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Dr. Baliram Hiray Hi-Tech Textile Cluster Services Pvt. Ltd An effort to encourage Technology upgrading in Malegaon Textile Industry. 
Dr. Baliram Hiray Hi-Tech Textile Cluster Services Pvt. Ltd is Special Purpose Vehicle (SPV) to run a Common Facility Center (CFC) demonstrating sustainability and value-chain upgrading options in the largest of traditional power-loom based clusters contributing to capacity-building and livelihood of thousands of weavers and operators
About Malegaon Textile Cluster 
The Cluster of Malegaon has about 6000 (5856) power loom units of which about 450 units are registered units. The core cluster firms provide employment to over 60,000 weavers and operators produce over 1.2 crore metres of grey fabric per day. The turnover of the cluster is about Rs. 3,974 crore per annum and production in terms of fabric is about 330 crore metre per year. The Cluster provides employment to a large segment of the Minority population and weaker sections of society. The average investment in equipment and machinery of a core enterprise, namely, a power loom unit is Rs. 9.6 lakh considering a simple average of 24 looms per enterprise. There are evidently about 1.5 lakh outdated, and invariably second hand power looms in the cluster and about 100 auto-looms. A couple of Ginning and Spinning mills as well as traditional Batch-process Bleaching Unit provide job-work service to support the activities of core cluster enterprises. A network of traders in the region are involved in supply of inputs and marketing of output to other regions, like Pali and Balotra and Surat (usually) for value-addition before marketing of end-products. 
The critical constraints confronted by cluster firms are: • There is non-availability of sectional-warping facilities which makes it necessary for auto-loom holders to procure ready     beams from other locations, albeit at higher cost implications.
• There are no auto-sizing facilities in the cluster to produce superfine varieties of cotton fabric of higher GSM as to help     cluster firms upgrade their product and market mix.
• There is very little Ready-for-Dyeing (RFD) processing facility.
• There are no adequate testing lab facilities in the region.

Cluster firms are in a precarious situation and the only initiative to help them move up the value chain by means of an appropriately structured CFC is most critical for the region. So to overcome these constraints Dr. Baliram Hiray Hi-Tech Textile Cluster Services Pvt. Ltd is establishing a CFC in Malegaon region.
The purpose of CFC is mainly for:
• ensuring upgrading of pre-weaving sizing and warping activities along the manufacturing process, which is a necessary    precursor to encourage simultaneous upgrading of looms by individual power loom units, enhancing market-price yield and    competitiveness of the cluster
• ensuring higher margins and income-accruals to power loom units in weaving activity 
• facilitating value-addition to cluster products by means of RFD facilities
• quality focus on sourcing of yarn as well as weaving and RFD processing of fabric 
• competitive market orientation of firms in the medium and long-term
• enhancing productivity, quality and value in weaving and marketing of fabric
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Nature of Business

Service Provider

Legal Status of Firm

Limited Company (Ltd./Pvt.Ltd.)

Annual Turnover

Rs. 2 - 5 Crore

GST Number

27AAECD1803H1Z0

Pre-Weaving Services
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Pre-Weaving Services

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n past there was no facility of sectional warping in the cluster. Ready beams of warped polyester yarn have to be sourced from outside. CFC is providing sectional warping facility to Cluster. Sectional warping is undertaken typically for polyester and also for dyed yarn. Presence of such facilities ensure consistent quality. 

Sectional warping equipments consist of creel mounted in a frame where polyester (or dyed) yarn bobbin is held in creel. Sets of yarn coming from creel is warped on beam with auto stop motion (in case of possible yarn breakage). The advantages of related advanced equipment is in terms of facilitating higher productivity in subsequent weaving in looms with (fabric of) minimum defects. 

High Speed Sectional Warping equipment may be viewed in terms of equipment with: working width of 2.4 meter, beam flange dia of 800 mm and creel with individually controlled tensioners with 504 creel ends. The capacity of the equipment is 600 kgs per shift of 12 hours duration. 


Direct Warping and Auto-Sizing 

Direct warping and auto sizing includes a creel mounted in a frame where the cotton yarn bobbin are held in creel. Set of yarn coming from creel goes to a saw box which contains sizing material. Thereafter, set of the sized yarn is passed through a drying chamber to dry the sets of yarn. This dried set of yarn is warped on a beam. The advantage of use of such equipment is in terms of facilitating cluster productivity in subsequent weaving in looms with (fabric of) minimum defects. 

Direct warping and sizing is undertaken for cotton yarn. The critical equipment in this context is a direct warping machine. A machine with capacity of 2500 kg per single shift of 12 hour duration is envisaged. The specification of the equipment may be viewed in terms of equipment with: working width of 1.8 metre, beam flange dia of 750 mm and creel with individually controlled tensioners with 640 creel ends. Presently, 27’s to 44’s count cotton is largely (traditionally) sized and worked on by cluster firms.

The auto-sizing equipment envisaged include an auto-sizing machine with specifications in terms of 1800 mm as working width, beam flange dia. 750 mm and creel with 16 beam capacity.

