Beekaylon's blog on sustainable manufacturing

How Yarn Engineering Impacts Carpet Performance: From Denier to Crimp

Wed, 15 Apr 2026 09:33:44 GMT

From Denier to Crimp

Walk into any space—an office lobby, a hotel corridor, or a living room—and you’ll immediately notice the carpet. What you don’t notice, however, is what determines whether that carpet will still look and feel the same a year later.

Why do some carpets flatten within months, while others retain their structure and appearance for years?

The answer lies deeper than fibre type or design. It lies in yarn engineering.

Long before a carpet is woven or tufted, its performance is already being shaped—at the level of the yarn itself.

Beyond Fibre: The Hidden Layer of Performance

In most conversations around carpets, the focus tends to be on material—polyester, nylon, wool. While material choice is important, it is only part of the story.

Within synthetic fibres, especially polyester, the engineering of the yarn plays a defining role in:

- Durability under foot traffic

- Softness and tactile feel

- Resistance to crushing and matting

- Visual richness and texture

This becomes even more critical in the case of Bulked Continuous Filament (BCF) yarn, which is widely used in carpets due to its structure, consistency, and performance characteristics.

At Beekaylon, BCF yarn is engineered with a strong focus on balancing these parameters—ensuring that the end product performs as intended across different applications.

What Makes BCF Yarn Different?

BCF yarn is not spun from short fibres. Instead, it is made from continuous filaments that are extruded, textured, and bulked to create a yarn with volume, resilience, and uniformity.

This structure offers several inherent advantages:

- Consistency across batches

- Better resistance to shedding compared to staple yarns

- Enhanced durability, especially in high-traffic environments

- Superior bulk and coverage, contributing to fuller-looking carpets

Globally, synthetic fibres dominate the carpet industry, with polyester and nylon accounting for a significant share of residential and commercial carpet manufacturing. Within this, BCF yarn continues to be a preferred choice due to its balance of performance and cost-efficiency.

But even within BCF yarn, not all yarns perform the same.

That’s where engineering variables come in—but increasingly, it’s also about functional enhancements built into the yarn itself.

At Beekaylon, BCF yarn is engineered not just for structural performance, but for the conditions in which the final product is used. Beyond parameters like denier and crimp, Beekaylon’s BCF yarns are developed with application-specific features such as stain-proof properties that help maintain appearance over time, fire-retardant variants for enhanced safety in commercial environments, UV stability to resist colour degradation in sunlight-exposed areas, and antistatic properties that reduce dust attraction and static build-up. For applications where comfort is key, super soft BCF yarns offer a more refined tactile experience without compromising durability.

This shift—from standard yarn to performance-engineered yarn—is what enables manufacturers to design carpets not just for use, but for real-world conditions.

The Core Parameters That Define Performance

Denier: The Foundation of Strength

Denier refers to the thickness of individual filaments.

- Higher denier → thicker filaments → greater durability

- Lower denier → finer filaments → softer feel

In practical terms:

- Carpets designed for airports, offices, or hotels typically use higher denier yarns for durability

- Residential carpets, where comfort is a priority, often use lower denier for a softer touch

The key is not choosing one over the other—but choosing what suits the application.

Filament Count: The Texture Factor

Filament count refers to the number of filaments within a yarn.

- More filaments → smoother, silkier texture

- Fewer filaments → coarser, more rugged feel

This directly impacts:

- Surface feel

- Light reflection (and therefore visual appeal)

- Perceived quality

High filament count yarns are often used in premium carpets and rugs, where softness and aesthetics are critical.

Crimp: The Source of Resilience

Crimp is the waviness or texture introduced into the yarn during processing.

It plays a crucial role in:

- Creating bulk

- Allowing the carpet to bounce back after compression

- Maintaining structure over time

Without adequate crimp, carpets tend to:

- Flatten quickly

- Lose their visual depth

- Show wear more prominently

In BCF yarns, controlled crimping is what gives carpets their long-term resilience.

Twist: Holding It All Together

Twist refers to how tightly the filaments are wound together.

- Higher twist → better durability and wear resistance

- Lower twist → softer feel but less structural integrity

Twist also affects:

- Surface definition

- Resistance to fraying

- Overall lifespan

In high-performance carpets, twist is carefully calibrated to ensure the yarn holds its structure under repeated use.

It’s Not One Factor—It’s the Combination

One of the most common misconceptions is that improving a single parameter will automatically improve performance.

In reality, carpet performance is the result of a balanced combination of all these factors.

For example:

- A high-denier yarn without sufficient crimp may still flatten over time

- A soft, high-filament yarn without adequate twist may lack durability

This is where expertise in yarn engineering becomes critical—understanding how these variables interact, and optimising them for specific end uses.

From Yarn to Application: Where It All Comes Together

Different environments demand different performance outcomes.

High-Traffic Commercial Spaces Require:

- Higher denier

- Strong twist

- Robust crimp

→ Focus on durability and shape retention

Residential Interiors Require:

- Softer filaments

- Higher filament count

→ Focus on comfort and feel

Decorative and Design-Led Carpets Require:

- Balanced engineering

- Attention to texture and appearance

At Beekaylon, BCF yarn solutions are developed keeping these varied applications in mind, ensuring that manufacturers can achieve the desired balance between performance, aesthetics, and cost-efficiency.

Why This Matters More Than Ever

As the global carpet industry evolves, expectations are changing.

Buyers today are not just looking for cost-effective solutions—they are looking for:

- Consistency in quality

- Predictable performance

- Materials that align with specific use cases

At the same time, the scale of production has increased, and even minor variations in yarn can lead to noticeable differences in the final product.

Understanding yarn engineering is no longer a niche technical concern—it is becoming a core decision-making factor.

The Takeaway

Carpet performance doesn’t begin on the loom. It begins at the yarn.

From denier and filament count to crimp and twist, each parameter plays a role in shaping how a carpet will perform, feel, and age over time.

BCF yarn, with its continuous filament structure and engineered properties, offers a powerful foundation—but it is the precision of engineering that ultimately determines the outcome.

For manufacturers, designers, and buyers alike, a deeper understanding of these factors leads to better products, better choices, and better long-term performance.

Why India Is Becoming a Preferred Hub for Recycled Polyester Yarn

Thu, 22 Jan 2026 07:02:12 GMT

The global textile industry is growing rapidly, but so are concerns around waste, resource depletion, and environmental impact.

Polyester, known for its versatility, durability, and affordability, dominates the global fibre landscape and accounts for a significant share of overall fibre production. As demand grows, the industry is being compelled to rethink how polyester is produced, sourced, and reused in a more responsible way.

In this context, recycled polyester yarn (rPET yarn) has emerged not merely as a sustainable alternative but as a critical requirement for future-ready textile supply chains. Among major global textile hubs, India is increasingly being recognised as a preferred destination for recycled polyester yarn manufacturing, valued not just for scale, but also for capability, compliance, and long-term reliability.

Global Polyester and the Sustainability Imperative:

Polyester is the most widely used fibre in the world, forming the backbone of apparel, home textiles, and technical fabrics. Despite its dominance, global textile recycling rates remain extremely low, with less than one percent of textiles being recycled back into new textile products. This highlights a substantial gap between production volumes and circular outcomes.

The recycled polyester market, however, has seen consistent growth over the last decade. This growth is being driven by brand commitments, regulatory pressure, and rising awareness around environmental impact. Textile recycling and rPET yarn are no longer peripheral sustainability initiatives but central pillars in the industry’s transition toward circularity.

India’s Structural Advantages in Recycled Polyester Yarn:

India is one of the world’s largest textile-producing nations, with deep-rooted capabilities across fibre production, spinning, fabric manufacturing, processing, and garmenting. This scale naturally generates large volumes of textile and plastic waste, creating both a challenge and an opportunity.

As collection, segregation, and recycling infrastructure improves, increasing amounts of post-consumer PET waste are being channelled into value-added recycled polyester yarn production. India’s evolving recycling ecosystem allows manufacturers to think beyond short-term availability and build more consistent, scalable recycled yarn programmes.

Another key strength lies in India’s vertically integrated manufacturing ecosystem. Recycling, polymer processing, yarn spinning, and downstream textile operations often exist within close proximity. This integration enables better quality control, improved traceability, reduced lead times, and faster product development cycles. For global buyers, this translates into consistent specifications, predictable supply, and lower sourcing risk.

Global Demand and India’s Export Readiness:

International brands are rapidly increasing their use of recycled fibres to meet sustainability and climate targets. Industry frameworks and initiatives encouraging recycled polyester adoption have pushed rPET yarn into the mainstream. While recycled polyester still represents a smaller share of overall polyester production, demand continues to rise steadily.

India’s export-oriented textile industry has decades of experience working with international buyers and compliance standards. As sustainability requirements become more complex, Indian manufacturers have demonstrated increasing capability in meeting expectations around traceability, documentation, and performance consistency.

Beekaylon’s Innovation:

Sustainability today goes beyond recycling alone. Brands increasingly expect materials that combine environmental responsibility with durability, performance, and lifecycle impact reduction.

At Beekaylon, this philosophy is reflected through its recycled polyester yarn offerings under the Poly-go-round brand. Poly-go-round focuses on delivering high-quality recycled polyester yarns that offer consistency, performance, and suitability across a wide range of textile applications, while supporting circular material flows.

In addition to recycled polyester solutions, Beekaylon brings strong expertise in Polyester Dope Dyed Yarns . In the dope dyeing process, colour is added at the polymer stage itself, eliminating the need for conventional dyeing at the yarn or fabric level. This results in significantly lower water consumption, reduced energy usage, and minimal chemical discharge, while delivering superior colour consistency, excellent light fastness, and long-term performance.

By offering both recycled polyester yarns through Poly-go-round and a comprehensive range of dope dyed polyester yarns, Beekaylon enables brands and manufacturers to meet sustainability objectives while maintaining efficiency, quality, and design flexibility.

Beekaylon’s partnership with CiCLO further strengthens this approach. CiCLO is a textile ingredient technology designed to reduce synthetic microfiber shedding during use and at end-of-life, addressing one of the most pressing environmental challenges associated with synthetic textiles. This collaboration reflects a shift toward holistic sustainability rather than isolated interventions.

Challenges and the Road Ahead:

Despite steady progress, recycling rates across the textile industry remain low, and textile-to-textile recycling continues to face technical challenges, particularly with blended fabrics. Additionally, competition from low-cost virgin polyester persists in markets with limited regulatory enforcement.

However, ongoing investment in recycling infrastructure, technology partnerships, and quality systems is helping close these gaps. The convergence of scale, manufacturing capability, and innovation positions India as a long-term and reliable hub for recycled polyester yarn.

Conclusion
India’s emergence as a preferred hub for recycled polyester yarn is driven by integrated manufacturing, improving recycling infrastructure, rising global sustainability demand, and forward-looking innovation. With initiatives such as Poly-go-round and strategic partnerships like CiCLO, companies like Beekaylon are helping shape the future of circular textiles.

For global brands seeking recycled yarn solutions that balance performance, traceability, and sustainability, India is increasingly becoming the sourcing destination of choice.

Sources

Textile Exchange – Recycled Polyester and Circularity Reports
Grand View Research – Recycled Polyester Market Analysis
Fortune Business Insights – Textile Recycling Market
Fashion for Good – Sorting for Circularity: India
Down To Earth – Textile Waste and Recycling in India
ScienceDirect – Polyester Fibre and Sustainability Studies
Renewable Matter – Textile Recycling and Circular Economy

Beekaylon Synthetics PVT. LTD has been awarded Preferred Manufacturer status for 2026

Wed, 14 Jan 2026 19:54:17 GMT

CICLO awards Beekaylon with Preferred Manufacturer Status for 2026

At Beekaylon Synthetics Pvt Ltd, we take pride in being pioneers in the synthetic yarn processing industry, specializing in high-quality polyester yarns. As one of the largest manufacturers of dope-dyed yarns in India, we are committed to delivering exceptional products that meet the diverse needs of our clients. Our expertise and innovative approach position us at the forefront of the market, ensuring that we provide not just products, but solutions that drive success in the textile industry. Trust Beekaylon for all your synthetic yarn needs, where quality meets excellence. As a Preferred Manufacturer, Beekaylon Synthetics will continue to be highlighted as a trusted partner within our network and benefit from enhanced visibility with brands, retailers, and other industry stakeholders throughout 2026.

BCF Polyester Yarns in Carpets and Upholstery: A Complete Buyer’s Guide

Fri, 07 Nov 2025 08:02:08 GMT

Carpets and upholstery fabrics are often judged by their aesthetic appeal, comfort, and longevity. Behind the scenes, the choice of yarn plays a major role in determining performance, durability, and cost effectiveness. Bulk Continuous Filament or BCF polyester yarns have become a key material for manufacturers of carpets, rugs, and upholstery. This guide explains what BCF polyester yarns are, why they are used in carpets and upholstery, what buyers should look for, and how sustainability, certifications, and emerging trends are shaping the market.

1. Understanding Polyester Yarn and BCF Technology

What is Polyester Yarn?

Polyester yarn is typically made from polyethylene terephthalate PET and is a synthetic filament or staple fibre widely used across textiles. It is valued for strength, colorfastness, stain resistance, and cost effectiveness. In interior textiles polyester is engineered to meet requirements for longevity and appearance retention.

What is BCF Yarn?

BCF stands for Bulk Continuous Filament. BCF yarn is produced by extruding polymer melt into continuous filaments, texturising or bulking them, and winding them into packages ready for tufting or weaving. Continuous filaments provide uniformity and long term resilience compared to staple yarns. Key features of BCF yarn include volume which contributes to the plush or full look of carpets and upholstery, continuous filaments which reduce shedding and pilling, and production flexibility in denier filament count and dyeing methods including solution dyed or conventional dyeing.

2. Why BCF Polyester Yarns Matter in Carpets

Performance Requirements for Carpet Face Yarns

Carpets must withstand foot traffic, maintain appearance over years, resist crushing or matting, manage stains and fading, and in some segments meet fire or VOC safety standards. BCF polyester yarns meet many of these requirements and are used extensively in residential, commercial, hospitality, and automotive flooring.

Advantages of Polyester BCF Yarns

Durability and Resilience: BCF polyester offers good abrasion resistance and maintains structure under traffic. Appearance and Colour Options: Polyester supports bright colours and solution dyeing for superior colour retention. Cost benefit: Polyester BCF often costs less than nylon while providing acceptable performance for many applications. Sustainability Potential: Recycled polyester rPET is increasingly used for BCF yarns, supporting circular economy goals.

3. Polyester Yarns in Upholstery Fabrics

Upholstery applications require abrasion resistance appearance retention stain resistance blend compatibility and comfort. Polyester filament and textured yarns including bulked yarns play a significant role in seating for residential hospitality and automotive markets. Buyers should consider denier and bulk which affect drape and texture functional finishes such as antimicrobial easy clean and flame retardant and colourfastness and lightfastness depending on exposure.

4. Sustainability Certifications and Quality

Sustainability Moves

The shift toward recycled polyester rPET and mono polymer carpet systems is gaining momentum. Buyers should ask what percentage of recycled content is used whether the yarn is solution dyed and whether the carpet system is designed for recyclability. Traceability and third party accreditation including GRS and Oeko Tex help validate sustainability claims.

Key Certifications and Standards

Oeko Tex for chemical safety, GRS Global Recycled Standard for recycled content, ISO 9001 and ISO 14001 for management systems, local standards such as BIS in India and automotive specifications for interior VOC testing and abrasion should be considered when specifying yarns for performance critical applications.

5. Beekaylon's Expertise in BCF Polyester Yarn

At Beekaylon innovation in Bulk Continuous Filament BCF polyester yarns is a cornerstone of our commitment to quality and performance. Our BCF yarns are engineered to deliver exceptional bulk resilience and colorfastness making them ideal for carpets rugs and upholstery applications that demand both aesthetic appeal and long term durability. With a fully integrated manufacturing setup and stringent quality assurance protocols Beekaylon ensures consistent yarn performance across dyeability softness and texture. Whether for residential flooring automotive interiors or contract furnishing our BCF range combines strength sustainability and design flexibility helping customers achieve superior end product performance while reducing environmental impact.

6. Buyer Checklist: What to Look for When Choosing BCF Polyester Yarns

Denier and filament count to determine yarn thickness and feel
Yarn bulk and texturising which influence plushness and resilience
Dyeing method solution dyed yarns provide better colourfastness and lower environmental footprint
Colourfastness and lightfastness for upholstery and carpets exposed to light
Abrasion and wear performance confirm with Martindale Taber or tuft bind tests
Pile structure and compatibility with intended carpet construction
Functional finishes antimicrobial flame retardant stain resistant or UV resistant
Supplier testing and certifications including third party EPD or GRS
Sustainability and traceability percentage recycled content and end of life considerations
Supply chain reliability consistent denier colour and timely delivery

7. Emerging Trends and Future Outlook

Market Growth and Dynamics

The global BCF yarn market is projected to grow driven by demand in residential and commercial interiors. Polyester is expected to witness strong growth among polymers due to its balance of performance and cost. Sustainability and circular economy practices along with product innovations are influencing buyer decisions.

Innovation in Yarn Design and Functionality

New BCF yarn systems enable structured colours tri colour effects and textured surfaces that expand design possibilities. Yarn systems with built in functionality such as antimicrobial or flame retardant properties are gaining traction especially in hospitality automotive and healthcare sectors. Digital design and smart textiles may further influence yarn selection in the coming years.

Conclusion

Selecting the right yarn is fundamental to the performance appearance and sustainability of carpets and upholstery. BCF polyester yarns offer a strong combination of resilience design versatility and potential for recycled content which makes them suitable for a wide range of interior applications.

Sources and References

Oerlikon Barmag. Carpet BCF insights and technical resources.
Textile World. Advances in BCF yarn technology.
Fibre2Fashion. Polyester in home textiles market overview.
Globethread Canada. Carpet yarn portfolio and comparisons.
Environmental Product Declarations registry. EPD and recycled BCF examples.
Carpet and Rug Institute. Material and performance standards.
Lucintel. Bulk continuous filament yarn market outlook.

Resilient Paths and Self-Belief: Lessons from Rushin Vadhani

Thu, 11 Sep 2025 08:01:11 GMT

In this episode of the Spinning Values podcast by Beekaylon Synthetics, hosted by Kartik, marketing expert, educator, and author Rushin Vadhani discusses crucial life lessons of resilience and self-belief that have shaped his career. The conversation explores his journey in the corporate sector, especially in marketing with companies like Aditya Birla Group and Reliance. Rushin also covers branding in the textile industry and the evolution of his career towards academia. His book 'Awesome I' emphasizes personal growth and overcoming challenges, offering valuable advice for young professionals. The podcast underscores themes of continuous learning, adapting to change, and connecting emotionally with one's audience.

You can get the book here:
https://amzn.in/d/4lkVJX8
https://www.flipkart.com/product/p/itme?pid=9789334331677
https://play.google.com/store/books/details/Rushin_H_Vadhani_Awesome_I_Inspire_the_real_you?id=In1-EQAAQBAJ

Flags are not just Fabrics – Its identity of our freedom, struggle & soul

Wed, 13 Aug 2025 05:51:29 GMT

Flags are not just pieces of fabric. They are powerful symbols of identity, unity, and struggle. For nations, a flag represents everything its people have stood for — their dreams, their battles, and their future.

As we prepare to celebrate Independence Day, it’s the perfect time to reflect on what the Indian flag truly means — beyond just its colors or where it’s hoisted.

Across the world, flags have carried meaning for centuries. From ancient battlefields to Olympic podiums, a flag is a visual story of pride. Japan’s rising sun, South Africa’s rainbow design, or America’s stars and stripes — all these flags represent national journeys. So does ours.

The Indian flag, known as the Tiranga, has a powerful history that many of us never got to read in detail.

In 1906, the first unofficial Indian flag was hoisted in Kolkata. It had three horizontal stripes — green, yellow, and red — with symbols like the sun, crescent moon, and the phrase "Vande Mataram."

In 1921, freedom fighter Pingali Venkayya designed a new version — red and green to represent Hindus and Muslims. Later, Gandhi suggested adding a white stripe to represent peace and all other communities. He also added the spinning wheel — the charkha — to symbolize self-reliance and India’s Swadeshi movement.

Finally, on July 22, 1947, just before independence, the Constituent Assembly adopted the version of the national flag we know today. The spinning wheel was replaced by the Ashoka Chakra, a wheel with 24 spokes, representing justice, movement, and eternal progress.

Each color on the Indian flag has a meaning.

Saffron stands for courage and sacrifice.
White symbolizes truth, peace, and purity.
Green reflects prosperity, growth, and the land of India.
The Ashoka Chakra in navy blue shows the path of righteousness and constant movement forward.

Now, here’s something most people don’t know — how our Indian flags are actually made.

The Indian National Flag is not made just anywhere. It is made only by certified units under the Bureau of Indian Standards (BIS) guidelines. The flag must be hand-spun and handwoven using khadi , a homespun cotton cloth that Mahatma Gandhi promoted during the freedom struggle.

There is one official and historic organization that has been making most of our national flags — the Karnataka Khadi Gramodyoga Samyukta Sangha (KKGSS)in Hubballi, Karnataka. It is the only BIS-certified unit allowed to manufacture and supply the Indian flag.

Every flag is made with strict specifications — the colors, the size, the stitching, the placement of the Ashoka Chakra — everything must follow exact guidelines. Even the number of threads per inch in the khadi cloth is regulated.

The process of making the Indian flag is not just manufacturing. It is a form of national service— done with dignity, discipline, and deep respect.

For Gen Z and young Indians, the flag is more than just something we raise on August 15 or January 26. It’s a reminder of how far we’ve come and how much responsibility lies ahead.

The Tiranga represents unity in diversity. It tells us that we belong to something bigger than ourselves. It is a symbol of sacrifice, resilience, and hope.

This Independence Day, don’t just wear the flag as a badge. Understand it. Respect it. Let it remind you of the freedom you enjoy — and the values that shaped it.

India’s Polyester Yarn Industry: Trends, Exports & What Lies Ahead

Mon, 07 Jul 2025 04:17:34 GMT

India stands as the second-largest producer of polyester yarn in the world, generating 4.5–5 million tonnes annually, with around 80% of that consumed domestically. Looking beyond production, this article explores the driving forces, export dynamics, challenges, and future trajectory of India’s polyester yarn market.

Production & Market Growth: Scaling the Synthetic Surge

India’s synthetic fiber market reached approximately 4.52 million metric tonnes in 2024 , and is set to grow at a 5.6% CAGR through 2030 . Within this, polyester filament yarn (PFY) accounted for 2.53 million tonnes in 2024 , projected to exceed 3.06 million tonnes by 2030 at a 3.24% CAGR . Polyester now represents a dominant 77–80% share of India’s synthetic fiber production , driven by global demand for athleisure, technical fabrics, and sustainable alternatives.

Asia-Pacific leads the global synthetic fiber market, with India rapidly emerging as a key player alongside China and Vietnam. In India, western states—like Gujarat—serve as industrial hubs, with well-developed clusters supporting exports via ports such as Mundra and Kandla.

Export Performance: Standing Strong through Shifts

Between November 2023 and October 2024, India dispatched 28,254 polyester yarn shipments to over 100 countries —notably to Turkey, Brazil, and Bangladesh. Globally, India ranked third in polyester yarn exports , following China and Vietnam .

Meanwhile, India’s textile and apparel exports totaled $19.9 billion in FY24—a 2.6% increase year-on-year—despite declining man-made fibre exports. This complex picture shows that, while consumption is growing, India’s status oscillated from exporter to importer due to rising imports of industrial yarn in 2024.

Emerging Trends & Growth Drivers

Several factors are propelling the polyester yarn market forward:

Athleisure & Technical Textiles: As lifestyle and performance apparel grow, PFY’s tensile strength, elasticity, and moisture-wicking properties are in high demand.
Sustainability & rPET: Brands and consumers increasingly favour recycled polyester yarns, including variants like Poly‑Go‑Round.
Government Incentives: Under initiatives like the PLI scheme and BIS/QCO quality standards, investments in MMF capacity and technology are incentivized.
Technical Innovation: Partnerships for high‑modulus low‑shrinkage yarns and biodegradable fibers continue to broaden applications in automotive, industrial, and ecological textiles.

Challenges on the Horizon

Despite expansion, the industry faces hurdles:

Rising Imports: In 2024, India saw a 5.9% year‑on‑year spike in industrial yarn imports , while exports rose 7.6% — highlighting increasing demand but competition.
Moderate Capacity Use: Though consumption surged, capacity only grew ~2%, indicating a need for infrastructure scaling.
Cost & Compliance Pressures: Raw material prices, energy costs, and tighter quality regulations add operational strain.

The Road to 2030: Opportunity Ahead

India’s synthetic fiber sector is projected to grow from USD 3.24 billion in 2024 to USD 6.53 billion by 2033 at a 7.5% CAGR . With government support—such as mega textile parks and financial incentives—the industry is poised to scale manufacturing, enhance export capability, and deepen sustainability. Brands with GRS‑certified rPET and innovative biodegradable yarns will lead this new era.

Beekaylon's Role: Innovation in Every Yarn

At Beekaylon, we pride ourselves on driving these trends with a future-ready product portfolio:

Poly‑Go‑Round (GRS‑certified): Recycled polyester yarn produced from PET bottles and yarn waste—closing the loop on textile circularity.
Puriflex: Ultra-stretch polyester yarn tailored for activewear, narrow fabrics, and elastic applications.
Motofibre: Automotive-grade yarn built for strength, durability, and heat resistance.
CiCLO‑Enhanced Polyester: Biodegradable yarns designed to break down like natural fibers—reducing microplastic pollution.
BCF Yarn: Bulky continuous yarns for carpets, upholstery, and resilient home textiles.
Flexilastic: Range of ultra-stretch polyester yarns designed for exceptional elasticity, flexibility, and recovery. Ideal for yoga wear, activewear, and athleisure, Flexilastic ensures superior comfort and performance, enabling fabrics to move effortlessly with the body.

By investing in continuous polymerisation, GRS certification, and eco-innovation , Beekaylon ensures its yarns are ready for today’s demands—and tomorrow’s challenges.

Conclusion

India’s polyester yarn industry stands at a transformative crossroads. With rapid domestic growth, a proactive shift toward sustainability, and renewed exports, the sector is primed for leadership. Challenges remain, but the combination of government policy, private investment, and bold innovation can navigate them.

At Beekaylon, we're more than manufacturers—we're partners in progress, weaving together performance, purpose, and planet-conscious solutions. Join us as we spin the next chapter of India's textile legacy.

Sources & References

TechSci Research – India Polyester Filament Yarn Market
�� https://www.techsciresearch.com/report/india-polyester-filament-yarn-market/22108.html
TechSci Research – India Synthetic Fiber Market News
�� https://www.techsciresearch.com/news/7464-india-synthetic-fiber-market.html
Prismane Consulting – Synthetic Yarn Market Report
�� https://prismaneconsulting.com/report-details/synthetic-yarn-market-demand-volume-price-range-and-industry-outlook-report
Volza – Polyester Yarn Export Data from India
�� https://www.volza.com/p/polyester-yarn/export/export-from-india/
Fibre2Fashion – India’s Textile & Apparel Export Stats (FY24)
�� https://www.fibre2fashion.com/news/textile-news/india-s-textile-apparel-exports-dip-3-24-in-fy24-up-6-91-in-march-294557-newsdetails.htm
Fashionating World – Industrial Yarn Import/Export Trends
�� https://www.fashionatingworld.com/new1-2/polyester-industrial-yarn-imports-to-decline-in-2025-exports-to-rise-us-customs
IMARC Group – India Synthetic Fibers Market Report
�� https://www.imarcgroup.com/india-synthetic-fibers-market
IMARC Group – India High Modulus Low Shrinkage Yarn Market
�� https://www.imarcgroup.com/india-high-modulus-low-shrinkage-polyester-yarn-market
Market.us – Global Polyester Fiber Market Trends
�� https://market.us/report/global-polyester-fiber-market/

Myths Around Polyester Yarn – Debunked!

Sat, 05 Apr 2025 07:11:41 GMT

Polyester yarn has long been a staple in the textile industry, but it’s also surrounded by myths and misconceptions. Many people believe that polyester is uncomfortable, harmful to the environment, or inferior to natural fibers. In reality, modern polyester yarns are innovative, high-performing, and sustainable. Let’s debunk some of the most common myths surrounding polyester yarn.

Beekaylon: Leading the Way in Sustainable Polyester Manufacturing

We are among the leading manufacturers of dope dyed yarn in India, offering high-quality products used across diverse applications, from fashion and home textiles to industrial and automotive sectors. The company is deeply committed to sustainability, integrating eco-friendly raw materials and innovative solutions into its production processes. Beekaylon’s Poly-Go-Round brand exemplifies its dedication to circularity, while its partnership with CiCLO® reinforces its commitment to reducing plastic waste and enhancing biodegradability. With a strong focus on responsible manufacturing, Beekaylon continues to shape the future of sustainable polyester textiles.

Conclusion

Polyester yarn has evolved significantly, overcoming misconceptions and proving its value in the textile industry. With continuous advancements in technology and sustainability, polyester remains a reliable, durable, and eco-friendly choice for modern textiles. Companies like Beekaylon are leading the charge in making polyester more sustainable and versatile, ensuring a greener future for the industry.

BCF Yarn - A Deep Dive

Thu, 16 Jan 2025 09:20:16 GMT

The textile industry is a constantly evolving sector that balances the art of innovation with the demands of functionality and sustainability. Among its many offerings, Bulk Continuous Filament (BCF) yarn stands out as a versatile and essential material, particularly in the carpeting and flooring segments. In this comprehensive guide, we will explore the fundamentals of BCF yarn, its varieties, market dynamics, applications, and Beekaylon’s significant contribution to this domain.

What is BCF Yarn?

BCF yarn is a type of synthetic yarn produced through a continuous filament process. Unlike staple fiber yarns, BCF yarn does not require spinning; instead, it consists of long, continuous filaments that provide unique properties such as strength, elasticity, and uniformity.

Typically made from polymers like polypropylene, polyester, or nylon, BCF yarn is characterized by:

Softness and Bulk: It offers a bulky texture, ideal for plush applications like carpets.
Durability: Its robust structure makes it resistant to wear and tear.
Color Fastness: Advanced dyeing processes allow for vibrant, fade-resistant colors.

Varieties of BCF Yarn Available in the Market

The diversity of BCF yarn arises from the types of polymers used, the production techniques, and the intended applications. Common varieties include:

Polypropylene BCF Yarn: Known for its affordability and lightweight properties, this type is widely used in residential carpets and rugs.
Polyester BCF Yarn: Offers enhanced durability and stain resistance, making it a preferred choice for high-traffic areas and commercial flooring.
Nylon BCF Yarn: Regarded as the premium option, nylon BCF yarn provides superior resilience, elasticity, and longevity.

