Sagar Manufacturers Pvt. Ltd., one of India’s leading spinners, has taken its commitment to excellence a step further with Uster FiberQ, an innovative automated raw material management solution. Over the past year, this cutting-edge system has helped the company produce more than 2,000 laydowns, driving consistent yarn quality, optimising fibre yield, and improving operational efficiency. The results have been remarkable, with the company reporting a payback period of just three months.

Known for its high-quality cotton yarns and knitted greige fabrics, Sagar has always prioritised advanced technology and eco-friendly practices to maintain its reputation for excellence. The adoption of Uster FiberQ aligns perfectly with the company’s strategic focus on integrating innovation and automation to achieve manufacturing excellence and customer satisfaction.

Before FiberQ, Sagar already prided itself on effective raw material management. However, the company sought to raise the bar further. “Uster FiberQ is a game-changer in terms of high-quality consistency with minimal production cost,” says A.K. Saini, Chief General Manager Operations at Sagar Manufacturers Pvt. Ltd.

The FiberQ solution combines advanced technology and textile expertise, automating processes traditionally handled manually. This automated system minimises human effort while ensuring consistent results. According to Saini: “FiberQ has ticked all the boxes. We’ve seen improved quality consistency, a reduction in yarn imperfections, and zero quality complaints from customers.”

Tangible results, proven efficiency

Sagar’s experience with FiberQ has yielded impressive outcomes, including better fibre utilisation and significant improvements in yarn quality consistency. The elimination of seldom-occurring faults like white specks and barré underscores the system’s impact. Furthermore, yarn realization increased by 0.3% to 0.5% on average, and the need for ‘cut and creel’ operations has been eliminated, enhancing production efficiency.

Over the past year, FiberQ has facilitated more than 2,000 laydowns across all production units, offering fast and efficient operations. The system also provides easy access to laydown history, allowing visibility into the performance of different cotton lots.

Customer feedback has been overwhelmingly positive. Sagar’s improved quality consistency has enhanced fabric appearance, enabling customers to produce larger, uniform batches of knitted and dyed fabrics while reducing manufacturing costs. Additionally, the ability to offer larger yarn lot sizes with consistent quality and colour properties has strengthened Sagar’s position in the competitive textile market.

Subscription service and advisory support

Uster FiberQ is offered as a yearly subscription service, which includes not only the software solution but also valuable advisory services from Uster’s expert textile technologists. This unique combination provides spinners with continuous support and optimization opportunities.

“The advisory services have been extremely beneficial,” says Saini. “We’ve gained insights from best practices proven in mills worldwide, enabling us to identify greater optimization opportunities.”

These services ensure that a textile engineer with deep mill experience is always available to support customers. From installation to periodic assessments, Uster’s end-to-end approach tracks quality from fiber to yarn. This comprehensive service model is a hallmark of Uster’s commitment to helping spinners achieve sustainable success.

The subscription-based model for FiberQ represents a shift in the industry, introducing a software-as-a-service approach to raw material management. While this concept has been established in other industries, it is relatively new in textiles.

“At Sagar, we are convinced that the value we get from this solution completely justifies the recurring investment,” states Saini. By renewing its FiberQ subscription, Sagar underscores its confidence in the system and its potential to drive ongoing improvements.

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