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Sri Bhagirath Textiles Ltd

Sri Bhagirath Textiles Ltd

Yarn & Fabric Manufacturing — 5 Decades of Excellence
5 Units + HO & Central Warehouse
Systech Texora — Spinning, OE & Knitting Operations
Yarn & Fabric ManufacturingSpinningKnittingUSTER IntegrationQR Code InventoryLive ProductionManufacturing P&LMulti-Unit
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The Challenge

Unifying a Large-Scale Textile Operation Across Spinning, OE & Knitting

Sri Bhagirath Textiles Ltd, a traditional group in the textile business for over 5 decades, started as a cotton supplier and grew through backward integration into yarn and fabric manufacturing. Today they are one of the country's leading producers of yarn and fabric, synonymous with excellence in quality. With infrastructure spanning 5 units, a head office, and a central warehouse — comprising Spinning, OE, and Knitting operations with a capacity of 1 lakh spindles producing 80 tonnes of yarn per day and 50+ knitting machines producing 25 tonnes of fabric per day — they needed a single platform to unify operations, costing, production, and finance across this scale.

Multiple units operating on fragmented legacy systems with no unified visibility
Bale management was manual — no integration with USTER for fibre properties, no traceability from purchase to laydown
Entire inventory across units was untracked — no QR code or scan-based system
No real-time WIP, waste, or yarn/fabric realization tracking across Spinning, OE, and Knitting
Manufacturing costing was approximate — no precise cost-to-production mapping
Production data entry was manual with no live production visibility
Energy costs not tracked at a granular unit-per-kg level
Sales dispatch planning, e-way bills, and e-invoicing were disconnected processes
Maintenance of machinery was reactive, not planned
Finance and statutory compliance were not integrated with operations
Manufacturing P&L and balance sheets were periodic, not live

The Solution

Systech Texora — Complete Digital Transformation for Spinning, OE & Knitting

Implemented Systech Texora across all 5 units, head office, and central warehouse — covering the full lifecycle from bale purchase to yarn and fabric dispatch. The solution unifies Spinning, OE, and Knitting operations under one platform with precise costing, live production, QR-coded inventory, and fully integrated finance.

🏷️ Bale Management System — RMI USTER-integrated for fibre properties, auto debit notes, QR code for every bale, mixing plan, and mixing issues right up to bale laydown
📦 Complete QR Code Inventory — Entire inventory across all units and central warehouse codified with QR codes for instant traceability
🏭 Multi-Unit Performance — 5 units with individual performance tracking, central warehouse management, and inter-unit transfers
💰 Precise Costing — Accurate cost-to-production mapping across Spinning, OE, and Knitting operations down to the last rupee
📊 Online WIP, Waste & Realization — Real-time work-in-progress tracking, waste monitoring, and yarn/fabric realization analytics
⚡ Live Production — Real-time production dashboards with IoT integration in progress for manless data entries
🚚 Sales Dispatch Plan — Dispatch planning integrated with e-way bill and e-invoice generation
⚙️ Energy Management — Granular energy tracking down to unit-per-kg (UKG) for cost optimization
🔧 Maintenance Module — Planned maintenance scheduling for machinery across all units
🏦 Fully Integrated Finance — Complete statutory compliance, banking, and financial reporting connected to operations
📈 Live Manufacturing P&L & Balance Sheets — Real-time manufacturing profit & loss and balance sheets — an ultra-special feature delivering live financial visibility
🧶 Spinning & Knitting Coverage — The entire solution uniformly covers both Spinning and Knitting operations
Implementation Timeline:24 weeks phased rollout across 5 units with zero production downtime

The Results

Measurable business impact

Inventory Accuracy
Manual tracking99.5% with QR codes
Near-perfect traceability
Manufacturing P&L
Periodic & approximateLive & precise
Real-time financial visibility
Production Visibility
Manual entries, delayedLive dashboards
Real-time across 5 units
Energy Tracking
No granular dataTracked to UKG
Precise cost optimization
User Adoption
45% (legacy systems)96%
Easily adoptable by users
Costing Precision
±5% variancePrecise to the rupee
98% improvement
✅ USTER-integrated bale management with QR code traceability from purchase to bale laydown
✅ Entire inventory across 5 units and central warehouse QR-codified for instant tracking
✅ Real-time WIP, waste, and realization tracking across Spinning, OE, and Knitting
✅ Live manufacturing P&L and balance sheets — financial visibility that was never possible before
✅ Precise costing across all operations replacing approximate calculations
✅ Live production dashboards with IoT integration underway for manless entries
✅ Sales dispatch planning seamlessly linked with e-way bill and e-invoice
✅ Energy management tracked to UKG enabling targeted cost reduction
✅ Planned maintenance module ensuring uptime across all units
✅ Fully integrated finance covering statutory, banking, and operational needs
✅ Users find the system easily adoptable — last-mile customization completely addressed
✅ Single platform unifying 5 units, HO, and central warehouse under one view
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We have been in the textile business for five decades and have seen many systems come and go. Systech ERP is the first that truly covers our entire operation — from USTER-integrated bale management to live manufacturing P&L across all our units. The precision in costing and the real-time visibility into production, waste, and realization is something we never had before. Our people adopted it because it was built for how a textile business actually runs.

Naveen Rander, Managing Director
Sri Bhagirath Textiles Ltd

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