Customer Success Story from Hayleys | SUNTECH Textile Machinery

SUNTECH & Hayleys
Delivering High Quality Fabrics to End Customers

Hayleys is a leading manufacturer of weft knitted fabrics in Sri Lanka, supplying high-end brands and retailers across Europe, North America, and Japan. With a fully integrated manufacturing process that includes knitting, dyeing, printing, brushing, and finishing, Hayleys ensures complete control over quality at every stage of production.
SUNTECH & Hayleys
Delivering High Quality Fabrics to End Customers

To maintain its rapid growth and uphold product excellence, Hayleys continually invests in research and development. As part of this commitment, SUNTECH supplies multiple fabric inspection machines, enabling Hayleys to enhance quality control and ensure only the finest fabrics reach its customers.

Background

Hayleys, a pioneer in weft knit fabric manufacture in Sri Lanka, commenced operations in 1992. Presently, recognized as a world class fabric manufacturer with a high degree of innovative capabilities. Hayleys Fabric PLC, has an annual turnover of USD 72 Million with a capability of delivering over 3 million meters of fabric per month. Hayleys thrived on exploring the possibility of tomorrow to deliver fashion-forward fabric loved by apparel giants globally. Hayleys also focuses on environmentally friendly processes and uses the best practices in sustainability, environment, health and safety to drive its business. These initiatives have helped the company attract the world's top brands to its product portfolio.

Hayleys' collaboration with SUNTECH started in 2014. Over the past decade, Hayleys has invested in nearly 30 SUNTECH machines and a significant amount of accessories. Strict equipment requirements and standards are the foundation of our partnership. SUNTECH continuously helps Hayleys maintain production efficiency and high delivery standards, which has made us a trusted supplier for Hayleys and established a long-lasting, solid partnership.

Honored Customer Journey

With our collaboration starting in 2014, Hayleys has purchased around 30 fabric inspection machines and they have been in good condition so far. As the demand for cutting-edge production capabilities has grown, Hayleys has deepened its partnership with SUNTECH, particularly in the fabric inspection process, by investing in the latest equipment to meet the need for high-quality fabric deliveries. Through customized solutions tailored to unique customer needs, SUNTECH has helped Hayleys optimize inspection processes and enhance product quality, solidifying their position as a trusted industry leader.

Recently, SUNTECH updated and launched a VIP system, recognizing Hayleys as one of our most valued partners. This year marks the tenth anniversary of our collaboration, highlighting the depth and strength of our partnership. We look forward to visiting Hayleys soon to learn about their production developments, to better understand customer needs and express gratitude for their enduring trust and collaboration.

Looking ahead, Hayleys and SUNTECH are ready to continue their journey, leveraging cutting-edge technology and a shared vision to push the boundaries of textile excellence. This vibrant partnership showcases the power of innovation, dedication, and an unwavering pursuit of industry excellence.

Challenges & Why SUNTECH

Business Challenges

To promote the development of the textile industry, the Sri Lankan government has introduced various support policies, such as tax incentives and encouragement of foreign investment. However, the industry still faces significant challenges. Rising raw material prices are one issue, but the most pressing concern is the increasing labor costs. Compared to the low wages in Bangladesh and India, Sri Lanka's cost advantage in textiles has diminished. To remain competitive, Hayleys must invest in updating production equipment to ensure efficiency. In particular, the fabric inspection process requires a lot of repetitive checks, leading to a high demand for labor, and ensuring quality and high standards in inspections poses a significant challenge.
Product Requirements

Hayleys primarily exports its fabrics to the United States, Europe, and Japan. In the competitive global market, maintaining top-notch product quality and high delivery standards is crucial for retaining these customers. To address issues like low efficiency in fabric inspection and reducing human error, Hayleys has invested heavily in inspection equipment over the past decade to ensure the highest pass rates for fabric deliveries. Most importantly, these solutions must be user-friendly, allowing operators to work easily and effectively minimize operational mistakes.
Why SUNTECH

From the very beginning of our customer interactions, SUNTECH's product team engages closely with clients to understand their specific needs. Based on their pain points, we deliver tailored solutions that improve both product performance and user experience. Additionally, SUNTECH boasts a comprehensive technical after-sales team, ensuring timely support when needed. One customer’s fabric inspection machine, which has been in operation for over 10 years, remains in excellent condition, with occasional accessory purchases. Our services also include local maintenance and regular visits, helping customers address machine usage and maintenance issues promptly and efficiently.

SUNTECH Solutions to Help Out

Classic Fabric Inspection Solution

SUNTECH's classic fabric inspection machine has transformed Hayleys' quality control processes, allowing their team to scan fabrics at an average speed of 20-25 meters per minute—nearly double the previous rate. By investing in these innovative solutions, Hayleys has driven operational excellence and quality assurance to new heights.

The Fabric Inspection Machines, purchased by Hayleys, features tension-free inspection machines for knit fabrics that automatically control fabric tension. These machines are versatile, handling a wide range of fabrics including tension-sensitive elastomeric and lycra fabrics, as well as stable woven, technical, and upholstery materials. They can be configured to operate from plait/loose fabrics to roll or with various other fabric inlet and outlet options. Compared to other tension control fabric inspection machines, the fabric inspection machines offers more stable, precise, and rapid tension adjustments significantly improving defect detection efficiency.

Additionally,the integrated four-point system has simplified the quality control workflow, reducing training time, and minimizing inspection errors. The system accurately records fabric defects and numbers providing comprehensive inspection reports. This enhancement has streamlined operations improved fabric quality and consistency, and dramatically reduced customer complaints and returns solidifying Hayley's reputation for exceptional qualityand customer satisfaction.

Reviews from Hayleys

Hayleys expressed their gratitude to SUNTECH and its partners for their invaluable support

In the past a decade of cooperation, SUNTECH has become our most reliable textile machinery supplier in China. They provided us with detailed product usage and installation instructions, which allowed our machines to continue to operate normally and effectively improved our fabric inspection efficiency. We look forward to closer contact and cooperation with SUNTECH in the future.

-- Rohan Goonetilleke

(CEO)

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