Typically, companies introducing products or services before the market is ready for them tend to struggle or eventually shut down. However, Hyderabad-based Kolour Spintek Ltd which began manufacturing spandex-based yarns in 2000, at a time when spandex use was minimal, defied this trend. Today, the company supplies yarns not only to the socks industry but to a wide range of textile applications.
From Socks to Denim: The Growing Applications of Spandex Yarns
“Our yarns initially found use in socks, which accounted for 90% of our sales in the early years. Before spandex, rubber was used for stretch in products like socks. However, rubber had a harsh feel, so it was often wrapped in polyester yarns and used as elastic. Now, spandex is replacing rubber not just in socks but in many other products, as well said Mr. Abhishek Golecha, Director of Kolour Spintek Ltd, in an interview with The Textile Magazine.
Over time, the applications of spandex expanded to t-shirts and women’s leggings. The usage surged when the denim industry began incorporating spandex in jeans. Initially, only 10% of denim jeans contained spandex, but today, that figure is 90%.
Next, spandex was introduced into medical textiles, such as crepe bandages. It’s also used in gloves, replacing rubber, which needed frequent replacements. Spandex gloves, however, can last several years. Now, the company is even receiving inquiries from unexpected sectors, like automobiles and aerospace.
Kolour Spinteks Evolution: From Humble Beginnings to Major Growth
Founded in 2000, Kolour Spintek Ltd started as a small company manufacturing spandex-based yarns when the Indian market for stretch garments was practically non-existent. Despite this, the Golecha family was confident that spandex-based yarns had a promising future due to their comfort and body-fitting properties.
“We initially imported technology for covering machines from South Korea to produce spandex yarns. We began with a production capacity of just 6,000 kg per month, which has now grown to 300 tons per month. The industry started booming as garment brands recognized the benefits of using spandex in all types of clothing, Mr. Golecha added.
“In recent years, the company upgraded its infrastructure by acquiring covering machines from the Swiss companies and texturizing machines from Germany.We believe that to supply consistent and high-quality yarns, it’s crucial to have state-of-the-art machinery, he explained.
Competitively Priced and Innovation-Driven: Kolour Spinteks Approach
“Kolour Spintek now also manufactures a lot of yarns for the seamless knitting industry which was being weighed down by suppliers charging very high prices. By breaking into that space, we have not only reduced their overall costing by more than 20%, we have also managed to make them export competitive,” Mr Golecha stated.
Kolour Spintek produces around 700 products with varying thicknesses of spandex and nylon. Their spandex yarns range from 20 deniers, where 9,000 meters weigh just 20 grams, to 1,120 deniers. For nylon yarn, they offer products from 20 deniers to 300 deniers, with hundreds of combinations in between.
Knowledge & Innovation
“We have a dedicated R&D department, but over the years, we have also learned a great deal from the knowledge shared by foreign fashion brands that use our yarns. This has enabled us to produce innovative yarns and improve existing ones. These brands, with decades of experience, are moving away from sourcing from China and are now sourcing from India, bringing their expertise with them,” Mr. Golecha stated.
Future Plans: Vertical Integration and Expansion into Nylon Yarn Production
Looking ahead, Kolour Spintek plans to start spinning nylon yarns. Currently, they buy Partially Oriented Yarns (POY) and convert them into nylon yarns, but they aim to manufacture Nylon POY to further control the quality of their products.
“The industry we operate in is highly niche and technical, with a significant barrier to entry. It’s not just about technology; it’s about fine-tuning it to meet the demands of discerning brands. As a result, there are very few players in this market. But no company in India offers the range we provide,” he concluded by saying.
