Tag: Innovation

Sustainability Spotlight | The classic blue denim
To name a piece of versatile, durable, and timeless clothing, very few would hesitate to pick the go-to pair of blue denim. Tracking the evolution of denim in the fashion industry, it is often surprising to people to know that the initial design for denim was made for miners and seafarers. The durability of denim made it an instant favorite for all heavy lifting work in the 1800s.

Over time, denim has crossed oceans and continents to lodge itself firmly in fashion history. What evolved from a completely practical utilitarian trend turned into a rebellious cultural shift in the 1960s and eventually a lifestyle choice. (read: The history of Denim Jeans).

But as it transforms from workwear to casual, how did manufacturers re-create that same worn-down look?

Wearing The Pair Down

Denim washing and finishing is a highly resource-intensive process. Conventional methods of mass production also use a large amount of water, chemicals, and energy to produce a pair of jeans. To find out more, we took a trip to Unit 23, Shahi Exports’ Denim Unit in Bengaluru.

Pulling off Denim

Shahi set up the Denim Division in 2010, with Unit 23 in Bengaluru. Currently, Shahi has two denim garmenting units (Units 1 & 23) and a laundry with a production capacity of 12 million pieces per year. Since then, this newest addition has led the growth towards sustainable operations internally and with the customers.

“Judiciously utilizing the four essential resources— chemicals, energy, water, and our people define sustainability for us. Sustainable operations are not limited solely to environmental factors, but the well-being of our workers is equally important,” Mr. Nandheesh Gowda, General Manager, Laundry.

Shahi has adopted the Laundry 5.Zero strategy that has been predicted to revolutionize the denim industry.

We bring together cutting-edge technology from all over the world to make a truly global product, not just fashionable but sustainable.

Scrubbing the Chemical Out

Rethinking the production from the design stage, keeping in mind circularity, is key to ensuring the sustainability of the product. The design team at Shahi starts working from the initial stage– design to minimize the environmental impact of the production. We opt for lighter shades of denim which require a light wash. They demand significantly shorter washing cycles, thus reducing the environmental impact.

A pair of jeans can be ‘weathered or distressed’ using wet and dry finishing processes. Traditional methods of distressing the fabric require workers to scrub them by hand. As the scrubbing sheds layers of blue dust, it is harmful to workers’ health. The finishing process may also require washing with chemicals. Aligning with Laundry 5.Zero, Shahi uses laser technologies to reduce the use of grinders and scrubbers.

The intensity of the distressed look depends on three major factors: wavelength, power density, and pulse width of the laser beam. A computer inputs the desired design and guides the laser over the fabric to create a fading or distressed look. It concentrates heat to decompose the dye according to the desired wash style.

This novel technique provides an alternative to traditional methods such as acid washing, sandblasting, and using potassium permanganate and therefore helps us create a safe and comfortable working environment for our workers. Additionally, laser technology increases our flexibility, speed, and precision to meet significant production needs.

Shahi has developed a single window to facilitate the purchase of chemicals. It helps us to screen the required information about a chemical before purchasing it. The single window is compliant with international standards such as the Zero Discharge of Hazardous Chemicals Manufacturing Restricted Substances List. It makes sure that we do not use any restricted chemicals harmful to the environment in our production and eases the procedure to procure the chemicals. Streamlining the process also helps Shahi align with the needs of our customers. The larger goal is to protect our production workers, local communities, and the environment from the impact of banned or hazardous chemicals and, ultimately, the consumer.

Shahi constantly collaborates with the best chemical suppliers to better their processes in the Denims Division.

Sustaining the Classic Blue

The classic blue in denim is created through water-intensive washing processes. A significant way to develop a more sustainable operation for producing denim is to focus on its water consumption. Shahi explored technology providers from around the world to bring down our material liquid ratio (MLR) from 1:6 to 1:1.

The principle

e-Flow technology was ideal for reducing water consumption. The technology turns the chemicals into nanobubbles before being subjected to the washing machine. Nanobubbles of air act as a carrier to transmit chemicals into a garment with a minimal quantity of water and zero discharge. This has led to an average of 95% water savings for every denim washed.

Another technology is the G2 Ozone washing machine, which generates ozone from the air to catalyze the indigo fiber dyeing and produces the authentic worn-down look in the desired shade. The water consumed is reduced by 65% and the energy by 20%. The ozone is re-converted into oxygen and released into the air, leaving no harmful by-products.

While reducing water consumption in denim production is essential, it is equally important to reduce dependence on fresh water as much as possible. By installing state-of-the-art effluent treatment plants, Shahi recycles and reuses 100% of its water usage. Our denim laundry achieved the Zero Liquid Discharge (ZLD) standard in 2019. We constantly monitor the water conserved in laundry through our Environmental Impact Measurement (EIM) tools.

Going the Extra Mile on Energy

85% of the electrical energy consumed in Unit 23 is renewable. Additionally, the unit utilizes zero coal for its operations. Shahi set up a solar power plant of 84 megawatts and 9 megawatts of wind power. We aim to suffice 100% of our electricity needs with renewable sources by 2026. Substituting conventional sources for low carbon and sustainable alternatives for thermal energy is a top priority for Shahi.

We have several initiatives running across the units, for example— converting most of our high-speed diesel-fired boilers into agro-waste or PNG-fired boilers to generate steam.

Our newer units are built to incorporate green building principles to minimize energy consumption and leverage natural lighting on the shop floor. All the new units harness sunlight to illuminate our shop floors, and the architecture facilitates natural ventilation that reduces heat dissipation from electric lighting fixtures. The reduced temperatures on the shop floor impact our workforce and their environment directly.

Synergizing People and Resources

People and their well-being are integral to sustainability at Shahi, and worker well-being focuses on providing a safe and healthy environment and creating opportunities for growth.

