By Arun Rao
From Converting Twisting Machines to Manufacturing Advanced TFOs
Alcone Tex Engineering Pvt Ltd’s journey from a modest yarn twisting operation to a leading innovator in textile technologies is a remarkable story of determination, ingenuity, and commitment to improving production efficiency. Founded by Mr. Bharatkumar Movaliya, the company has continuously adapted to the demands of the textile industry, driving innovations in yarn twisting, filament yarn technology, and other related textile machinery.
Beginnings: From Yarn Twisters to TFO Conversions
The story of Alcone Tex Engineering dates back to 1982 when Mr. Bharatkumar Movaliya began operating a yarn twisting factory with just 45 machines. During the early years of his business, Mr. Movaliya faced a critical decision when the time came to purchase new Two-for-One (TFO) twisters. Rather than buying new machines, he chose to convert his existing yarn twisting machines into TFOs. This innovative approach marked the beginning of his journey towards setting up a manufacturing TFO’s.
Initially, the aluminum spindles required for the TFO machines were produced using regular lathe machines. However, Mr. Movaliya’s most significant breakthrough came when he was able to achieve a substantial reduction in electricity consumption with the converted TFOs, compared to the imported machines.
Over time, Mr. Movaliya successfully converted all 45 of his yarn twisting machines into TFOs. In addition, he extended his help to friends and family members in the industry, assisting them in converting a total of 150 twisting machines into TFOs.
Foundation of Alcone Tex Engineering: Manufacturing TFOs and More
In 2003, driven by his growing success in converting yarn twisting machines into TFOs, Mr. Bharatkumar Movaliya established Alcone Tex Engineering Pvt Ltd. The company was created with a vision to manufacture high-quality TFOs and develop other related textile technologies.
In 2010, Alcone Tex Engineering also designed and developed TFOs for cotton yarn, catering primarily to cotton yarn spinning mills across India. Over the years, the company expanded its product range to include both single and double-deck Spun and Cotton yarn twisters.
Filament Yarn Twisting: Compact and Enlarged TFO Technologies
The company also introduced filament yarn twisting technology with their Compact TFO and Enlarged TFO models. Among these, the Enlarged TFO—also known as the Uptwister—became a game-changer in the industry.
Unlike conventional TFOs that are limited to twisting yarns within a small range of twists per meter (TPM), the Uptwister is capable of twisting yarns in a wide range from 100 to 4,000 TPM. This feature eliminated the need for textile manufacturers to purchase multiple machines for different TPM requirements. As explained by Mr. Kankesh Movaliya, Director at Alcone Tex Engineering, the Uptwister’s ability to cover such a wide range of TPMs provides a cost-effective solution for mills that previously would have needed to invest in new machinery to handle higher TPM yarns.
Meeting the Needs of Job Work Entrepreneurs: A Compact Solution
Alcone Tex Engineering also dedicated itself to understanding and addressing challenges faced by smaller job work entrepreneurs in the yarn twisting industry. Through direct feedback from twisting factories and workers operating the machines, the company gained valuable insights into how they could further improve their products.
One of the most notable innovations was the development of a more compact version of the Uptwister. Understanding that many small entrepreneurs in Surat operated in rented premises with limited space, Mr. Bharatkumar Movaliya designed a compact version of the Uptwister. This compact model reduced the machine’s width by five inches but maintained the same specifications and features as the standard model. This modification enabled job workers to install four machines in the same space that previously housed only three, increasing production by 25%. The success of this model led to the export of nearly 150 compact Uptwisters, benefiting small manufacturers who needed to maximize space and production capacity.
Manufacturing Excellence: Strict Quality Control and After-Sales Service
Alcone Tex Engineering’s manufacturing facility is located on a 1,530 square-yard plot, with a built-up area of approximately 900 square yards. The company manufactures the main structure of each machine in-house and produces its own dies for external components. Alcone is committed to maintaining strict quality control and ensuring that every part of their machines meets the highest standards. Even the smallest variation of 0.5mm in the dimensions of a component is considered unacceptable and results in rejection.
The company’s commitment to quality extends beyond manufacturing, with a robust after-sales service program. Alcone Tex Engineering provides a one-year warranty on spare parts, but continues to offer free after-sales service throughout the machine’s lifecycle. The company only charges for spare parts when customers require them, and they offer technical support and guidance whenever needed.
Thanks to the durable design of their machines, Alcone’s products experience minimal vibrations, leading to a longer machine lifespan and reduced electricity consumption compared to competitor models available on the market. This durability and energy efficiency further enhance the value proposition for customers.
Expanding Beyond India: A Global Reach
In 2012, Mr. Kankesh Movaliya joined the family business after completing his degree in international business management. With a vision to expand Alcone Tex Engineering’s presence beyond India, he worked towards taking the company’s products to international markets. In 2013, Alcone Tex Engineering successfully exported its first TFO to Pakistan. Today, Pakistan is Alcone’s second-largest market after India, with over 800 TFOs sold.
Alcone Tex Engineering’s global footprint has also extended to other countries, including Egypt, Turkey, Uzbekistan, and Bangladesh. The company now exports a significant portion of its production, with many customers choosing Alcone’s machines for their proven efficiency, durability, and cost-effectiveness.