Talking about the global scenario, Mr. Rajesh said the US and Europe account for two-thirds of the world consumption of home textiles and 75 per cent of what they consume comes from China, India and Pakistan. China which had a 16 per cent market share in the US home textile market in 2005 has now raised

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it 32 per cent. India, with 11 per cent share in US imports of home textiles has increased it to 35 per cent in the same period, overtaking China in 2013. Today China, with its escalating cost, expensive labour and growing population and per capita income, consumes most of its produce in-house. The world is finding fewer propensities to export out of China and is looking for other destinations to source its merchandise. Pakistans share of global home textiles business has gone down, and Bangladesh is suffering from its own challenges like political stress, human rights violation and reckless pollution of the environment. Indias market share in global home textile exports has been continuously increasing over the last few years. The market share growth is expected to continue, supported by factors such as surplus cotton in the country, competitive factor costs

Mrs. Dipali Goenka, Executive Director, Welspun India Ltd.

Huntsman echoes Welspuns spirit of innovation


Huntsman Textile Effects has a successful, collaborative relationship with Welspun spanning for over 13 years. The company is a progressive partner that prides itself on product innovation, quality and sustainability. It has always been supportive in adopting new technologies. It is this spirit of innovation, excellence and collaboration that has positioned Welspun at the forefront of the textile industry and a global leader in home textiles. As a global business partner, Huntsman Textile Effects has harnessed its cutting-edge technology, strong technical support and know-how to help Welspun improve its efficiency, drive higher standards in environmental sustainability for its mill and to increase cost optimization. This strong partnership has made a difference to the textile industry and has helped Welspun achieve their business objectives.

Mr. Kent Kvaal, VP- Sales & Technical Resources, Global Textile Effects

Huntsman is the global leader in developing total textile solutions across all aspects of the textile chain. The company is committed to developing sustainable, high-performing processing and effects chemicals that have low environmental impact and enable significant reductions in energy and processing time. With Welspun expanding into carpets and technical textiles, we see more opportunities to offer our cutting edge research and technology to develop value-added solutions and innovative products with intelligent effects that meet their business needs. Huntsman believes that innovative technology is the key to offering better service and in improving economic and environmental sustainability. It will continue to work closely with Welspun to bring in new technologies, total solutions and provide robust technical support that will help the company achieve its 2020 vision.
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DyStar helps Welspun cater to the demanding global requirements


DyStar has been associated with Welspun since 2005. The company feels that the innovation and commitment of Welspun to markets across the world and to its customers is a key factor for the company to become a global leader in home textiles. Welspuns state-of-the-art manufacturing plants, systems and processes have helped it achieve this leading position. DyStar is a leading provider of products and services for the global textile industry. With a heritage of over 100 years in product and application innovation, the company is closely working with Welspun to run its e-control process effectively to maximize output with consistency and reproducibility of shades and working on achieving first-time results in the Pad Dry Pad Steam continuous application process. DyStar also helps Welspun achieve new demands from the markets on the requirements of highest wash and wet rub fastness in bed sheetings and bleach safe requirements in terry towels for the US markets. With DyStars global presence, innovative products and technical knowhow it can be a long-term partner of Welspun in establishing the technical textiles and carpets projects. Welspun has its complete focus on textiles and aims to emerge a global leader.
and the supportive policy regime. and 22 per cent share in the towels imported by America. Today we are the second largest cotton crop producing country in the world and the only nation having surplus after consumption. We stand single in terms of self-sufficiency and export almost 25 per cent of cotton and 30 per cent of cotton yarn produced in the country. China, Pakistan and Turkey import a major portion of their consumption. There is a

This decade belongs to India


Mr. Rajesh further observed: This is the decade for Indian textiles, particularly cotton and, more importantly, home textiles where India has built a global scale with world class technology, skills, understanding customers and innovating new products. I am very optimistic and strongly believe that this decade belongs to us. Today, 45 per cent of the towels and 50 per cent of the bedsheets imported into America are from India. Welspun accounts for 40 per cent of all towels exported out of India 44

A section of the audience at the WELVISION 2020 conference

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clear advantage of raw materials in the country for the next 12-15 years, and Indian companies need to take advantage of this and invest in technology. ted to invest Rs. 2,500 crores in the next three to four years to develop our business. Today, we have a capacity to manufacture 40,000 tons in towels and 45 million metres flat sheeting fabric which we wish to grow to 60,000 tons and 72 million metres respectively in the next three years. We are adding 2,50,000 new spindles, apart from modernising all the existing spindles. We also plan to invest in automation processes

Investing for the future

As a company, Welspun has made large investment in creating capacities across the entire textile manufacturing, from spinning to weaving to dyeing, processing and finishing. We have commit-

LUWAs decade-long relationship with Welspun


Luwas relationship with Welspun began a decade ago in 2004 at a time when Welspun had laid the foundation for its new greenfield plant at Anjar, to become the worlds largest home textile manufacturer. For most of Welspuns air engineering needs, Luwa is its trusted partner for providing the right type of system to attain maximum performance out of its production machines at a competitive cost. Welspun, being one of the most important customers, Luwa has supplied its complete range of products, starting from air-conditioning to humidification systems for the companys spinning plants, TexFog high pressure humidification system for the nonwoven plant, air-conditioning system for the synthetic fibre BCF unit to Loomsphere systems for its terry towel and sheeting plants, air conditioning systems for its motor cooling in the steel plant and ventilation for its thermal power plants. There are many areas where Luwa will be working as an important partner Mr. Gottfried Abrell, CEO, LUWA for Welvision 2020. Plant efficiency audits, energy audit, technical seminars and training for the technical and maintenance team are the areas where Luwa is working closely with the Welspun team. It plans to have various interactive and training sessions with Welspuns engineers at its different sites so as to impart proper training to get maximum operational efficiency from the existing Luwa products. The philosophy of Welspun to provide world-class products and services to its customers and attain market leadership in all its businesses reflects its proper and detailed planning of investments. Decisions are made very thoughtfully considering all the factors, including the technical and commercial aspects, on a long-term basis. The Welspun focus on empowering its employees whom it considers as its biggest asset is also benefiting it to a great extent. Luwa, with its vast global network, will jointly work out the best solutions for any of its future requirements and for its overseas investments. 46
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Van de Wiele Groups long standing partnership


Bonas Indias association with Welspun is for almost two decades, from 1996 onwards. Since then it has been moving with the group in its mission of emerging as a global leader. In 1996, Mr. B.K. Goenka, Chairman, Welspun, personally placed his first order for 12 jacquard heads with Bonas. The company now has 62 jacquard heads at its Vapi unit and eight jumbo jacquard heads at Anjar, installed on air-jet and rapier weaving machines. Welspun is Bonas biggest customer in the terry towel sector, and the name helped it to establish leadership in the jacquard terry towels market. The company has invested in state-of-the-art equipments to manufacture polypropylene yarns widely used in woven and tufted carpets. It has a Cobble carpet tufting machine and Titan over edging machines which are part Mr. Anand Agate, of the Van de Wiele Group, the world leader in carpet and velvet weaving General Manager, Bonas India machines. The company also has plans to set up an extrusion plant to manufacture polypropylene yarn, to become one of the key partners in Welspuns carpet venture. Welspun has a dedicated team of experts committed to get the best out of the new generation electronic jacquards and the professional approach towards the weaving process. Bonas feels that Welspuns mission of serving with passion, growing with speed, innovating with quality, excelling with ethics and sharing good profits with the shareholders could be the factors behind its success as a leading global home textile manufacturer. The company hopes to continue helping Welspun attain its vision for 2020.
to make ourselves more efficient. We have signed a $100 million contract with HP for IT solutions. We have invested over Rs. 200 crores for the welfare of our people for constructing huge dormitories, staff and workers colony, schools, colleges and world class medical facilities in the next three to five years, said Mr. Rajesh. Welspun is currently executing a major expansion of its spinning capacity by adding another 170,000-spindle project in Anjar, mak48
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ing it possibly the single largest facility under one roof in the country. The company is planning to add another 60,000 spindles in Anjar and more spindleage in Vapi. It recently added 140 looms in Anjar and is planning to add another 130 looms in 2014-15. Addition of another 100 looms for towels is also under study. Post this capex, the companys captive supply of yarn and greige fabric is expected to grow to 75 per cent from the current level of 30-35 per cent, thus reduc-

650 Tsudakoma airjet looms in operation at Welspun


Tsudakoma has been partnering with Welspun for nearly 12 years. The company has been supplying airjet looms for both sheeting and terry weaving for its home textiles division. Working with Welspun is a matter of great pride and satisfaction for Tsudakoma. Its experience at Welspun has been very enriching, and inputs from the operations team of Welspun have also helped the company enhance its technology. Tsudakoma has supplied nearly 650 sets of wide-width airjet looms to Welspuns Vapi and Anjar units. The keen interest and deep involvement of the promoters of the company at both macro and micro levels, backed by a strong technical and marketing team, are the key factors behind the Welspun success. Tsudakoma aspires to go hand in hand with Welspun in its journey towards 2020 and beyond. As one of the leading manufacturers of weaving and weaving preparatory machines in the world in the apparels and technical textiles field, it hopes its partnership with Welspun will only grow stronger year on year. Tsudakoma has been represented in India by Inditech International. Apart from the looms, Inditech has supplied Barudan cross hemming machines. In addition, the company has supplied the polyester and nylon spinning plants at Silvassa.