In a study with the Good Business Lab, we observed that Replacing fluorescent lights with LEDs reduces energy consumption by roughly 85%, reducing the average indoor temperature by 2.4°C. Incidentally, a transition to LED lights also increases the workers’ productivity on the shop floor. 83% of all the lights at Unit 23 comprise LED lighting. We launched a campaign to replace conventional T8 task lamps with LED lighting for individual workers’.

What does it really take to pull it off?

With conscious consumerism on the rise, and the industry grappling with limited resources, the beloved go-to pair of denim will have to transform itself into its most low-impact versions that require minimal resources — and also maximize its life cycle. This means that manufacturers and brands have a pivotal role in revolutionizing the industry right from the designing stage.

Shahi invested significantly in state-of-the-art machine equipment to upgrade the factory and laundry facilities. To name a few of our many initiatives in the Denims Division—
- Laser machines from Jeanologia,
- Chemical auto dosing,
- Using Ozone, e-Flow, and other water-efficient technologies,
- Developing a single-window chemical purchase window to prevent the entry of restricted chemicals, and
- Collaborating with the best chemical suppliers.
Making it even better

But, Shahi is not stopping here. Our teams constantly look for ways to produce denim wear, maintaining Laundry 5.Zero principles; or synonymously ‘The Jeans of the Future.’ The key is to find the perfect set of equipment and technologies that complement each other in energy, water, and chemical consumption.

We are working on additional strategies like:

Unit 23 showcases sustainable operations at every step of the way and progressively eliminates processes that degrade the environment in bringing a piece of denim alive. We look forward to what the future of the denim industry beholds.
June 13, 2022
Puneesh Lamba honoured as the IoT ICON at the CIO Power List 2022

Puneesh Lamba, Chief Technology Officer of Shahi, received the recognition for IoT Icon in the CIO Power List 2022. The CIO Power List, presented by CORE Media, recognizes India’s most influential Chief Information Officers (CIOs), IT Leaders, and Digital Leaders. They have demonstrated extraordinary vision and outstanding work in the last year in enterprise technology. They have leveraged technology to improve processes, customer touchpoints, and experiences.

An exclusive ceremony was held on 20th-21st May 2022 in Mumbai, honoring over 130 CIOs across two main categories: Business Icons and Technology Icons.

Business Icon recognitions are conferred upon select CIOs/IT Leaders from 23 categories and across 13 different industry verticals, while Technology Icons upon leaders across 20 different technology categories.

“Congratulations to all the CIO Power List 2022 winners. In the new digital economy, these CIOs and Digital Leaders are at the forefront, driving transformation that enables organizations in staying ahead with innovation for growth and success in the global marketplace. The CIO Power List recognitions are bestowed upon visionary leaders. It is our privilege to honor them as they rise above disruption and establish IT as the biggest driving influence on enterprise transformation and new business models”, said Anoop Mathur, Founder, and President, CORE Media.

Making the Power List

The CIO Power List 2022 awardees are finalized based on an algorithm considering a wide range of data collected on CIOs and Digital Leaders across multiple channels. This includes data collected from their online reputation, business publications, and features, combined with data on awards, honors, and recognitions won; achievements, a random sampling of social media engagements, and a national survey of peer CIO review. Additionally, there are inputs from the CIOs themselves on their key moments in the past year.

From the CTO

“This award is the testimony to the fact that Shahi has taken huge strides in digitizing its operations. Solving business problems by leveraging technology has become a practice in Shahi; hence we are a more productive, efficient, and progressive company. Our “Digital First” approach has helped immensely in delivering value to our customers and employees.” – Puneesh Lamba

Puneesh is responsible for building Shahi’s IT & Digital strategy and execution. He carries 28 years of experience as a Senior IT & Digital Leader across industries in India, the USA, and Europe. He has worked for multinational companies like General Electric/Genpact and TATA Consultancy Services and Indian Conglomerates like Escorts Ltd., Punj Lloyd, CK Birla Group, and Ballarpur Industries.

As one of India’s pioneers in embracing disruptive technologies like Artificial Intelligence, Robotic Process Automation, the Internet of Things, and Predictive Analytics, Puneesh is a proponent of digital means to enable business strategy growth. He has won many prestigious awards like CIO100, CIO200, CIO500, Power List, and CIO 1000. He is also a jury member at NASSCOM, Frost & Sullivan, and 9Dot9 media.

June 8, 2022
How Shahi created a first-of-its-kind circular dress
Inspired by nature, held by three pillars: innovation, design, and chemistry.

Does waste equal food? In the pre-industrialized economy, products had a natural biological cycle where the inputs naturally decomposed and served as nutrients for the planet. Products made out of metal were refurbished to make new ones. All the inputs derived from Earth ideally should go back to it. But, today, does waste still equal food for the planet? How do we envision growth in today’s world while prioritizing the environment? Is there a way we can manufacture products aligning with the growing population and their lifestyle choices without harming the environment, in fact, by nurturing it?

On asking a few people about what Cradle to Cradle is, I received a myriad of answers. Someone said it is probably a place where a baby sleeps. Some others hit it a little closer: a process for people to know how a product is truly made; a benchmark for sustainable products; and a design philosophy that genuinely outlines the lifecycle of a product focusing on the recycling mechanisms.

Anant Ahuja, Head of Organizational Development at Shahi, says,

“Cradle to Cradle represents a way to make products that are in tune with nature and manufactured sustainably. The resources that are required to manufacture must be replenished and extracted ethically. You can imagine a world where we can produce as much as we want, and the reason we can do it is due to the positive impact and the life cycle of the product. We turn the waste into fuel.”

