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First Thies iMaster H2O dyeing units in India
Aug '11
India's domestic textiles and clothing market is set to soar in the next few years, and looking to grow successfully with it is Kothari Processors, based in Sankrail, a short distance from West Bengal's capital, Kolkata.

The three owners who formed the company in 2006 – Sanjay Sarda, Manish Periwal and Harimohan Kothari – have been friends since their school days.

“We all had different skill-sets to bring to the business, so it was a natural team up,” says Mr Sarda; and had been running a knitting business since 1998. He teamed up with Harimohan Kothari who was already manufacturing innerwear, to form Kothari Processors Private Ltd – starting dyeing operations in July 2007.

“There was a real demand in this region, so it made perfect sense,” Mr Sarda explains. “Our focus is purely on the domestic market, and the uncertainty level is much lower than for other operations which have to constantly chase contracts with the international brands. This situation is almost a luxury, and our output is based primarily on children's wear and inner wear. Most of our customers are supplying value products and we don't service luxury or niche markets.”

Around 80% of the company's output is pure cotton, with the remainder being cotton blends with polyester, viscose or Lycra. Kothari's own garment making-up plant accounts for around 15% of the finished fabric output.

The installation of an ecoMaster fabric dyeing unit in 2010 began the company's relationship with Thies, and also expanded its monthly output of finished fabric to 300 tons.

The successful service of this machine was one of the key reasons the company opted to install the as-yet market untested iMaster H2O units.

There was, however, a second reason. Considered almost a fourth member of the Kothari Processors management team is Manash Dey, Senior Sales Manager for Voltas, which only recently became the agent for Thies GmbH & Co in India.

“Most of the decisions we've arrived at over the past thirteen years have been very logically influenced by Mister Dey,” says Mr Sarda. “There was a trust established immediately and in one way, rather than having a machinery agent, it's as if we have a consultant.”

The iMaster H2O units – a double chamber version and a single chamber machine – have been running successfully since February 2011.

“The first advantage of the Thies machines in general, compared to our older machines, is that we are carrying out continuous dyeing with a much lower liquor ratio,” said Mr Sarda, adding that the Thies ratio is 1:4 compared to around 1:6 for the other machines. “Obviously this translates into savings in the use of dyestuffs and chemicals, but it's an advantage we have yet to calculate.”

“The real immediate benefit we've experienced with the iMaster H2O, though, is in the quality,” adds Dyehouse Manager SK Jha. “For knitted fabrics we're achieving much better dimensional stability as a result of the low pulling height and the influence of the nozzle leading to much better fabric relaxation inside the machine. This for us, is the real plus point of this new machine.”

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