ACNielsen ORG-MARG

Situation Analysis for SME

Sector

Submitted to TERI

By

Surat Cluster

ACNielsen ORG-MARG

SUMMARY OF FINDINGS

• There are approximately 550 units in this cluster who are engaged in textile

processing.

➢ ANNUAL TURNOVER

Annual Turnover (In crores)

54

45

24

53

5863

4038

59

17

24

29

1416 17

7 68

12 10

6

0

10

20

30

40

50

60

70

2005-06 2006-07 2007-08

Upto 1 crore 1 to 2 crores 2 to 3 crores 3 to 5 crores

5 to 15 crores 15 to 25 crores Above 25 crores

ACNielsen ORG-MARG

➢ PRODUCTION

Annual Production (In Meters per Day)67

55

65

35

48

57

8 7 7

1816

14

1

711

4541

25

0

10

20

30

40

50

60

70

2005-06 2006-07 2007-08

Upto 5000 meters 5000 to 10000 meters 10000 to 30000 meters

30000 to 50000 meters 50000 to 80000 meters Above 80000 meters

➢ ENERGY REQUIREMENTS

• CUMULATIVE FUEL USAGE

Qty consumer per annum

Number of Units using the fuel

Electricity 144143128 Units 192

Coal / Hard Coke 378600 Tonnes 97

LDO 7822500 Liters 131

Lignite 297900Tonnes 86

Natural gas 19170000 SCM 30

HSD 2749200 Liters 14

ACNielsen ORG-MARG

• USAGE OF ELECTRICITY (IN UNITS CONSUMED PER ANNUM)

Usage of Electricity (In Units consumed per annum)

14%

3%

24%

55%

4%

Upto 300000 Units

300000 to 600000 Units

600000 to 900000 Units

900000 to 1200000 Units

Above 1200000 Units

• USAGE OF COAL / HARD COKE (IN TONNES PER ANNUM)

Usage of Coal / Hard Coke (In Tonnes per annum)

8%

33%

45%

13%1%

Upto 2000 Tonnes

2000 to 3000 Tonnes

3000 to 6000 Tonnes

6000 to 12000 Tonnes

Above 12000 Tonnes

• USAGE OF LDO (IN LITERS PER ANNUM)

Usage of LDO (In Liters per annum)

4%

33%

53%

5%

5%

Upto 30000 Liters

30000 to 50000 Liters

50000 to 75000 Liters

75000 to 100000 Liters

Above 100000 Liters

ACNielsen ORG-MARG

• USAGE OF LIGNITE (IN TONNES PER ANNUM)

Usage of Lignite (In Tonnes per annum)

1%

31%

45%

23%

Upto 2000 Tonnes

2000 to 5000 Tonnes

5000 to 100000 Tonnes

Above 10000 Tonnes

• USAGE OF NATURAL GAS (IN STANDARD CUBIC METERS PER ANNUM)

Usage of Natural Gas (In SCM per annum)

20%

63%

17%

Upto 500000 SCM

500000 to 750000 SCM

Above 750000 SCM

ACNielsen ORG-MARG

➢ RAW MATERIAL REQUIREMENT

• CUMULATIVE RAW MATERIAL USAGE

Qty consumed per annum

Number of Units using the raw material

Chemical 13453500 Liters 125

Brass 319989600 Meters 150

Yarn 247500000 Meters 80

• USAGE OF CHEMICAL (IN TONNES PER ANNUM)

Usage of Chemical (In Liters per annum)

12%

12%

34%

36%6%

Upto 25000 Liters

25000 to 50000 Liters

50000 to 100000 Liters

100000 to 200000 Liters

Above 200000 Liters

• USAGE OF FABRIC (IN METERS PER ANNUM)

Usage of Fabric (In Meters per annum)

13%

27%

31%

14%

7%

7%

1%

Upto 50000 Meters

50000 to 100000 Meters

100000 to 1000000 Meters

1000000 to 2000000 Meters

2000000 to 5000000 Meters

5000000 to 10000000 Meters

Above 10000000 Meters

ACNielsen ORG-MARG

• USAGE OF YARN (IN METERS PER ANNUM)

Usage of Yarn (In Meters per annum)

23%

4%

9%

63%

1%

Upto 1000000 Meters

1000000 to 2000000 Meters

2000000 to 3000000 Meters

3000000 to 6000000 Meters

Above 6000000 Meters

ACNielsen ORG-MARG

FIELD OBSERVATIONS

✓ Surat, an emerging city in the state of Gujarat, is known as the textile city of

Gujarat. Textile industry is one of the oldest and the most widespread industries

in Surat. The industrial area in Surat is mainly occupied by textile industries.

✓ The textile industries in Surat are associated with production of yarn as well as

processing of Fabric, jari works & Embroidery works.

✓ Main Industrial areas are Sachin, Pandesara, Katodana & Palsana as well as

Udhana.

✓ There are around 200 units of textile processing in Sachin, 200 in Pandesara,

app. 100 units in Katodana and some 100 spread across Palsana & Udhana.

