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White page Bangalore .pdf


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White Paper on
Bangalore Garment
Manufacturing
Industry
2010

2

About us

Our
Services
Market Analysis
Trade Analysis
Training and Consultancy
Seminars and Workshops
Industry targeted events
– Fairs, Buyer Seller
Meets
Fashion and Product
designing
Colour and Trend
Forecasting
Print and web magazines
Fashion Forward Trends
(FFT)
Apparel Online India
Apparel Online
Bangladesh
Stitch World
Resource Guide

Apparel Resources is as an organization with
over two decades of deep interaction with
the Apparel and Textile industry in the Indian
subcontinent under the name and style Apparel
Resources. We are an established name as a
knowledge partner to not only the industry but
also to the academicians and students. The
organization is actively involved in Research &
Development, Industrial Training and Consultancy
initiatives. Apparel Resources has been involved
in conducting surveys, publishing annual Top
100 rating of companies in the garment industry
besides insightful research/ analysis of textile
and apparel trade statistics, especially related to
global trade.

3

Scope of
White Paper
Every manufacturing region has some core
strengths and buyers world over not only
appreciate but expect certain benchmarks from
each of these hubs. Among the most progressive
and organized garment manufacturing regions
in India today is Karnataka, more specifically
Bangalore. Known for core strengths in structured
garments this manufacturing base is feeding both
international buyers and domestic brands.
The White Paper analyses what makes Bangalore
such a favored destination for buyers. Over
50 companies were contacted and inferences
drawn. The White Paper also looks at the future
prospects of he region and government initiatives
for investment in the textile sector.

4

table of content
• Introduction: White
Paper On Bangalore

5

• Product Strengths and
New Directions

6

• Shortage of Labour the
biggest Challenge

8

• Moving into the interiors

9

• Incentives to Textile &
Garment Industry in Karnataka

11

• Advantage Karnataka

14

• Government Initiatives to
Uplift the Backward Regions

15

• Why Bangalore?
Be it Exports or Domestic

17

5

WHITE PAPER ON
BANGALORE

Region evolving from structured
products to fashion – Professional
approach to manufacturing the
way of life
Major Garment
Players in
Bangalore


Gokaldas Exports



Gokaldas Images



LT Karle



FFI



Shahi Exports



Texport Group



Bombay Rayon



K. Mohan



Go Go International



Mandhana Industries



Raymonds



Madura



SKNL

Over the time Bangalore has earned the reputation of being one
of the most strategic destinations for professionally run apparel
companies in India with proficiency in manufacturing ‘tailored’
products and large capacities. The city is the home of big names
like Gokaldas Exports, Gokaldas Images, LT Karle, FFI, Integra
besides being the chosen manufacturing destination for exporters
of other regions like Shahi Exports, Texport Group, Bombay Rayon,
K. Mohan, Go Go International, Mandhana Industries, Raymonds,
Madura, SKNL and a host of Mumbai-based exporters. Though
there are hundreds of units in and around Bangalore, there are
but 12 major players controlling the industry, all others are small
and medium players with niche product strengths or working as
contract factories for bigger players both in the international and
domestic retail.
In fact, Bangalore was the choice of many exporters moving out
of Mumbai/Delhi, as it had the right climate, manpower, support
structure in terms of technology and accessories, and attitude to
foster bigger runs. With a down to earth approach to business, the
work culture in the city is more committed than the north. Shahi’s
voyage to Karnataka started in 1988 with 200 machines and 400
associates and today the company has over 23,000 machines.

6

Product Strengths and New
Directions
Some of the best international and national brands in shirts, bottoms,
outerwear, suits, blazers and sportswear are sourcing from Bangalore.
Factories like Silver Spark, Gokaldas Images, Silver Crest, RVV and
Arvind have excelled in fully constructed garments, while LT Karle,
Gokaldas Exports have expertise in outer wear and sportswear. Casual
bottoms is the forte of companies like Texport Overseas, Golden
Seam, Texport Industries, K Mohan and Denim is being manufactured
by companies like FFI, Ever Blue, Gokaldas Images, Shahi. Shirts are
coming from factories like Laguna, Integra, Bombay Rayon, Go Go
International to name a few leading ones. Laguna claims to have the
only dedicated setup in India for very high-end formal shirts at par
with Italian standards and in the four years of operation the company
has already crossed Rs. 120 crore turnover.
While the list of exporters is not exhaustive, it suggests that there is
specialization in product range and even companies like Gokaldas
Exports, Gokaldas Images and Shahi Exports which are doing multiproducts have dedicated factories for different product range,
unlike in the north, where most factories are flexible units that can
manufacture many products as per buyer demand. This need for
specialized factories is of course fed by the nature of the product
which is more technology-dependent. A casual bottom for A&F could
require as many as 65 different machines for its unique operations.
Even as factories in the north rule, the ladies wear market with
interesting techniques, handwork and product development
strengths, Bangalore is slowly but surely moving in that direction.
Hindustan Clothing and Marketing (HCM), started just a year ago is
already offering fashion ladies wear to buyers like Primark, New Look,
C&A, Zara, Landmark and with the positive response it has received
from buyers it is looking to expand machine strength from 750 to
around 2000 by the end of 2011.

