Engineer, Terry Towel Product Development · Welspun Living

Highlight: developed a sustainable terry towel with regenerated cellulosic (lyocell) yarn in both warp and weft, from first sample to testing.

• Developed terry towels for retailers in the US, UK, Europe and India, such as Walmart, Costco and IKEA.
• Prepared 150+ final tech packs per month for bulk production, article by article, and kept product and material master data correct across SAP, BeProduct PLM and Excel.
• Costed and tracked 200+ free-of-charge samples per month.
• Analysed fabric samples for construction and performance, and checked them against buyer specifications.
• Set up and carried out quality checks on softness, absorbency and durability, with regular inspections.
• Handled orders and material flow in SAP: sales orders, purchase requisitions and orders, stock transfers and labels.
• Presented monthly development and OTIF reports to management, coordinating marketing, production, supply chain and logistics.

Senior Officer, Yarn-Dyed Product Development · Vardhman Textiles

• Developed yarn-dyed fabrics for international fashion brands, with a focus on processing from dyeing to finishing.
• Planned processing samples and prepared 10+ process and test reports every day.
• Defined and documented process routes step by step, from dyeing to finishing, and selected finishing chemicals to meet the required physical parameters.
• Analysed fabric quality and physical test results for every development.
• Discussed test results and technical requirements directly with customers, negotiated changes and turned them into development documents.
• Kept structured, traceable records of process, fabric quality and physical test results.

Internship Trainee, Spinning · Alok Industries

• Analysed yarn performance data (U%, IPI, hairiness, thin places) across different machine settings.
• Recommended a new spacer and winding setting that cut yarn imperfections (IPI) by 18%.

Ring-Spun Yarn Quality Trial

Tested 100s combed compact cotton yarn on the Uster Tester 5. Compared a 2.75 mm and a 2.5 mm spacer on the ring frame, and four winding settings on the link coner (700/900 m/min, 7/9 cN), before and after conditioning.

Result: the 2.5 mm spacer reduced the imperfection index from 520 to 427, 18% fewer yarn faults. Best overall setting: 2.5 mm spacer, 700 m/min, 9 cN.

Key learning: lower winding speed reduced hairiness by 4% and higher tension cut thin places by 12%. Small machine settings decide yarn quality, and data makes the decision clear for production.

Natural Dyes on Handloom Fabrics

Developed shade cards for 12 natural dyes, including madder, myrobalan, pomegranate rind and annatto, on cotton, silk and linen, comparing aluminium sulphate, citric acid and ferrous sulphate mordants. Applied the best combinations in screen printing, block printing and hand painting with steam fixation.

Key learning: the same dye gives very different shades with different mordants, but reproducing a shade and keeping it lightfast is the real challenge. That decides whether natural dyes can work in a commercial product.

Stitch Type & Density vs. Seam Efficiency

Tested 216 seam samples: 6 fabrics, 4 stitch types (lockstitch 301, double-needle lockstitch 302, 4-thread chain stitch 607, 5-thread overedge 516), 3 stitch densities (10, 15, 20 SPI) and 3 sewing thread counts (21, 27, 60 tex), measured on an Instron tester to ASTM D1683.

Result: the 4-thread chain stitch gave the highest seam efficiency (61%), lockstitch the lowest (13%). Efficiency rose with stitch density and with coarser thread; satin fabric performed best (59%).

Key learning: the right combination of stitch type, density, thread and fabric depends on the end use. Construction choices decide whether a product passes quality, and what it costs to make.