Corporate Presentation
SATIA GROUP - TC TERRYTEX LTD Business Partners for Terry Towels
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TC TERRYTEX LTD
- Vertically Integrated across Textile Value Chain
Cotton Farming
TC TERRYTEX LTD has presence
across the Textile value chain
Ginning
Spinning
F
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A
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Yarn Dyeing
Weaving
Processing
P
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TC TERRYTEX LTD- The Company
TC TERRYTEX LTD is the nouveau venture of Satia Group. Satia Group is
one of the oldest and most respected groups of North India with interests
in Paper, Yarn and now Terry Towels. Established in 1980 Satia Group
commands a current turnover of USD 180 Million.
Associated Companies of Satia Group are:
- SATIA PAPER MILL LIMITED
- SATIA SYNTHETICS LIMITED
- TC SPINNER PVT LTD
- TC TERRYTEX LIMITED
The factory of TC TERRYTEX LTD is very conveniently reachable. It is
situated on the National Highway-21 at Lalru, near Chandigarh.
Approach by Air - Factory is well connected with the Air Services. It is just
16 miles (25 Km) away from Chandigarh Airport. Flight from New Delhi to
Chandigarh is only of 45 minutes duration.
Approach by Car - Factory is just 4 hours drive by Car from New Delhi.
Approach by Rail - Factory is well connected by Railway service. The
factory is located 6 miles (10 Km) from Ambala Cantt Station.
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TC TERRYTEX LTD- Infrastructure
TCTL has the most sophisticated manufacturing set-up in South
Asia. The factory is spread across 150,000 Sq Meters and is
equipped with worlds latest Airjet TSudocama, SMIT Rapier looms,
Jacquards from Bonas and running at 550 RPM with vario-pick
facility.
SPINNING CAPACITY – 85000 Spindles – 25550 MT per annum
WEAVING CAPACITY –
7000 MT per annum
65 Dobby looms + 16 Jacquard looms –
DYEING CAPACITY – 7500 MT per annum
STITCHING CAPACITY – 7500 MT per annum
AUTOMATED COLOR KITCHEN - Data Color, USA
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TC TERRYTEX LTD- Infrastructure
T.C. TERRYTEX LTD.
Equipment List
Sr. No.
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EQUIPMENT DETAILS
Loom
Rapier Loom with Jacquard
Smit Rapier with Dobby
Tsudakoma Airjet
Knotting Machines
Knotting Frame
Fabric Dyeing
Fabric Dyeing Machine
Fabric Dyeing Machine
Fabric Dyeing Machine
Fabric Dyeing Machine
Hydro Extractor
Rope Opener
Continuous Tumble Drier
Relax Drier
Drier
Stenter
Damping Machine
Yarn Dyeing
Package Dyeing Machine
Package Dyeing Machine
Package Dyeing Machine
Package Dyeing Machine
Package Dyeing Machine
Package Dyeing Machine
MAKE
COUNTRY QUANTITY
SMIT & Bonas
SMIT
Tsudakoma
Knottex
Knottex
Italy
Italy
Japan
Germany
Germany
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4
61
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BRAZOLLI
BRAZOLLI
BRAZOLLI
BRAZOLLI
SWASTIK
BANICO
ANGLADA
HARISH
PENINSULA
HARISH
HARISH
ITALY
ITALY
ITALY
ITALY
INDIA
ITALY
SPAIN
INDIA
INDIA
INDIA
INDIA
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Fong's
Fong's
Fong's
Fong's
Fong's
Fong's
Hong Kong
Hong Kong
Hong Kong
Hong Kong
Hong Kong
Hong Kong
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1
1
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TC TERRYTEX LTD- Product Range & Designing
Product Range – Our design range encompasses a wide range in
both Yarn dyed & Piece dyed qualities across Dobbies and
Jacquards:
Bath ensembles
Beach towels
Christmas Towels
Specialty Towels
Bath Robes
Embroidered towels
Kitchen towels
Embellished Towels
Bath Mats
Bath Wraps
Designing – In house design studio with latest hardware and
software from NedGraphics facilitates outstanding product
development.
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TCTL Test Standards
REQUIREMENT FROM IKEA
Mechanical requirements:
Tensile strength warp/weft
Pile loop extraction
Terry ratio
Dimensional change after washing and drying
Deviation from size
Deviation from indicated weight, fabric
Determination of yarn count
Determination of no. of threads
Deviation of fibre content, fabric
Change of appearance after washing
Absorption
Before wash 30 sec
Before wash max
After 1 wash 30 sec
Chemical Requirement.
