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Production of terry towels and bathrobes

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Starting capital – from 10 million rubles.

On the domestic market, one of the most profitable areas is the segment of textiles, which has been rapidly developing in recent years. This is due to the increase in the income of citizens, as well as the massive construction of new buildings and hotels. According to experts, the demand for textile products for the home has grown 2.5 times over the past 3 years. Consequently, this direction has good development prospects.

In the segment of textiles, the predominant are: the production of bedding (sales fluctuate around 35 million sets in 1 year, or about $ 2.5 billion in monetary terms) and terry towels (around $ 350 million in wholesale sales and 450-600 million dollars – retail sale).

Market volumes of production of terry dressing gowns are close to the production of towels and exceed 8 billion rubles. According to the latest estimates, the volume of the terry towel market in our country per year exceeds 55 million square meters. But this figure is not entirely accurate for the reason that it is almost impossible to correctly take into account the percentage of illegal products imported into Russia. The growth rates of this market segment are 6-8%.

Most likely, this business decision will interest investors. Most of the terry towels and bathrobes produced in Russia are of very low quality, while their price is greatly overpriced. Most of the products are imported from Asian countries. At the same time, the percentage of terry products of low quality is 54-56%. Almost all foreign suppliers have a couple of intermediaries, which leads to an increase in the cost of the product.

It turns out that the Russian consumer has to buy what is on the shelves: low-quality inexpensive bathrobes and towels (brought to us from Asian countries: China, India, Pakistan) or expensive high-quality products (most often, these are textiles from European countries, their percentage in this segment – 2.5-3%). According to statisticians, most buyers, regardless of where they live, choose the first of two evils. But identifying the clear leader in annual sales is quite problematic. None of the entrepreneurs in the textile market even tries to reduce the cost of the technological process, while maintaining the high quality of the products.

The demand for towels and bathrobes has always been and will continue to be high, as these are items of paramount importance. Competitiveness in this market segment is minimal, so the dynamics have remained unchanged over the past few years.

One of the leaders of Russian factories for the production of towels and bathrobes from terry is the company “DM-Textile”, which produces more than 6 million square meters of terry products per year, and this is more than one third of the total volume of the domestic market. Also, such domestic manufacturers of terry products as Yartsevsky KhBK, Triotex and Mostekstil are not lagging behind. Experts have no doubt that in the near future a considerable number of medium-sized enterprises will appear in this segment, which can significantly increase competitiveness. Perhaps soon the key technique for attracting a customer base may not be to improve the quality of products, but to lower prices for them.

The range of products manufactured by enterprises working in this direction: towels and dressing gowns made of terry, sets for baths, sets for children, bedding (most often, these are sheets) and simple fabric made of terry (one- and two-sided), cotton velor.

Manufacturing process

The key to the high quality of the manufactured products is the correctly selected raw materials, as well as the choice of dyes that are used in the technological process. In terry products, the presence of a high percentage of artificial fibers is unacceptable, because these products are intended for washing at high temperature conditions, which do not tolerate any synthetics. The only assumption in the production process of terry products is the use of polyester thread in the production of a linen warp.

The most commonly used raw material for the manufacture of terry products is cotton:

  • Texas with long fibers (length can reach up to 7-8 centimeters).
  • South Pakistani (length can reach up to 6 centimeters).

Most manufacturers choose the second option due to its lower cost and excellent performance.

Recently, textiles with the addition of bamboo, more precisely, fibers extracted from its stems, are gaining popularity. Not so long ago, it was imported from Asian countries (Turkey and China), but over the past few years, more and more domestic manufacturers have started their own production of these products. Bamboo fibers are obtained through a step-by-step process of processing the stems using steam and high pressure. Bamboo fabrics, in turn, are obtained in 2 of the most studied ways.

 

 

 

 

 

  1. The first, expensive and high quality: the fibers are combed in special installations in a gentle way. They are rightfully considered to be of high quality and at the same time inexpensive, because expensive equipment is required for their manufacture.
  2. The second option for the production of fabric from bamboo raw materials is breaking the fibers. This process is much easier and takes several times less time, so such products cost an order of magnitude less. But their quality sags a lot in comparison with “combed” products. This is because broken fibers, when they become wet, very often rub against each other, which has a bad effect on the appearance of the product and its service life.

Basically, this method is used to make small and medium sized towels. Beach towels, bathrobes, sheets and other textiles are made from fabrics with the addition of third-party fibers (mainly cotton). This makes it possible to achieve a greater price / quality ratio, while leaving all the quality indicators of bamboo raw materials.

Mahra is a one- or two-sided fabric made of flax, cotton or bamboo fibers, covered with a pile from the loops of the main threads. For example, terry nap is created by the technology of automatic warp feeding, which is slightly stretched, which is why it is so unstable and uneven. In addition, the pile adheres more strongly to the fabric. Therefore, pile fabrics are often denser than terry cloths. But the pile has a slight massage effect, does not cause itching and irritation, and has a good absorption rate. Therefore, it is used to make towels and robes, slippers, bedding, sheets, pillowcases, insoles, and so on.

Terry fabrics differ from each other in the type of thread twisting, in the height of the loops and in density. Both the appearance and the quality of the output products depend on this. The density of terry cloth is measured in gsm. and it lies in the range of 350-800. The higher the density, the fluffier the terry product. Due to the fact that the terry is made mainly from natural raw materials, it often wrinkles.

Organization

To start the production process for the production of terry products, you need to buy equipment:

  1. Weaving machines,
  2. Belt warping and kuftomotalny devices,
  3. Malima,
  4. Plants for grading and sizing.

A full set of foreign used equipment will cost in the region of 2.7-3.2 million rubles. This is the minimum that you can find in all kinds of auctions. The output volume of 1 machine will be in the region of 40 meters in an 8-hour working day.

In addition, factories for the production of terry fabrics additionally master the sewing of all kinds of products. To do this, you need to purchase the following settings:

  • Tape apparatus,
  • Electro-closing installation
  • A couple of sewing machines.

If you are going to make only fabric canvases, then it will be enough to hire 3-5 workers as personnel. If you want to make sewing of textile products, then you need to additionally hire cutters, seamstresses and packers.

Most of the Russian manufacturers like to place orders for the manufacture of textile products for the home outside our country – at Chinese, Pakistani and Indian factories. Basically, all of them are located in the regions where the raw materials necessary for this production are grown. This allows you to significantly save on transportation costs. The labor force there is an order of magnitude cheaper than ours, so the cost of their products, taking into account transportation across the border, is lower than that of domestic products.

Factories for the manufacture of towels and bathrobes from terrycloth sell their products through wholesale buyers, retail chains, specialty stores working on order with restaurant chains, hotel services.

Payback and profitability

According to experts, the start-up capital for an average factory for the production of fabrics from terry using machines and machines of the latest generation is more than 10 million rubles. This includes: the lease of a production area for workshops and storage facilities, the purchase of machines and installations, their installation and repair in case of breakdowns, staff salaries.

The business project implementation time is 1-1.5 years, the payback time is 3-3.5 years.

 

Galileo – Terry towels

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