#### **Overview** Indo Rama Synthetics (India) Limited is India’s **largest dedicated polyester manufacturer**, established in **1986** (some sources cite 1989), and headquartered at its integrated manufacturing complex in **Butibori, Nagpur, Maharashtra**. The company operates under the strategic umbrella of **Indorama Ventures Public Company Limited (IVL)**, a global leader in PET resin and fiber production headquartered in Thailand. As a subsidiary of IVL, Indo Rama benefits from strong synergies in **technology, raw material sourcing, finance, and global operations**, enhancing its competitive edge in both domestic and international markets. --- #### **Production Capacity & Facility** The Butibori plant is one of the **most integrated and cost-efficient polyester facilities in India**, with a **cumulative production capacity of 672,000 tons per annum (TPA)** as of late 2023 and through 2025. This reflects a significant expansion from the earlier capacity of **610,050 TPA** reported up to mid-2023. The capacity breakdown includes: - **Polyester Staple Fibre (PSF):** ~231,000 TPA - **Polyester Filament Yarn (PFY):** ~189,000 TPA - **Draw Texturised Yarn (DTY):** ~175,000 TPA (expanded with 39 new texturizing machines) - **Polyester Chips (Textile Grade):** ~252,000 TPA - **Bottle-Grade PET Resin:** **650 tonnes per day (TPD)** (~237,000 TPA annually), **commissioned in June 2023** This expansion represents a strategic pivot toward **higher-value, margin-accretive products**, particularly **value-added DTY and bottle-grade PET resin**, aimed at reducing exposure to cyclicality in staple fiber markets and capturing strong domestic demand for packaging resins. --- #### **Key Strategic Developments (2023–2025)** - **PET Resin Expansion:** Launched a new PET bottle resin line with 650 TPD capacity (effective June 2, 2023), leveraging IVL’s global expertise in PET. This positions Indo Rama as a key player in India’s growing bottled beverage and packaging industry. - **DTY Capacity Addition:** Commissioned **39 new texturizing machines**, significantly expanding DTY output and improving product mix and margins. - **Debottlenecking Initiatives:** Successfully increased daily production capacity from **1,743 tonnes to 1,920 tonnes** through efficiency improvements and process optimization. - **Capital Expenditure:** Executed a **₹600 crore capex program** initiated in 2022, focused on: - Installation of a **700 TPD PET resin line** (phased commissioning between Jan–Jun 2023) - SSP (Solid State Polycondensation) project - Recycled and specialty filament yarn production This investment is estimated to increase production volume by **~40% in FY2023–24**, boosting profitability and revenue. - **Expansion into High-Margin Products:** Strengthened **full dull filament** and **low IV chips** offerings to meet niche market demands. --- #### **Integrated Operations & Cost Efficiency** The Butibori facility is **fully integrated**, covering polymerization, spinning, texturing, and resin production. This integration enables: - **Cost-effective manufacturing** - **Operational reliability** - **Supply chain control** - **Scalable production** **Captive Power Generation:** - **71.08 MW** of in-house power capacity, comprising: - **40 MW** from coal-based steam turbine generators (STG) - **31.08 MW** from furnace oil-based diesel generator (DG) sets - Ensures uninterrupted operations with backup for its sanctioned 51 MW DISCOM load --- #### **Technology & Operations** Indo Rama operates a **state-of-the-art facility** with technical collaborations and equipment from leading global technology providers: - **DuPont (USA)**, **Toyobo (Japan)**, **Zimmer AG (Germany)** - **Oerlikon Barmag, Autefa, Chemtex (USA)** - **Polymetrix AG (Switzerland)** – for PET resin technology The company continuously upgrades its systems and processes to maintain industrial competitiveness, product quality, and operational efficiency. --- #### **Raw Material Sourcing & Risk** - **Primary Raw Materials:** - **Purified Terephthalic Acid (PTA)** - **Monoethylene Glycol (MEG)** Both are petrochemical derivatives, making the business **highly sensitive to crude oil price volatility**. - **Strategic Advantage:** As part of Indorama Ventures, Indo Rama enjoys **secure and stable access to PTA and MEG**, especially during supply shortages, giving it a significant advantage over non-integrated competitors reliant on imports (particularly from China). --- #### **Market Presence & Customers** - **Domestic:** Serves **20+ Indian states**, with strong presence in key textile hubs - **International:** Exports to **34 countries across five continents** - **Key Markets:** Turkey, MENA, Brazil, Argentina, Mexico, Europe (Germany, France, Spain, Italy), Bangladesh, Nepal, Sri Lanka - **Export Contribution:** ~17.46% of total turnover - **Customer Segments:** - Yarn spinners - Fabric weavers and knitters - Non-woven and hygiene product manufacturers - Technical textiles and automotive suppliers - Packaging industry (for PET resin) --- #### **Growth Strategy (2023–2025)** 1. **Product Diversification:** Shift toward high-margin, value-added products (e.g., DTY, specialty fibers, PET resin). 2. **Operational Efficiency:** Cost optimization, debottlenecking, and improved yield management. 3. **Sustainability & Quality:** Focused on **recycled yarns**, **green manufacturing**, and **quality certifications**. 4. **Market Expansion:** Leveraging **IVL’s global distribution network** to strengthen international footprints. 5. **Backward Integration Advantages:** Continued focus on securing raw materials through parent’s global operations. --- #### **Management & Workforce** - **Workforce:** ~**1,443 employees** - **Leadership Appointments:** - Mr. **Vishal Lohia** appointed in early 2025 to manage increased operational complexity due to scale and diversification - Mr. **Hemant Balkrishna Bal** served as Site Head (Dec 2019–2022), bringing 38 years of global experience ---