Formaldehyde
pH value
Flammability requirements:
Flammability of textiles/ clothing textiles
Plain fabric
Raised fabric
Color Fastness Requirement
Colour fastness to light
Colour fastness to rubbing
Dry staining
Wet staining
Colour fastness to washing
staining
Colour change
Colour fastness to perspiration acid and alkaline
staining and colour change
Migration of colours into PVC
staining
Colour fastness to water
Staining
Colour change
Optical brightening agents ( OBA)
Method
Standard
ISO-13934-1
EN-15598
EN-14697
ISO 6330/3759/5077
ISO 22198
ISO 3801
ISO 7211-5
ISO 7211-2
ISO 1833
ISO 6330
≥180
≥0.757
.5/-57
.+2/-6
.+2/-0
.+5/-4
±5
±5
±39
TED
ISO-9073-12
100
200
200
ISO-14184-1
ISO-3071
≤20
4.0-7.5
16 CFR 1610/IOS TM≥3.6 CPSIA12
0007
≥4.1 CPSIA12
ISO-105-B02
≥4-5
ISO-105-X12
≥4
≥3
ISO-105-C06
≥3-4
≥4
ISO-105-E04
≥3
ISO-105-X10
≥3-4
ISO-105-E01
≥3-4
≥3-4
NOT Allowed
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Colour consistency in colour conformity
(lab dips & batch to batch)
•By using same quality of yarn (same source, batch no, count, T.P.I,C.S.P,
TM etc)
•Same source and batch no for dyestuff and chemicals.
•Thorough check before using a new batch of dyestuff and chemical for
production.
•We are using HUNTSMAN DYE STUFF for best reproducibility.
•Dyeing m/c are fully automatic and controlled by micro processor
supported by color kitchen and color dispensing system from Data color.
•Develop the receipt from shade swatch and issue a unique recipe no.
Thus the said recipe is being used for all dye lots of that particular color.
• We have SAP system in place and exact recipe being used at all times
for color conformity can be reviewed at any time and by anyone.
•Please refer next slides for JPEG of our color continuity charts.
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Our Strengths within Product
Development
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Vertically integrated set up with support from spinning units, thus we
can do value added/innovative yarn such as Cotton- Bamboo, Air fill,
Cotton Modal, Cotton Linen, Slub , Low twist etc.
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Weaving techniques :- Variable pile height, Thick & Thin, Waves, Weft
Inserts, Surface textures in Dobby and Jacquard.
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Sampling fabric dyeing machines and can do lots as small as 50 kgs,
400kgs, 800kgs,1200kgs.
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Strength in Yarn dyeing with small dyeing machines of 50 kgs each.
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In house design studio with latest hardware and software from Ned
Graphics.
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Our designers with extensive exposure of the overseas market
provide us feedback and support on latest innovations and
developments in different designs, techniques and pattern.
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Development timelines
1. From Pantone & sketch to sample –
1. 15 days for Plain dyed products
2. 21 days for Yarn Dyed products
3. 15 days for Dobby products.
4. 21 days for Jacquard products.
2. From approved sample to production start –
1. 20 days from approved sample/trims approval and
procurement.
2. Overall 45 days for Piece Dyed Dobby products.
3. Overall 75 days for Yarn Dyed and Jacquard products.
4. Final lead times are dependent on loom space booking and
availability.
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TC TERRYTEX LTD- Philosophy and Responsibility
Responsibility (Towards the environment, workers and the
customers) - The factory uses the Reverse Osmosis treatment and a
zero discharge plant with a water treatment capacity of 2 million
liters of water everyday with an additional water recycling capacity of
90%.
Philosophy of the company – We strive to remain on the cutting edge
of technology and also to maintain, develop and hire the best people,
enabling us to building long-term mutually beneficial relationship
with the customer.
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TC TERRYTEX LTD- Process Flow Chart and Critical
Control Points
Process Flow chart & Critical Control points
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Incoming Yarn Parameters testing and lot passing is done by TQM/Lab
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Yarn is checked for CSP, TM, TPI
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Once ok Yarn is passed and acceptance given to warehouse to accept yarn
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Yarn is issued to Direct Warping as per requirement under SAP SO
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Yarn is issued for Yarn Dyeing as per requirement under SAP SO
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Beams are issued for Sizing
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TQM ensures all Beams pass through proper cycle time and proper sizing chemical application is done
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Dyed Yarns are issued to Sectional Warping and TQM ensures that proper warping is done as per required design
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Beams are then knotted and prepared for 1st run.
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When the 1st piece is woven a thorough check of piece is done by a team from TQM department/Marketing
department/design department/weaving department
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Piece is evaluated for Size, grey weight, picks/cm, ends per cm, design element, border and hem checking is done, aesthetic
appeal. Correction if any is done on the weaving at this point of time
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TQM department/Design department is present for weaving till initial one hour of weaving and evaluates production and
checks for thread breaking, machine running
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Above is done for every new quality running on loom for the first time.