Each type caters to specific needs, whether it's affordability, performance, or luxury. Manufacturers also offer customizations, such as anti-static treatments, UV resistance, and eco-friendly versions made from recycled materials.

Market Dynamics: Indian and International Perspectives

Indian Market

India, as a burgeoning player in the global textile industry, has seen a steady rise in the production and consumption of BCF yarn. Factors driving this growth include:

Increased Urbanization: Rising demand for modern interiors has led to higher usage of carpets and rugs.
Export Potential: Indian manufacturers are increasingly catering to global markets, thanks to their cost-efficient production processes.
Technological Advancements: Indian textile companies are adopting state-of-the-art machinery to produce high-quality BCF yarns.

In 2023, India’s textile exports reached approximately $44 billion, according to the Ministry of Textiles, with synthetic yarns like BCF contributing significantly. According to the Ministry of Textiles and industry reports, the domestic carpet market is projected to grow at a CAGR of 10% over the next five years, further driving BCF yarn demand.

International Market

Globally, the BCF yarn market is driven by demand from developed economies like the USA and Europe, where carpeting is a staple in homes and commercial spaces. Trends influencing the international market include:

Sustainability: Growing consumer preference for eco-friendly and recycled yarns.
Innovation: Continuous advancements in polymer technology to enhance performance and aesthetics.
Customization: Demand for bespoke solutions tailored to specific industries, such as automotive interiors or marine carpeting.

The global BCF yarn market was valued at approximately $11 billion in 2022 and is expected to grow at a CAGR of 4.5% through 2030, fueled by technological innovations and expanding applications, according to market research reports by Grand View Research and Statista.

Applications of BCF Yarn

BCF yarn’s versatility makes it suitable for a wide array of applications:

Beekaylon’s Contribution to BCF Yarn

Beekaylon Synthetics is a prominent player in the production of BCF Yarn, renowned for its commitment to quality and innovation. The company utilizes advanced technologies such as Neumag S+ machines that enable them to produce high-quality Bulk Continuous Filament Yarns.

Key Features of Beekaylon's BCF Yarn:

Tri-color Capabilities: Beekaylon specializes in producing tri-color BCF yarns that allow for vibrant multi-colored designs within carpets.
Diverse Material Options: They offer a range of products including Polyester (PET), Nylon (PA 6), and Polypropylene (PP) based BCF yarns.
Testing Facilities: Beekaylon employs state-of-the-art testing machines to ensure quality control across their product range. This includes digital thickness gauges and carpet testing machines that evaluate appearance retention and recovery characteristics.
Sustainability Focus: The company emphasizes sustainability by manufacturing nylon and polyester yarns from 100% recycled polymer chips. Their "Poly-Go-Round" product line showcases their commitment to eco-friendly practices while offering functional properties like UV resistance and antimicrobial features.

In conclusion, Bulk Continuous Filament (BCF) yarn represents a significant advancement in synthetic yarn technology. Its unique properties make it indispensable across various industries such as carpet manufacturing, upholstery, and industrial textiles. As market trends continue to evolve towards sustainability and durability, companies like Beekaylon Synthetics are leading the way with innovative solutions that meet contemporary demands while maintaining high standards of quality.

Conclusion

BCF yarn is a cornerstone of modern textile innovation, bridging the gap between functionality and aesthetics. Its wide-ranging applications, combined with advancements in material science, make it an indispensable resource for industries worldwide.

Beekaylon’s commitment to excellence and sustainability ensures that it remains at the forefront of this transformative sector. Whether you’re seeking durability, versatility, or eco-conscious solutions, Beekaylon’s BCF yarns offer unmatched quality and performance.

For more insights into textile innovations, visit Beekaylon’s Spinning Values blog and discover how we’re weaving the future of textiles today.

Digitalization and the Future of Textile Design

Mon, 09 Dec 2024 05:38:01 GMT

The textile industry is at the cusp of a digital revolution, with AI, machine learning, and advanced digital tools transforming how we approach textile design. These innovations are not only enhancing creativity but also optimizing processes to create efficient, personalized, and sustainable solutions for the modern market.

Role of AI and Machine Learning in Textile Design

AI and machine learning have become integral to the textile design process, enabling designers to predict trends, streamline production, and create customized solutions for customers. These technologies analyze massive datasets, from consumer preferences to past sales trends, offering insights that guide design choices. Machine learning algorithms can also simulate textile patterns and colors, reducing the need for physical prototypes and saving resources.

For instance, predictive models can determine how fabrics will behave under different conditions, improving durability and functionality. AI tools such as generative design software empower designers to explore a multitude of design possibilities in seconds, fostering innovation at an unprecedented pace.

Digital Tools for Personalization and Efficiency

Digital tools like CAD software and 3D modeling are transforming the design landscape by enabling virtual prototyping. Designers can now visualize fabrics in a virtual environment, tweaking textures, patterns, and even drape without needing physical samples. This not only accelerates the design process but also significantly reduces waste.

Furthermore, digital printing technology is allowing for unparalleled personalization in textile production. Customers can order fabrics with unique patterns, colors, or designs tailored to their preferences, while businesses can produce small batches efficiently without incurring high costs.

Beekaylon’s Commitment to Innovation

At Beekaylon, innovation is more than a commitment—it's a way of life. This ethos is evident in groundbreaking developments like Puriflex, a yarn designed to bring superior performance and versatility to diverse applications, and our collaboration with CiCLO, which enables the production of biodegradable synthetic fibers for a more sustainable future. Additionally, our state-of-the-art Continuous Polymerization Plant stands as a testament to our dedication to efficiency and environmental responsibility, ensuring a seamless process from raw material to high-quality yarn.

These milestones reflect Beekaylon's relentless drive to redefine industry standards while addressing global challenges. By combining advanced technology with a vision for sustainability, we continue to shape the future of textiles.

To further our commitment to innovation, Beekaylon actively invests in cutting-edge technology and research to stay ahead in the fast-paced textile industry. Our collaboration with global partners enables us to incorporate emerging technologies, such as artificial intelligence and digital analytics, into our processes. This ensures that we not only deliver superior quality but also contribute to creating a more sustainable and efficient textile supply chain.

From pioneering eco-friendly solutions to embracing automation in yarn production, Beekaylon sets benchmarks that inspire the industry to evolve. Whether it's through transformative product lines or technological advancements, our unwavering focus on innovation helps us meet the dynamic demands of customers while safeguarding the environment for future generations.

Digitalization: The Catalyst for Personalization

In the evolving textile industry, the integration of digital tools has allowed designers to cater to individual preferences on an unprecedented scale. AI-powered platforms analyze consumer data to create patterns, colors, and designs that align with market trends and personal tastes. This personalization is not only enhancing customer satisfaction but also reducing waste by aligning production with actual consumer demand. For instance, virtual design tools allow customers to visualize and modify designs before production, ensuring a more accurate translation of their preferences into finished products.

Machine learning algorithms have also brought efficiency to design processes. These systems can quickly analyze existing designs, predict trends, and propose new ideas, freeing up designers to focus on creativity. This combination of personalization and efficiency is transforming the traditional workflow, making it more adaptive and forward-thinking.

Bridging Tradition and Technology

While the industry rapidly moves towards digitalization, it also strives to retain the essence of traditional textile artistry. Tools such as digital looms enable the incorporation of intricate, heritage-inspired patterns into modern textiles. AI can replicate traditional craftsmanship in a way that respects its original charm while optimizing it for contemporary production techniques. This fusion ensures that the richness of tradition is not lost in the race toward technological advancement.

With digitalization, the boundaries of textile design are expanding, blending history and innovation seamlessly. The industry now stands at an exciting juncture, where technology doesn't overshadow tradition but enhances its value, creating textiles that are meaningful, sustainable, and uniquely beautiful.

A Sustainable and Digital Future

The integration of digital technologies in textile design is not just about efficiency and creativity—it’s also about sustainability. By reducing waste through virtual sampling and enabling on-demand production, the industry is moving closer to a circular economy. With digitalization as its cornerstone, the future of textile design promises to be more inclusive, innovative, and environmentally conscious.

As the industry evolves, companies like Beekaylon are leading the charge, ensuring that textiles of tomorrow meet the demands of a digitally savvy and sustainability-focused world.

3D Printing in Textiles: A Revolution in Fabric Innovation

Tue, 22 Oct 2024 07:27:55 GMT

3D Printing in Textiles - An Overview

Textile manufacturing is experiencing a transformation like never before, and at the heart of this change is 3D printing. What started as a technology for industries like aerospace and automotive has now found its way into the world of fabrics and fashion, bringing new possibilities for how we design and produce textiles. And the best part? This shift is not only about creating cutting-edge designs—it’s about sustainability, customization, and pushing the boundaries of what’s possible.

A Greener Way to Make Fabrics

One of the biggest advantages of 3D printing in textiles is its potential to make the industry more sustainable. Traditional methods often involve using a lot of water, energy, and materials—resulting in waste. With 3D printing, fabric is made layer by layer, using just the right amount of material for the design. This cuts down on waste, making the whole process more efficient and eco-friendly.

Even better, many of the materials used in 3D printing are recyclable or biodegradable, which means the environmental footprint is significantly reduced. With growing concerns about the planet, 3D printing offers a practical solution for the textile industry to rethink its methods and reduce its impact on the environment.

Tailored to Perfection

Customization is another exciting benefit of 3D printing. Normally, creating tailored fabrics or garments can be costly and time-consuming. But with 3D printing, it’s much easier and faster to create designs that are unique to each person’s preferences—whether it’s the fit, texture, or pattern.

Imagine being able to order a piece of clothing that’s made exactly to your measurements and style choices, with no need for alterations. That’s the kind of flexibility this technology brings, and it’s changing the game for everything from high fashion to sportswear. The ability to personalize clothing opens up a new world of possibilities for both designers and consumers alike.

Innovative Designs Like Never Before

Perhaps the most exciting part of 3D printing in textiles is the design freedom it offers. Complex structures, intricate patterns, and shapes that were once impossible to achieve with traditional methods are now within reach. Designers can experiment with new materials and create fabric that’s not only aesthetically interesting but also highly functional.

For industries like medical textiles and performance wear, this means the ability to create fabrics that are stronger, more flexible, or even reactive to the wearer’s body—think of smart fabrics that adjust to temperature or track your health. This opens up so many possibilities for what textiles can do beyond just looking good.

How Beekaylon is Innovating

Beekaylon’s Commitment to Innovation in 3D Printing and Sustainable Textiles

At Beekaylon, we are proud to be at the forefront of textile innovation, leveraging advanced technologies such as 3D printing to revolutionize the industry. Through our brands like Poly-Go-Round , Puriflex and our partnership with CiClo, we are driving sustainability and customization in textile manufacturing. Whether it’s creating eco-friendly fabrics or exploring new avenues for durable, lightweight materials, our commitment remains rooted in delivering high-quality solutions that meet the ever-evolving demands of the market. Beekaylon ensures that these cutting-edge innovations contribute to a more sustainable future, offering clients versatile and environmentally responsible textile options.

At Beekaylon, we’ve always believed that innovation is key to staying ahead. That’s why we’re excited about the potential of 3D printing and how it’s reshaping the textile industry. While we continue to explore the applications of 3D printing, we’re also committed to sustainable practices, using eco-friendly and recyclable materials wherever possible.

Our goal is to not only stay on top of the latest trends but to lead the way in developing durable and customizable fabric solutions that meet the needs of our customers. Whether it’s improving the quality of our textiles or finding more efficient ways to produce them, we’re always looking for ways to innovate and push the boundaries of what’s possible.

Wrapping Up

It’s clear that 3D printing is revolutionizing the textile industry. The ability to create sustainable, customizable, and innovative fabrics is changing the way we think about manufacturing and design. And as more companies, including Beekaylon, embrace these advancements, the future of textiles is looking more exciting than ever.

This technology is still evolving, but one thing’s for sure—3D printing is set to reshape the fabric of our lives, from what we wear to how we produce it.

Ep. 12 - Michiel Swagemaker - Swatech.eu

Mon, 23 Sep 2024 09:43:05 GMT

Ep. 12 - Michiel Swagemakers, Swatech

# Insider Insights: The Journey of Swatech with Michiel Swagemakers

In the ever-evolving landscape of the textile industry, innovation and customer-centric practices set apart the leaders from the followers. In episode 12 of "Spinning Values" by Beekaylon, Kartik Chaudhry hosts Michiel Swagemakers, the dynamic founder of Swatech, a leading yarn agency in Europe. Michiel shares his extensive journey, offering insights into Swatech's operations, the importance of confidentiality in business, and how the company maintains its competitive edge.

## Introduction to Swatech

Swatech, founded by Michiel Swagemakers, is a trailblazer in the carpet yarn market in Europe. Rooted in the Netherlands, this small yet impactful agency bridges the gap between producers in Turkey and India and carpet manufacturers across Western Europe. Their exceptional customer-centric approach and confidential business practices are the cornerstones of their success.

## The Importance of Confidentiality

One of the unique propositions of Swatech is its commitment to confidentiality. Michiel emphasized that being confidential and keeping new developments with a customer secret is vital. "You develop something with a customer. So customers are either willing to work with you or not," said Michiel. This ethical practice ensures that Swatech maintains trust and long-term relationships with its clients.

## Swatech's Market Reach and Products

Swatech specializes in carpet yarns, catering to a diverse clientele across Belgium, Holland, Germany, Denmark, England, Spain, and France. Their products range from BCF yarns to fine yarns used in various segments of the textile industry. Swatech's partnerships with prominent producers such as Beekaylon ensure a steady supply of top-quality yarns, further solidifying its position in the market.

### Key Products from Beekaylon

Michiel highlighted the two primary types of products procured from Beekaylon: FDY yarns and BCF yarns. FDY yarns are fine yarns used across the textile industry, while BCF yarns are exclusively used in carpets. Swatech also ventures into recycled polyester, aligning with the growing demand for sustainable products.

## The Carpet Market in Europe

The carpet market in Europe is multifaceted, comprising residential carpets, rugs, and contract carpets for commercial use. According to Michiel, the demand for soft flooring in residential areas has seen a decline, but the contract carpet market remains steady. The turf business, particularly artificial grass, is on the rise, indicating a shifting landscape in the industry.

## Innovations and Technological Advancements

The textile industry has undergone significant technological advancements over the years. Michiel noted that from the 90s, there has been a shift from staple fiber yarn to man-made BCF yarns. Innovative machinery has enabled higher output, better quality, and lower costs, making it possible to produce more complex and vibrant yarns.

### Swatech's Unique Proposition

What sets Swatech apart is its blend of commercial acumen and technical expertise. The company's focus on quality, confidentiality, and long-term business relationships has contributed to its reputation and success. Michiel's team, including Luke and Yuke, brings decades of experience and youthfulness, ensuring that Swatech remains at the forefront of innovation.

## Sustainability in Textiles

Sustainability is a critical focus for Swatech and the broader textile industry. Michiel underscored the importance of recycled content in textiles and the need for circularity in the product lifecycle. Although Swatech can influence the production process, the challenge remains in managing the end-of-life phase of textile products.

## Advice for Young Professionals

For aspiring professionals entering the textile industry, Michiel offers invaluable advice: "Have a goal, both short-term and long-term, and work towards it with honesty and discipline." He emphasizes the importance of being genuine, hardworking, and continually learning to succeed in this dynamic field.

## Conclusion

Michiel Swagemakers’ insights offer a glimpse into the intricate workings of Swatech and the textile industry at large. His journey from studying textile techniques in Germany to founding a successful yarn agency underscores the importance of innovation, customer-centric practices, and sustainability.

To learn more about Swatech and stay updated with their latest developments, visit their [website](https://swatech.eu) or follow them on [LinkedIn](https://www.linkedin.com/company/swatech-yarns-and-more).

Catch the full conversation on "Spinning Values," available on Spotify, Apple, or the [Beekaylon website](https://beekaylon.com). This episode, produced by Inscape Media and hosted by Kartik Chaudhry, is an inspiring story of innovation, dedication, and the future of textiles.

Embracing Fashion from Eco-Friendly and Recycled Materials

Wed, 03 Jul 2024 00:13:11 GMT

The fashion industry is undergoing a significant transformation as it grapples with its environmental impact. One of the most promising solutions lies in the use of eco-friendly and recycled materials. This approach not only reduces waste but also promotes a more sustainable and ethical fashion industry. Here’s a closer look at how these materials are revolutionizing fashion and how you can incorporate them into your wardrobe.

The Environmental Impact of Traditional Fashion

The traditional fashion industry is notorious for its environmental footprint. It accounts for 2 to 8 percent of global carbon emissions, with significant contributions from water consumption, microplastic pollution, and landfill waste[3]. Fast fashion exacerbates these issues by promoting a culture of disposable clothing, leading to massive amounts of textile waste.

How to Incorporate Sustainable Fashion into Your Wardrobe

Choose Quality Over Quantity: Invest in high-quality pieces that will last longer and withstand trends.
Shop Secondhand: Thrift stores and online resale platforms offer a wide range of pre-loved clothing, reducing the demand for new items.
Support Sustainable Brands: Look for brands that prioritize eco-friendly materials and ethical production practices. Many brands are transparent about their sourcing and manufacturing processes[2].
Care for Your Clothes: Properly maintaining your garments can extend their lifespan. Follow care instructions and consider repairing items instead of discarding them.
Recycle and Upcycle: When your clothes reach the end of their life, recycle them responsibly or get creative with upcycling projects.

Innovative Ways to Incorporate Recycled Materials into Fashion

The fashion industry is increasingly turning to recycled materials to address its significant environmental impact. Here are some innovative ways that designers and brands are incorporating recycled materials into their collections:

1. Chemical and Mechanical Recycling Technologies

Innovative technologies are transforming post-consumer textiles through chemical and mechanical recycling processes. These methods break down used fabrics into their raw fibers, which can then be regenerated into new textiles. This approach not only reduces waste but also promotes a circular economy by keeping materials in use for longer periods[3].

2. Recycled Polyester from Plastic Bottles

Recycled polyester, made from PET plastic bottles, is becoming a popular choice for sustainable fashion. This material helps reduce plastic waste and the demand for virgin polyester. Brands are blending recycled polyester with other fabrics like cotton to create durable and eco-friendly garments[5].

3. Upcycling Pre-Consumer Off-Cuts

Pre-consumer off-cuts, the textile waste found on factory floors, are being upcycled into new garments. These materials are sorted, shredded, and re-spun into new yarns, which are then used to create new clothing items. This process not only reduces waste but also conserves resources by reusing existing materials[5].

4. Digital Platforms for Waste Management

Some brands are using digital platforms to manage and trace textile waste. For example, H&M Group launched a pilot project where waste is sorted by material composition and color, then handed over to recyclers. This system provides valuable data for planning recycling solutions and ensures that waste is effectively recycled into new products[4].

5. Regenerative Fiber Projects

Projects like NuCyl and Circulose are pioneering the use of recycled cotton by partnering with brands to create new garments from textile waste. These initiatives divert waste from landfills and use advanced technology to regenerate fibers, promoting a closed-loop system in fashion production[5].

6. Recycled Wool and Cashmere

Recycled wool and cashmere are gaining popularity as sustainable materials. These fibers are often sourced from pre-consumer off-cuts and post-consumer garments, then processed and re-spun into new yarns. This method not only reduces waste but also provides high-quality, sustainable alternatives to virgin wool and cashmere[5].

7. Innovative Fiber Regeneration Techniques

New fiber regeneration techniques are emerging, allowing for the creation of high-quality textiles from recycled materials. These techniques involve breaking down used fabrics into their molecular components and reassembling them into new fibers. This approach can produce materials that are as strong and durable as their virgin counterparts[3].

Conclusion

Incorporating recycled materials into fashion is a crucial step towards a more sustainable and ethical industry. By embracing innovative recycling technologies and processes, the fashion industry can significantly reduce its environmental footprint and promote a circular economy. As consumers, supporting brands that prioritize recycled materials and sustainable practices can drive further change and help create a more sustainable future for fashion.

The shift towards eco-friendly and recycled materials in fashion is a crucial step in addressing the industry's environmental challenges. By making conscious choices about the materials we wear, we can significantly reduce our carbon footprint and promote a more sustainable future. Embrace the change and be part of the movement towards a greener, more ethical fashion industry.

Citations:

Sustainable Fashion

[1] https://www.weforum.org/agenda/2023/06/recycled-material-could-solve-most-of-fast-fashion-s-sustainability-problems-here-s-how/

[2] https://www.thehonestconsumer.com/blog/ethical-sustainable-fashion-blogs

[3] https://stateofmatterapparel.com/blogs/som-blog/35-sustainable-materials-for-eco-friendly-fashion

[4] https://www.sustainablefashionmatterz.com/sustainable-fashion-blog [5] https://www.greenmatch.co.uk/blog/2016/06/the-most-inspirational-blogs-on-sustainable-fashion

Recycled Materials

[1] https://www.weforum.org/agenda/2023/06/recycled-material-could-solve-most-of-fast-fashion-s-sustainability-problems-here-s-how/

[2] https://www.weforum.org/agenda/2024/04/secondhand-clothes-sustainable-fashion-circular-economy/

[3] https://textilefocus.com/enhancing-recycled-post-consumer-textiles-innovative-technologies-for-promoting-sustainable-fashion/

[4] https://hmgroup.com/report-stories/turning-waste-into-fashion-with-recycled-materials/

[5] https://baliston.com/blogs/blog/what-types-of-sustainable-recycled-materials-are-used-in-modern-fashion-production

Ep. 11 - Enhancing communication skills in the Textile Industry - Ami Ved

Sun, 09 Jun 2024 04:34:06 GMT

Mastering Communication: Insights from Ami Ved on the Spinning Values Podcast

In the latest episode of the Spinning Values Podcast, produced by Inscape Media for Beekaylon Synthetics, host Kartik Chaudhry welcomes Ami Ved, a seasoned communications coach and soft skills specialist. With 19 years of experience, Ami shares invaluable insights on how effective communication can drive success in industries, including the textile sector, which represents a significant segment of the market.

Introduction to Ami Ved

Ami Ved kicks off the conversation by introducing herself and her extensive background in communications and training. Over the past two decades, Ami has worked with numerous corporate and individual clients, including a notable decade-long stint in China teaching English as a foreign language. This global experience has enriched her understanding of diverse communication dynamics, which she now brings to her sessions with various clients, including BFSI sector corporations and prominent firms like Brother International, JM Financial, and BNP Paribas.

The Evolution of Communication Skills

Kartik delves deeper into Ami's journey, discovering her transformation from a customer service representative to a communication trainer. Her story is a testament to her passion for training and her drive to be on the other side of the stage, inspired by the foreign trainers she encountered early in her career. Ami’s dedication to mastering accent training and customer service skills, especially during her time in the call center industry, provided her with a robust foundation for her subsequent roles in training and personal development.

The Role of Communication in Medium-Sized Businesses

One of the pivotal topics discussed in the podcast is the significant impact of communication on medium-sized businesses, particularly in the textile industry. Ami emphasizes that effective communication minimizes errors, builds trust, and fosters better collaboration across various stages of production and supply chain management. She explains how skills such as storytelling and executive presence can enhance a company's brand image and create a cohesive working environment.

Overcoming Natural Advantages in Communication

Ami addresses a common misconception that some individuals are naturally better communicators due to their upbringing or environment. While acknowledging that these factors can play a role, she insists that communication is essentially a skill that can be developed with practice and dedication. Drawing from her own experiences and those of her diverse clientele, Ami firmly believes that anyone can improve their communication skills, provided they put in the necessary effort.

Accent Neutralization and Its Global Importance

A crucial part of Ami’s training focuses on accent neutralization. Whether you're an IT professional from Karnataka or a sales executive in Mumbai, neutralizing one's accent can significantly enhance clarity and mutual understanding in international and cross-cultural business contexts. According to Ami, this is less about adopting a specific accent and more about eliminating strong regional dialects to communicate effectively on a global platform.

Conveying Brand Values

In the podcast, Ami highlights the importance of communication in conveying brand values. From the initial greeting to the final pitch, every interaction a representative has with clients reflects the company’s brand. This necessitates a comprehensive communication strategy encompassing verbal, non-verbal, and written skills. By fostering effective communication, businesses can build a strong brand image and ensure consistency in their messaging, both internally and externally.

Diversity and Inclusion Through Communication

The discussion also touches upon how communication training can support diversity and inclusion initiatives within organizations. Ami outlines four key areas: training that focuses on cultural competence, creating an open and respectful workplace, encouraging diverse perspectives, and enhancing employee satisfaction. Through targeted communication training, businesses can foster an inclusive environment that values and leverages diverse viewpoints.

Ami Ved’s Entrepreneurial Journey

Ami shares her inspiring journey of establishing her company, Speak with Ami. Despite the challenges of starting anew in a saturated market, she leveraged her skills and platforms like LinkedIn to build a successful business. Her story underscores the importance of perseverance, consistent effort, and leveraging digital platforms in entrepreneurial success.

Conclusion

The Spinning Values Podcast with Ami Ved offers a treasure trove of insights on the critical role of communication in business success. From minimizing errors and building trust to fostering a strong brand image and supporting diversity, effective communication is indispensable. Ami’s extensive experience and practical advice make this episode a must-listen for anyone looking to improve their communication skills and drive their business forward.

To listen to the full episode and learn more, visit [Beekaylon’s Spinning Values Podcast] (https://beekaylon.com/spinning-values).

The Trace of Transformation: How Blockchain Technology is Revolutionizing the Textile Industry with Unparalleled Traceability Benefits

Sun, 28 Apr 2024 08:59:42 GMT

The textile industry is no stranger to innovation, but the emergence of blockchain technology has set the stage for a revolutionary transformation. With its unparalleled traceability benefits, blockchain is reshaping the way textiles are produced, tracked, and verified.

By leveraging the power of blockchain, textile manufacturers can ensure transparency throughout the supply chain. Each step of the production process, from raw materials to final product, is recorded on an immutable and decentralized ledger. This enables brands and consumers to have complete visibility into the origin, authenticity, and quality of a textile.

Moreover, blockchain technology enhances traceability by encrypting and linking every transaction and interaction along the supply chain. This means that any attempt to alter or tamper with the data is instantly detectable, safeguarding against counterfeiting and fraud.

The benefits of blockchain in the textile industry extend beyond accountability and transparency. It also allows for efficient inventory management, streamlined logistics, and improved sustainability practices. With blockchain, brands can confidently showcase their commitment to ethical sourcing, providing consumers with the peace of mind that they are purchasing products with a minimal impact on the environment and human rights.

As blockchain continues to revolutionize various sectors, the textile industry is embracing the technology's transformative potential. Through its unmatched traceability benefits, blockchain is paving the way for a more transparent, ethical, and sustainable future in textiles.

The Textile Industry and its Challenges

The textile industry plays a significant role in the global economy, providing employment to millions of people worldwide. However, it is not without its challenges. One of the major concerns in the industry is the lack of transparency and traceability throughout the supply chain.

Traditionally, the textile supply chain has been complex and fragmented, making it difficult to track the origin of raw materials, monitor the various stages of production, and ensure ethical practices. This lack of transparency has led to issues such as counterfeit products, unethical labor practices, and environmental degradation.

Consumers are becoming increasingly conscious of the products they purchase, demanding more information about the materials used, the working conditions of the workers, and the overall sustainability of the textile industry. This shift in consumer behavior has created a need for greater transparency and traceability in the textile supply chain.

The Need for Traceability in the Textile Industry

Traceability is a critical aspect of the textile industry, as it allows brands and consumers to know the journey of a textile product from its inception to its final destination. It provides information about the origin of raw materials, the manufacturing process, and the distribution channels involved.

Traceability is particularly important in the textile industry due to the complex nature of the supply chain. Textiles often go through multiple stages of production, involving different suppliers, manufacturers, and distributors. Without traceability, it becomes challenging to ensure ethical practices, prevent counterfeiting, and address issues related to quality control.

Moreover, traceability is crucial for brands that wish to showcase their commitment to sustainability and ethical sourcing. By providing transparency and traceability, brands can build trust with consumers, who are increasingly demanding products that align with their values.

How Blockchain Technology Works

Blockchain technology is a decentralized ledger system that records and verifies transactions across multiple computers or nodes. It provides a secure and transparent way to store and share information, without the need for intermediaries.

At its core, blockchain consists of blocks of data that are linked together in a chain-like structure. Each block contains a set of transactions or information, along with a unique identifier called a hash. The hash is created by applying a cryptographic algorithm to the data within the block.

Once a block is added to the blockchain, it becomes virtually impossible to alter or tamper with the data within it. This is because changing the data in one block would require changing the data in all subsequent blocks, which is computationally expensive and easily detectable.

Blockchain technology also relies on a consensus mechanism, which ensures that all nodes in the network agree on the validity of transactions. This consensus mechanism eliminates the need for a central authority or third-party intermediaries, making blockchain more secure and efficient.

Benefits of Blockchain Technology in the Textile Industry

Blockchain technology offers a wide range of benefits for the textile industry, particularly in terms of traceability and transparency. Here are some of the key advantages:

Real-World Examples of Blockchain Implementation in the Textile Industry

Several companies and organizations have already started leveraging blockchain technology to improve traceability and transparency in the textile industry. Here are some real-world examples:

Challenges and Limitations of Blockchain Technology in the Textile Industry

While blockchain technology offers immense potential for the textile industry, it is not without its challenges and limitations. Here are some key considerations:

Future Prospects of Blockchain Technology in the Textile Industry

Despite the challenges and limitations, the future prospects of blockchain technology in the textile industry are promising. As the technology matures and evolves, it is expected to overcome many of the current limitations and offer even greater benefits. Here are some potential future developments:

1. Interoperability and Integration with IoT

With the advent of the Internet of Things (IoT), the textile industry can benefit from the integration of blockchain technology with IoT devices. By connecting sensors and RFID tags to the blockchain, textiles can be tracked and monitored in real-time, providing even greater transparency and traceability. This integration can also enable automated data collection and improve supply chain efficiency.

2. Smart Contracts and Automation

Smart contracts, which are self-executing contracts with the terms of the agreement directly written into code, can further streamline processes in the textile industry. For example, smart contracts can automatically trigger payments to suppliers once certain conditions are met, reducing the need for manual intervention and improving efficiency. This automation can also help in ensuring compliance with ethical and sustainability standards.

3. Industry-wide Collaboration and Standards

To fully harness the potential of blockchain technology, industry-wide collaboration and the establishment of standards are essential. This includes the development of common protocols, data formats, and interoperable systems. By working together, stakeholders in the textile industry can create a unified and transparent supply chain ecosystem that benefits everyone involved.