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Beck-Packautomaten makes Indian foray with Welspun


Beck-Packautomatens association with Welspun dates back to 1990s through Christy of the UK, which Welspun acquired in 2006. However, the first business with Welspun was concluded in December 2012 along with its associate for the Indian sub-continent, Teconnect India. Beck-Packautomaten has pioneered many developments in the field of automatic film packaging and shrink wrapping in finding customized solutions for highly demanding applications in home and technical textiles. Beck-Packautomaten has never before ventured into India, and its first experience with Welspun has been delightful and encouraging. Its entire team in Germany and its associates in India have started to focus on exMs. Beate Beck-Deharde, General panding business and make their presence felt across the sectors. The sucManagement, Beck-Packautomaten cess of Welspun, in its view, is attributed to the conduct of its business processes that turns inputs like knowledge and raw materials into products and services that create value for the customers. The companys customer focus, scale of operations, innovation both in product and process, coupled with management of talent, and stakeholders delight constitute the essence of Welspuns success as a global home textiles player. Beck-Packautomaten has so far supplied and installed four machines for Welspun, and the next machine is expected to be installed in the next couple of weeks. The company is delighted to know about Welspun unveiling its Vision 2020 and hopes to have a role as a key partner for secondary packaging of goods, may it be home textiles, technical textiles (wipes or automotive textiles) or floor coverings.
ing its dependence on external suppliers. Apart from ensuring quality and availability of key intermediate products, the backward integration will also contribute to improving the profitability of Welspun significantly. Welspun strongly believes in the India growth story. In the domestic retail space, it operates through its brands Welhome and Spaces for the towels and home textile range. Cur52 rently the domestic market constitutes five per cent of the companys total turnover, growing at 2530 per cent year on year. By 2020, the domestic market would constitute 20 per cent of our total turnover, said Mr. Rajesh. The company did venture into the retail market with its own retail stores across the country but wound up all its stores a couple of years ago due to losses. Now the company is working on the store-in-store concept with major retailers like Shoppers Stop, Pantaloons and many others. Globally, carpets is as good, or in some markets much bigger than home textiles. In the US, for example, the market size for towels is $3-4 billion compared to carpets which is nearly $6 billion. Identifying an opportunity in this segment, Welspun has forayed into manufacturing carpets and has invested Rs. 250 crores in setting up a dedicated manufacturing line for rugs and carpets. It is fully integrated, thanks to the BCF line at Welspun Syntex, which gives it a competitive edge. Welspun has capacity to manufacture 20,000 tonnes between rugs and carpets, producing 25 million units annually.

Carpets

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The company is already utilising 50 per cent capacity. We are already working closely with potential global customers and the response has been very encouraging. We are confident that this will be an important part of our future business, added Mr. Rajesh.

Technical textiles
Further, seeing the tremendous potential in the Advanced Textiles market, the company

EVS online inspection system


Elbit Vision Systems (EVS) has been associated with Welspun for more than half a decade. It certainly appreciates the opportunity to partner with a company like Welspun, one of the leading players who sets the standard for global textile quality. EVS has recently installed its latest IQ-TEX4 colour camera online inspection system with shade variation analyser in Welspuns finished fabric line, which helps in labour reduction, yield enhancement, space saving and better quality. Its automatic inspection systems are far more accurate, consistent and reliable than the best human inspectors. Using full colour high resolution cameras, LED illumination units and multiple viewing angles, the IQ-TEX4 system can see defects down to fractions of millimetres at speeds well over 80 metres per minute. These cameras do not blink, never Mr. Sam Cohen, CEO, EVS turn away or fall sick. By knowing the location, size, type and severity of each defect contained in a finished lot prior to cutting, an optimized cut map can be created with a simple click of a button. This optimized map will automatically control the high speed de-batching table and instruct each operator on what defects to flag or remove, and where to make roll cuts. Utilizing these proven methods yield enhancements could increase up to three per cent by doing nothing more than making smarter and better informed decisions. The shade variation analyser provides online shade variation using the CIE L*A*B* standard for measurement with built-in 5-5-5 colour matching program. The companys online inspection system is already an integral part of Welspuns quality monitoring department in Advanced Textiles. EVS has spent the past 20 years developing the best vision inspection and process monitoring solutions for the textile market, and today it is very proud to have its solutions confirmed by the leading global supplier of these goods. EVS looks forward to being a key supplier to Welspun in its vision for 2020 and beyond!

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Inspirons heat recovery solutions


Inspiron supplied the Motex, Model B340, 10F Combi Chain Type, in September 2004 to Welspun. This machine is now being overhauled with modern features and automation, reflecting the companys professional approach with regard to upkeep of plant & machinery. The machine has been playing a significant role in the growth of Welspun. Welspun also intends to contribute significantly to environment protection through energy saving. Inspiron is supplying 10 KAPrec heat recovery units to save the energy let out to the environment and recirculate and reheat the MOTEX stenter at the Anjar facility. This is expected to result in 10-12 per cent energy saving in the drying process, 15 to 18 per cent in the drying and heat setting process and 22-25 per cent in the heat setting process. This will drastically reduce the load on fuel consumption, thereby contributing to reduction in carbon footprint.
forayed into this segment starting with the nonwoven category. It has put up a new plant which has started production in October 2012. In a short span of time it got itself certified to J&J, Covadian, Rocklin and Reckitt Benckiser. Some of the specialised products that WIL is currently manufacturing in Advanced Textiles are top end baby care wipes, hygiene wipes, filtration

Mr. Prakash Bhagwati, Chairman, InspirOn Engineering

cloth and automotive nonwovens. The company is well placed with high-end global scale capacity, skilled workforce, product knowledge & expertise and co-ordinated marketing

approach to capitalise on the technical textile growth. It is thus well placed to strengthen its position as a global player. Mr. Rajesh further disclosed: We are quite new to this segment. Right now we are wetting our feet to understand what the nonwoven and industrial textiles business is all about. This will take another year to mature; we will then take a final decision. Currently we are doing more of commodity products. As we mature and grow, we will define the areas which we will focus on. Automotive and industrial filtration systems could be segments to look at. Welspun has so far invested Rs. 150 crores on the technical textiles

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Mr. Arvind K. Singhal, Chairman & MD, Technopak

Mr. Prashant Agarwal, Jt. Managing Director, Wazir Management Consultants

project and plans another Rs. 75-crore investment in needle punch lines during 2014-15. Asked about inorganic growth opportunities, he said that Welspun is not averse to such opportunities. The company did acquire a couple of businesses globally, out of which the most successful has been the UK towel

brand Christy, which has given the company a dominant share in many global markets, including the US, the UK, Europe and Asia. The company has also been exploring the possibility of setting up manufacturing facilities outside India, which might have favourable trade agreements with the US or the EU. But,

for now, it feels there is enough opportunity in what it is doing right now. Referring to the potential threats for business, Mr. Rajesh said: The biggest threat to any business out of India is trade blocks. When our competing countries get preferential access to markets like the US and

the Europe, that puts us in a disadvantage. For example, Pakistan has duty-free access to the EU and the US for a period of 2 to 3 years. if this becomes permanent, then over a period of time it will become difficult for Indian manufacturers to compete if we dont sign similar contracts. Another major

Novozymes partners Welspun in offering environment friendly technologies


Novozymes has been associated with Welspun from 2011. Welspun has always encouraged and adopted all new technologies which can help them upgrade their quality as well as ensuring that their CSR are upheld. This openness and vision, along with its continued focus on constantly updating the skill and knowledge of its employees has been instrumental in Welspun achieving success globally and creating a new benchmark for Indian textile companies. Being a pioneer and world leader in enzyme technology, Novozymes has the complete range of enzymatic solutions for processing textiles. It is working closely with Welspuns R&D team to offer the company new Ms. Merete Frgemand, Technical solutions that can help in improving product quality and provide value- Service Director - Asia Pacic added offerings to the end customers through in-house innovations. Novozymes anticipates huge demand for environmental friendly products with special emphasis on savings in basic utilities like water, power and increased productivity. With such requirements becoming a necessity, Novozymes could foresee big scope for enzymatic solutions being adapted to the home textiles segment in the near future.
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challenge will be manpower. We understand that the world is changing, the aspirations of the people are changing. As principal employers, if we dont understand this and dont take corrective action, it is impossible to run a factory with a workforce of 20,000 people. It is not the factories we set up but it is what we do with the people who are working with us which will differentiate us from the rest. We are doing a lot to improve the overall quality of living of all our employees. If we dont take care of our employees we will be out of business. In fact, the Welvision 2020 event conducted at Anjar was part of the

company efforts to give global exposure for its employees, providing an opportunity for them to hear and interact with their global suppliers and partners. Welspun is planning many such events in the future, for which it has built stateof-the-art infrastructure comprising a convention center of global standard and conference halls. All these are housed under a grand memorial built in memory of the companys founder, the late G.R. Goenka, fondly known as Babuji. Mr. Rajesh concluded on a highly optimistic note by saying that, with an incredibly favourable policy environment, skilled manpower, a burgeoning middle class and rising disposable income which will make it the second largest market in the world probably in the next 20 years, Welspun is all set to achieve its vision for 2020 and beyond.

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WEAVING

Growing Indian appreciation for

STUBLIs
new technologies
Staubli has always led the weaving industry in terms of technological innovations. Be it the dobbies, jacquards or warp prepartory machines, Staubli has continuously worked on further improving the productivity and performance of its machines. All these efforts have resulted in further increasing its engagement with its customer and increasing its marketshare. In a recent interview, Mr. Fritz LEGLER, Vice President - Product Management and Marketing, spoke about the companys performance in 2013 and its expectations for the future.
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Mr. Fritz Legler, Vice President Marketing, Sales & Service, Staubli Sargans AG,

How was the year 2013 for Stubli? What were the key highlights during the year? The official figures for 2013 is not out yet but our own analysis and market intelligence suggest that the investment activity in key markets was much better than anticipated and far bet-

ter than in 2012. Our standard shed forming technologies dobbies and cam motions were profiting from this trend. Furthermore, Stubli increased its market share for Jacquard machines in key markets. Warp preparation technology with automatic drawingin or beam knotting ma-

chines was in demand, and Stublis benefits over alternative solutions were clearly seen. Our other brands, e.g., Schnherr for solutions in carpet weaving or Deimo for electronic controllers, were also gaining strength in their respective markets. Highlights in 2013

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were certainly the market introductions of our latest dobby generation S3000/S3200 Series or our new cam motions 1671/1681/1781 Series. Our new Jacquard machines SX are gaining market share as are our drawing-in machines of the DELTA & SAFIR lines or our famous TOPMATIC beam knotting machines. Moreover, our new carpet weaving machine, Schnherr ALPHA 500, is attracting a lot of interest. Our existing as well as prospective customers appreciate the innovative drive of our company. Which were the global markets which did well during 2013, and how did Stubli perform in these markets? Besides India there

were the usual claimants and leading markets which contributed to an improved market environment. Countries like China, Turkey, Pakistan or Bangladesh held their own but also, for instance, Italy did rather well in certain market areas. Stubli was in a position to profit from this situation. How was the Indian weaving market in general in 2013, and how was Stublis performance during this period? There was quite a bit of enthusiasm right after India-ITME held in December 2012 which gave the weaving industry some impetus. However, some of the planned and official support vehicles like, for instance, the