The Concept

Cradle to Cradle is a revolutionary design concept integrating two distinct fields — design and science to achieve a high level of sustainability. By focusing on doing ‘more good than less bad,’ Cradle to Cradle Certified® products create a positive ecological impact rather than simply minimizing their environmental footprint. The goal is not just to substitute harmful chemicals and other raw materials with more sustainable alternatives but also to rethink the lifecycle of products — from design to disintegration. The emphasis is on increasing durability. Once disintegrated, the value of the materials used in production is not lost but rather preserved and brought back to the loop.

Cradle-to-Grave vs Cradle-to-Cradle

Every raw material used counts. Each material holds immense value and should not end in a grave.

Five different aspects measure the holistic development of a Cradle to Cradle Certified® product: material health and re-utilization, renewable energy, carbon management, water stewardship, and social fairness. Each of these is given an achievement level based on the guidelines ranging from Bronze to Platinum. The products based on these principles can range from buildings and construction materials to cosmetics and textiles.

‘Arth,’ what does it mean?

In late 2018, Shahi was presented with an opportunity to become India’s first woven apparel and textiles manufacturer to create Cradle to Cradle Certified® products with our ‘Arth’ collection in partnership with C&A.

Arth symbolizes our responsibility towards the planet in a quest to find meaning behind ‘doing more good than less bad.’ Shahi received the Gold achievement level owing to its holistic performance on the parameters set by the Cradle to Cradle Products Innovation Institute. Everything that comes from the Earth must return to it.

“The concept of Cradle to Cradle presents an opportunity to present our commitment towards circularity: everything that we utilize goes back safely to the environment. It was a pioneering step to add such product manufacturing capability to our organization. The dress (product) has motivated us to explore better raw materials and technologies; as it is also backed by a continuous improvement principle along with zero environmental impact and elimination of waste generation concept. We hope that we continue to work on exciting and innovative projects such as this one with our other stakeholders.”

– Rajneesh Rai, General Manager, Environmental Sustainability and Laboratory.

In this article, we share our learnings, insights, and the benefits, and opportunities for building our first Cradle to Cradle Certified® product by looking at the overall product development, materials, resources, social fairness, and the way forward.

Rethinking product development

Our product’s design and production processes are based on a circular economy model. At the end of its lifecycle, a Cradle to Cradle Certified® product is returned to the biosphere either as compost or reprocessed to make new products. Here is how we took on the opportunity to change our production pattern for this collection.

Design

Designing a Cradle to Cradle Certified® product demands many resources, dedication, perseverance, and openness to explore new areas. It took us more than 18 months from the inception of the product to deliver to our brand partner C&A. This period also includes the certification process for our facilities. The process has been significantly different from any other product we have manufactured. The changes in the processes also made us appreciate the speed of adaptation and the appetite for innovation at Shahi.

When we started designing the product from scratch, our progress was slow due to the lack of knowledge and resources available, coupled with the nationwide lockdown in early 2020. We began with a series of questions on which resources and techniques can be used in a Cradle to Cradle Certified® dress. They revolved around printing over the product, label of the garment, and use of Cradle to Cradle Certified® raw materials such as buttons and thread. The journey was made more accessible and collaborative with active involvement from C&A and the Cradle to Cradle Products Innovation Institute.

The Arth collection sports a relaxed mid-length dress with buttons made from natural coconut, which breaks down with a biological cycle. The dress made us go back to the basics of designing. The boundaries put on using certain chemicals, dyes, and trimmings helped us become more innovative in constructing the Cradle to Cradle Certified® dress.

The ideation process required us to extend our imagination beyond the aesthetics of the design. We emphasize how easily the product can be disintegrated and put back in the cycle without losing any value. Keeping in mind the core principle of Cradle to Cradle Certified®, the focus has been to balance the dress’s design and durability. For this reason, the dress has a clean finish with minimum accessories.

Sona Mishra, the designer who developed the dress, says, “To make a Cradle to Cradle Certified® product, you must go back to your basics: silhouettes, minimal accessorization, and use of Cradle to Cradle Certified® raw materials, dyes, and auxiliaries. We were really able to bring out the essence of a truly circular product with this process.”

Material

The fabric was made at our state-of-the-art Woven Processing Division (WPD) in Shimoga using 100% Global Organic Textile Standard certified organic cotton. More than 96% of this cotton is rapidly renewable, and 86% of the water used in the fabric processing was recycled. The finished products are 100% carbon neutral and recyclable. The brand tag on the products was designed in-house using recyclable materials and procured from a verified vendor.

The Cradle to Cradle Certified® Product Standard lists restricted chemicals to avoid while manufacturing the products. An official Restricted Substance List indicates the maximum concentration of each restricted substance allowed in the products.

The material health and re-utilization category ensure that Cradle to Cradle Certified® products uses chemicals that are:
- Safe for society and the planet.
- It can be further recycled or bio-degraded through biological and technical cycles.
To avoid contamination with other chemicals, we diligently cleaned all the machines and equipment to be used to produce the

Machines were clearly marked and cleaned out for the Arth Collection

Arth collection. The production lines were separated and clearly marked for Cradle to Cradle Certified® production. We used alternative chemicals accepted under the Cradle to Cradle Products Innovation Institute guidelines.

Making a Cradle to Cradle Certified® product definitely demands more investment in raw materials. The key is to find the right blend that synchronizes together. Due to limitations in using chemicals for dyeing, we went ahead with two basic shades for the fabric: Black and Henna. evaluated the Material Health Certificate for products that adhere to restricted substances.

The material chemistry was independently assessed by MBDC Laboratory, USA on restricted substances and impacts on human health and the environment.

Our product developers, designers, and the environment team spent several months inventorying, assessing, and optimizing the material chemistry to achieve the platinum standard on material health and material re-utilization category. A platinum standard implies a material re-utilization score of 100, and the product is actively being recovered by a technical or biological mechanism.

The Footprint

The Cradle to Cradle design principle ensures that the products utilize renewable energy to minimize the release of greenhouse gasses along with efficient use of water during manufacturing. Shahi achieved the gold standard under Renewable Energy and Carbon Management and the platinum standard under Water Stewardship.

