We have been successful in recycling used filter cloth

A premium industrial fabric manufacturer, Khosla Profil excels in technical textiles fabric manufacture. Being India’s leading manufacturer of industrial filter fabrics, it is Asia’s only producer that specialises in technical textiles fabric manufacturing, having fully integrated operations right from fibre/ chips to finished made-ups. Khosla Filter fabric meets the requirements of industries like Drugs & Pharmaceuticals, Dyes & Pigment, Metal & Mining, Food & Beverage, Edible Oil, Paper, Ceramic, Clay, Starch, Breweries, etc by delivering top-notch textile fabric manufacturing as per the requirement of the industry. From industrial fabric to filtration fabric, Khosla Profil offers customised fabric solutions to each of its clients. In this interview, Pramod Khosla, Chairman & Managing Director, Khosla Profil, discusses with Divya Shetty about his company’s initiatives to recycle waste and digital practices being adopted to reduce paper usage.

What is the significance of sustainability in the textile industry? And what initiatives is Khosla Profil taking to support it? 

Given the harm we have done to the environment, I believe that sustainability is not just a theoretical concern but rather a pressing necessity.

We in the textile industry, particularly those who work with filtration fabrics, have the power to solve this budding issue. Khosla Profil has implemented some exceptional sustainability methods over the past three years.

We began recycling 100 per cent of the waste produced in our manufacturing facility. By recycling all of the waste generated during extrusion, weaving, twisting, finishing, and laser cutting, our facility has achieved zero waste status.

In our recycling facility, the entire scrap from every stage of production is now analysed, and this is turning into a major revenue stream.

After realising the potential of recycled material, we began to make chips and are now selling them outside.

Recycling is not the only aspect of sustainability. So, we started looking at how we could possibly complete the cycle by reusing it. Hence, we began replacing our company-wide products that were being used and discarded, especially packaging supplies like paper tubes for all deliveries and paper cones for twisting and packaging.

The tubes that we now make from the granules, are all made from our own recycled material. This process puts the recycled material back into use and eliminates the need for paper. I’d call it a modest contribution, yet a sensible contribution in terms of completing the cycle by recycling and reusing.

Due to our position as a market leader in filtration fabrics, we supply a sizable volume of fabric each year to industries including metal and mining, drugs and pharmaceuticals, dyes and pigments, starch, and others. The filter cloth is currently disposed of in landfills after use, which is harmful to the environment.

After two years of extensive testing, Khosla Profil was able to revive the abandoned filter cloth. For instance, we use 3.5 to 4 tonnes of fabric for every ten tonnes of filter cloth that is discarded. We were finally able to separate the cloth and make it recyclable after two years of arduous work.

We must give credit to a few of our multinational customers who encouraged us to find a way to separate the fibre from the material. We have conducted the trials and have been very successful in our attempt. We create new products, such as fan covers and toothbrush handle by, using this separated material.   Our clients who are currently working with us are elated with this move and expect that we replicate this model globally.

We have made substantial progress by not only assessing waste recycling but also reusing the waste by producing new products.

How is the company adopting digital measures? 

Our adoption of an ERP system has significantly decreased the amount of printing and duplication. I believe that 75 per cent of our printing is for export documentation, so the government needs to closely examine this issue. Even today, the amount of paperwork is unbelievable. The government need to take action in this regard to lessen the amount of paperwork there.

It is quite concerning that the customs office still requires us to submit hard copies. This is the one factor preventing us from fully digitising our business processes.

There has undoubtedly been significant digitalisation internally at Khosla Profil. For example ,we are pasting RFID chips on the roll after production & then taking it off when dispatching & reusing for fresh rolls. Again, eliminating lot of paper usage.

Barcoding and RFID chips are a crucial next step in the digitalisation of the textile sector. Be it in our engineering stores or in our production, we have installed computers on the shop floor everywhere required. Our whole business is now operated digitally. Regardless of how the data is processed—spinning, twisting, or weaving—it is immediately entered into the computers and replaced with digital information thanks to the installation of data monitors at each department.

Even our marketing team places orders online rather than through paper, no matter where they are stationed throughout India. Similarly in the company more & more Engineers are been trained in the ERP system & more reports were generated which were earlier done manually. The reliance on paperwork is now as minimal as possible.

What future expansion plans does Khosla Profil have?

Our expansion plans are right in place. We always work with a vision and those are always rolling at the end of every year where we add another fifth year. We intend to increase our production of non-woven and produce fibreglass in greater quantities for our products. These two are our focus area.