Automation Enigma
While the Indian textile industry shows strong interest in automation, Divya Shetty explores the major hurdles hindering its adoption and examines potential solutions to overcome them.
The textile industry is witnessing a transformative shift, with automation emerging as a focal point of innovation and competitiveness. As global demand for efficiency, quality, and speed intensifies, textile manufacturers are increasingly turning to automation to streamline operations and reduce human error. From automated spinning and weaving machines to AI-powered quality control systems and robotic garment handling, the integration of smart technologies is redefining traditional production models. This growing buzz around automation is not just limited to large-scale manufacturers; even mid-sized and emerging players are exploring digital solutions to remain relevant in a rapidly evolving market. The push towards automation is further accelerated by the rise of Industry 4.0, where interconnected systems, data analytics, and real-time monitoring are becoming industry norms. Vikas V Banduke, Vice President – Automation, A.T.E. Enterprises, says, “Automation is a key component of Industry 4.0 and enables visual interactions between machines and operators through graphical representations on systems like SCADA.”
Moreover, challenges such as labour shortages, rising input costs, and the need for sustainable practices are nudging companies to adopt tech-driven solutions. Governments and policy frameworks are also playing a pivotal role, offering incentives for adopting advanced manufacturing technologies under initiatives like “Make in India” and the Production Linked Incentive (PLI) scheme. While the potential benefits of automation—such as higher productivity, improved quality, and better resource utilisation—are significant, the shift also raises questions around workforce displacement and the adaptability of legacy systems. Nonetheless, the momentum is clear: automation is no longer a futuristic concept but a present-day necessity in the textile industry. As the sector navigates this dynamic landscape, the buzz around automation continues to grow louder, signalling a paradigm shift that is reshaping how textiles are produced, managed, and delivered. Dr Siddhartha Rajagopal, Executive Director – TEXPROCIL, states,“The newer developments in technology, use of advanced raw materials, domestic sales, green textiles and environmental sustainability, are adding lustre to the textile sector by identifying newer applications. Increased deployment of AI and IoT are providing data-driven insights to make better decisions. Investment in modern technologies can lead to innovation and knowledge transfer, improving the overall productivity and efficiency of the sector.”
Where are we now?
The Indian textile industry has made notable progress in adopting automation, especially in the last decade, as global competition and consumer expectations have pushed manufacturers to enhance productivity, quality, and efficiency. Many large and mid-sized textile units have integrated automated systems in spinning, weaving, dyeing, and garmenting processes. Technologies like computerised knitting machines, automated looms, digital printing, and robotic handling systems are increasingly being used to reduce manual intervention and improve precision. The adoption of AI and IoT for real-time monitoring and predictive maintenance is also gaining traction in modern textile mills.
Addressing a key challenge faced by textile exporters in accurately measuring the GSM (grams per square meter) of fabrics, Manjit Singh Saini, CEO and Technical Director of Paramount Instruments, has introduced an innovative solution. He informs, “GSM AI stands for Grams per Square Meter through Artificial Intelligence. It enables highly precise GSM measurement for knitted, woven, and nonwoven fabrics, eliminating the need for traditional tools like cutters, pads, balances, and blades. Users have to simply place a fabric sample regardless of its shape or size into the machine, and the GSM is measured instantly with unmatched accuracy. We firmly believe this innovation represents the future of GSM measurement technology, setting new global standards in textile testing.”
“Our SAFIR PRO automatic drawing-in machines provide our clients with very high and error-free drawing-in rates, quick and easy style changes without tampering with the quality of their products. Thanks to the TIEPRO warp-tying machines quality warp beams and perfectly tied warp threads are achieved ensuring improved and reduced manual operations during the weaving process, says Fritz Legler, Global Head of Marketing and Sales WPS for Textiles and Textile Divisional Marketing Officer, Staubli AG.