TUFS, took longer to materialize. This delayed project financing propositions. Letter of credits were not readily available for some time. Moreover, later into the year announcements by the American FED to reduce or taper industry support provided through what they call quantitative easing (i.e., bond buying activity), FDI or investment moneys left India, which brought down the strength of the local currency. This in itself helped the Indian industry to boost garment, yarn or fabric exports. This increased utilization of plant in a positive way. Stubli managed to gain market share within its textile activities such as Jacquard machines or

warp preparation activities (drawing-in or beam knotting machines). Can you highlight some of the key innovations in products and technologies at Stubli in recent years? It is our guiding principle that we provide fast moving technology to our customers. This can only be achieved through high investment into R&D activities to bring about innovative solutions which firmly address our customers needs. Recent innovations are now being introduced into India also. Some examples would be our latest generation of dobbies (S3000 and S3200 Series) and cam motions (1600 and 1700 Series). Stublisdobbies of the 3rd generation enable weaving machine running speeds in excess of 1000 rpm with, for instance, the S3260 version. Another example would be the SX-Jacquard machine which is favored by Indian weavers over alternative solutions. Our SX Jacquard machine is predominantly used in India in all common application fields such as upholstery, terry and so forth. In the area of warp preparation, a typi61

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WEAVING

cal example would be our latest generation of drawing-in machines of the SAFIR line which provides much higher productivity compared to manual drawing in. Finally, our brand Schnherr offers the latest generation of carpet weaving machines of the ALPHA 500 Series. Far-reaching application know-how with its Multi Weft Selector (MWS) system, high density carpet weaving as well as its 5 meter machine, help increase the flexibility and investment security for our customers. What are your expectations from 2014? Do you see any interesting global trends evolving which can drive business in the weaving segment? This is about crystal ball gazing istnt it? There might be general trends like the reindustrialization move in the US or increasing cost structures in certain countries which help shift some of the value-adding in our global textile industry. Having said this, we cannot see drastic changes when it comes to our more specific weaving 62

industry. Some of the hype seen in 2013 was probably to the detriment of the current year. There will almost certainly be a more reasonable or standard level of investment in 2014. Lets keep our fingers crossed that there will not be, for instance, a global currency crisis as seen in the past. With the Governments push to modernize the Indian weaving segment, do you see good growth opportunity in this market? There will be growth opportunities going forward. Stubli welcomes any initiative supporting this idea and direction. However, sometimes the

mills of India grind slowly there is always a danger that there will be too much red tape involved! Time will tell if the next government will implement necessary structural changes. Can you provide some update on the Indian operations, your sales office in India? Due to the importance of the market, Stubli has been active with its own Indian set-up since 1993. In 2012 we had moved to our new building the Stubli House in Mumbai where we house our three divisions Textile, Connector and Robotics. We keep steadily growing our local teams based on market demands. As an example, we are currently

training two new Sales Engineers and four new Service Technicians in our textile division. Our local General Manager, Mr. S. Mahajan, keeps feeling the pulse of the local industry and plans resources accordingly. Local staff will also be properly trained at our European production units to fully immerse in our innovations and fast moving technology. In summary, we have full-fledged operation in India with a current strength of 27 members in our Textile Division, three in Sales and 20 in Service support backed with a showroom/demonstration center along with machines to offer training to our customers here at Mumbai. w

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PROCESSING

InspirOn meet on stenter role, a big success


Prakash Bhagwatiled Ahmedabadbased InspirOn Engineering Private Ltd. recently organized an innovative clients meet at Tirupur. The unique feature of the event was an interactive session wherein textile processing in the context of modern stenters like Motex was deliberated in detail.
Motex, a market and technology leader, has been providing precise controls for various operations carried out in textile processing where stenter has its major role. The top Marketing Executive of InspirOn explained Motexs special features and functioning to the participants. InspirOn Engineering, which with its sustained market leadership, is striving to develop Motex as a versatile technology can look beyond its present functions. It has roped in Diagonal Consulting (India) having a team of experts with formidable and wellproven industry, research and academic background and experience. A very senior expert from Diagonal shared his valuable experience in value addition through functional finishes and pragmatic approach to make stenter operation friendly and productive. The huge success of the event has encouraged InspirOn to continue with such interactions in other regions of the country. w

Mr. Prakash Bhagwati, Chairman, InspirOn Engineering

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SPINNING

SAVIO

fares well in 2013


India remains the second largest market

S
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avio is a global leader in the yarn finishing machine sector, operating worldwide in the manufacturing and marketing of automatic winders, continuous shrinkage and bulking winders, two-for-one twisters, and rotor spinning frames with factories in Italy, China and India. Savio is a technology-driven company and is continuously working on further improving the quality and operational efficiency of its machines. The year 2013 has been quite good for the company globally and in India. We spoke to the management team consisting of Mr. Paolo Puntoni, Marketing Director, Mr. Mauro Moro, Commercial Director, and Mr. Valter De Carli, Regional Sales Vice-President, on the companys performance in 2013 and plans for the current year.

How was the year 2013 for Savio? The 2013 market has been quite comparable to the previous year, in terms of delivered volumes. We expect that ring spinning frames deliveries could reach the same level of 2012 (around 12 millions). On this assumption we can estimate that the total number of installed spin-

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dles, by the end of 2013, should be in a range of 255-260 millions. Its important to mention the ring spinning delivered volumes, since this data represent also an important parameter to determine the automatic winder ones. How many machines did Savio sell in 2013 and which are the major markets for Savio worldwide? China, India, Indonesia, Pakistan and Bangladesh together with Turkey are confirmed as the main textile markets for Savio, as happened in the last 10 years. The end result of all above is given by the high number of about 2,000 winders delivered in 2013, in addition to

more than 100 twisting machines. In terms of products and technology, what were the key highlights for Savio worldwide? Savio worldwide has been offering since many years a product portfolio gathering friendly user machines, in order to process the widest range

of yarn counts and materials. Savio automatic machines are also designed to face the lower availability of textile laborers and higher personnel cost of our customers. The investments in higher automation have been significantly increased, in Far East too. The fully automatic ma-

chines, as in our winding segment, naturally imply additional sophisticated devices if compared with the manual ones, and such requirement has to cope with the low availability of personnel and skilled technicians. This is the achievement that Savio has made since some years, add-

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SPINNING
ing innovative functions on the Polar IDLS/ Link winder, which also have been reconfirmed with its last product Polar E Premium, recently launched in the market. Furthermore, the Savio Group is today the only player in the market which can offer the whole technology for the winding process, because of the knowhow of the yarn and splicer quality (through its sister companies LOEPFE and MESDAN), in addition to the well-known skills in the package formation. How did Savio perform in the Indian market during 2013? What were the key highlights during the year? In 2013 India imported almost 250 Saviowinders, and forecasts for 2014 indicate a moderate increase in volumes. Its confirmed to be the second largest market for Savio. It is a complex, demanding and challenging field which for sure is the worlds first when it comes to technical competence.Savios fully-owned factory at Pollachi near Coimbatore at present serves as a worldwide manufacturing hub for both families of two-for-one twisters: the Cosmos model and the high-end Sirius model. With annual production touching about 15,000 TFO spindles, SavioIndia Ltd. is planning to optimize manufacturing to cope with the growing demand from domestic as well as overseas markets. Looking into the future, how does Savio perceive the business scenario globally? From the technology and products development, we believe that the main focus will be on the green environment, which for our segment is represented by energy consumption, noise level and safety. With ITMA 2015 Milan in view, Savio winders will always be more equipped with sustainable technologies, able to produce power and compressed air savings, to reach minimum wear of the parts and minimum yarn waste. High-end fully automatic and user-friendly machines are another must, considering that today automation has become a global trend. Savio has responded to the increasing requirements of automation by implementing and presenting fully automatic machines both in the winding and twisting sectors. However, the main focus for automation is represented by the linked and the free standing winders, which will be the core segment for further development. w

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CORPORATE
Jain, DyStars Global Sustainability Manager, elaborated: First we reduce our own impact by being responsible in the use of resources. Secondly, while delivering the best quality products to our customers, we also assisted them in decreasing their own environmental and social footprint through the use of clean, safe and efficient products and Best Available Technology. The publication of the 2012 Report underlines the fact that Sustainability Reporting will continue to play a significant role in the DyStar strategy as it helps us to engage with all our stakeholders and to maintain our leadership in this area of work. With over a century of heritage, DyStar is a leader in both product and application innovation for the textile and leather industries. From being specialised in coloration, the business has since evolved into a sustainable solution provider, offering the industry an extensive range of colorants, auxiliaries and services. With its presence in over 50 countries, the

DyStars
holistic approach towards sustainability
DyStar has just announced the release of its third annual sustainability report which provides a valuable insight into the companys progress and initiatives towards sustainability during 2012 following the guidelines of Global Reporting Initiative (GRI).
Some key points include the companys reduction of its GHG emissions by approximately 13 per cent which is a great step towards its internal target of a 20 per cent reduction by 2020. The success of DyStars initiatives has further affirmed the companys dedication to providing the most sustainable solutions and products to meet customers needs, while protecting the environment. Based on a twintrack approach towards sustainability, Dr. Charu

Our holistic approach towards sustainability and relentless efforts to achieve our goals resulted in significant improvements through the year 2012

Harry Dobrowolski, CEO, DyStar


DyStar Group ensures efficient expertise is delivered to global and local customers in brands & retailers, mills and dye-houses. Subsidiaries include DyStar Textile Services which houses Color Solutions International (CSI), Texanlab and Sustainable Textile Services. For details, visit www. DyStar.com

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SPINNING

MOHLER
Mohler Machine Works Pvt. Ltd. (MMW), Coimbatore, formerly known as AB Industries, is one of the leading manufacturers of overhead travelling cleaners (OHTCs) in India. The Mohler brand, launched in 2008, and is very popular in the Turkish and Bangladesh markets, is now being increasingly used in Indian textile mills as well.
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bags huge export orders for OHTCs


