Automation: Weaving Success

With global buyers placing greater emphasis on speed, traceability, and sustainability, automation has shifted from being a choice to a necessity. Divya Shetty analyses the readiness of companies in adopting automation.

In the heart of India’s textile industry, machines are not just humming—they’re thinking, learning, and transforming production floors. Automation is rapidly redefining the contours of the textile and apparel industry, emerging as a cornerstone of competitiveness, sustainability, and workforce transformation. Companies are increasingly turning to automation not only to enhance productivity and precision but also to meet the rising global demand for cost-efficient, high-quality products. By integrating smart machinery and digital tools across textile manufacturing, garmenting, knitting, dyeing, and packaging, businesses are streamlining processes, reducing human error, and ensuring consistent quality standards aligned with international benchmarks.

Equally significant is the sustainability advantage. Automated dyeing and finishing, for instance, minimise water and chemical use, lowering environmental impact while improving resource efficiency. Meanwhile, workforce transformation is unfolding as repetitive, labour-intensive tasks give way to technology-driven roles, necessitating upskilling and fostering new career opportunities in machine handling, data analysis, and process optimisation. In this evolving landscape, automation is not just a choice but a decisive factor shaping the industry’s future.

Driving the shift to automation

Automation in India’s textile industry is being driven by rising global demand for cost competitiveness, the need for consistent quality, and sustainability imperatives. Smart machinery, robotics, and digital solutions are increasingly adopted to reduce manual errors, improve efficiency, and conserve resources. Growing emphasis on waterless dyeing, energy-efficient operations, and compliance with international standards is further accelerating the industry’s shift towards automation-led transformation.

According to Ajay Patodia, CFO, Dollar Industries, “The most notable automation advancements in his company has occurred in knitting, dyeing, cutting, and packaging. This transition was fuelled by the need for greater precision, faster turnaround times, and consistent product quality. Increasing consumer expectations and the demand for compliance with international standards also played a major role. To stay competitive in the fast-evolving hosiery and innerwear market, we recognised the need to modernise our manufacturing processes and build a more agile, future-ready infrastructure.”

In India, the garment sector has quickly adopted automation, not only in quality control but also across several other segments. “Over the last few years, we’ve integrated automation in weaving, dyeing, and quality control processes. The shift was driven by two key needs—maintaining consistent product quality across large orders and meeting shorter delivery timelines for domestic and international clients. This also helps us handle complex designs with precision that manual processes could take far longer to achieve of,” adds, Vishal Pacheriwal, Director of Parnika India.

Table 1: Key innovations and players

Source: Texpertise Network (Messe Frankfurt)

Sector	Key insight	Notable innovation or company
Textile production	Robotics, AI, data-driven control boosting efficiency & flexibility	Adotc, Dürkopp Adler, Mikkelsen Innovation
Textile care and laundries	Smart, automated operations optimising resources and reducing waste	Advanced sensor systems; up to 90% automation
Textile recycling	AI for sorting garment components to enable scalable recycling	Valvan’s Trimclean technology

At Madame, we’ve seen the most significant automation in cutting, stitching assistance, fabric finishing, and inventory management. The shift was driven by the need for precision, speed, and consistency – particularly as fashion cycles shorten and customer expectations for quality and timely delivery rise. Automation has allowed us to reduce manual errors, optimise fabric utilisation, and streamline the overall production workflow,” adds Akhil Jain, CEO and MD, MADAME.

Automation also enables better monitoring and control, helping us track and reduce waste, optimise resource utilisation, and move toward circular production models.

Ajay Patodia, CFO, Dollar Industries

Efficiency and market edge

With the adoption of automation, the gains have been significant. By integrating automation into the production workflows, the companies have increased throughput and minimised manual errors, which previously impacted both quality and timelines.

According to Kapil Pathare, Deputy Managing Director, VIP Clothing, “One of the key benefits has been the improved accuracy in production planning. With systems that are digitally connected, we now have better visibility into inventory, raw material usage, and production timelines. This enables proactive decision-making and tighter control over production costs. In a competitive and price-sensitive market like ours, such efficiency is vital; it allows us to retain cost leadership without compromising on the product.”

