Himanshu Thukral
Managing Director Lion Fabrics Private Limited
Creating premium and innovative products
Lion Fabrics Private Limited was incorporated in 2014 by HR Thukral Group with an aim to provide the finest quality of denim fabrics. With the use of modern technology, industry standards, timely and quality deliveries, and an experienced workforce, the company believes in creating the best products that translate into smiles on the customers’ faces. Managing Director Himanshu Thukral speaks to Fibre2Fashion about denim manufacturing and the company’s USP.
Tell us about how you established Lion Fabrics and the objective behind it?
Denim has always been an integral part of the Lion Group. Our journey started in 1988 when Arvind Mills had set up the first denim plant in India. At that time, my father started his own denim distribution brand under the name Lion Jeans. He successfully created the brand in more than 15 states. In the later part of the Aughts decade, we ventured into the fabric business. In 2015 our journey towards backward integration into producing denim fabric started and in 2018 the first denim fabric rolled out from our factory in Bhopal.
Being associated with denims for more than 30 years, working closely at garment and fabric level, our objective was clear from day one, i.e., to provide the finest quality of fabric which can be transformed into an exquisite pair of jeans.
Which are your major markets in India and abroad?
Since inception the primary focus is to create premium and innovative products. Organised brand segment in India, majorly operating from Bengaluru, are our major customers. They appreciate the newness and are open to innovative products. Post pandemic there has been a stronger demand for sustainable fabrics from international brands. For the last couple of years, we have been closely working with factories from Bangladesh for developing sustainable products.
What are the major trends in denim in terms of stretch, colour, wash, weave and fabric compositions?
Recent increase in cotton prices has disrupted the entire textile supply chain. But disruption always leads to innovation and denim is no exception. For the replacement of cotton fibres, numerous man-made fibres like viscose and polyester yarns have been used, which has opened a new door for innovation. In terms of product, it has further improved fabrics’ strength and comfortability. In domestic market, dobby structures with high stretchability are doing good in the premium segment, with basic twill structure. Youthful brands demand vibrant over dyed fabrics with an increase in stretchability to enhance comfort. As denim is being used in offices and is worn for longer hours, high stretchability plays an important role in maintaining flexibility and comfort.
Has the pandemic had any impact on the demand for denim? If yes, how?
Denim demand declined, especially post first COVID-19 wave due to work from home, as activewear was more in demand. But since last year the demand is back and companies have developed high stretchable products to match the demand for comfort.
What new technologies in denim manufacturing are you exploring?
In addition to indigo, these days brands are demanding a wider basket of vibrant colours. Blue will always retain its legacy, but the youth want more colours in the denim fabrics for their daily wear. We are expanding our infrastructure in dyeing and processing to provide for such fabrics.
How do you incorporate sustainability into your operations and products?
There is a saying that we haven’t inherited resources from our ancestors but have borrowed them from our children. At Lion Fabrics we truly believe in this statement. Sustainability is not only using recycled raw materials such as yarns and dyeing chemicals, but also a more holistic approach towards all actions that we take every day. Since the state of Madhya Pradesh receives a good amount of rain every year, for our water needs we have constructed a rainwater harvesting tank in 16,000 square metres with a capacity to store 100 million litres. We have also installed a fully integrated ZLD (zero-liquid discharge) plant which results in 98 per cent water recovery. Further, to reduce our carbon footprint in terms of energy used, we are installing 2 MegaWatt solar plants.
How big is your capacity and what is your USP?
Our annual production capacity is 15 million metres. The infrastructure is designed to produce finest fabrics. Rope dyeing to dobby looms to the latest technology in finishing machines help us differentiate from our competitors and make our products stand apart. Having a smaller capacity has its own strengths such as:
1.New product development cycle happens at a faster pace.
2.Adaptation to new processes and systems is quick.
3.Flexibility in MOQ (minimum order quantity). We can cater to smaller order quantities in a wide range of fabrics for brands.
4.Given our sustainable practices in energy, water and raw materials, we are environmentally friendly.
5.Geographically located in the central part of India.
What is your growth for the last two years? What is the target set for the next two?
In the last fiscal year, the company witnessed a significant improvement in top line as well as bottom line. The top line increased by 42 per cent compared to the previous financial year. The export sales increased by 145 per cent year-on-year (YoY) in FY22. In terms of volume there was a growth of 29 per cent YoY. This year also, we are expecting a higher revenue. In the first quarter of FY23, there was an improvement in the top line by 27 per cent compared to the previous quarter. Additionally, we are planning to increase our capacity, which will generate more revenue in the coming years.
Where do you see Lion Fabrics in the next 3 to 5 years?
In the near future, we are expanding our current production capacity with a forward integration plan to set up a garmenting unit. Madhya Pradesh, due to its policies and geography, is an ideal place for garment units and very soon a lot of prominent garment manufacturers in the country are likely to expand in the region.
By 2027, we should be a ₹1,000-crore company, fully integrated from fibre to a finished garment creating an ethos of innovation, transparency and environment friendly.
Published on: 05/12/2022
DISCLAIMER: All views and opinions expressed in this column are solely of the interviewee, and they do not reflect in any way the opinion of Fibre2Fashion.com.
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