Renamed as Mohler Machine Works Pvt. Ltd. on April 1, 2013, with the change in the constitution of business, MMW is now manufacturing all the three OTCs power duct, chain link and belt drive for all the makes and models of ring spinning machines, speed frames, winders, auto coners, open-end and link coners, as also for warping and weaving machines (looms). The experience and knowledge gained by the company founders, Mr. V. Balasubramanian, Textile Technologist, and Mr. V. Benny Jerald, Mechanical Engineer, over a period of more than 20 years in the textile industry have been incorporated in the development of the Mohler OTC, now considered the best in its class. Interacting with The Textile Magazine recently, Mr. Benny Jerald, now the Managing Director of MMW, said that the success of business is mainly due to the focus and commitment of the management to provide quality products and roundthe-clock services offered to each and every customer. He said that the Mohler OTC is on par with any European make since it is produced from quality inputs like Tata steel, Lapp cable, FAG bearings, Siemens / Mitsubishi PLC control systems, etc., which speak for the quality and processed by using the laser cutting machine, CNC turret punch, NC bending machine, nine tank powder coating process, and MIG welding. According to him, MMW has been in the domestic market since long, and some of the leading names in spinning and weaving industries like Arvind Ltd., Shri Govindaraja Textiles Pvt. Ltd., S.Kumars Ltd., Nandan Exim, KPR Mills, Bhaskar

Mr. V.Benny Jerald, Director, Mohler Machines Works Pvt Ltd.

Industries Pvt. Ltd., Pallava Textiles and Madura Coats are the regular users of the Mohler brand OTCs. The company has been growing at an

annual rate of 25 per cent, thanks to the product quality and unmatched services extended to the customers. More than 75 per cent of the total turnover is for export. With the present infrastructural facilities, MMW has been able to manufacture more than 150 sets of OTCs every month at its sprawling production facility admeasuring 10,000 sq.ft. located in Coimbatore. Mr. Benny Jerald further observed that

Mohler has also been customercentric by delivering quality products and offering prompt and timely after-sales service, thus emerging the largest exporter of OTCs in India. The company is now exploring new overseas markets where it would hopefully fare better considering its success in the domestic market. The company also proposes to introduce new products, for which it is in discussion with some of the globally

Mr. Balasubramanian, Director, Mohler Machines Works Pvt Ltd.

reputed manufacturers. The launch of the new products is scheduled for June next, he added. w

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JOINT VENTURE

LEEDs

total environment management solutions

Mr. J.M.Balaji, Head-Marketing, Lakshmi Ring Travellers

In a populous country like India, effluent and waste water from industries and households is a perennial problem which has always attracted concern of the environmentalists. There are not many agencies or individuals to find permanent solutions to issues related to waste water management and solid waste 70

disposal without affecting the water bodies and thereby the environment. There is an increasing awareness about the need to adopt scientific methods for safe disposal of waste. Lakshmi Energy and Environment Designs Ltd. (LEED) is a part of the Lakshmi Ring Travellers (LRT) group of Lak-

shmi Machine Works Ltd. (LMW), Coimbatore. LRT, global leaders in ring travellers, was incorporated in 1974 and its operations were organized into independent business clusters comprising of ring traveller division, engineering, foundry, CNC profile cutting division, water treatment and waste to

energy division. In order to focus on the emerging concept of energy and environment management solutions, LRT floated its new company recently called LEED. As the name suggests, LEED was formed to serve industries in total water management and solid waste management areas.

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The company provides state-of-the-art treatment plants from its overseas technical collaborations, a few technical institute from Turkey and technical tie-ups with leading professional consultants from across the globe. The companys product range consists of providing complete solutions in the field of water and waste water treatment, solid waste management and waste to energy.

Organic waste converter

Waste water treatment

LEED has different divisions for waste water treatment which include sewage treatment plants (STPs), effluent treatment plants (ETPs), reverse osmosis plants (ROPs), zero liquid discharge

plant (ZLDs), salt recovery solutions, mechanical evaporator, bio remediation, and chemicals and operation and maintenance. The company helps in setting up Zero Discharge Biological Effluent treatment plants for all verticals, right from textile industries to real estate. It provides design,

construction and operation and maintenance contracts for installing zero discharge effluent treatment plant in these areas. With advanced technology and superior quality raw materials, these plants efficiently remove pollution effluents and keep the environment safe. The company manu-

factures and supplies wide range of skid mount sewage treatment plants (STP) which uses advanced technology to filter contaminated water, so that industries can set up the plant to ensure good flow of fresh and pure water. The plants setting up cost ranges may range from ten lakhs to a few crores depending upon the needs of the customer. LEED offers any equipments required in water treatment like agitators, auto bar screens, clarifiers, dosing systems, evaporators, filters, floculators, RO, softeners, UF, aeration systems, anarobic coagulation systems, cooling towers, all types of pumps and membrane digestion systems.

Waste to energy

Since there is an enormous increase in the quantity of waste materials due to human
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JOINT VENTURE
activities, the company has taken several initiatives to minimise, reuse and recycle such wastes using technologically advanced solutions thereby reducing greenhouse gas emissions. The companys waste to energy division provides solutions for converting any solid waste into useful energy. We have products for the entire environment solutions. In the case of bio gas plants, we have solutions for capacities starting from 100 kg of waste per day. When the waste is less than 100 kgs we provide solutions for composting. We have an organic waste convertor (OWC) which can convert food waste into manure within 21 days. The OWCs have capacities ranging from 10-100

STP Skid Mount

Clean, green energy from agricultural waste


LEED manufactures fuel pallet manufacturing machines which can convert all kinds of garden and agricultural waste into fuel pallets. These fuel pallets are environmentally sustain-

kgs, says Mr. J.M. Balaji, in an exclusive interview to The Textile Magazine.

able, economically viable and technically feasible and provide productive solutions to garden waste management. These pallets can be used as a cooking fuel in biomass cooking stoves. They have a very high calorific value and can substitute any other material at almost half the cost. The machine can produce almost one

Reverse Osmosis Plant

tonne of pallets a day. These machines can be installed anywhere and can generate good revenue by selling these pallets at Rs. 6-7/kg. By using these products the customer can reap the benefits within a short period of two-three years, says Mr. Balaji. Energy and environment designs being a new concept, the company is confident of a huge market demand for its products. Talking about the companys target for the year, Mr. Balaji adds: Our concept is a new one. With low maintenance and a fool proof mechanism, we are confident that there is a good market for our products. Going forward we have decided to focus not only in India but outside the country also. w

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SPINNING

PROSINO

targets sale of 500,000 rings in India by 2015

Dr. Pietro Prosino, Director & Sales Manager, Prosino, and Mr. Diven G. Dembla, Managing Director, Precision Rubber Industries Pvt. Ltd. (second and third from left respectively)

P
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rosino S.r.l. was established in 1946 at Grignasco near Milan, Italy, to manufacture spinning and twisting rings for textile industries. The company manufactures products on a single fully integrated site with turning facilities, heat treatment and surface polishing process which guarantee a value-added finished product with competitive pricing. The product is known worldwide as BORGOSESIA RINGS.
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Early in the 1960s, Prosino started expanding its exports to the European and US markets and later on to India. In 1995, it diversified and commenced manufacture of turned and heat treated rings for high precision ball

and roller bearings. The companys manufacturing extended to hydraulic motors, aerospace, industrial valves, bicycles and many other specialised mechanical engineered industries. The company has a strong foundation with the proud third generation Prosino family management, successfully updating new programs by adapting the original textile sector with a new range of products to meet the continuously evolving business. In recognition to our world class quality, our company was able to establish a strong commercial link with the Swiss major, RIETER AG and later with other associated companies in the group. Prosino employs 92 workers and has produced nine million pieces of rings the current year increasing its quantity year on year since its inception. Our companys rings form 95% of the production while accessories related to rings forms the rest. We export nearly 85% of our total ring production to countries all over the world, said Dr. Pietro Prosino, Director and Sales Manager, Prosino Borgosesia Rings, at

the recently-held Texfair exhibition. Since India has a great market potential and is an optimistic one, Prosino S.r.l. has recently entered into a new marketing agreement

with Precision Rubber Industries Pvt. Ltd., the manufacturer of Precitex brand products, in India, for its rings. Indian market has a demand for standardised ring sizes which is an added ad-

vantage to our company. We have sent our sales and technical team to the JV company to train and educate the people. Previously we have been selling 3,00,0004,00,000 in India. Now after a break, we are trying to establish our product back, added Dr. Prosino. Precitex manufactures world class aprons and cots in India which are designed and developed to suit various machine applications and also exports these products to major destinations across the globe. Precitex shall play an important role in the partnership and plans to export the rings to neighbouring countries like Nepal. Texfair is a good launching platform for our products. The response for our products in the fair was encouraging and we see some good potential for our rings. With world class quality and good pre and post sales service we expect to reach half a million rings in India in the next two years, said Mr. Diven Dembla, Managing Director, Precitex.

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COVER STORY

POLYTEX
olytex Chemical Engineering Ltd., a Chinese company, provides complete plant solutions for chemical polymer fibre equipment, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyamide 6 (PA 6), PA 66, PLA and PBS lines, solid state poly condensation line, spinning and PSF production line, dye chemical devices, etc. Polytex has successfully set up many projects and provided technical services to chemical and man-made fibre manufacturers in China and other parts of the world, including India, which is one of the worlds most promising chemical and manmade fibre markets. The company has the ability to build PET continuous polymerization plants with an annual capacity of 100 76

complete turnkey solutions for polymerization & fiber line


Executes 3 major projects in India

to 800 TPD or 36,000 to 290,000 metric tons. The process includes saving energy and water through recycling, reduction of gas emission and high quality melt process. The Chinese manufacturer has made great progress in modification of the PET technology and in carrying out PETG polyester plant and water soluble continuous polyester projects. In the field of PBT, Polytex has successfully implemented 100,000 tons per year and more than 20 lines of middle-sized recycled polyester direct spinning.

CP lines. Recovery heat is used to improve temperature in the paste preparation system. Primary and secondary HTM systems can be switched and used together in esterification reaction. Heat recovery of vapour in process tower is used for the chiller system.

