A steady annual growth rate of 25% is a clear indicator of the development witnessed by the sock manufacturing sector in India. The sector is estimated to be having over 3000 manufacturing units out of which 85% are in and around Delhi/NCR, out of this, over 95% is unorganized and fragmented. No wonder, sock knitting machine manufacturers are entering the India market with the prospects of gaining full advantage of the growth potential.
In a recent launch ALT, Bangalore with Da Kong, a Taiwanese manufacturer of sock knitting machines introduced its DK-B318 series machines in India. Many exporters and manufacturers came to inspect the machine. Among the important visitors were Neeraj Singh, Production Head, Zonack Knitting, Noida (Bonjour brand). “We are currently using 230 sock knitting machines and plan to expand to a 1000 machines in the next 3 years”, said Neeraj.
The machine is available in two variants – DK-B318 and DK-B318-8T, fully computerized, single cylinder hosiery machine that allows for more colour combinations, patterns, sock designs, and higher productivity. The product range is capable of manufacturing men socks, women socks, kids’ socks, long socks, plain socks, terry sport socks, hair bands, wrist bands, elbow bands and head bands. The B318 offers plain weave only while the B318-8T besides the plain weave also offers terry weave manufacturing capability. “Highlight of the Taiwan-manufactured knitting machines’ is the use of genuine German and Italian parts. Therefore the breakdown chances are nearly zero for these machines,” said Madhu Kapoor, MD, ALT.
Key features of the machine
The machine runs on a drumless, fully computerized brushless servo motor, thus saving on the energy cost. It is equipped with UPS, which stores the memory of the program and knitting action even when the power shuts. When the power is restored, machine continues to knit. It is also equipped with an internal 3.5 inch disk drive for easier data reading and storage. Two cams double pick up and double press down needles during heel steps give higher quality and productivity than the traditional one cam single picking and pressing type.
Other features include, option of up to 1 main feed (8 yarn fingers) plus 6 pattern feeds (16 colours) and pneumatic system to control yarn fingers. Elastic yarn feeding is controlled by elastic stepping motor for varying course size on the same sock. Elastic yarn feeding is optional for single or two colours. Stitch quality, speed, course length, size quantity, patterns, chain programs, etc. can be controlled and set-up by machine computer panel. A 2-MB memory capacity allows machine saving more pattern programs and sock sizes.
Though training is needed for operating the computerized machine, an operator can be trained in a single day, making him capable of managing up to 20 machines at a time. “We have set a target of selling 3000 machines in the first year. For this purpose we have contacted big sock manufacturers of India, State Governments and NGO’s. With the help of the Indian Army, we are planning to install machines in some of the most remote parts of India. This is also a Corporate Social Responsibility (CSR) Initiative undertaken by our organization,” said Kapoor.
The price range of the machine is $ 14,000 to $ 17,000, but with a productivity of 600 socks a day or 300 pairs, Da Kong claims an ROI of two years with life span of 15 years, with easy availability and replacement of consumable parts. The company claimed that the machine offers 30 to 40% higher productivity than its counterparts, whereas the capital cost is more by only 15 to 20% and the maintenance costs minimal.
