Lavino Kapur has world class manufacturing setup for the best cotton products.
Why Us
One Stop Shop
Vertically integrated manufacturing setup
- Complete product range of both semi-finished and finished cotton products
- Capability of transforming semi-finished cotton products into finished cotton products through processes like pad punching, carding and calendaring, rolling and cutting etc.
- Various packaging options such as drawstring bags, zip-lock bags, polypropylene (PP) cans & boxes, and blister packs
- Sustainable product and packaging solutions for our customers
- In-house packaging capabilities to reduce delivery times
- Option to deliver our finished products on pallets to the customer’s warehouse and distribution centres
- Warehousing facilities in the UK and Europe at present and can make the necessary arrangements in other countries as required
- Onsite laboratory to tests raw materials, consumables, packaging materials, semi-finished products, and finished goods, providing excellent quality control
Why Us
Manufacturing Facilities
All-inclusive state-of-the-art-plant situated near Mumbai, India
- Mechanical cleaning and bleaching of cotton up until the production and packaging of the finished products under one roof
- Capacity to produce 6000 tpa of absorbent cotton products
- In-house machinery for manufacturing drawstring bags, offers substantial reduction in lead times
- Ultra-modern hydro-entanglement plant for making cotton fleece and pads, imported from renowned European companies- the first in India
- Automatic equipment for converting fleece into pads, automates the entire pad manufacturing process. This also includes punching of pads, filling them in bags, sealing the bags, passing the bags through metal detectors, and automatically printing batch codes, ensuring full traceability of products
- Equipment supplied by manufacturers from Switzerland, France, Germany, Italy and the Netherlands
Why Us
Supply Chain
Location & Access
- Located in the largest cotton producing region of India
- Locally available packaging material suppliers
- Proximity to India’s largest container port Jawaharlal Nehru Port Trust (JNPT), Mumbai-Delhi rail route and Mumbai-Ahmedabad highway
- 120 km from Mumbai, India’s financial capital gives easy access to a large talent pool
- Access to well-established warehouses in the UK and the Netherlands
Experience & Process
- Years of experience in cotton helps us select the right type of input fibres
- Our staff is trained to select only the best quality raw material
- Testing of all raw material on Advanced Fibre Information System (AFIS) machines to ensure appropriateness of fibre length and maturity
- Testing of bleached cotton in our onsite laboratory ensures conformance to global pharmaceutical standards
Sourcing
- Long-term relationships with our suppliers, some of them over four decades long
- Regular audits of our suppliers premises
- Input material cotton comber noil is a very clean by-product generated from textile mills during their spinning process
- BCI, Fair Trade and Organic Cotton from our reputed suppliers and manufacture products when required
Why Us
Quality
Long-standing relationships with our customer’s, some of them dating back to 1970s are testimony to our quality
- We use only high-quality input fibres to meet consistent high quality standards
- Special cleaning methods to help meet our customers’ stringent quality requirements
- Advanced bleaching techniques help achieve impeccable spotlessness, while retaining the natural properties of cotton
- Bleached cotton fibres tested in our onsite, state-of-the-art laboratory for conformance to British, European, Japanese and American pharmacopeial standards
- Cotton pads manufactured using an eco-friendly process, hydro-entanglement, impart multi-directional strength to cotton and prevent fibre shedding on use
- Microbiological tests of our products, personnel and equipment ensure all our products are produced in the most hygienic conditions, consistently
- Advanced MIS system for up-to-the-minute details of production, consumption, worker turnout, repairs and maintenance and information for each batch of finished product
- Unique batch code on each retail pack provides complete traceability
Why Us
External Audits & Certifications
- Certified by ISO 9001:2015; BRC; BSCI; GOTS; FSC
R&D
- Our on-site laboratory and a robust quality assurance system test raw material, consumables, packaging material and finished products to ensure that we consistently meet high-quality standards
- Our products are also tested for microbiology (an additional requirement, not required for such products)
Certifications by leading global organizations audited by globally renowned retailers and healthcare organizations
- Japanese, British, European and US Pharmacopeia norms
- Comprehensive and well maintained QMS – ISO 9001:2015, BRC & GOTS (organic cotton products), FSC and Fairtrade certified. We are also BSCI compliant
Why Us
ENVIRONMENT & SUSTAINABILITY
Passionate about preserving nature and fighting climate change since our first plant in 1970s
- Investment in energy efficient equipment and green practices
- Recycle and reuse water through our hydro-entanglement plant, kier and caking process and chillers
- Recovery of hot water from steam condensate resulting in lower fuel consumption for heating the water
- Installation of filters in our thermic fluid boiler ensuring a better transfer of heat for our drying process and lower fuel consumption
- Upgraded to the latest burner systems for our boiler for more efficient functioning
- Use Hydrogen Peroxide (H2O2), the most eco-friendly bleaching agent in the bleaching process
- Eco-friendly hydroentanglement process for cotton pads to bind cotton fibres instead of binders or adhesives
- Routine audits of our chimneys to control emissions
- Effluent Treatment Plant on our factory premises to process and treat waste water
- Setting up of the first Common Effluent Treatment Plant (CETP) in Tarapur to ensure all the water leaving factory premises is treated to reduce biochemical oxygen demand (BOD) and chemical oxygen demand (COD) levels
- Compliance with REACH, a regulation of the European Union, which aims to protect human health and the environment from potential risks of chemicals
- Lowering fuel consumption through LED lighting, a heat exchanger system, special insulations, compressors with Variable Frequency Drives (VFD), water-cooled chiller & latest technology compressed air pipelines
- Sustainable product and packaging solutions
- Modification of our cotton buds producing machinery to manufacture cotton buds with FSC certified paper stems
- Bio-degradable and compostable packaging material such as Poly Lactic Acid (PLA) / Corn Starch
- Paper box packaging
- Bags made from LDPE and boxes made from polypropylene (PP) packaging options