4. Integration of AI and Machine Learning

The integration of artificial intelligence (AI) and machine learning with blockchain technology can further enhance the capabilities of the textile industry. AI algorithms can analyze the vast amounts of data stored on the blockchain, providing valuable insights into consumer behavior, market trends, and supply chain optimization. This data-driven approach can help brands make informed decisions and improve overall performance.

How Businesses can Adopt Blockchain Technology in the Textile Industry

For businesses in the textile industry looking to adopt blockchain technology, here are some key steps to consider:

1. Identify Pain Points and Objectives

Start by identifying the specific pain points and objectives that blockchain can address in your business. Whether it is improving traceability, enhancing transparency, or streamlining logistics, understanding your goals will help you determine the right implementation strategy.

2. Determine the Right Blockchain Solution

There are various blockchain solutions available, ranging from public blockchains like Bitcoin and Ethereum to private or consortium blockchains. Consider the specific needs of your business, including scalability, data privacy, and interoperability requirements, when choosing the right blockchain solution.

3. Collaborate with Stakeholders

Blockchain implementation requires collaboration among various stakeholders, including suppliers, manufacturers, retailers, and consumers. Engage with these stakeholders to create a shared vision and ensure their buy-in throughout the implementation process. Collaboration can also help in establishing industry-wide standards and best practices.

4. Pilot Projects and Proof of Concepts

Start with small-scale pilot projects or proof of concepts to test the feasibility and effectiveness of blockchain technology in your business. This allows you to identify any challenges or limitations early on and make necessary adjustments before scaling up.

5. Ensure Data Privacy and Security

Given the sensitive nature of data in the textile industry, ensure that appropriate measures are in place to protect data privacy and security. This may include encryption, access controls, and compliance with relevant data protection regulations.

6. Monitor and Evaluate Performance

Continuously monitor and evaluate the performance of the blockchain implementation, including its impact on traceability, transparency, and efficiency. This will help you identify areas for improvement and make data-driven decisions to optimize the benefits of blockchain technology.

Conclusion: The Potential of Blockchain Technology in Transforming the Textile Industry

Blockchain technology has the potential to revolutionize the textile industry by providing unparalleled traceability benefits. Through its ability to ensure transparency, accountability, and efficiency, blockchain can address the challenges of the textile supply chain, from raw materials to final products.

By leveraging blockchain, textile manufacturers can showcase their commitment to ethical sourcing and sustainability, providing consumers with the confidence that they are purchasing products with a minimal impact on the environment and human rights. With real-world examples already demonstrating the benefits of blockchain in the textile industry, it is clear that the technology has the power to reshape the industry for the better.

As businesses in the textile industry embrace blockchain technology and overcome the challenges and limitations, the future looks promising. With advancements in interoperability, integration with IoT and AI, and industry-wide collaboration, blockchain has the potential to create a transparent, ethical, and sustainable future for the textile industry.

Amrish Shahi - From Yarn Innovations to Fashion Statements

Sat, 06 Apr 2024 08:42:46 GMT

Embracing Innovation in Textile Design:

A Conversation with Amrish Shahi

In the ever-evolving world of textiles and fashion, innovation at the yarn level is revolutionizing the industry. The Spinning Values podcast recently welcomed Amrish Shahi, a trailblazer in textile design who is making waves from yarn to final product with his unique approach. Hosted by Rajeev Nedumaran, episode 10 dives deep into Shahi's philosophy and the impact of his work on the textile industry.

A Revolution from the Yarn Up

Amrish Shahi has been at the forefront of textile innovation for over two decades, transforming the industry's approach to design and sustainability. With a background in science and a rich career that started with his education at NIFT, Shahi's journey is nothing short of inspirational. His unique perspective on design, focusing on the yarn level, has not only set him apart but also paved the way for future designers.

Shahi's approach is about starting with the core— the yarn. Instead of waiting for mills to dictate trends, Shahi dives into the building blocks of textiles, collaborating directly with yarn spinners and fabric makers. This proactive method allows for groundbreaking innovation in fabric and garment design, pushing the boundaries of what is possible in textile production.

The Impact of Innovation

The conversation with Shahi on the Spinning Values podcast revealed several crucial insights. First and foremost, his method demonstrates the power of innovation at the yarn level. Brands that prioritize such innovation find themselves leading the market, not just following trends but setting them. This approach, according to Shahi, results in truly unique products that require minimal intervention down the line— a testament to the foundational quality of the work.

Moreover, Shahi's work challenges and changes the established industry workflows, fostering a more direct relationship between brands and yarn manufacturers. His efforts debunk the notion that exhaustive design interventions are necessary at later stages. Instead, if the yarn itself is innovative, everything that follows can maintain simplicity while achieving remarkable results.

The Future of Textiles: Sustainability and Technology

Shahi envisions a future where sustainability and practicality go hand in hand. As consumer needs evolve, the demand for durable, functional, and sustainable garments grows stronger. He emphasises the importance of sustainability, not just as a buzzword, but as a core principle driving the industry forward. Brands like Patagonia serve as beacons in this regard, showcasing that it's possible to marry ethical practices with commercial success.

In detailing his journey and philosophy, Shahi offers a trove of wisdom for aspiring designers. He underlines the importance of finding one's unique voice, staying patient, and embracing the emotional aspects of design. For Shahi, design is as much about emotion and expression as it is about functionality and aesthetics.

A Beacon for Future Designers

Amrish Shahi's dialogue with Rajeev sheds light on an innovative path forward for the textile industry. It's a narrative that emphasizes the power of starting small—in this case, at the very fiber of the industry—to provoke large-scale change. His startup, the Simple Life, encapsulates this ethos, practicing "degrowth" by taking on select projects that align with their values, demonstrating that quality and impact outweigh quantity.

In conclusion, Amrish Shahi's conversation on the Spinning Values podcast not only provides a fascinating look into the mind of a visionary designer but also serves as a clarion call for the industry. By focusing on innovation at the yarn level, embracing sustainability, and recognizing the emotional power of design, the future of textiles looks brighter and more promising than ever.

Dr. Neha Mehra on Bridging the Gap from Classroom to Industry in Textile Engineering

Wed, 21 Feb 2024 09:41:25 GMT

Spinning Values: Evolving Textile Industry and the Role of Education

In this episode of 'Spinning Values', a podcast by Beekaylon Synthetics, Dr. Neha Mehra from VJTI, one of India's top institutions in textiles and technology, discusses the evolving textile industry and the importance of internship programs. She emphasizes the need for incorporating changes in the industry into educational curricula to ensure students are well-prepared for professional life. Dr. Mehra also highlights various innovative projects carried out at VJTI, involving topics like wound healing, mosquito-repellent fabrics, and more. Additionally, she emphasizes the importance of automation and Industry 4.0 in textile manufacturing and encourages students to focus on learning concepts and avoiding shortcuts for long-term benefits. She also discusses the importance of sustainability in the industry, highlighting contributions from companies like Beekaylon Synthetics.

00:00 Introduction to the Podcast
00:31 Welcome to Spinning Values
00:43 Guest Introduction: Dr. Neha Mehra
07:45 The Importance of Industry-Institute Interaction
09:54 The Role of Faculty in Bridging the Gap
10:54 The Importance of Curriculum Alignment with Industry Advances
17:47 The Impact of the New Education Policy
23:08 The Importance of Internships in Textile Engineering
28:31 The Role of Automation and Technology in Textile Industry
31:42 The Importance of Sustainability in the Textile Industry
35:48 Advice for Aspiring Textile Engineers
40:41 Conclusion and Wrap Up

Thank you for listening to this episode. Please do share with others who might be interested in this topic.

Budget 2024 and the Textile Sector: Analysis and Outlook

Mon, 12 Feb 2024 02:13:15 GMT

Amidst the anticipation surrounding the Interim Budget 2024, Finance Minister Nirmala Sitharaman took the podium on February 1, delivering her shortest-ever speech lasting 56 minutes. As stakeholders in the textile sector eagerly awaited announcements that would shape the future of their industry, the interim budget, while pragmatic, opened avenues for hope and optimism.

The textile and apparel industry had harbored hopes that the interim budget would unveil tax incentives and bolster textile infrastructure, thereby fortifying manufacturing capabilities and amplifying export potential. While these expectations weren't fully met, the budget did showcase positive strides that set the stage for future growth and development.

Notably, the increased allocation of approximately 27.60% for the Ministry of Textiles for the fiscal year 2024-25 compared to the previous year is indeed a commendable stride forward. This enhanced allocation encompasses various schemes such as PM MITRA Park, NITTM, A-TUFS, ISDS, RoTDEP, and RoSCTL, among others. Additionally, provision for the Cotton Corporation of India to execute MSP operations for cotton underscores a commitment to bolstering cotton farming communities.

The extension of the Rebate of State and Central Taxes and Levies (RoSCTL) scheme for two years has been warmly received by the textile and apparel industry. The scheme's continuation is deemed essential for long-term trade planning, and the augmented allocation in the budget reflects a concerted effort towards sustaining this crucial initiative.

Moreover, measures aimed at incentivizing green power adoption, including bio-manufacturing and renewable energy sources like rooftop solar and offshore wind, signify a progressive stance towards reducing the industry's carbon footprint. Initiatives geared towards aligning with sustainability goals resonate deeply with Beekaylon's ethos of environmental stewardship.

Furthermore, the relentless focus on enhancing logistics infrastructure to alleviate transaction costs and enhance global competitiveness bodes well for the textile industry's growth trajectory.

In light of these observations, Beekaylon remains optimistic that the forthcoming full-fledged budget, slated for announcement around July, will address the pressing demands of the industry. As stalwarts in the polyester yarn manufacturing landscape, we remain steadfast in our commitment to pioneering sustainable solutions that not only elevate industry standards but also align with the nation's vision of economic resilience and environmental stewardship.

Source: https://www.thehindu.com/business/budget/interim-budget-2024-textile-industry-expresses-disappointment/article67800837.ece#:~:text=The%20total%20budget%20allocation%20for,towards%20the%20cotton%20MSP%20operations .

How ESG is Shaping the Textile Industry: Sustainable Transformation

Wed, 31 Jan 2024 06:23:53 GMT

How ESG is shaping the Textile Industry

The global textile industry, a significant player in the world economy, is undergoing a transformative shift driven by Environmental, Social, and Governance (ESG) principles. ESG considerations are becoming increasingly central to decision-making, and companies are recognizing the importance of sustainable practices. In this era of conscious consumerism, where environmental and social impacts matter as much as the products themselves, the textile industry is embracing change.

The ESG Triad: A Holistic Approach

ESG encapsulates a holistic approach to corporate responsibility, urging businesses to consider the environmental, social, and governance impacts of their operations. In the textile industry, this translates into a reevaluation of supply chains, manufacturing processes, labor practices, and corporate governance structures.

Environmental Stewardship: Redefining Manufacturing Practices

In response to the environmental component of ESG, textile companies are redefining their manufacturing practices. Embracing sustainable raw materials, reducing water and energy consumption, and minimizing waste have become key priorities. Innovative technologies, such as water recycling systems and eco-friendly dyeing processes, are being employed to ensure a more environmentally responsible production cycle.

Social Responsibility: Empowering Communities

ESG's social dimension emphasizes the well-being of the workforce and the communities in which companies operate. This includes fair labor practices, diversity and inclusion initiatives, and community engagement. Textile companies are increasingly recognizing the significance of these factors in building a resilient and socially responsible business model.

Governance Excellence: The Pillar of Accountability

Governance, the third pillar of ESG, focuses on corporate accountability, transparency, and ethical business practices. Establishing robust governance structures ensures that companies adhere to ethical standards, foster accountability, and maintain transparency in their operations. This instills confidence among investors, consumers, and other stakeholders.

Beekaylon Synthetics: Pioneering Sustainable Textiles

Amidst this shift, companies like Beekaylon Synthetics are emerging as leaders in sustainable textile practices. Beekaylon Synthetics recognizes the imperative to balance profitability with social and environmental responsibility. The company has seamlessly integrated sustainable methods into its operations, setting a precedent for the industry.

Sustainable Methods at Beekaylon Synthetics: A Snapshot

Beekaylon Synthetics has embraced sustainability across its value chain. From adopting eco-friendly raw materials to implementing energy-efficient production processes, the company is committed to minimizing its carbon footprint. Additionally, Beekaylon Synthetics places a strong emphasis on ethical labor practices, ensuring fair wages and safe working conditions for its employees.

Investing in Innovation: Beekaylon Synthetics' Commitment to R&D

In the pursuit of sustainable textiles, Beekaylon Synthetics invests heavily in research and development. The company is at the forefront of developing innovative, eco-friendly materials that not only meet but exceed industry standards. This commitment to innovation positions Beekaylon Synthetics as a trailblazer in sustainable textile solutions.

A Sustainable Tomorrow with Beekaylon Synthetics

India: a global hub of textile excellence

Sun, 07 Jan 2024 05:46:20 GMT

Explore the Vibrant Textile Legacy of India: A Journey Through Famous Locations and Their Specialities!

Unveil the secrets of India's textile treasures!

Dive into India's textile treasures! of India's textile history as we embark on a journey through famous locations that have been instrumental in shaping the nation's diverse textile heritage. From the northern plains to the southern shores, each region offers a unique narrative, craftsmanship, and specialty that continues to captivate the world.

Embark on a fascinating journey as you explore the vivid textile heritage of India. Each location has its own unique stories, craftsmanship, and designs that reflect the diversity and beauty of our nation. These textiles are not just fabrics, but living legacies that have been passed down through generations, embodying the spirit of our rich cultural heritage.

Join us in series of Pearls of Wisdom, celebrating the timeless beauty of Indian textiles and supporting the talented artisans behind these exquisite creations.

Let's embrace the heritage, craftsmanship, and vibrant colors that continue to make .

Ep. 8 - Heartfulness Meditation: Achieving Personal Excellence in the Corporate World - Tushar Pradhan

Wed, 13 Dec 2023 07:09:36 GMT

Ep. 8 - Heartfulness Meditation - In Conversation with Tushar Pradhan

In this episode of Spinning Values by Beekaylon Synthetics, Kartik Chaudhry has an insightful conversation with Tushar Pradhan, a practitioner of Heartfulness Meditation. Tushar discusses the differences between Heartfulness and Mindfulness Meditation, explaining that Heartfulness helps individuals access the 'soul of the spirit'. They delve into the relevance of Heartfulness Meditation in corporate settings, discussing how it can enhance personal excellence and help manage stress. Tushar also shares his journey of self-discovery, including his transition from a successful career in finance to discovering heartfulness as a means of self-exploration.

00:00 Introduction to Heartfulness

00:28 Welcome to Spinning Values Podcast

00:46 Guest Introduction: Tushar Pradhan

02:24 Tushar Pradhan's Journey

03:44 Transition to Heartfulness Meditation

05:03 Understanding Heartfulness Meditation

06:00 Tushar's Inspiration for Meditation

09:25 The Role of Spirituality in Meditation

20:17 Heartfulness in the Corporate World

23:36 Addressing Corporate Stress through Meditation

27:31 Implementing Heartfulness in Corporate Settings

30:27 Conclusion and Contact Information

Smart Textiles: Unraveling the fabric of the future

Fri, 08 Dec 2023 19:34:07 GMT

Understanding Smart Textiles

In a world where technology is seamlessly integrated into every aspect of our lives, the textile industry is undergoing a transformative revolution. Smart textiles, also known as e-textiles or electronic textiles, represent a cutting-edge intersection of technology and fashion. These fabrics have the potential to reshape not only the clothes we wear but also the way we interact with our environment. In this blog post, we delve into the significance and vast potential of smart textiles.

Smart textiles refer to materials that incorporate electronic components and technology to provide added functionality. Unlike traditional fabrics, smart textiles can sense, react, and adapt to various environmental conditions. The integration of conductive materials, sensors, and microelectronics into textiles opens up a world of possibilities for innovation.

Examples in the Market

Several forward-thinking companies have already ventured into the realm of smart textiles, showcasing the possibilities of this innovative technology. Notable examples include:

Google and Levi's Project Jacquard:

Collaborating on a line of connected clothing, Project Jacquard by Google and Levi's introduced denim jackets with touch-sensitive fabric. Wearers can control their smartphones, receive notifications, and perform various tasks by simply touching their jacket sleeves.

Under Armour's Athlete Recovery Sleepwear:

Under Armour, a well-known sports apparel brand, launched sleepwear with bioceramic technology. Designed to aid muscle recovery, these garments use infrared technology to absorb and reflect infrared wavelengths, promoting better sleep and faster recovery for athletes.

Future Prospects and Announcements:

As the smart textiles landscape continues to evolve, we anticipate exciting developments from both established players and emerging innovators. Keep an eye out for future announcements, as researchers and companies explore groundbreaking technologies, such as self-healing fabrics, flexible displays, and textiles with embedded artificial intelligence.

For more than 40 years, Beekaylon has been at the forefront of Innovations in Synthetic Yarns. We’ve delivered the fabrics, fibers, and nonwovens that industries and companies trust for performance, protection, and versatility of use. Beekaylon has a wide variety of products serving a diverse range of markets from automotives to home furnishings. Being the market leaders in polyester filament and dope dyed yarn, we strongly believe in innovation. That is the reason we have invested heavily in setting up a cutting edge R & D wing to develop new products for the market.

Thanks to our in-house R & D, we have developed Flexi yarns ( Flexilastic ), Antimicrobial yarns ( Puriflex ), Recycled Polyester Yarns ( Poly-Go-Round ), Wicking yarns, Odour free yarns and even Fire-retardant yarns. Apart from being one of the largest dope dyed yarn manufacturers in India, Beekaylon is also a nominated partner & supplier for CiCLO yarns.

In conclusion, smart textiles represent a fascinating blend of technology and textiles, offering a myriad of possibilities across various industries. As researchers continue to push the boundaries of innovation, and companies introduce new and inventive products, we can expect smart textiles to become an integral part of our daily lives, creating a more connected and intelligent world.

Continuous Polymerization in Polyester Yarn Manufacturing: A Seamless Innovation

Sun, 05 Nov 2023 00:47:39 GMT

Polyester yarn, a versatile and widely-used textile material, owes much of its success to innovations in manufacturing processes. One such innovation that has revolutionized the production of polyester yarn is continuous polymerization. This method has not only improved efficiency but also raised the bar for quality and sustainability in the textile industry.

Understanding Polyester Yarn Manufacturing:

Polyester yarn, made from polyethylene terephthalate (PET), has a synthetic origin. The process begins with the production of polymer chips, which serve as the raw material for yarn production. Traditional methods involved batch polymerization, where polymer chips were produced in discrete batches, introducing inefficiencies and complicating quality control.

Enter Continuous Polymerization:

Continuous polymerization, as the name suggests, is a seamless and uninterrupted process for producing polymer chips. It offers several key advantages:

Efficiency: Unlike batch polymerization, which involves start and stop process, continuous polymerization is an ongoing process. This results in reduced downtime, energy savings, and enhanced productivity.
Quality Control: Continuous polymerization allows for consistent quality throughout the production process. It minimizes the variations seen in batch processes, ensuring a higher quality end product.
Environmental Benefits: This method often requires fewer resources and generates less waste compared to batch processing, making it a more environmentally friendly option. Reduced energy consumption is also a significant benefit.
Customization: Continuous polymerization offers greater flexibility for tailoring the polymer chips to specific requirements, such as yarn denier or texture.

Implications for the Polyester Yarn Industry:

The adoption of continuous polymerization has transformed the polyester yarn manufacturing industry in several ways:

Improved Quality: Yarns produced from polymer chips produced through continuous polymerization are known for their consistent quality. This is particularly vital in applications where yarn strength, uniformity, and durability are critical.
Sustainability: Reduced energy consumption and waste generation make continuous polymerization an eco-friendly choice, aligning with the textile industry's increasing focus on sustainability.
Cost Efficiency: The continuous process is more cost-effective in the long run due to improved efficiency and reduced resource usage.
Customization: Manufacturers have the flexibility to tailor polymer chips to meet the specific demands of various yarn types, opening up new possibilities for product diversification.

Beekaylon has embraced backward integration by venturing into the production of polyester resin through the continuous polymerization process (CP). This strategic move not only ensures the quality and stability of our polyester yarns but also shields us from the fluctuations in resin prices. We have added a cutting edge Continuous Polymerisation Plant in our manufacturing facility producing PET Chips, having a Capacity of 9000 MT per Month.

We're proud to power our processes with a biomass heating system, ensuring we steer clear of fossil fuels as a primary energy source. This not only reduces our carbon footprint but also reflects our dedication to sustainability.

But that's not all! We take energy efficiency to the next level. By harnessing system-rejected heat, we transform it into chilled water for our air conditioning system. This ingenious approach not only saves energy but also makes a significant contribution to our mission of environmental responsibility.

This integrated approach not only makes a significant contribution to our mission of environmental responsibility, but, also gives us a competitive edge in delivering consistent, high-quality polyester yarns while maintaining cost-efficiency.

In conclusion, continuous polymerization has not only streamlined the manufacturing of polyester yarn but has also raised the industry's standards for quality and sustainability. As consumer demands for eco-friendly and high-quality textiles continue to grow, this innovation serves as a cornerstone in the polyester yarn manufacturing sector, ensuring its relevance and prosperity in an ever-evolving textile landscape.

Significance & Implications of BIS Certification on Polyester Yarns

Mon, 23 Oct 2023 04:50:52 GMT

Polyester yarn, with its versatile applications and wide use in various industries, is a critical component of the textile sector. To ensure the quality and safety of polyester yarns, the Bureau of Indian Standards (BIS) certification plays a pivotal role. In this article, we will explore the significance and implications of BIS certification on polyester yarns.

Understanding BIS Certification:

The Bureau of Indian Standards (BIS) is the national standards body of India, responsible for the development and implementation of product quality and safety standards. BIS certification is a mark of quality and conformity to these standards.

Significance of BIS Certification for Polyester Yarns:

Quality Assurance: BIS certification ensures that polyester yarns meet specific quality benchmarks. This is crucial for both manufacturers and consumers, as it guarantees that the product is of a defined quality.
Consumer Confidence: BIS certification instills confidence in consumers. When they see the BIS mark on a product, they can trust that it meets the established quality standards.
Competitive Edge: For manufacturers, BIS certification provides a competitive advantage in the market. It demonstrates their commitment to quality, which can be a significant selling point.
Legal Compliance: In some cases, BIS certification may be mandatory, especially for products that have safety implications. Compliance with BIS standards is essential to avoid legal repercussions.

Implications of BIS Certification on Polyester Yarns:

Quality Control: Manufacturers must adhere to stringent quality control processes to meet BIS standards. This ensures that the polyester yarns are of consistent and reliable quality.
Enhanced Reputation: BIS certification enhances the reputation of both manufacturers and the polyester yarn industry as a whole. It signals a commitment to produc i ng quality products.
Consumer Satisfaction: Consumers can purchase BIS-certified polyester yarns with confidence, knowing that the product is safe and reliable.
Market Access: BIS certification may be a requirement for market access, especially for export-oriented businesses. It opens doors to a broader customer base.
Safety: BIS standards often include safety measures. For polyester yarns used in critical applications, such as medical or industrial settings, the safety implications are of utmost importance.

In conclusion, BIS certification for polyester yarns is not just a mark; it's a commitment to quality, safety, and consistency. It ensures that polyester yarns are manufactured and distributed in compliance with established standards, benefiting manufacturers, consumers, and the industry as a whole.

At Beekaylon. we take pride in offering BIS-certified yarns, reflecting our commitment to quality and your satisfaction. Explore our range of certified polyester yarns and experience the difference that BIS certification can make in your projects.

Beekaylon is at the forefront of manufacturing innovative Polyester yarns and as part of this philosophy diversified into BCF yarn manufacturing in the year 2019. Currently, Beekaylon has the capacity of 850 Mt per month.

Our company has also embraced backward integration by venturing into the production of polyester resin through the continuous polymerization process (CP). This strategic move not only ensures the quality and stability of our polyester yarns but also shields us from the fluctuations in resin prices.

This integrated approach positions us at the forefront of the industry, giving us a competitive edge in delivering consistent, high-quality polyester yarns while maintaining cost-efficiency.

Remember, when you choose BIS-certified polyester yarns, you're choosing quality, safety, and reliability.

Mahatma Gandhi and his Impact on Indian Textiles: A Legacy Woven in Khadi

Sun, 01 Oct 2023 19:16:31 GMT

Mahatma Gandhi, fondly known as the Father of the Nation, was not only a symbol of India's struggle for freedom but also a champion of self-sufficiency, non-violence, and sustainability. His profound impact on Indian textiles, particularly through his advocacy of Khadi, is a testament to his visionary leadership and commitment to empowering the masses.

1. The Khadi Revolution:

At the heart of Gandhi's textile legacy lies the Khadi revolution. Khadi, a simple handspun and handwoven fabric, became the symbol of Gandhi's vision for a self-reliant and independent India. He believed that Khadi was not just a fabric but a means to connect the people of India to their roots, to the rural villages, and to the dignity of labor.

Gandhi himself was a devoted spinner, often pictured with a Charkha, the traditional spinning wheel. Through his actions, he encouraged millions of Indians to spin their own Khadi cloth, promoting economic self-sufficiency and empowering rural communities. The Khadi movement was not just a clothing choice but a powerful political and economic statement.

2. The Simplicity of Dress:

Gandhi's attire, consisting of a loincloth and a shawl made of Khadi, was more than just a clothing preference; it was a symbol of simplicity and humility. By wearing clothes spun and woven by his fellow countrymen, Gandhi set an example of living in harmony with one's environment and supporting local industries.

This choice of attire resonated deeply with the masses, as it was not only affordable but also a reflection of the principles of self-reliance and self-respect. Gandhi's simplicity in dress was an embodiment of his philosophy of living with minimal material possessions and emphasizing inner qualities over external appearances.

3. The Preservation of Handicrafts:

Gandhi was not just a proponent of Khadi but also a staunch advocate for the preservation of India's rich tradition of handicrafts. He recognized that India's rural economy thrived on these time-honored crafts, and their decline threatened the livelihoods of millions. To address this, he encouraged the revival of traditional weaving techniques and the support of rural artisans.

Under his guidance, various Khadi and village industries were established to empower artisans and promote their crafts. This not only rejuvenated the handicraft sector but also contributed to the economic upliftment of rural India.

4. Legacy of Sustainability:

Gandhi's impact on Indian textiles transcends his lifetime. His emphasis on sustainability, eco-friendliness, and ethical production methods in textiles was far ahead of his time. Today, as the world grapples with environmental challenges, his principles find renewed relevance.

The Khadi movement, with its focus on handspun and handwoven fabrics, represents a sustainable alternative to mass-produced textiles. It champions the use of natural fibers, minimal energy consumption, and support for local communities. These principles align with modern notions of ethical fashion and sustainability.

In conclusion, Mahatma Gandhi's influence on Indian textiles is indelible. His promotion of Khadi, simplicity in dress, support for handicrafts, and commitment to sustainability have left an enduring legacy. The Khadi movement continues to inspire both the textile industry and individuals to make responsible choices that honor India's heritage and contribute to a more sustainable future.

As we celebrate Gandhi Jayanti, let us remember and celebrate the man who not only spun yarns of revolution but also wove together the fabric of a nation's identity.

Today, at Beekaylon, as a yarn manufacturing company, we honor Gandhi's legacy by supporting the preservation of Indian textile heritage. Join us in celebrating the man who spun a yarn of change for our nation.

Chandrayaan-3 : Lessons for Indian Businesses

Sun, 17 Sep 2023 01:28:44 GMT

In the grand chronicle of India's space exploration endeavors, Chandrayaan-3 emerges as a poignant chapter, etching its significance in the lunar space. This lunar exploration mission, aimed for nothing less than a soft landing on the moon's surface. Supported by the unwavering vision of Prime Minister Narendra Modi, and led by Chairman S. Somnath, Chandrayaan-3 stood as a testament to India's indomitable spirit.

The Journey Begins

In 1999 and 2000, the Indian Academy of Sciences and the Astronautical Society of India proposed a lunar mission. This sparked the creation of a National Lunar Mission Task Force (NLMTF), bringing together ISRO and Indian scientists. Their goal: a feasibility study to kickstart India's lunar exploration.

On 15 August 2003, then-Prime Minister Atal Bihari Vajpayee announced the lunar project, budgeted at ₹350 crore. In November, the government approved the Chandrayaan project, focusing on an orbiter for mineralogical and chemical mapping.

During the orbiter's assembly, President A.P.J. Abdul Kalam inspired the inclusion of the Moon Impact Probe (MIP). Launched from 100 km altitude, it captured lunar surface images, collected telemetry data, and analyzed the lunar atmosphere.

Beyond lunar exploration, this venture established India's deep space network, costing ₹360 crore. On 22 October 2008, Chandrayaan-1 launched successfully, marking a new chapter in India's space odyssey, where dreams, determination, and innovation united to explore lunar mysteries.

The Remarkable Mission

Chandrayaan-3 was the third iteration in the Chandrayaan series, building upon the successes of Chandrayaan-1 and Chandrayaan-2. However, its journey was not without challenges. The mission faced an initial setback in 2019 when it failed to achieve the soft landing. Yet, it was the response to adversity that underscored the mission's significance.

Efficiency and Cost-effectiveness

One remarkable aspect of Chandrayaan-3 was its efficiency and cost-effectiveness. The mission demonstrated how, even in the realm of space exploration, stringent budget constraints could be managed without compromising on quality and ambition. Chandrayaan-3's success on a limited budget serves as an inspiring example for businesses in India, showcasing the importance of resource optimization and cost-consciousness.

Persistence

Chandrayaan-3's journey epitomizes the value of persistence. ISRO's unwavering determination to correct course and attempt the mission anew highlighted that success often hinges on persistence in the face of adversity. In the corporate world, resilience and the ability to adapt to setbacks are invaluable traits.

Collaboration

Space missions inherently require collaboration on a global scale. Chandrayaan-3 was a testament to the power of international collaboration, as ISRO collaborated closely with esteemed counterparts. In the corporate sphere, alliances and collaborations can foster innovation and open new avenues for growth.

Teamwork

The success of any space mission hinges upon the collective efforts of countless individuals. Chandrayaan-3's saga underscores the importance of teamwork, both within ISRO and in conjunction with international partners. Corporate endeavors, too, thrive when teams work cohesively and synergistically.

Meticulous Planning and Execution

Space missions, by their very nature, demand precision and attention to detail. Chandrayaan-3's meticulous planning and execution showcased the significance of methodical approaches. Similarly, in the corporate domain, careful planning and flawless execution are essential for achieving strategic objectives.

Lessons for Indian Businesses

Chandrayaan-3's journey is more than a lunar mission; it's a testimony to values and lessons that resonate across industries:

In conclusion, Chandrayaan-3 is a triumph not just for India's space exploration but also a beacon of values that extend to every facet of life, including the corporate world. In the grand tapestry of success, it is the threads of values and learning that strengthen our endeavors.

