The manual doffing process in texturing plants—where workers scurry to cut and replace full yarn packages—is being quietly automated. In June 2026, Barmag (Suzhou) Technology Co., Ltd. and Surat-based Hitech Automation Solutions PVT LTD. entered an exclusive partnership to integrate Hitech’s Doffmatic auto-doff system onto Barmag’s existing manual eFK texturing machines. The move targets the installed base, not just new machine sales.
Why Doffing Automation Matters
Doffing has long been one of the most labor-intensive steps in texturing. Operators must monitor package diameter, cut the yarn at the target length, remove the full package, and insert a new tube. The process is repetitive, time-sensitive, and prone to defects. Industry data shows doffing labor can account for 15%-20% of direct labor costs in a mid-sized texturing plant.
Hitech’s Doffmatic system automates this cycle: it detects completion, cuts, removes, replaces the tube, and re-threads automatically. By pairing this with its eFK series, Barmag offers a clear upgrade path for the large installed base of manual machines.
The Retrofit Market Logic
For fiber plants, replacing manual texturing machines with fully automatic new ones requires heavy capital and production downtime. A retrofit module allows stepwise automation while retaining the main machine structure. The Barmag-Hitech deal targets exactly this middle ground.
This partnership resonates strongly in dense processing clusters like Surat, India, and Shengze and Keqiao in China. Surat, Hitech’s home base, is one of the world’s largest synthetic fiber processing hubs with a vast stock of older machines. In China’s Jiangsu and Zhejiang provinces, plants face rising labor costs and recruitment difficulties. Barmag’s Suzhou facility can provide local technical support and retrofit services, lowering the adoption barrier.
Impact on Buyers and Plants
First, labor structure changes. A doffing team of 3-4 workers per shift can be reduced to one roving inspector after installing Doffmatic. In the Yangtze River Delta, where textile worker monthly wages have surpassed RMB 6,000, the savings are tangible.
Second, production stability. Manual doffing pace depends on worker skill and stamina; automation ensures 24/7 standardized operation, reducing downtime from changeover delays. For plants producing high-end micro-denier or colored yarns, improved package consistency lowers rejection rates in downstream weaving.
However, retrofitting has thresholds. The Doffmatic system must interface with the existing eFK control system; plants need to assess electrical compatibility. Initial investment runs in the hundreds of thousands of RMB per machine, requiring a careful payback calculation based on machine count, product mix, and order volume.
Trends and Practical Advice
This partnership reflects a broader shift from “automation as new-machine standard” to “automation as installed-base upgrade.” The typical replacement cycle for texturing machines is 8-12 years. Modular upgrades rather than full replacement are becoming a pragmatic choice.