Technical Textiles with Application for Defence Textiles Government of Gujarat
Contents Project Concept 3 Market Potential 7 Growth Drivers 9 Gujarat Competitive Advantage 10 Project Information 11 - Location/ Size - Infrastructure Availability/ Connectivity - Raw Material/ Manpower - Key Players/ Major Fabric Suppliers - Potential Collaboration Opportunities - Key Considerations Project Financials 21 Approvals & Incentives 22 Page 2
Project Concept Technical Textiles in Defence Project concept The project envisages to setup a manufacturing unit of technical textile Defencetech/ Protech products and its application in defence sector, based on the growing demand and easy availability of raw materials, infrastructure, and established supply chain setup in Gujarat. What is technical textile for Defence? Technical textiles that are used in the defence sector are called Defencetech. These are speciality textiles that provide safety to the wearer during high-risk engagements like protection from bullets and explosions, and also from extreme atmospheric conditions. Defencetech primarily forms a part of Protech (protective clothing) and also consists of some products of Sportech (technical textiles used for sports purposes) and Buildtech (construction textile components and fabrics used in building and construction industry). The Ministry of Defence (Government of India) is one of the major consumer of Defencetech for the use of armed forces. What comprises Defencetech? Bullet proof jackets High altitude clothing Tarpaulins Nuclear Biological & Chemical suits Sleeping bags Tents Baseline survey of the Technical Textile industry in India, Office of the Textile Commissioner, 2 July 2016 An Overview, technicaltextile.gov.in website, http://www.technicaltextile.gov.in/overview.html, 3 July 2016 Support to Technical Textiles (para no 6 ), Industries Commissionerate website, http://ic.gujarat.gov.in/?page_id=2300, 2 July 2016 Page 3
Market Potential Market overview of Defence tech in India The entire market of Defencetech is mostly catered by domestic production with imports accounting for minimal share. There is high potential for growth of Defencetech due to growing terror threats across the world as well as policy initiatives undertaken by the national governments aiming to provide better safety measures to soldiers and army personnel. The procurement of majority of the products, including bullet-proof jackets, high-altitude clothing, sleeping bags, tents and tarpaulins, by the India s Ministry of Defence, is approximately 2/3rd of the total procurement. 0.99 Market size of Defencetech* (INR billion) 0.87 15.75 16.88 0.97 19.5 2012-13 2013-14 2015-16 (F) Domestic consumption Exports *Derived on the basis of markets for key products (bullet proof jackets, high altitude clothing, sleeping bags, tents, tarpaulins, NBC suits) Defence Ministry s growing expenditure on technical textiles Annual purchases made by the Ministry of defence (INR billion) 2.9 3.2 32 3.8 The annual purchases of technical textiles are expected to rise at 9% CAGR to ~INR3.8 billion during 2015 16, led by growing demand for the key products used by the defence personnel. Bullet proof jackets and high-altitude clothing accounts for the majority of the purchases. 2012-2013 2013-2014 2015-2016 (F) Textile market potential - Gujarat Baseline survey of the Technical Textile industry in India, Office of the Textile Commissioner, 2 July 2016 Protech (Protective and safety clothing and textiles), Office of the Textile Commissioner website, http://www.technicaltextile.gov.in/protech.html, 2 July 2016 Gujarat, the growth engine of India, http://www.ibef.org/download/gujarat-november-2015.pdf, 2 July 2016 Annual Repot, Shrilakshmi Cotsyn Limited, http://www.shrilakshmi.in/financial/annual-report-2014-15.pdf 2016 Top Markets Report Technical Textiles, International Trade Administration website, http://trade.gov/topmarkets/pdf/textiles_top_markets_report.pdf, 2 July 2016 The Government of Gujarat plans to invest US$3.28 billion in the textile industry by 2020 and create one million jobs in the industry. Textile exports in 2013, accounted for 12% in Gujarat and aims to increase the exports to 25% by 2017. Gujarat contributes over one-fourth of India s technical textile overall production output, and is expected to increase to 50% by 2020. Page 4
