By Arun Rao
Omax Cotspin Pvt Ltd, a name synonymous with sustainability in the textile industry, stands apart as a manufacturer and exporter of exclusively sustainable cotton yarns and fabrics. Eschewing conventional production methods, the company prioritizes traceability and ethical sourcing while holding numerous certifications that validate its commitment to eco-friendly practices. In an exclusive interview with The Textile Magazine, Mr. Jayesh Patel, Director of Omax Cotspin, elaborates on the company’s journey, sustainable innovations, and forward-thinking strategies that have driven its success.
A Legacy of Sustainability and Traceability
Omax Cotspin’s unique market proposition is its sole focus on sustainable cotton yarns and fabrics. The company has built a reputation for producing yarn that complies with various globally recognized certifications such as BCI (Better Cotton Initiative), IC1, IC2, NPOP, and NOP organic certifications. Omax Cotspin also boasts Fairtrade certification and is part of the Primark Sustainable Cotton Program, ensuring the highest levels of ethical and environmental standards.
In addition to these impressive credentials, Omax Cotspin offers a high level of product traceability, allowing customers to trace the lifecycle of their yarns from farm to fashion. “To bolster our sustainability credentials, we have invested in two windmills and a solar energy project. By the end of September, a mega solar project will be operational, ensuring that 100% of our electricity needs are met through renewable energy sources,”Mr. Jayesh Patel explains.
Technological Achievements and Productivity Milestones
Omax Cotspin’s commitment to excellence is reflected in its impressive productivity metrics. When operations began, while other mills typically achieved a production rate of 190 grams of yarn per spindle, Omax Cotspin surpassed industry norms by reaching 260 grams per spindle per day. This extraordinary achievement was made possible due to the expert guidance of consultant Mr. CK Swamy, along with the use of high quality Shankar 6 cotton, known for its consistent high quality.
The company’s foundation is deeply rooted in tradition, with Mr. Jayesh Patel representing the third generation of a family whose cotton trading roots stretch back decades. The family’s journey began with cotton procurement and ginning in the town of Dhrangadhra in the cotton growing Saurashtra region of Gujarat, eventually leading to the establishment of their own ginning factory in 1987. With the vision to move beyond trading and into manufacturing, the Patels decided to enter the spinning industry in 2012, marking the start of Omax Cotspin’s journey.
Strategic Expansion and Integration
The first major milestone in Omax Cotspin’s history came when Gujarat introduced its first Textile Policy. Omax Cotspin became the first company to benefit from this policy, enabling them to set up a 25,000 spindle spinning mill alongside their existing ginning unit. “We sourced our machinery from industry leaders such as blow room to ring frame from LMW and winding machines are of Murata, ensuring that automation and efficiency were at the core of our operations. Notably, we prioritized women in our workforce, and today, 70% of our staff are women, whom we provide with transport facilities from their homes and villages,” shares Mr. Patel.
Building on this initial success, Omax Cotspin expanded further in 2016 with a second 25,000-spindle mill, followed by a 550-rotor open-end spinning unit. This cutting-edge facility includes Autocoro 9 machines from Saurer and blow room and carding machinery from Trützschler. Equipped with a state-of-the-art laboratory featuring Uster testing equipment, the company ensures that its quality control remains top-notch.
The third spinning unit, added later, further increased capacity, bringing the company’s combined ring and open-end spinning output to 55-60 tons per day. To diversify its operations, Omax also added a knitting unit and a women’s innerwear and apparel stitching unit. “We may be the only textile mill in Gujarat with an integrated setup, which includes a cotton gin, spinning mill, knitting unit, and garment manufacturing unit, all under one roof. The only segment we currently lack is fabric processing, which we plan to add soon,” reveals Mr. Patel.
Global Reach and Brand Nominations
Omax Cotspin’s reputation for quality has garnered the attention of international brands. The company exports 80% of its yarn, with a significant portion going to Bangladesh, largely due to nominations from global brands that manufacture garments in the region. “Omax Cotspin has been nominated by renowned brands like H&M, C&A, TESCO, Primark, Decathlon, and Zara. The rise in cotton prices has led many brands to explore blended cotton-polyester yarns, and we’ve adapted by introducing these blends to our product lineup,” observes Mr. Patel.
In addition to Bangladesh, Omax exports its products to markets in Vietnam, China, Sri Lanka, and select European countries, further strengthening its global footprint.
Corporate Social Responsibility
Omax Cotspin takes its corporate social responsibility seriously, investing heavily in the well-being of its workforce and the local community. The company provides meals—ranging from breakfast to dinner—at highly subsidized rates for all staff and workers. Additionally, Omax manages a hospital offering affordable healthcare services to both its workers and the residents of Dhrangadhra. The company’s commitment to education is evident through its management of a school in their native village, the renovation of a government school near the mill, and plans to open a new school in the near future.
Industry Challenges and Cotton Sourcing
Mr. Patel also highlighted the pressing need for government intervention to improve cotton yields in India. “India’s average cotton yield stands at 450 kgs per hectare, compared to 850 kgs in Pakistan, 1,000 kgs in the USA, and 1,850 kgs in Brazil and 1,900 kgs in China and Australia. There is an urgent need for the government to assist farmers in improving these yields,” he stated.
The rising cost of Indian cotton has led many companies, including Omax, to consider importing cotton to remain competitive. “Despite the 11% import duty, we expect around 30-40 lakh cotton bales to be imported in 2024. We’ve already seen 9-10 lakh bales brought in. Indian cotton offers an average realization of 70-71%, whereas US cotton provides 78%, making imports an attractive option,” Mr. Patel explains.
The Road Ahead: A Vision for Sustainability and Innovation
As Omax Cotspin looks to the future, the company remains committed to maintaining its leadership in sustainable yarn production. “The key to our success lies in taking proactive steps—whether it’s producing certified sustainable yarns, using renewable energy, or staying ahead of market trends. We’ve always made the right moves at the right time, and that’s what has set us apart,” concludes Mr. Patel.