As we celebrate Chandrayaan-3's resolute journey, let us remember that in the pursuit of greatness, it's these values that truly matter.

As the moon's surface welcomes India's triumphant footsteps, we at Beekaylon join the nation in applauding the incredible success of our Chandrayaan mission. Just as threads of ambition and innovation come together to weave a remarkable tapestry, the dedication and brilliance of our scientists and space explorers have led to this historic achievement.

At Beekaylon, we are inspired by the spirit of exploration and the pursuit of the extraordinary. This momentous feat reminds us that no endeavor is too ambitious when we thread our dreams with determination.

Congratulations to ISRO for making us all proud and reminding us that the sky is not the limit – it's just the beginning.

Click on the link to learn more about B eekaylon.

Ep. 7 - The Yarn Bazaar Journey - In Conversation with Pratik Gadia, CEO & Founder

Mon, 21 Aug 2023 07:06:09 GMT

Episode 7: Empowering the Yarn Industry Through Innovation and Vision

Welcome back to another captivating episode of the Spinning Values Podcast by Beekaylon. In this episode, we have the privilege of diving into the inspiring journey of Pratik Gadia, the visionary founder of The Yarn Bazaar, a revolutionary platform transforming the yarn industry.

At the age of 15, Pratik Gadia embarked on an extraordinary journey in the fabric business, joining his family's fabric manufacturing unit. Over the years, he not only gained intimate knowledge of the industry but also led the family business for a remarkable 7 years. This early exposure equipped Pratik with a deep understanding of the industry's intricacies and challenges, laying the foundation for his future endeavors.

In our conversation with Pratik, we uncover how his experiences in the family fabric manufacturing unit led him to identify significant gaps and pain points within the industry. This realization became the driving force behind the creation of The Yarn Bazaar , a game-changing marketplace for yarns.

The Yarn Bazaar stands as a testament to Pratik's vision of modernizing the yarn industry. It has seamlessly evolved into an efficient and transparent platform where yarn buyers and sellers can engage in transactions with unparalleled ease. Pratik's determination to effect change is evident in his aspiration to make The Yarn Bazaar a globally recognized and trusted name in the yarn industry.

One of the most compelling aspects of The Yarn Bazaar is its unwavering focus on empowering small-scale yarn buyers and suppliers. Pratik recognizes that the true path to industry transformation lies in supporting those who form its backbone. Through proprietary processes and flexible unsecured financing options, The Yarn Bazaar empowers yarn sellers to expand their reach and boost sales, all while enjoying improved margins. Simultaneously, buyers benefit from reduced raw material and procurement costs, ushering the yarn industry into a new era of technology-driven efficiency.

Pratik's dedication to overcoming the challenges that have long plagued the yarn industry is unwavering. Together with his passionate team, he is committed to facilitating the growth of fabric manufacturers and yarn suppliers. Their tireless efforts ensure that these businesses can operate with unparalleled ease, transparency, and fairness, ultimately setting a new standard for the industry.

Join us in this insightful episode as we explore the inspiring journey of Pratik Gadia and the transformative impact of The Yarn Bazaar on the yarn industry. Gain a deeper understanding of how innovation, vision, and dedication can come together to create lasting change in even the most traditional sectors.

Thank you for tuning in to another episode of the Spinning Values Podcast. Don't forget to subscribe and share this episode with those who seek inspiration through innovation. Stay tuned for more captivating conversations on values, vision, and the power of transformative ideas.

Nylon vs. Polyester: Exploring the Differences in Synthetic Fibers

Thu, 10 Aug 2023 09:33:18 GMT

Synthetic fibers have revolutionized the textile industry, offering a wide range of versatile and durable options. Two popular synthetic fibers, nylon and polyester, are widely used in various applications, from apparel to carpets. In this article, we will delve into the characteristics and differences between nylon and polyester, shedding light on their unique properties and helping you make informed choices when selecting materials for your needs.

Nylon and polyester are both versatile synthetic fibers with their own unique characteristics and advantages. Nylon excels in strength, elasticity, and abrasion resistance, while polyester offers superior durability, moisture resistance, and ease of care. Understanding these differences can help you choose the most suitable material for your specific application, whether it's clothing, home furnishings, or outdoor gear. Ultimately, personal preferences, performance requirements, and intended use should guide your decision in selecting between nylon and polyester.

Beekaylon has a wide variety of products serving a diverse range of markets from automotives to home furnishings. Being the market leaders in polyester filament and dope dyed yarn, we strongly believe in innovation. That is the reason we have invested heavily in setting up a cutting edge R & D wing to develop new products for the market.

What is BCF Yarn?

Thu, 20 Jul 2023 07:50:41 GMT

BCF yarn stands for Bulk Continuous Filament yarn.

It is a type of synthetic yarn that is produced using a continuous extrusion process

The term "bulk" refers to the thickness or volume of the yarn, while "continuous filament" indicates that the yarn is made up of long, continuous strands rather than shorter staple fibers.

BCF yarn is commonly made from synthetic materials such as polyester, nylon, or polypropylene. During the manufacturing process, the molten polymer material is extruded through spinnerets to form continuous filaments. These filaments are then cooled, solidified, and twisted together to create the BCF yarn. One of the main advantages of BCF yarn is its high strength and durability. The continuous filaments make the yarn resistant to pilling, fraying, and shedding, resulting in a longer-lasting product. BCF yarn is widely used in various applications, including carpet manufacturing, upholstery, textiles, and industrial fabrics.

In the context of carpets, BCF yarn is often used to create the carpet fibers. The bulkiness and strength of BCF yarn make it suitable for withstanding heavy foot traffic and maintaining its appearance over time. It is available in different thicknesses and can be produced in various colors and textures to meet specific design requirements.

Overall, BCF yarn is a versatile and robust material used in the production of various textile products, particularly carpets and upholstery, due to its durability and performance characteristics.

Beekaylon produces one of the finest quality BCF Yarn and has the world's best technologies for producing Bulk Continuous Filament.

Our BCF capabilities

We have the latest Neumag S+ machines to produce BCF yarns. A unique aspect of Beekaylon's production process is that we are capable of producing tri-color BCF yarns. We also have the capacity to produce Polyester(PET) BCF, Nylon (PA 6) BCF as well as Polypropylene (PP) BCF yarns.

To ensure right quality of BCF, we have installed a host of Yarn Testing Machines. We also have Digital Thickness Gauge and Hexapod Tumbler Carpet Testing Machines to test/evaluate appearance retention, carpet thickness, comparison and recovery, etc.

Pilot Tufting & Weaving Machines help us to pre-test BCF Yarn Quality and also enable us to create Designs & Patterns on Rugs & Carpets. We also offer Stain Proof, Fire Retardant, Super Soft, UV Stable and Antistatic features.

Sustainability is important for Beekaylon and in this regard we manufacture Nylon and Polyester yarns from 100 percent recycled polymer chips. Our Yarn, Poly-Go-Round, offer a wide range of products in recycled polyester yarns with multiple possibilities which can be combined with other functional properties like UV resistance, antimicrobial, biodegradable, temperature control etc, dyeing and other applications. Additionally we can work on lower MOQs, and accommodate personalised requests in terms of yarn denier, filaments and technical characteristics.

In conclusion, Bulk Continuous Filament (BCF) yarn is a significant innovation in the world of synthetic yarns. Its continuous extrusion process and the use of long, continuous filaments offer numerous advantages, including high strength, durability, and resistance to wear and tear. BCF yarn, commonly made from synthetic materials like polyester, nylon, or polypropylene, finds extensive applications in the textile industry, particularly in carpet manufacturing and upholstery. Its ability to withstand heavy foot traffic and maintain its appearance over time has made it a popular choice for carpet fibers. Whether you're looking for a long-lasting carpet or robust industrial fabric, BCF yarn's qualities make it an indispensable material in various products. As technology continues to advance, we can expect further improvements and refinements in BCF yarn production, allowing for even greater versatility and performance in the world of textiles.

Textile Industry & The Growth of Allied Industries

Wed, 14 Jun 2023 05:58:00 GMT

The Textile Industry ranks as one of the most vibrant industries today with the global textile industry market size valued at USD 959.87 Billion in 2022 with a projection of USD 1371.84 Billion by 2030.

When it comes to India, the textile industry has always held immense importance both historically and economically. This is one of the oldest and largest sectors in the country and provides a significant amount of employment besides contributing significantly to India's GDP. There is also a thriving ecosystem of allied industries that support and enhance it which includes spinning and weaving, chemicals, dyes, textile machinery, technology, logistics and sustainability.

Spinning and Weaving: Backbone of the Textile Industry

When we talk about the Textile Industry, the backbone is the spinning and weaving processes which are closely interconnected. Spinning is the process that creates yarns that serve as the raw material for weaving. Weaving then transforms these yarns into fabrics with different patterns, textures, and properties as required. This is done either manually on handlooms or with power looms in cases where large-scale production is called for.

Notable amongst yarn manufacturers is Beekaylon, one of the largest manufacturers of dope dyed yarns in India. These comprise Dope Dyed POY, FDY, Draw Texturised, Air Texturised, twisted, and packaged dyed polyester filament yarn. Some of the innovations introduced include anti-microbial yarn available under the brand name Puriflex.

Chemicals and Dyes: Enabling Innovation and Colour

Textile manufacturers rely on a wide range of chemicals such as colorants, pigments, surfactants, and finishing agents to achieve the desired properties and effects on fabrics. Besides colouring, these are also used in printing, and finishing processes.

Dyes add colour to fabrics, yarns and fibres. The extensive palette of shades allows designers and manufacturers to indulge their creativity and meet diverse consumer preferences.

Today, advances in dyeing and printing technologies have opened up unexpected new possibilities which include digital printing, a range of stunning special effects and more. This enables the creation of unique and intricate designs and even personalised textile creations.

Technical & Smart Textiles

There is a growing market for smart and technical textiles that incorporate specific properties for specified applications. For instance, Beekaylon’s automotive yarn sold under the brand name Moto-Fiber is flame retardant, UV-resistant, and antibacterial. Beekaylon's Flexilastic is extremely stretchable and is used in athletic wear textile applications such as narrow fabrics and elastic tapes.

Textile Machinery’s Role

The growth of the Textile Industry naturally spurs a growth corollary in textile machinery. These machines automate and streamline the textile manufacturing process, increasing efficiency, productivity, and quality. These are needed at various stages of textile production such as spinning, weaving, knitting, dyeing, printing, finishing, and garment manufacturing.

They also focus on sustainability by developing machines that consume fewer resources, generate less waste, and are more environmentally friendly.

Driving Technology & Innovation

The growth of the Textile Industry has been instrumental in driving technological advancements and innovation through R&D. Automation and robotics have come into use in manufacturing to digital printing besides the rise of smart textiles and sustainable practices, the industry has encouraged research and development in new technologies.

Sustainability and Circular Economy

In recent years, there has been a growing awareness and demand for ethical and sustainable fashion. There has been increasing concern amongst consumers about the social and environmental impact of their clothing choices. This has resonated in the industry as well increasing fair trade, organic, environment-friendly and cruelty-free fashion. This shift in consumer behaviour has made the Textile Industry take a relook at their processes and embrace more sustainable and responsible practices.

Sustainable fabrics such as polyester which are made from PET are gaining popularity. Beekaylon has been quite proactive and come up with “Recycled Polyester Yarn" branded as Poly-Go-Round . This is manufactured from used PET bottles and yarn waste. This in turn is converted into chips, using environment-friendly recycling processes. Promoting the circular economy brings many benefits such as preventing climate change, reducing waste and pollution, increasing competitiveness, improving profits and community-based initiatives.

How Beekaylon plays a role in this growth

Beekaylon shines as a leader in the industry due to the foresight, planning and visionary moves that make us a trendsetter. Ranking among the largest manufacturers of dope dyed yarns in India, we contribute immensely to the growth of the industry and have increasingly expanded to new geographical boundaries. By bettering our processes, we have not only made our products better but have enhanced their properties and environment-friendliness.

We believe that the growth of the Textile Industry and its allied industries is dependent on continuing to evolve and adapt to the changing global landscape. Through innovation, sustainability, and responsiveness to consumer demands, the industry can thrive while minimizing its impact on the environment and promoting social well-being.

Changing trends in Fashion & Apparels

Mon, 17 Apr 2023 05:21:00 GMT

Exploring changing trends in Fashion & Apparels

The pandemic brought social life to a standstill and homes turned into office spaces as well. With life undergoing such a major transformation, this brought about a whole new perspective on fashion. While corporate protocol at office spaces called for formals, working from home brought with it a relaxed vibe and most people opted for loungewear. Comfort was key and this also had a positive effect on the work front. Fashion fads disappeared. Post the pandemic, traces of pandemic dressing still has their impact though people have returned to work at their office spaces.

Post the pandemic, the urge to dress up well has increased, yet no one wants to go in for heavy clothes that weigh a ton or tight-fitted clothes. Colours have started getting brighter and there’s a bit of bling that has crept into styles too. Comfort is now high on the list of desired style attributes. Lightweight fabrics, easy-to-maintain clothing and relaxed fits have come into play. With companies relaxing their rules a bit too, comfort reigns,

Casualisation is in!

Many companies now have a hybrid model of work, therefore when it comes to dressing too, employees are looking to a greater deal of flexibility. The whole new concept of ‘Casualisation’ is now in as formals seem to have fallen from grace! Brands too have sensed the demand for comfort wear and come up with new offerings. For instance, last year a leading brand introduced a whole new line of lounge wear and comfort wear for women. Men’s clothing too has undergone a sea change and office wear is veering more towards comfort.

The hygiene factor

The pandemic has increased awareness of the need for increasing levels of hygiene. After all, stemming the spread of Covid was greatly linked to extensive hygiene practices. This attitude has spilled over to the realm of textiles too. With a lot of innovation and R&D going into this area, textile manufacturers have come up with anti-microbial fabric offerings. The demand for this is growing and set to grow as more and more people turn to these to protect them from diseases especially skin infections and foul odours.

Now what exactly is antimicrobial clothing? This is specially treated fabric which works towards protecting the wearer against organisms that could affect health such as bacteria, mould and other dangerous forms of microbes. These work similarly to antimicrobial sanitizers and soaps, they provide protection by attacking pathogens on a cellular level and this reduces their scope for growth and reproduction.

Beekaylon is one of the leading company that manufactures inherent Antimicrobial Yarn known as Puriflex . This is a synthetic fibre infused with antimicrobial properties and works towards curbing microbial growth, it has been created to cater to certain applications. Antimicrobial agents are generally applied on the surface or inside. Such agents can be included during various stages such as spinning or extrusion processes, solution dyeing and sometimes during finishing. Beekaylon uses permanently infused AM++ ions as antimicrobial agents and the advantage is that these are durable and remain effective even after extensive washes and usage.

The Athleisure Revolution

Post and during the pandemic, athleisure has come into vogue in a big way! These clothes are both fashionable and great for sports too. In a nutshell, this is casual, comfortable clothing that looks good too. Attending meetings online in these was quite the rage during the pandemic and its popularity continues.

The other factor that drove the athleisure trend is that the pandemic brought about plenty of awareness of the need to build immunity and better health. Sedentary lifestyles made one more vulnerable to COVID-19. The result was that many started working out and taking to one form of sport or the other. This called for athleisure clothes ranging from t-shirts, shorts, leggings to track pants. When it comes to active athleisure, there are several different performance attributes that wearers seek before they purchase. These include comfort, flexibility, moisture-wicking properties and so on. Research studies from shoppers show that they look for athleisure wear made from comfy fabrics and offer flexible fits that can easily adapt from the gym workout session to casual wear around the home.

Beekaylon yarn finds usage in the creation of athleisure garments. The range of Flexilastic ultra-stretchable yarns have been designed to improve sports performance and comfort by up to 58%. These high-quality yarns are much sought after to make quality fabrics. Beekaylon also has yarn with sweat-wicking properties that find a place in sportswear manufacturing

Is sustainability important for customers?

Post-pandemic, people have become more aware of climate change and the issue of sustainability has gained greater credence. Compared to two years ago, consumers are ready to shell out more on sustainable clothing. This has a gentler impact on our planet and is being increasingly favoured. Rather than paying merely cosmetic homage to the concept, fashion brands are now sincerely embracing sustainability and this goes beyond brand image and publicity campaigns. Many, especially the younger generation are now keen to buy clothes that are made with environmentally sustainable practices or values. This has made brands sit up and take notice and come up with a slew of innovative and sustainable fabrics.

Beekaylon has been working to make its products sustainable and offers products that help. Beekaylon offers recycled yarns like Poly- Go -round , Dope dyed Yarns & CiCLO Fibres and Yarns are highly sustainable and degrade at the same rate as natural fibres such as wool. This makes it a very attractive proposition.

The way forward

Post the pandemic, fashion has evolved to be more functional and with a greater thrust towards comfort and specific performance attributes. Beekaylon has been one of the prominent yarn manufacturers who have been constantly looking towards creating value for customers through innovation, sustainability and improving performance.

Performance Apparel : An in-depth review

Sat, 04 Mar 2023 21:25:00 GMT

Sportswear and athleisure clothing are two types of clothing designed to provide comfort, hygiene and performance.

Sportswear and athleisure clothing are two types of clothing designed to provide comfort, hygiene and performance. They are both considered active wear. These are high quality technical fabrics designed to be breathable and comfortable. Performance apparels are becoming more popular due to their ability to support healthy lifestyles. Examples of active wear comprise of products like compression leggings, running shorts, moisture absorbing tees, etc.

In 2021, the global activewear market reached a value of USD 303.44 billion, and it is projected to experience a compounded annual growth rate (CAGR) of 5.8% from 2022 to 2028. The market growth is linked to the increasing trend of contemporary clothing for both workout sessions ,yoga wear and daily wear.

Popularity of Performance Apparel:

Performance apparels are becoming more popular due to their ability to support healthy lifestyles in a number of ways. First, performance apparels are designed with specialized fabrics that are moisture-wicking, breathable, odour-free and quick-drying. These features help to keep the body cool and dry during physical activities, which can help prevent discomfort and skin irritation caused by sweat buildup. Additionally, performance apparels are often designed with compression features that help to increase blood flow and oxygen delivery to the muscles, which can improve performance and speed up recovery time.

Athleisure becoming

a fashion trend

Athleisure has become a fashion trend due to the increasing demand for clothing that is comfortable, practical, and fashionable. The trend started with the popularity of yoga pants and activewear as everyday clothing, and has since expanded to include a wide range of athletic wear, such as sneakers, sports bras, and even sweatpants. Athleisure has influenced the fashion industry by blurring the lines between sportswear and everyday clothing, leading to the creation of hybrid clothing that is both functional and fashionable. The trend has also inspired fashion designers to create high-end athletic wear that incorporates luxury fabrics and designs, making it more appealing to fashion-conscious consumers.

Advancement in textile technology:

Technology has improved the functionality and effectiveness of performance apparels by enabling the development of advanced materials and designs.

Moisture-wicking and breathable fabrics are now made using innovative manufacturing techniques that increase the surface area of the fibers, allowing for better moisture management.

Compression technology has been enhanced to improve the delivery of oxygen to the muscles, reducing muscle fatigue and speeding up recovery time.

In addition, advancements in 3D printing and smart textiles have enabled the creation of apparels with built-in sensors that track body temperature, heart rate, and other physiological data. This technology helps athletes monitor their performance and make adjustments in real-time, optimizing their training and maximizing their potential.

Overall, technology has transformed performance apparels into high-tech tools that enhance athletic performance and promote a healthier lifestyle.

Here are some popular examples of performance apparel in the industry:

Beekaylon and Activewear:

Beekaylon’s offers Flexilastic -Ultra Stretch range of Polyester yarns. It brings inherent mechanical stretch & remarkable recovery to fabrics with enhanced performance, style, comfort in the continuously changing market. With the changing social scenario, people want their apparel to look good but comfortable to enable all activities throughout a busy day! This fabric can be used for sportswear, gymnastic clothing, activewear, fashion apparels, narrow fabrics, elastic tapes & other textile applications.

Other innovations from Beekaylon driving the world of performance apparel:

Poly-go-round:

At Beekaylon, we understand the impact of sustainable manufacturing processes. Considering the requirement, we have developed “Recycled Polyester Yarn" branded as Poly-Go-Round - which is our initiative to conserve the environment. It is manufactured from used PET bottles & yarn waste which is then converted into chips, using environment-friendly recycling processes. Poly-Go-Round does not depend on additional petroleum products and thus effectively conserves natural resources and reduces environmental burden without compromising on quality.

CiCLO:

CiCLO is a masterbatch additive available with a multitude of advantages. Products made with CiCLO fibers and yarns reduce the persistence of synthetic microfiber pollution in our oceans and synthetic textile accumulation in landfills. Long term studies show that CiCLO polyester fibers biodegrade at rates similar to natural fibers such as wool.

Beekaylon has the expertise to produce CiCLO yarns in POY, FDY, DTY, Cationic, Recycle etc variety of yarns for Textile Applications. These are sustainable yarns used by leading sports brand such as Decathlon for its sportwear category.

Conclusion:

Wearing performance apparels is important for a healthy and active lifestyle because they provide numerous benefits to the wearer. Performance apparels are designed to be moisture-wicking, breathable, anti-odour and quick-drying, which helps to keep the body cool and dry during physical activities, reducing the risk of discomfort and skin irritation. They also provide support and compression to the muscles, which can enhance athletic performance and speed up recovery time. Wearing performance apparels can also promote a more active lifestyle by providing comfort, functionality, and fashion, making it easier and more enjoyable to engage in physical activities. Overall, incorporating performance apparels into your daily wardrobe can help support a healthy and active lifestyle.

Union Budget 2023-24: A Textiles & Apparels Perspective

Tue, 07 Feb 2023 17:19:00 GMT

A Deep Dive into this year's budget and its implications for the textile industry.

The new budget for 2023-24 contains a sizeable increase in grants for the textile industry, with a total allocation of Rs. 4,389.34 crore. These and other features of the budget show the government’s priorities for the textile industry. Let’s do a deep dive into this year’s budget.

The total allocation for the sector is an impressive 22.6% higher than the previous year's budget and shows the government's commitment to aiding the growth of the sector. Additionally, there have been allocations of funds towards programs such as National Technical Textiles Mission (NTTM), PM-MITRA and textile development cluster scheme, which are designed to promote capacity building and investments in this area. All in all, this financial support should create a favourable environment for the continued success of India's textile industry.

The 2021 Union Budget of India is largely considered a progressive, growth-oriented and forward-looking budget, aiming to boost infrastructure development, green growth, youth power and inclusive development. Through the Production Linked Incentive (PLI) scheme, the budget covers more sectors to increase exports, investment and support for MSMEs. Nonetheless, certain decisions will have their negative impacts on the economy.

The Government has come under fire for their decision to raise the Basic Customs Duty on textile machinery from 5% to 7.5%, which will affect potential investments in the sector. It is hoped that the import duty for all types of textile machineries will be kept at 5% for the next three years or until domestic manufacturers are able to meet domestic demand. This could potentially hurt global competitiveness and recent incentive plans announced such as PLI Scheme and PM MITRA Scheme, due to the absence of Technology Upgradation Fund Scheme which was active till March.

The textile industry is set to benefit from the 2022-23 Indian budget allocated for modernisation and advancements.

From an allocation of Rs. 650 crore for ATUFs in 2022-23, this figure has increased to Rs. 900 crore in 2023-24; this will enable quicker payment processes for any pending cases.

To help with the productivity of extra long staple cotton, there will be a cluster based and value chain approach using public private partnerships, providing raw material security for the garment industry. Additionally, five new HS Codes have been identified for further classification of cotton as per staples length.

The support from the Cotton Corporation’s Price Support Scheme has been withdrawn but they are yet to predict the full impact of this action.

The Increased allocation to both RoDTEP and RoSCTL have also been increase as well as a corpus of Rs 9,000 crore revamping credit guarantee schemes which aims provide collateral free guaranteed credit worth RS 2 lakh crore.

Furthermore, an interest equalization scheme (IES) has been implemented with an allocation of Rs 2376 crore in 2022-23 increasing to Rs 2932 crore in 2023-24.

Efforts are also being put into creating a green infrastructure that will reduce our carbon footprints while making apparel facilities sustainable too.

This efforts to promote sustainability within the textile industry as well as technology such as Industry 4/0 courses including coding, AI and robotics via Pradhan Mantri Kaushal Vikas Yojana 4.0 show great promise in creating a credible workforce adept at current manufacturing jobs quickly and skilling country's youth for international opportunities through Skill India Centres .

Lastly, states are encouraged to set up Unity Malls promoting and selling ODOPs (One Distrcit One Product), GI products and other handicraft products locally and from other states too encouraging local produce on a larger scale than before.

The government has allocated a 38% increase in the allocation of Technology Upgradation Funds (ATUFs), going from Rs.650 crore in 2022-23 to Rs.900 crore in 2023-24.

This will enable quicker payment for pending cases, allowing the textile industry to stay up to date with necessary materials and supplies.

Additionally, a cluster-based value chain approach with Public Private Partnership (PPP) is being implemented to enhance productivity of extra-long staple (ELS) cotton by connecting farmers, states, and industries together through sources, services, and market linkages.

In Conclusion:

Despite the decision to raise the base customs duty on textile machinery, industry experts feel it is a forward looking budget for the industry. Here are a few comments from industry stalwarts:

“It’s a forward-looking, growth-oriented budget. Change in the direct tax will boost saving and make our economy resilient to face the tough time. Removing a large number of compliances converting over 3400 legal provisions into decriminalisation and amending 42 Central Acts, will help smooth revival of businesses,” - Narendra Goenka, Chairman, AEPC

“The priority given to infrastructure development will go a long way for reduction of logistics cost, a major need for the exporting units. The focus given on green growth, is a major discussion point by the knitwear industry now in Tirupur cluster,”

- K.M.Subramanian, President, TEA

As expected nothing really for Textile Industry in budget except more disposable income in hands of consumers due to tax cuts plus with inflation taming means more consumption. The separate HS Codes for ELS Cotton indicates the intent of the Government to differentiate the same in import duty going ahead,” - Sanjay K Jain, MD TT Ltd & Chairman, ICC National Textiles Committee

The Future of Synthetic Yarns

Fri, 09 Dec 2022 05:26:00 GMT

The development of synthetic fibers has revolutionized the textile industry. These fibers are made by combining chemicals into long chains of molecules called polymers. They're much stronger than natural fibers, and can be dyed and blended to create many different colors.

Why Do We Need Synthetic Fibers?

Synthetic fibers are often more durable than natural ones. This means they can withstand high temperatures and resist damage better. They also tend to last longer because they don't break down as quickly. Natural fibers like cotton and wool degrade when exposed to sunlight, air, water, and other elements.

The first synthetic fiber was invented in 1851 by Charles Goodyear. He created rubber from vulcanized animal intestines. In the early 1900's, DuPont developed nylon, which is still used today. Nylon is stronger than silk and has a higher melting temperature than wool. Today, we use polyester, acrylic, and spandex in our clothing. These materials are much lighter than cotton and wool, making them easier to wear.

The most common types of synthetic fibers include polyester, acrylic, nylon, and spandex. Polyester is the most popular type of synthetic fiber. It is strong, lightweight, and easy to dye. Acrylic is similar to polyester, but it is softer and more flexible. Nylon is very strong and resistant to heat and chemicals. Spandex is a stretchable material that is commonly found in athletic apparel.

Why Are Synthetic Fibers So Important?

Synthetic fibers are an essential part of modern life. They are used in everything from clothing to household products to medical devices. However, there are some limitations to the use of synthetic fibers. For instance, they are not as durable as natural fibers, so they tend to wear out faster than other materials. Also, they are often less biodegradable than natural fibers. This means that they will remain in landfills longer than natural fibers. There are two main reasons why people use polyester fibers. First, polyester is very durable. It does not break easily and lasts longer than cotton. Second, polyester is very easy to dye. Dyes work well on polyester because it absorbs them quickly. Cotton, on the other hand, takes much longer to absorb dyes.

What Are Some Applications For Synthetic Yarns?

Synthetic yarns are being used in everything from clothing to medical devices. Here are some examples of how they're being used today:

The use of synthetic fibers has grown exponentially since the 1950s. Today, there are many different types of synthetic fibers available. These include polyester, nylon, acrylic, spandex, and others. Each type of fiber has its own unique properties. For example, polyester is strong and resilient, while nylon is soft and flexible. Spandex is stretchy and elastic. And acrylic is heat resistant.

What Is the Future of Synthetic Yarn?

As technology continues to advance, so will the use of synthetic yarns. We'll continue to see innovations in the future, such as 3D printing with synthetic yarns.
The future of synthetic yarns is bright. In fact, we're already seeing some amazing developments in the field. For example, scientists at the University of California, Berkeley, have developed a new type of yarn that's stronger than steel. And researchers at the University of Texas at Austin have created a new kind of yarn that could be used to create clothing that doesn't require ironing.

The future of synthetic yarns isn't limited to clothing. Scientists are working on developing other uses for synthetic yarns, such as creating artificial muscles. Researchers at the University of Illinois have been able to develop a synthetic muscle that is stronger than human muscle tissue. And scientists at the University of Michigan have created a synthetic material that can be used to create a variety of different types of fibers.

Bio Synthetic Yarn from Heiq

Yarn is made up of strands of fiber twisted together. It comes in many forms, from cotton to wool to silk. Cellulose fibers are long chains of sugar molecules that make up plant cell walls. They are found in wood, grasses, and trees. Bacterial cellulose is a form of cellulose produced by bacteria. It is stronger than regular cellulose because it contains fewer water molecules.

Beekaylon's Innovative Textile Products

Beekaylon is the largest manufacturer of dope dyed yarns in India and a pioneer in the Synthetic Yarn Processing (Polyester) industry. Established in 1979 in a small city in India, Silvassa, it has grown into a globally renowned brand with customers across the world. The world-class manufacturing facility is manned by professionals and brings out innovative yarns and products that delight customers. Sustainability is one of the core values that it believes in and abides by.

Conclusion

Synthetic yarn fibre accounts for about 62% of the world market today. That is about 80 million metric tonnes and it is projected to 100 million metric tonnes by the year 2030. Most of the synthetic yarn is made from fossil fuels. But the problem with recycling is that, it requires energy as well! Which uses up the energy saved by recycling. So, the only way out is to make synthetic fibre out of renewable sources of energy, which is going to be the biggest challenge for Textile Industry going forward.

