The company is the first in the world to launch fully automated servo-controlled twin cots grinding machine. As Devarsh Shah, Director, Sabar Group, explains, this will make a big difference in the textile industry
At ITMA 2019, Ahmedabad-based Sabar Group became the first company in the world to launch a fully automated servo-controlled twin cots grinding machine named ‘Servocot’ as against hydraulically operated machines which they have been supplying since inception. The automated machine is equipped with a servo drive and so helps achieve a higher level of accuracy while grinding cots under any temperature conditions.
“For example, in Uzbekistan, the temperature in summer is 35 degrees Celsius and in winter it is -15 degrees Celsius. In an oil-based hydraulically operated machine, there will be a difference in oil density in both summer and winter, which can lead to variation in pressure in the hydraulically operated machine, which then has to be manually controlled,” explains Devarsh Shah, Director, Sabar Group.
“While, in the Servocot, there is no such challenge and so accuracy can be attained under any temperature conditions. The new technology also controls the cots diameter, whereby any cots below or beyond tolerance limit of 0.3 mm will be automatically rejected. The biggest benefit for spinning mills is that they now will get a uniform batch,” he elaborates. In the hydraulically operated machines, the machine operators have to set the parameters before undertaking cots grinding, while in the new model it can be operated even without skilled labour and the parameters can be set through a panel board.
The new technology is also a time-saver as machine downtimes to grind cots has been reduced. More importantly, there is no maintenance needed for the servo-driven machines, which is one of the biggest benefits of the technology. The company has already sold 10 units of the Servocot since the launch at ITMA 2019. With the shift to automation picking pace among spinners, Sabar Group expects that there will be good demand for these machines in the future.
An enviable track record
Sabar Group was established in 1961 by the great grandfather of Devarsh Shah, K.D. Marfatia, and at that time the unit manufactured around 30 lathe machines per month under the brand name ‘Tiger’. Even in that period, these lathe machines were exported to the developed countries of Europe. In 1969, the company developed, manufactured and launched the first cots grinding machine for the textile spinning industry. Since then, Sabar Group has been producing these machines as well as other roll shop machines. The roll shop machines also include cots mounting-demounting machine, UV treatment machine, top roller greasing machine, spindle lubricating machine, clearer roller cleaning machine, bobbin roving end opening machine, spindle centering device, etc.
“We offer the whole maintenance package of machines required by a spinning mill all of which total to 10 machines, which we call one set. Normally most mills purchase the whole set. Till date, we have sold 3,000 such sets in around 39 countries,” Shah informs. The company has two manufacturing facilities to manufacture roll shop machines and together these two units can produce around 70 sets per annum with 50+ employees on board. Sabar Group is headed by Devarsh’s father, D.H. Shah, while his brother Abhishek looks after domestic sales. In 2018, the company celebrated their golden jubilee of being in the textile business. “We have always pursued excellence in manufacturing, which has led us to offering the best quality machines. During the past 50 years, based on feedback from customers, we have continuously improved the technology and quality of all our machines to get an accuracy of 0.01 mm in our cots grinding machines,” Shah states.
Quality matters
Explaining the importance of accuracy, he says: “In the top roller of ring frame or speed frame machines, there is a LH and RH cot. When the cot is grinded, the grinding has to be similar on both sides and so accuracy is given the highest priority.” “This is something we have achieved at 0.01 mm and which does not change even in machines sold 30 years ago. If the cots are not grinded with accuracy, then the final yarn will not be produced as per the desired quality,” he adds. The company counts leading textile mills in India as their loyal customers which include Vardhman, Trident, Reliance, Arvind, Sutlej, SEL Manufacturing, RSWM, Winsome and Raymond, to name a few. Its major exports are to Bangladesh, Pakistan, Vietnam, Mexico, Indonesia, Thailand and Uzbekistan.
At ITMA 2019, they bagged orders for the first time from a US-based spinning mill. According to Shah, till 2014, their main focus was on the domestic market which accounted for 65% of local business with exports accounting for the rest. After he joined the company, Shah realised that there was a lot of scope in increasing exports, which has now resulted in exports accounting for 65% of the revenue, with domestic sales notching up 35%. However, domestic sales also continued to grow year-on-year in the same period. “There are only 4-5 companies in the world that manufacture the whole range of roll shop machines like us. In the previous years, many companies tried their hand, but failed as they could not offer the accuracy that is needed by the mills,” he states.
“After having burnt their hands, spinning mills now only source these roll shop machines from established companies,” he adds, while touching on the topic of competition. In terms of after-sales services, Sabar Group has stationed service engineers in the southern, northern and western regions of India. They have also stationed service engineers in other countries like Vietnam and Bangladesh, as their installation base is very high in those two countries. The company is also in the process of developing a new maintenance machine for the spinning industry and hopes to launch it by mid-2020.
Positive prediction
Shah foresees a bright future for Indian spinning mills since they have access to good quality home-grown cotton and expects that the current slowdown in the industry will surely not last long. “I expect the turnaround to begin from mid-2020,” he says. He also expects the Indian spinning industry to grow well in the next few years, particularly in Maharashtra – a phase similar to that seen in Gujarat since 2012, as Maharashtra has announced a slew of policies and incentives for the textile industry. “In case of other countries, the spinning industry will continue to grow in countries like Bangladesh, Vietnam, Indonesia and Uzbekistan,” he says.