With India emerging one of the key global markets for the textile industry, there is a steady influx of overseas textile machinery manufacturers into the country. However, not all those new entrants are able to establish a firm presence in this highly competitive market. Only a select few like ITEMA, the Italian weaving machinery major, could do it. The European brand, with its tradition of almost 200 years and an installed base of over three lakh weaving machines in operation, has made significant inroads into the Indian market in recent times. Arunachala Weaving Mills, located on the outskirts of Coimbatore, is one among the Indian firms that has carved a niche for itself with ITEMA machines.
Arunachala Weaving Mills commenced operation in 2005. Going into details on the gradual development of the company, Mr. V.K. Prabu, its Managing Partner, said: “We started in 2005 with 16 projectile weaving machines and were producing about 25,000 metres per month. In 2006 we added another 8 machines, all second-hand imported ones. We subsequently started our own vendor operation in 2009. However, we wanted to take the next step forward, in terms of technology, capacity addition and increased productivity, and that is when the deal with ITEMA happened.”
It was in 2013 that Arunachala Weaving finalized the deal with ITEMA for a set of 24 wider-width airjet machines. This was a bold move considering the fact that others in the region were still using very conventional, traditional narrow-width projectile machines.
According to Mr. Varghese K. Xavier, Assistant General Manager – Sales, ITEMA India, by taking this bold step, Arunachala Weaving Mills had taken a technological jump and had since grown from strength to strength, with its current monthly production in the region of over 130,000 metres.
It didn’t take long for Mr. Prabu to decide on the next lot of ITEMA machines. “After looking at the performance of the initial lot of 24 machines, we decided to go in for another 24 airjet machines in January 2015,” he said referring to the repeat purchase. In fact, he is so impressed with their performance that he wants to place another order for 48 ITEMA machines, most probably by the end of this year.
Slew of advantages
The decision to go in for ITEMA machines was a well-thought-out one. Mr. Prabu said: “It was not an overnight decision. As someone who belongs to a family associated with the textile industry for long, we were analysing various options. I had heard good things about ITEMA and the prowess of their weaving machines. I had also heard a lot about the high drive, highly energy-efficient motor used in their machine. The technology in the motor is such that it draws only that much energy that is required. There is absolutely no wastage of energy. So, I approached them and they took me to their Italian factory.”
Mr. Prabu also took Indian-made yarn for testing its compatibility with the ITEMA machines. “We tried every possible combination involving different thread counts, fabrics, CVC, etc., and were mighty impressed with the end results, leading to the final purchase decision,” he added.
This was one of the first installations in India of the robust A9500 model airjet weaving machines from ITEMA.
There was no looking back for the CRISIL – SC 2B rated company after buying the first lot of machines. Much impressed, Mr. Prabu remarked: “Our productivity increased. These machines helped in quicker production cycles. Moreover, they also require less manpower, all of which add to their attractiveness.”
According to him, it was not only about increase in productivity but also about increase in value addition. “See, with other machines production of about thread count of 400 will cost around Rs. 150, whereas with this machine a thread count of 1000 costs only around Rs. 400. These versatile machines work with effortless ease with higher thread counts, whether it is 800, 1000, 1100, CVC fabrics, technical textiles, etc.”
Another important factor in Arunachala Weaving Mills going in for ITEMA machines is the fact that it offers the entire “package” unlike many other competing brands. Pointing out to the difference, Mr. Prabu said: “With ITEMA you get all the necessary accessories such as beams, drop wires, frames, etc., along with the weaving machines. This is not the case with certain other brands, wherein you will need to buy different accessories from different vendors. This makes life difficult later on if there were to be issues with different components. With ITEMA, we have a single point contact, which enables quicker resolution of technical issues.”
Further, sharing his views on the prompt technical support factor, Mr. Prabu said: “ITEMA gives consistent technical support services. In our particular case it helps that they have a set up in Coimbatore. However, I know for sure that their technical support team is just a phone call away, for any weaving company in any part of the country, for they have quite a big team of professionals on their rolls. What happens with some other brands is that you have a team of 1 or 2 engineers serving the entire country, which is not the case with ITEMA.”
ITEMA India is an extremely organized company, ready to answer every customer need, from sales to after-sales services, with excellent spare parts, technical support and repair center services. With offices in Mumbai, New Delhi, Ichalkaranji and Coimbatore, more than 50 employees, including the Managing Director, Mr. Updeep Singh, and 35 qualified technicians, ITEMA India is able to promptly support customers all over India.
Another important advantage with ITEMA weaving machines is their weight, which adds to their sturdiness. “These machines (A9500) have a mechanically heavy structure which makes them sturdy and ideally suited for a variety of textiles,” added Mr. Varghese Xavier.
Mr. Prabu also stated that these machines are very user-friendly and require only a few hours of training for an operator to get well versed with their running. Moreover, there are no pollution issues involved with these machines, with the noise levels also being within limits and having soft impact, all of which adds to the long list of advantages.
Mr. Prabu further highlighted the fact that machine rejection rates are almost negligible. “We cater to some of the most prestigious as well as discerning customers, and I take pride in stating that the rejection rates have been next to negligible.”
Strong infrastructure focus
As someone with a passion for energy conservation and a will to experiment, Mr. Prabu ensured that he has sound infrastructure in place in the first place. For example, he had installed harmonic filters that help in energy conservation in Arunachala Weaving Mills.
Delving into this crucial factor, he said: “I have never been shy of trying out new technologies and concepts. We have installed the best-in-class full feature air compressors from a top global brand. One interesting and unique thing that we did was to install energy-efficient aluminium pipelines with the air compressors. Till now people were using about a 6 inch diameter heavy pipeline. This is a bit costly, since you need to have support for the pipeline, plus the installation cost. However, in our case, we installed an 80 mm diameter aluminium pipeline, which requires minimal support and is more energy efficient, since the pressure variation is negligible. This in turn means machine maintenance and defects are minimal.”
This innovation has enabled the company to minimize pressure drop to a level of 0.02%, which is almost zero, resulting in about 2% reduction in energy consumption, which at the end of the day translates into significant savings on energy bills. The company already has access to wind power and is now planning to go in for 30% solar-powered operation in the near future.
Ready for production in 18 days
With sound infrastructure in place, the synchronization of technology vis-à-vis the installation of the ITEMA machines became a much smoother process, so much so that the second lot of 24 machines started production in just 18 days of their installation.
Throwing light on how it was possible, Mr. Prabu elaborated: “Everything was planned to a ‘T’. Everyone involved with the installation, i.e., my team consisting of about 15 technicians and around 20 men involved in the unloading process, plus the 5-member team from ITEMA, worked with clockwork precision to make this incredible achievement possible.”
Arunachala Weaving Mills, which clocked a turnover of Rs. 100 crores last fiscal, is getting ready to instal another set of ITEMA weaving machines. “After installation of ITEMA weaving machines our productivity has jumped by about 25-30%. We have planned to go in for another lot of 48 machines, most probably by this year end,” he said referring to the company’s immediate future plans.
For ITEMA the journey in India till now has been eventful. It has been growing from strength to strength. In the last two years ITEMA India has experienced a period of unprecedented growth, being able to install its technologically advanced weaving machines, both rapier and terry, in important Indian weaving mills. This is no surprise given the company’s robust product portfolio and full commitment to technical support services, factors which have seen the company further consolidate its presence in the Indian market.