Dope dyed Vs Conventional Dyeing – The solution for Sustainability

Sat, 02 Jul 2022 23:14:00 GMT

Dope dyed Vs Conventional Dyeing

– The solution for Sustainability

Conventional methods of textile dyeing have been flagged as one of the major contributors to polluting the environment. Most of us don’t realise that behind trendy and beautifully coloured clothes, there lies a toxic history. Conventional dyeing consumes a large amount of water and chemicals and a lot of the wastewater is generated, which makes its way into the drinking water table polluting it. The world has been constantly looking for sustainable solutions and Dope dyeing has emerged as one. This apart, the demand for this has been growing due to a greater market emerging for synthetic fibres, such as polyester, nylon, and viscose across diverse applications. The benefits that it brings along such as colour consistency and fastness besides a reduction in water and dyestuff consumption have pushed its demand too.

The global dope dyed yarn market is set for substantial growth with demand growing in sectors such as textile, automotive, and home furnishing. The dope dyed yarn market is likely to touch an estimated $16 billion by 2027 with a CAGR of 6.4% from 2021 to 2027.

What is Dope dyeing?

Dope dyeing which is also known as solution dyeing is an innovation in the dyeing process that is environment-friendly. Choosing dope dyeing results in a significant reduction in the amount of pollution generated during the manufacturing process.

Conventional yarn dyeing consists essentially of the yarn being placed in a vat of kettle of dye and subjected to the necessary conditions for dyeing such as pressure and heat. There are three major methods used, Skein dyeing, Package dyeing and Space dyeing.

The conventional dyeing process includes first creating the raw white yarn is (textured) and then dying it whereas the process for dope dyed yarns involves mixing the raw white chips with coloured masterbatch chips resulting in a coloured Partially Oriented Yarn (POY) / Fully Drawn Yarn (FDY).

How is it sustainable?

Conventional dyeing processes rely on wet processing which involves the usage of hot water and chemicals to make the colour adhere to the fibre. According to the Global Efficiency Intelligence, on average, about 11 litres of water are needed for each metre of dyed fabric. This translates into around 100-150 litres of water to process just 1kg of textile material making it quite water-intensive. In Dope dyeing, there is a reduction of 80% in the usage of water.

Dope dyeing makes a highly sustainable option as it uses fewer chemicals and energy since the process is quite short. Less wastewater is generated and this reduces the environmental footprint of the final products. Greenhouse emissions are reduced too.

Benefits

The dye holds strong to the yarn and therefore the advantage is that this enables Master Batch addition for an increased number of washes. Dope dyeing is ideal for bright colours, durable and resistant to fading even with regular exposure to sunlight. The cost of dope dyed yarn is lesser than the conventionally dyed ones. As this is custom mixed, it offers precise colour matching. There’s a shorter lead time for yarn buyers as buyers see the colours before they buy.

Beekaylon – The leader in dope dyed yarns in India

Why is Dope dyeing the future?

With the world looking towards more sustainable dyeing solutions that are healthy for the planet, dope dyeing is growing in popularity. Many global brands have now increased the proportion of dope dyed yarns in their production to support sustainability and earn carbon credits.

Advantages of synthetic yarns over natural yarns

Mon, 23 May 2022 10:55:00 GMT

In 2020, 52% of fibres produced globally were polyester

In 2020, 52% of fibres produced globally was polyester and it's used in outdoor apparel, clothes, upholstery, home furnishings and bags. While natural fabrics such as cotton and silk have been used for thousands of years, polyester is younger but has been quickly adopted. Polyester or synthetic fabrics owe their popularity to the fact that they are far more versatile, cheaper and can be customised to a great extent. The reason why the fashion industry loves it and other industries needing specific applications such as fire-retardant fabric for firefighters or sweat-wicking fabric for sportswear choose this over natural fabric.

The current price of raw material to manufacture natural yarns has gone up substantially. This has impacted the textile value chain with spinning mills bringing down production and some incurring losses to meet prior customer commitments. Domestic cotton prices for instance have nearly doubled compared to last year. While cotton yarn per kg hovers around Rs.446 per kg, polyester starts at Rs.80 per kg and averages around Rs.200 per kg depending on its properties. The result is that many have switched from manufacturing natural yarns to polyester.

Natural vs Polyester Yarns

Natural yarns are made using fibres from natural sources, this could be extracted from plant sources such as cotton, linen or jute, animal hair such as angora and kashmere or even certain types of insect cocoon, for instance silk. Polyester on the other hand is manufactured from the polymerization of petroleum-derived ethylene glycol and purified terephthalic acid. These are melted down to produce polyethylene terephthalate (PET) which is made into semi-crystalline fibres. Depending on the final application sought, these are sometimes chemically treated and then woven into polyester fabric. Polyester can be quickly and easily mass produced.

Stronger & Versatile

Polyester yarn is strong, does not easily tear, lose shape and pill making it more durable and long-lasting compared to natural fibres. It's also lightweight, fast-drying and absorbs dyes better making it popular with fashion designers. Its versatility allows polyester yarn to be transformed into fabric for sportswear, uniforms or furnishings each bearing different properties. It has a soft and tactile surface which makes it amenable to introducing a wide range of coatings, digital printing works well too.

Cheaper & Easy to maintain

Polyester yarn tends to be cheaper as the raw materials that it’s made from are cheaper and it can be mass produced at relatively low costs. Polyester also scores marks when it comes to maintenance as it's easy to maintain and crease-proof unlike natural fabrics.

Customised yarns are possible!

The mind-boggling possibilities of customising polyester yarn is a great advantage for manufacturers. Yarn customised with specific characteristics to suit the end product can be created. During the manufacturing process, the yarns undergo the extrusion process where the required characteristics such as anti-bacterial, anti-static, anti-UV, fireproof, waterproof or dyes are introduced. The fibres can even be woven so tightly that the end product be made waterproof and impenetrable by outside elements such as wind, rain, or cold and therefore ideal for raincoats. This is not possible with natural fibres.

Beekaylon, The Pioneer

Beekayalon caters to customers across the globe and is one of the pioneers in the Synthetic Yarn Processing (Polyester) industry in India and ranks as the largest manufacturer of dope dyed yarn in the country too. It has a wide range of Polyester Filament Yarns such as Automotive Yarns, Bath Rug Yarns, Home Furnishing Yarns, Hosiery & Narrow Woven Yarns besides those manufactured for a certain functionality such as Flame retardant yarns, UV resistant yarns and Anti-microbial yarns.

Beekaylon’s state-of-the-art production facility at Silvassa has a significant advantage with the latest technologies in place. We also have industry tie-ups with leading masterbatch suppliers to match the exact color chemistry and significantly reduce color and shade development time.
With the integration of vertical control of supply chain management, Beekaylon has a smooth functioning process flow and a top notch quality assurance system in place. Moreover, for varied market applications for our various customers, we have added value with Downstream Draw Texturizing, Air Texturizing, Autoclave heat setting, Superba Heat setting, multi folding, cabling, plying and Twisting plants in place.

Why choose the greener fabric, Poly-Go-Round, made from rPET yarn?

Thu, 10 Mar 2022 23:18:00 GMT

Why choose the greener fabric,

Poly-Go-Round, made from rPET yarn?

The world is currently, reeling under a major plastic pollution crisis, the gigantic amount of plastic waste flowing into oceans and marine areas is likely to almost triple by 2040 and there is an increase of up to 37 million tonnes each year says the UN Environment Programme. To prevent ecological disaster, the need of the hour is to use and promote sustainable products which don’t pollute but help preserve our planet for future generations. In this context, rPET yarn has been developed as an eco-friendly alternative to conventional synthetic yarns that are harmful to our environment. At Beekaylon, we are proud that we produce Poly Go Round - made from rPET yarn for diverse uses ranging from uses in the automotive industry to fabrics.

How does polyester contribute to the environmental crisis?

PET today is a household name and is used in many products around the home. PET stands for polyethylene tetraphyte and is a polymer that ranks as the world’s fourth most common plastic resin. It has diverse applications, you will find it being used in the manufacture of everything from food packaging to clothing. While the commonest use is packaging material such as disposable food containers and bottles, many of us don’t even realise that what’s known as polyester fabric is made from PET as well! What makes it so attractive is that it’s non-toxic, highly durable yet lightweight.

PET is manufactured from crude oil which takes a huge toll on the environment when its being extracted. The next problem is the high durability of PET products which means it takes anywhere from five to seven centuries to degrade if it ends up in landfills. The slow rate of degradation coupled with the growing volumes of PET production have made it a major cause of the plastic waste crisis being faced globally. In fact, some countries have plastic waste heaps the size of small cities.

What is rPET and how is it obtained?

rPET is the short form of recycled polyethylene terephthalat e and applies to any PET material which comes from a recycled source. rPET is obtained by recycling PET plastic bottles and other PET products. The discarded PET waste material comes to waste processing centres. Here, they are sorted and then shredded into tiny flakes which are melted then to detach the core PET ingredient inside. These flakes are then separated by type and colour and any remaining contaminants are removed. These are then subjected to deep cleaning. This clean plastic is now put into mixing silos where they are homogenised. The next step to making this into a resin is to add necessary additives. The final step is Reactive Compounding where the base polymers are melted and blended with these additives. The rPET material obtained is then used.

How does rPET yarn help in protecting the environment?

Poly-Go-Round made from rPET yarn is a sustainable alternative from Beekaylon which can be used in diverse applications ranging from automotive to home products. This is made using rPET and one of the biggest advantages is that manufacturing this needs just 50% of the energy needed to make PET material. As this method relies on recycling existing PET products, these do not end up in landfills. Switching to rPET products such as rPET yarn also helps to reduce greenhouse gas (GHG) emissions by over 79% and cut down on the toxic material going into the oceans. Using rPET results in 65% fewer emissions, besides this 50-65% less Carbon and Sulphur Dioxide are released and 90% less water is needed. This also brings down the carbon footprint. When you choose this greener fabric, you not only get a quality product but also take pride in doing something valuable for the environment.

Beekaylon has produces 100% sustainable yarns which are made with combination of recycle & biodegradable material, unique offering for multiple applications.

Spinning Values Podcast - Ep. 5 - Customer Centricity in Manufacturing

Fri, 25 Feb 2022 06:31:00 GMT

Customer Centricity in the textile sector:

In conversation with Pratul Kumar, Progility Consulting

After a bit of a break, we are back with episode number five. Our guest today is Pratul Kumar from Progility Consulting, a management consulting firm providing profitability and productivity improvement services, for clients in the B2B area. I had a chat with him discussing customer centricity and why it is important to the textile sector. This episode is packed with insights. As always, thanks for listening.

Spinning Values Podcast: Episode 5

Listen to Pratul Kumar, Progility Consulting, as we discuss the importance of customer centricity for manufacturing companies.

The biggest gap is always between the strategy and the execution. In this episode we sit down with Pratul Kumar from Progility Consulting to discuss how this is a critical issue for companies and how we need to plug the gap. Do subscribe to this podcast on your favourite podcast app.

Transcript of the Conversation with Siddharth Ladsariya, YVO.

Ep. 5 - Pratul Kumar Pratul: If you see globally, the biggest gap is always between the strategy and the execution. And many, many companies have experienced this. We need to understand what is preventing us from reaching that strategy from a point of view of your management systems, your business processes, your people, their capability and attitudes, and fundamentally, the organization structure. We try to really understand that what is really limiting us from executing on that strategy.
Rajeev: You're listening to Spinning Values, a podcast on technology and innovation in the textile space. I'm your host Rajeev. This podcast is an initiative by Beekaylon Synthetics. After a bit of a break, we are back with episode number five. Our guest today is Pratul Kumar from Progility Consulting, a management consulting firm providing profitability and productivity improvement services, for clients in the B2B area. I had a chat with him discussing customer centricity and why it is important to the textile sector. Hi Pratul, thanks for joining this podcast Spinning Values powered by Beekaylon.
Pratul: Thanks. Rajeev. for having me on the show. Things are going very well. I'm sure after a COVID one is recovering well in your family and your friends network. So I hope everyone is getting better.
Rajeev: Thanks for asking. I hope things are going well for you as well. What's the effect of the pandemic on the manufacturing sector? Has it recovered right now, or is it back to how it was before? How do you see it going.
Pratul: well, so if you look at, from an India perspective, when a lot of the recovery has already happened.. Of course there is some amount of supply chain disruptions, which,still pockets of the industry is facing. But overall, I would say that, Indian manufacturing is well on its way of recovery. The latest statistics also suggests that, we're almost back to normalcy now. Bearing a couple of sectors. that's the good news for the economy as well.
Rajeev: Great. I just wanted to,find out what your field of interest is because it's something really unique that you do as far as manufacturing sector is concerned. I understand that you're into change management, from a productivity point of view and as well as process efficiency. In particular customer focus. So can you, give us a brief of what you do and what your organization.
Pratul: So let me start first with my organization, which is a Progility Consulting. I started this organization last year, in fact. And I've spent, about 25 years in the management consulting in industry. Having started Progility Consulting, our core focus is to work with B2B industrial product clients and to help them improve, two clear things. One, the profitability and the second productivity. And these two concepts have great interlinkage, between themselves. and we help management teams, we help people on the floor. We help the middle management.So, right from working with the senior management team on bringing in strategic clarity as to how they should really lay down the strategies, to working with the middle management team in operationalizing that strategy and working with the very, front end team in,executing the strategy, in making the change management, we work across layers, of the organization. Fundamentally, we are actually a implementation consulting firm. So we are not really in the business of providing just advice. We work with the organization and we make sure that the organization sees a very clear and tangible outcome. On, the solutions which we have jointly developed. So we make sure that they see a clear shift in terms of the profitability, clear shift in terms of productivity, and the customer focus. So these are the areas of work. And as I said, I spent about twenty-five years with various, multi-national consulting firms,spending time on similar practice areas with companies like EY, Pricewaterhouse. And then finally I started this consulting organization.
Rajeev: You said you are an implementation agency and not just pure consulting. That means you have to deal with, various types of,employees.From the top management to the workers on the floor. How does that work? Like how do you translate broad strategies into actionable tactical,things that, somebody on the shop floor can implement.
Pratul: How do you translate strategy into action? Yeah. And that's a very interesting question, Rajeev, I think, the whole philosophy, if you see globally, the biggest gap is always between the strategy and the execution. And many, many companies have experienced this. They have that, at the boardroom level.it's not easy, I would say, they have a lot of clarity on the strategy part. The top management is extremely clear what strategies to take. Of course, we help a lot of companies to clarify that, to make sure that it is very sound and very detailed. The gap between the strategy and execution has always remained and it's a big gap. What we help companies to understand is first of all, we need to understand what is preventing us from reaching that strategy from a point of view of your management systems, your business processes, your people, their capability and attitudes, and fundamentally, the organization structure.
Pratul: So these are the four elements. We try to really understand that what is really limiting us from executing on that strategy, which part of the business process or which part of the management system is not really helping us get there. And that's the hard part. The softer aspect is around the behaviors, the capability.
Pratul: So we work on that aspect as well. Looking at the strategy, we translate that into, areas of where and how the company can really make an impact by changing the management systems. What will you do in terms of business processes? And in all of this,the biggest differentiator is to get the alignment of people in any organization. We have seen, there are multiple stakeholders who are involved and every stakeholder has a very different view of what needs to be done for them to reach to a particular strategy or to particular end result, but getting of them aligned. Getting all of them to think together. To focusing on these building blocks of the organization helps us to get very practical. a strategy to a implementation group, blueprint, core is do we have the alignment of everyone, what needs to be changed? And that's a very detailed work that helps companies to really understand which part of the business, they need to really change, to move in the direction of achieving the strategy.
Rajeev: In a company like Beekaylon,who have long legacy in this market. And they've done things in a certain way for a long time. Is there a resistance to change in such companies? Do you find it difficult in implementation?
Pratul: Before coming to that question, let me give my perspective on a lawn. So as you rightly said, they have a very long legacy in the polyester industry and whatever I have understood, if you see, in polyester industry, a lot of companies in India have had a very, rapid growth. Pratul: But their balance sheets were very leveraged, right? So a lot of companies to achieve that growth levels in terms of sales growth, and to achieve that level of financial performance, they over leveraged on their balance sheet. But Beekaylon, if you really see, is one company in the polyester industry, which has retained it, it's focused on the balance sheet very strongly.
Pratul: So it has a very strong balance sheet, and it has been able to grow in very, very sustainable manner, which reflects in the long-term thinking, that, if a business has to be sustainable, your fundamentals have to be in place. And then of course, over a period of time, you will see the growth coming in would in terms of your customer base, your product base, everything increasing.
Pratul: Along with them. you will actually end up increasing your capacities as things progress. And that is very clearly evident in the strategy they have taken. and, the best part about Beekaylon is that, the promoter family is very involved in the running of the business. they're fully into the operations.
Pratul: They are taking day-to-day decisions. Of course it's a family run business, but at the same time, they have been able to bring that level of professionalism in the day-to-day operations. That's how,I know Beekaylon. Before we actually engaged with Beekaylon, the whole thought process was,can we understand from customers what is in the customers mind?
Pratul: And we did a very detailed survey. We spoke to many customers across segments of, Beekaylon's products, to understand what do we feel. Both from a point of view of product quality, the service quality,the approach of management and interestingly two things came out very clearly. One, most of the customers said that the quality of Beekaylon is not to be questioned. We did many discussions and everyone had the same feedback that never ever, they had a issue with the quality of the products. And that's really great. The second thing, and even higher than quality they said is that Beekaylon is one very ethical organization, which makes shows that all our business with them is done in a very ethical manner. and this industry is because it's linked to a lot of commodities. There is a tendency by other players to really take advantage of the pricing sometimes. But most customers, the feedback was that Beekaylon is very clearly very, ethics driven and we have never had even one dispute with Beekaylon. So these two were positive feedback. one improvement area, which everyone said was around, having all this as the good part. What they're actually experiencing is that they're on time deliveries are really good. In terms of when I say it needs a lot of improvement from what was promised to them and when it gets delivered. So, with that perspective, we started working internally with Beekaylon to really understand, what's really happening? If the product is good, the customers are coming back again and again to you,why is the service not really in place. And what can be done? And let me add here that it's not an issue with Beekaylon only. It's a problem which is industrywide. In B2B industrial sector, if you see the customer experiences lower by 50% compared to a B2C Company. So as a B2C customer, my experience with the company will be much higher, and this is a global statistics, but in a B2B environment, that experience level falls to about 50 percent. So, having understood this problem, then we started a very detailed, internal mapping of what could be the possible reasons and where we need to make a change impact in terms of what, which part of the business we change to make,improvement in the customer's life and eventually their experience. So that was the initial,context of this whole,But, and, like we discussed,Beekaylon has a long legacy and they've done things in a certain way. They're a family owned business and you know so on and so forth. How did they realize, that they have to change? Because the going is good, why should we fix that stuff, which is not broken, as they say, how did they take that decision of actually right.
Rajeev: We need to change, that itself is a pretty significant step for a very traditional business organization. That's the big step, that means that they have already made up,the promise that they will bring a change in the way they are operating. So I totally agree with you. I think, there were two realizations, one, pockets of customers had these, often. feedback from customers, they had got that, the on-time deliveries are not as per the industry standards. So that was one of the, feedbacks they have been getting. The second was also that,internally they were feeling that, because of too many orders and Beekaylon was one organization where they always had orders more than the capacity they had.
Pratul: So they were always fully loaded. So they always had this realization that are we losing out on important orders because we are doing a lot of firefighting to meet needs of the customer. Who's actually, you know, shouting at this point of time. So because of delays and those delays could be from a customer who has given us a very small quantity and is not really a strategic to our long term plan, but still we will be losing out on other customers and other profitable customers just to make sure we are servicing him. So I think from these two points of view, this realization came to them. That there's is something which needs to be changed. and of course,the entire management team, as I said, has a vision to really be a top quartile performer in the polyester industry.
Pratul: So they are moving in that direction. and this is one of the step, this is the first step towards that direction. And out of your research, was there a realization that we need to focus on certain type of customers and not certain type of customers? Was there a sort of a rationalization from that part?
Pratul: Yeah. interestingly, when we started looking at this problem of on-time delivery, we were trying to understand it from multiple perspectives. And this happens in every organization. This is not Beekaylon specific. That as the organization keeps growing the number of SKUs, the stock keeping unit,keeps on growing. As the growth happens is very natural. And beyond the time it becomes that, the are your basket, your product basket has become too large. And that adds a lot of complexity in manufacturing. Because that means number of changeovers are going up. Number of, quality checks will go up.
Pratul: Number of audits will have to be more. So the more wider your product basket is. It's going to have a much higher impact on the complexity. Similarly, as you are growing, in your initial days, you would add lot of customers who would help you to enter the market, but over a period of time, that customer base also keeps increasing because you are trying to chase growth. but beyond a point, you'll always have a customer base, which is not everyone is strategic. Not everyone has the same need. Not everyone wants to be serviced in the same manner. And this is where I firmly believe that B2B industrial organization and especially textile organizations, if you see historically, they have been extremely focused on efficiencies, and the whole textile industry has been competing on that.
Pratul: Especially in India, the whole competition has been, are you more efficient than me? Or can your cost be lower than me, but in chasing all this, and this is very good. You know, many, many industry sectors are not even close to the efficiency levels, which one could find in textiles, both because it's a very old industry, but at the same time, the engineering levels, the quality of machines are so high in textile, that the efficiencies are already built in. You can't really run a textile business at 80% productivity level or at 80% efficiency level. Like you have to run it at a 95 or a 92% to make sure that you're surviving. So that's the table stakes in textile business. But having said that, one, one thing which organizations need to focus now going forward is what is happening with my product basket, what's happening with my customer and that customer base, which I have, what kind of needs they have? Do we need to service everyone in the same manner? Does each customer category needs the same similar time of response, time to the orders. And if you go deep, if you understand the customers deeply enough, you'll realize that some customers. and every customer is price sensitive. I'm not saying that, but there are customers within this pocket who would give a higher value to making sure that the deliveries on time,it matters price for them comes number two. So price is something which everyone is sensitive about, but, on-time delivery, listening to the customers.
Pratul: These are the which have started gaining a lot of importance. So we worked a lot on developing a method through which you can segment your customer base. And that's what we did exactly for big along. We came up with a framework to really help them understand what is the customer base like? And can you categorize them into pockets? Pratul: And we are not saying whether customers are important or not. All we are saying is, a different customer set has a different need and needs to be serviced differently. Another set of customers have got a totally different need and they need to be serviced totally differently. It is for you to understand this dynamics and design your response, design your supply chain in a manner which will satisfy both.
Pratul: And that exactly is the journey Beekaylon is on. I would not say that we have really covered this. These are still initial days. And this is, this is the direction we are taking to making sure that each customer gets, their critical needs get covered in the best possible manner by Beekaylon, so that they remain with us for a longer time.
Pratul: So customer centricity, as a concept and philosophy is what we're driving at Beekaylon.
Rajeev: Interesting. How does that affect productivity? Because you have thousands of looms running non-stop day in and day out and you're right now you're segmenting your customers based on different needs and so on. How does that affect productivity? how do you, correlate that?
Pratul: That's a very interesting question. So, there is one aspect around customer segmentation. There is another aspect called is product segmentation. And product segmentation helps you understand what's the demand pattern of your product. What patterns they are telling you. If you look into your history, look into your data, it'll tell you what is the pattern of this particular demand. and many of these products are going to all the sets of customers you have, right? So if one is very intelligent about understanding the patterns and understanding how we can manufacture it in a manner, that we don't lose our productivity, but we still are able to manufacture what the customer sets are looking for. So we also, develop the framework,to help them categorize the product basket, to understand the demand pattern and then develop manufacturing plans accordingly so that it ties well to the needs of the customer. And as I speak, this is all, it's a very long and long drawn transformation journey for Beekaylon.
Pratul: So this is going to take a lot of time, but we are moving in that direction where we are by bits and pieces, we are bringing in this concepts of how we can, understand customers, better understand the demand and the products which we are offering. How do we tie all this together into a plan, which optimizes productivity. And optimizes customer service. So, the next part, I really interested knows how do you, affect change? I mean your top management, of course, they accept change and they accept that you have to change in order to grow. And, even if it's difficult, they do it. But as you go down, lots of levels. do you inculcate, these habits into the general worker, your employees who are actually running the looms? I think, the fundamental thing about change and,there are many, books, many thought process on how to drive change. And it's, there's no one, one answer to this, but, everyone has his own methods and everyone has his own approach. I think the one critical approaches that, if you want to bring change, the first and foremost thing is that you need to get people involved into understanding the change. So when we first started,the work at Beekaylon, the first thing we did was we involved a lot of people from the plant, from their head offices to first of all, really understand what is the issue?
Pratul: What is the need for change? And that has to be clarified them through multiple ways. One to look at their past, look at the data, look at the analysis, do a lot of interesting, meaningful, discovery processes, spend time on the floors, to really see what is happening. Spend time with people to understand what's happening in their jobs and bring all this insight for people really decide, is this what, the way they should be really, operating, is this really right for us? So the first is to let them accept the problem itself or all the way the better word could be, the challenges which are there in the system. Let them, first of all, get a deep understanding of where are we today and is this something, this is should be really running our business? And the biggest missing part is, we expect people to change without telling them why. So that why question has to be answered in very detailed, manner, it's a painful exercise. People in India are so involved with the jobs or they spend lifetime with the companies. So for them to disassociate themselves from what is being shown as an issue, rather than, taking it personally.
Pratul: It always happens, and that is where our role comes in, where we keep on telling them that, the person is independent here. It's about the issue which we are discussing. And the issue is that, we feel there's something wrong with the process. The performance is not coming up today.
Pratul: So we was spend a lot of time in helping, first of all, people understand the issues. Second step is to also involve them in defining. So, if this is the issue, what do you think we should be doing? Rather than being a very prescriptive kind of a change, we let them define the change for themselves.
Pratul: And of course we are there as facilitators, but we don't want to be prescriptive about it. We want them to adapt to it by understanding the issues. They come up with ideas that, these are the ideas we think we should be doing. This is the way we should be changing it. Rather than just giving them a report saying that, you have to change from tomorrow. That really works. Pratul: We are dealing with mature individuals. So we take that approach and then we also help them develop those ideas into full-blown, working models and working sheets so that people start adapting to that. And then of course, a lot of training, a lot of persuasion, a lot of handholding needs to be done so that this whole change actually starts percolating down, to the level.
Pratul: And people start using it as a system of their own,a way life of their own, and they have designed, they should have the pride that this new method, this new way of working is designed by us rather than being prescribed by somebody else. Rajeev: Right then, how do you make it a habit so that it continues even after you the project at Beekaylon. That a system that you set up, which makes sure that it continues forward and they keep learning from it?
Pratul: Yeah, so I think, sustainability of change, is,a very big challenge. You why it's easy, easier to bring in change, but to sustain that. And when I use the word sustain, I do not really expect people to continue following everything, what we have said, but what they need to continue is the philosophy of improvement.
Pratul: So Sustenance is actually in my view means philosophy of continuously improving that is sustenance. So they should be in the habit of continuously challenging their own methods, own processes.
Pratul: And coming out with improved methods and for that to happen, it needs lot of drive from the leadership,in any organization, if that drive is not there, it will be difficult to sustain it for a longer term.
Pratul: And that's the hard part. Top management may not have all the time with themselves, but, without them,it's too difficult, it's easier said, but,very difficult to achieve. The second part is, we bring things to a close only when it has already become part of their habit.
Pratul: So we don't really, prescribed or, we don't, once they have completed using it. Once the change is visible, the results have come, they have sustained it over a period. Then only we say that this is the new method, and this is the old method gets totally replaced. See the difference between a change and transformation is that in transformation, you will not have the reference of the old at all. It's a completely new method today. So once the new methods really sets in and it's irreversible. We can't really go back. Then we say that, we have made it permanent, so that it becomes irreversible in no case, we can go back that fallback is there. and it takes a lot of effort to achieve that.
Rajeev: How's it playing out generally in Beekaylon? Are you seeing a lot of progress and a sea change, like a before or after? And how are the customers reacting to this?
Pratul: We have done this project in multiple environments and, it's very easy to claim success and that everything has been achieved. And I'm in Beekaylon also we have seen multiple improvements happening in terms of productivity improvements in terms of on-time delivery improvements. And those have happened, but I will still, as a consultant and as a trusted advisor to Beekaylon, I still feel that we have a lot of ground to cover. Many improvements have still to happen to really come to that level, that, we are truly in the top quartile performance on various of these parameters. So we have, started the journey. It's a long drawn process. Of course, initial and results are very encouraging. People have adapted quite well to the changes. We see a lot of involvement, a lot of willingness. In people to bring on the new ways of working. and, it's a long way to go, in terms of, becoming the benchmark in performance in these areas.
Rajeev: So going forward, where do you see these kind of projects, in this sector? Do you see more adoption amongst companies for these kind of, practices?
Pratul: Yeah. So as I said, customer centricity is going to be one central theme, which is going to drive, choosing you over others, in B2B and the biggest factor, which is driving this change. It's because of B2B buyer is also in his personal life, he's buying B2C and his experience that ease of mind through shopping websites and, these, large marketplaces, the see that ease of buying happening. and they will expect the same from a B2B supplier as well. So I think the whole mindset shift on how to become more and more customer centric, how to improve the customer experience,that is going to help you retain your customers.
Pratul: Efficiency is going to be table stakes costs are going to be, entry for you to really get an entry into any client. That's going to be the norm. But what is going to differentiate you from any other competitor is going to be how more customer centric you are. What kind of experience you offer then the other company is not able to offer.
Pratul: So my philosophy and advice to all textile firm is that, going forward, customer centricity and innovation. So when I say innovation in your product basket, coming out with new and new products that is really going to keep you, in the top league of performance, and in the top quarter of your, customers., So that's the mantra one would have to adopt. Rajeev: Thanks Pratul for your time and amazing insights into why customer centricity is important. And why this is going to be the key differentiator going forward for the textile sector. I hope this chat was useful for our listeners. I certainly found it really insightful. This is spinning values brought to you by Beekaylon Synthetics. Thank you for listening and see you in the next episode.

Things you never knew about Antimicrobial Yarn: An exhaustive guide

Tue, 08 Feb 2022 08:09:00 GMT

What is Antimicrobial Yarn?

Antimicrobial Yarn is a synthetic fiber with antimicrobial properties that inhibit microbial growth and, in specific applications.

Antimicrobial Yarns have Antimicrobial agents applied, either at the surface or within. These agents could be added during the spinning or extrusion processes or as a special ingredient during solution dyeing. In addition, some fibers are given antimicrobial treatment during the finishing stage. Adding the antimicrobial agent is usually dependent on the application and sometimes budget.

Antimicrobial Textiles have been around for longer than you think

The addition of Antimicrobial agents to cloth dates back to 3000 BC. The Egyptians used naturally available spices and herbs to preserve their mummies. For hundreds of years, the Chinese used bamboo as a building material for its strength and an antimicrobial substance called Bamboo-Kun .

