Modernization leads to 75% increase in overall capacity
Modernization is a continuous process, and there should be co-ordinated efforts to modernize both machinery and manufacturing processes on a regular basis. Globally, an accepted fact is that mills that maintained the process of modernization systematically could manage to sustain their growth in the long run.
Modernization in fact is needed to raise production, reduce the cost of production, rationalize labour, cut the maintenance and power cost per unit of production, etc. All these parameters were fully realized by the Ahmadabad-based knitted fabric manufacturer, Bhoomi Textiles. the company decided to expand and modernize by installing the latest multi-purpose SUPER SLIT line from Corino of Italy.
Bhoomi Textiles was started in the late 1980s under the guidance of brothers Yugesh Shah and Shirish Shah. They had a sound background in the textile arena and are pioneers in initiating knitted fabrics and garment export activities. Headquartered at Narol, Ahmadabad, the company operates through four facilities across the country.
Specialists in knitting, dyeing, printing and finishing of all kinds of knitted fabrics, the Shah facility is equipped with state-of-the-art technology to process both lighter and heavier fabrics. The company’s machinery line-up uses the most exclusive equipments sourced from the best of vendors. The management is very particular about using the right technology at critical stages which in turn aids the company in controlling the quality right from the raw material stage to finished products.
Bhoomi Textiles today is one of the leading manufacturers and exporters in India, exporting world-class textiles for more than 40 years under the banner of “Raj Exports” which is an hundred-year-old parent company.
Raj Exports, the senior brand, started exporting to the African market way back in the 1930s. The company started supplying Khanga and Kitanga printed fabrics to African countries like Sudan, Kenya and Tanzenia during the Second World War. Later, in the 1970s, demand for various printed and dyed knitted and other stretchable fabrics and garments grew, and hence Bhoomi Textiles commenced supply to both the domestic and international markets.
Bhoomi Textiles is integrated under one roof under the same management, with adequate infrastructure to meet world market standards. The company recently exported and modernized fabric manufacturing by installing machines like Corino Super slit and stenters from Ehwha from Korea, dyeing machines from Fong’s and Thies, weft straightener and temperature controls from Mahlo of Germany and fabric finishing compactors from Bianco of Italy.
The Corino factor
The recent addition of Corino “SUPER SLIT” machine, with its automatic turntable, soft rope dewatering device, slitting basket, opening module, anti-pilling tank, dewatering padder, softening padder and the folder exit, is most customer-friendly. The anti-pilling system for fabrics pre-treated with enzymes has greatly helped in reducing the fabric contamination due to the fibre wastes.
Mr. Niraj Shah, Director of Bhoomi Textiles, states: “Even though the Corino line is slightly expensive, comes with a whole lot of advantages like huge saving of power, less manpower, only one person required to operate the entire machine when compared to my conventional machine which required the presence of 4-5 people resulting in better quality and more production.”
Corino “SUPER SLIT” is a flexible system that ensures minimum tension on elastic and delicate fabrics, combined with higher productivity. Even if it is mainly used for slitting the tubular knitted fabric, this line guarantees performance for every kind of open width fabric.
Bhoomi Textiles modernisation was done in phases over a period of four years. It has helped the company increase the daily fabric manufacturing capacity from 8,000 kg to 14,000 kg.
In the restructuring and modernization, the company decision to go in for Corino machine was made and was part in obtaining an astonishing 75 per cent increase in production capacities. This is the direct result of installing various ultra-modern equipments. This modernization has helped to achieve global standards and cater to international brands.
Corino’s Indian agents A.T.E. has played an important role in connecting the Italian manufacturer to a number of Indian customers and is striving even harder to provide hassle-free after-sales service to its esteemed customers.
Raj Exports, the parent company of Bhoomi Textiles, has cutting-edge facilities and state-of-the-art garment manufacturing machinery. Their garment facility is equipped with fully computerized cutting, sewing, printing and embroidery machine. Raj Exports mainly produces and supplies kids wear and ladies fashion to various retailers and importers worldwide. The presence are working closely with top multi-national and retailers in determining colours and trends for the future. Once approved, the garment gets manufactured from one of their production sites in Tirupur or Sri Lanka and is dispatched well in advance to many global retailer for the upcoming seasons. With a production capacity of more than 6 million pieces per annum, the company is gearing up to cater to much wider audience across the vertical.
Quality checks are carried out during every stage of production. Experienced technocrats are involved during every audit of quality and customer’s quality requirements are adhered to strictly.
Raj and Bhoomi together posts an annual growth of 20% year on year. The company’s director, Mr. Niraj Shah has ambitious plans for the future. The chair persons are planning to invest heavily in backward integration, hence the company is gearing up to set up a spinning plant, 60kms from Ahmadabad by 2017.
During a Textile Magazine exclusive, Niraj Shah talks about the future potential India holds within the textile vertical – “Countries like Bangladesh produce garment at a cheaper rate is because of their privileges which is not sustainable. Looking at a long term commitment, India is definitely more sustainable and our future looks bright for another 10-15 years.” Hence he’s confident about the management’s decision in setting up a new spinning unit and expanding fabric manufacturing, secondly to relocate the existing processing facility to a newer greener site holds great prospect for the company in the years to come.