Vishal Fabrics Ltd, although a late entrant in the Indian denim fabric manufacturing sector has emerged as a beacon of innovation, quality, and sustainability. Established in 2016 within a textile park near Ahmedabad, the company is a subsidiary of the diversified Chiripal Group. This strategic positioning has enabled Vishal Fabrics to leverage the group’s extensive resources and expertise, propelling it to the forefront of the denim manufacturing industry.
State-of-the-Art Manufacturing Infrastructure
Vishal Fabrics’ manufacturing facility is equipped with cutting-edge technology to ensure high-quality production. The company started with 172 Tsudakoma looms then added 80 more. Later on, looms of another Chiripal Group subsidiary Nova Denim were transferred to Vishal Fabrics due to which the company now has 439 looms in total. The facility also boasts nine sheet dyeing slashers sourced from Jupiter Comtex, enhancing dyeing efficiency and fabric quality.
The textile park has several more Chiripal Group subsidiaries which include spinning mills with a total of 250,000 spindles. Vishal Fabrics utilizes both open-end and ring-spindle yarns, sourced primarily from the Chiripal Group owned spinning mills. Approximately 90% of the yarns are sourced from these group spinning mills, ensuring consistency and quality in the final product, with only polyester or spandex based yarns sourced from outside.
Robust Production Capacity and Product Range
“Denim fabric production capacity of Vishal Fabrics is around 54 million meters per annum. The company specializes in manufacturing denim fabrics ranging from 5 ounces to 15.5 ounces, catering to diverse market demands. Production is order-based, ensuring tailored solutions for clients. The company manufactures around 250 varieties of denim fabrics in a month out of which 30-35% are regular selling fabrics,” Mr Suketu Shah, Business Head – Denim at Vishal Fabrics told The Textile Magazine.
The company also offers functional finishes like fire retardant, water repellence, odour resistance, etc as when a customer orders the same, but since the denim garment is washed regularly, the functional finish wears out after 20 washes, due to which, functional finishes are not popular in denim garments.
Commitment to Quality Assurance
“Our denim fabric quality standards are as good as those defined by Levi’s. Additionally, our testing follows the AITTC standard for fabrics and chemicals and ASTM standards for yarn. Moreover, we check every chemical consignment that we receive. First and foremost, the yarn is tested and then when it is warped, the warping beam is again tested and so on for all stages,” Mr Shah said.
“We also have separate quality testing auditors, who report to the QC head and not the plant head. This further ensures that the final fabric meets the highest quality standards as defined by Levi. 10% of packed fabrics are rechecked again. This ensures that the fabric inspection team remains alert at all times. In a nutshell, we have developed a system rather than relying only on manpower,” he added.
Customer-Centric Approach and Product Customization
Understanding the diverse needs of its clientele, Vishal Fabrics offers customized denim fabrics upon request, provided the customer commits to substantial order volumes. The company’s after-sales technical team, stationed in Mumbai and Delhi, offers expert guidance to denim garment manufacturers, fostering strong customer relationships. This personalized approach has been instrumental in the company’s success, with even the Managing Director personally knowing each customer by name.
Innovation in Product Development
“Vishal Fabrics’s product development team comprises five specialists, each with expertise in different segments of denim fabric manufacturing. The team is actively involved in developing new denim fabrics based on market trends and customer input. Additionally, the department has an in-house laundry facility and 25 stitching machines, enabling the development of specialized washes and finishes. Their presence at exhibitions and key client meetings ensures a deep understanding of customer needs, facilitating the creation of innovative solutions,” Mr Shah informed.
Vishal Fabrics has now introduced denim fabrics made from combed and also compact yarns. The look and feel of these fabrics is very good. Chinese denim fabric manufacturers are manufacturing fabric blended with rayon which offer a very soft feel and has suppleness. The company is developing products which will have similar suppleness but without using rayon or cellulose fibers.
Sustainability Initiatives
Vishal Fabrics is committed to sustainable manufacturing practices. The company has implemented a zero-liquid discharge (ZLD) system, reusing 97% of the water used in production processes. Plans are underway to transition from coal to biomass in boilers, further reducing environmental impact. The company also generates 40% of its electricity through solar power, contributing to energy sustainability.
Compliance and Certifications
Vishal Fabrics holds several compliance certifications, including BCI, Oeko-Tex and REACH, underscoring its commitment to environmental and social responsibility. These certifications validate the company’s adherence to international standards in sustainable and ethical manufacturing practices. Vishal Fabrics ensures the absence of child labor and also conducts regular fire system audits and drills. Workers’ welfare is prioritized, with subsidized food and on-site housing provided.
Market Presence and Export Expansion
Initially focusing on the domestic market, Vishal Fabrics has established a strong presence with major denim brands in India. The company is now exploring export markets, aiming to expand its reach and capitalize on global opportunities.
Evolution of Denim Fabric in India
“Since the introduction of denim fabric in India in 1986, the industry has undergone significant transformations. The evolution from rigid, heavy-duty fabrics to lighter, more versatile options reflects changing consumer preferences and technological advancements. The increase in weaving width from 36 inches to 78 inches and the shift from open-end to ring-spindle yarns in 1997 are notable milestones in this journey. Vishal Fabrics has been at the forefront of these changes, continuously adapting to market demands and technological innovations,” Mr Shah stated.
According to Mr Shah, the first denim fabric manufacturing plant set up in 1986 had a production capacity of just 10 million meters per annum. The capacity of this plant gradually increased and reached 90 million metres per year in 2001. In the meantime, other denim fabric manufacturing plants were set up in and around Ahmedabad. But a major portion of denim capacity was added after 2003, which includes Nandan Denim.
“Between 2003 and 2011, almost 20 plants were set up. Again between 2011 and 2016, around five production plants were set up in Surat. Five more denim plants were set up after 2016 in Bhilwara. The Indian denim fabric production capacity has now reached 1,700 million meters per month. This capacity has remained stagnant since the last few years, although few new plants have been set up, but there are other denim manufacturers who have reduced capacity or shut shop,” he shared.
As against the Indian denim fabric capacity of 1,700 meters per annum, in Pakistan it is 600-700 million meters per year, while Bangladeshi annual denim fabric capacity is around 1,100 million meters per year and Chinese denim fabric capacity is around a massive 17,000 million meters per annum.
Future of Denim
“Demand for denim garments will never die. Denim fabric garments have been around for several decades, and demand will be there in the future too. Plus, we have the advantage of a young population. However, the Indian government should relax labor laws or provide incentives to help set up huge garment factories, which in turn will provide employment to millions of people. Last year there was turmoil in Bangladesh, but Indian garment industry could not capitalize due to our small garment production plants. In Bangladesh, there are several garment factories which have capacity of 300,000 pieces per day. Sky is the limit for the Indian denim fabric industry if an appropriate and conducive atmosphere is created,” he concluded by saying.