A significant factor in achieving this standard has been the state-of-art machinery available at the Wovens Processing Division that optimizes resource consumption throughout the entire process. The garments were made in two units (Unit 9 and 28) that successfully qualified the environmental and social requirements as laid down by the Cradle to Cradle Products Innovation Institute.

Energy

The Wovens Processing Division facility in Shimoga runs on the power produced by our solar grid in Bellary, allowing us access to 96% renewable energy during the production process.

Water
The fabric was made in our processing mill, a Zero Liquid Discharge Facility.

Carbon Emissions

Cradle to Cradle certification, in many ways, is a step towards transparency. Accounting for the entire production process to make an authentic carbon neutral product, we purchased carbon credits to balance out the emissions for our boiler and garmenting units which now operate on renewable energy.

Labor and Social Fairness

Our factories run several technical and soft skill training programs to support our workers.

At Shahi, worker wellbeing is of utmost importance. Worker wellbeing focuses not just on providing a safe and healthy environment but also on creating opportunities for their growth. Shahi was the first manufacturer to co-create and pilot Gap Inc.’s P.A.C.E. program. Inspired by the immense power of the program, Shahi co-developed STITCH with Good Business Lab to enhance the core competencies and capacities of the supervisor to manage their key roles effectively. Our homegrown tool, Inache, is another example of our commitment to ensuring a healthy work environment by enabling workers’ voices. Inache is an anonymous two-way communication platform where workers can call or send an SMS about their complaints, grievances, suggestions, or questions. It goes to a central dashboard and then to the designated factory staff for response and resolution. It assists us in continuously monitoring and improving the grievance redressal system that facilitates transparency and a connection between the management and the workers.

These initiatives contributed to our achievement of the gold standard in the social fairness category.

Fair working conditions and respectful treatment of workers go hand in hand with any sustainable and circular venture. The Cradle to Cradle 4.0’s social fairness standards has emphasized ensuring a safe and conducive work environment. The broader focus areas include sound infrastructural arrangements, community engagements, and career growth. These parameters encourage responsible business practices and strong ethics across all stakeholders involved in the supply chain. Social fairness is analyzed under five distinct parameters: Management, Human Rights, Labor, Environment, and Anti-corruption at the facilities.

Building sustained relationships

C&A’s support and eagerness to collaborate in creating this collection revealed how important the role of brands as strategic partners in this effort to transition into a circular economy is. The Global Sourcing and Sustainability team at C&A said,

“Shahi continues to be a steadfast strategic partner for C&A and a driving force for innovation across the global fashion supply chain. When we began bringing Cradle to Cradle Certified® products to market, it was clear that Shahi would be a key partner in scaling Cradle to Cradle across categories. For a product and supply chain to become Cradle to Cradle Certified®, it takes an incredible amount of detail and commitment. However, it takes supply chain partners with a deep understanding of sustainability, innovation, and their importance to customers, brands, and suppliers. Shahi is a leading supplier in this regard, and we are deeply grateful for their continued partnership in driving circular innovation. We look forward to working together to drive to Cradle Certified® innovations and other ground-breaking sustainability initiatives forward.”

Shahi possesses the flexibility to direct resources in testing and refining sustainable and circular products. This allows for a co-creative space for research-based collaboration between brands and suppliers that holds the potential to drive change in the apparel and textiles industry.

Doing more good than less harm

The Arth collection has provided us with lots of learnings. The most crucial is that developing circular products at scale is possible. The need of the hour, is to encourage more conversations and awareness around Cradle to Cradle Certified® products. The demand for such a product must be established from a strategic point of view to build a circular economy collaboratively. Brands and customers form an essential part of driving this demand.

Shahi is looking forward to working with more and more brands on Cradle to Cradle Certified® products and getting closer to bettering our environment and production methods with each step. Its design principles enable a supplier like us to create products while nurturing the planet— doing more good than less harm. With our certified mill, we hope to collaborate with more and more sustainability-driven brands to create products that preserve their value.

Our journey towards a sustainable supply chain does not end here. We have been spearheading textile and garment innovation in India with projects like growing cotton with Superabsorbent Polymer (SAP) in partnership with HKRITA and recycling pre-consumer cotton waste with Usha Yarns, among others.

For business inquiries on Cradle to Cradle Certified® products, please contact: od@shahi.co.in
March 29, 2022
Insights from speaking engagements: 2021

At Shahi, we believe in sharing our experiences and learning with all the stakeholders in the fashion industry and beyond. This is an ongoing post to share insights from our speaking engagements in 2021. Read insights from previous years’ engagements: 2020, 2019.

December 14, 2021 | SLCP Signatory Webinar

Manjunatha Sriramaiah, Assistant General Manager of Compliance at Shahi spoke at the Social Labour Convergence Program Signatory Webinar 2021 held in December. He highlighted how Shahi became an early signatory to SLCP owing to the program’s numerous benefits, including value-added service for our customers, capacity building for our employees, and the tool’s credibility. Currently, 76% of our facilities have completed the SLCP self-assessment, saving us 4,416 hours due to reduced audits.

Read more in our case study.

December 14, 2021 | #ETConvergenceSeries Industry 4.0: Connected Operations for smart manufacturing

Our Chief Technology Officer, Puneesh Lamba was featured on a panel at the coveted ET Convergence Series. He spoke about automated and smart manufacturing in the apparel industry and the potential it holds to develop more robust businesses. This panel was organized by The Economic Times and powered by Amazon Web Services (AWS), and Deloitte. Other esteemed guests on the panel represented MTR Foods, DP World, Patanjali Ayurved Limited, Carl Zeiss and Sigma Electric Manufacturing.

