Third in line after T-shirts and bottoms, sweaters are a major product category for Bangladesh. Of the total apparel exports in 2023 which have been worth US $ 47.38 billion, sweaters contributed around US $ 6.10 billion which is 12.87 per cent of the total exports. Interestingly, sweaters constitute a little more than 29 per cent specifically in Bangladesh’s knitwear exports valued at US $ 20.87 billion, up by 5 per cent as compared to what it was in 2016. The data shows the growing potential of sweater manufacturing in the country, leaving much room for growth and improvement.
Sayem Group – a leading sweater manufacturing company in Bangladesh – is dedicated to tapping a larger market share in the sweater category. Sayem Fashions Ltd., and Radiant Sweater Ltd., are two units of manufacturing within Sayem Group, aspiring for complete customer satisfaction owing to the high-quality sweaters at competitive prices (FOB prices start at US $ 4 and go up to US $ 25) with a track record of 95 per cent on-time delivery.
Established in 1999, Sayem Group has become a name to reckon with for the manufacturing of pullovers, cardigans, sweaters, jumpers, vests, scarves and woolen caps etc., for men, women and children. The production capacity of both the factories combined is around 320,000 pieces per month for both basic and high-end sweaters ranging from 3gg – 12gg which makes it clock an annual revenue of around US $ 20 million.
“We have 600 jacquard machines installed in our factories – all advanced machines. The production processes of sweaters are comparatively simpler. They differ from the procedures involved in denim production, such as dyeing and other complex techniques. Our focus lies in obtaining quality yarns, winding them, navigating the jacquard linking process and ultimately finishing the product. This approach is reflected in the scale of our factories, where we prioritise efficiency. Our quality speaks volumes for ourselves,” mentioned Abrar Sayem, Director, Sayem Group while speaking to Team Apparel Resources.
Efficiency improvement is the focus
Sayem Group introduced automatic jacquard knitting machines from Shima Seiki that have been complemented by some Chinese machines for experimentation. The air-conditioned knitting floor at Sayem Group is equipped with measures to prevent static electricity and to ensure the yarns do not dry out. Yarn cones, aligned with the day’s production target, are strategically stored on racks positioned adjacent to the knitting machines. This setup not only minimises style changeover time but also optimises machine idle time, enhancing efficiency and productivity.
Sayem Group currently operates at 1:5 man-to-machine ratio, where one operator manages five jacquard machines, with plans to achieve 1:8 in future. The average floor efficiency in Sayem Group’s factories hovers around 65 per cent
The group also maintains its commitment to manufacturing excellence. Lean linking lines have been established for sweaters, streamlining linking, inspection, finishing and packing operations in a sequential single-line set-up. The innovative linking department layout has increased efficiency by 10 per cent compared to conventional set-ups. “Linking operations are executed on the automated linking machines, outperforming performance of conventional linking machines by delivering a 15 per cent – 20 per cent increase in output,” mentioned Sayem.
| Sayem Group works with renowned fashion brands and retailers in traditional markets such as New Yorker, Whispering Smith, Dansk Supermarked, Tally Weijl, Gemo GmbH, Marisa, Takko Fashion USPA, Stooker Brands amongst many others. |
These machines, equipped with patented mechanisms, overcome issues like low elasticity in linked seams, seamlessly performing overlocking, linking and yarn trimming in a single operation – a combined job typically requiring three individuals. Particularly suitable for aligning stripes and complex patterns in sweaters, these machines contribute to Sayem Group’s efforts towards achieving manufacturing excellence and operational efficiency.
Sweaters suffice the capacity at Sayem Group, thanks to market diversification
Markedly, Sayem Group keeps its focus on manufacturing sweaters only despite the fact that it is broadly believed to be a seasonal business which it is not as geographically many countries encounter winters throughout the year. This strategic decision is driven by the substantial market share available for the company to capture in the sweater industry. The manufacturing facilities of Sayem Group operate consistently throughout the year. However, there are only three months as exception during which they operate at 80 per cent capacity due to fluctuations in orders and workflow.
Sayem gives credit to the group’s foray into non-traditional destinations to address market demands, maintain consistent production and increase reach. “Specifically, we cater to markets in Korea, Australia and Brazil during periods when demand is lower in Europe and the United States,” mentioned Sayem, adding, “However, Australia poses a challenge due to its price-sensitivity. On the other hand, the group’s business in Korea is thriving, demonstrating large volumes and favourable pricing.”
Moreover, in addition to geographical diversification, Sayem Group’s product range has expanded. Currently, it is producing many fine gauge sweaters that find demand even in Europe during the spring, extending the traditional sweater season. Furthermore, its product line includes knit T-shirts, which though thicker than regular T-shirts, provide a similar feel. This unique style, resembling a hanging T-shirt at the back, has garnered orders even during the summer, particularly for the UK market.
New B2B marketplace is proving to be a boon
Recently launched by Sayem Group, Merchant Bay is a B2B marketplace for apparel sector which aims to identify a gap in the ‘co-creation process’ between global brands and manufacturers. Merchant Bay aims to connect brands with global designers and leverage AI integration for instant design variations, strengthening Bangladesh’s position in design. The platform’s core focus is on converting inspiration into real products efficiently, reducing time in procurement and sampling. “Our immediate plan involves onboarding scaling brands through a subscription service, providing extended supply chain support and launching AI features, with a goal of reaching 100 brands globally by the end of the year,” concluded Sayem.