In World War II, Antimicrobials were widely used by the Allied and Axis coalitions to prevent textiles from rotting. Other applications included tents, tarpaulins, and truck covers. In addition, fabrics were commonly treated with a unique mixture of copper, antimony salts, and chlorinated waxes.

When these chemical agents resulted in health and pollution-related issues, modern guidelines were set for the production of Antimicrobial textiles during the early 1960s. Some of these broad guidelines include:

The Antimicrobial agent must be suitable for textile processing
They must be durable during processes like laundering, dry cleaning, and hot pressing
They must be safe for use on skin or area of application
All Antimicrobial agents must be environmentally-friendly.

The need for Antimicrobial Yarn

A microbe, by definition, is a microorganism, especially a bacterium or a fungus causing disease or fermentation. Under most normal conditions, a single bacteria cell could proliferate to 1,000,000+ cells in under seven hours . Microbes’ unchecked growth could lead to adverse health conditions for humans.

These microbes constantly seek surfaces to grow, and textiles usually made from natural fibers are a perfect example. They are porous, warm, and hard-to-clean - perfect for microbe growth! When microbes grow on textiles, they deteriorate the material’s mechanical strength and cause stains on the fabric. There have been several cases when microbes have wrecked their havoc on full shipping containers on fabrics, leading to textiles now being packed in airtight packaging.

But the effect of these microbes on humans is far more significant - unfavorable odors and infections, to name a few. These are a few reasons why Antimicrobial Yarns were developed and used in several applications today.

Top Applications of Antimicrobial Yarn

1. Antimicrobial Hospital Wear and Linen

Clothing used by both patients and doctors in hospitals is naturally bound to bustle with harmful microbes. One must also consider other textiles like bed linen and blankets. But these applications are only the surface of current applications in the healthcare industry.

Antimicrobial textile dressings are increasingly used to treat wounds and manage wound infections. Since wound dressings are in direct contact with broken skin, they must meet the following criteria.

The Antimicrobial dressing must possess a broad-spectrum antimicrobial effect
It should be non-toxic and safe to use on broken skin
It should not cause allergic reactions
It should help in developing bacteria that are resistant to the Antimicrobial agent

For such applications, commonly used Antimicrobial compounds are not recommended for use on broken skin. Ions of Silver, Copper, and Zinc are non-toxic to human skin and have proven to be effective antimicrobial agents for wound management. Amongst naturally occurring materials, Melaleuca Alternifolia oil (commonly called tea tree oil) has shown realms of promise in treating wound infections. Apart from being a natural antimicrobial agent, it has anti-inflammatory attributes and activates monocytes.

Other applications of Antimicrobial Yarn in the healthcare/hospital industry include earbuds, scrubs, masks, and other protective kits.

Commercial Applications

Public places and commercial centers like movie halls, malls, etc., see much human traffic every day. Textiles used in these applications could be categorized as high exposure and, therefore high risk. This would include floor carpets, seat covers, blinds, curtains, contact surfaces in public buses, cabs, and more. It would essentially help if these surfaces were made from Antimicrobial materials.

Usually, these textiles are surface-modified by techniques like electrospinning, nanotechnology, plasma treatment, polymerization, microencapsulation, and sol-gel. Apart from making the material Antimicrobial, these processes also impart functional attributes like water-repellent and flame-retardant.

Common Apparel

Specific garments tend to stay out of the sun and accumulate moisture when used, like the inside of caps, sportswear, sanitary pads, and inner garments.

On the other hand, winter wear is stored for long periods and rarely washed.

The structure of wool makes it a perfect breeding place for microbes.

Antimicrobials in these applications help keep the microbes in check and offer socially-favourable advantages like odour control.

Household or Home Textiles

Home Textiles could play a huge role in passing microbes from one person to another since they are typically exposed to several people under the same roof. Such examples include carpets, floor mats, floor rugs, curtains, bed linen, pillows, and more.

Special Applications

Such applications include military-grade uniforms, dusting cloths, mops, tents, and more.

Generally, fabrics used in these applications undergo various Antimicrobial treatments to control a broad range of bacteria, fungi, and viruses.

Types of Antimicrobials Agents and Examples

A microbe, be it a bacterium or fungus, has an outer wall of polysaccharides. This wall is responsible for the integrity of cellular components and protects them from external factors. Beneath this cell wall is a semipermeable membrane that encases the intracellular organelles and enzymes responsible for chemical reactions within the cell and nucleic acids that carry genetic information. The survival and growth of microbes depend on the cell’s integrity and function.

Antimicrobial agents are classified by their action on a cell’s function or integrity. If they only inhibit cell growth, they are termed Biostatic Antimicrobials . If they can kill these microbes, then they are termed Biocidal Antimicrobials .

Most Antimicrobial agents used in the commercial textile industry are Biocides. Their chemical and structural composition determines how they target microbial cells. Here is a list of how these Antimicrobial agents fight microbes.

Damage/inhibition of cell wall synthesis, which is critical for the life and survival of bacterial species.
Inhibition of cell membrane, as it regulates the flow of substances, therefore resulting in the leakage of vital solutes for the cells’ survival.
Inhibition of protein synthesis, the basis of cell enzymes and structures, therefore causing the death of the microbe or inhibition of its growth and multiplication.
Inhibition of nucleic acid synthesis (DNA and RNA) due to the binding of the Antimicrobial agents to components involved in the synthesis. This also leads to the death of the microbe or inhibition of its multiplication.
Inhibition of other metabolic processes essential for bacterial DNA synthesis.

Here is a brief list of the main antimicrobial agents used in textiles and the main fibres with which they are used.

Each of these Antimicrobial agents present both advantages and challenges. To understand what would be best for your application, please reach out to our experts at ho@beekaylon.com .

PURIFLEX: Antimicrobial Yarn from Beekaylon

Even at low concentrations, various non-essential metals have been found to have a toxic effect on a large number of microbes. Their biocidal effects are triggered by the following:

Metal reduction potential and/or
By the metal donor atom selectivity and/or
Speciation (the formation of new species in the course of evolution).

In general, metal ions bind to donor ligands like O, N, and S, and replace the original metals present in microbes leading to cellular dysfunction.

Of the various metals, Silver has become the metal Antimicrobial agent of choice, for the textile industry. Its rock-solid reputation stems from Silver’s strong polymicrobial colonisation properties. Silver possesses bactericidal activity against a wide range of Gram-positive and Gram-negative bacteria. Some of them are Pseudomonas Aeruginosa, Staphylococcus Aureus, Staphylococcus Epidermidis, Escherichia coli (E. Coli), and Klebsiella Pneumonia.

After extensive research of the benefits of Silver and its antimicrobial properties, we developed PURIFLEX , our brand of Antimicrobial Yarn.

PURIFLEX features permanently infused Silver-based AM++ ions that remain effective even after extensive washes and usage. It is a novel way to prevent bad odours in garments like sportswear and innerwear while being friendly to both the human skin and the environment at large.

About Beekaylon

Beekaylon is a leading synthetic yarn manufacturer. We are best known to our customers for our innovations and strong value systems. Our products cover a wide range of applications from apparel to elastic tapes. From Partially Oriented Yarn (POY) / Fully Drawn Yarn (FDY) to Draw Textured Yarn (DTY) / Air Texturised Yarn (ATY), Stain-Resistant Yarn, Moisture Management Yarns, and UV-Resistant Yarns. We offer the full range of specialty yarns.

And we have recently added a revolutionary new product to the mix - Bulk Continuous Filament (BCF) Yarn with a wide range of commercial applications - from wall to wall carpets for cinema halls, mats, and rugs for residences, to furnishing for high-end automobiles. Know more at www.beekaylon.com or write to contact@beekaylon.com .

Disclaimer: Beekaylon Synthetics Private Limited, hereafter termed as Beekaylon hereby states that it has carried out the due diligence to confirm the accuracy of contents in this blog. Beekaylon assumes no responsibility or liability for any errors or omissions in the content of this blog. The information contained in this blog is provided on an “as is” basis with no guarantees of completeness, accuracy, usefulness, or timeliness and without any warranties of any kind whatsoever, express or implied.

Beekaylon: Offering value-addition with focus on sustainability

Thu, 06 Jan 2022 22:35:00 GMT

Our feature on The Textile Magazine, Dec 2021 Issue.

With the integration of vertical control of supply chain management, Beekaylon has a smooth functioning process flow and an excellent quality assurance system in place.

The year 2022 will be a very eventful year for Beekaylon, one of India’s largest manufacturers of dope dyed POY, FDY, BCF, draw texturised, air texturised, twisted, cabled and heat-set polyester filament yarns. This is because it will mark the biggest expansion spree in the company’s history. Click on the image below to read the article.

7 Innovative Fabrics and Technologies that will find their way to your wardrobe by 2025

Wed, 01 Dec 2021 21:09:00 GMT

"Future Fabrics and Technologies" - a glimpse into what's to come.

1. Energy Harvesting Yarns

Georgia Tech researchers have already developed energy-harvesting yarns that could be integrated into washable textiles. These yarns collect static electricity caused by friction. Researchers claim that this “supercharged” fabric should be able to harvest enough electricity to charge your phone. So don’t be surprised if your kid’s newest sweatshirt comes with a USB port.

2. Haptic Feedback Sportswear

Did you know that the Nadi X yoga pant from Wearable X could help you perfect your yoga postures? This pricey pant features built-in accelerometers and vibrating motors woven into the fabric around the hips, knees, and ankles. They are programmed to guide you through your Yoga Aasanas through gentle vibrations.

By 2025, you could very well expect big sportswear brands to launch collections that will help you get better at the gym, soccer, or even ballet!

Did you know that our range of F lexilastic ultra-stretchable yarns helps improve performance and comfort by up to 58%? Know more.

3. Clothes with sensors to collect Medical Data

Collecting medical data is no longer limited to wearables and medical device probes. Several brands have already begun marketing their innerwear and shirts with strategically placed ECG, respiration, and physical activity sensors. These garments can collect data for up to 75 hours and upload it to the cloud without frequent charging or making the wearers feel conscious. These products could play a huge role in monitoring the people on both sides of the spectrum - the health-conscious and the chronically ill. Guess hospitals now can finally retire those indecent patient gowns!

4. Fabrics that help you control your Phone

Imagine having a jacket that lets you know when you get calls, messages, app notifications, and even allows you to drop pins on your favorite locations - all this without taking your phone out of the pocket. That is what the Levi’s Commuter Trucker Jacket promises to deliver. It comes with the Jacquard smart-tag developed by Google, woven right in. The tag allows users to control their phones with various gestures that could also be quickly reassigned. So no, that funny cyclist you saw this morning wasn’t slapping himself on the wrist.

5. Communicative Coutures

While your current clothes might reflect your personality a little, the collections from CuteCircuit could help you make a statement - literally. Yes, the brand’s clothes and accessories have built-in electronics to display social media messages. Hmmm, so when do they get speakers?

6. Sneakers made from discarded Plastic

According to National Geographic, we produce about 600 million tonnes of plastic every year. About 45% of this is for single-use purposes, and a whopping 91% of this category is not even recycled! When these plastic materials pollute the oceans, they break down into microplastics. And guess what? These microplastics have been found everywhere, from Mount Everest to the Mariana trench. Furthermore, these microplastics break down into microfibres that are being increasingly detected in Drinking Water Supply Systems.

Popular brands like Adidas are now championing the cause of using ocean plastic and plastic bottles to make shoes and swimwear. And a million pairs of these shoes have been sold till now.

We are playing our part to help the planet with Poly-Go-Round , our recycled polyester yarn made from used plastic bottles. Know more.

7. Self-Cleaning Clothes

Scientists have made further improvements on Antimicrobial Yarns by building metal nanostructures on cotton threads. When exposed to sunlight, these nanostructures self-clean surface-level grime in about 10 minutes. Hold on. This technology is still a work in progress. So don’t throw out your washing machine yet.

While you are doing your laundry, please take a minute to know more about PuriFlex , our range of antimicrobial yarns for Denim, Sportswear, Hosiery, Home Textiles, Uniforms, Floor Carpets, and more.

About Beekaylon

Know more at www.beekaylon.com or write to contact@beekaylon.com .

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Spinning Values Podcast: Ep. 4 - Giving back to society through volunteering

Mon, 06 Sep 2021 00:09:00 GMT

Small Act - Big Impact :

In conversation with Siddharth Ladsariya,

Founder, Young Volunteers Organisation

In this episode, we catch up with Siddharth Ladsariya, one of the founders of Young Volunteers Organisation (YVO), an organisation that seeks to connect the corporate world with NGOs that work with various causes and communities across India.

Spinning Values Podcast: Episode 4

Listen to Siddharth Ladsariya, as we discuss volunteering & CSR.

With a raging pandemic, volunteering and CSR have become crucial in contributing to the communities that businesses operate in. Is it time to give back and build some good karmas? Do subscribe to this podcast on your favourite podcast app.

Transcript of the Conversation with Siddharth Ladsariya, YVO.

Siddharth Ladsariya

We definitely started off with the platform just to connect, donors or volunteers with, people doing actual good work on the ground. But today we have evolved ourselves as a platform where any youth, who wants to do anything good for society? he joins YVO. He sees YVO, he understands how good and how nice it feels to do good for society, whether in a small way or in a bigger way. And we encourage, and we facilitate him to live his dreams and passions towards betterment of society.

Rajeev

This is spinning values brought to you by Beekaylon. And you're listening to Rajiv. We have a special guest on our show today, who's unlike any other previous guests, It has nothing to do with synthetic yarn, but it is all about change. Someone who believes that even a small thing you do to change the world around you, can have a significant impact. Let us meet Siddharth Ladsariya, one of the founding members of Y V O young volunteers organization. YVO's mission is to be the social impact platform of choice for donors and young volunteers by showing them that even the smallest act can make a large impact to India's development. Thanks Siddharth. Thanks for coming on the show. spinning values, powered by Beekaylon.

Siddharth Ladsariya

Thank you Rajeev for having me here.

Rajeev

So we've been doing phone tag or email tag for quite some time. Right. So it's finally good to talk to you.

Siddharth Ladsariya

Pleasure.

Rajeev

Thanks Siddharth. Thanks for coming on the show. this episodes a bit different from the other ones that we've done so far, which is really focused on the product side, so the inspiration for this episode came from Shohin where he suggested that let's do an interview. or an episode, which is outside of what we do, and that's how I got in touch with you and this whole thing happened. so just to start off with, can you just, tell our viewers something about you, and the organizations that you lead.

Siddharth Ladsariya

Yeah. So thank you, Rajiv. My name is Siddharth Ladsariya born and brought up in Mumbai, pursued my engineering. Worked for a couple of years at ICICI bank. And then did my MBA from the U S. And, since coming back from the U S I have been actively investing in startups in India, invested in more than 150 startups, and also, run a company called Everest fleet, which is, one of the larger fleet management companies in India, employing more than 1,500 people.

Rajeev

what inspired you to start, a young volunteers organization?

Siddharth Ladsariya

All right. So while I was studying in the us, I often, seeing the youth there, the children the young adults, they were always very deeply involved in giving back to society in whichever way, whichever form, and for some reason, growing up in India, we never felt this from our heart within that, we, young professionals, especially educated people that we never got the opportunity or we never found a way how to give back to society.

So I've seen them. it was really an eye opener that, if, every individual, every youth is involved. And pretty deeply in giving back. So that, with that thought, started off thinking that how can we create such a, such a thought process in, in the youth of, India and a few years later over a casual conversation with friends.

We started brainstorming on how we can, replicate or how we can make this, successful in India. we identified three major constraints why we were not being able to, get involved in, giving back. One was that young professionals do not have time. They're all building their careers.

Time is extremely precious thing for them. They don't have large amounts of money where they can, go out and, extend, spend significant amount of time for donating that money. And thirdly, the transparency bit that in India, generally the word NGO because of, small, negative instances, the trust levels were not as great So with this, we started off and, try to get, people more and more involved. we have more than 60 volunteers. Typically they're professionals, startup entrepreneurs, businessmen, lawyers, doctors, et cetera. we told them that the kind of time commitment that we expect out of our volunteers is something in that in the four to six hours a month, which was something which was easily digestible by most people.

So we solved the problem of time that, we don't expect you to give more than, this many hours. Of course, if anyone is more passionate and they can spend the kind of bandwidth they're free to do, that was one part. Money. We started off with, why don't you donate 306 rupees every month, which is a small amount of money for most, youth in India.

but the donation, let us try to do it, sustainably, let us try to donate every month. This 306 over a period of time, we made it 506 rupees. And again, we solve that. You don't need to, give large amounts of money or you don't need to, you can just give small amounts of money in a sustainable fashion.

This eventually took the, to the form of, becoming an SIP of good Karma's as we like to call it that, systematic investment plan for good karmas. what we try to tell all our people was this small act of yours, of 306 or 506 rupees can create a big impact collectively. So, our tagline of YVO small act big impact.

Then third coming to transparency. We were very lucky to have, mentors, very good mentors, for us who guided us and told us how to address each of these problems. So, We do an exhaustive, due diligence on any NGO that we donate to, before donating and even after donating and even six months after donating to ensure that all the money has been rightly utilised.

We're also advised that, why don't we make our organization a zero admin cost organization, which is that not even one rupee we take from the donors to run this organization, that organization is run by the volunteers ourselves. And that's how we became a zero admin cost organization.

so we only donated for sustainable causes. When I say sustainable, it means that you not teach a person how to fish, but don't give him fish to eat. So typically causes, which resonate to us was education skilling women environment, water conservation, all the causes, which changes the life of a person for a long period of time for our family for a long period of time.

I would like to take this opportunity to give an example of a few, causes that we've donated to the first donation that we made was the amount of 40,000 rupees, six years ago. was an organization called Snehalay, what they were doing was they were rehabilitating women from the sex trade into mainstream society.

But when these women came into mainstream society, they realized that they don't have any skill to earn a living. So, Snehalay was involved in teaching them how to sew and, So then they can learn, sewing and make a living for themselves and come back to mainstream society. And we donated sewing machines for that cause, and today after six years, we are proud to say that thousands of women have been rehabilitated from that trade into mainstream society, living a dignified and honorable life.

one of the NGOs that we donated to was Deeds where they are involved in training deaf and dumb youth into becoming, waiters and chefs in restaurants. And then they are placed into restaurants. So suddenly an individual who was not contributing to a family in terms of financial or monetary, suddenly he became a bread earner for that family.

An organization where we donated, called Keshav Shristi. They teach women how to make bamboo handicrafts in, villages and tribal areas. Now, these women, by making these bamboo handicrafts and selling them into the market, they increase their family earning of around seven to 10,000 rupees a month, which is a huge amount of money. And with this money, they can spend it on their children's education or their own health. So, these are some causes that we have been donated to. As I told you, transparency touching back on that subject, we ensure that all our bank statements are uploaded on our website each and every receipt that we get is uploaded on our website.

We inform the donors every month, by an email or a WhatsApp, on how each and every rupee was utilized and how many lives it impacted and how it impacted them. so, our donors have really appreciated the level of transparency that we have been following and their trust on us has only been increasing with time.

Rajeev

It seems to me that your organizations is more like a bridge between, NGO, which are actually doing some really good work, at various levels and. People who want to invest or donate their time or resources to those causes. Am I right in saying that?

Siddharth Ladsariya

Yes, you have hit it exactly. Right. this is what we do. So, Definitely a bridge. But now with time we have also evolved into a few initiatives. so we started off a six and a half years back with 40,000 rupees a month. Today we are donating 10 lakh rupees a month. We started off at 15 odd volunteers. Today, we have 60 plus volunteers. Now, these volunteers that we got, they realized that, with time that, giving back to society was actually a good thing and they started enjoying it. So then these volunteers of ours, they wanted to unleash their energies into giving back to society. So each one of them had some certain passion or the other.

So let me give you an example of one volunteer of ours. She lost her sister to a road accident in the U S when they went to claim the body, they realize that the system had already pledged her organs. which none of the family members knew. she got so passionate about that. Cause that she started, organ donation, vertical within, YVO and now she lives her passion by encouraging and, spreading awareness for organ donation.

A few of our volunteers were very passionate about helping animals. So we started a vertical called love for animals, within YVO. in this pandemic, a lot of our volunteers, they really resonated with the cause of mental wellbeing and wellness. So we started a mental wellbeing, vertical, one more vertical that a few of our volunteers started was a future leaders program where we go and train students, the youth and educated professionals to become empathetic citizens of the future

So we definitely started off with the platform just to connect, donors or volunteers with, people doing actual good work on the ground. But today we have evolved ourselves as a platform where any youth, who wants to do anything good for society? he joins YVO. He sees YVO, he understands how good and how nice it feels to do good for society, whether in a small way or in a bigger way.

And we encourage, and we facilitate him to live his dreams and passions towards betterment of society.

Rajeev

That's pretty awesome to hear, sidd. Just amazing you work that have been doing since the beginning. What about the pandemic and its effects and. How has YVO and your volunteers helped in this regard? Can you talk about some of the initiatives that you have done in this space?

Siddharth Ladsariya

Firstly, this pandemic is nothing short of world war three that we've gone through. So every NGO, every individual, every person has tried his level best to help each other, help the society in whichever fashion in whichever way possible. while we say that we only, donate for sustainable causes but we also understand that when epidemics or pandemics happen, we have to, unleash our energies into the need of the hour.

So YVO have been involved, into epidemics like, nepal earthquake or Chennai floods. When coming to the current, COVID, initially, we started off with helping migrant laborers, rehabilitate themselves in the initial few months, which was a pretty difficult plight for them in those times.

And then of course, we moved on to helping, hospitals with PPE kits, providing food to frontline workers, BMC staff, police personnel, and, then we realized that, there are certain. families who have lost their bread earners, during this pandemic and a lot of children have become orphans.

So we came up with the project where we help these families who have lost their bread owners or the children have become orphans to live a sustainable life and ensure that they get educated as well. so with this we went out on a mission to help these families. We are proud to say that we have more than thousand supporters to who helped us support this cause and collected over a Crore of Rupees, helping more than 400 families to lead a sustainable life for the next few years. And to also ensure that the children, get educated in those families..

Rajeev

Amazing. It's really good to hear that people are doing such amazing work. Talking about corporate social responsibility. What's your view on that? Some companies treat it like it's a check box that they have to tick. How has the awareness improved and how have companies responded during this pandemic?

Siddharth Ladsariya

So definitely the awareness of corporate social responsibility has been increasing over the past few years. And it has been increasing over, in a rapid pace companies, are now. treating corporate CSR, not only as a compliance thing, but also as a way of life or a way of the company.

The issue was that again, the intent was always there, but people don't know how and where to do what.. so, we have seen a lot of, uptake in the initiatives by a lot of companies, and MNCs and, one thing, what we've realized

And a lot of companies have also realized is that if you create a culture and DNA, which is giving back, goodness, niceness, as a company or as a business also, you tend to prosper more because you're all your stakeholders, which are your employees or your investors, or your customers, or your vendors, they relate to you or your product better than what they would do from a company, which is not having that kind of culture and DNA.

So this, we have seen a huge change and lots of research and studies around it, which are now, companies are doing this willingly, even at YVO,. We have a lot of, entrepreneurs who are volunteers at YVO and who are running their own companies, large companies, mid-size companies. And, we have started seeing that these volunteers have started implementing this culture and DNA in their own organizations also.

So yes, yes, this pandemic has definitely, It's accelerated the giving, back attitude and nature for individuals also, and for companies also.

Rajeev

Right. in terms of working with YVO, do I need to be a business owner to be involved with YVO or just be any professional?

Siddharth Ladsariya

No, you just need to be young at heart to be involved with YVO. Yes, we have a lot of professionals. There's no other criteria. You need to have a, good intent to give back to society and young at heart. So as I was telling you, so we have, more than 60 volunteers currently from all walks of life.

where we expect them to spend four to six hours per month, voluntarily to, taking up, initiative or the other, we have divided YVO into seven teams. the teams are one is the NGO team, which basically does due diligence of an NGO and finalizes, which NGO and which cause we donate and post due diligence of the NGO.

So that's the heart and soul of YVO Then we have a marketing team, as the word suggests they are involved in online and offline marketing for YVO. We have a growth team which takes care of various new initiatives and growth related activities of YVO. We have a tech team, which handles the backend technology platform.

We have an admin. and we have an events team, which facilitates, events, which YVO does offline events and online events, that we do. As YVO, we encourage our volunteers to become part of some, of these teams and, contribute in a meaningful way.

And we also encourage our volunteers, to get into or do something, which they are most passionate about So come to YVO, join YVO, drive your passion, do good for society. Live your dreams and feel nice about it.

Rajeev

Great Siddharth. So just to close out this conversation, can you tell our listeners how they can get in touch with YVO and how they can get to work with you?

Siddharth Ladsariya

Yeah. So we have a website www.yvorg.in. So, the users can log into it our website. They can read everything about us. They can contact us through the website and, otherwise, feel free to connect with us through any of our social media handles. And we would love to engage with our users.

Rajeev

Great. Thanks Siddharth!. Great, to know that you guys are doing so much work, there's something that I can do sitting in Auckland do let me know.

Siddharth Ladsariya

Thanks a lot, Rajeev.

Rajeev

And that's a wrap for episode four, ladies and gentlemen. If you want to start saving up on good karma, YVO is the organization to be. In the immortal words of John F. Kennedy, ask not what you're country do for you, but what you can do for your country. Every accomplishment starts with the decision to try.

As we express our gratitude, we must never forget that the highest form of appreciation is not to utter words, but to live by them. Siddharth and his fellow volunteers are living by their deans.

It is time for you and me to do as well. Till next time, stay safe. And be productive.

Spinning Values Podcast - Ep. 3 - Solution Dyeing & its advantages [Part 2]

Fri, 30 Jul 2021 20:28:00 GMT

Solution dyeing & its advantages :

In conversation with Dr. V.G. Kulkarni,

Global Director Technology and Business Development, Fibers, Americhem USA

In this episode, we talk to Dr.VG from Americhem on solution dyeing & its advantages. We go in-depth on why this is a sustainable and state of the art solution for the synthetic fibre industry. This is an detailed conversation with one of the foremost minds in the industry. Not an episode to be missed out on!

Spinning Values Podcast: Episode 3 - Part 2

Listen to Dr. V.G. Kulkarni, as we discuss solution dyeing & its advantages.

Solution dyeing is an component for Beekaylon Synthetics. In part 2 of episode 3 we go into a detailed discussion with Dr. VG on this topic. Do subscribe to this podcast on your favourite podcast app.

Transcript of the Conversation with with Dr. VG Kulkarni

Dr. VG - Solution Dyeing - Episode 3 - part 2

Solution dyeing in itself addresses three major sustainability aspects. Conservation of water uses less energy and it limits the wastewater generations. And more importantly, the technologies available today while we can improve it further. We can put it into use today and address some of the major sustainability needs of the textile industries.

Rajeev

This is spinning values, a podcast initiative by Beekaylon synthetics. And I'm your host Rajeev. At spinning values, we bring you every month an interview with leading experts on synthetic yarn technology from around the globe.

We break down complex concepts and explore ideas that are at the forefront of sustainable manufacturing in today's circular economy.

This is episode number three, and we are talking to Dr. VG. Kulkarni from Americhem. A globally recognized manufacturer of custom color Masterbatches , functional additives, engineering compounds and performance technologies. Dr. VG as he is popularly known, heads technology and business development at Americhem.

Welcome to part two of episode three. In part one, we discussed BCF and its applications. In this final part of episode three, Dr. VG does a deep dive into the world of masterbatch design and why it is a sustainable solution for the textile industry.

So without further ado, let's get into the discussion.

Welcome back to the show Dr. VG.

Dr. VG

Hi Rajeev.

Rajeev

As many of our listeners might be listening to this episode for the first time. So. can we start with a brief intro about yourself Dr. VG, and a little bit of your background.

Dr. VG

yes. my name is Vaman Kulkarni. . most people in the industry know me as VG. I have over 30 years of experience in the. polymer and plastic industry. A lot of it in the fiber industry. I've been with the Americhem also about 30 years. And currently I lead the technology development and business development for our fibers group..

Rajeev

So in part one, we did a deep dive into BCF and its applications, its importance and so on. what are we going to discuss today? Dr. VG?

Dr. VG

Yeah, it's primarily I think about the textiles and how solution dyeing can help textiles in the overall big picture of sustainability of textile materials.

Rajeev

So it's going to be textile solution dyeing and its importance, its advantages and so on. Alright, let's get the ball rolling. here's my first question to you. Can you give our listeners an overview of textiles and the concept of solution dyeing and what is its relationship with sustainability? How can that be a sustainable solution?

Dr. VG

Yep. Yeah. Let's start with the textiles In a broad sense textiles are materials that are made by weaving yarns. Yeah. The basic materials are fibers that are derived from two sources synthetic and natural and natural can be plant origin like, cotton or or rayon or could be from animal origin, like silk or, wool. Synthetic on the other hand derived from materials such as polyester, nylon and acrylic.

So, and if you look at the use of these materials in textiles, synthetics make about two thirds of all the fibers used in textiles and naturals make about one third of it. And if you look at individual fibers in use in the overall field of textiles, polyester is by far the largest volume fiber it accounts for a little over 50% of all the fibers used in textiles.

And cotton is the second most used which accounts for roughly about 25% or so. And when typically when people talk of textiles one typically associates with clothing, but textiles are used in a, quite a range of applications beyond apparel. be it home furnishing or automotive fabrics or industrial fabrics, touching upon uh, the concept of a solution dyeing quite simply.

we can put it as a technique used for coloring synthetic fibers. Okay. So when you look at color in textiles, generally two methods are used for coloring. One, we call it classic dyeing, which has been historically used to color natural fibers. the second one is solution dyeing or spin dyeing. so in the classic dyeing you first make the white fiber or use the naturally occurring white fibers.

And the coloring is done in a second step. So it's, you could call it fiber first and then coloring. Whereas in a solution or spin dyeing process. You first add the colorant to the molten polymer and then force the molten polymer through a spinnaret and make fibers out of it. So in a sense, in solution dyeing, you are combining the spinning and coloring into one step. So the two key differences between the two, the classic dyeing and the spin dyeing, or the solution dyeing. In classic dyeing again, as we talked about fiber first and then color and in solution dyeing polymer colored first and then fiber is formed and, and that other differences also the colorants that we used for two different methods is also different.

obviously solution dyeing is a technique for synthetic fibers. it is not applicable to natural fibers such as cotton because they're already in the form of a fibers.

Rajeev

Right.

Dr. VG

And then the key topic of sustainability and how does masterbatch and solution dyeing play into sustainability? the sustainability by itself is a very complex concept for most people.

it's it's about being environmentally friendly. but you know, if you were to Google, what is sustainability in a you'll end up with quite a few definitions? the, some of the key ones are, meeting today's needs without compromising the future for it. Second one could be caring for planet.

