With Goller washing machines and heating system, we have no creases in the goods and we require 30% less water, which is great!
Dr.paolo Monti, F.lli Monti S.p.A Holding
Dr. Paolo Monti, director and head of finishing in the “F.lli Monti S.p.A. Holding has a a doctorate degree in chemistry and he has been working in the entirely family-owned company, as a representative of the third generation. Dr. Monti loves photography and naturally as an Italian, driving and riding motor bikes. In his leisure time, he likes to restore old Vespa scooters. PTJ is pleased to publish this interview, which is conducted by Jürg Rupp, Director, Corporate Relations and Communications, Fongs Industries.
The fact that product flows can shift is also evident with regard to fabric production at Tessitura Monti spa, in Maserada, Italy. For the new company mill in India, which works to the same quality standards, as those employed in Italy, machines from Goller Textilmaschinen GmbH, have been installed for the entire wet finishing area. The decision to use the Goller wet finishing equipment in India was taken as a result of the very positive and established experience in Italy.
The Monti Company was founded as a weaving mill 1911. Since then, Monti has produced fabrics for shirts, women’s blouses and children’s clothing, as well as home textiles. Until two years ago, the company also manufactured yarns. These activities were closed, in order to allow a focus on weaving and dyeing.
According to Dr. Paolo Monti, company director and head of finishing, the “F.lli Monti S.p.A.” holding currently has sales of some EUR 100 million of which 65% relate to exports. The three weaving mills in; Maserada (I), the Czech Republic and India each produce a third of total production amounting to 16 million metres of fabric annually. All the fabrics from Italian and Czech production are finished in Maserada, the Indian production is sold in its entirety to international customers and in the Indian market.
Excellent reputation
Tessitura Monti enjoys an excellent reputation as a high-quality supplier for shirt materials of which 95% are produced from dyed yarns. The vast majority of the customers are also active in this area and 100% cotton yarns are largely employed. Fine linen yarns are also utilised for the summer collections and 50:50 cotton/wool blends are used for the winter collections.
 In response to a question concerning the most important milestones in the company’s history, Dr. Paolo Monti replied “My grandfather’s weaving mill produced cheap fabrics for bed linen and working clothes. Nets were also manufactured. Production was expanded between the two world wars and at that time the company had more than 1,000 looms. Fortunately, the production facilities in Maserada were not damaged during World War II and this meant that work resumed relatively quickly. Production in the 1950s was largely focused on dyed yarn terry products.The switch to 100% cotton fabrics for men’s shirts took place in the 1960s. Due to the prior experience with high-quality, fine, yarn-dyed articles, this change was completed smoothly and standards improved steadily. Moreover, linen yarns were introduced in the 1980s and remain a part of current production.”
External production expansion
The decision to extend production to other countries was taken in 2000, the choice falling on India and the Czech Republic. The reasons are relatively evident, Monti wishing and having to meet the needs of the local markets.
Are identical products manufactured in India? Dr. Paolo Monti, “Yes. We produce exactly the same products in India, on precisely the same machines. It is impossible to differentiate between the European and Indian fabrics. Moreover, in order to secure this identical quality, our specialists from Italy visit India on a monthly basis.”
Creativity is vital
Dr. Paolo Monti sees marketing as being the biggest problem of the past 20 years, “In view of globalisation, we have to offer increasingly large collections. Everything has to be done at growing speed and quality requirements are also steadily rising. Today, we have to be a genuine all-rounder and the Indians are also demanding specialities at the highest level. This direction also corresponds with our typical Italian corporate philosophy, “Non mollare”, which means never ceasing to maintain quality.”
The collection contains over 70 diverse qualities, which also have to be subjected to a variety of finishes. Dr. Monti describes “easy care” and “non-iron” as important characteristics. “We have to retain a leading position with regard to the creation of new products. We also set priorities in the development area with the aim of remaining that vital one step ahead and constantly offering the market something new. We are intensively involved with nano-technology, which demands completely new dyes. We believe this area possesses great potential as the finished fabrics offer very different aspects to those finished using conventional methods.”