Special circulating water system and air cooler are used in the project which reduce power and water consumption during production. Polytex is the only one engineering company in the world which can help manufacturers modify a batch polymeriza-

tion plant into a

Technical know-how

The purified terephthalic acid (PTA) chain transportation system designed by Polytex has run successfully in many

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continuous polymerization unit without discarding any equipment. The company has successfully modified three more lines, the capacity of which has increased from 30 TPD batch-poly plant to 150 TPD CP line. On the other hand, Polytex can help manufacturers build a three reactor continuous polymerization production facility from making PBT from PTA (pure terephthalic acid) and BDO (butanediol). The production line can have a capacity of 30 to 450 metric tons per day. Currently, Polytex is contracting to build 400 tons per day PBT line. The advantages of Polytexs PBT polymerization solutions include energy saving and high quality production.

Recycled polyester process


Polytex also provides solutions relating to sustainability and recycling. It has independent technologies and patents for recycling polyester and can build a recycling polyester production facility with a daily capacity of 20 to 200 metric tons. The company has a patent for recycling polyester for melt direct spinning pre-oriented yarn (POY), fully drawn yarn (FDY) or polyester staple fibre (PSF) and drawing films. The materials which are used for recycling include PET bottle, waste polyester filaments and staple fibres. It can also modify an existent chips spinning plant into a recycling polyester continuous po-

Indian customers
India is a very important market for Polytex, contributing to 30 per cent of its total turnover. The company has successfully implemented continuous PET engineering projects for three major customers in India since 2009. At Jindal Industries, it executed a 60,000 ton per year film grade continuous polyester plant, which is the first of its kind. For Nakoda Industries, it implemented a 1,30,000 ton per year yarn grade continuous polyester plant, first for POY and FDY manufacturing in the same plant in the Indian market. As for Raj Rayon, a 1,50,000 tons per year yarn grade CP plant was implemented, the first of its kind, from contract execution to successful start-up within 11 months. Since India is a potential market with a large population, there is enough scope for the polyester industry to

lymerization plant.

develop rapidly. Polytex promises to deliver its best performance and offer quick service to the industry in India.

R&D Centre

The Chinese company has also developed more solutions for the production of advanced materials in co-operation with over 20 polymer research centres all over the world. It has also invested and constructed an engineering R&D base (70,000 m3 plant specializing in research and development of new type polymerization line and fibre line) in China to meet the special requirements of its customers. The company has a huge demand for its high performance solutions in the Chinese market which contributes to 60 per cent of its business. The companys major international customers include Henan Kaixiang Chemical Company (120,000 tons per year), the Jiangsu Jianghe Group and the Henan Jinda Group. w 77

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TESTING

ensure optimum spinning efficiency

USTER device for cotton testing to

otton is the worlds favorite fiber, and a superb raw material for many textile end-uses. But it is by no means easy to work with. As a natural product, its many variabilities present several challenges related to the kind of cotton to choose and the way it is being processed into good quality yarn profitably. Testing is the answer here. Accurate testing of fibers using the USTER AFIS PRO 2 would ensure that spinners make the most of their valuable raw material by precisely optimizing their processing machinery.

Spinners everywhere are all too familiar with the challenges of processing raw cotton into best-selling yarns their customers will appreciate. Cotton presents several problems if a yarn is to be made at to the specified quality with a reasonable profit for the mill. A particular headache for spinners is the level of neps, too many of which cause troublesome defects and can leave conspicuous

white specks in the yarn. Tackling the problem before spinning calls for reliable quality data, covering key parameters for neps. And this is where the USTER AFIS PRO 2 comes into its own, providing accurate information on the total nep count and size, fiber nep count and size, seedcoat nep count and size, and the maturity. Armed with this knowledge, spin-

ners can optimize their spinning preparation processes to achieve the consistent quality levels their customers demand.

Fiber maturity, a vital test parameter

Selecting the right raw material and the best way to process it are crucial for spinners, and the results from suitable fiber testing routines are

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essential aids. Good decisions here determine the quality level of the finished yarn, which in turn is a major element in the spinners sustained profitability. The role of the USTER AFIS PRO 2 fiber testing instrument from Uster

Technologies in process optimization is wideranging, but it can be neatly exemplified by focusing on one specific area of concern to spinners: fiber maturity. The challenge here is to identify and deal with immature fiber content. Immature fibers are a real menace in spinning, causing breakages, unacceptable nep counts, excessive short fibers, and even high levels of waste. At spinning, these problems inevitably lead to the unwanted combination of high yarn defect levels and low raw material yield. Downstream in subsequent process stages, neps caused by immature fibers will appear as white

specks in the dyed fabric, rendering the material off-quality and adversely affecting profits. Spinners can protect themselves from these risks, thanks to the USTER AFIS PRO 2. The systems data from a sequence of material tests from blowroom to finisher drawframe allows constant monitoring and accurate information on nep levels (especially fiber neps), fiber maturity, immature fiber levels and short fiber content. It is then possible to adjust the fiber mix and machine settings to take account of these raw material parameters, cutting down the risk of poor quality yarn impacting on company profitability. Proper measurement of the most important fiber parameters is the key to optimized control of machinery settings, production rates and waste levels. Accuracy is essential, of course, and the performance of the USTER AFIS PRO 2 here is paramount in equipping mill managements with the information they need to get these choices right consistently, achieving both quality and profitability goals. This accuracy has recently been proven in

a series of independent trials by ICA Bremen, one of the worlds leading cotton authorities. Says David McAlister, Product Manager, Fiber Testing at Uster Technologies: Less variation and greater accuracy over the most critical fiber properties have proven the superiority of AFIS. Mills certainly need this accuracy to help ensure their machine settings are correct, to target the most appropriate production

rates and to minimize damage to their valuable fiber raw material. As well as improvements in product quality, spinners will also benefit from reduced waste a vital economic aspect for any mill and avoid the risk of off-quality product or returns from customers. w 79

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ENERGY EFFICIENCY

Sustained textile industry drive to enhance

ENERGY EFFICIENCY

rom the clothes we wear to the curtains in our homes, thousands of everyday items we rely on are produced

SRF Industries
SRF Industries, as a group, has grown into a global entity with operations in four countries. Apart from its leadership in technical textiles business, the company is a market leader in refrigerants, engineering plastics and industrial yarns as well. It also enjoys a significant presence among key domestic manufacturers of polyester films and fluoro specialities. Building on its in-house R&D facilities for its technical textiles business, it strives to stay ahead in business through in-

by the textile industry. However, dyeing and finishing of one ton of fabric with lots of harmful chemicals can result in polluting up to 200 tons of water. It also involves consumption of a tremendous amount of energy for steam and hot water. With the industry mostly concentrated in countries still developing environmental regulatory systems, such as China, India, Bangladesh and Vietnam, textile manufacturing causes environmental degradation. To address the rapidly deteriorating environment at the global level caused by the textile industry, voluntary organisations, along with a group of apparel retailers and brand partners, have come up with a few initiatives to curb pollution in the sector while saving the industry money. This initiative does not call for large-scale retooling of the textile industry but easy-to-implement and low-cost opportunities that pay for themselves in less than a year.

novative operation and product development. SRF is of course conscious of the challenges of operating in a highly competitive environment. Since the technical textile segment contributes to over 50 per cent of its turnover, the company has implemented a few energy saving practices in this segment to further reduce its operating cost. At its Kashipur technical textile facility, the company saved 37,440 kwh of power in 201213 by switching off one of the two dust collectors and by shifting it nearer to the dust generating

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area. It saved 1,37,808 kwh per annum by installing the variable frequency drive (VFD) in the 55 KW thermal fluid heater (TFH) circulating pump. It also was able to retain 31.2 tonnes of furnace oil during the year by installing an air pre-heater (APH) in the TFH. Further, the company could manage to save 28,224 kwh of energy by replacing three high wall split air-conditioners with chilled water-based air handling units (AHUs) in the same period. At its Manali unit, in Tamil Nadu, SRF enhanced the capacity of the cooling tower pump to 90 kw and stopped operating two pumps with 75 kw and 55 kw power. By doing so, the unit was able to save 17,166 kwh a month. Isolation of loom air supply during stoppage of loom for more than five minutes could reduce its energy consumption to 6,666 kwh a month. Automatic switch-off of the motor in the drapper loom during loom stoppage for more than five minutes resulted in a monthly saving of 12,500 kwh of energy. An inverter provision for K1 air compressor

to control the loading based on HP air pressure reduced monthly energy consumption by 8,333 kWh. The unit was also able to save 2,416 kwh of energy by running air washers instead of AHUs during winter. The Viralimalai unit of SRF has improved its fuel consumption by installation of energy-efficient DGS and by replacing mercury vapour lamps with LEDs. The unit achieved a monthly saving of 1,000 units by introducing the load energy saver in the warp twister. A timer-based controller was provided in the HSD cooling tower motor which reduced 600 kwh a month. At the Gwalior facility of the company energy efficiency was achieved by switching off idle transformers and installing energy-efficient lamps and pumps. The unit also saved 30 kw per hour by installing an energy-efficient PSA nitrogen plant and another 18.6 kw per hour by installing FRP boxes in

the Toray twister motor exhaust system. SRFs Gummidipoondi technical textile unit achieved a saving of 12,200 kWh a month by optimising operation of the HT & LT air compressors and by reducing the air pressure at the dipping and nitrogen plant at 7 kg per sq. centimetre instead of 9 kg. Energy consumption was also reduced by 2,520 kwh a month by lowering the suction gun air pressure of 15 kg per sq. centimetre to 14 kg. A monthly saving of 3,289 kwh was recorded by reducing the speed of the cooling tower fan. This helped save fuel consumption and cut the operating cost.

