‘In Coming Years, Processing Will Play A Crucial Role In Enhancing The Performance, Sustainability And Appeal Of Synthetic Textiles’

The textile processing sector is undergoing significant transformation, driven by multiple factors. One of the most critical shifts is the growing dominance of man-made fibres over natural fibres, says Prashant Mangukia.
 
How do you see the evolution of customer preferences impacting the textile processing sector?
Customer preferences are evolving in several ways, primarily driven by market dynamics and changing product trends.

One major shift is the growing preference for man-made fibres over natural fibres. This change has directly impacted us, prompting the need to design and customize our machines to efficiently process these new fibre types.

Another key trend is the shift in investment patterns. Greenfield projects have become less common, with businesses now making investment decisions in a phased manner. This has influenced our production planning, as traditional greenfield projects typically follow a one year to one-and-a-half-year timeline. However, with rapid market fluctuations, customers now demand faster deliveries to capitalize on emerging opportunities. This shift has pushed us to enhance our production capacity and optimize processes to meet these evolving expectations.

How have automation and digitalization transformed Yamuna’s processes in terms of efficiency and productivity?
Automation has always been an integral part of our machines, continuously evolving over time. We started with PLCs, then transitioned to industrial PCs, followed by Industry 4.0, and now many aspects are moving towards AI-driven solutions.

Currently, almost all our machines are equipped with PLCs and have the capability to connect with a central ERP system, allowing customers to effectively monitor machine efficiency. We are also developing AI-based software that will enable predictive maintenance, allowing machines to anticipate potential failures and schedule preventive maintenance automatically. Additionally, this system will help customers manage spare parts inventory by predicting which components need to be ordered, ensuring they are prepared for maintenance.

Another key focus of our automation efforts is energy efficiency. Our machines are designed to log and analyze energy consumption data, tracking key parameters such as power usage, spare part consumption, and overall production output. Over time, this data will allow customers to forecast operational costs more accurately.

As for AI integration, while it has already been implemented in machine controls and process parameters, we are currently working on advancing it further. Our R&D team is focused on expanding AI capabilities to enhance predictive maintenance and machine history analysis, taking automation to the next level.

How is Yamuna addressing environmental concerns related to waste and resource management?
Sustainability is no longer a luxury—it is a necessity. Every machine we design and deliver is developed with sustainability in mind.

While sustainability is a broad concept that is difficult to quantify precisely, our efforts are focused on making our machines more resource-efficient. For instance, in wet processing machines, inputs such as water, steam and power are automatically controlled by the machine itself, rather than relying on manual operation. This ensures optimal resource utilization and minimizes waste.

Another key aspect is ensuring precision in processing. Our machines are designed to produce high-quality fabric on the first attempt, reducing the need for refinishing or re-dyeing. This not only minimizes material waste but also helps customers improve efficiency and lower their environmental footprint. Through these innovations, we are continuously working to enhance sustainability in textile processing.

What emerging trends do you believe will have the greatest impact on the textile processing sector over the next 10 years?
The textile processing sector is undergoing significant transformation, driven by multiple factors. One of the most critical shifts is the growing dominance of man-made fibres over natural fibres. As cotton availability declines and production capacity reduces, fibres like viscose, nylon and polyester are increasingly replacing it.

The key challenge in processing lies in replicating the feel and finish of natural fibres in man-made alternatives. Achieving this requires advanced processing techniques, innovative finishing solutions, and continuous R&D efforts. In the coming years, processing will play a crucial role in enhancing the performance, sustainability and appeal of synthetic textiles, ensuring they meet the evolving demands of both manufacturers and consumers.

What trends do you expect to see in textile processing machinery for technical textiles in the coming years?
In India, technical textiles have been one of the fastest growing segments within the textile industry over the past decade. What was once a niche sector has now expanded into large-scale production, driven by technological advancements and increasing applications across various industries.

As technical textiles continue to evolve, conventional processing machinery is no longer sufficient to meet their unique requirements. Unlike regular textiles, technical textiles are functional and application-driven, necessitating specialized machinery. This requires a different mindset and approach to machine design.

For example, in the construction industry, textiles now play a crucial role in applications like geogrids. While we have been manufacturing stenters since 1990, our entry into geogrid processing five years ago required significant modifications. We had to redesign the machine to handle six metre wide materials, far beyond the standard width and strength of regular textiles.

Moving forward, the processing industry must continuously innovate and upgrade machinery to cater to the diverse and demanding needs of technical textiles. Customization, precision engineering and advanced automation will be key trends shaping the future of technical textile processing.

Can you provide insights into Yamuna’s flagship products and their contribution to the technical textile industry?
Our flagship product is the stenter, along with our specialized coating line, both of which are integral to the technical textile industry. Coating plays a critical role in enhancing the functional properties of technical textiles, making them suitable for diverse applications. To cater to these needs, we have developed a uniquely designed stenter with an integrated coating system specifically for technical textiles.

How does the selection of machinery impact the performance and functionality of technical textiles?
The processing and finishing of technical textiles require meticulous selection of machinery, as standard processing solutions are often inadequate. Several factors influence the effectiveness of technical textile machinery:

• Material Considerations: In some cases, metallurgy needs to be modified to withstand the demanding conditions of technical textile processing.
• Precision Control: Drive and tension control must be adapted to handle different fabric properties, as technical textiles cover a vast spectrum of applications.
• Functional Integrity: Unlike conventional textiles, errors in technical textile processing are often irreversible. If the material is damaged or improperly processed, it loses its functional properties.
• Strength & Durability: For high-strength applications, such as geotextiles, the machinery must be capable of stretching and processing fabric in a way that maintains its tensile strength.
• Delicate Controls: Some technical textiles require minimal stretching but precise handling. The machine must be equipped with the right drives and control systems to ensure that the fabric retains its intended functionality.

Ultimately, machinery customization and optimization are essential to achieving the desired performance characteristics in technical textiles.