Vandenaari Sarees
Precision Control Driving Fabric Quality and Performance
Client Snapshot
The Operation
Machine Setup
- 32 Picanol Ultimax Jacquard machines
- Operating at EPI 198
The Challenge
What the mill was facing
At EPI 198, maintaining consistent performance across multiple machines requires high levels of control and alignment. The unit was facing:
- Limitations in achieving higher picks consistently
- Machine downtime affecting production flow
- Yarn stress and breakage in dense weaving conditions
- Variations impacting fabric consistency and finish
In high-precision setups, even minor misalignments can lead to compounding inefficiencies.
AAS Products Deployed
Healds + Spring Assembly Sets across 32 Picanol Ultimax Jacquard machines
Results Achieved
The numbers speak
Picks Improvement
Downtime Reduction
Yarn Breakage Reduction
Picks Output Achieved
7,00,000+
Picks Output
Before
Baseline
After
7,00,000+
Picks Improvement
Before
Baseline
After
+25%
Yarn Breakage
Before
Baseline
After
−16%
Downtime
Before
Baseline
After
−19%
Operational Impact
- Improved alignment and controlled movement across machines
- Reduced variation leading to more consistent fabric output
- Lower yarn stress resulting in smoother weaving cycles
- Ability to maintain high-speed stability at dense configurations
Across all 32 Picanol Ultimax machines, the deployment delivered a 25% increase in picks reaching 7,00,000+ per machine, along with 16% reduction in yarn breakage and 19% reduction in downtime. Fabric consistency and finish quality improved measurably through better alignment and controlled system behaviour.
Full ROI achieved in 6 months
Project Gallery
From the installation
Client Insight
"When alignment and control are right, performance follows. The system has improved both machine stability and fabric quality.
Business Takeaway
The bigger picture
In high-end weaving setups, performance is not limited by machines — but by how precisely the system is controlled.
- Even advanced machines can deliver higher output with better system alignment
- Better alignment leads to less downtime and yarn stress
- Fabric quality improves with consistent system behaviour
Precision in setup directly translates into production and quality gains.