✓ Maximum units are functioning from 15 to 20 years. & all are mechanised.

✓ The major raw material (grey cloth) is being procured from local

manufacturer/traders.

✓ Energy cost is app 12 to 15% of the total production cost. Labor is not a

problem as migratory labor is easily available.

✓ Majority of the units are purchasing grey fabric , on an average the roll is 100

mtr & the average processing time is 2 to 5 hr.

✓ There are certain units , process houses which are completely integrated

houses starting from yarn to fabric to dyeing/printing, finishing but majority of

the units are into dyeing /printing of grey fabric – cotton,viscose,synthetic.

Energy/Fuel

✓ Electricity is supplied by Gujarat State Electricity Board. Power is available for

24 hr. Weekly one day power cut. Area wise day fixed for power cut like,

Wednesday, Thursday, Friday & Saturday. Unit rate Rs. 6 to 8/- depend on the

basis of consumption & type of connection.

✓ Gas Supplied by Gujarat Gas Company limited in Industrial area for Yarn heat

setting, Jet Dyeing, Heat exchanger & Boilers. During the interactions with the

units it was found that the units don’t get sufficient gas, due to shortage of gas,

on an average in an month the units are closed for 7 to 10 days.

✓ Coal & wood getting from local traders

ACNielsen ORG-MARG

Equipments

✓ Relax Rotary Drum Machine (High temp. up to 140° C., Working pressure - 4

Kg./cm², Capacity - 200 kg. / 400 kg.)

✓ Jet Dyeing Machine. (Capacity 200 to 500 kg (single tube), Liquor ratio – 1:1

(Wet fabrics), Dye – 30 to 400 grms/ mtr. High temp upto 140 Deg. C, Fabric

speed – 300 mtrs/min.)

✓ Long tube Fabric Dyeing Machine / Long Tube Soft Flow Fabric Dyeing

Machine, (fabric speed upto 400/metres. The range is highly popular amongst

the clients because of its low liquor ratio and lowest power Consumption.

Capacity 100 kg to 200kg, heating time 25 to 30 min. & cooling time 15 to 30

min.)

✓ “O” Type Soft Flow Fabric Dyeing Machine, (fabric speed up to 300 Mtrs /

Min., subject to quality of fabric. Liquor ratio starting with 1:5 for polyester and 1:8

for cotton.)

✓ “U” Type Soft Flow Fabric Dyeing Machine, (Fabric Speed up to 400 Mtrs. /

Mins, , heating time 25 to 30 min. & cooling time 15 to 30 min.)

✓ Open Width Fabric Mercerizing machine with Caustic Recovery Unit,

(Working Width 1200 to 3200mm, Roller Width 1400 to 340mm, Fabrics Woven

Fabrics Made of Cotton, Mercerizing Technology Chainless - Hot Mercerizing,

Fabric Speed 10 to 40 Mtrs./Min. Temperature - 60°C, Time - 40-50 Sec.)

✓ Relax Rotary Drum Washer, (Capacity 250 to 400 kg & temperature 140 °C)

✓ Printing Machine (8 to 9000 mtr. Printing in 24 hr)

✓ Central Machine (50,000 to 1.5 lac mtr. In 24 hr.)

✓ Boilers (Steam), (Upto 15 ton capacity (3 to 5 ton capacity maximum using in

surat))

ACNielsen ORG-MARG

Process

Grey cloth (washing & bleaching) using Jet dyeing machine

Weight reduction (in jet dyeing machine

Scouring (one type of heavy wash) , Mercerising

Heat setting ( using Hot Air Stanter Machine) for brightness and shine

Printing Loop Agers – Rotary

printing machine,

screen printing

Washing again

(Chemical wash &

steam heat)

Pressing Finish products

ACNielsen ORG-MARG

Raw Materials ( Grey cloth)

Washing

ACNielsen ORG-MARG

Chemical washing

Jet Dyeing machine

ACNielsen ORG-MARG

Flow Dyeing machine

Washing tank

ACNielsen ORG-MARG

Dye bath

Boiler

ACNielsen ORG-MARG

Ready for printing work

Printing machine

ACNielsen ORG-MARG

After printing

ACNielsen ORG-MARG

SERVICE PROVIDERS

Equipment Supplier’s

✓ Texfab Engineers (I) Pvt Ltd Mr. Mukesh Pachauri Road No.57, Plot No. 5716, GIDC Estate, Surat- 395 003 Phone. : 0261-2397243/ 2397844,M- 09898042000

✓ Indtex Boiler pvt. Ltd.

Mr. Gunvant Nayak Plot No. 1601, Phase 1,GIDC Naroda, Ahmedabad – 382330. Ph- 079 22823370, M-98250 15168

✓ Devrekha (Textile Dyeing Machinery Supplier),

A-2, 6/102, GIDC,Sachin, Surat-394230. Ph- 0261-2398881/2398882

✓ Shridhar Engineering

76/B, Central Road No. 5, Udhna, Udhyognagar Surat - 394 210 Ph-0261-2279829.M- 09825118894

✓ Bhagyarekha Engineers Private Limited, A-2, 6/102,

G.I.D.C. Sachin, Surat – 394230

Ph-0261-2398881 / 2398882, M-9825148739.

