Asian Fabricx Private Limited was established in the year 1974 involved in the export of all kinds of home textile products. The company is headed by Mr. N. R. Venkataachalam, the Ex-Executive Committee Member of Handloom Exports Promotion Council as the Founder-Chairman, and his son Mr. V. Ashok Ram Kumar is the Managing Director of this firm. The company is located in Karur, Tamil Nadu.
A Diverse Product Portfolio
Asian Fabricx Private Limited boasts an extensive product portfolio encompassing a wide range of home textile categories. These include dobby, jacquard, yarn-dyed, embroidered, and printed textiles. Their offerings span across various home essentials, including bedspreads, cushion covers, curtains, shower curtains, kitchen linen, table linen, blankets, throws, chair pads, shopping bags, and more.
Manufacturing infrastructure
The group has a total of 4 world-class vertically integrated manufacturing factories spreading across 100,000 sq. m, producing 70 million pieces of home textiles per annum.
The company facilities have Yarn & Fabric warehouses, warping-weaving, Yarn & Fabric dyeing facilities, soft flow fabric dyeing, CPB fabric dyeing, continuous processes of bleaching-mercerizing-washing, rotary printing-ageing-curing-preshrinking ranges, cut-sew-pack, Quilting & Embroidery, Automated cutting & sewing facilities, pillow making plant, computerized production Hanger systems, FG warehouse, dispatch.
“We have a valuable workforce totaling approximately 4,000 individuals engaged in the aforementioned facilities, with women comprising 60% of our dedicated team. We collaborate with approximately 150 sub-suppliers who partner with us to supply raw materials, fabrics, packing materials, and accessories, among others. This collaboration directly or indirectly supports around 10,000 families involved in the home textiles manufacturing industry. We maintain an ongoing partnership with our raw material suppliers, focusing on innovation, competitiveness, and sustainable materials,” stated Mr. Ashok Ram Kumar.
Since its inception, the company has established a formidable global presence. Its primary international markets include Europe and the USA. Mr. Ashok Ram Kumar enthusiastically stated, “Our exports span across the globe, aligning with the needs and directions of prominent brands.”
Some of the highlights of the company’s recent initiatives and facility upgrades, which include:
- SAP-ERP updates with 2020 Hanna version
- Bio-mass boiler with TFH project
- HTHP yarn dyeing plant
- Shuttle less looms with sizing capacity
- Building a women’s Hostel for accommodating 1,000 workers
- Augmenting wind energy capacity by adding 20 megawatts of windmills
The company has taken rapid strides in Industry 4.0, automation and digitization. According to Mr. Ashok Ram Kumar, the following are the salient features of the process upgrades:
- Implementing integrated IOT in manufacturing processes
- Manufacturing excellence with the help of auto spreading & auto cutting, auto length slitting / hemming / cross cutting-cross hemming, computerized Unit hanger systems, semi-automatic filling machines, Pattern sewing machines, Finished Goods conveyor systems, etc.
- Data digitization / real time data management to track & improve inventory levels, transaction controls, Quality Assurance and boost the efficiencies.
- 3-D Designing Virtual Software for product development, Digital printing, CAD designing and Spectrophotometer for colour measurements.
- Strong traceability established in ERP systems for claimed materials and product level traceability with mass balance from yarn to product.
Sustainability focus
The manufacturing facilities of the company are committed to sustainability, with a goal of achieving 100% renewable energy consumption. They have already made significant strides by harnessing 8 megawatts of solar power and 60 megawatts of wind energy. Additionally, ongoing initiatives aim to reduce greenhouse gas emissions by 2.5% by 2024. Waste water recovery and reuse are prioritized, with Zero-Liquid-Discharge (ZLD) plants achieving a 95% recovery rate. The facilities plan to implement biofuels in their boilers starting in mid-2024.
Asian Fabricx exclusively uses 100% Better Cotton Initiative (BCI) materials and boast a slew of certifications, including GRS, RCS, GOTS, OCS, OEKO-Tex, SA8000, ISO9001, ISO14001, and ISO45001. An Integrated Chemical Management Program is in place, and KAIZEN programs drive continuous improvements in energy, water, carbon, and chemical management.
Waste management practices ensure that 0% of textile manufacturing waste goes to landfills, with an emphasis on up-cycling and reusing LD polyethylene waste. LEAN manufacturing practices, including 6S, 6 Sigma, KANBAN, TLS, ANDON, among others, further underscore the company’s commitment to sustainable and efficient operations.
Advantages galore
When queried on the company’s key strengths, Mr. Venkataachalam mentioned, “As a valued partner we believe in long-term business association and aligning strategy well with the customers. We have a complete and secured sustainable manufacturing to gain customer confidence.“ He also listed down a few other advantages, including:
- Complete and secured sustainable manufacturing to gain customer confidence.
- Expertise in home textiles industry, having a long journey.
- Many products with sustainable materials, innovative blends and variety of techniques
- All ranges of home textiles product category- including different types and sizes – dobby, jacquard, yarn dyed, embroidery, etc.
- Capable to take up special processes, techniques, technology and materials.
- NABL accredited in-house laboratory to secure the quality parameters during development stage itself.
- Dedicated, design and development teams for In-depth design working, analysis & engagement with customer’s design team for collaborative designing.
Ambitious growth plans
The company has seen consistent growth in business over the years. It has grown from around USD 25 million in 2010 to USD 70 million in 2022. Spelling out the company’s future plans, Mr. Ashok Ram Kumar stated, “We have extensive plans to double our existing business to reach around USD 150 million by 2030.”
The company is celebrating its 50th year in 2023. Announcing the commencement of the celebrations Venkataachalam said, ”I am sharing a plenty of happiness and expressing my sincere gratitude to all our esteemed customers, suppliers, wonderful employees and other stakeholders, for having contributed with overall excellence during this 49 years of journey.”
“Asian will continue to deliver happiness in every product that walks into homes with built-in values, innovative, sustainable and responsible solutions,” he said signing off.
