A new Econtrol process offers key benefits as Asia’s largest towelling manufacturer and India’s market leader in home textiles, Welspun India Ltd; plans to enhance its competitiveness with extended continuous dyeing techniques for a wide range of new cotton sheeting products in a recently opened purpose-built facility.

Covering an area of more than 600,000 m², the current Phase I facility and the ongoing Phase II expansion facility will allow Welspun to increase towelling production and also enter the bedding market for the first time; producing a comprehensive range of sheeting and decorative bedding products.

The new facility makes Welspun India’s largest fully integrated textiles producer with spinning, weaving, dyeing, fabric processing, cut and sew and make-up carried out in the same vicinity.

The company is Asia’s largest manufacturer of terry towels as well as one of the largest exporters to more than 30 countries around the world, including supplies directly to the top 12 of the world’s leading retailers.

According to Joint Managing Director, Rajesh R. Mandawewala, the company was keen to identify product lines to augment and compliment the towel businesses. “We recognised many common synergies between sheeting and towelling, even in some instances, the same customer,” says Rajesh Mandawewala.

He continues, “Further market research and investigation confirmed our expectations – the end result being the set-up of a purpose-built facility in Anjar capable of producing up to 100,000 m/day of sheeting.”

Monforts the key

“Key to setting up the new fabric process finishing section in Anjar was a number of Monforts finishing lines” confirms Welspun India Ltd President – Projects and Commercial, Updeep Singh.

Comprising a Monforts five unit Thermosol dyeing range, a Montex stenter plus a Monfortex Sanforiser for controlling shrinkage, all these have been installed over the past 12 months. The lines will shortly be completed with the installation of a second Montex stenter.

The Thermosol dyeing range features Monforts E Control process which offers Welspun a number of increased continuous dyeing options.
“This includes the ability to dye darker shades,” says Vice President – Sheeting T.M. Venkatapathi.

In addition to finishing, the 8-chamber Montex 6000, similarly ordered through Monforts local representative A.T.E Marketing, includes a padder to allow light and medium shades dyeing with an elevated 2-chamber Thermex curing unit.

All the Monforts units feature a working width for 3.2 m wide fabrics – mainly 100 % cotton but also with numerous polyester and Viscous cotton blends to suit customers requirements.

Updeep Singh also confirms that the Monforts were ordered for its reputation for product quality and ease of maintenance. “Uniform consistency is assured with the Monforts” he continues, adding, “The Monforts also allow us to provide value added benefits.”