Market Potential Market size of key products of Defencetech in India 0.54 Market size of bullet proof jackets (INR billion) 0.57 4.69 5.25 0.63 6.58 2012-13 2013-14 2015-16 (P) Domestic consumption Exports Government taking initiatives towards procurement of high-altitude clothing Significant shortfall of bullet proof jackets in India In India, the potential for usage of bullet proof jackets is very high. India has a 1.18 million strong army and there is a requirement of 3.53 lakh bullet proof jackets. The government is taking significant steps for procurement of 1.8 lakh bullet proof jackets by 2017. The existing supply is still behind the mandatory target of the adequate number of bullet proof jackets in India. India s market size of high-altitude clothing (INR billion) High altitude clothing is majorly used by the army for protection against extreme weather conditions like extremely low temperature, high velocity winds, snow fall. Under the Make in India initiative, the government is encouraging Indian suppliers for the first time to give the samples of their products for super high altitude clothing to the army for soldiers at Siachen. 6.09 6.58 7.68 India s market size of sleeping bags (INR billion) 2012-13 2013-14 2015-16 (F) Growing demand for sleeping bags 0.11 0.11 0.24 0.28 0.11 0.37 It is mandatory for all soldiers to have a sleeping bag. The replacement market for armed forces is the major demand for sleeping bags that offers high demand growth and the market is expected to grow at 11% CAGR over 2012-16. Page 5 2012-13 2013-14 2015-16 (P) Domestic consumption Exports Baseline survey of the Technical Textile industry in India, Office of the Textile Commissioner, 2 July 2016 Protech (Protective and safety clothing and textiles), Office of the Textile Commissioner website, http://www.technicaltextile.gov.in/protech.html, 2 July 2016 Gujarat, the growth engine of India, http://www.ibef.org/download/gujarat-november-2015.pdf, 2 July 2016 Textiles, http://trade.gov/topmarkets/pdf/textiles_top_markets_report.pdf, 2 July 2016 http://indianexpress.com/article/india/india-news-india/coming-soon-make-in-india-special-clothing-for-soldiers-at-the-worlds-highest-battlefield/ http://www.ibtimes.co.in/indian-army-soldiers-get-bullet-proof-jackets-after-decade-672763 http://indianexpress.com/article/india/india-news-india/coming-soon-make-in-india-special-clothing-for-soldiers-at-the-worlds-highest-battlefield/
Growth Drivers During 2008-2013, the exports of technical textile witnessed a surge as it grew at a CAGR of ~27%. It is further expected to grow at a similar rate driven by large demand of technical textiles in the international markets. Exports for technical textiles (INR billion) Incentives provided to textile and apparel sector from the Government of Gujarat (INR million) 3,900 71.2 21.7 1,340 68 76 100 400 FY11 FY12 FY13 FY14 FY15 FY16 FY08 FY13 During FY16, incentives provided increased ~3 times Y-o-Y and are expected to rise further. Growing demand from Defence tech Demand for protective clothing has increased significantly due to growing emphasis on health and safety of military personnel. Protective clothing is lightweight, perform better and yet they are strong and durable. Domestic market for bullet proof jackets is expected to grow at 12% per annum during 2016 19. Due to change in norms regarding requirement of minimum number of bullet proof jackets, the overall market share is expected to rise. Page 6 Growing emphasis on health & safety of armed forces High growth potential for bullet proof jackets Expected rise in exports Rise in terror threats Baseline survey of the Technical Textile industry in India, Office of the Textile Commissioner, 2 July 2016 Indian diaper market to witness rapid growth in near future, VC Circle, 2 September via Factiva Manufacturing Sector Profile, Vibrant Gujarat website, 7 October 2014 India is a net exporter of protective clothing and the growth in its exports has been 66% from the period 2007 08 to 2012 13. The higher growth is expected due to increase in demand of protective clothing for defence from other countries. Due to constant warnings of terror threats as well as recent terror attacks across the world, there is growing concern for undertaking more safety measures and tight security, due to which the demand for Defencetech is expected to rise.