Again, being environmentally friendly, socially responsible ecological balance, and all those concepts, the use of renewable resources could be another or these days, everybody talks about carbon efficiency, carbon footprint, and all. So the bottom line in sustainability is that we have one planet. And limited resources. sustainability is tied to your and my daily activities, making better use of our resources recycling instead of wasting smarter use of energy and so on and so forth. I think that, that in, in is a good broad view of sustainability and we can discuss more as we go along.

Rajeev

Yeah. So keeping on the same topic of sustainability, can we deep dive into what it actually means for the textile industry?

Dr. VG

okay. Sure. so like food and shelter textile is a basic need. Okay. So in a broad brush statement, meeting, the needs of the textile industry or the meeting, the textile needs, of the global population while being mindful of environmental, social and economic constraints in a nutshell is the sustainability goals.

Okay. it must address all aspects of the life cycle of textiles every process from raw material all the way to the end of life. So ideally we would like to have all fibers from renewable resources, or recycled materials, for example, without using any of the fossil fuel, use limited natural resources such as water and energy and limit waste.

And more importantly as we'll talk about a sustainable coloring methods as coloring is very important to textiles. Okay. And at the end of life whether we can recycle it or is it biodegradable? So, so that that's the ideal case scenario. But we don't have, we don't live an ideal cases all the time.

So if you look at the sustainability through the two largest textile fibers and how we can address them now, whereas we talked about polyester is the largest textile fiber used. So today bulk of polyester and other synthetics are made from petroleum resource. Okay, but they use limited amount of water during production. Cotton, on the other hand, is a renewable resources, but it needs a large amount of land, a significant amount of water to grow. And then use of pesticides and other stuff. following up on that dyeing is another very water intensive process. Now, if you look at all of this coloring is so central to all the textile materials that we use.

I mean, both the materials that you and I use in a very small portion of those is white in color, predominantly they're all colored. So, while there are multiple opportunities for sustainability in textiles, Addressing coloring. Or smart coloring it's a big one. let's look at the some statistics, for example, some estimates put some 5 trillion liters of water is used in the dyeing process.

And approximately 20% of the waste water globally encountered comes from fabric. In addition, dyes and chemicals can end up as affluence and roughly about 10% of carbon emissions of carbon footprint that, some people equate that to the dyeing process in the textiles. Now we talked about polyester being, eh large synthetic fiber used in the textile industry.

They can be colored by solution dyeing and it solution dyeing in itself addresses three major sustainability aspects. Conservation of water uses less energy and it limits the waste water generations. And more importantly, the technologies available today while we can improve it further. We can put it into use today and address some of the major sustainability needs of the textile industries.

And lastly, in the end of life, when the textile, whether it is automotive seat fabric or apparel, and it is used, what are our recycling options? And generally synthetics have more recycling options compared to natural.

Rajeev

So that was an interesting take on sustainability, Dr. VG, because sustainability is always seen from. One angle. You mean?

Yeah, exactly. So it's it's only one side of things that people see because that's what is more the popular view of it. the other side, people don't actually know. see it. So it's an interesting take on the sustainability aspect of it, It's not a popular view. So, keeping that in mind, mostly the concern today about plastic waste and its impact on environment. Polyester being such a large portion of textile industry. Can you sort of enlighten our listeners about sustainability in regard to polyester and what kind of value addition that we can do.

Dr. VG

Yeah, certainly Rajeev as you, yeah. As you rightly pointed out for many people, when they think of plastics in general, or the plastic litter that they see around it. The immediate thing is, oh, it's all derived from a petroleum. We should not be using it. Yeah, we should ban it. So, that's in a nutshell, what talk about taking a single concept and then doing that.

But, in sustainability, we have to take a 360 view of things. Okay. So again, not going too much into plastics. that could be a different podcast by itself, focusing ourself on a polyester, which is the largest a textile fiber. So, okay. So let's look at it through the lifecycle of polyester first, the resin and the fiber production.

Granted a bulk of polyester today is made from petroleum resources. Okay. However, only a small portion of petroleum about 1% or less is used in making polyester fiber, in contrast quite a bit of petrol is used to drive and your and my automobile and many other energy needs Secondly, some polyester is already been made from renewable resources.

like for example is made from bio-derived Meg or PTT poly trimethylene terephthalate it is made from bio-derived. So in addition to the bulk of the polyester, being derived from petroleum researches albeit uses a small amount of petroleum there are efforts to have renewable resources had it.

Secondly, recycling. Okay. From an end of life perspective, polyester is one of the largest recycled polymers. Okay. A large amount of fiber is made from recycled water bottles. that are being discarded. Number one, it keeps plastic bottles from landfills. Okay. Secondly, textile waste and discarded textiles are also being converted into into, back into fibre.

A recycled fiber. If you look at it uses less energy to make the same end article related to the watch and polymer you'd need fewer resources, lower carbon dioxide emissions, and the list can go on and out. So, and we will recycled polyester. has a good future and continuously will expand.

We will need to be more effective in providing effective means of recycling. So, and we touched upon coloring so sustainable coloring. we talked about unlike natural fibers, polyester canvas solution dyed, and it's an environmentally friendly process. Some of the challenging areas biodegradability of synthetic fibers work is going on in there.

all people also talk about microfiber release into the water streams. research is going on that, but if you look at the overall picture you can see that there is lot of effort that is going into. The entire life cycle of the polyester textile industry, from the point of sustainability.

Rajeev

That kind of gives us a clear view of what sustainability means for the textile industry, sort of a 360 degree view of it. That is pretty interesting. Let's look at the masterbatch industry that's helping sustainability to polyester textiles. How does it relate to coloring and value addition?

Dr. VG

Certainly Rajeev, first and foremost, let's dive a little bit into solution dyed because that is what the masterbatch industry brings to the table. So, okay. We touched on some elements of this earlier in the talk. So first of all, it's an environmentally friendly process. It does not use water.

So practically no effluent. it uses less energy. We, as we talked about, since we are doing it, the spinning and coloring into one step, And these are the sustainable benefits that one can get from solution dyeing using Masterbatches. But at the same time, the masterbatch design offers you to, with the.

Product performance, we could have better coloring, a higher quality color, or better color control, or excellent color fastness in outdoor application and so on. So, so it, it not only addresses the three fundamental issues with the, of the sustainability being. in a water and energy and, and pollution, it, it provides a total higher quality color and synthetics being two thirds of the textile fiber industry.

I think if we could add up a solution dyeing, I think it can be a very great, sustainable contribution to the textile industry. And. Speaking of recycle, we talked about recycled polymer is increasing day by day. So you've combined a masterbatch solution dyeing with Masterbatches with recycled polymers.

It is like a sustainability on steroids are turbo charged!. So it's, first of all, the polymer is used as recycled.. That contributes to sustainability and coloring, using masterbatch that contributes to additional. So it's a perfect fit from that point of view. Second, when we talk about recycle quality most right.

recycled polymers. In the generally is, has a little bit of yellow tint to it. So what the masterbatch industry does is it makes possible. To use the recycled polymer, but addressing some of the drawbacks, be it color or be some deficiency in its part. So what we, bring two solutions in there, here one we called renewable additive basically by adding this, we are making the recycled fiber look more like virgin.

Secondly, the recycle content probably can have in most cases, a lower IV and less properties, and we can bring the IV and properties back. Okay. So, and in addition, there are certain applications in textiles, for example, in Cationic dyeing or atmospheric dyeing. the polyester as we know traditional polyester that is used to make textiles, it cannot be dyed under the atmospheric conditions and cannot be dyed with cationic dyes.

Both of these properties are incorporated during the polymer manufacturer of the virgin resin. But when you're doing recycled fibers from the bottles bottle grade resin recycled bottles, that polymer is not capable of being dyed under these conditions. So masterbatch is a very effective way. in many cases, the only way to add cationic dyeble property.

As well as atmospheric or easy dye properties.

Rajeev

We talked about the evaluation and solution dyeing. So let's talk about color Also talk about functional additives, right? So, can we do a deep dive into functional additives?

Dr. VG

Yeah, certainly. Yeah. again, color is an important property in a practically every textile material is colored, but the colored. Often needs to be combined with other functional properties because the articles are used under different conditions. For example, take a awnings or outdoor fabrics.

Okay. When you use textiles in outdoor, two things are critical. Number one, they're durable color. And number two, what we talk about the UV stability or property retention, when it is used in outdoors, it's constantly exposed to sun and sun, then UV, it can have a negative impact on the properties. So a masterbatch can address color as well as UV or tenacity retention, not fiscal, proper retention.

If you look at the, for example, anti-microbials as value addition, they can be used in performance apparel that textiles used in healthcare industry or other applications, generally microbes, some of the textile finishes and et cetera, that are apparent on the fiber. they can act as food for bacteria.

So because of that, they can create foul odour or staining of the textiles and use of antimicrobial additives imparts anti-microbial and anti viral properties to the fabric. So, Textiles are also used in for example, ESD garments are, are protective suits that are used in clean rooms, for example, and, and in floor coatings, and they need static dissipative properties as you know, plastic by themselves and polyester.

Untreated polyester they are insulators. So anti static or conductive yarns could be prepared by using Masterbatches and that could add, be used as a value added fibers. And lastly, let's take another example of a flame retardants, for example, plastics are inherently flammable, Now textiles are used in home, furnishing transportation, hotels, restaurants, cruise lines, you name it.

So all of those areas, flame retardancy is an useful property. And in fact it is a necessary property for many of these applications, you know, historically , some of the flame retardants in polyester textiles was done through polymerization route, or flame-retardant chip, for example, but we can introduce flame retardancy through use of masterbatch.

And the beauty of using flame retardancy Masterbatches is you can design, you can tailor, make the flame retardancy, depending on the applications. So it gives you a flexibility from that standpoint.

Rajeev

Right, sir, so we talked about the color. We talked about value addition of masterbatch or solution dyeing. and what solution dyeing brings to the textile industry as a whole. Can you summarize all of this and bring it together for our listeners?

Dr. VG

Yeah. Yeah, certainly we as masterbatch producers along working with fiber producers, okay. Can have a huge impact on how we color polyester. And not necessarily polyester the synthetics as a whole and use more of recycled contents. So by providing a responsible way of coloring by providing a means of using more recycled content, I think the fiber producer and the masterbatch producer can add significantly to the textile value chain.

Responsible coloring, that that's a key thing, again, we talked about, we can say water and energy and minimize pollutions, and. it's a truly environmentally friendly way there is no other thought about it. And the key thing is among all the ways, all the different ways sustainability can be incorporated into the textile industry.

I think a responsible coloring and use of recycled content is. I would not say easy, but it's relatively easy. The technology is here, we need to adapt it. So again, one of the key thing is the design of the Masterbatches. Okay. Not all Masterbatches are created equal.. we have the opportunity as a masterbatch industry to raise the bar to bring out the best.

Whether it is color, whether it is functionality to the textile materials.

Rajeev

So this a lot of talk about climate change and the various policy decisions that governments are taking in order to kind of wind back the clock to previous levels. Of CO2 emissions or whatever the case may be. And when Joe Biden's administration has a very lofty ambitions in order to, stop climate change because the clock is ticking.

So keeping all that in mind, what do you see the future looking like 10, 20 years from now.

Dr. VG

Yeah, that's an interesting question Rajeev!, first of all, let's say that the impact of textile industry on a planet issue. it involved the whole life cycle, ranging from the raw material to the disposal. they end up article, but more importantly, it involves everybody, whether it is the policymakers or the resin producers, the fiber producers, and also the users. like you and me.. Okay. And so players in all segments of the life cycle have an opportunity. for innovation here. I expect the polyester will continue to be the dominant textile fiber. I don't see any alternative to that. The solution dyeing as a coloring technique or the sustainable coloring method should continue to expand..

You know, if you're looking at it, all things considered the polyester textiles are, very effective in serving the global population, the needs of the global population. so if you look at the overall eco balance, it it's a reasonably favourable.. If you look at the 360 view and it can only get better with the cradle to cradle innovation that is ongoing.

So, and one other thing that we don't talk about about textiles and plastics also, while today some of these are derived from petroleum, they also help in saving petroleum through lightweighting and recycling. so again, the bottom line is we all can be part of the solution, so we all need to do our part.

Rajeev

Thanks Dr. VG. Yeah. Valuable views on this. it gives the listeners a 360 degree view on this subject because most often the media shows this through a kind of a colored prism, and not the actual fact of the matter. So this gives a different perspective to the whole issue. So thanks.

Thank you. for this part one, and part two series of BCF and a solution dyeing, I think it's going to be pretty useful for the listeners. And so thanks for your time.

And that was a wrap for episode three of spinning values. That was a fantastic conversation with Dr. VG. Spinning values is brought to you by Beekaylon Synthetics. If you want to know more about Beekaylon or want to listen to the past two episodes, then head over to Brands.Beeyalon.com.

There is a wealth of information of sustainable products and solutions. Do share this podcast with someone, who's interested in sustainable solutions for the textile industry. So catch you in the next episode. Till then stay safe and stay productive.

Ep. 3 - BCF & Its Applications [Part 1]

Sat, 03 Jul 2021 09:23:00 GMT

BCF & Its Applications:

In Conversation with Dr. V.G. Kulkarni,

Global Director Technology and Business Development, Fibers, Americhem USA

In this episode, we talk to Dr.VG from Americhem on BCF and its applications. We delve into detail on PET, its use as a BCF fibre. We also touch upon the solution dyeing process and the value addition it brings to the end customer. This is an in-depth conversation with one of the foremost minds in the industry. Not an episode to be missed out on!

Spinning Values Podcast: Episode 3 - Part 1

Listen to Dr. V.G. Kulkarni, as we discuss BCF & its applications.

BCF is a strong growth area for Beekaylon Synthetics. In this episode, we sat down for a two part series going in-depth into BCF and its applications. Do subscribe to this podcast on your favourite podcast app.

Transcript of the Conversation with with Dr. VG Kulkarni

Dr. VG - BCF - Episode 3 - part 1

Dr. VG: Solution dyeing is very sustainable. It's energy efficient and does not use water. Secondly, the fiber is colored uniformly throughout , related to the post-date fiber. In a sense you can think of it as, since the polymer itself is colored first, you can think of it as color is an integral part or locked into the fiber.

Rajeev: This is spinning values, a podcast initiative by Beekaylon synthetics. And I'm your host Rajeev. At spinning values, we bring you every month an interview with leading experts on synthetic yarn technology from around the globe.

We break down complex concepts and explore ideas that are at the forefront of sustainable manufacturing in today's circular economy.

Hello, Dr. VG. Thanks for your time. For coming on this podcast, just to set the context. Can you please. Introduce yourself and give us a little bit of a background before, talking about BCF.

Dr. VG: Yeah. my name is , Vaman Kulkarni and I have a technical background in chemistry and polymer science graduated from University of Akron. And I've been with Americhem 30 plus years working in the area of Polyesters and Masterbatches coloring functional additives. and I lead the technology development as well as business development globally.

Let's start with what a BCF stands for. You know it stands for bulk continuous filament. It is the type of yarn that is used to make carpets by and large synthetic fibers are the main polymers used in this market segment.. Basically there are three major classes of polymers.

You have nylons polyesters, and polyprolene. the nylon family includes both the nylon six and as well as six six, and the polyester family is by and large a PET or Polyethylene Terephthalate but it also includes a which is also known as Sorona. So it's one of the brands. Like one good thing to note here that although PET has been used in textiles for many years as a BCF fiber, it's a relatively recent that probably started in the early two thousands.

You know, primarily because of three key drivers here one the significant improvement in the BCF technology, secondly the lower cost of PET and the large amount of PET polymer that is available, as well as the recycled polymer. if you look at it over the last 10 years or so, PET has gained considerable market share at the expense of both the polypropylene as well as nylon. So it's primarily used in residential carpeting and today in almost command. So almost about 50% market share in that segment.

Rajeev: So that's about a brief overview of what BCF is and what are the different components of BCF Coming to the differences between these and why one is preferred over the other. Can you throw some light on that?

Dr. VG: Sure, Rajeev. You know, the fiber system, which is the face fiber of the carpet on which we literally walk it makes a big difference in the performance of the carpet. If you look at the big picture we're compensated used broadly we can put them into three classes residential commercial or hospitality.

Each application is very different and the performance criteria are different in the best properties of each polymer can be leveraged to meet the performance in those segments. If you look at nylon it's best known for its durability, it's highly wear resistance, crushing and matting as you walk.

That's the reason and that it is the dominant resin used in commercial carpets, which tend to see heavy duty use. One key thing is it is not inherently a stain resistant but the technology for imparting stain resistance is pretty well taken care of so it's a dominant polymer in the commercial carpeting area. If you look at polyester it's main driving points of high luster it's softness it's inherently a stain resistance. And it has a sustainable feed stock from recycled polymer, from water bottles and the soft drinks. It's good resistant to sunlight. So because of the performance advantages of polypropylene as well as cost advantages or nylon, a large chunk of a polymer is used in BCF today. And the propylene, it's main drivers are cost inherent stain resistance.. Yeah.

You know, it has poor resilience related to nylon or polyester. So it is used in specific construction of in carpet to, to leverage the advantages of cost and stain resistance

Rajeev: Dr. VG, can you talk about coloring and value addition in BCF?

Dr. VG: Sure. Solution dyeing or the spin dyeing technology. What we call is the dominant coloring process in BCF. It is unique and different from a traditional dyeing you know, think of it this way in, in traditional dyeing. The polymer is first converted into a fiber and then dyed.

Whereas in the solution dyed process, you first color the polymer and then extrude the fibers. So in a sense you know, colorant, in the form of a masterbatch, typically, is added to the polymer melt and then extruded into the fiber. So you are combining the spinning and coloring it into one step.

And first and foremost this methodology of coloring adds value through differentiated color. So to speak, number one, solution dyeing is very sustainable. It's energy efficient and does not use water. Secondly, the fiber is colored uniformly throughout , related to the post-date fiber. In a sense you can think of it as, since the polymer itself is colored first, you can think of it as color is an integral part or locked into the fiber. And that gives a good abrasion resistant as well as laundering. And it allows for product differentiation. You can do a lot of. Customized solutions for performance and secondly you can add additional attributes in addition to color because the polymers Inherently not stable to sunlight. One can enhance the stability of the polymer by adding UV additives. And you can add additional functionalities, be it anti-microbial frame retardant or others. , and these properties can be either combined with color or can be run as a stand alone products.

Rajeev: I understand that you lead Americhem in terms of the technology part of it, as well as the marketing part of it. So in terms of Americhem how different is your product from the others and how does it contribute to Beekaylon's product as well? So how does it differentiate in the market?

Dr. VG: Okay, you can think of it as two major things the solution dyeing process the master batch which is you can think of it as the core of the heart of the solution dyeing. That is the product that we offer to the BCF manufacturers. Two major things that we bring about one. The end product performance. And secondly, the operability during the BCF manufacturer. So for the first we'll look at the color very tight color tolerance is needed in BCF. When you're looking at large areas, large surfaces of the carpet colored uniform, it is is very critical.

Secondly the colors and the physical properties of the carpet they have to stand up to extreme sunlight and provide UV resistance to the carpet fiber and thirdly they can need, needs to stand up to tough cleaning and bleach. Yeah, for frequent cleaning of the carpet so that the original appearance of the carpet is not deteriorated.

And lastly the colorfastness to the oxides of nitrogen and ozone are very critical for longevity of the carpet.. So these are the, what we call the end use, end product performance attributes but for the BCF manufacturer itself, the masterbatch is categorized by extended pack lives so that they don't have to change the packs frequently. Which in terms translate into higher yields and obviously you have to look for the best yarn properties of the BCF.

Rajeev: So it's kind of a critical component as far as go-to market is concerned, in terms of your end product differentiation.

Dr. VG: Yep. Certainly. Then let me add a couple of things here. As I said, it's all about the masterbatch design. And that's the value component of solution dyed BCF we've talked about various polymers being used in carpets. We talked about nylon, polypropylene and polyester.

Look at it. If each one of the polymer has a different chemistry in that process, that a different temperature, for example, polyester and nylon six, six are processed around 290 degrees Celsius and nylon six is processed around 2 65 or so. And polypropylene is typically processed around 230 to 240 degrees Celsius and all these product, all these polymers are different chemicals and they interact with the colorants differently in addition, the colorant since it is going through the spinning process at the elevated temperature has to be stable at the thermally at those temperatures. One of the key thing is we utilize colorants that have in a heavily characterized for that application, both in terms of thermal stability, as well as suitability for that polymers.

Secondly accurate color matching is very critical. As we talked about you'd be looking at large surfaces a typical cross section of a BCF fiber is trilobal some variation there off related to most textiles, which are circular in cross section.

And because it is try Lobel its, reflectance characteristics are different and which in turns it how you perceive the color, how you see the color is. And it takes a highly skilled color matchers to get accurate color matching so that you know, even minor differences are not visible when you are looking at large areas of the carpets.

And finally you know, we talked about , the properties, be it sunlight be it bleach resistant. you know, Those all have to be addressed. And in essence, really that's what we bring to the table here.

Rajeev: Covered a number of aspects of BCF and the advantage of a master batch and what you bring to the table in terms of product differentiation for the end customer. What is the future of BCF and solution dyeing Dr. VG?

Dr. VG: you know, When you talk about flooring systems you have a different flooring systems available and BCF is. Or the bulk continuous filament is the thing for soft flooring or carpets. And I believe that BCF has a whole The future is very promising.

Last year in 2020 was rather a soft year for many businesses and and it was soft year for BCF also you know, once the pandemic is is behind us. I think all three segments being a residential commercial about automotive should see, a strong growth in 2021. And the solution dyeing will continue to dominate both from a sustainability standpoint of view, and most importantly, eh from a pollution standpoint of view, there is no wastewater treatment and all that. The sustainability and environmentally friendliness is one of the key, factors that , I see a strong growth for solution dyeing now, not only in BCF across coloring synthetic fibers as well.

And as far as the polymers are, concerned I do expect that the polyester will continue to grow and should remain , one of the largest to follow them on for the application. And also should see , you know, the highest growth of all the three polymers. geography is concerned. The north America should remain as the largest region, but we see a strong growth in Asia and India.

Rajeev: Right. So you've been associated with Beekaylon for the past few years. Am I? Right. Yeah. So you also mentioned that this, you expect strong growth in. the APAC region. How do you see your presence in India and specifically to Beekaylon. how's it going forward? What is your view on that?

Dr. VG: We have been offering solution to the BCF markets for over three decades. Initially it started out in North America. we offered a solution to all different polymers in Asia and India specifically we see polyester because of the resin availability et cetera.

You know, We see a strong growth in Asia and India. you know, We now have a production facility in Pune, India for the past three years and were very excited to expertise in BCF both in terms of our service capability to the Indian market. And we very much look forward to working with the Beekaylon and making them successful.

Rajeev: Great. Thank you, Dr. VG. So this brings to a close the segment on BCF. So what are we going to talk about in the next episode Dr. VG?

Dr. VG: So what we'll focus on is the textiles as a whole use of Masterbatches and sustainability in how the masterbatch industry can offer a sustainable solution to coloring of textiles. So that, that should, that will be the focus of our next conversation.

Rajeev: Great. Thanks. Thanks Dr. VG. I think we've covered a lot of ground. This episode, I'm looking forward to talk to you on masterbatch and its applications and advantages in the next episode.

Dr. VG: Thanks.

Rajeev: Thanks Dr. VG. For your time. That's the end of part, one of episode number three. Where we talked about. BCF and its applications. In part two. We'll be talking to Dr. VG on Masterbatches and its application and advantages.

Spinning Values Podcast - Ep. 2 - BCF Yarns and The Beekaylon Story

Sat, 17 Apr 2021 20:27:00 GMT

BCF Yarns and the story behind it:

In Conversation with Martin Van Dam,

Chief Product Officer, Beekaylon Synthetics

Martin Van Dam, from the Netherlands, is the Chief Product Officer of Beekaylon Synthetics. In this fascinating conversation, he tells the story of how he became the CPO of Beekaylon and the importance of BCF Yarns (Bulk Continuous Filament) to Beekaylon.

Spinning Values Podcast: Episode 2

Listen to Martin Van Dam as he tell the story of his association with Beekaylon & its BCF Yarns(Bulk Continuous Filament) operation.

What started off as a business conversation quickly transformed into a strong association with a global industry veteran and an Indian company with a strong legacy. Do subscribe to this podcast on your favourite podcast app.

Transcript of the Conversation with Martin Van Dam, Chief Product Officer, Beekaylon Synthetics.