✓ Shiv Tex Engineers, Plot no-511, Road no-5, GIDC,

Sachin-3942301 Ph-0261-2399992

✓ Energy Pack Boilers pvt. Ltd

12, Satguru Nanik East Goregaon, Mumbai-63.

✓ Garg Corporation Boiler supplier,

6/14, Road no-A, GIDC, Pandesara, Ph-2890174.

Machinery Spares

✓ Bhanderi Impex , G 44 Princess Plaza, Varachha Road, Surat, Ph-0261-2543311

ACNielsen ORG-MARG

✓ Himson Textile Engineering Industries Pvt Ltd . Hiralal Colony, Ashwini Kumar Road, Surat, Ph-0261-2551348 , 2553528 , 2551350 , 2551349

✓ Shree Gayatri Reed Mfg Co, C 37 Sagar Industries, Surat,Ph-0261-2531190 , 2533582

Raw Materials suppliers

✓ A C Shah & Co , Nr Leopracy Hospital, A K Road, Surat.Ph-0261-2552348 ,

2548755 , 2542716

✓ Altret Performance Chemical Gujarat Pvt ltd, 12/2881 Altret House, M G Road,

Surat, Ph- 0261-2451807, 2451808 , 2451809

✓ K Tech India Ltd , 7/B Bata Compound, Naupada Thane W, Surat, Ph-

2225476486, 2225476496

✓ United Organic, U 19, Bombay Market, Surat, Ph-0261-2897256

✓ Polyester yarn supplied Reliance, JCT

✓ Shree A One Sales Corp. 10, Divya nagar complex, GIDC,

Pandesara, Ph-2896221

✓ Ram Trading Company, Udyog Nagar, Udhana, Surat-2277824

✓ Pragati texchem. 508, City centre, U.M. Road, M-9925012571.

Coal suppler

✓ Swastik Coal Corporation (India) Ltd. ✓ Coastal Energy pvt. Ltd, Shop no-7/8, 3rd floor, Raghans plaza, God Dod road,

Surat, Ph-3053465 ✓ Shree Ji Bio fuels, Plot no-931, GIDC, Sachin

For industrial wastage water treatment plant

Globe Enviro Care Limited, Plot No. PP/1, Off-Road No2, B/H-KayTex Mills, GIDC-Estate, Sachin, Surat.

Association

The Southern Gujarat Chamber of Commerce & Industry Mr. Chetan Shah, President Samrudhi Makkal Pool, Nanpura SURAT – 395001 0261-3917777

ACNielsen ORG-MARG

Pandesara Ind. Co. Op. Society Ltd, 2nd floor, Plot no-195, Opp-Vintex Mill, GIDC, Pandesara

Industries Commissionerate Government of Gujarat Mr. Dhaval PARIKH DIC M.S. Building C-Block, 2nd Floor, Nanpura SURAT – 395001

0261-2465925

ACNielsen ORG-MARG

Bankers

• Allahabad Bank (1/864, Alaknanda Appt.,Timlayawad, Surat, Gujarat, Ph-0261-2470024)

• Andhra Bank (Swati Appt., Timaliyawad, Surat, Ph-0261-2474069)

• Bank Of Baroda (Sangna soci.,Below Archies Gallary, Adajan Road, Surat, Ph-0261-2786307.)

• Bank Of Madhuri (Manoj Market, Opp. Surat Text-tile, Ring Road, Surat, ph-0261-2322396.)

• Bank Of Maharashtra (Prime Arcade, Adajan Road, Surat, Ph-0261-2730518.)

• Central Bank Of India (Timlayawad, Opp. Kailash Restaurant, Nanpura,Surat, Ph-0261-2472047.)

• Dena Bank (Shree Appt., 1 st Floor Nanpura, Surat, Ph-0261-2476425.)

• Indian Overseas Bank (4/3366, Nr. Hajoori Chamber, Zampa Bazaar, Surat. Ph-0261-2420349.)

• The Surat Textile CO OP Bank LTD ( The Surat Textiles Tower, Nr. Mahavir Market, Ring Road, Surat, Ph-0261-2320196.)

• Bank Of Baroda (Udhna Land State, Central Road,10 Udhana, surat, ph-0261-2277467.)

• State Bank Of India (Nanpura Branch, Athugar Street, Timaliyawad, Surat, Ph-0261-2472144.)

• The Sachine Industrial CO-OP Bank (Shrinathji Comp., Opp. Jivan Jyot Cinema, Udhana, Surat, Ph-0261-2273323.)

• The Varachha CO-OP Bank Ltd. (Vishwaj Bhavan, Nr Viddh kutir Varachha Road, Surat, Ph-0261-2580591.