By Arun Rao
Import Substitution through Indigenous Innovation
Metallic zari yarn manufacturer and Surat based Adlon Industries has developed the capabilities to manufacture a particular variety of metallic zari yarn that used to be imported from Europe and thereby introduced an import substitute product and supplies these yarns at a highly competitive price when compared with the price of the imported zari yarn.
“Earlier garments exporters in Tiruppur and other parts of Tamil Nadu used to use a metallic zari yarn which was imported from a European country, which was very costly for them. We did research and development and introduced not just a similar but a superior quality of metallic zari yarns, when compared on various parameters like elongation, strength, durability and resistance with the imported yarn,” Mr Mahendra Zadfiya, Director, Adlon Industries Pvt Ltd told The Textile Magazine.
Infrastructure
Adlon Industries started manufacturing metallic zari yarns in 2018 with just four TFO machines along with a dyeing machine and were at that time supplying only in the Surat market. By 2021, the company installed 12 more TFO’s and continued to sell in Surat. The company has four production plants of which three plants are in the same location, while built up area is 75,000 sq. feet with around 500 employees.
Expansion from Surat to Global Markets
In 2021, Adlon Industries decided to foray beyond Surat to other parts of India and also to other countries. “To do so we participated in several exhibitions pan-India and also in other countries. Alongside, we also set up a R&D department to develop new metallic zari yarn qualities. We also hired a technically qualified team in the same period. By 2022, we had 95 TFO’s which has reached 125 TFO’s now and our production capacity is 250 tons per month. Our base yarns are polyester, nylon and viscose,” he added.
Strategic Clientele across Fashion & Textile Sectors
The company has also been nominated by leading global fashion brands and is supplying yarns to vendors of H&M, Zara, D’Decor, Sephora and more. Within Indian apparel brands, they are also supplying to vendors of reputed brands of Aditya Birla Lifestyle, Sutlej, Raymond, Siyaram, Pothy’s, Ramraj among many others.
Product Variety
Mr Zadfiya further said, “We only produce on make to order basis only. We also launch atleast one new variety of metallic zari yarn every month. We produce 600 varieties of zari yarn, with the difference being in deniers and colours. We also supply zari yarn depending on whether the fabric will be conventionally or digitally printed.”
The metallic zari yarns are supplied in denier range beginning from 10 to 50 deniers in case of nylon yarns as against minimum 20 deniers supplied by other companies. The company claims that it is the only company in India to use 40 denier superfine Viscose Modal yarn to produce metallic zari yarn which can be used even for weaving fabrics on airjet looms.
Quality Control & Assurance Practices
For quality control, Adlon Industries follows the 5S systems and uses SAS program. All the yarns that are purchased from the market are first tested before loading on the machines and then again tested on various parameters once the metallic zari yarn is produced. Before packing, the yarn is tested for TPM, washing fastness, colour matching, rubbing test, etc. During packing too, there is a final physical check to ensure that there will be no quality issues in the yarn at the customer end.
Commitment to Compliance
“We proudly hold the distinction of being India’s first company to receive both OEKO-TEX and GRS certifications in the metallic yarn category. This achievement highlights Adlon’s leadership in sustainable textile manufacturing, ensuring its products meet the highest global standards for environmental safety, recycled content, and ethical production practices,” he informed.
Foray into Sewing & Embroidery Threads
The company is now in the process of adding stitching and embroidery threads to its product portfolio and has started trail production on both products. These threads will be sold to their corporate customers among others and will also be exported. These threads will only be manufactured from recycled PSF and initially will introduce them in 750 colours and shades and keep increasing the colours and shades gradually.