Banduke also adds, “We have the expertise to successfully undertake automation and upgradation of older textile machines using modern controls and the latest software, if these machines are in good mechanical condition. This results in a significant improvement in the performance of older machines – in terms of productivity, quality, and reduction of operating cost. A.T.E. also offers stand-alone products to upgrade mill productivity and quality: pre-reduced indigo dosing systems for denim manufacturing (bulk as well as portable); and dye and chemical dosing systems for the processing range like CDR, CBR, etc.”
Upside of automation
Automation has emerged as a game-changer across industries, offering a multitude of benefits that significantly enhance productivity and competitiveness. Among the most notable advantages are increased efficiency, consistency, and cost-effectiveness. Through the integration of smart technologies and Industry 4.0 concepts, businesses are not only streamlining their operations but also unlocking new avenues for innovation, customisation, and supply chain optimisation.
Increased efficiency: One of the primary benefits of automation is increased efficiency. Automated systems can operate 24/7 without fatigue, enabling faster production cycles and higher output. For example, in the textile industry, automated looms and dyeing machines reduce the time and manpower required to manufacture fabrics, allowing companies to meet tight deadlines and fluctuating market demands. Similarly, in automotive manufacturing, robotic arms perform welding, painting, and assembly tasks with remarkable speed and precision, far outpacing human labour. Legler comments, “Industry 4.0 is an advanced technology that responds to the present demands of textile manufacturing. This advancement is game changer as we can now manufacture efficient, durable and intelligent weaving machines granting easy access to optimised yarn handling, real-time data analysis and predictive maintenance of machines.”
Consistency and quality control: Automated systems minimise human error and ensure uniformity in production. For instance, in food processing, automated packaging machines maintain exact weight, size, and sealing parameters, reducing product waste and increasing consumer trust. In electronics manufacturing, precision robots assemble components with micron-level accuracy, maintaining quality standards across large production volumes. Rajagopal said, “The T&C sector can be made future ready through pioneering blockchain technology to provide “real-time end-to-end” traceability of the origins of the product and entire value chain. Towards this end, the branding of Indian cotton is a step in the right direction. Under the guidance of the Ministry of Textiles, TEXPROCIL along with CCI and industry bodies is offering dual benefits of certification and traceability for cotton grown in Indian farms under the “Kasturi Cotton Bharat” programme.”
Cost-effectiveness: From a financial perspective, automation brings cost-effectiveness by reducing labour costs, minimising material waste, and lowering error rates. Although the initial investment in automation technology can be high, the long-term savings and productivity gains often outweigh the upfront expenditure. Banduke suggests, “Many textile plants operate older machines that are not compatible with modern automation systems, leading to increased maintenance costs. Upgrading legacy equipment to work with automation requires additional investment in retrofitting and system integration, further adding to the financial burden. Additionally, the transition phase can result in production stoppages, affecting both output and revenue.”
Smart factory technology: The adoption of Industry 4.0 and smart factory technologies takes automation a step further by integrating artificial intelligence (AI), machine learning (ML), the Internet of Things (IoT), and data analytics. For example, a smart factory can use IoT sensors to monitor machine performance in real time, predict maintenance needs, and prevent unplanned downtime, significantly increasing operational efficiency.
Supply chain optimisation: Lastly, automation enhances supply chain optimisation through real-time tracking, automated inventory management, and predictive logistics. Companies like Amazon use robotic warehousing and AI-driven demand forecasting to manage global operations with remarkable agility and accuracy.
Automation is not merely a tool for reducing costs but a catalyst for transformation and innovation, empowering industries to operate smarter, faster, and more competitively.
The enigma deepens
Integrating automation into textile manufacturing comes with several challenges, and the issues you mentioned—shortage of skilled labour, MSMEs’ limited expenditure, and rising plant maintenance costs—play a significant role. Here’s a breakdown of the key challenges:
Lack of skilled workforce: As part of advanced automation, the programming of PLC, SCADA, and Drives requires specialised skills that are not easily available in the market. Additionally, many workers in textile factories lack exposure to automation, making training programs essential, which in turn adds to costs and time. Moreover, employees who are accustomed to manual processes may be reluctant to transition to automated systems.