December 9, 2021 | Business for Social Responsibility

How to Enable a Just, Fair, and Inclusive Transition to Circular Fashion by BSR

Business for Social Responsibility (BSR) organized this panel discussion to launch the report ‘Keeping Workers in the Loop.’ The conversation revolved around the opportunities around circular fashion while emphasizing its impact on the job market for garment workers, especially women. Gauri Sharma, Senior Manager, Organizational Development, spoke about the context of circular economy and how the responsibility of a manufacturer is not just limited to recycling but also includes women in circular jobs. Incorporating their traditional techniques of repair, upcycle, and the like into the circular models makes for a more collaborative model. We must endeavor to ensure good quality jobs that align with frameworks such as SLCP.

Click to watch the recording.

November 3, 2021 | Manufactured Podcast

Gauri Sharma, Senior Manager, Organizational Development, was invited to co-host a series on the fourth season of the Manufactured podcast hosted by Kim Van der Weerd. These episodes were in conversation with Matthew Wallace, CEO of DXM. Inc

DXM is a technology-driven on-demand manufacturing company co-owned by Shahi Exports, Brandix, MAS Holdings, Busana Apparel Group, and Carhartt. Gauri and Matthew speak about how building a soft relationship between various stakeholders in the industry is equally important as technological innovation in ensuring circular business models.

Episode 1: View more

Episode 2: View more

October 14, 2021 | Sankalp Global Summit

The Sankalp Global Summit was a three-day event that saw over 2521 delegates from 104 countries. Rajneesh Rai, General Manager, Environmental Sustainability, spoke on the panel ‘Getting to Net Zero – the Role of the Private Sector’ on Shahi’s tremendous progress and leading the way in being part of the solution by setting bold commitments to reducing the greenhouse gas emissions.

He highlighted some of the key achievements at Shahi, such as the Cradle to Cradle Certification for the ‘Arth Collection,’ declaring Science-Based Targets at some of our factories, among others. He also pointed out how favorable government policies and commercially viable technologies will help stakeholders transform into a sustainable ecosystem.

October 13, 2021 | Sedex South Asia 2021

SEDEX is a membership organization that provides online platforms to manage and improve the working conditions in the global supply chains. Srinivasa Rao Venkatesh, Chief Compliance Officer at Shahi spoke at the ‘Managing Supply Chain Risks in the Textile Industry,’ highlighting some of the risks faced by the industry, such as health and safety, licensing, and working hours.

These further expand to post-lockdown challenges, including job losses, and issues affecting migrant workers. He concluded by enumerating potential solutions we deployed at Shahi to enhance capacity building, monitoring, workforce empowerment, and providing a fair and respectful workplace.

September 9, 2021 | PI Apparel

PI Apparel is a membership community for apparel and footwear manufacturers that engage with the industry’s challenges and technologies. PI Apparel organized a sustainability spotlight in September where our Head of Organizational Development, Anant Ahuja, moderated the session on ‘What are the Practical Steps We Need to Take in Terms of Infrastructure, People & Technology to Underpin a More Sustainable Operation’? The session focused on the culture of sustainability among different organizations and how brands and suppliers can leverage technology to drive sustainability. The key to an impactful journey towards sustainability is collaboration at the core of business models.

September 1-2, 2021 | Thrive 2021, KGA Managers’ Conference

This year, KGA Manager’s Conference engaged with the theme ‘Lead with Empathy, Win with Agility’ to discuss the challenges and risks triggered by the pandemic. Anant Ahuja, the Head of Organizational Development at Shahi, participated in the ‘Sustainability: Imperatives & Roadblocks’ session.

He spoke about how at Shahi, collaboration with brands and research institutions supplement sustainable practices. Examples include the ZDHC Roadmap to zero programs, NIFT Chair 4.0, Cradle to Cradle Certified® Gold products, and a trial with HKRITA. He also shared a few suggestions on how KMART Group as a brand can help suppliers on their journey towards becoming sustainable. Here, sharing knowledge with suppliers, developing a capacity plan, and small interventions such as sourcing closer to the market and consolidation of shipments are a few steps that can considerably impact suppliers.

August 2, 2021 | Tamarind Chutney

A Webinar on ‘Technology and Innovation in Circular Fashion’

The webinar was co-organized by Tamarind Chutney and Chintan (Environmental Research and Action Group) with the support of Fredrik Ebert Stiftung (FES) Foundation. The panelists discussed the growing global recognition for moving from a wasteful linear supply chain to a closed-loop, a circular one.

Gauri Sharma, Senior Manager of the Organizational Development team, spoke about the need for innovations and technology to solve critical challenges and enable this transition. She described how Shahi is working on projects such as Cradle to Cradle products, HKRITA- SAP, microbial dyeing, and recycling, among others. She also spoke about suppliers’ challenges, including the price-sensitive nature of the industry, transactional and short-term relationships with brands, and lack of transparency.

Watch the webinar view more

July 15, 2021 | Walmart Global Sourcing Sustainability (Regenerative Retailer) Summit

The summit explored how the suppliers can work together with brands actively to pursue sustainability goals aimed at sourcing responsibly, eliminating waste and emissions, selling sustainable products, and protecting nature.

In the virtual session, he shared Shahi’s vision of ‘doing more with fewer resources’ along with the company’s progress in improving its impact in four distinct areas: energy, chemicals, water, and materials.

June 1-4, 2021 | United Nations Responsible Business and Human Rights Forum

The UN Human Rights Office for Southeast Asia organized five virtual sessions at the 2021 UN Responsible Business and Human Rights Forum. Anant Ahuja, Head of the Organizational Development at Shahi, spoke at ‘The Next Decade of Migration, Fashion and Human Rights’ panel, centered around the role, vulnerabilities, and experiences of migrant workers and the impact of future business trends on them, especially the female labor in the fashion supply chain.

