Indo Count Industries is one of India’s leading vertically integrated textile companies. The company has integrated the entire value chain of textiles from spinning, weaving to processing, cutting and sewing. In addition to the core manufacturing processes, the company has integrated procurement, design, and packaging to ensure a total end-to-end solution for its clients. Indo Count has three manufacturing units in Kolhapur. It acquired Pranavaditya Spinning Mills Ltd. (PSML) in 2007.
The company has a total of 80,016 spindles (which includes PSML’s) producing around 14,000 tonnes of cotton yarn annually. Indo Count is the third largest manufacturer exporter of bed sheets with a global footprint spanning 16 countries across four continents. The company’s clientele includes some of the top global retailers and renowned international brands. The current product range of the company is one of the most diversified in the industry ranging from 100 per cent cotton to blended yarns.
“The Home Textile industry is in a consolidation phase on account of buyers’ concentration towards selected suppliers with large market shares and growth potential. Our homes textiles business made us proud when we were accorded the status of a preferred supplier by a leading retailer in the US and were ranked the fourth largest bed sheets supplier to the US, from across the globe. This is a remarkable achievement as the US is one of the biggest and most competitive markets. The consolidated financial performance of the company for fiscal ‘14 was exceptional, given the challenging and volatile environment globally. Our company’s overall revenue grew by 23.1 per cent to Rs. 1,497.91 crores as compared to Rs. 1,217.10 crores in the previous year. Our net profit grew by 274.1 per cent to Rs. 110.39 crores compared to Rs. 29.51 crores in 2012-13”, says Mr. Anil Kumar Jain, Chairman and Managing Director, Indo Count Industries Ltd.
Strategy for building momentum
The current manufacturing capacity of the company is being enhanced to reach 68 million metres of fabric per annum by end-2014 which converts to 17 million sheet sets per annum. The company plans to double its processing capacities in the near future and is evaluating options of expanding its manufacturing base in Maharashtra. The company also has plans to strengthen its horizon to other markets. This will mitigate the risk of leaning heavily on the economy of a single country. Indo Count also plans to add more bedding products, like utility bedding and fashion bedding to its portfolio.
Home Textile Division
The Home Textiles Division of Indo Count continued its fast-paced growth, building momentum with another record-breaking performance for the year. The US is the largest market for the company accounting for a major share in the total exports of home textile products. The company has been consistently engaging with the top retail chains and brands and has built deep and lasting relationship with them. Being closer to its key customers has enabled the company to emerge as a preferred supplier of choice. Indo Count has received several accreditations from prestigious customers in the US.
The company has been consistently building on its capacity and capabilities over the last few years. The Chairman says: “Our integrated facility in Maharashtra comprises of the best-in-class men and machines. The capacity at the plant is being enhanced keeping in view the increasing demand for quality woven cotton bed linen from across the globe. At present the plant has a capacity to produce 45 million meters per annum leading to 12 million bed sheets per annum.”
The plant is capable of executing every part of the process under one roof with various international certifications. It continues to endeavour through sustained R&D to reduce usage of energy per meter. The division uses Benninger machines from Switzerland, Tsudakoma of Japan, Monforts & Osthoff of Germany, Juki of Japan, Mathis from the UK, Zimmer from Austria and Airoli of Italy in its facility to produce quality products. The company’s home textiles are exported to markets like the US, Canada, Brazil, Mexico, France, Germany, Austria, Spain, the UAE, Korea, Japan, Russia, Australia and the UK.
Spinning Division
Spinning is one of the older businesses of the company that commenced production of yarn over two decades back. Over the years, the company has built substantial capacities with two units located at Kolhapur in Maharashtra. Both these units focus on sourcing the best quality of cotton to produce high-quality yarn. These plants have a professionally qualified team with decades of experience. The products are subject to the most stringent quality control measures at every stage from raw material to end product.
The company’s satisfied and delighted customers range from Italy, Turkey, Korea, Japan, China and Hong Kong. It produces 100 per cent combed yarns and knitted grey fabrics in its plants. The units have a capacity to spin 38,500 kgs of yarn per day. Indo Count has Rieter, Schlafhorst, Volkmann TFO, Xorella & Uster, Mayer & CIE and LMW machines and equipment in its spinning units.
Indo Count’s initiatives have included the successful roll out of SAP ERP across all manufacturing facilities. The result of these measures has significantly enhanced integration between operational and financial verticals. It is in the process of extending SAP ERP to distribution centres across the globe.
Rewards and recognitions
Indo Count is the third largest manufacturer and exporter of bed sheets from India. It is the fourth largest supplier of bed sheets from across the globe to the US and the 14th largest supplier of home textiles across the globe to the US. Indo Count has ranked 454th by revenue among the listed companies in India. The company has also received a trophy from Texprocil for the third highest exporter of bed sheets from India for 2012-13.
Indo Count has been consistently investing in research and development over the years to create innovative new products aligned to changing consumer preferences and evolving lifestyles. These new products enhance and augment the range of products of its customers and help them grow their business with more relevant and appealing products. The company has a long-term and global vision to create a world-class infrastructure focussed on quality, not only in its final products, but in an all-encompassing quality solution to its clients.
Bleach safe – Colour fastness achieved with reactive dyes instead of expensive vat dyes thus keeping the product the same colour and shine even after repeated wash.
Fade resist – Developed a unique recipe through which the product achieved a very good fastness to light.
Performance sheet – Using proper yarn and special weave and then finishing in a unique way gives a good performing sheet.
Durawhite – The products remain as bright and white like original even after repeated home laundering.
Moisture management – The product is a blend of cotton and man-made fibre to balance wicking property for better moisture management along with natural property of cotton.
Pro-guard finish – The product will have functional property of repelling oil and water stain as well as releasing soil stain.
Microfresh – It will not allow microbial growth and would remain fresh and odor-free.
Key developments
Indo Count has successfully introduced “Infinity Cotton” created from an opulent blend of few finest cotton in the world in order to get a superior yarn with exceptionally soft hand feel making it one of the world’s best cotton sheets. Its bedding offers luxurious quality of lustre with high level of performance, balancing the temperature between the body and the bed.
The company has developed a sheet which accommodates this attribute and is called ‘Thermal Balance’. Its ‘True Grip’ fits thin to thick 7” to 18” mattress with stitches making the sheet to stay on the mattress. The elastic used in the corners keeps fit on different size of mattress.