KPR Mills
KPR Mill Ltd. specialises in readymade knitted garments, knitted fabrics and cotton yarn, including value-added compact and melange yarn. It has its stateof-the-art production facilities in and around

Tirupur. The company has its high priority to energy conservation schemes and takes effective steps to implement them wherever possible. Energy saving continues to be the thrust area for the management which keeps studying newer methods to achieve it. At the companys Karumathampatti spinning unit, the old belt-driven reciprocating type compressor has been replaced by the Atlas Copco screw compressor with inverter drive to avoid belt transmission loss and increase the output efficiency in the air line system. The variable frequency drives installed in the WRS centrifugal 75 kw motor with pressure controller to maintain the required pressure consistently by varying speed have been modified by draft air technologies. At the compact spinning unit, the company has installed variable frequency drives in the spinning blower motors and humidification plants to optimize the energy output by maintaining the required machine parameters and department relative 81

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ENERGY EFFICIENCY
humidity. The existing fans in the overhead cleaners have been replaced by energy saving ones in all 72 ring frames. At its Neelambur plant, a lighting energy saver unit of Beblec make has been installed for total lighting system, and significant saving has been achieved in overhead travelling cleaners by optimizing the hours of operation. At the Arasur unit, all the frames pneumatic suction tubes have been modified to improve the suction level and simplex OHTC operations controlled based on machine running by timer controls. At the Sathyamangalam unit, significant energy saving has been realised in the lighting system by replacing most of the old conventional ones.

Gokak Textile Mills


Gokak Mills, a part of the Shapoorji Pallonji Group, was established in 1885. Gokak initially set its pace for developing yarns for handlooms and then entered into tyre cords, best quality industrial yarns, weaving and knitting yarns catering to worldwide markets. The century-old company has one of the most modern mills in the country which have diversified into producing dyed yarns, canvas, terry towels, knitted garments and other downstream products. Since inception, the company has always taken forward its business with a concern for nature and environment by contributing its part of energy saving. In 2012-13, the rear-

rangement of blow room waste evacuation system in its mill seven enabled considerable power saving to the company. Auditing of pulleys in the autoconer machines and proper machining in workshop has enabled reduction of load on motors of Savio autoconers. The company had rearranged the power capacitors near load centres and replaced the derated capacitors. It had overhauled, lubricated and replaced old inefficient bearings by new ones in all DJ5 ring frame machines in its mill two. In the humidification plant the blade angle of the supply air fan was changed in order to reduce the load on the fan motors. It was also able to estimate the quantity of air leakage by installing a rotameter and accordingly was able to arrest leakage in all autoconers. All these efforts improved the energy efficiency of Gokak Mills and helped to achieve cost effectiveness.

Investment plans
For 2013-14, Gokak Textile Mills has invest-

ment plans for provision of front stop motion in speed frame machines and enable stopping of pneumafil fan motors to save power. A frequency converter to be provided in pneumafil fan of ring frame machines. Automatic power factor control panels (APFCs) are to be installed and some existing manual APFC panels to be converted to auto mode. The company plans to introduce lower dia suction tubes in these machines. Refurbishing of 224 kg dyeing machine shall be undertaken which enables it to improve its efficiency. Rearrangement of power feeding shall be done from grid power house to mill two by increasing the cross section. The company also plans to install power transformers nearer to load centres for mills 1, 2 and 3.

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Mafatlal Industries
Mafatlal Industries Ltd., one of Indias largest textile manufacturers, has an extensive range of products comprising a cumulative sale of over 80 million metres per annum. The company offers a wide range of fabrics (suiting and shirtings, twills, voiles, prints, poplins, cambrics, fine lawns, school uniforms, corporate and institutional wear, bed and bath linen, among others, in

polyester or viscose and polyester wool blends), speciality fashion denims and readymade garments. The company produces some of the finest fabrics in the country in a count range of 7s to 140s, addressing the needs of some of the most demanding customers in India and abroad. Energy efficiency has been the textile majors prime focus to achieve cost effectiveness. In 2012-13 the company installed stop motion sensors in six of its speed frame machines and

SITRA fans which save energy. The compressed air management program (CAMP) by SYSTEL helped in energy efficiency of air compressors by reducing its air leakages. Humidification costs were reduced by rationalizing ring frame locations. The capacity of the Atlas Copco compressor cooling tower water circulation pump motor was reduced from 11 kw to 5.5 kw. The company installed a 2HA2QT Kirloskar reciprocating compressor of 90 kw motor in place of an old

lubricating compressor of 132 kw motor. A system for water recovery from cooling system of Sanforiser was also installed. Air dryers of compressors have been modified resulting in lower consumption of power. Power consumption in the effluent treatment plant was reduced by adopting the bubbling system in place of the surface aeration technology. Systems and equipment at the demineralised water plant (DM) were modified to recover water for reuse. w

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COVER STORY

RICHARD HOUGHs
all-out effort at Asian market expansion
How was the year 2013 for RHL globally? What were the key highlights of the year? Richard Hough has had a resounding year with many breakthroughs and successes. The highlights include development of the revolutionary RoberteXfibre squeezing roll. This is the first-ever fibre squeezing roll that is fully chemically resistant to pH 0-14. Sales of RoberteX have gone very well so far due to the huge customer interest in this product. Additional breakthroughs have been in deflection compensating squeezing rolls. Normally any roll under load in a dewatering machine will require a parabolic camber to counter the deflection. Grinding machines which are able to form a parabolic camber are not readily available in India. By purchasing a deflection compensating roll, our customer only needs to machine the roll parallel on regrinding. This is a huge breakthrough as regards roll accuracy and hence higher performance of the squeezing roll. The Richard Hough family of squeezing rolls, consisting of Roberto, RoberteX and Resilio can all be supplied in deflection compensating design. The Resilio rolls have been well developed, and one major customer in China recently found that they reached such a high level of dewatering that the drying cylinders behind the final squeezer were not required. The roll grows from strength to strength, and record

Mr. Anthony Ashton, RHL Managing Director

R
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ichard Hough Ltd.s (RHL) aggressive market expansion and product innovations met with great success in 2013. The company has increased its marketshare and presence in the Asian market, with India in particular doing very well last year. Mr. Anthony Ashton, Managing Director, is quite happy with the performance in 2013 and is looking forward to another successful year ahead.
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sales have been reported this year in India, Indonesia, Morocco, the US and Pakistan. Which were the key markets in which RHL performed well during 2013? How was the Indian market for the group during the year? Our key markets are India, China, Bangladesh, Indonesia and the US. The Indian market has grown considerably during 2013, by as much as 50 per cent over 2012. Besides, now we have our customers spread over the whole of India, and Richard Hough rolls are running in almost all the processes like sizing, squeezing, wet processing and calendering for the weaving and knitting industries. What are your plans for 2014 across all major global markets, particularly the Indian market? Plans for 2014 are a continuation of expansion in Asia. Further to our participation in SIMA Texfair in Coimbatore in December, we are joining the Dhaka Textile & Garment Fair, Saigon Textile and Garment, Vietnam and Intertex, Jakarta, during April 23-26, as well as ITMA Asia in Shanghai in June. We have new products in the pipeline. The squeez-

ing technology cannot stand still. We have an innovative improvement in terms of elasticity and chemical resistance to our Roberto material. This will be available from February. Also, a completely new dewatering concept will be released at ITMA Milan 2015. What makes RHL products superior to those available in the market? Richard Hough relies on invention as its tradition and continuous improvement of its products is its philosophy. Our in-house R&D facilities put us far ahead of others, and so Richard Hough products are not really comparable but are known to set the trend for others to follow. Manufacturing and serving customers across the globe for more than 200 years is not easy to duplicate. Besides, Richard Hough has the largest range of rolls to offer to customers for varied process parameters/ needs which helps the customer to meet his requirement from one source. The company has a suitable roll for sizing, squeezing, padding, mercerizing, finishing and calendering. The Richard Hough

family of squeezing rolls offers huge energy savings. Roberto, Resilio and RoberteX all contribute much in terms of increased dewatering power and long life. In addition, the Richard Hough range of MaxExtractor rubber squeezing rolls give the end-user the same quality as can be obtained from the European machine makers. Richard Hough cotton and Syncast nylon calender rolls remain at the cutting edge of the industry and the roll of choice from the worlds major calender manufacturers such as Andritz, Ramisch Guarneri, Standex and Alliance Machine, both of the US. Virtually every Geotextile calender in the US is now fitted with Richard Hough Syncast rolls. What are the major innovations in terms of technology expected in the roller segment in the future? The squeezing rollers of the future will be

aimed at moving towards a sustainable world, with the main aim of saving valuable energy, and consequently helping the textile processor by making savings from the bottom line. Expensive vacuum extraction will be made obsolete by the innovative squeezing roll technology. Looking further ahead, new polymers and composites are the way forward to further improve the squeezing roll performance. w

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TECHNOLOGY

ColorDry water-free dyeing system introduced at

NIKEs Taiwan plant


NIKE, Inc. celebrated the opening of a water-free dyeing facility featuring high-tech equipment to eliminate the use of water and process chemicals from fabric dyeing at its Taiwanese contract manufacturer, Far Eastern New Century Corp. NIKE, Inc. has named this sustainable innovation ColorDry to highlight the environmental benefits and unprecedented coloring achieved with the technology.
The opening event follows NIKE, Inc.s February 2012 announcement that it had taken a strategic stake in Dutch start-up, DyeCoo Textile Systems B.V., a company that invented a technology to replace water normally used for dyeing with recyclable CO2, reducing energy use and eliminating the need for added chemicals in the process. On average, an estimated 100150 litres of water is needed to
Mr. Eric Sprunk, Chief Operating Ofcer, NIKE, Inc.

process one kg of textiles today.

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Vice President at FENC. The dyehouse opening and technology demonstration was attended by NIKE, Inc., FENC and DyeCoo executives along with other NIKE, Inc. vendors and Taiwanese Government officials. They also heard that the Netherlandsbased DyeCoo will soon open an office in Taiwan to service increasing demand for its technology. NIKE, Inc.s commitment as an investor and technical partner is unique in supporting DyeCoo to reach its true potential. IKEA also invested in DyeCoo, and Industry analysts estimate that more than 39 million tons of polyester will be dyed annually by 2015. NIKE, Inc.s Chief Operating Officer, Mr. Eric Sprunk, believes that as businesses recognize the need to reduce dependence on constrained resources, manufacturing innovation can play a key role. NIKE, Inc. innovates not only in designing of our products but also in how they are made. We see sustainability and business growth as complementary, and our strategy is to prioritize relationships with factory groups that demonstrate a desire to invest in sustainable practices and technologies. Our collaboration with Far Eastern and DyeCoo, to develop and scale the ColorDry process, is an important milestone on our path towards manufacturing innovation, said Mr. Sprunk. Initial indications from Far Eastern New Century Corp. (FENC) show the ColorDry process is both more efficient and consistent than traditional, resource-intensive dyeing methods. Compared to traditional dyeing methods, the ColorDry process reduces dyeing time by 40%, energy use by around 60% and the required factory footprint by a quarter. Its also the most saturated, intense and consistent color weve seen, said Mr. Kuenlin Ho, Executive
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both companies have connected us with supply chain partners. I see enormous possibilities to reshape the dyeing industry and adjacent industries as we work together to expand the application of our technology beyond polyester, said Mr. Geert Woerlee, of DyeCoo. Consumers can expect to see NIKE, Inc. ColorDry products in the marketplace soon.