He discussed a few practical examples of how Shahi is contributing to the wellbeing of migrant workers including implementing our skill development program since 2013, establishing the Migrant Support Centre in 2021, and our goal to provide access to vaccines to our entire workforce.

April 27-29, 2021 | Sustainable Apparel and Textiles Conference

The two-day event organized by the Innovation Forum addressed how apparel brands can adapt practices to deliver on growing stakeholder expectations and drive circularity while reducing the climate impact on the fashion supply chain. Anant Ahuja, Head of Organisational Development at Shahi spoke about the challenges, particularly the power imbalance faced in the textile industry, and how adhering to practices such as on-time payments and making long-term commitments with suppliers will help improve the buyer-supplier relationship.

April 13, 2021 | Transformer’s Foundation x Manufactured Live Event

The live panel discussion organized by Tranformer’s Foundation and Manufactured Podcast focused on consolidation and vertical integration in the fashion supply chain in a post-pandemic world, and how vertical integration supports sustainability within the suppliers. Anant Ahuja, Head of the Organizational Development at Shahi, reflected on Shahi’s journey and the values of sustainability and worker wellbeing that have been passed over generations. In the session, we discussed the several benefits of being vertically integrated including improved traceability, speed, cost, and time-saving mechanisms. Shahi hopes to bring together manufacturing expertise to further improve the vertical integration across the industry.

Watch a recording of the full panel discussion:

February 24- 26, 2021 | ReWire: Sustainability 2021

This 3-day virtual event was organized by MOTIF and The Mills Fabrica with selected disruptors in the sustainability industry. The event spotlighted emerging ecosystem standards, new materials, and a pathway towards circularity to fuel innovation across the fashion supply chain.

On the panel, “The infrastructure of sustainability” on February 24, 2021, we talked about our approach towards energy conservation and clean energy transition. In 2019-20, 77% of the electrical energy consumption across Shahi was carbon neutral. On February 25, 2021, we presented our new research project with The Hong Kong Research Institute of Textiles and Apparel. We are reclaiming textile waste to grow cotton more efficiently as a way to support cotton farmers. Register for free to access the session recordings view more.

February 23, 2021 | Manufactured Podcast, Season 3

Manufactured is a podcast started in 2020 to provide an insider perspective on sustainability in the fashion supply chain. Two members of Shahi’s Organizational Development team, Anant Ahuja and Gauri Sharma were invited to speak for the latest double-episode which is now in its third season.

We believe in the power of being transparent, sharing our experiences, and gaining valuable feedback to improve further through platforms like Manufactured. Part 1 of the podcast covers Shahi’s journey over the last 45 years, and our perspective on collaboration between buyers and suppliers to drive sustainability. Part 2 of the podcast covers how Shahi has benefitted from becoming a vertically integrated supplier, and insights on our collaboration to drive circularity in the fashion supply chain.

February 19, 2021 | Hong Kong University of Science and Technology (HKUST), MBA Session on Supply Chain Sustainability

The session organized by HKUST as a part of their MBA Program focused on sustainability considerations in the global supply chains. We were invited as a guest speaker to offer the MBA students a perspective on how Shahi, India’s largest apparel manufacturer, and exporter, embrace sustainability through focused social and environmental initiatives. The interactive session included questions from the students on the challenges of implementing a multitude of worker wellbeing programs, disseminating best practices across the industry, and managing a large workforce during the COVID-19 crisis.

Please write back to us at od@shahi.co.in for more information.

February 9, 2022
Shahi is accelerating digital operations in the apparel industry
Efforts at Shahi have taken a shift in the last year, and going digital has become the mantra. The focus is primarily on three objectives: improvement in growth, productivity, and experience. While growth and productivity are the focus of every organization globally, experience drives Shahi Exports. It means providing an excellent experience to our customers, employees, and other stakeholders. However, we cannot build this experience without a conscious effort to do it thoughtfully and sustainably.

As part of the strategy to develop this all-around quality experience, we have been engaging novel digital solutions. Using emerging technologies can help an organization unlock new opportunities, including ways to reduce our impacts on the environment.

A few of my favorite initiatives that we have been able to do this year is effectively converting physical activities to virtual ones in a short span of time due to reduced customer and employee travel in the wake of the COVID-19 pandemic. These have helped us save time and money and have reduced our carbon footprint due to significantly reduced fossil fuel usage. These initiatives range from virtual tours of our factories by customers using augmented reality-based solutions to leveraging blockchain-based fiber to retail traceability to ensure ethical sourcing practices.

Where the world is at

Globally, leaders aim to enhance organizational performance through digital technologies. These have become the core of every organization’s strategy these days. Boards have realized that leveraging the right technology to solve the correct problems can give them an edge over the competition. Labor-intensive companies have a big opportunity to transform themselves into tech-driven companies.

The wave of leveraging emerging technology, before the pandemic, gave the world some outstanding new companies in media, shared resource usage, gaming, education, and technology itself. These companies disrupted the existing business models making some even larger companies go out of business. The pandemic changed the context of all such disruptions. People who were shy to use digital technologies or even online meetings had to do it mandatorily now. Many of them cannot imagine going back to old ways.

We divided our digital initiatives into ‘foundational,’ ‘desirable,’ and ‘disruptive’ categories. While foundational and desirable types have precedents in the industry that we can emulate, it is the disruptive initiatives that we take the lead in to solve problems in a novel and more efficient manner.

Utilizing the RRP Mantra

Automation and intelligent solutions optimize manufacturing processes.

Anything that moves from table to table moves at a snail’s pace compared to anything that moves from system to system. To make automated decisions in augmented or virtual reality provides an experience as good as seeing the real thing and collaborating around it. Internet of things technology is also used extensively to calculate and improve productivity at shop floors and move the technology right to the network’s edge.