Restricted spending capacity of MSMEs: High initial investment poses a challenge for small and medium-sized manufacturers (MSMEs), as they often struggle with capital constraints, making it difficult to invest in automation technologies like robotic looms, automated inspection systems, or AI-driven fabric analysis. Additionally, concerns about return on investment (ROI) further discourage smaller companies from adopting automation, as the benefits are not always immediate, though in the long term, it always pays off.
Increasing costs of plant upkeep: Many textile plants operate older machines that are not compatible with modern automation systems, leading to increased maintenance costs. Upgrading legacy equipment to work with automation requires additional investment in retrofitting and system integration, further adding to the financial burden. Additionally, the transition phase can result in production stoppages, affecting both output and revenue.
Sector-specific hurdles: Unlike industries with standardised materials, textiles involve diverse fabric types that require flexible automation solutions that can suit and work with all varieties. Additionally, automated defect detection systems need high accuracy to ensure precision and quality control, which can be costly to implement. Furthermore, the demand for customisation in textile products makes it challenging to standardise fully automated processes.
Automate by making it inclusive and affordable
While automation presents a compelling opportunity to modernise manufacturing and address persistent challenges, its adoption remains uneven—particularly among Micro, Small, and Medium Enterprises (MSMEs), which constitute a large segment of the sector. The key to enabling widespread automation lies in addressing industry-specific challenges, leveraging emerging trends, and creating a supportive ecosystem that reduces entry barriers for smaller players.
One of the foremost challenges to automation adoption in the textile industry is the shortage of skilled labour. This limits both operational efficiency and the ability to manage advanced machinery. Automation, ironically, is also the solution—by reducing dependency on manual intervention and ensuring consistent quality. However, high initial investment costs and rising plant maintenance expenses act as deterrents, especially for MSMEs with limited capital. To mitigate this, a focus on modular and scalable automation solutions is essential. Companies can begin with semi-automated systems or single-task robots—such as automated fabric cutters or GSM testers—and gradually scale up as productivity improves.
Emerging trends such as AI-powered quality inspection, IoT-enabled production monitoring, and robotic material handling offer cost-saving potential in the long term. Leveraging these trends through shared infrastructure models—like cluster-based automation hubs—can help distribute costs among multiple small units. Moreover, open-source software platforms and cloud-based manufacturing systems can reduce technology ownership costs while improving accessibility and data-driven decision-making.
Government support plays a critical role in democratising automation. Initiatives like the Production Linked Incentive (PLI) Scheme, Technology Upgradation Fund Scheme (TUFS), and SAMARTH (Scheme for Capacity Building in Textile Sector) aim to modernise production processes and skill the workforce. Expanding these schemes to specifically subsidise automation tools and offering low-interest credit lines or grants for digital transformation can make modern technology more accessible to MSMEs. Additionally, public-private partnerships can drive pilot projects that showcase automation’s benefits in real-world MSME settings, encouraging adoption through demonstrable outcomes.
Creating a robust ecosystem that includes training centres, automation vendors, and financing institutionsis equally important. Collaboration between technology providers and MSMEs can lead to the development of customised solutions that cater to the unique needs and budget constraints of small-scale operations. Government-sponsored innovation hubs or textile parks can serve as innovation labs, enabling MSMEs to experiment with automation before full-scale deployment.
Furthermore, policy support for upskilling workers in operating and maintaining automated machinery will address the current skill gap and make the transition smoother. Schemes that incentivise employment linked to automation adoption can drive workforce participation and productivity in tandem.
In conclusion, automation is no longer a luxury but a necessity for the Indian textile industry to remain globally competitive. By focusing on low-cost, scalable solutions; leveraging current technological trends; and strengthening government support for MSMEs, the industry can usher in a new era of inclusive and efficient manufacturing. A collaborative approach between industry stakeholders, technology developers, and policymakers is essential to make automation not just feasible but future-ready for all segments of the Indian textile ecosystem.
