Khodiyar Tex and Fabrics
Unlocking Higher Output on Existing Machines
Client Snapshot
The Operation
Machine Setup
- Rifa Rapier Jacquard machines (Chinese setup)
- Operating at EPI 200 (Satin Jalla)
The Challenge
What the mill was facing
Operating at EPI 200 on rapier jacquard machines — especially Chinese setups — comes with clear limitations:
- Restricted production output
- Higher yarn breakage under dense configurations
- Increased machine downtime affecting consistency
There is often a belief that such machines cannot deliver significantly higher performance without major capital investment.
AAS Products Deployed
Healds + Spring Assembly Sets
Results Achieved
The numbers speak
Picks Improvement
Downtime Reduction
Yarn Breakage Reduction
Picks Output Achieved
4,67,000+
Picks Performance
Before
3,83,000
After
4,67,000+
Yarn Breakage
Before
Baseline
After
−16%
Downtime
Before
Baseline
After
−12%
Capacity Impact
Before
18 machines output
After
Equivalent to 24 machines
Operational Impact
- Higher output from existing machines without additional investment
- Improved stability in dense satin weaving setups
- Reduced interruptions leading to better production flow
- Increased confidence in pushing machine limits
The deployment increased picks from 3.83 lakh to 4.67 lakh+ per machine, delivering a 22% improvement, along with 16% reduction in yarn breakage and 12% reduction in downtime. The unit effectively achieved 24-machine output from 18 machines, without additional capital investment.
Full ROI achieved in 6 months
Project Gallery
From the installation
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Client Insight
"Jo production pehle possible nahi lagta tha, woh ab consistently mil raha hai. Aaj 18 machines par lagbhag 24 machines ke barabar output mil raha hai — even on Chinese machines with satin jalla jahan 29000 se zyada raaj lage hai.
Business Takeaway
The bigger picture
This case demonstrates that machine limitations are often overestimated.
- Deliver significantly higher output from existing machines
- Operate efficiently at high EPI configurations
- Improve overall production economics without expanding machine capacity
With the right system enhancements, even standard setups can exceed expected performance thresholds.
