- Plot 3079, Phase-3, GIDC Chhatral, Ta. Kalol, Dist. Gandhinagar, Gujarat, India
- +91 9925027798
rohan@DFRtextiles.com
Nestled within a sprawling 13,000 square feet expanse, our cutting-edge manufacturing facility stands as a testament to our unwavering commitment to excellence. Strategically located a mere 35 kilometers from Ahmedabad city, our facility serves as a hub of innovation and precision. With an integrated approach, we offer a comprehensive range of capabilities, encompassing weaving preparatory to fabric finishing, all conveniently housed under one roof. This seamless integration allows us to streamline production processes, ensuring optimal efficiency and meticulous attention to detail at every step.
We source raw materials such as yarn and fiber from reputable manufacturers, both in India and abroad. Our meticulous approach considers various critical parameters including yarn tenacity, twists, filament count, CSP (cotton system of parameters), fiber length, and diameter. These parameters are carefully determined to align with the specific applications of our fabrics, ensuring optimal performance and delivering maximum value to our customers.
Below is a short description of various departments at our manufacturing facility.
Our yarn twisting department is equipped
with advanced machinery, including a 144-
spindle TFO (Two-for-One) machine and a 12-
spindle drum winder. This department plays
a crucial role in our manufacturing process as
it is responsible for imparting twists to the
flat yarns we acquire.
Twisting yarns is a critical step in the weaving
process, offering several benefits. Firstly,
twisting enhances the strength and durability
of the yarn, resulting in a more robust and
reliable final fabric product. Additionally,
twisting improves the yarn's cohesion,
reducing the likelihood of fraying or
unraveling during weaving. It also promotes
better yarn elasticity and resilience, allowing
for improved weaving efficiency and
performance.
Our weaving preparatory department boasts cutting-edge
technology, with a state-of-the-art sectional warping
machine at its core. This advanced machine allows us to
achieve exceptional precision and efficiency in preparing the
yarns for weaving.
With a special 600-spools creel, each equipped with an
electronic tension-controlled device, we can effortlessly
handle a wide range of yarn types and diameters. From
smaller diameter monofilaments to larger count
multifilament and spun yarns, our creel system ensures
optimal yarn handling and tension control. The warping
machine is equipped with additional features such as a
separate waxing device, static eliminator unit, and pressure
roller system, all aimed at enhancing the quality and
performance of the warping process.
Our sectional warping machine incorporates innovative
drum construction, designed to withstand high crushing
force. It features direct drive on both sides of the drum,
ensuring optimum transmission efficiency and enabling
higher beaming tension. To achieve precise and accurate
warping, the machine is equipped with an online laser yarn
built-up monitoring system, allowing for real-time
monitoring and adjustment as needed.
In addition, all our beams used in the warping process are
German-made Q4 category, renowned for their exceptional
performance and durability. These beams are specifically
designed to handle the highest levels of tension required in
warping, making them ideal for various applications,
particularly the handling of monofilaments. With these
premium quality beams, we ensure optimal stability and
reliability throughout the warping process, resulting in
superior quality fabrics that meet the highest industry
standards.
Our weaving department is equipped with state-of-the-art Germanmade Dornier rapier machines, renowned for their exceptional
performance in the production of our technical fabrics. These brand
new machines provide us with a competitive advantage in weaving
high cover factor fabrics and handling various types of
monofilaments with ease.
One of the distinguishing features of Dornier machines is their high
beat-up force, coupled with German metallurgy. This combination
enables us to achieve superior weaving results, including fabrics
with high compactness and low air permeability. Compared to
fabrics woven on conventional weaving machines, those woven on
Dornier machines exhibit outstanding quality and performance.
It's worth mentioning that all our Dornier weaving machines are
brand new. We do not rely on second-hand Dornier machines
dismantled from Europe, which is a common practice in the
technical textiles industry to mitigate the high capital costs
associated with acquiring new machines. By investing in new
Dornier machines, we ensure consistent quality and reliability in our
weaving processes, resulting in top-notch technical fabrics.