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TECHNOLOGY

GRUNDFOS solar pumps


help tackle worsening power crisis
Grundfos Pumps India Pvt. Ltd., a forerunner in sustainable pump solutions, has announced that it has so far sold more than 8,800 solar pumps across the country. It has sold and installed its solar pump solutions across States such as Maharashtra, Bihar, Chhattisgarh, Madhya Pradesh, Gujarat, Uttar Pradesh, Tamil Nadu and Andhra Pradesh. Through these solar pump solutions, the company has helped create a positive impact on the socio-economic lives of thousands of people in rural India.
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Mr. Ranganath N.K., Managing Director, Grundfos India

Grundfos solar water pumping solutions offered in multiple rural and tribal areas have helped in some degree in surmounting some of the core challenges the country is facing, viz., poverty alleviation, food security, water availability and access, provision of education and healthcare, energy security and environmental protection. Commenting on this key milestone, Mr. Ranganath N.K., Man-

aging Director, Grundfos India, said: In India, over 700,000 villages do not have access to water. An off-grid, self-sustaining solar pumping solution is the quickest way to provide water to millions. As a company which is committed to a greener and cleaner planet, Grundfos India constantly focuses on offering energy efficient and sustainable pumping solutions, among which solar water pumps is one.

Mr. Rishi Kapoor, Founder of Sunlit Future, an Aurovillebased solar energy solutions & energy efficiency consultancy which provides high quality solar energy solutions in India, testifies to the quality of Grundfos pumps. Asked about his experience with using Grundfos pumps, he said: We have installed Grundfos SQ Flex mostly in rural and tribal areas of India where electricity is unavailable. These pumps come with a long life and have lasted for about 1520 years. Grundfos pumping solutions have offered affordable, reliable and clean water

to countless villagers. The SQ Flex/SP Flex, submersible borewell solar pumps, and the CR flex, surface solar pumps systems, can be adapted to any water supply need according to the conditions of the installation site as they are very light weight and flexible with regard to the energy supply and performance. Commenting on Grundfos solar pump solutions, Mr. Nirmal Nathan of Rose Gardens, a sustainable organic farm in Trichy, said: I purchased three Grundfos SQFlex pumps about two-anda-half years ago for my organic farm. According to me, Grundfos pumps are the best in the world. SQ Flex in particular is self-regulatory and requires minimum labour. In the absence of sunlight or when the water level is very low, the pump switches off automatically. In four years, one can expect the return on investment and for the next 15 years, one can reap its benefits. It is not just the product but the service offered by Grundfos that is also matchless. The crippling power crisis in most parts of India has got the Government in a bind, apart from hav-

ing a pernicious influence on the growth prospects and the trajectory India aims to course through in the years ahead. In an economy that is chronically stricken with energy issues, a 12.5 per cent energy shortage in power and electricity supply is not breaking news. Encountered with a daunting task of ensuring power and water to the various sectors, the Government is forced into a catalytic phase to look for alternate/renewable solutions to surmount this grave issue. Of the multiple renewable solutions are available, embracing solar power as the solution to adequately support the current critical scenario appears to be a prudent move by the Government. Solar pumps are useful where grid power is unavailable, or of poor quality and unreliable. Solar pumping systems are widely used for agriculture and livestock, rural/tribal area water supply, forest, and a host of other areas where electrification is a challenge. Industries and commercial buildings have also taken recourse to harnessing solar power.

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PRODUCT LAUNCH

MAHINDRA POWEROL
ahindra Powerol, a part of the $16.7 billion Mahindra Group, has announced the launch of its new diesel generator, Leaf DG, in Chennai. The leafshaped compact design of the generator breaks away from the traditional box design and aims to make the product visually more appealing, thus attracting more consumers. It is available in the range of 7.5 kVA, 10 kVA and 15 kVA. The product makes an entry into the Chennai market to bridge the peak power deficit of 11.7 per cent in Tamil Nadu. At the launch function, Mr. Ashok Sharma, Chief Executive, AFS Strategy, Agri & Allied Businesses, Mahindra & Mahindra Ltd., said: Mahindra Powerol generators are known for their quality, superior performance and customer centricity. With the launch of this model, we are setting a new benchmark in these areas. We are transforming the diesel generator from a 90

launches new range of diesel generators

Mr. Palaniappan, Senior Vice President, and Business Head Mahindra Powerol, Mahindra & Mahindra Ltd., launched the new diesel generator - Leaf DG in Chennai

machine into a thing of beauty. The new generator, in addition to easier use and better performance, is in line with the taste and expectations of todays smart and evolving customer. Said Mr. Palaniappan, Senior Vice President and Business Head, Mahindra Powerol: Our internal study revealed that due to poor aesthetics, customers generally placed the diesel generators at the back of their buildings or in the backyard. Hence, we decided to come up with a new de-

sign which would encourage customers to proudly showcase their diesel generator in front of their homes, buildings and outlets. The elementary design emerged from the contest which we had organised at the prestigious N, Ahmedabad. The winning design was then further enhanced by our in-house team before it was sent for volume production. The new compact leaf diesel generator has unique features like the new leaf-shaped enclosure (now patented),

graphics on the enclosure body to improve aesthetics, glossy finish powder coating and leafshaped suction louvres. Mahindra Powerols new diesel generator proves to be an innovative design in the power back up industry, and the company hopes it will lead to new markets. Apart from the design improvement, it is manufactured with a reduction in the total footprint (up to 0.4M) and in the noise levels up to 2.5dBA. w

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PRODUCT LAUNCH

High performance speciality lubricants much superior to conventional ones


The Indian textile industry is set for strong growth, buoyed by increasing domestic consumption and export demand. The industry is estimated to be worth $220 billion by 2020. Recent developments in technology and growing market demand, with no compromise on product quality, higher speeds, longer runs between planned maintenance and zero tolerance for unplanned downtime are the factors behind staying competitive in the sector.
Conventional lubricants have played a vital role in operating textile machinery, but these standard lubricants are often unable to keep up with the everincreasing performance requirements of modern machinery. It takes something more than the regular lubricants to cater to the emerging demand. A synthetic high performance lubricant is the right answer. The choice of a lubricant should largely be governed by the technical and performance requirements and not just the cost of it. Synthetic high performance lubricants cost a little more, but effectively turn out to be much more economical in the long run. Textile speciality lubricants offer effective and efficient lubrication solutions to the modern textile machinery items like spinning machines, synthetic fibre spinning machines, synthetic fibre processing machines, twisting and spool machines, special machines, sizing machines and looms, and textile finishing machines. The benefits of using high performance synthetic lubrication solutions are maximum operational & performance reliability, low operating & servicing costs, long maintenance intervals, and energy efficient & environmentfriendly solutions. Synthetic high performance lubricants for the textile industry can offer productivity advantages throughout the many conversion and specialty processes, from machinery used in opening, carding, drawing, and yarn spinning of natural and synthetic staple fiber, to melt spinning, winding, and texturizing of continuous filament yarn, thread, and high tenacity tire cord, as also in the machinery used in warping, sizing, fabric formation, non-wovens, dyeing, printing, drying, and finishing. Such a wide range of processes and lubrication needs call for a number of specialized lubricants specially designed to optimize specific applications. With a comprehensive line of lubricant solutions, ONWO can help your world class manufacturing operation to continuously improve productivity and quality, reduce energy costs, downtime, use of spare parts and overall expenses related to machinery maintenance.

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TECHNOLOGY

JEANOLOGIAs
lead in sustainable technology for garment finishing
The Spanish major now dominates S. American market
Jeanologia of Spain, the world leader in sustainable development of technologies for garment finishing, has positioned itself in the South American market. The company which recently bagged the WGSN Global Fashion Award for best sustainable design team in the world, participated in Colombiatex held on January 21 and 22 and also in the fashion show Premire Vision Brazil where it presented its latest technologies.
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Mr. Enrique Silla, President, Jeanologia

In particular, at Colombiatex, the company displayed the Flexi HS laser technology, ecowashing G2, E-soft and E-Mark software. At the event, a Jeanologia

designer worked with Colombian designers using the software E-Mark for getting the highest returns on their production. Also, the designers were able to make their own

samples with the latest Jeanologian designs. On January 21, a special show for media was held where advanced technologies developed by the Spanish company