Gujarat - Competitive Advantage Gujarat has a very established textile sector with more than 1,500 medium and large textile units and 18 textile-related product clusters. Major units of technical textiles are mainly concentrated in Ahmedabad, Surat, Vadodara and Kutch. The large number of textile units is attributable to high availability of raw material as Gujarat is the largest producer of cotton in the country with production of ~100 lac bales. Approximately one-third of the cotton is produced in Gujarat and it also accounts for more than half of the petrochemical output of India. Gujarat also has large number of manpower with required skill set attributable to better educational infrastructure and Industrial Training Institutes. Surendrana gar, Manavadar and Gondal Kutch Saurashtra Textile Hubs in Gujarat Ahmedabad Ankaleshwar Surat Gujarat governments' initiatives to flourish the textile industry The Government of Gujarat intends to invest ~US$3.28 billion in the textile industry by 2020. It aims to create 2.5 million jobs in the industry. The Government is planning to introduce Technical Textile Mission to attract an investment of ~US$1.6 billion (~INR 100 billion) for establishing at least 2,000 technical textile manufacturing facilities. Two new Technical Textile (TT) zones to be developed in Ahmedabad and Surat district. Three dedicated textile SEZs in Ahmedabad are also planned Vibrant Gujarat Summit 2015," 3 July 2016. A report on Chemical industry, Tata Strategic Management Group, 3 July 2016 Page 7
Project Information Project at a Glance Location Area Mehsana, Gujarat 4500 sq. km. Project site Mehsana (Gujarat) 9 sub-districts 10 towns 606 villages 9 CD blocks Mehsana is one of the 33 districts of Gujarat and is located in the northern part of the state with a geographical spread of 4500 km 2. The district shares border with Banaskantha district in the north; Ahmedabad and Gandhinagar districts in the south; Patan and Surendranagar in west; and Sabarkantha district in east. The district is strategically located and is at a distance of around 75 km from Ahmedabad. Over the last few years, the district has seen significant industrial development. Mehsana is divided into nine sub-districts. Among these, industrial development is mainly concentrated in Kadi and Mehsana Taluka, while other regions like Kheralu, Vadnagar and Satlasana still remain backward. Some of the textile companies based in Mehsana are; Sanrhea Technical Textile Aeon Nonwovens Private Ltd. Ashima Ltd Unit fabrics (cotton cloth) J K Polymers Uranus Internationals Location suggested: Kadi Industrial area Mehsana district consists of many industrial areas, including Mehsana-II, Kadi, Visnagar and Kukarwada. Below are the details of the three major industrial estates. Page 8 Industrial area Area (In Hectares) Rate Per Sq m (INR, FY13) Kadi 79.57 435 Mehsana-II 126.69 1,440 Mehsana-I 46.52 1,725 Kadi can be a suitable location to setup the plant as the land prices are relatively cheaper and it is also a hub for cotton with over 100 cotton mills in operation and is known as Cotton City of India.
Project Information Logistics & Connectivity Mehsana is well-connected with different parts of Gujarat as well as with other states in India Rail Road Mehsana is connected with other districts of the state like Patan, Porbandar and Ahmedabad by rail. It is further connected to Kandla port via rail network through Ahmedabad and Gandhidham. Mehsana has a 51 km four-lane toll road connecting it with Ahmedabad, Gujarat. The district is well-connected with Gandhinagar (68km), Vapi (458 km), Palanpur (72km), Rajkot (299km) and Surendranagar (143km). Air Port The nearest airport to the district is the domestic and international airport at Ahmedabad located at a distance of 77km. The nearest port is at Dholera, 110 kms from Ahmedabad. The port has potential to cater to ship building and ship repairing industries; offers opportunity for developing berths for salt export. Dholera is being promoted as the Special Investment Region for Gujarat. Utility Water Power Water for industrial purposes can be obtained from four sources viz. Gujarat Water Supply and Sewerage Board (GWSSB), an irrigation canal, dams, and The main source for the power supply is Gujarat Energy Transmission Corporation Limited. surface reservoirs. http://www.mapsofindia.com/maps/gujarat/districts/mehsana.htm http://www.nsdcindia.org/sites/default/files/files/gujarat-sg-report.pdf http://dholera-sir.in/dmicgujarat.html Page 9
Project Information Manufacturing process: Example - Bullet proof jacket Layers of fibers A bulletproof jacket comprises a vest-shaped sheet of advanced plastics polymers composed of many layers of either Kevlar (thread produced by spinning a solid fiber from a liquid chemical blend) or Spectra Shield. The layers of woven Kevlar are sewn together using Kevlar thread, while the non-woven Spectra Shield is coated and bonded with resins and then sealed between two sheets of polyethylene film. Making of panels Kevlar threads are fed into a machine which wraps and stretches them into yarn (a long continuous length of interlocked threads) which is then weaved in large industrial processing machines. By this process, ballistic material manufacturers produce the final sheet material from which bullet proof panels are made. While Spectra used in bullet proof jackets is usually non-woven and its panels are cut and stacked in layers. The panel provides protection and is placed inside of a fabric protective cover/ shell that is made from a polyester/cotton blend or nylon. The end product An industrial cutting press is used to cut multiple layers of ballistic material to make bullet proof panels, which are then put into a protective cover/ shell. The protective cover/ shell is either sewn or heat-sealed in order to protect the ballistic material inside against moisture. How to make a bullet proof vest?, http://www.bodyarmornews.com/how-to-make-a-bullet-proof-vest/, accessed 28 August 2016; Bulletproof vest, http://www.madehow.com/volume-1/bulletproof-vest.html, accessed 28 August 2016. Page 10 Quality check A bulletproof jacket undergoes stringent protection testing processes against the lead bullets at low/ high velocity. The jackets are also tested both wet and dry, as the fibers used to make a vest perform differently when wet.