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3 TQM personnel are always present in each shift to cross check all production.
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Grey checking and storage - 100% grey checking is done before storage. Defects if any are highlighted back to all concerned in
Weaving/TQM/Designing/Production head
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Defects which can be corrected are mended here.
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Grey lot preparation for dyeing is done. TQM and PPC ensures that the right batch is issued
TC TERRYTEX LTD- Process Flow Chart and Critical Control Points
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Dyeing Recipe is issued through SAP system. Right chemicals and recipe are issued as per lab dip approved and requirement for bulk dyeing.
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Ropes are marked so that the pile direction is pre determined and pile stays uniform while dyeing cycle works.
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Once dyeing is complete - each and every dye lot is taken to Lab for color fastness testing, Home laundering testing, color continuity record keeping, shade matching, absorbency
tests and hand feel confirmation.
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Lots are held in aisle in Dyeing Section and marked under waiting area unless TQM approves of all parameters as per Customer protocol. If tQM rejects lot for any reason then Dyeing
Department head needs to take back the goods for re-processing.
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Once TQM gives go ahead the lot is then passed on through the Turbang machine (air tumble dryer) and stenter. TQM ensures width of the fabric required is as per order
requirement.
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The fabric is then taken to Length cutting, Length hemming, width cutting and then final packing.
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TQM ensures length hemming and cross cutting is done properly as required by customer in final product. Product is then moved to finishing section for width stitching, labelling,
hanger application, folding, accessories application and into carton
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We follow a system of One Stitcher and One checker cum folder as a team.
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Each line has one supervisor who controls all stickers and packers. In each line there are 8 Juki machines.
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Supervisor checks for proper labelling, proper stitching, folding, accessories application.
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Before all stitching activity is started - a team of people comprising Marketing Department, TQM, PPC, Finishing head, Finishing Supervisors, QA team makes one piece in each style
and signs off.
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This signed sample is displayed in Finishing for everyone to see.
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Each line's production after supervisor approval sends a trolley for inspection of ready goods to QA team in finishing house.
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QA does 100% inspection of the 1st trolley offer for a new product. If product is ok then it is passed through Metal detector and sent to carton packing.
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If trolley is failed then the Supervisor and all members of line are called to understand defects and problems.
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After 1st trolley inspection all further trolleys of the product are checked on AQL 2.5 level.
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Once goods are packed in cartons and carton marking application along with any stickers is done, TQM does final inspection of goods before calling for final inspection from outside
agency/buyer inspection.
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If goods are ok then goods are moved to warehouse and confirmation to marketing department to call final inspection is done.
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TQM department is also part of team for container loading of goods.
TC TERRYTEX LTD – Audits & Certifications
TC Terrytex has been accredited with following Certifications:
1. OekoTex certificate for Terry Towels & Dyed Yarns.
2. GOTS Scope certificate from Control Union for manufacturing
Organic Cotton products.
3. GOTS OE Scope certificate from Control Union for manufacturing
Organic Cotton blended products.
4. ISO 9001-2008 certificate.
5. GSV (Global Security Verification) Certificate.
Audits:
TC Terrytex has been successfully audited by KOHLS, TJ MAXX,
Bon-ton, TOYS R US, Lidl, Target Stores, Marks and Spencer's,
Woolworth, Disney a few of them. All reports and certificates can be
made available on receipt of requirement from customers.
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DOBBY BORDERS…….
DOBBY BORDERS…….
JACQUARD BORDERS…….
BEACH TOWELS…….
DIFFERENT TEXTURES…….
PACKED SAMPLES……..
TC TERRYTEX LTD- SATIA GROUP – FACTORY TOUR
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PDQ BOX OR KITCHEN TOWELS PACKAGING……..
TC TERRYTEX LTD- SATIA GROUP – FACTORY TOUR
TC TERRYTEX LTD- SATIA GROUP – FACTORY TOUR
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TC TERRYTEX LTD- SATIA GROUP – FACTORY TOUR
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TC TERRYTEX LTD- SATIA GROUP – FACTORY TOUR
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TC TERRYTEX LTD- SATIA GROUP – FACTORY TOUR
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TC TERRYTEX LTD- SATIA GROUP – FACTORY TOUR
TC TERRYTEX LTD- SATIA GROUP – FACTORY TOUR
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We look Forward to..
…..Accept Challenges & Grow Together
TC TERRYTEX LIMITED
Works Address – Village Sarsini, Near Lalru, Tehsil Dera Bassi,
District SAS Nagar, Mohali – 140501, Punjab, India.
Phone - +91-1762-506606-08,
Fax - +91-1762-506555
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Email – info@tctl.in
Website – www.tctl.in