In dyeing and finishing, automated systems have improved colour consistency and reduced wastage. “Similarly, automated cutting machines have streamlined fabric utilisation. These improvements have not only reduced per-unit production costs but have also enabled us to meet market demands more quickly, which is critical in a fast-moving consumer segment like ours,” opines Patodia.

Some government initiatives for MSMEs and textile modernisation have been helpful, but the textile sector still needs more accessible financing for high-tech machinery. Subsidies or low-interest loans for automation adoption could accelerate India’s position as a global textile leader..

Vishal Pacheriwal, Director of Parnika India

Automation has enabled to increase output without compromising craftsmanship. “For example, the time to produce certain intricate fabrics has been cut by almost 30 per cent, which means we can offer competitive pricing while still delivering premium quality. It also reduces wastage in raw materials, making every meter count,” informs Pacheriwal.

Automation also supports flexible manufacturing, which helps the company switch between product variants quickly. This agility is crucial, especially in an environment where fashion trends change rapidly and customer demands are more dynamic than ever. The ability to scale up or down efficiently helps us stays ahead of the curve.

Automation has been a game-changer in terms of efficiency and scalability. Real-time monitoring tools have minimised machine downtime, while automated warehousing and inventory processes have accelerated fulfillment. Together, these improvements have enhanced cost-effectiveness, enabling companies to stay competitive without compromising on quality.

The human side of automation

Automation in the garment and textile manufacturing industry is often perceived as a threat to jobs, but in reality, it is transforming the workforce by driving upskilling rather than minimising employment. With the introduction of advanced technologies such as automated cutting, stitching, dyeing, and quality control systems, the demand for traditional manual roles may be declining, but new opportunities are emerging for workers to operate, maintain, and optimise these machines. Workers are being trained in digital monitoring, data-driven decision-making, and advanced production management, which enhance their technical expertise and employability. Far from reducing workforce participation, automation is fostering a shift towards higher-value roles that require problem-solving, creativity, and technical knowledge. This evolution enables employees to contribute to greater efficiency, sustainability, and product innovation. By upskilling the workforce, the industry is not only safeguarding jobs but also ensuring long-term competitiveness in global markets, where technology and skilled manpower go hand in hand.

One of the concerns is the adaptability of automation in diverse fabric types and processes, since fashion manufacturing involves frequent style changes and smaller batch runs compared to large-scale commodity textiles..

Akhil Jain, CEO and MD, MADAME

Our company sees automation not as a replacement for our people, but as an enabler for higher productivity and innovation. We are conducting skill-gap analyses across departments to identify emerging competencies required in automated manufacturing, supply chain digitisation, and data-driven decision-making. Our in-house and external training programs focus on areas like machine interface operation, quality analytics, and digital maintenance. We maintain transparent communication with our teams, involve them in automation planning, and recognise early adopters. Cross-functional workshops and pilot projects ensure employees gain practical experience with new systems before full-scale rollout. By combining technology adoption with continuous human development, we are building a workforce that is future-ready while preserving our company’s core values and craftsmanship,” noted Patodia.

Pacheriwal also sees automation not as a replacement but as an enabler for his workforce. His team undergoes continuous training—both in operating modern machinery and in advanced design and quality control techniques. This allows traditional artisans to adapt to technology while still contributing their unique skills to the final product.

“We firmly believe that automation should empower people and not replace them. In our organisation, we are taking a proactive, people-first approach to this transition. Our existing workforce is one of our most valuable assets, and we are committed to helping them grow alongside the technology. We have implemented structured training programs to upskill our employees across functions. From operating and maintaining automated machines to interpreting data dashboards and quality metrics, we’re equipping our people with the knowledge and tools they need to thrive in a digital-first environment. Many workers who previously did manual stitching or inspection tasks are now taking on more supervisory or quality assurance roles. This shift not only enhances productivity but also improves employee morale and career prospects,” states Pathare.

Jain firmly believes automation does not replace people – it transforms roles. His company is investing in training programs, digital literacy workshops, and skill-building modules to ensure our workforce adapts to advanced technologies. Roles are shifting from manual labour to machine supervision, data monitoring, and quality assurance, giving employees opportunities to work in safer, higher-value tasks while ensuring job security and growth.