7

Working with Systems
Because of the nature of product manufactured in the region, most of
the garments are made in modular setups though batch system and
assembly line are also popular formats. The average size of factories
are also much bigger than what is found in Delhi and there are
around 10-12 players who have 1000 machines or more under one
roof.
Some of the best technologies for manufacturing of structured
products are available in the city and management concepts like six
sigma, 5 S, lean management are found extensively at the production
units. The IE department is an integral part of most units and
production schedules are laid out based on SAM calculations. ERP
and other IT-enabled software are used to create TNAs and online
monitoring systems.

The traditional manufacturing
stronghold of the region
Shirts

both casual and formal

Bottoms

denims and non denims

Outerwear
like jackets

Suits

formals and blazers

Sportswear

8

Shortage of Labour the
biggest Challenge
Even as the city expands into the outskirts to unfold the growing
industry, shortage of labour is crippling operations. In fact, beyond
the macro issues like escalating prices of cotton, appreciating rupee,
shrinking margins and increasing wage rates that are impacting the
apparel industry in general, the biggest constraint in Bangalore today
is the shortage of labour. Every exporter in the region is spending a
good amount of time and money to work out strategies on how to
retain labour and also seek out new pool of workers. At any point
of time there is a 15-20% shortage of operators on the sewing floor.
Many expect the situation to improve after June, though the factories
will still not see 100% attendance.
According to survey findings of exporters in Bangalore,
the key reasons for the acute shortage are many:


Increasing opportunities in alternate industries like retail,
automobile, electronics and IT-related assembly units



NREG Scheme, which is a respite for less efficient workers



Back to back festivals in the region over the past few months



Piece rate system during peak season.

Some of the initiatives to tackle the problem of
labour problems include:


Taking factories into the interiors,



Aligning with skill development initiatives like IL&FS for regular
supply of trained manpower from BPL section of society,



Running buses into the nearby villages to pick up workforce from
outside the city,



Taping migrant labour from other states by providing hostel
facilities Taping NGOs for workers – also a part of CSR effort,



Conducting intensive training programmes to skill fresh hands



Relying more on automated solutions to cut down manpower
requirement.

9

Moving into the interiors
Proactive is the only word that can describe the response of the
industry to the increasing gap between the supply and demand of
workers in the city. One of the major thrusts is to take factories into
the interiors. In fact most of the new units that are coming up are in
rural areas around Bangalore within 100 km of the city. The new unit
of Laguna is coming up at Kannakpura around 60 km from the city.
Companies like Gokaldas Exports, Bombay Rayon, Integra, Texport
Garments, Scotts Garments, Arvind Mills to name some prominent
ones have tied up with IL&FS to absorb workers trained by the IL&FS
from remote areas. While the training cost is borne by government
funding, the IL&FS identifies and trains youth from below the poverty
line segment of society and places them with factories who commit
to employ such workforce. Technopack also has a skill development
project and Bombay Rayon is absorbing large quantities of workers
trained by them.
Already most of the bigger units have busses running for workers
living in villages around Bangalore. While this is a major expense,
it is a source of steady workers and the employers are assured of
committed labour. Further, some companies like Golden Seam feels
that while the labour wages are cheaper in the villages by around
15%, the consistency in quality is an issue. So they prefer to induct
raw hands and train them internally to suit their product profile and
working culture.
Meanwhile, the rising number of companies offering subsidized
hostel facilities has increased the number of workers from outside
the city and even outside the State. One of the advantages cited
for encouraging migrant labour is that with a mix of workers from
different regions and communities the chances of lines closing down
because of a festival common to all is less, further workers are less
inclined to waste time talking and socializing. However, on the reverse
side if one person from a particular region leaves, he takes the whole
group with him!
Factories are gearing up to deskill operations and substitute
manpower with technology wherever possible. Specialized machines


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