Twenty people are employed in the “ideas department”, which in view of the huge collection and the related massive expenditure is an absolute “must”. Dr. Paolo Monti, “Our customers know that we offer the biggest collections twice a year, as well as providing the ongoing development of special articles for certain customers.
Of these articles, 25 - 30% can be supplied from stock.” Recently, fabrics using Ne 200/2 twists have been launched with great success.
The machine pool
The finishing department can process the complete range of cotton and blended fabrics, as well as providing surface finishing such as calendering and emerizing. The Italian facility in Maserada employs a Goller washing machine with six washing compartments.
 How did the co-operation with Goller begin? Dr. Paolo Monti, “We were in the process of selecting machinery for our new plant in India, which included washing and mercerization systems. We thought, as we are already working with Goller in Maserada, then why not in India, too? We carried out extensive tests with mercerization and washing tests using Goller machines and the results were extremely positive. The next task was to discuss the subsequent steps and during this procedure, we sensed that our relations with the people from Goller were constantly improving and that the levels of mutual trust were steadily rising. We got on particularly well with Mr. Horst Lang, who was always very open to our requests. We are also pleased that Goller is now part of the FONG’S Group.”Tessitura Monti has been operating with the Goller machines for a year in Maserada (I). Dr. Paolo Monti, “We are completely satisfied. There are no problems and this also applies to our relations with Goller’s representatives in Italy with whom we enjoy excellent teamwork. All in all, we are delighted.”
Reduced water consumption
The operation in India uses a GOLLER-DESIZA desizing unit, an EFFECTA washing machine with four compartments, which is the same model as is employed in Italy, where a machine with six compartments is in operation along with a PERFECTA cold wet-in-wet mercerization system. This year, Monti will process 5 million metres in Kolhapur (IND), a figure that is set to rise to 10 million metres during next year.
Dr. Monti was asked about the results up to now. “We have had the same positive experience in our Indian plant. The washing machine is working well, as is the heating system. Moreover, we have no creases in the fabrics and one cannot ask for more. Of special importance for us is the fact that we now use 30% less water than in the past, which is a sizeable amount. The mercerization system is also running smoothly and we have been able to combine our experience with that of the Goller experts. The layout of the equipment is simple and precisely matches our operations, which saves a great deal of time during cleaning. Everything is clean, operating smoothly and allows problem-free maintenance.
The market situation in the light of globalisation
How does Dr. Monti see the market situation in the light of globalisation and massive competition? “At present, the situation is much better than it was a few years ago. The demand for top quality and new products has increased and customer attitudes have also altered. Today, many customers produce the same products in various plants around the world. Everyone is looking for the same quality, irrespective of where the goods originate, for example our customers want dimensional stability of 0.5%. And although these demands are continuing to rise, we are well equipped to deal with them.”
Up to now, Tessitura Monti was very export-oriented, selling 65-70% of its production internationally. However, in view of the global flow of products, these figures are becoming increasingly blurred. Dr. Paolo Monti, “In view of our production in various countries, this aspect of our business has shifted. For major customers such as “Marks & Spencer”, “Prada”, “Hugo Boss” or “Banana Republic”, we send fabrics to a range of destinations. We have over 1,500 customers worldwide, who anticipate smooth service of the highest quality from us.”
Dr. Monti says that at present, the top seller among men’s shirts is provided by articles using Ne 200/2 twists. For women’s blouses, the current hit is formed by blends of cotton with polyester or Elasthane (Lycra), the so-called mono- or bi-elastic “comfort fabrics”. Moreover, fabrics finished using nano-technology are also attracting increasing interest.
Maintaining constant standards
Tessitura Monti is recognised as a market leader, but the competition is becoming ever tougher. We asked Dr. Monti how his company intends to maintain its position. “We have a long history and the retention of our experience and expertise at the highest level constitutes our everyday objectives. We cannot afford to relax in this connection. We have a highly motivated and professional team with young people, who are focused on the market of today and tomorrow. We are always receptive to new customer wishes and seek to retain our role as a leading European company that is also a global player. It is to this end that we constantly give our all.”
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