Cotton Yarn Dyeing
| Product Code | N.A. |
| Quality and Standards | As per IS 1670 :1970 IS 1671:1977 IS 8014 :1983 |
| Uploaded on | July 2007 |
Introduction
The art of dyeing is a branch of applied chemistry in which a use of both physical and chemical principle is made in order to bring about a permanent Union between the dyes and the textile material. For dyeing the cotton yarn in various shades, the art lies in colouring the textiles in such a manner that the colour may be fast or may not ordinarily be removed by such operations as working, rubbing, sunlight etc. to which the textiles are usually subjected. The dyeing can only take place when the dyeing is in solution/or finely divided or dispersed condition and the fibres are subjected to this dye in solution condition and then this dye being rendered insoluble or fixed by same means. There must exist same marked physico-chemical affinity between the fibres and the dye, which would naturally depend upon the respective properties of both. The dyed cotton yarn is used in the following fields.
- Ready-made garments
- Hosiery industries
- Bag closing industry
- Sports goods
- Umbrella and carpet making
- Book binding
- Handloom textiles
- Furnishing textiles
Market Potential
Despite the marked inroads of synthetic fibres into the textile industry, cotton continues as a major textile fibre. At present, cotton constitutes 78 percent of the total fibre consumed by the textile industries. There is demand for cotton dyeing units as the consumption of cotton textiles has increased. The proposed purchase grey yarn from the mills and can be dyed and sold in the market. There is also possibility to take up the job work from the mills and dye the yarn on as per their requirement. Since there are large number of textile mills in Maharashtra state there would not be any problem in getting sufficient work for such type of units. Besides this there is good scope for exporting the dyed yarn to foreign countries.
Basis and Presumptions
- The project profile has been prepared on the basis of single shift of 8 hours each day, 25 days in a month and at 75% efficiency.
- It is presumed that in the 1st year the capacity utilisation will be 70% followed by 85% in the next year and 100% in the subsequent years.
- The rates quoted in respect of salaries and wages for skilled workers and others are the minimum rates in the State/ neighbouring states.
- Interest rate for fixed and working capital has been taken @ 14% on an average, whether financed by bankers or by financial corporation.
- Margin money required is minimum 30% of the projected investment.
- Pay Back period of the project : After the initial gestation period of one and a half years, it will require 5 years to pay back the loans.
- The building/workshed is considered of its own
- The rates quoted in respect of machines, equipment and raw materials are those prevailing at the time of preparation of this project profile, and are likely to vary from supplier to supplier and place to place. When a tailor made project profile is prepared necessary changes are to be made.
- Working capital for 2 months has been taken into consideration for smooth running of the project.
Implementation Schedule
Activity |
Period |
| Preparation of Project Report Calling quotations Preparation |
1 Month 2 Weeks |
| Provisional Registration as SSI | 1 week |
| Financial Arrangement | 3 months |
| Purchase and procurement of machinery | 2 Months |
| Installation of Machines | 1 month |
| Electrification | 1 month |
| Recruitment of Staff and Workers. | 1 months |
Technical Aspects
Process of Manufacture
The most popularly used colours for cotton dyeing are Aurammic G. victoria blue, brilliant green crystals, rhodamine yellow G, rhodamine dye blue, melachite green etc. The class of dye used depends on the end use, colour and shade required, quality desired and the process adopted. However direct, reactive and mordant dyes are the most common classes of dyes used in the industry. The grey yarn which may be in the form of hand or solution to penetrate in the yarn. These soft cheeses are creeled on to stand and then loaded in to the machine chamber. Then the dye bath is prepared containing the requisite amount of dyestuff and other chemicals like alum, soda etc. The yarn packages are subjected to high temperature high pressure dyeing for 30 minutes to 1½ hour. The packages are removed from the chamber, excess dye solution is washed and finally dried. The different methods practiced in the industry are given below :
Process flow diagram for Dyed cotton yarn |
| Cotton Yarn |
| Winding on soft package |
| Winding or reeling |
| Quality control |
| Packing |
| Storage |
| Market |
Quality Control and Standards
There is no standard specification formulated for cotton knitted cloth. The quality of knitted fabric mainly depends on raw material quality, therefore quality yarn must be used for the manufacture of knitted cloth. Hosiery yarn should be purchased from reputed spinning mills only. Spare parts should be kept ready for immediate replacement in order to maintain the targets.
