Knitted Socks (Cotton/Nylon)
| Product Code | 260103/260301 |
| Quality and Standards | Nylon Socks-IS 5084:1990 Socks Cotton-IS 3329:1973 |
| Production Capacity | Quantity: 1,50,000 Dozen Pairs Value : Rs. 34380000 |
| Uploaded on | August 2007 |
Introduction
In the hierarchy of human needs, clothing occupies the second top most priority coming only next to the food. The use of socks by the armed forces fighting in high altitude and in adverse climatic conditions has now been finding its ways among executives and school children. Wearing of any kind of shoes without socks is termed as incomplete. Socks are simple items and one of the basic necessities of people of all ages and income strata. Socio-economic changes and fashion awareness amongst the masses have brought in a sea change in the living styles in India.
Socks of various types and designs can be produced by using cotton yarn, acrylic yarn, polyester yarn, nylon yarn of different counts, quality and shades. The elastic portion on the top of socks is produced by using rubbered yarn or lycra yarn. This project is prepared for the manufacture of men's socks for domestic market in various sizes to ensure that this commodity is available in a wide range. Subsequently, the unit may diversify for similar products like children socks, women stockings etc. depending upon the market demand from time to time.
Market Potential
The demand for the socks has been increasing gradually for the last few decades particularly in India and other developing countries. The largest consumer of socks are the Europeans and Western countries who have been using this item as part of their dresses for a very long period. The European and Western countries have been producing socks, from where these items used to be imported into India and other countries.
However, as the item has gradually become popular, the socks have also been produced in India initially to meet the domestic demand and subsequently for export purposes. Over the past few years as the standards of living went up, the socks which were earlier worn to provide comfort to the feet have now become part of fashion commodities. The socks industry has a very bright future as its demand both in India and abroad has increased substantially.
A Survey conducted recently show that only 2% of population in India wears socks and therefore, 98% market is yet to be exploited, while consumption of socks in most advanced countries is extremely high. The existing production capacity in the country is grossly inadequate to meet the domestic and international demand. It is, therefore, feasible to set up more socks knitting units.
Basis and Presumptions
The building is considered of its own. The project is based on single shift basis and 300 working days and time period for achieving maximum capacity utilisation considered from 3rd year from the date on which production is started. Costs of machinery and equipment mentioned in this report refer to a particular make and approximate to those prevailing at the time of preparation of this project. The cost of installation and electrification is taken @ 10% of cost of machinery and equipment. Non-refundable deposits, project report cost, trial production, security deposits with State Electricity Board are taken as pre-operative expenses.
Depreciation has been considered as 10% on plant and machinery, 20% on furniture and fixtures and 25% on workshop accessories. Interest on capital loan is considered as 14% per annum. Minimum 25% of total investment is required as margin money. Break-even point has been calculated on full capacity utilisation.
Implementation Schedule
The implementation schedule of this project may take a total period of six months approximately for starting the production.
Technical Aspects
Process of Manufacture
Initially, the size and design of the socks to be knitted are decided and accordingly, the machines are selected and set. After setting the machine with the required design and size, the predetermined colour yarns are loaded on the bobbin stands in the creel assembly of the machine and fed into the knitting elements of the machine.
Socks are knitted in continuous process and several operations are performed before a socks is completed. Knitting is done in stages begining with elastic portion for which elastic yarn is used. The leg portion is knitted followed by heel and foot portion ending up with the toe portion of the socks. The toe portion of socks is closed by stitching on overlock machine. Socks thus produced will have acquired dirt which have to be removed by washing in socks washing machine containing mild detergent. After washing, socks are charged into hydroextractor to remove excess water and dried in dryer tumbler. Visual examination is done to remove any faults and finally ironed to remove wrinkles and also to provide proper shape. Socks are reversed and paired manually by attaching pins at different places and packed in polythene bags. About 10 pairs of socks are put into paper board box for sending it to customers.
Quality Control and Standards
Strict quality control is required to be implemented/monitored in each stage of operation cycle of manufacturing process. Raw materials (Yarn) should be purchased only from reputed manufacturers and should have excellent fastness properties as the quality of socks largely depends on yarn quality. The Bureau of Indian Standards have specified following Indian standards for knitted socks.
Cotton socks – IS 3329:1973
Nylon socks – IS 5084:1990
Production Capacity (per annum)
Product |
Quantity |
Value (Rs.) |
| Plain Socks (Doz. pairs) | 90,000 | 17820000 |
| Terry Socks (Doz. pairs) | 60,000 | 16560000 |
| Total | 1,50,000 | 34380000 |
Motive Power
62 HP of power is required to run this unit. For interruption-free running of the unit, a genset is proposed to be installed as stand-by arrangement.
Pollution Control
No Pollution is generated in the manufacture of socks. As such no pollution control measure is required to be undertaken.
Energy conservation
Energy can be saved by adopting proper house-keeping methods.
