A US Cotton Trust Protocol certified supplier. Learn more
PT Gokak is Indonesia’s largest core spun yarn spinner, yet it is able to offer highly customized products.
A key shift in supply chain strategy has been to look for suppliers who can offer innovation and agility as well as stability.
For mills, this means balancing the ability to provide highly customized products with the capacity to produce consistent quantities of yarn while maintaining quality standards.
But can a large mill also offer highly customized products? Looking at PT. Gokak, it can.
“PT Gokak follows a focused approach towards all our customers. We value them as partners and understand their specific requirements in terms of quantity, quality, price and importantly after sales service,” said Mahaveer Kolhapuri, President Director.
“We have a very strong marketing team who are in constant touch with all our customers. Because we are not a very big organisation our decision making is fast and timely,” he said.
The company has the largest core spun yarn capacity in Indonesia and provides a basket of yarns such as cotton carded, cotton combed, cotton core spun yarns, cotton slub yarns, cotton open end yarn, polyester viscose yarns and polyester viscose core spun yarns.
We value our customers as partners and understand their specific requirements in terms of quantity, quality, price and importantly after sales service.
Almost 100 percent of PT Gokak’s sales are to repeat buyers. From its start as a small domestic player the company now has customers on four continents and supplies yarns to many well-known global brands.
During the past year, the company has seen a surge in orders from Bangladesh, with the nation accounting for about 30-40 percent of total exports.
Now PT Gokak is looking to grow its exports in the US and South America.
An Innovative New Yarn Concept
In recent years Gokak started producing MOSAIC yarns on attachments supplied by Pinter Spain. Mosaic yarns are made from blends of cotton/polyester and cotton/polyester/viscose. They have developed about 30 different patterns in mosaic yarn and are the only producer of these yarns in Indonesia. In addition, they also manufacture slub yarns and have their own in-house twisting capacity.
Forty Years of Stable Growth
The company was established as a joint venture between Gokak Textiles India, Thakral Brothers and Tolaram group. The company was registered in 1979 and started commercial production in 1982. Over the years ownership changed and now it belongs to the prestigious Shapoorji Pallonji and Company (SP Group Conglomerate).
PT Gokak was established with 20,000 spindles and expanded and modernised over the years. Modernisation was done through the year 2000 and major replacement was carried out in the year 2007. PT Gokak added significant capacity in core spun yarns during the years 2016-2019. From 2016-2019, the company invested in a major expansion of its core spun yarn capacity.
Initially the company was manufacturing cotton yarns and cotton mercerised yarns. Subsequently capacity was added to make polyester/viscose blended yarns. Today they make cotton yarns combed and carded, polyester/ viscose blended yarns and open-end yarns.
Today, capacity has reached 65,000 ring spindles, 1,320 Open End Rotors and a twisting capacity of about 2300 Spindles. Monthly production is about 1650 metric tons and annual production is about 19,500 metric tons.
How Quality and Transparency are Driving Sales
In addition to investing in state-of-the-art equipment, innovation and outstanding customer service, PT Gokak invests in world class raw materials to ensure that its products meet the highest international standards.
One way they do this is through choosing U.S. grown cotton.
“US Cotton is a brand by itself and many of our customers demand yarn made by US cotton. We have been using US cotton for four years as it has given us good spinning value, consistent quality of yarns and a good yield in terms of yarn realisation.
“Since we buy a specific growth of USA cotton, we get good consistency in the cotton quality and supply. This helps us to reduce production losses. Being a contamination free cotton, it helps us to market our yarns to those customers who look to buy contamination free yarns,” said Mr. Kolhapuri.
“One of the most important points about US cotton is the availability of a quality report for each bale. This enables us to plan the production in advance.
The US Cotton Trust Protocol (USCTP) is a good initiative and definitely will add value for us as well as our customers,” he added.
PT Gokak has started marketing its yarns with the US Cotton Trust Protocol.
“Having this Trust Protocol has certainly enhanced the image of our company and products.
“CCI has also been active in conducting seminars/webinars which update our knowledge of the overall industry. They feature prominent speakers who are well versed in important subjects and can impart knowledge,” he said.
CCI has recently visited PT Gokak virtually and with help of HoloLens and was able to provide some valuable inputs.
“They will send a technical person to our factory for further study and to improve overall performance. Having data from many factories, they are in a position to share this and bring about meaningful change beneficial for the user.”
Future Vision
Pt Gokak has plans to add more compact attachments on the existing ring frames, which will give an edge on quality.
“We have plans to go for automation in various departments to reduce the dependence on high-cost labour,” said Mr. Kolhapuri.
The company intends to increase its combed yarn capacity by 25 percent. As part of its 3-year plan, PT Gokak is looking to expand its capacity by about 30 percent. It is also developing products like Dual Core, Siro yarns and Core Spun Yarns using Lycra, as well as considering the possibility of making Modal/cotton blends.
Learn More https://gokakindonesia.com
The COTTON USA Advantage
- Family growers who are committed to working their fields sustainably and leaving them better for future generations.
- A long history of innovative harvesting and ginning technologies resulting in higher-quality cotton.
- One of the highest rates of adoption in the world for Precision Agriculture, which minimizes water and pesticide usage.
- U.S. farmers operate under voluminous, stringent, and enforceable regulations.
- A commitment to transparent partnership that is unmatched anywhere.
- One of the most comprehensive systems for monitoring and measuring all the key metrics involved in sustainability.
U.S. Cotton Facts
- 2/3 of U.S. cotton land uses only rain water
- U.S. cotton water use efficiency has improved by 82% over the past 35 years
- Cotton is carbon footprint neutral, meaning the plants remove more greenhouse gasses than production produces.
Sustainability Goals
The U.S. cotton industry is building upon the strong environmental gains already achieved over the past 35 years. The aim is to help members meet their current needs while making the world a better place for future generations.
Specific goals include:
- Reducing by 13 percent the amount of land needed to produce a pound of cotton fiber
- Reducing soil loss by 50 percent, in balance with new soil formation
- Increasing water use efficiency (more fiber per gallon) by 18 percent
- Reducing greenhouse gas emissions by 39 percent
- Increasing soil carbon in fields by 30 percent
- Reducing energy to produce seed cotton and ginned lint by 15 percent
Learn More www.cotton.org
Certified Sustainable
The Trust Protocol is aligned with existing sustainability programs including the U.N. Sustainable Development Goals. It brings quantifiable and verifiable goals and measurement to sustainable cotton production, and drives continuous improvement in six key sustainability metrics – land use, soil carbon, water management, soil loss, greenhouse gas emissions, and energy efficiency. The Trust Protocol is designed from the ground up to address the unique regulatory and larger farm growing environment in the United States.
How the Trust Protocol Works
Through a combination of a unique credit accounting system and the Permanent Bale Identification (PBI) system, the Trust Protocol helps ensure the commitments behind our cotton. Each of the Trust Protocol credits are backed by real sustainability data and third-party verified.
Measures and Verifies Sustainability Commitments
The Trust Protocol enables brands and retailers to better track the cotton entering their supply chain and to further quantify and report on their individual sustainability goals and objectives.
Continuous Improvement in the Fields
The 16,000 cotton farms in the United States have been committed to continuous improvement for decades. Over the past 35 years, U.S. cotton production has used 79% less water per bale and 54% less energy. We have reduced greenhouse gas emissions by 40%, and land use per bale by 49%. We need to continue to innovate and introduce new practices that will serve to further position U.S. cotton as one of the most sustainable cotton growing nations in the world.
Learn More https://trustuscotton.org/about/
