Magazine
The Indaco Jeans Factory, is one of the leading players in denim garment manufacturing built on innovation, sustainability, and technology at its forefront. Situated 100 kms from Mumbai city in Tarapur (MIDC), Maharashtra, TIJF is one the few factories with a 'Design-to-Delivery' approach that makes it a one stop destination for a new and progressive denim garment making experience. The Founder, Prasad Pabrekar, inherited the laundry business from his father along with passionate genes, that enabled him to build India’s leading youth denim brand– Spykar Jeans in the year 1992. After selling Spykar Jeans in 2014, Prasad furthered his quest for finest quality of jeans manufacturing with 'The Indaco Jeans Factory'.
Under the guidance of an eminent leader like him, with over three decades of industry know-how, TIJF has become a leading player in denim industry. Under its vertically integrated jeans production setup, TIJF has a robust capacity to manufacture 2.5 million pairs of jeans per year and employs more than 1000 people across two facilities.
Along the way, it has religiously made efforts towards being compliant, and today is accredited by SA8000, SEDEX four Pillar, and Bestseller Group. With a strong vision in mind, today, TIJF is the denim partner of choice for some of the top brands in the world like Spykar Jeans, Jack & Jones, Vero Moda (Bestseller Group), Lee Cooper, Flying Machine, OVS, and more.
“To stay ahead of time, the company has invested in leading edge technologies and smart laundry systems that use less water, chemical, and energy. Specialized and automated machines in cutting and sewing departments are used to improve production efficiency and garment quality, along with a dedicated focus on process innovation”, shares Prasad. Washing or laundry plays an integral part in jeans making. European technology like smart flow & smart foam is used to create myriad washes, from vintage to fashion with minimum ecological impact.
Here, water is replaced by nano spray and foam leading to considerable savings in water and heating energy. Another breakthrough technology they use is Laser from Jeanologia, Spain. Laser is a people & planet friendly technology that uses zero water and minimum heat to remove a fine layer of indigo on top of your jeans to create whiskers, patterns, rip & repairs, and abrasions for an authentic used look. It also eliminates the use of Potassium Permanganate, a harmful chemical used as a discharging agent. TIJF uses ETP (Effluent Treatment Plant) systems to recycle and reuse the water that is used in its facility.
Presently, up to 85 percent water is reused back in the process and soon this number is going to be upgraded to a massive 95 percent. In addition to taking serious water saving measures, the company uses solar energy to power machinery which in-turn contributes 40 percent to their total energy mix. Adding to all, the company emphasizes on worker health & safety, and is committed to providing a safe & ethical working environment for all. Their integrated strategy of ‘Design to Delivery’ means having R&D, Design, Sampling, Cutting, Embroidery, Stitching, Laser, Handwork, Washing, Printing, and Transport department under one roof, making it is easier to service partner brands quickly without relying on external sources.
Sustainability is ingrained in the company philosophy with a focus on 3p’s- People, Planet & Process, making them an indivisible part of its future goals
Sustainability is ingrained in the company philosophy with a focus on 3P’sPeople, Planet & Process, making them an indivisible part of its future goals. With latest technology investments and a balanced expansion plan, TIJF aspires to increase their production capacity by 40-50 percent, making 7.0 million jeans in the next one year.
“Another future milestone for TIJF is, gearing up for an IPO by 2025. With ambitious plans to scale up their client base in both the domestic and overseas market, TIJF wants to be a pioneer in the denim industry with a commitment to delivering nothing but excellence”, concludes Prasad.
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