With the integration of vertical control of supply chain management, Beekaylon has a smooth functioning process flow and an excellent quality assurance system in place
The year 2022 will be a very eventful year for Beekaylon, one of India’s largest manufacturers of dope dyed POY, FDY, BCF, draw texturised, air texturised, twisted, cabled and heatset polyester filament yarns. This is because it will mark the biggest expansion spree in the company’s history. Beekaylon has undertaken a massive expansion project at an investment of approximately USD 50 million. The company has entered into backward integration by adding a continuous polymerisation (CP) unit with the capacity of 9,000 metric tonnes per month. It will be adding additional POY and texturising machines to the tune of 130 tonnes per day which will take its total production capacity in filament yarns to 9900 metric tonnes per month. The facility will be operational from December 2022.
The Beekaylon story started in 1979 in a small city called Silvassa. This is an extraordinary story of a visionary entrepreneur Late Shri Kishanchand Khemani who had a dream to establish a leading textile yarn company. Over the years, Beekaylon has strengthened its position in the yarn business by attracting some of the most prominent customers from not only India but across the world in various segments such as automotive, carpets, bath rugs, home textiles, and apparel and elastic tapes. “Our assurance of excellent quality yarns along with top-notch service and transparency in dealing is what has helped us retain our customers,” says Shohin Khemani, Director, Beekaylon.
Manufacturing Infrastructure
Beekaylon’s state-of-the-art production facility at Masat and Velugam (Silvassa area) has a significant advantage with the latest technologies in place. The company’s manufacturing unit is equipped with Barmag and Beijing Chong Lee spinning lines to produce dope dyed POY, cationic POY, full-dull cotlook POY, semi-dull POY, bright POY, micro-filament POY and FDY with a capacity of up to 6,000 tonnes per month currently. Beekaylon has established industry tie-ups with leading master-batch suppliers to match the exact colour chemistry and significantly reduce colour and shade development time. With the integration of vertical control of supply chain management, Beekaylon has a smooth functioning process flow and an excellent quality assurance system in place.
“For varied market applications for our various customers we have added value with downstream texturising, air texturising, heat-setting, intermingling and twisting plants in place,” informs Shohin. Beekaylon manufactures products that have a large application base, ranging from home textiles, dress material, home and automotive furnishings to circular knitted fabrics for sportswear and active wear, yarn for carpets and bath rugs and also yarn for elastic tapes and socks. The company is uniquely positioned in the marketplace with one of the largest varieties of colour offerings in (PFY) yarns.
Bulk Continuous Filament Yarn (BCF)
In 2018, Beekaylon extended its ultra-modern production facility at Velugam for flooring and carpet application and BCF yarns, introducing to the market a new revolutionary product. Beekaylon has invested in the world’s best technologies in operation. The company has installed the latest Neumag S+ machines to produce BCF yarns. A unique aspect of Beekaylon’s production process is that it is capable of producing tri-colour BCF yarns. Beekaylon also has the capacity to produce polyester (PET) BCF, nylon (PA 6) BCF as well as polypropylene (PP) BCF yarns with total flexibility in mono colour. The company is now investing in additional Neumag machines which will increase its production capacity by 350 tonnes per month. This is expected to start commercial production by July 2022. The company is also adding new heat-setting machines from Superba and cabling machines from Volkmann by March 2022.
With these expansions (both the CP plant as well as the additional BCF lines) the company aims to increase its turnover by almost 65% from the current levels.
Sustainability and Technology
Beekaylon has embarked on a ‘Stay Green Journey’ where many of the company’s initiatives are focused on sustainable manufacturing. Some of the key initiatives include partial use of clean renewable solar energy across all factories, installation of ETP plant and offering sustainable,recycled & biodegradable products is undertaken. Beekaylon is one of the leading Indian suppliers of dope dyed yarn for polyester yarns with nil or least use of water. It employs approx.1700 people across all its manufacturing units. The company believes in the growth of its employees and upliftment of society to help build a strong progressive society.
It provides employment to the local population along with catering to the education and healthcare needs of both adults and children. It prioritizes women employment, contributes to development projects initiated by the local government.
The company has recently partnered with Datatex for ERP solutions. “From financial year 2022-23 we will be going live with our new ERP system known as Datatex. This system will capture all data points in manufacturing and sales operations and will streamline our multiple processes across a variety of products offered in textiles and BCF,” Shohin informs.
Vision 2025
Sharing the company’s vision for 2025, Shohin states, “For us the year 2022-23 is when Beekaylon will achieve new heights of success. As per our expansion plans and investment of USD 50 million, we aim to increase our turnover by almost 65% from the current levels. We will be adding world-class TMT POY lines to our portfolio to produce the best-in-class polyester yarns which will further strengthen our position in the market. By 2027 we further wish to further add continuous polymerisation as well as POY and texturising capacity of 4500 tonnes per month, thereby increasing our capacity by almost 50% more that is being undertaken.”
“By 2026 we also wish to double our BCF yarn production capacity to 1,600 tonnes per month. We will strive to continue to being the largest dope dyed yarn suppliers in India,” he adds. Capacity expansion is not the only thing. By 2025 the company also wishes to have many more systems in place. “In 2020 we started this journey by going in for continuous improvements in various aspects of the company which would ultimately help us add more systems in place as well as improve our efficiencies as well as profitability. Titled ‘Project Saksham’, this journey of continuously evolving will help us stay one step ahead of our competitors,” Shohin states.
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Product Mix
• Partially oriented yarn (POY)
• Fully drawn yarn (FDY)
• Draw textured yarn (DTY)
• Air textured yarn (ATY)
• Twisted polyester yarn
• Dope dyed yarn
• Raw white yarn on perforated tubes
• BCF cabled and heat-set yarn.
Functional Yarns
• Flame-retardant yarns
• UV-resistant yarns
• Anti-microbial yarns
• Recycled yarns
• Biodegradable yarns
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Brands by Beekaylon
- Puriflex: Antimicrobial yarns with infused AM++ ions. Provides protection and freshness for carpets and floor coverings.
- Poly-Go-Round: Recycled polyester yarns with GRS certification.
- Flexilastic: Ultra-stretch polyester yarns. It brings inherent mechanical stretch and remarkable recovery to fabrics with enhanced performance.
- CiCLO®-Partnered Sustainable Yarns: Beekaylon has the expertise to produce CiCLO-induced yarns in POY, FDY, DTY, cationic and recycled variety of yarns for textile applications.
- Moto-Fiber – yarns for automotive segment
- Pyro-Shield – flame retardant yarns
- Aerolite – Micro fiber Yarns