Project Information Raw material requirements: Example - Bullet proof jacket Raw Material Kevlar fabric Spectra Shield Kevlar thread Kraton rasin Polyethylene film Polyester/ cotton blend fabric Nylon padding Metal/ ceramic bonded/ fiberglass plates Elastic webbing Metallic buckles Velcro closures Manufacturer/ Supplier National Safety Solution (Mumbai), Speciality Safety Engineers (Mumbai), Core Safety Group (Mumbai), Super Safety Services (Mumbai) Polyone Polymers India Private Limited (Mumbai) R. V. Plast (Ahmedabad), Baroda Packaging (Mumbai), Shah Plastics (Pondicherry) Vaibhav Laxmi Textiles (Surat), Parvati Creation (Surat), Nirav Silk Mills Private Limited (Mumbai) Creative Carbon Private Limited (Ahmedabad), Nylopick Industries (Ahmedabad), R. P. Tex (Ahmedabad) Bhagwati Forge Industries (Bharuch), Diamond Metal Corporation (Ankleshwar), B. S. Engineers (Ahmedabad) Sun Narrow Fab Pvt. Ltd. (Surat), Viken Tape Private Limited (Surat) Harilal Lakhamshi Industries Private Limited (Ahmedabad), Ejeyes Components Private Limited (Mumbai) Kamlesh Industries (Ahmedabad), Mahavir Traders (Mumbai) Manpower requirement: Example - Bullet proof jacket Responsibility Number Manager 1 Supervisor 3 Clerk 2 Sewers 30 Quality check 2 Product Tesing 2 Packaging and shipping 2 Total 42 Page 11 How to make a bullet proof vest?, http://www.bodyarmornews.com/how-to-make-a-bullet-proof-vest/, accessed 28 August 2016; Bulletproof vest, http://www.madehow.com/volume-1/bulletproof-vest.html, accessed 28 August 2016.
Project Information Major players Product wise Key products Bullet Proof Jackets High Altitude Clothing Sleeping bags NBC suits Tents List of leading machinery suppliers Product Supplier Name Machinery used Location Tarpaulin Bullet proof jackets Tents Key considerations Gujarat Machinery Pvt. Ltd. Shri Gurukrupa Engineering Works Shenzhen Jiazhao Hightech Co., Ltd. Shenzhen Sinopwr Machine Ltd. Key players Shri Lakshmi Cotsyn Defence, TATA Advanced Materials, Anjani Technoplast, MKU Pvt. Ltd, SMPP Pvt. Ltd., Start Wire (India) Ltd. Shri Lakshmi Cotsyn Defence, Entermonde Polycoaters, Ordnance Factory Board, Kusumgar Corporates: K C international, Standard Newar Mills, Tirupati Taxco Pvt. Ltd., Naveen Textile agencies, Shri Lakshmi Cotsyn Defence Ordnance Factory Board, Shri Lakshmi Cotsyn Defence A V enterprises, Standard Newar Mills, Tirupati Taxco Pvt. Ltd. and K C International. Tarpaulin Manufacturing Machine HDPE tarpaulin heat cutting machine High frequency Bullet proof Jacket making machine High frequency welding tents making machine Ahmedabad, Gujarat Vadodara, Gujarat Guangdong, China Guangdong, China Inadequate awareness about the benefits of technical textiles among end-users which is hampering the potential demand of technical textiles in India Absence of defined standards and regulations promoting usage of products made from technical textiles, which leads to lack of sufficient demand for technical textiles. Lack of indigenous availability of specialised raw-materials hampering cost competitiveness Lack of skilled manpower for new technologies like nonwovens Lack of technology/consultancy support to manufacturers of technical textiles Potential collaboration opportunities Global and Indian Defencetech/ Protech product manufacturers can either setup their own manufacturing units or can outsource the manufacturing of Defencetech/ Protech products to contract manufacturers to realize cost benefits. Defencetech/ Protech product manufacturers can also collaborate with research institutes like Ahmedabad Textile Industrial Research Association (ATIRA), Apparel and Leather Technics (ALT) Training College and National Institute of Design (NID) for manufacturing speciality products. Page 12 Gujarat Growth and Prosperity for All, Vibrant Gujarat website, 25 August 2014 Manufacturing Sector Profile, Vibrant Gujarat website, 7 October 2014