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TECHNOLOGY
were demonstrated. The same day, Mr. Jess Blay, Area Manager of Jeanologia, delivered a speech on sustainability and development. Further, at the celebration of the Premiere Vision Brazil, Jeanologia exhibited the E-Mark software developed exclusively for the apparel design laser intended for more efficient production, but also allowing creation and improvement of designs on jeans. This is a user-friendly software, fast to design and multilingual. It has also a constantly updated database, artificial vision control, design preview, production time estimation and analysis of remote control. It helps optimize productivity and minimize production errors. Mr. Enrique Silla, President of Jeanologia, observed that both Colombian and Brazilian markets are aware of the problems facing the textile industry and also of the environment and the health of workers. These markets have understood the technology and are now prepared to go a step further for getting the highest returns by performing in a sustain94 able, efficient and automated way while caring for the final look of the garment. Referring to the potential of these two markets, he said: 95% of garment finishing processes using laser and ecoBe Kool, Pronto, Studio F, Kenzo, Willdy, Atmosfere, Supreme, CI Jeans, Chevignon and Tennis, already use these sustainable technologies developed by Jeanologia. Jeanologia has been washer uses ozone and oxygen from the atmosphere, allowing washing clothes to achieve color reduction in garments, particularly jeans, T-shirts and tops, obtaining the effect washed by the sun while allowing sav-

logical techniques in the Colombian market are based on our technology, while in Brazil it is 70%. The President disclosed that the leading brands in the Brazilian market such as Calvin Klein, John John, Colcci, Forum, Carmin, Damyller, Lana Perfume, Morena Rosa, Osmoze Stream Zara, Renner C & A, Marisa and Oppnus Sawary and Colombian brands such as Army,

developing for the last 20 years ecological textile technologies such as textile laser, oxygen and ozone garments washing and garment softening by nano bubbles. More specifically, the textile laser reproduces vintage and usage effects on garments avoiding use of harmful techniques and allowing energy, time, water and chemicals saving. Also, the G2 eco-

ings of more than 60 per cent in water and energy and about 80 per cent in chemicals. It has also developed the nano-technology with E-soft that softens clothes with nano bubbles, saving 80 per cent of energy and softener and 98 per cent of water. Additionally, this technology uses no chemicals and avoids completely the discharges to the environment. Jeanologia aims to

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TECHNOLOGY
reduce water consumption and save energy and chemicals in textile processing. Mr. Silla said: Today, there is a global technological movement in textiles determined to transform this industry into a cleaner one with regard to the health of workers while being more efficient. This is a new technology era where pollution and harmful processes have no place. Both big brands and end-consumers demand a cleaner and more sustainable industry. ladesh are developed with the backing of the Jeanologia technology. Leading manufacturers and brands such as Inditex, H & M, Gap, Levis, Uniqlo, Wrangler and Lee, among others, use these technologies for their garment finishing. Specifically, this textile laser reproduces jeans wear and tear avoiding the use of harmful techniques that could damage the health of workers. With this it is possible to increase the designs range and textures, enabling a perfect garment reproducibility while allowing saving in energy, water, chemicals and time during the manufacturing process. The Flexi 3e is designed to offer maximum flexibility in production. It also offers unlimited possibilities for its versatility in marking clothes both in table and mannequin, always adapting to production needs. The machine includes a rotating head that allows to work both horizontally and vertically as it has fixed table or mannequin. It is perfect for all kinds of garments, from jeans to skirts, shorts, shirts, jackets and even accessories. Referring to the importance of Bangladesh in the textile market, Mr. Enrique Silla, said: Bangladesh is one of the leading textile manufacturing countries with about 44,000 factories, making it the country with the largest textile production in the world. Jeanologia considers Bangladesh as a very important market and has always wanted to be close to their customers, offering the best service, understanding the market needs and creating a center to be trained in friendly technologies. The Spanish company has customers across five continents. Its exports of machinery and services account for 90 per cent of its turnover. Jeanologia products and solutions are currently being used in more than 45 countries, including Mxico, Colombia, Brazil, USA, Germany, Italy, Portugal, India, China, Russia, Japan, Morocco and Bangladesh. Specifically, major brands such as Levis, Polo Jeans, Abercrombie & Fitch, Edwin Japan, Pepe Jeans, Diesel, Hilfiger Denim, Salsa Jeans, and other large retailers such as GAP , Uniqlo, Zara, have placed their trust in this leading Spanish company and the techniques and technologies developed by it. w

The company role in Bangla market


Almost 85 per cent of laser processes for garment finishing in Bang-

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EVENTS

ITAMMA Guntur Catalogue show


evokes good response
The Indian Textile Accessories & Machinery Manufacturers Association (ITAMMA) organized a catalogue show at Guntur in Andhra Pradesh on January 10. With 65 registered exhibitors participating in it, the four-hour event was well attended by more than 800 industry professionals.
The main objective of the show was to expand ITAMMAs presense in the Guntur market and to showcase the business potential of this promising textile hub in the South. There was excellent interaction between user industries and the suppliers within the short time available, according to Mr. Diven G. Dembla, ITAMMA President. Visitors from Guntur and the neighboring region got a rare opportunity to observe the quality machines and accessories for spinning, weaving and wet processing. ITAMMA has so far organized many product-cumcatalogue shows at various textile centres, both in India and abroad, thus giving opportunities to its members to interact with user industries. These shows which receive tremendous response have proven to be a cost-effective tool in reaching out to the user industries in the shortest possible time. w

Picture taken during the inauguration

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EVENTS

Exhibitor focus on digital textile technology at HEIMTEXTIL


apparel & fashion industry. A majority of home textile firms have stayed away from large investments in digital printing for the two main reasons of lack of a stable high-speed digital system for pigment printing on cottons and the huge investment involved in wider-width equipment set-up for bedlinen & curtains. Commercialisation of pigment ink for highspeed industrial printers is being addressed with OEMs at various stages of the development & testing process. SPG Prints, Netherlands, showcased its pigment ink technology at Heimtextil. The ink was seen running on a La Mecchanica Leopard 8 printer (Fig. 1). Mr. Jos Notermans, Business Unit Manager, Digital Textiles, SPG Prints, commented on the companys pigment ink technology: We are happy with the current results, and the market will see us commercially launching the

Mr. Aditya Chandavarkar, CEO, Inkjet Forum India

he recent Heimtextil exhibition at Frankfurt proved more international in its outlook by hosting 2,658 exhibitors from 62 countries and attracting approximately 66,000 visitors over the four days, 66 per cent of whom were from countries other than Germany. The most represented international visitor nations included Italy, China, Turkey, the UK, the US, France, India, Spain, the Russian Federation and Poland.
business. With the newly emerging trends for industrialscale digital printing of home textiles, Heimtextil saw presence of leading digital textile printing technology, and software and design providers exhibiting in the Design & Technics Hall. Digital textile printing is well accepted and has been largely successful with the growth of the fast fashion trend in the

With 80 per cent of exhibitors and 94 per cent of visitors claiming to have achieved their goals during the show, it was quite evident that the exhibition was a good platform for doing 98

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EVENTS
nology developments in digital textile printing for carpets and pile fabrics. The conference also provided an insight into the potential for digital textile printing in the home textile & furnishing industry. Mr. Aditya Chandavarkar, Founder, Inkjet Forum India, who was a part of the invited speaker panel, provided an Indian perspective on the potential for digitallyprinted home textiles and interior furnishing products. This years Heimtextil combined the best of business with design innovation and emerged as one of the leading textile, home furnishing, interior design and wallcovering trade fairs. w

inks in 6-8 months. The other leading technology providers present at Heimtextil included Reggiani Macchine, Kornit Digital, POD Iberica and Durst & HP . Mr. Oliver Luedtke, Marketing Manager, Kornit Digital Europe, observed: We are very happy with the response we have received, it is the first time we are exhibiting at Heimtextil, and we will definitely exhibit in a bigger way next year. Kornit is a specialist in pigmentbased inkjet technology. There was also an informative conference program on the digital textile printing theme organised by the World Textile Information

Network. The European Digital Textiles conference included presentations from some of the pioneers of digital textile printing for home textiles, as well as industry

observers, strategists and creative thinkers. The conference discussed at length the commercial opportunities the digital system offers, the latest market trends and tech-

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99

LOGISTICS

DHL Supply Chain has just announced additional investment to strengthen its logistics infrastructure in India, besides an outlay of Rs. 685 crores ($110.5 million) earlier decided upon. The company has also moved swiftly to execute these investments by adding one million sq.ft. of warehousing space with three multi-user sites in Mumbai, Pune and Gurgaon. There are also plans to open additional facilities in Tier-1 cities in India this year.
Mr. Paul Graham, CEO, Asia Pacific Middle East and Africa, DHL Supply Chain, has said: DHL is strongly committed to investing in markets of growing importance. By increasing our footprint and with continued investment in our people, we are taking another step in the right direction to pursue DHLs global strategy and support the develop100 ment of our business in India. With its fast track growth over the past few years, the company has announced Mr. Vikas Anands appointment as Managing Director of DHL Supply Chain India Pvt. Ltd. Currently managing the business as COO, Mr. Vikas has been with the organization for more than 10 years and has served in

Mr. Paul Graham, CEO, Asia Pacic Middle East and Africa, DHL Supply Chain

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LOGISTICS
various capacities. Vikas has led the India team from the front, and DSC India has delivered excellent results under his leadership over the last few years, said Mr. Oscar de Bok, CEO - South and Southeast Asia, DHL Supply Chain. Mr. Vikas Anand observed: According to recent research, the 3PL market in India is growing at a faster pace than its GDP due to increased outsourcing. It will account for 13% of the total logistics market in 2015, up from 6% in 2008. With Transportation forming over 70% of this market, one of my priorities will be to continue expanding our modern fleet, among other things. The company has a well-spread transport branch network in 20 cities, offering containerized custom-made vehicles, in addition to its advanced Transport Management System that enables realtime tracking of its vehicles. To provide fresh impetus to its business, DHL Supply Chain will now operate as a separate legal entity, DHL Supply Chain India Pvt. Ltd. The freight forwarding and customs brokerage 102 business will continue to operate under DHL Logistics Pvt. Ltd. This will enable both the forwarding and supply chain business units to pursue their ambitious growth strategies and provide a competitive edge in a highly fragmented logistics market. Through our longterm presence in India and our large investments over recent years we have been able to provide a competitive advantage to our customers resulting in an accelerated growth of our supply chain business in India. I am confident our continued investments in people, systems, transport and infrastructure in India will ensure our customers have the best

Mr. Vikas Anand, Managing Director, DHL Supply Chain India Pvt. Ltd.

options for their supply chains in India, added Mr. Oscar de Bok. By setting up world class infrastructure in India, DHL Supply Chain is offering differentiated solutions and improving cost efficiencies, with talent being the key

enabler. With its ambitious expansion plans, the company will have 10,000 employees by 2015 servicing all major sectors and fully satisfying all customer requirements. w

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Published by R. Natarajan from and on behalf of Gopali & Co., Quanta Zen Apartments, No.38/2, Thomas Road, 2nd Street, T.Nagar, Chennai-600017 and Printed by B. Ashok Kumar at Rathna Offset Printers, 40, Peters Road, Royapettah, Chennai-600014. Editor: R. Natarajan