Challenges on the journey

Although the advantages of automation are evident, implementing it at scale presents its own challenges. The biggest obstacle lies in the significant capital investment it demands, especially for mid-sized companies like ours. Procuring advanced machinery, smart software, and seamless system integration requires substantial funding, which must be carefully balanced against other operational priorities.

Another obstacle is ensuring compatibility with long-standing legacy systems. With decades of operations behind us and many workers who have been part of the journey since the beginning, several processes were originally built around manual execution. Introducing automation into such established workflows demands significant customisation and thoughtful change management.

“Innerwear manufacturing isn’t one-size-fits-all. Different fabric types, garment styles, and finishing details require highly tailored automation solutions—not off-the-shelf products. This calls for collaborative problem-solving with equipment providers and sometimes even co-developing new solutions” tells Pathare.

A stronger ecosystem that fosters collaboration between Original Equipment Manufacturers, textile technology innovators, and garment manufacturers will help accelerate this transition.

Kapil Pathare, Deputy Managing Director, VIP Clothing

The availability of skilled technical talent—whether machine operators, maintenance specialists, or automation engineers—is a pressing issue. The industry needs a more robust talent pipeline to support this technological evolution. “The biggest challenges that we faced was adaption of new automation process by our workforce. While automation increases productivity, ensuring our workforce is equipped to operate, monitor, and maintain advanced systems is a continuous challenge, especially for employees transitioning from traditional processes,” informs Patodia.

Companies that specialise in intricate designs such as handloom and embroidery often struggle to adopt automation, as it fails to capture the authenticity and finesse of traditional craftsmanship. Pacheriwala says, “The primary challenge is balancing scale with the authenticity of handcrafted ethnic wear. Certain processes, like embroidery or finishing touches, still require human artistry. Additionally, high-capital investment in advanced machinery means we have to plan expansion in phases to maintain financial stability.”

Table 2: Government policies supporting automation in the Indian textile industry

Policy / Scheme	Key features	Impact on automation
Production Linked Incentive (PLI) scheme for textiles	Incentives for manufacturing man-made fibres (MMF) and technical textiles.	Encourages investment in modern machinery, automated production lines, and smart systems.
Technology Upgradation Fund Scheme (TUFS) / Amended TUFS (ATUFS)	Financial assistance through subsidies on capital investment.	Helps mills adopt automation, robotics, and digital manufacturing technologies.
SAMARTH (Scheme for Capacity Building in Textile Sector)	Focuses on skilling and reskilling workers in emerging technologies.	Ensures workforce can operate advanced automated machines.
National Technical Textiles Mission (NTTM)	Promotes R&D and adoption of advanced technologies in technical textiles.	Facilitates automation in high-tech segments like geotextiles, meditech, and defence textiles.
Make in India and Digital India Initiatives	Push for domestic manufacturing and digital adoption.	Encourages integration of Industry 4.0 technologies like IoT, AI, and robotics in textiles.

Funding the future

With global buyers placing greater emphasis on speed, traceability, and sustainability, automation has shifted from being a choice to a necessity. Nations capable of delivering high-quality textiles at scale, with reliable lead times and reduced waste, are set to gain a competitive edge in the global market.

According to Pacheriwal, “While India is known for its heritage and craftsmanship, the global market demands both speed and consistency. Automation, when integrated thoughtfully, will help Indian textile players like us compete not just on design but also on delivery timelines, quality assurance, and cost efficiency.”

Patodia also thinks that automation will be a key driver of India’s competitiveness in the global textile value chain. It can help bridge quality gaps, ensure faster delivery, and meet global sustainability and compliance standards. Embracing automation is no longer a choice but a necessity to stay relevant in export markets and to support the vision of ‘Make in India’ with world-class manufacturing.

Jain concludes by saying, “As global buyers increasingly demand faster lead times, transparent supply chains, and sustainable production, automation-enabled efficiency, traceability, and quality assurance will play a defining role. If India scales automation wisely, balancing cost with innovation, the country can strengthen its position as a value-driven global textile hub over the next decade.”

Automation not only helps in achieving international quality standards but also supports ambitions for export growth. By reducing dependency on manual processes completely, we can streamline operations, shorten lead times, decrease product rejections rates, and increase consistency—making us more attractive partners for global retailers and consumers.