Pradeep Dodhia
Managing Director Dodhia Synthetics Limited
Our vision has been continuous innovation
India-based Dodhia Synthetics Limited specialises in manufacturing of recycled polyester dope dyed, dyed yarn, space dyed and specialty yarn. Having established firmly in the domestic market, there has been a paradigm shift in the group’s vision since last six years to diversify into international markets. This has led the group to foray into export of specialised yarns. The group has been successful in establishing itself in European countries, and it is now targeting the US and Canada. Speaking to Fibre2Fashion, Managing Director Pradeep Dodhia discusses synthetic yarn production and the company’s future plans.
What are the advantages of using synthetic yarn in textile production?
Durability: Synthetic yarns such as polyester and nylon have greater tensile strength compared to natural fibres, making them more durable and long-lasting.
Resistance to wrinkles: Synthetic yarns can hold their shape and resist wrinkling, unlike natural fibres like cotton.
Versatility: Synthetic yarns can be customised to create a wide range of textures and patterns, making them suitable for various applications and styles.
Cost-effective: Synthetic yarns are generally less expensive than natural fibres, especially in large-scale production.
Low moisture absorption: Synthetic yarns absorb less moisture than natural fibres, making them more resistant to mildew and mould.
Easy maintenance: Synthetic yarns can be easily washed and dried, and require less care and attention than natural fibres.
Availability: Synthetic fibres can be produced in large quantities, ensuring a steady supply for textile manufacturers.
How has the demand for dyed yarn evolved in the recent years?
The demand for dyed yarn has been increasing steadily in recent years, particularly in the textile and fashion industries. Consumers are increasingly seeking unique and vibrant colours and patterns in their clothing and home furnishings, and dyed yarn offers manufacturers a wide range of customisation options to meet these demands. Additionally, advancements in dyeing technologies and sustainable dyeing processes have also contributed to the growing demand for dyed yarn.
According to market research, the global dyed yarn market was valued at around $9.5 billion in 2020, and is expected to grow at a compound annual growth rate of around 4.5 per cent.
What role does sustainability play in your production processes and product development?
Sustainability is an important consideration for many businesses today. Sustainable practices can help to reduce environmental impact, conserve resources and promote a healthier future for all. Many companies are looking for ways to reduce waste, use renewable materials, and lower energy consumption in their operations. At Dodhia group, the belief is that ‘waste can indeed give way to wealth’. In keeping with the group’s credo of Quality, Innovation and Possibility, we recently launched Petopoly – a planet friendly yarn, that reduces dependence on non-renewable natural resources and helps environment by keeping bottles and plastics out of landfills and oceans.
How do you plan to remain competitive in the rapidly evolving textile industry?
We have developed an infrastructure that can cater to any customer product requirements in value-added polyester filament yarn. All processes are in-house and we can develop as per required market demand.
Our biggest advantage is flat organisation. Management is connected to the market and customers directly resulting in very fast decision making. Also, we are involved in constant product innovation giving very niche solutions to our customer requirements.
Consumers are increasingly concerned about the environmental impact of the products they buy, so we always prioritise sustainable practices such as producing POY from PET bottles, reducing waste, and improving energy efficiency. We have also introduced lean manufacturing and kaizen across all our manufacturing units. It has helped in waste reduction, increasing efficiency, reducing cost, and improving lead time.
What is the company’s current production capacity and are there any plans for expansion?
Cotton sizing – We have 10 machines installed and work on job basis.
What are the major challenges faced by the synthetic yarn industry in India, and how does your company address these challenges?
Fluctuating raw material prices: The prices of raw materials used in the production of synthetic yarn such as petroleum and polyester fluctuate frequently, which can negatively impact the profitability of the industry.
Increasing competition: Synthetic yarn manufacturers in India are facing strong competition from producers in other countries such as China and Vietnam.
Lack of skilled labour: The textile yarn industry requires skilled labour, but there is a shortage of trained professionals. Also, lot of start-ups and IT companies are attracting skilled labour away from manufacturing industries.
What are the latest advancements in synthetic yarn manufacturing processes?
Recycled synthetic yarns: Many manufacturers have started focusing on sustainable production. With technology advancement, it is now possible to produce yarn/fibre from many recycled materials like PET bottle, PET lump waste etc.
Biodegradable synthetic yarns: With the growing concerns about environmental sustainability, researchers and manufacturers are focused on producing synthetic yarns that are biodegradable. Soy, corn starch, and PLA are some of the biodegradable polymers that are being used for synthetic yarns.
Integration of smart materials: Smart materials such as temperature-sensitive and light-sensitive, fire retardant and anti-microbial fibres are being integrated into synthetic yarns for various applications in textiles, and customers are paying premium for it.
What are the key factors driving the growth of the synthetic yarn market and how does the company leverage these factors to expand its market share?
The key factors driving the growth of the synthetic yarn market include increasing demand for textile and apparel products, rising population and urbanisation, and growing preference for eco-friendly and sustainable textiles. In order to expand the market share, we are constantly investing in research and development to create innovative and sustainable synthetic polyester yarn, expanding its distribution channels and partnerships, and adopting marketing strategies to communicate its unique selling proposition. Additionally, through lean manufacturing and kaizen implementation, we also focus on improving our production efficiency and cost-effectiveness to offer competitive pricing and attract price-sensitive customers.
How does the company balance the need for product innovation with the need to maintain cost competitiveness?
Our vision has been continuous innovation and we have been achieving this by constantly improving technical and technological capabilities in order to create niche products with low cost and attractive features.
Also, as mentioned earlier, lean manufacturing and kaizen practices have helped us identify wasteful processes and improve efficiencies in our operations, resulting in cost savings and faster lead-time for new products.
What are the company’s plans for expanding its presence in the global synthetic yarn market, and what are the key markets it is targeting?
Keeping in mind the growing demand for sustainable yarns, we are planning to further expand in recycling yarn production and add more products to our current portfolio. There is ever increasing demand for synthetics yarn from Europe, North America, as well as emerging markets with a growing textile industry in countries like Vietnam Bangladesh etc. Even the demand for sustainable yarn for domestic market will increase once the local brands demand for it.
Published on: 12/06/2023
DISCLAIMER: All views and opinions expressed in this column are solely of the interviewee, and they do not reflect in any way the opinion of Fibre2Fashion.com.
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