IS 1670 : 1970
IS 1671 : 1977
IS 8014 : 1983
Production Capacity (per annum)
| Quantity: | 2000 Kgs. per day or 6,00,000 Kgs.Value (Rs.) |
| Value : | Rs. 324. lakhs processing charges. |
Motive Power
A total of 50 kW or 70 HP power is required to run at full capacity and this can be drawn from state electricity boards.
Pollution Control
In the textile dyeing industry, considerable amount of polluted water is discharged from which harmful chemicals should be neutralised before leaving them into the drainage system. The use of various toxic chemicals and chemical based dyes may be avoided/reduced. The units should not use rice-husk and rubberised material as a fuel in dyeing unit. The smoke of this is very harmful for the human beings. This type of unit should only be started in an area where the common effluent plant facilities are available or the unit installed this type of facilities in the unit's premises to avoid any health hazards.
Energy conservation
Another important international aspect of the recent period is energy conservation. The energy conservation will make the industries to reduce their production costs and thereby stay more competitive in the market. This matter should be the concern of every person involved in the day to day operations of any industry. Idle running of various machines, heaters, boilers, lights, fans, air conditioners etc. Should be completely avoided. Suitable capacitors and energy saving devices should be incorporated wherever possible to minimise the wastage of energy. Steam should not be wasted and sufficient insulation should be provided to the dye chamber.
Financial Aspects
Financial Aspects
Land and Building (Rented) (per month) |
|
| Builtup / Covered area | 1,500 sq. mt. |
| Open/Un-covered area | 900 sq. mt. |
| Total area required | 2,400 sq. mtrs. |
| Average charges @ 2000/ sq. mtrs. | 4800000 |
Machinery and Equipments
Description |
No. |
Amount (Rs.) |
| 200 Kgs Cap HTHP Yarn Dyeing machine with automation S.S. stock tank 200 kgs capacity open machine type Rapid ADLT Driver and 4 S.S. cheese carries | 1No. | 4060000 |
| Steam Boiler 2 tonnes capacity with water softening plant for boiler | 1No. | 980000 |
| Electric Hoist 2 tonne capacity | 1No. | 100000 |
| Laboratory Beaker Dyeing plant | 1No. | 55000 |
| Process water softening plant and effluent treatment plant | 1No. | 1500000 |
| Package winding machine | 1No. | 1210000 |
| Rewinding machine | 1No. | 1040000 |
| Stainless Steal Dye and springs (1500 Nos.) | 150000 | |
| Water storage tanks (Civil construction) Cap. 80,000 litres each | 2 No. | 450000 |
| M.S. Tanks Cap: 4 MT. | 2 No. | 190000 |
| D.G. Set 200 kVA | 1No. | 590000 |
| Lab and testing equipment | 100000 | |
| Rewinding machine | 1No. | 1040000 |
| Process control and instrumentation equipment | 100000 | |
| Miscellaneous equipment | 100000 | |
| Total | 10625000 | |
Other Fixed Assets |
Amount (Rs.) |
| Insurance, Transport, erection cost of pipelines and cables etc. | 160000 |
| Electrification and wiring | 200000 |
| Office furniture | 100000 |
| Pre-operative expenses | 100000 |
| Total | 560000 |
| Total Fixed Capital | 15985000 |
Working Capital (per month)
Staff and labour Wages
Designation |
Nos. |
Salary (Rs.) |
Amount (Rs.) |
| Marketing manager | 1 | 16000 | 16000 |
| Sales Officers | 2 | 8000 | 16000 |
| Store Keeper | 2 | 4000 | 8000 |
