KARL MAYER Textilmaschinenfabrik GmbH
Bühlstrasse 25
63179 Obertshausen
Germany




Blueprint for efficient denim production in India - KARL MAYER Textilmaschinenfabrik GmbH

KARL MAYER’s Warp Preparation Business Unit is continuing along its successful path in India. At the end of 2012, this German textile machinery manufacturer received an order from Arvind to deliver a denim processing machine to its factory in Ahmedabad. The Indig-O-Matic slasher/dyeing line went into operation in October at this company, which is one of the biggest fabric and apparel producers in India. Since then, the machine has been operating efficiently – much to the delight of the company. “This new machine enables us to react flexibly and quickly to the changing demands of the market. It is also extremely productive,” explains the managing director, Susheel Kaul. He bought the Indig-O-Matic as a double-sheet version, enabling production to be almost doubled for the same space requirements. The dimensions of the dyeing zone are the same as in the conventional version and only the number of beam creels and beaming machines has to be doubled. Another feature of the new Indig-O-Matic operating in Arvind’s factory is that the dye baths are equipped for nitrogen dyeing. Susheel Kaul explains that he can achieve dyeing results that he has never been able to achieve before. “There is also less environmental pollution with the nitrogen dyeing process. This aspect is becoming increasingly important here, too,” he went on to say. With the delivery of the Indig-O-Matic to Arvind, KARL MAYER’s dyeing machine with integrated nitrogen technology celebrated its Indian premiere. The advantages of nitrogen technology can also be exploited in India now. By using nitrogen, the phase transition of the dye onto the fibre from a reduced to an oxidised state into the ambient air can now be slowed down. Since only liquid substances can be absorbed by the yarn, the reaction time of the dye can be extended. The dye is fixed better onto the cotton fibre and the core of the yarn remains undyed, as with the ring dyeing process typically used for denim. This results in optimum dye- and rubfastness for the same high weaving efficiency. The nitrogen technology also enables the amount of textile auxiliaries used in the machine to be reduced – which makes an important contribution to the increasingly important issues of environmental protection and sustainability. However, KARL MAYER’s new Indig-O-Matic machine operating in Arvind’s factory is not only the first denim machine with nitrogen dyeing technology in India, it is also the first indigo dyeing machine that can process the fine yarns used to produce cotton shirting. Here too, this innovative warp preparation technology is supporting the move away from using jeans fabric to produce typical, hard-wearing workwear and towards using it to produce more stylish denim fashions. Arvind Limited was founded in 1931 as a family run company. The company started with the fully integrated production of high-end, superfine fabrics and became extremely successful in this field. As the years went by, Arvind was able to expand its production capacity continuously and increase its exports all over the world. One clear strategy was behind the company’s constant expansion: a combination of state-of-the-art production technology and innovative product development. Nowadays, this manufacturing giant operates in a variety of segments, including denim, woven and knitted fabric production, advanced materials, Arvind Brands, retail, and the Mega Mart and Arvind Store department stores. The company began producing denim at the end of the eighties. This early start marked Arvind out as one of the pioneers in the Indian denim business. In the years that followed, this broadly based textile specialist, which has a current annual capacity of more than 110 million metres, became one of the world’s leading denim producers. Its ranges include selvedge denim, woven fabrics with names incorporated into the selvedge, and stretch selvedge fabrics, as well as concept lines, such as indigo voile and denim fabrics made from hand-spun yarns. In addition to conventional cotton, the main fibres processed include jute, silk and linen yarns. Natural indigo and vegetable dyes are used to produce the dyestuffs. Internationally renowned brands, such as Wrangler and Levi, are among Arvind’s clients.