Financial Aspects
Financial Aspects
| Land and Building | |
| Land 600sq.mt. @ Rs. 2000p.s.m. Amounting Rs.1200000 | |
| Factory shed | |
| Factory shed | 250 sq. mt. |
| Store (Raw material) | 50 sq. mt. |
| Store (Finished goods) | 50 sq. mt. |
| Office etc. | 25 sq. mt. |
| Total Covered Area | 375 sq. mt. |
| Total Construction Cost @ Rs. 3000/sq.mt. | 1125000 |
| Total Investment in land and Building | 2325000 |
Machinery and Equipments
Description |
No. |
Rate (In Rs.) |
Amount (Rs.) |
| Automatic power socks knitting machine for the production of 3 colour jacquard socks with horizontal stripes plaiting system colour by colour motif and mesh with colour modes M1 MC3 | 30 | 250000 | 7500000 |
| Automatic power socks knitting machine for the production of terry socks with 2 colour motif and horizontal stripes and broad rib elastic top upto 23 steps | 20 | 150000 | 3000000 |
| Power driven overlock machine (high speed) | 8 | 58000 | 464000 |
| Rotor cabinet socks setting machine with built-in boiler and 36 frames | 1 | 480000 | 480000 |
| Garment washing machine 50 kg. | 2 | 180000 | 360000 |
| Hydroextractor 25 kg. | 1 | 85000 | 85000 |
| Dryer Tumbler 25 kg. | 1 | 180000 | 180000 |
| Wash room trolleys | 3 | 10000 | 30000 |
| Steam press (Central boiler type) | 2 | 200000 | 400000 |
| 30 KVA Generator Set complete | 1 | 150000 | 150000 |
| Personal Computer (Pentium IV Processor) | 1 | 50000 | 50000 |
| Course/Wales checker | 1 | 15000 | 15000 |
| Laendro meter | 4 | 50000 | 50000 |
| Other miscellaneous assets | LS | 20000 | 20000 |
| Total | 12784000 | ||
Other Fixed Assets |
(Rs.) |
| Erection and installation | 1300000 |
| Electrification | 100000 |
| Office furniture | 50000 |
| Pre-operative expenses | 50000 |
| Total | 1500000 |
| Total Fixed Capital | 16609000 |
Working Capital (per month)
Staff and labour Wages
Designation |
Nos. |
Rate (In Rs.) |
Amount (Rs.) |
| Marketing Manager | 1 | 15000 | 15000 |
| Mercandiser/Coordinators | 1 | 12000 | 12000 |
| Sales Officer | 1 | 10000 | 10000 |
| Accountant/Cashier | 1 | 6000 | 6000 |
| Computer operator | 2 | 4000 | 4000 |
| Store-keeper | 1 | 5000 | 5000 |
| Peons | 2 | 3000 | 3000 |
| Watchman | 2 | 3000 | 6000 |
| Production Staff | |||
| Production Manager | 1 | 15000 | 15000 |
| Supervisors | 2 | 6000 | 12000 |
| Skilled workers | 32 | 4000 | 128000 |
| Pressing man | 8 | 4500 | 36000 |
| Unskilled workers | 15 | 3000 | 45000 |
| Total | 300500 | ||
| Perquisites @ 20% | 60100 | ||
| G. Total | 360600 | ||
Raw Material (per month)
Description |
Qty. in Kgs |
Rate/ unit (Rs.) |
Amount (Rs.) |
| Cotton yarn/ Acrylic yarn | 6000 | 180 | 1080000 |
| Nylon Yarn | 1500 | 300 | 450000 |
| Elastic Yarn | 300 | 380 | 114000 |
| Detergent for washing | LS | 5000 | |
| Packing material | LS | 15000 | |
| Total | 1664000 | ||
Utilities (per month) |
(Rs.) |
| Electricity bill | 40000 |
| Water Charges | 2000 |
| Fuel for generator | 10000 |
| Total | 52000 |
Other Contingent Expenses (per month) |
(Rs.) |
| Postage/stationery | 3000 |
| Repair and maintenance | 28000 |
| Transport/travelling charges | 5000 |
| Insurance | 3000 |
| Telephone Bills | 5000 |
| Miscellaneous expenses | 5000 |
| Total | 49000 |
| Total Recurring Expenses (per month) | 2125600 |
| Total Working Capital for 2 months | 4251200 |
Total Capital Investment
| Land Machinery and equipmen t | 16609000 |
| Working capital for 2 months | 4251200 |
| Total | 20860200 |
Machinery Utilisation
Capacity utilisation is considered as 75% of installed capacity. However, it can be improved when the unit reaches its second year of operation. Maximum capacity utilisation can be achieved in third year from the date on which the production is started.
Financial Analysis
Cost of Production (per year) |
(Rs.) |
| Recurring expenses | 25507200 |
| Depreciation on Building @ 5 % | 116250 |
| Depreciation on machinery @ 10% | 1278400 |
| Depreciation on office furniture @ 20% | 10000 |
| Interest on total investment @ 14% | 2920428 |
| Total | 29832278 |
Turnover (per year) (Sales)
Product |
Qty. |
Rate/Dz Pair (Rs.) |
Amount (Rs.) |
| Plain Socks (Doz. pairs) | 90000 | 198 | 17820000 |
| Terry Socks (Doz. pairs) | 60000 | 276 | 16560000 |
| Total | 34380000 | ||
| Net Profit (per year) | 4547722 | ||
| Net Profit Ratio (Net profit/Turnover per year) | 13.23% | ||
| Rate of Return on Investment (Net Profit/Total Capital Investment) | 21.8% | ||
Break-even Point
Fixed Cost |
(Rs.) |
| Depreciation | 1404650 |
| Interest on capital investment | 2920428 |
| 40% of wages of staff and labour | 1730880 |
| 40% of other expenses | 220800 |
| Insurance | 36000 |
| Total | 6312758 |
| B.E.P. | FC×100 -------------- FC+profit = 58.13% |
Addresses of Machinery and Equipment Suppliers
- M/s. Vishit Synthetics (P) Ltd.
Saritaderahan, Opp. Jaihind
Press, Ashram Road,
Ahmedabad-380009. - M/s. Meghaylen Synthetics Pvt. Ltd.
10, Jasvillem, IIIrd Floor,
9, New Marine Lines,
Mumbai-400020. - M/s. Crompton Pvt. Ltd.
29, Chitalsar Nagpada, S.V. Road,
Thane-400607. - M/s. Suryalan Synthetic Inds. (P) Ltd.
216, Jolly Bhavan,
10, Sir V. Thackeray Marg.
Mumbai-400020.
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