Rajeev Hello and welcome. This is Rajeev again with episode number two of Spinning Values podcast, powered by Beekaylon Synthetics. welcome to the show Martin.
Martin Van Dam
Thank you very much.
Rajeev So we have Martin Van Dam he's in Netherlands and he's the technical guru for Beekaylon shall we say? So, without further ado, I introduce technical head of things. Mr. Martin Van Dam, Martin, why don't you introduce yourself and tell the viewers what you do and your association with Beekaylon.
Martin Van Dam Right. Just to explain a little bit to about myself. I have been in the yarn and the carpet manufacturing for 30 years. So my small advantage might be that I also know the product that our customers are making from our, let's say yarns and I have been working for some global manufacturers in the past.
So I have been working for some of our co our current competitors of course. And yeah, just to explain that I'm I have been in touch with Beekaylon since let's say mid of July, 2019. So I did fly over to Mumbai and to have some talks with the family and with the people and their ideas about. How we could establish Beekaylon in the BCF market as well. Everybody already, of course, did know, Beekaylon as a Supreme supplier of B O Y D Y yarns with a 40 year history with a very good name in the market. So that was giving me already a very comforting feeling and the idea that this could be the right connection between myself and Beekaylon.
Once I visited the new factory. And when I saw the factory, it was really astonishing. it was like a being a child again in a candy store. It was like coming into a place where I could see that there was really a good thought about how to set up a factory with the state of the art machinery, of course, BCF as a technology where we can spin yarns with filaments and where we can say, okay, we can be very flexible in all the major parts of the end views of the yarn.
Yeah, just to to highlight the three biggest parts where yarn our yarns can be used to BCF yarns is contract and style applications, residential carpet, and of course, automotive industry and automotive. I mean the flooring of the automotive industry. So the molded parts and the overmatch residential, any residential carpet, you can imagine broadloom racks.
Bath mats anything you can think about. And then the contract application, of course, hospitality, hotels contract tiles, carpet tiles. That was really something where I saw that. Okay. This is the opportunity for me to be able to develop and to work with a company who is not only looking at today's hectic business, but also a company was able to.
Look at the future and to be able to see where the world is going, where our industry is going. yeah, that was really surprisingly pleasant for me to see that walking into the factory, just to see BCF machines, which is German machines. Neumag which is state of the art.
The best machines you can buy for money in principle. And just to explain what is BCF is in principle, a yarn, which you can extrude and extrude means in principle, you have a chip and the chip is melted and is pushed in principle. Very simplistically explained, pushed through a spinneret and a spinneret is a round device with all kinds of small holes. And those holes can have different shapes and the different amounts. And we can play with that, to see where we are going for the end use of this yarn, depending on the end use, we can change, let's say the number of filaments, the amount of filaments, the shape of the filaments that detects the thickness of the yarn.
We can adjust. So we have in principle already that base of machines best you can, by looking further in the company also state-of-the-art newest cabling machines, also German grounded Volkmann machines, which is also state-of-the-art perfect machines with all the devices to control the absolute quality.
What is a cabling machine do in BCF. You can use the yarn as a single yarn for certain applications to make the yarn suitable for residential carpet tiles automotive. You can also twist them or air entangled them. And heatset them. heat setting again. Superba machines, which is the best money can buy with the best stable process in the world.
So my heart was beating like, Oh, this is absolutely fantastic. Then walking through the factory, I came upstairs and even there, it was more exciting for me because there are small sampling machines for almost all the steps in the process. So we have a development center upstairs, which allows us to not only wait for customers to tell us what they need, but also to be able to be proactive.
And to make samples and even make small carpets by using a KB or an MTF machine, which is a one needle machine, which is trying to replicate industrial machines on small scale. So instead of sending a customer only a piece of yarn, we are already able to send them a small piece of carpet where the customer can see how its end product will look like.
And that was absolutely fantastic. That was step number one for me, went in the Beekaylon story. So we very quickly agreed that I would be their global let's say, product development manager. So being responsible for the technical aspects and for, let's say the developments having worked all over the world in principle for 30 years, I did know all the major.
Let's say carpet manufacturers globally in Europe, Australia, New Zealand, Asia Pacific. ASEA, USA. Having worked for companies in the U S companies in Europe, companies in Asia, Pacific, knowing a little bit the differences in the demands for the different areas, because the carpets you have in New Zealand, or I have in Europe are different.
And there's just let's say a matter of of the market and about what customers think about it, how they use it, what is taste. Colours are of course always a matter of taste as well. And you see differences globally. So there was, that was step number one. Then of course, I also needed to be able to create the teams in the factory.
Right. Because you can have the best car in the world. If you don't have a driver with a license, it's not going to work. So the good thing is that also within Beekaylon, we were able to create teams with a lot of experience with a lot of knowledge about textile, but also about BCF already. And then working with the global sales teams.
it was very satisfying to set up, let's say a model where we could guarantee quality better than in any other company I've ever worked for. So we created as much as possible SOP with the knowledge which everybody put in, where are the bottlenecks in processes. So where are the risks of quality in the process?
Where are our opportunities compared with other companies? Just to explain, let's say the three most used polymers are polypropylene, polyester, and polyamide nylon. And those, all those three products have their differences in applications. If you look at the PP, it's mainly used for residential and for relatively commodity products in let's say carpet towels, our machines are very suitable for all the three polymers.
So we have multi polymet BCF, extrusion lines. BCF. If you look at it, It is a continuous filament bulk continuous filament. That means that in principle, you can make carpets with a different weight and with a different application. So if you are looking at the highest end of the market, we would recommend polyamide six.
We would recommend for resilience to use that because the resilience of polyamide is higher than the resilience of polyester or PP polypropylene. We had the advantage that we did know, of course the market, we did know the customers and we were able to talk with customers to give us the opportunity to sample and looking at that. Then the advantage of knowing what the customer is making is helping us.
And what we thought was very important is that we have people in every region who are representing us in the proper way. So building the team to manufacturer was one thing building a team to develop was the second part. But having a team, which is also corresponding with customers on weekly basis or on a monthly basis to really understand the needs of customers was really one of the major parts of the success we are having. Of course, for me, it was quite easy in the beginning to say, okay, I think we will be able to fill up our total capacity within a certain timeframe. And before. We really work together. I already asked her, I said, listen, I will, I'm willing to invest in, let's say in growing the company, but I need to know if we are expanding if it's necessary.
And the answer was very clear. Yes. Because the area which the company did buy has the opportunity to put additional buildings to put additional factories warehouses. So the setup was already there. And I can tell you that due to the success we had, even with the Corona situation globally, we were able to let's say, fill up the capacity of our plant quite fast.
So even some things got delayed due to the COVID restrictions due to the fact that we could have the zoom meetings. We had agents on the right places. We could do the sampling in the proper way. We could convince the customers that we were not only trying to sell them yarn. But we were willing to work with them on developments.
So we were able to let's say already be proactive and work with the customers on not only today's business, but on the business of tomorrow. And that was one of the major things, which I think differentiates us from say most of the other manufacturers, having people inside who are capable of working with customers.
Doing what customers want to do and thinking about the future than the one of the major parts also in that whole story is that Beekaylon is really investing huge amounts of money and time in research and development. We want to be sustainable as possible. We want to be trying to even create circular products.
To let's say to look at our environment as well. We are looking at our personnel our staff, how are we working with the staff? As an example, you might have seen that we have our programs for COVID vaccinations going on, which is really astonishing. If you see what the company is trying to do to protect their most valuable assets, which is personnel, which is your staff.
Your staff is your biggest asset. Like I said before, you can buy the best car in the world. If you don't know how to drive it, you will be in an accident. And our machinery is to state-of-the-art the best money can buy. But our biggest asset is our really experienced and well-trained personnel and implementing SOP.
So we have a lab. we do the test, not only when we start production, but during the whole process, every step is tested, not once, but twice to assure that whatever we send to a customer is absolutely state of the art. And if you look at how quick we were able to develop ranges with With the biggest global players.
Right. It's absolutely fantastic. And even as we speak, we are now looking at, okay, we can make a hundred percent recycled PET. We are working on the a hundred percent recycled, PA six. We are working on antimicrobial yarns. All those benefits we have and that proactive position that Beekaylon is taking. Is getting our customers excited and willing to work with us.
And of course, you're only as good as your last supply. Of course every company has an economic aspect, but our targets to win competition battles is quality. And that's what was one of the reasons why I joined. Because we are able to guarantee the best quality we can supply. If you look at the most critical markets we are working with, customers are giving us the opportunity to work with them because of our service and quality. And that's really amazing. And they also know that we are, Once we do the business, we have running products with them. We are having the normal day by day supplies, but we are already working again on the products for next year. Yeah. Because achieving a good customer supplier relationship is one thing.
Keeping that is the most important one. And over the 30 years, I can really be honest that I see that we are really doing an amazing job on that. And it's all thanks to the team. Right? I have worked in many companies and sometimes you see groups and it's normal, right? Everybody works in a certain area of a manufacturing company and some of them is just logistics, sales, development, production, and I have never experienced the more. Let's say resolute team as I have with peak alone. So everybody is working together instead of only in their own small area. That's what we always try to do.
So we are really looking at all the areas in the world, the differences between products because we want to be able to supply anything in automotive, anything in residential and anything in contracts and hospitality applications that our customers need. So we want to have a very broad palette of possibilities and yarns.
And having all those machines and all those possibilities, we can say that we can supply to any customer, whatever he needs. So if you look at Europe, we work with the high end of the market in Europe, in Australia, New Zealand, in USA, Japan, Asia, Pacific And it's really not because we are nice people.
We are, but we are supplying, let's say a premium product, which is always the most essential part of doing business with anybody being trustworthy doing what you tell that you will do and doing it also, right. It's I can promise you something, but I have to keep my grants. And that's something where I am really happy with the fact what we are doing with Beekaylon and. We can supply, let's say the highest end of the market carpet tile producers by combining different yarns, different colors, we are able to supply anything in automotive, BA six polyester, whatever customers need. We are able to do it in the residential market. And we are not only saying that we want to have the big volume products.
Of course you want that, but we are also looking at, let's say the specialty. The higher end of the markets, the new developments, and as a company with which has done the huge investments that Beekaylon has done looking at factory machines, personnel, they invested huge and they keep on investing because we are extending already.
So we have already the possibility to set machines with their own guidance systems. So everything is controlled, not only by humans, but also by technology. And that was also able to, to that is that makes us able to guarantee the quality on all the steps in the process and being as flexible as possible.
The main target is making new developments, creating the future for our customers and ourselves. So only not have a business today, but also have the business tomorrow and be able to already think about where the world is going.
Right. I don't have to explain. Everybody is looking at environment. Everybody is looking at green of solutions, having less CO2 footprint in the world being sustainable. For example, we are working with, let's say one of the few renovated companies in the world, like DSM Niaga those products Niaga if you turn around to Niaga it says again, so those guys are really working on mutual benefits from suppliers and final customers who put up a chain of recycling.
So to create, for example, a mono product. Where all the parts of a carpet are made from the same material where we can collect it afterwards and reuse it so that we don't need to use new raw materials. And especially looking at polyester, for example, where we are already doing this quite successfully, that we are able to reuse.
We use polyester from bottle flakes, for example, all the waste, which are in the oceans in the season. Whatever we can reuse it. We don't have to do to go to direct polymerization, to make chips again from raw material, which come from our earth. And I always say, you should consider waste, not as waste, but as a raw material again.
We don't see customers as customers. We see them as partners in a very demanding competitive business. we always talk about spinning values and I think that's not only your phrase for Beekaylon That's their DNA. I think that's why it fits. That's why I am so happy to be part of this Beekaylon project.
Rajeev
Amazing. I think it's fascinating to hear from such a senior industry veteran like yourself being so excited. And as of you, you have the curiosity of a young child. Again.
Martin Van Dam No, but it's true. It's what I said at the beginning. When I walked in to the first conversation or when I saw the setup, I was being this little boy again in this candy store. Right. Seeing all those different possibilities, that really was amazing. And of course also the trust I have in Beekaylon and Beekaylon trust in me is building up such a strong relationship. That is absolutely fantastic. And then having, let's say the experience which some of our team members are having with the customers and the customers knowing me from my past, but also knowing that I'm working with Beekaylon now, giving us the opportunity to prove ourselves is absolutely fantastic.
Rajeev You make a very interesting and important point Martin, the sense that it is not just the products. It's the people behind the products which actually create the value and the phrase spinning values is such a powerful concept. it it actually ties into the actual product that Beekaylon produces but also the philosophy that the founders of the company have instilled.
Martin Van Dam
I always say that was one of the things where I wanted to dedicate 10 years of my life and my business experience to do that. And that only works if you work with people and with a company who is also having that same target. So it was very important to have the same mutual target with all the respect in the market for all our customers. And I also wanted to say that everybody is working very respectfully with each other. I always say that our chain of operation is as strong as the weakest link in that chain, but you can fix that in different ways. And I think we are working very respectfully with our staff. With our people and with our customers and our suppliers.
Rajeev So just to kind of summarize the whole thing Martin the biggest advantage that you see going forward is that Beekaylon brings in as it's number one it's its value system. And number two, it's focus on quality assurance, R and D and innovation. Right? So even though there are other producers and manufacturers in India and around the world, this is what sets Beekaylon apart.
Martin Van Dam That sets us apart. Having this global team like we are having and having the knowledge about what our customers are doing in combination with. proactive development, research and development in all aspects in sustainable products and the amount of money that companies are willing to invest in that we are really different from any other supplier in the world. And that's really something where I say, yes, state-of-the-art machines, the latest you can buy the best you can buy the best people in the world. And the best ears in the world to listen to customers and having a view into the next decade. That's combination of all those aspects are really something which makes me extremely proud and happy to be part of that. Amazing. So there you have it. ladies and gentlemen, Martin Van Dam from Beekaylon Synthetics. Thanks Martin. Thanks for your time. That was an amazing conversation. I learned a lot. I learned a lot and it is amazing to see. A global team working with an Indian company. and it's refreshing to see such words from such a global industry veteran like you and, you know, it's pretty remarkable.

Spinning Values Podcast - Ep. 1 - Making Biodegradable Synthetic Fibres a Reality

Wed, 24 Feb 2021 22:17:00 GMT

Biodegradable Synthetic Fibres:

In Conversation with Alastair Drew, CiCLO Textiles

At Beekaylon, we understand the impact of sustainable manufacturing processes. We are excited to bring you Spinning Values - A series of conversations, every month, with our partners and clients, exploring sustainability and innovations in the textile sector.

Spinning Values Podcast:

For our opening episode, we sat down with Alastair Drew, CiCLO Textiles,

to discuss their revolutionary product, which when combined with synthetic yarn, during melt extrusion process, will help accelerate the biodegradation rate of synthetic textiles in the landfills and in the oceans.
Do subscribe to this podcast on your favourite podcast app.

Transcript of the Conversation with Alaistair Drew, CiCLO Textiles

Rajeev

Welcome to Spinning Values. a podcast brought to you by Beekaylon Synthetics. And I am your host Rajeev. This is a show where we talk about sustainability and innovations in the textile industry. Do you know that every single day, 44 million pounds of synthetic textiles are sent to the landfills in the US alone. So what if you make these textiles bio-degradable? To discuss this, we have Alastair Drew from CiCLO textiles. Synthetic yarns when combined with CiCLO becomes bio-degradable. According to one of the founders of this company. And I quote, CiCLO fibers were invented from a conviction that built to last shouldn't mean here, forever. Let us find out more about CiCLO.

Hello and welcome to the podcast, Alastair.

Alastair

Hi Good Morning.

Rajeev

Yeah this is a good evening here I'm from Auckland You're in Hong Kong.

Alastair

Yes yes. Just to admit it's mid-day actually. So it's actually technically it's good afternoon.

Rajeev

Alright Awesome So can we go into the show with a bit of an understanding of what your role and what you do.

Alastair

Sure

Yeah My name is Alastair Drew and I represent the CiCLO business in Asia and Europe. And most of my work is business development. Developing relationships with brands and retailers in the apparel & garment sector well as developing relationships with supply chain partners one of which we're here to talk about today Beekaylon. So that's really my job trying to convince people of the technology get over the messages develop commercial relationships.

Rajeev

Right, so focusing on CiCLO to start with what exactly does your company do can you give us a brief overview.

Alastair

Sure. Yeah basically CiCLO technologies reduce pollution in the oceans plastic pollution in the oceans and reduce the persistence of synthetic textiles that go into landfill. I mean basically CiCLO technology creates biodegradable hotspots on the surface of the polyester and the CiCLO itself it's the thing that we sell to fiber manufacturers. And they embed our technology Into the polyester during the melt extrusion phase of the manufacturing process. So I mean fundamentally we are a sustainable fiber.

Rajeev

Right. So the product that you manufacture or your technology is basically combined with the synthetic yarn that Beekaylon produces.

Alastair

Yeah that's correct. They embed our technology Uh we sell them what is called a master batch.

And they use a very small percentage of that to manufacture polyester filament yarns during their process in their factory. So looking at the supply chain and the whole production process How do you see the relationship with Beekaylon and why is it important in the whole green space.

I mean Beekaylon is a very important business partner for us. We call them a certified manufacturer of CiCLO Yarns. Basically we rely pretty heavily on Beekaylon to professionally represent CiCLO in the Indian market. And they conduct the sales and marketing activity. Selling, representing us to their customers. I mean they've got a very wide customer base in India and we work with them to reach their customers and potentially other customers outside of India of course as well where they export to. And of course their primary role is to manufacture good quality fibers containing CiCLO technology. Our role really is to provide the education the technology and also to conduct tests all of the fibers that they make. So they will send us a sample from each batch they make we test that. That's important for our customers. Our customers want to be reassured that we are testing and checking the product and issuing the right certification to Beekaylon. Then Beekaylon issue those certificates to their customers. I mean they've been great to work with They're very focused on sustainable innovation and they're great at marketing as well. hence this podcast.

Rajeev

Awesome. That's great to hear, Alastair. Yeah, so let's deep dive into the technology that your company markets and produces. So there's many aspects of modern life which are known to cause environmental harm. Like fossil fuels disposable plastic et cetera. But the impact of synthetic textiles is less obvious. Right. So I read an interesting line from your website, which says, made to last doesn't have to mean here forever. so in this context how does bio degradable process actually work?

Alastair

I mean it is quite a complex topic. And although I'm a technical sales I'm not necessarily a scientist that understands or can explain the deep science here. But you know I can give you a very not high level but what a good overview of the process. Basically bio degradation Is the ability of a substance to be broken down both physically and or chemically by naturally occurring microorganisms such as bacteria resulting in the creation of basic natural elements. For example some of these basic natural elements include things like carbon dioxide, methane, water, minerals and even some new microbial cells which we call biomass I'm really for bio degradation to happen kind of need three things I guess if we're going to try and keep it simple. We need microbes that are present the environment. We need moisture And we need time. Because biodegradation It doesn't happen fast happens at the pace of nature You know it's quite a relatively quite a slow process and of course for our products we don't necessarily want it to happen fast much quicker than never really is the key thing. Biodegradation could occur in aerobic conditions meaning environments that require oxygen. And those are environments like the ocean. And also what we call anaerobic conditions meaning environments without oxygen. An example of that is landfill where many of our textiles end up. Uh So biodegradation is really a natural process. Where microorganisms break down materials.

To summarize it I would say the molecular structure of organic material is broken down by microorganisms creating biogas and leftover matter called biomass.

Rajeev

Right So in this process how does CiCLO fibers How does it work like you add additives into the yarn and then it becomes bio-degradable?

Alastair

That's correct, yes. The addition of our technology into the fibers creates lots of if you call hotspots in the fiber will enable microbes to interact with the polyester when it's in the final resting place out of the ocean or soil or landfill and that kind of encourages the microbes and the bacteria. And the enzymes to kind of consume the plastic or see the plastic as food. So we are accelerating a process significantly by the addition of CiCLO into polyester.

Rajeev

so I just wanted to kind of clarify certain terms here Alastair. Because so many terms are being bandied about in the media on the internet. And many of them used interchangeably. Having said that, can you explain what the difference between biodegradable and compostable and are CiCLO fibers compostable?

Alastair

Let's first of all say that CiCLO fibers are not really designed to be compostable. And there's a good reason for that. Because Industrial composting is not usual end of life method for textiles. Your textiles simply don't go into a composting environment. But composting is aerobic biodegradation. But it's different to ocean or soil biodegradation. Yeah because ocean's soil or natural environments whereas composting is controlled. So really it's not a viable solution for textiles. Composting is used for organic matter mostly such as food waste, trees, grass, branches things like that. But textiles are not just not allowed into a composting environment. So we kind of don't really focus on composting. We focus on more I guess more natural environments. Let's just soil, sea water. And also obviously landfill where a lot of textiles do end up. But you know having said that we have 44 million pounds of synthetic textiles being sent to the landfill every single day. Wouldn't it be better If they get composted? Where do you see that technology coming out in the future?

I know that some companies are using the composting test. As a method of marketing and advertising their textiles. Like at the moment I can't see composting or industrial composting accepting fabrics or garments.

Rajeev

All right In that case my next question flows from that. Can textiles manufactured using CiCLO technology can they be recycled?

Alastair

In theory, yes. And the reason I say in theory is that many garments currently are made from wide range of different fibers. Synthetic fibers, natural fibers. And a lot of garments have buttons and zips and fasteners. So, actually recycling of garments is pretty complex. There are really other barriers to commercial widely adopted recycling of textiles. We won't be standing in the way of that.

Rajeev

Right It's possibly because the other material That's like you mentioned zips and buttons and such which had to be removed before it becomes recyclable, right?

Alastair

Yeah in a lot of cases. I mean I know some companies are quite rightly focusing on producing a garment. Let's say all from one material such as all polyester which means then would make easier to recycle the shore and if that was possible and became viable in the longer term about total polyester garments then the addition of CiCLO wouldn't stop that product being recycled.

Rajeev

Right or we can just reduce the number of clothes that we buy!

Alastair

Yeah Yeah. We should be recycling our products. And really to be honest with you many people already do recycling themselves. They pass on their garments to family and friends or they give them to charity. You know these clothes often have a really useful second or third life already that's a kind of recycling. And I guess we can call that I think probably down cycling even at the end of that second or third life at the moment a lot of those products are going You know into landfill. I think only 15 percent of garments and textiles down cycled into natural fibers. You know most of those are cotton and wool. So you know at the moment biodegradation of textiles in landfill is a reasonable solution for these garments that make their way to landfill until there is a mass adoption of alternatives. I can see CiCLO is providing a a really good benefit. Plus of course CiCLO could be used to enhance the biodegradation of microfibers that are being released into the atmosphere and into the oceans. You know we do support recycling and we want our products to be helping the total sustainable solution.

Rajeev

Here's my next question. Are CiCLO fibers toxic? And what happens to the microfibers? Does that become biodegradable as well?

Alastair

Fibers that contain CiCLO find their way into the drains and down through into the wastewater treatment plants. Ultimately potentially out into the ocean and waterways they will be biodegradable in this sea water environment. And in the soil environment and I know also just to say there are many companies working on reducing the shedding of fibers through new constructions of the fabrics new finishing processes. I know some people who even developing washing machines is trying to capture these fibers. Our garment factories that are also washing and dyeing they are starting to look seriously at filtering all of their affluent to prevent these fibers going into the ocean. But you know it is happening and there's more and more research being done to measure the amount of fiber given off during the washing process and CiCLO is a fantastic solution for those fibers to biodegrade. And sort of pick up on I think your the first point is that you Is it toxic or does it cause any harm the answer is no. We've done a third party testing. There's a company in Germany called Oeko-Tex and they've researched and reviewed the CiCLO product and issued us with a eco passport certificate. Which basically checks to make sure there's no restricted substances or harmful chemicals. we've passed that. So there's none of those issues at all. In addition we've done some long-term testing. We've tested what's left over. We talked about water and carbon dioxide being given off and some cellular structure. And we tested that to make sure that's not giving any toxic byproducts. So we're pretty confident we've got the necessary proof for brands and retailers that they require so that we can demonstrate that we're not harming the environment.

Rajeev

My final question before we close our conversation is that the products that other producers downstream take Beekaylon yarn infused with your technology the products they make out of that let's say I know carpets or garments so whatever it may be does it affect its durability does it affect its quality. Or is there any such impact?

Alastair

So talking about downstream from Beekaylon I mean I guess the first thing to say is that all of those downstream fabric mills or dyeing houses or when you're garment factories. No they don't have to do anything different. they can use their existing manufacturing. And processing machinery and equipment nothing needs to change as a result of CiCLO And we don't find any difference in physical properties or tensile strength or any applications or usage conditions that change. We've had a lot of development particularly in the garment sector. And a lot of fabric has been made and tested by our brand partners and retailers and they've all passed things like wear tests, wash tests that these brands carry out There's no performance loss, there's no loss of durability CiCLO biodegradation does not happen in the supply chain. Only happens when the fibers reach at the end of the life in the ocean or soil or landfill When we have the presence of microbes and moisture and time. So we're not going to see any biodegradation in our supply chain or in our closets or our warehouses. So we don't need to worry about that. So we think CiCLO fibers strike a balance between high-performance durability and sustainability. And I think as you nicely said earlier on our saying is that it's made to last doesn't mean here forever.

Rajeev

All this technology Alastair, it's kind of downstream. Unless we as humans use less products, use less clothes. Then, you know, the whole landfills. It will be filled up with less textiles. You know that might change the whole landscape. Am I a right? What do you think?

Alastair

So yeah I do see the need for more durable clothing that you're gonna use time and time again rather than discard easily and quickly. I see the circular economy developing. I see chemical recycling developing. I see that the whole industry. Right through the supply chain of garments and textiles is, it's doing a lot. We're not the only ones. CiCLO Isn't the only one that's putting a lot of effort Into to helping with this issue. Whether it's new retail solutions where people hire or rent clothing rather than buy it. There's a lot going on. There's a lot of second hand clothes being sold between peer to peer platforms. And the digital environment. So, I think there's lots going on. It's a really kind of exciting industry to be in with lots of innovation. but at the end of the day are we humans, even people like me, that aren't millennials, older consumers need to adapt and reduce our footprint.

Rajeev

Thanks Alastair. Thanks for your time. That was a really enlightening. conversation how can listeners get more information about CiCLO? where can we get information? Can you tell our listeners?

Alastair

Yes. Obviously we have a website. www.ciclotextiles.com . So yeah. Please connect with us and obviously connect, if you are in the market in India, then can connect with Beekaylon. The people there will be able to support, the initial inquiry. And if the inquiry goes deep into the technology then I can support.

Rajeev

Thanks Alastair. That was a really helpful and enlightening, as I said. Thanks for your time.

Alastair

Thank you for listening.

Rajeev

So that is the end of Episode One of Spinning Values, a podcast brought to you by Beekaylon Synthetics. Thank you Alastair for joining us and talking to us about such a crucial topic. In the coming episodes, we will be talking to companies that are coming out with such innovative solutions for problems that not only impact the textile industry, but everyone on this pale blue planet.

So until next time, reduce, reuse, or recycle. This is Rajeev signing off.

Five Ways Puriflex Differentiates  Floor Coverings & Carpets

Wed, 24 Feb 2021 21:22:00 GMT

Puriflex Anti Microbial Yarn from Beekaylon

Beekaylon’s innovation in antimicrobial yarns with infused AM++ ions.

Microbes or microorganisms are all around us. The most common ones are bacteria, fungi and virus. Under conducive conditions of humidity and temperature, microbes can multiply quickly causing foul odour, discolouration / stains and can be cause of illness. Antimicrobials can be successfully used to control the growth of certain types of microbes. Consumers today are recognising the need for freshness in textiles and floor coverings at home and commercial establishments and are demanding products with improved aesthetics and freshness with microbial resistance.

Microbes Build Up Over Time

Carpets may trap pollutants like dust mites, animal fur, cockroach allergens, particle pollution, lead, mould spores, pesticides & dirt. Toxic gases in the air can stick to small particles that settle into carpets. Viruses tend to remain infectious for about twice as long on non-porous surfaces as compared to porous surfaces. Because carpets and upholstery are considered porous surfaces — just like clothing, wood and similar materials — they’re less supportive to viruses than non-porous ones.

Anti Microbial Efficacy >99%

Beekaylon’s innovation in antimicrobial yarns with infused AM++ ions. Protection & Freshness for everyone to cherish all beautiful moments of life. These ions are infused permanently in the polymer during spinning which inherently provides an antimicrobial effect which remains effective even after extensive washes and usage. It’s a result of intensive in-house research and development where additives are fixed permanently on the surface and do not migrate during usage, hence making the yarn skin and eco-friendly. It's safe & convenient to use with ever lasting freshness for all its applications.

5 Advantages of using Puriflex

How sustainable is recycled polyester yarn?

Tue, 15 Dec 2020 14:02:00 GMT

Recycled Polyester Yarn & Sustainability

Recycled Polyester Yarn or rPET is manufactured from used PET bottles & yarn waste which is then converted into chips, using environment-friendly recycling processes. In 2017, the organisation spearheading the international efforts in sustainable manufacturing in the textile industry - Textile Exchange - created an rPET Commitment to encourage brands and retailers to publicly commit to accelerating their use of recycled polyester by 25% by 2020. Many international brands including Gap, Ikea, H&M, etc. signed up to this commitment to increase their adoption of rPET by at least 25% by 2020.

This commitment has been tremendously successful. The aggregate target was reached two years early, in 2018, when the combined rPET use of the commitment signatories grew by 36%

The Impact:

To put this in perspective:

2,868,000,000 bottles diverted from landfill.
35,329,509 kg reduction in human toxicity.
1,849,464 MJ saved on primary energy demand.
122,823 kg reduced Co2.

The IKEA ambition is to not use any virgin oil based polyester in textiles by 2030. To commit to use 25% more rPET by 2020 is a natural step towards our ambition. We are committed to use resources with the utmost efficiency and turn waste into resources. Lena Julle, IKEA Category Area Manager, Textiles

Recycled polyester, also known as rPET, is obtained by melting down existing plastic and re-spinning it into new polyester fiber. While much attention is given to rPET made from plastic bottles and containers thrown away by consumers, in reality polyethylene terephthalate can be recycled from both post-industrial and post-consumer input materials. But, just to give an example, five soda bottles yield enough fiber for one extra large T-shirt. This sounds like a great idea. But in reality, how sustainable is Recycled Polyester. At Beekaylon, we are guided by three guiding principles to create products and inspire our production methodologies.

Eliminate waste and pollution
Keep products in use
Regenerate natural systems

Let us look at this problem keeping these principles in mind. So, what are the main advantages of using Recycled Polyester (rPET)

Let us look at what Textile Exchange (TE) has to say about this. According to TE,

Using more rPET reduces our dependence on fossil fuels as the source of our fabrics. With the world shifting away from fossil fuels in all walks of life, this is ultimately a good thing
Diverting PET bottles reduces the need to send them to landfills and thus reduces soil contamination, air & water pollution
The production process also requires less energy consumption compared to virgin polyester
Garments created from rPET do not degrade in quality and minimizes wastage. This could potentially become a closed loop system

#1 - rPET prevents prevents plastic from the oceans

The NGO Ocean Conservancy estimates that over 8 million metric tonnes of plastic enter the ocean every year adding to the 150 million metric tonnes already circulating in the waters, thereby contaminating the marine ecosystems around the world. If this continues, by 2050 there will be more plastic in the ocean than there is fish!

Over 60% of seabirds and 100% of all sea turtles have plastic ingested inside them as they mistake plastic for food.

#2 - rPET is durable in quality and takes less energy to make

According to a 2017 study by the Swiss Federal Environment Agency, rPET’s production helps to reduce CO2 emissions by 32 percent in comparison to regular polyester. Converting PET into recycled polyester uses less water and energy than it would to produce virgin polyester. Most studies show that between 33-53% less energy is used to create recycled polyester vs virgin polyester. In addition, less CO2 emissions are produced and we do not need to use non-renewable resources (petroleum). We process recycled polyester yarns by extruding recycled chips. The recycled yarns are supplied to textile and floor covering manufacturers. This contributes to reducing our carbon footprint by reusing and recycling PET based products.

But more needs to be done

Though rPET takes 59% less energy to produce, it still requires more energy to produce when compared to natural products such as hemp or wool. (source - Stockholm Environment Institute) We cannot afford to get the foot of the pedal and continue to look at reducing the energy consumption in producing recycled polyester yarn. We need to promote the use of products like Poly-Go-Round by more brands in the marketplace.

Needless to say, converting plastic waste into a usable product and preventing it from reaching landfills or the ocean is critically important. Adopting sustainable manufacturing practices and increasing the adoption of recycled polyester yarn in textiles and floor covering products is important for us at Beekaylon Synthetics.

With 49% of the global fiber production, polyester is the most widely used fiber in the apparel sector: more than 63,000 million tonnes of polyester fiber are produced annually. With that as a background Poly-Go-Round is crucial to our plans to develop a sustainable future for our planet.

There are more challenges to overcome and we need to promote the acceptance of recycled polyester yarns amongst brands. Which is crucial for a sustainable future for our planet.

Beekaylon's blog on sustainable manufacturing

How Yarn Engineering Impacts Carpet Performance: From Denier to Crimp

From Denier to Crimp

Why India Is Becoming a Preferred Hub for Recycled Polyester Yarn

The global textile industry is growing rapidly, but so are concerns around waste, resource depletion, and environmental impact.

Global Polyester and the Sustainability Imperative:

India’s Structural Advantages in Recycled Polyester Yarn:

Global Demand and India’s Export Readiness:

Beekaylon’s Innovation:

Challenges and the Road Ahead:

Beekaylon Synthetics PVT. LTD has been awarded Preferred Manufacturer status for 2026

CICLO awards Beekaylon with Preferred Manufacturer Status for 2026

BCF Polyester Yarns in Carpets and Upholstery: A Complete Buyer’s Guide

1. Understanding Polyester Yarn and BCF Technology

2. Why BCF Polyester Yarns Matter in Carpets

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3. Polyester Yarns in Upholstery Fabrics

4. Sustainability Certifications and Quality

5. Beekaylon's Expertise in BCF Polyester Yarn

6. Buyer Checklist: What to Look for When Choosing BCF Polyester Yarns

7. Emerging Trends and Future Outlook

Conclusion

Sources and References

Resilient Paths and Self-Belief: Lessons from Rushin Vadhani

Flags are not just Fabrics – Its identity of our freedom, struggle & soul

India’s Polyester Yarn Industry: Trends, Exports & What Lies Ahead

Production & Market Growth: Scaling the Synthetic Surge

Export Performance: Standing Strong through Shifts

Emerging Trends & Growth Drivers

Challenges on the Horizon

The Road to 2030: Opportunity Ahead

Beekaylon's Role: Innovation in Every Yarn

Conclusion

At Beekaylon, we're more than manufacturers—we're partners in progress, weaving together performance, purpose, and planet-conscious solutions. Join us as we spin the next chapter of India's textile legacy.

Sources & References

Myths Around Polyester Yarn – Debunked!

Beekaylon: Leading the Way in Sustainable Polyester Manufacturing

Conclusion

BCF Yarn - A Deep Dive

What is BCF Yarn?

Varieties of BCF Yarn Available in the Market

Market Dynamics: Indian and International Perspectives

Indian Market

International Market

Applications of BCF Yarn

Beekaylon’s Contribution to BCF Yarn

Key Features of Beekaylon's BCF Yarn:

Conclusion

Digitalization and the Future of Textile Design

Role of AI and Machine Learning in Textile Design

Digital Tools for Personalization and Efficiency

Beekaylon’s Commitment to Innovation

Digitalization: The Catalyst for Personalization

Bridging Tradition and Technology

A Sustainable and Digital Future

3D Printing in Textiles: A Revolution in Fabric Innovation

3D Printing in Textiles - An Overview

A Greener Way to Make Fabrics

Tailored to Perfection

Innovative Designs Like Never Before

How Beekaylon is Innovating

Wrapping Up

Ep. 12 - Michiel Swagemaker - Swatech.eu

Ep. 12 - Michiel Swagemakers, Swatech

Embracing Fashion from Eco-Friendly and Recycled Materials

The Environmental Impact of Traditional Fashion

How to Incorporate Sustainable Fashion into Your Wardrobe

Innovative Ways to Incorporate Recycled Materials into Fashion

1. Chemical and Mechanical Recycling Technologies

2. Recycled Polyester from Plastic Bottles

3. Upcycling Pre-Consumer Off-Cuts

4. Digital Platforms for Waste Management

5. Regenerative Fiber Projects

6. Recycled Wool and Cashmere

7. Innovative Fiber Regeneration Techniques

Conclusion

Ep. 11 - Enhancing communication skills in the Textile Industry - Ami Ved

Mastering Communication: Insights from Ami Ved on the Spinning Values Podcast

Introduction to Ami Ved

The Evolution of Communication Skills

A Conversation with Amrish Shahi