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Direct Warping and Auto-Sizing
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Direct warping and auto sizing includes a creel mounted in a frame where the cotton yarn bobbin are held in creel. Set of yarn coming from creel goes to a saw box which contains sizing material. Thereafter, set of the sized yarn is passed through a drying chamber to dry the sets of yarn. This dried set of yarn is warped on a beam. The advantage of use of such equipment is in terms of facilitating cluster productivity in subsequent weaving in looms with (fabric of) minimum defects. 

Direct warping and sizing is undertaken for cotton yarn. The critical equipment in this context is a direct warping machine. A machine with capacity of 2500 kg per single shift of 12 hour duration is envisaged. The specification of the equipment may be viewed in terms of equipment with: working width of 1.8 metre, beam flange dia of 750 mm and creel with individually controlled tensioners with 640 creel ends. Presently, 27’s to 44’s count cotton is largely (traditionally) sized and worked on by cluster firms.

The auto-sizing equipment envisaged include an auto-sizing machine with specifications in terms of 1800 mm as working width, beam flange dia. 750 mm and creel with 16 beam capacity.

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Testing Lab

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  1. GSM test for fabric. This is particularly because of weight change after bleaching operation which needs to be tested, hence such testing requirements will increase considerably upon establishment of the CFC.
  2. Single Yarn strength test using a universal tensile strength testing machine.
  3. Yarn appearance test
  4. Yarn twist test
  5. Chemical test for identification of fibre blend, construction of fabric to count EPI (Ends per inch) and PPI
  6. The warp reel warps yarn from the bobbin to make into 840 yards (one lea) for testing breaking strength
  7. Yarn appearance board winding equipment wraps yarn on black board to check appearance of yarn like thin and thick places, neps etc
  8. Twist tester checks the numbers of TPI (twist per inch) of yarn
  9. The GSM balance helps test the count of yarn (number of lea’s of 840 yards in one pound is equal to count).
  10. GSM cutter with rubber pad and cutter helps to cut the fabric in circular form by cutter and then weigh the circular fabric to study the GSM.
  11. Universal tensile strength tester indicates breaking strength of single yarn hank (lea) and fabric in kgs or Newton.
  12. Pick glass is used to test fabric density that is number of ends per inch length wise and number of picks per inch width wise
  13. Electronic yarn tension tester helps check yarn tension while warping sizing and in loom.
  14. Portable moisture meter helps check moisture in cotton yarn and fabric.
  15. Fabric tearing strength testing is used to test the strength of finished fabric as due to chemical overdosing during processing it may loose strength.
  16. PH meter is used to check the acidic, alkaline and neutral nature of fabric or solutions used in processing.
  17. Tweddle meter is used for spot checking of caustic lye strength.
  18. Digital TDS meter helps analyse total dissolved solid in water or effluent.
  19. Non contact tachometer works like a torch when light is flashed on a moving part it displays the RPM.
  20. Digital multimeter is used to check the voltage current and resistance of the electrical circuit.
  21. Digital megger (insulation tester) helps spot checking of voltage and current of cable.
  22. Shore D circulation type hardness tester is used to taste the hardness of rubber and ebonite roll used in different equipment.

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Testing Lab Service

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  1. GSM test for fabric. This is particularly because of weight change after bleaching operation which needs to be tested, hence such testing requirements will increase considerably upon establishment of the CFC.
  2. Single Yarn strength test using a universal tensile strength testing machine.
  3. Yarn appearance test
  4. Yarn twist test
  5. Chemical test for identification of fibre blend, construction of fabric to count EPI (Ends per inch) and PPI
  6. The warp reel warps yarn from the bobbin to make into 840 yards (one lea) for testing breaking strength
  7. Yarn appearance board winding equipment wraps yarn on black board to check appearance of yarn like thin and thick places, neps etc
  8. Twist tester checks the numbers of TPI (twist per inch) of yarn
  9. The GSM balance helps test the count of yarn (number of lea’s of 840 yards in one pound is equal to count).
  10. GSM cutter with rubber pad and cutter helps to cut the fabric in circular form by cutter and then weigh the circular fabric to study the GSM.
  11. Universal tensile strength tester indicates breaking strength of single yarn hank (lea) and fabric in kgs or Newton.
  12. Pick glass is used to test fabric density that is number of ends per inch length wise and number of picks per inch width wise
  13. Electronic yarn tension tester helps check yarn tension while warping sizing and in loom.
  14. Portable moisture meter helps check moisture in cotton yarn and fabric.
  15. Fabric tearing strength testing is used to test the strength of finished fabric as due to chemical overdosing during processing it may loose strength.
  16. PH meter is used to check the acidic, alkaline and neutral nature of fabric or solutions used in processing.
  17. Tweddle meter is used for spot checking of caustic lye strength.
  18. Digital TDS meter helps analyse total dissolved solid in water or effluent.
  19. Non contact tachometer works like a torch when light is flashed on a moving part it displays the RPM.
  20. Digital multimeter is used to check the voltage current and resistance of the electrical circuit.
  21. Digital megger (insulation tester) helps spot checking of voltage and current of cable.
  22. Shore D circulation type hardness tester is used to taste the hardness of rubber and ebonite roll used in different equipment.

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