Project Financials Cost of setting-up a bullet proof vest manufacturing (annual capacity: 50,000 units) facility in Mehsana will be ~INR100 crores Project specifications INR Crore % of overall cost Land (17,000 sq mt @ INR ~580 per sq mt as of 2016) 1 1% Plant and machinery 70 70% Utility and other equipment 5 5% Miscellaneous fixed assets 7 7% Contingencies 3 3% Preliminary and pre-operative expenses 4 4% Margin money for working capital 10 10% Total cost 100 100% Payback period Annual production (number of bullet proof jackets) 50,000 Revenue per unit industry average (INR) 28,000 EBITDA margin industry average (FY15)* 11.0% Expected growth rate of Indian bullet proof jacket industry (FY12-16) 11.2% Example of a planned set-up in Kadi, Mehsana Page 13 Time (years) 1 2 3 4 5 6 Revenue (INR crore) 140.0 155.7 173.1 192.5 214.1 238.0 EBITDA (@11% of revenue)= Cash flows 15.4 17.1 19.0 21.2 23.5 26.2 Cumulative cash flows 15.4 32.5 51.6 72.7 96.3 122.5 Investment (INR crore) 100 Estimated payback period: ~5 years *Note: Average margin of Indian defence equipment market players Minimum viable size Fixed cost (30% of revenue INR crore) 42.0 Variable cost (60% of revenue INR crore) 84.0 Variable cost per unit (INR) 16,800 Minimum viable size: fixed cost/(revenue per unit-variable cost per unit) 37,500 units Bangladesh plans to set up a textile park in Mehsana, Gujarat; Bangladesh is planning to set up a textile park in Kadi, Mehsana which will involve an initial investment of INR2.4 3 billion. The proposed park will have spinning units with cumulative capacity of 1 lakh spindles. The country has sought around 100 acres of land from the Gujarat s government for the project. Honeywell Announces $20 Million Investment to Address Growing Demand For Spectra Fiber, June 2004, Defense industry bright spark: MKU, Stratpost, April 2012,
Approvals & Incentives Approvals For approvals, the project report should be submitted to respective District Industries Centres (DICs). DIC will forward the proposal to Industries Commissioner who will submit the report to State Level Approver Committee (SLAC) for final approval. Incentives from Government of Gujarat 5% interest subsidy on bank loans for five years for those who establish new plants for value addition chain like ginning, processing, weaving, knitting and machine carpeting. 7% interest subsidy on new plant and machinery for five years for cotton spinning, garment manufacturing and technology up gradation. Refund of value added tax (VAT) on expansion of new units in spinning and power tariff concession to cotton spinning and weaving units. Financial assistance for skill development centres, for technology acquisition and also for supporting energy and water conservation as well as for environmental compliance. Incentives from Government of India 5% credit linked interest subsidy under TUFS (Technology Up gradation Fund Scheme) scheme on purchase of Technical textile machinery approved by government Scheme for Integrated Textile Parks (SITP) : 40% capital subsidy to a maximum of INR40 crore on total project cost on projects approved by government. Also, 100% FDI allowed for textile sector The basic custom duty on imported technical textile machinery has been reduced from 10% to 5% and support to start-ups Source: Gujarat Textile Policy, Industries and Mines Department, Government of Gujarat, 5 September 2012 Manufacturing Sector Profile, Vibrant Gujarat website, 7 October 2014 Page 14
Ministry of Textiles, Government of India http://technotex.gov.in/ Industries & Mines Department www.imd-gujarat.gov.in Gujarat Industrial Development Corporation www.gidc.gov.in Office of Industries Commissioner www.ic.gujarat.gov.in Industrial Extension Bureau www.indextb.com Controllerate of Quality Assurance (Textiles and Clothing) www.dgqadefence.gov.in This project profile is based on preliminary study to facilitate prospective entrepreneurs to assess a prima facie scope. It is, however, advisable to get a detailed feasibility study prepared before taking a final investment decision. Office of The Industries Commissionerate Block No. 1, 2nd Floor, Udyog Bhavan, Gandhinagar 382 010. Gujarat Ph.: 23252683/23252617 Email ID: iccord@gujarat.gov.in