Kapil Pathare:  Automation has had a direct impact on our sustainability metrics

Automation is transforming industries across the board, and the textile sector is no exception. From spinning and weaving to garment manufacturing, every segment is increasingly integrating automation into its processes. Kapil Pathare, Deputy Managing Director, VIP Clothing, in this interview with Divya Shetty, discusses how automation is benefiting his company and the strategies he is adopting to manage his workforce amid this technological evolution.

Which areas of your manufacturing process have seen the most significant automation, and what drove this shift?

At VIP Clothing, we’ve focused our automation efforts on areas that have the highest impact on quality and efficiency, particularly stitching lines and fabric cutting operations. These functions are the backbone of innerwear production, where precision is non-negotiable. In a category like ours, comfort and fit are everything. Even the slightest deviation in stitching or cutting can affect product performance and customer satisfaction. That’s why these processes were prime candidates for automation.

The decision to automate was not just about speed—it was about elevating consistency, minimising human error, and enabling scale across a wide variety of product types. With multiple SKUs, designs, and fabric blends, the traditional manual approach posed challenges in maintaining standardisation. Automation allowed us to manage this complexity more effectively while ensuring high-quality output across the board. In addition, customer expectations today are evolving faster than ever. They want superior quality, fast turnarounds, and variety, pushing us to modernise our operations with technology at the core.

How has automation improved your production efficiency and cost-effectiveness in a competitive market?
The gains have been significant. By integrating automation into our production workflows, we’ve increased throughput and minimised manual errors, which previously impacted both quality and timelines. This has led to a marked reduction in fabric wastage and better resource optimisation. 

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.

Moreover, automation supports flexible manufacturing, which helps us 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 stay ahead of the curve.

With automation coming in, how are you addressing workforce upskilling and job role transformation?
We firmly believe that automation should empower people and not replace them. At VIP Clothing 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’ve 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.

What are the biggest challenges you face in scaling automation across your operations?
While the benefits of automation are clear, scaling it across the board is not without challenges. The most immediate hurdle is the capital investment required, particularly for mid-sized players like us. Advanced machines, smart software, and systems integration come at a cost, and this needs to be balanced with other operational priorities.

Another challenge is compatibility with existing legacy systems. Our industry has deep roots and we have been running our factory for decades, most of our workers have been with us right from the start, and many processes were initially designed for manual execution. Integrating automation into such workflows requires customisation and careful change management.

Also, 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.

Lastly, the availability of skilled technical talent—whether machine operators, maintenance specialists, or automation engineers—is a pressing issue. We need a more robust talent pipeline to support this technological evolution.

Do you believe automation will determine India’s global competitiveness in textiles over the next decade?
Absolutely. As global buyers increasingly demand faster delivery, traceability, and sustainable practices, automation is no longer optional—it’s essential. Countries that can produce high-quality textile products at scale, with predictable lead times and minimal wastage, will lead the global market.

For Indian brands like VIP Clothing, 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.

Have any government schemes or policies supported your automation journey—or what more is needed?
Yes, initiatives such as the Amended Technology Upgradation Fund Scheme (ATUFS) and the Production Linked Incentive (PLI) scheme have provided meaningful support. They’ve laid the groundwork for modernisation by encouraging investment in new technologies.

That said, we believe there’s room for more targeted interventions—particularly around digitisation, automation-led R&D, and affordable financing for mid-sized companies. A stronger ecosystem that fosters collaboration between Original Equipment Manufacturers, textile technology innovators, and garment manufacturers will help accelerate this transition. Policy frameworks that support long-term investment and talent development will also be critical. “As a company that proudly represents the ‘Made in India, for India First’ spirit, we believe such reforms can unlock both national and global potential for Indian manufacturers.”

Has automation helped you move closer to your sustainability goals—such as reducing water, waste, or energy use?
Definitely. Automation has had a direct impact on our sustainability metrics. For instance, digital fabric cutting significantly reduces offcuts and waste, while automated stitching ensures minimal rework. Smart energy monitoring systems and Passive Infrared sensor lights allow us to track and optimise electricity usage across our units, while data-backed insights help us reduce inefficiencies in production. Additionally, our 350 KW windmill generates clean, carbon-free energy, which is fed into the electrical grid—helping offset conventional power consumption and reducing wastage of electricity.

In the long term, we see automation as a key enabler in building a more responsible and environmentally conscious manufacturing model. As consumer consciousness grows, aligning sustainability with operational efficiency will continue to be a major focus—and automation helps us achieve both.