B Sankar: Improving cotton yield through better technology can help optimise cotton production

Perfect Group, based in Ahmedabad, is a leading manufacturer specialising in textile waste recycling machinery, bleached cotton conversion machinery, and machinery for web formation cotton rolls/ZigZag in both semi-automatic and automatic configurations. The company also produces blow room and carding sliver formation machinery, overhead travelling cleaners for various textile machinery, and roll shop and card room service equipment for spinning machinery. B Sankar, General Manager (Technical & Development), Perfect Engineering Corporation, in this interview, shares the tips on technological modernisation for improving the Indian T&A industry’s global competitiveness.

How is Perfect Engineering serving customers in the textile & apparel (T&A) segment?

Our mission is to deliver cutting-edge technology and high-quality products that enhance production efficiency and sustainability for T&A manufacturers. Through our focus on innovation and customer-centric solutions, we have established ourselves as a trusted partner in the industry. We are committed to developing indigenous “Make in India” technology, which is an important aspect of our growth.

As manufacturers of textile waste recycling machinery in India, we contribute significantly to sustainability and the circular economy within the T&A segment. Our impact can be seen in the following areas:

• Innovative recycling solutions: We provide advanced machinery that efficiently recycles textile waste into new fibres which includes synthetic and cotton blend yarn, weaving waste, fabric clip waste, and non-woven trim waste. Additionally, our cotton recovery plant effectively recycles dropping cotton waste from blow rooms and carding machinery, reducing the textile industry’s environmental footprint.
• Supporting sustainable practices: Our recycling machinery enables textile manufacturers to reduce waste, reuse materials, and adopt sustainable practices in their operations.
• Creating job opportunities: The establishment of recycling facilities creates job opportunities, benefiting local economies and communities.
• Collaborating with brands: We partner with fashion brands and retailers to implement textile recycling programs and ensure waste is managed and recycled responsibly.
• Educating stakeholders: We actively raise awareness about the importance of textile recycling and its economic and environmental benefits.

By focusing on these areas, we are playing a key role in transforming the textile industry into a more sustainable and eco-friendly sector.

What is your perspective on the current state of the Indian T&A and textile machinery & accessories (TMA) industries?

The Indian T&A industry is currently witnessing significant growth and transformation, driven by increased domestic demand and export opportunities. The TMA industry is evolving at a rapid pace, with advancements in automation and technology playing a key role in meeting the industry’s evolving needs. However, challenges such as supply chain disruptions, raw material price fluctuations, and geopolitical tensions (e.g., the political crisis in Bangladesh) continue to present obstacles.

The geopolitical uncertainty has created a demand-supply gap, especially as many Indian spinners have reduced exports to Bangladesh, which is traditionally a major importer of Indian cotton yarn. This shift presents an opportunity for India to ramp up its garment manufacturing and finishing capabilities. However, challenges persist, including limited infrastructure and the lack of advanced technology, especially in the garment sector. The Indian government needs to provide stronger support for new projects in garment manufacturing and finishing to strengthen this critical part of the industry.

With the Indian textile sector targeting $350 billion by 2030, what challenges or barriers could impede this growth?

Reaching the ambitious $350 billion target by 2030 comes with several hurdles:

• Geopolitical developments: Trade policy changes and geopolitical tensions can disrupt supply chains and export markets.
• High raw material costs: Rising prices of cotton and man-made fibres (MMFs) can escalate production costs, reducing competitiveness.
• Policy and regulatory challenges: Frequent changes in policies and a complex regulatory environment create uncertainty for businesses.
• Technological gaps: Lack of advanced machinery and modern technologies could hinder growth in terms of both productivity and product quality.
• Environmental concerns: Stringent environmental regulations regarding waste and pollution pose challenges.
• Skilled labour shortage: A shortage of skilled labor can impact production quality and efficiency.
• Market access: Barriers to international trade and tariffs could limit access to lucrative global markets.
• Changing consumer preferences: The shift towards sustainability and comfort wear means businesses need to adapt their product offerings.
• E-Commerce competition: The rise of e-commerce and startups creates new competitive pressures.
• Investment needs: Significant investment is needed to modernise infrastructure, improve manufacturing capacity, and adopt advanced technologies.

Tackling these challenges will require coordinated efforts from both industry stakeholders and policymakers to ensure sustainable and long-term growth.

How important is technological modernisation for improving the Indian T&A industry’s global competitiveness? What steps can be taken to accelerate technology adoption?