RRP is our mantra in process automation. First, we automated Repetitive, Rule-based, and Predictable processes and aimed to convert others into RRP processes by eliminating exceptions and process deviations. A simple example is the process of approvals. The first step will be a request, followed by a review, further discussion if needed, and then final approval. Digitalizing the process cuts down extensively on resources and time used to follow through each step.

Another example is the transfer and delivery of material. Tracking the movement of a package through a document that is manually checked at the gate of a facility exposes it to human error and forgery. We can mitigate this by adding a simple QR code to the document, making it unique, reducing human error, and ensuring that data about the movement of the package is stored on a network. This has been a practical exercise that has given us fantastic results in achieving much better productivity overall.

Exploring Ideas

Being disruptive requires a lot of experimentation and working with traditional partners. We have now started working extensively with disruptive start-ups and academia, as well as mining the massive pile of ideas that our employees generate as part of our innovation program. Our recent engagement with NASSCOM for their Manufacturing Innovation Challenge has helped us reach out to young innovators. We are now working on solutions and hope for great results.
Augmented mixed virtual reality to design a clothes in 3D fashion design software program creating virtual, true-to life garment visualization with cutting-edge simulation technologies for the fashion
Some of the experiments revolve around:

RFID-based productivity improvement.

Automatic guided vehicles,

Computer vision-based productivity improvement,

Automated measurement solutions,

Converting 2D images into 3D models with real-time collaboration,

AI-based identification of fabric composition,

Fabric inspection recording automation,

Natural Language Generation based training videos translation in vernacular languages,

RFID-based productivity improvement.
There are many more, and we are not afraid to experiment and fail, but we have seen that our success rate has outgrown our failure rate very fast and has enabled us to become a more innovative company.

Shahi has further improved its turnaround time through our interventions as an agile business. It has even helped our customers increase the accuracy of forecasts. Faster deliveries enable them to forecast their demand closer to the season. Accuracy, therefore, is significantly improved and reduces slow-moving or dead inventory. More robust forecasts act as an essential enabler of sustainable supply chains.

Track & Trace

Each fabric roll is given a barcode which tracks its movement from cutting through garmenting and packaging.

An initiative that has helped us immensely is our acclaimed ‘Track & Trace’ mega project. Track & Trace is one of our projects which has helped us immensely in reducing paper usage. Each fabric roll is assigned a barcode, and this code is used to scan it for all purposes -entry, storage, cutting, and shipping. This is leading to improved transparency in the supply chain. Additionally, it resulted in greater agility, lower cost, and higher visibility of fabric/garment movement. It also reduced manual data entry at multiple points, which is another focus area we had in our mind. This initiative’s end-to-end nature ensures that our efficiency at each stage (warehouse, cutting, sewing, packing, and shipping) is measurable and provides us with rich data for taking steps to improve it further. Before this initiative, the manual receiving from the mills and fabrics utilized our resources- time and effort inefficiently.

Track & Trace has improved the transparency along Shahi’s supply chain. Each fabric roll is assigned a barcode, and this code is used to scan it for all purposes -entry, storage, cutting, and shipping. Currently, we are working on the last phase of Track & Trace that will complete the entire chain by improving transparency at the packaging and delivery stages of the shipment to our customers.

Securing our digital assets

With more and more devices, web applications, and mobile apps connecting to the network, it becomes imperative to ensure no hindrance in business continuity. We must neutralize external threat actors before they can steal crucial data or damage the network infrastructure. Shahi Exports took considerable strides in ensuring that our data center, network, and applications on the cloud are best in class and our information security solutions and practices are of the highest possible standard.

Data is the new oil, and leveraging its value will give precious actionable insights and potentially impact business models. The future at Shahi will employ data science and analytics in our sustainability strategy, making for some fascinating possibilities for the industry. The ideas we are currently working on show a promising future of scaling up across all our operations. It all starts with encouraging ideas and taking small steps to get to a big solution.

Puneesh Lamba is the Chief Technology Officer at Shahi Exports Pvt. Ltd. He is responsible for building Shahi’s IT & Digital strategy and its execution.

Puneesh carries an experience of 28 years as a Senior IT & Digital Leader across industries in India, the USA, and Europe. He has worked for companies General Electric/Genpact and TATA Consultancy Services as well as Indian Conglomerates like Escorts Ltd., Punj Lloyd, CK Birla Group, and Ballarpur Industries.

Puneesh Lamba, Chief Technical Officer, Shahi Exports

As one of India’s pioneers to embrace disruptive technologies like Artificial Intelligence, Robotic Process Automation, Internet of Things, and Predictive Analytics, Puneesh is a proponent of digital means to enable business strategy for growth. He has won many prestigious awards like CIO100, CIO200, CIO500, Power List, and CIO 1000. He is a jury member at NASSCOM, Frost & Sullivan, and, 9Dot9 media.
January 5, 2022
Applications open for Shahi Industry Chair 4.0 at NIFT Delhi
Applications are open for the Shahi Industry Chair 4.0 at the National Institute of Fashion Technology Delhi. This program supports internship or dissertation projects for qualifying candidates.

The Shahi Industry 4.0 Chair for apparel manufacturing was established at NIFT to build a robust relationship between the industry and academia. It aims to facilitate research in emerging technologies that disrupt the apparel manufacturing sector. The potential area of study must fall under Industry 4.0. Each of these projects will result in a detailed document including the final design and technical specifications and a model or prototype or software.

What is Industry 4.0?

Global production and supply networks are undergoing fundamental shifts through increased automation of traditional manufacturing and industrial practices, using modern innovative technology, large-scale machine-to-machine communication (M2M), and the internet of things (IoT). This integration increases automation, improves communication and self-monitoring, and uses intelligent machines that can analyze and diagnose issues without human intervention.

The phrase ‘Fourth Industrial Revolution’ was first introduced by a team of scientists developing a high-tech strategy for the German government. Klaus Schwab, executive chairman of the World Economic Forum (WEF), introduced the phrase to a broader audience in a 2015 article published by Foreign Affairs*.