To further enhance our capabilities, we utilize the advanced
batching system from Neuenhauser, Germany. This system allows us
to produce large jointless fabric rolls, exceeding 2000 meters if
required by our customers. This ensures seamless, uninterrupted
production and facilitates efficient handling and logistics.
At DFR Technical Textiles, we prioritize quality
and precision in every aspect of our operations,
including our dedicated testing department.
With our in-house testing facility, we ensure
that our fabrics meet the highest standards of
performance and reliability.
Air permeability is a crucial factor in many
applications, and to guarantee optimal air
permeability, we utilize Swiss-made AP testers
from Textest, renowned for their exceptional
quality and accuracy. These state-of-the-art
testers are considered the best in the world,
allowing us to measure and maintain the perfect
air permeability of our fabrics.
In addition to air permeability, our testing
facility is equipped to assess various other
essential fabric properties. We have the
capability to measure tensile strength, hot air
shrinkage, thickness, and weight (GSM)
accurately. By conducting rigorous testing using
advanced equipment, we ensure that our fabrics
meet or exceed the required specifications for
each application.
Our fabric inspection department plays a vital
role in maintaining the impeccable quality of
our fabrics. Equipped with a state-of-the-art
fabric inspection cum rolling machine, we
ensure that every inch of fabric is thoroughly
examined for any defects, guaranteeing the
highest standard of excellence.
While our fabrics woven on the high precision
Dornier machines boast exceptional quality with
minimal defects, our fabric inspection process
provides an additional layer of assurance. Our
skilled team meticulously inspects the fabric,
examining it for any imperfections or
irregularities. In the rare event that a defect is
identified, our team promptly addresses it
through careful mending, ensuring that only
flawless fabrics leave our facility.
The fabric inspection cum rolling machine also
serves another important purpose. It allows us
to efficiently create smaller rolls from our large
batched fabric rolls, which can exceed 2000
meters. By utilizing this machine, we can
produce convenient 100-meter rolls that are
ready for immediate use, providing practicality
and ease of handling for our customers.
In our fabric processing department, we
understand the significance of the
calendaring process and its impact on the
performance of filtration fabrics. To ensure
utmost control and precision, we have
installed an advanced calender machine inhouse.
Our calender machine allows us to conduct
calendaring with exceptionally high pressure,
ensuring precise and consistent results. This
process plays a crucial role in optimizing the
characteristics of our filtration fabrics. It
enables us to adjust the air permeability of
the fabric, ensuring the ideal balance
between filtration efficiency and airflow.
Additionally, calendaring helps us achieve a
smooth surface texture, facilitating easy cake
discharge during filtration operations.
In our made ups department, we are committed to
providing end-users with comprehensive solutions
for their filtration needs. To achieve this, we have
established a dedicated cutting and stitching
department equipped with cutting-edge machinery
and equipment.
To ensure the highest level of quality and precision
in our stitching operations, we exclusively utilize
JUKI stitching machines, renowned for their
reliability and performance. These machines enable
us to deliver durable and well-crafted filter press
cloths, centrifuge cloths, belt filters, and other
filtration products.
As part of our commitment to meeting our
customers' specific requirements, we offer both
filtration fabrics and ready-to-use filter made ups.
Our state-of-the-art laser cutting machine plays a
crucial role in this process. By utilizing precise CAD
files, the machine accurately cuts the fabric into
various sizes, eliminating any chances of manual
error associated with traditional hand cutting
methods. This automated process ensures
consistent quality and exacting specifications for
each filtration product we produce.
To further enhance our capabilities, we have
invested in an automatic eyelet fixing machine from
Fepatex Netherlands. This machine efficiently and
accurately fixes eyelets to the filtration fabric,
providing added convenience and ease of use for
our customers.