Technological modernisation is critical for enhancing the global competitiveness of the Indian T&A industry. The adoption of advanced machinery, automation, and digital technologies can significantly improve productivity, reduce waste, and ensure high-quality outputs.

To accelerate technology adoption, stakeholders should:

• Invest in R&D: Companies should invest in research and development to innovate new solutions and optimise existing technologies.
• Collaborate with tech providers: Partnerships with technology providers will help the industry stay ahead of technological trends.
• Leverage government incentives: The Indian government should offer incentives and support programs to facilitate the adoption of cutting-edge technologies.

Particularly in the garment sector, India needs to invest in new manufacturing facilities and adopt state-of-the-art automated technologies to better balance the production capacities in spinning, weaving, and garmenting. Additionally, improving cotton yield through better agricultural practices and technology can help optimise cotton production.

What opportunities do you foresee for your company as the Indian T&A industry moves towards its 2030 target?

As the Indian T&A industry aims for its 2030 target, we see several opportunities for growth. We anticipate increased demand for our textile waste recycling and surgical cotton conversion machinery. Our innovative hard waste pre & post recycling solutions, featuring specialised technology for opening waste into high-quality fibres, are poised to become an ideal solution for the industry.

Our focus on sustainability aligns with the industry’s goals, positioning us as a reliable partner for T&A manufacturers. Additionally, we plan to expand our product portfolio, exploring new markets and strengthening our presence in the non-woven sector. Our recent advancements, such as the Fully Automated Cot Grinding Machine (ACG600), are already receiving positive feedback from users.

With an expanded workspace and state-of-the-art machinery from the USA and Japan, we are prepared to meet growing demand, particularly for textile waste recycling solutions. In the near future, we plan to set up an in-house pilot plant to process customer samples and provide them with high-quality recycled fibres for evaluation.

How is your company supporting T&A makers in their sustainability efforts?

We are committed to helping T&A makers achieve their sustainability goals by providing machinery that enables the efficient recycling of textile waste, reducing environmental impact. Our innovative hard waste recycling solution, featuring automation and larger storage bins, ensures high-quality fibre production with excellent spin ability, whether 100% cotton or blended with synthetic fibres.

Furthermore, pre- and post-consumer fabric clips, which are typically used in low-end textiles, can now be recycled for use in wearable clothing. This technology allows spinners to save on conversion costs, while our efforts to recover well cotton from dropping cotton waste during the blow room and carding processes help maximise cotton realisation. These innovations contribute to reducing the environmental impact of textile production and support sustainable practices in the industry.

What measures should the government take to strengthen the Indian T&A and TMA industries?

To strengthen the Indian T&A and TMA industries, the government should focus on the following:

• Infrastructure development: Invest in better infrastructure for the weaving, garmenting, and finishing sectors to boost India’s competitive edge.
• Financial incentives for technology: Offer incentives to encourage the adoption of modern technologies in textile manufacturing.
• Policy support: Streamline regulations to reduce complexity and uncertainty, particularly for the garment and finishing sectors.
• Support for cotton farmers and ginners: Provide incentives for farmers and ginners to improve cotton quality and production yield.
• Skill development: Invest in skill development programs and industry-academia partnerships to bridge the labor skill gap and drive innovation.
• Technical education reforms: Revise academic curricula to align with industry needs and ensure a skilled workforce.

Such measures would help position India as a global leader in the textile and apparel sector by 2030.

What are the emerging trends in the textile machinery & accessories industry?

Emerging trends in the TMA industry include:

• Automation: Increased automation to enhance productivity and reduce labor costs.
• IoT and AI integration: Use of Internet of Things (IoT) and artificial intelligence (AI) for predictive maintenance and operational optimisation.
• Eco-friendly machinery: Growing focus on the development of machinery that reduces environmental impact and enhances sustainability.
• Customisation and modularity: Rising demand for customised and modular machinery to meet specific customer requirements and increase operational flexibility.

What are your growth plans for the next two years?

In the next two years, we plan to:

• Expand manufacturing capabilities: We will increase our manufacturing capacity to meet rising demand, especially for textile waste recycling machinery.
• Invest in R&D: Our goal is to develop new solutions and improve existing technologies.
• Explore new markets: We will expand our reach both domestically and internationally to increase our market share.
• Enhance customer relationships: We aim to provide exceptional service and support, strengthening our position as a trusted partner in the T&A industry.

Our recent tripling of manufacturing capacity and addition of advanced engineering machinery will help us meet the growing demand, particularly for textile waste recycling machinery. Additionally, we plan to set up an in-house pilot plant for recycling hard waste to offer customised samples for customers, aiding in their decision-making process.