Who is eligible?

Students in the final or penultimate year of B.E./B.Tech/M.E./M.Tech from any recognized institute.

Candidates should have a good grasp of industrial vision systems, electronics, microcontrollers, electronic actuators, encoders, power transmission systems, motors, and basic pneumatics.

The scholarship will be for a period of 4-6 months, starting January 2022. Selected candidates will receive the scholarship as a monthly stipend of ₹15,000-20,000.

Deadline

The interim deadline for all applications is 5th January 2022, and applications close by 10th January 2022.

What do you need to apply?
1. 10+2 Board Examination Marksheets
2. CPI/CGPA until the most recent semester
3. Academic and professional credentials (share the URL of a maximum of two platforms like ResearchGate, Google Scholar, Linkedin, or a resume.)
4. Tell us about your experience or courses you have taken that are relevant to Industry 4.0 technology.
5. You will be asked to ideate over a challenge statement. Give us an overview of how you would solve it.
6. Tell us about any courses or topics you have studied that help address the challenge.
To apply, visit www.nift.ac.in/scholarshipsfellowships.

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*Schwab, Klaus (12 December 2015). “The Fourth Industrial Revolution”. Retrieved 15 January 2019.
January 3, 2022
Shahi Exports becomes India’s first woven apparel and textiles manufacturer to create Cradle to Cradle Certified® Gold products

In a massive step towards the transition to the circular fashion industry, Shahi Exports is proud to be the first woven apparel and textiles manufacturer in India to be awarded Cradle to Cradle Certified® Gold under Version 3.1, a globally recognized measure of safer, more sustainable products made for the circular economy. The collection of products that have received this certification is called ‘Arth’ (‘Meaning’ in Hindi) and comprises women’s dresses made for C&A.

“We are grateful to our partner C&A for working with us to create this truly innovative, first-of-its-kind, circular product. At every step of the design process, C&A and Shahi worked together to find the right alternative materials, chemicals, and other raw materials to achieve the Cradle to Cradle Certified® Gold level.”

– Ruchi Asija, Vice President, Marketing, Shahi Exports

Cradle to Cradle Certified® is awarded by the Cradle to Cradle Products Innovation Institute, a global non-profit dedicated to powering innovation for the circular economy through products that have a positive impact on people and the planet. Product designers, manufacturers, and brands around the world rely on the Cradle to Cradle Certified Product Standard as a transformative pathway for designing and making products with a positive impact on people and the planet. This certified product standard is rooted in the Cradle to Cradle® design principles established by William McDonough and Dr. Michael Braungart.

To receive certification, products are assessed for environmental and social performance across five critical sustainability categories: material health, product circularity, clean air & climate protection, water & soil stewardship, and social fairness. The product is assigned an achievement level (Bronze, Silver, Gold, Platinum) for each category. Shahi has achieved a Platinum performance level for Material Health, and the Gold level on the other four standard categories. The lead assessment body for this process was Eco Intelligent Growth (EIG) and the material health assessment body was MBDC.

The fabric for the ‘Arth’ collection was made at Shahi’s weaving mill and the garments were stitched at our apparel factory. The entire collection is made using Global Organic Textile Standard (GOTS) certified organic cotton, more than 96% of which is rapidly renewable cotton. Further, 86% of the water used in fabric processing was recycled at our mill having Zero Liquid Discharge. The finished products are 100% carbon neutral. The products are made keeping the principles of circularity in mind and are 100% recyclable.

“The Arth collection is a powerful example of how suppliers and brands can work together to design and create materials and products that meet shared objectives for circularity and sustainability,” said Christina Raab, Vice President of Strategy and Development for the Cradle to Cradle Products Innovation Institute. “By achieving one of the highest levels of Cradle to Cradle certification for the collection, Shahi Exports is not only demonstrating the scope of opportunity for supplier-brand partnerships but also the vast innovation and leadership potential of India’s textile mills.”

The Global Sourcing & Sustainability team at C&A said, “Shahi continues to be a steadfast strategic partner for C&A and a driving force for innovation across the global fashion supply chain. When we began bringing Cradle to Cradle Certified® products to market it was clear that Shahi would be a key partner in scaling Cradle to Cradle across categories. For a product and supply chain to become Cradle to Cradle Certified® it takes an incredible amount of detail and commitment. Most of all, however, it takes supply chain partners with a deep understanding of sustainability, innovation, and their importance to customers, brands, and suppliers. Shahi is a leading supplier in this regard and we are deeply grateful for their continued partnership in driving circular innovation. We look forward to working together to drive Cradle to Cradle Certified® innovations and other ground-breaking sustainability initiatives forward.”

July 26, 2021
Using textile waste to enhance cotton production: Results from a field trial with HKRITA

Shahi and The Hong Kong Research Institute of Textiles and Apparel (HRKITA) are collaborating to advance their shared goals of moving towards a circular economy and ensuring the long-term sustainability of the apparel supply chain. HKRITA’s technologies successfully transform cellulose powder recovered from recycling cotton-polyester blends into a superabsorbent polymer (SAP). The application of this SAP in cotton production was tested in the field by Shahi. Initial results indicate that applying SAP on the cotton plants did improve water retention, especially under extreme water stress, and hence enhanced cotton yield and quality. A larger experiment in 2021 will be conducted to validate these findings.

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November 26, 2020
Insights from speaking engagements: 2020

We love to connect with our industry peers and all other important stakeholders to share our experiences and exchange ideas. In this ongoing post, discover all the conferences and events we have spoken at in 2020.

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May 18, 2020
Insights from speaking engagements: 2019

We love sharing our work and learnings with industry and other important stakeholders. This post is an ongoing compilation of conferences and events we’ve spoken at in 2019. (more…)

December 12, 2019