| Accountant/Cashier | 1 | 4000 | 4000 |
| Clerks/Typists | 2 | 3000 | 6000 |
| Peon | 1 | 3000 | 3000 |
| Watchmen | 2 | 3000 | 6000 |
| Total A | 59000 | ||
Designation |
Nos. |
Salary (In Rs.) |
Amount (In Rs.) |
| Production Staff | |||
| Technical Manager | 1 | 15000 | 15000 |
| Dyeing master | 1 | 8000 | 8000 |
| Supervisor | 2 | 7000 | 14000 |
| Fabric checkers | 2 | 4000 | 8000 |
| Skilled workers | 8 | 4000 | 32000 |
| Fitter | 1 | 4500 | 4500 |
| Electrician | 1 | 4500 | 4500 |
| Helpers | 5 | 3200 | 16000 |
| Boiler operator | 1 | 6000 | 6000 |
| Total B | 108000 | ||
| Grand Total A+ B | 167000 | ||
| Add perquisites @10% | 16700 | ||
| Total | 183700 | ||
Raw Material
Description |
Qty. (Kgs.) |
Rate/(Rs.) |
Amount (Rs.) |
| Dyes and chemicals | 50,000 kgs. | 25/ kg | 1250000 |
| Packing material, polythene sheet wrapping, card board boxes etc. | LS | LS | 56000 |
| Total | 1306000 | ||
Utilities |
(Rs.) |
|
| Electricity bill | kWh @5/unit | 100000 |
| Water charges | 9000/ ltrs. | 10000 |
| Fuel, coal and furnace oil | LS | 100000 |
| Steam consumption | LS | 90000 |
| Effluent treatment charges | LS | 20000 |
| Total | 320000 | |
Other Contingent Expenses |
(Rs.) |
| Repair and maintenance | 20000 |
| Transportation and Cartage | 35000 |
| Postage and Stationery | 8000 |
| Telephone bills | 10000 |
| Insurance | 17000 |
| Sales and advertisement | 20000 |
| Miscellaneous expenses | 15000 |
| Total | 125000 |
Total Working Capital (per month) |
(Rs.) |
| Salaries and wages | 183700 |
| Raw Materials | 1306000 |
| Utilities | 320000 |
| Other expenses | 125000 |
| Total | 1934700 |
Total Capital Investment
| Fixed capital | 15985000 |
| Working capital for 2 months | 3869400 |
| Total | 19854400 |
Financial Analysis
Cost of Production (per year) |
(Rs.) |
| Total recurring expenditure | 23216400 |
| Depreciation on machinery @ 10% | 1062500 |
| Depreciation on Building @ 5 % | 240000 |
| Depreciation on other fixed assets @ 20% | 112000 |
| Interest on total capital investment @14% | 2779616 |
| Total | 27410516 |
Net Profit (per year)
| Turnover – cost of production | |
| 4989484 |
Net Profit Ratio
Net profit (per year)× 100 Turnover (per year) 23,84,000 × 100 15.4 |
Percent of Profit on Total Investment
Net profit (per year) × 100 Total Investment 25.13 |
Break-even Point
Fixed Cost |
(Rs.) |
| Depreciation on building @ 5 % | 240000 |
| 40% of salaries and wages | 881760 |
| 40% of utilities and other expenses | 2054400 |
| Depreciation on fixed assets | 1174500 |
| Interest on total capital investment | 2779616 |
| Insurance | 204000 |
| Total | 7334276 |
| B.E.P. | Fixed cost × 100 ----------------------- Fixed cost + Profit = 59.51% |
Addresses of Machinery and Equipment Suppliers
- M/s. Baltex Engineering Pvt. Ltd.
13th Floor, Jolly Maker Chambers
No. II, Nariman Point,
Mumbai-400021 - M/s. Paramount Instruments P. Ltd.
B-3/45, Paschim Vihar,
New Delhi-110063 - M/s. Erhardt Leimer India Ltd.
43, Dr. V. B. Gandhi Road,
Mumbai-400023 - M/s. Eastern Engineering Co.
Jeevan Udyog, II Floor, 278,
Dr. D. N. Road, Fort,
Mumbai - M/s. Srirang Equipment Company
472, Kamarajar Road,
Coimbatore-641004 - M/s. Ludhiana Dyeing Machinery Work
Link Road, Ludhiana - M/s. Kiran Dyeing Machinery Works
Partap Nagar,
Ludhiana - M/s. Electronic and Engineering Co.
EEC House, Plot No. C-7,
Dalia Estate, Andheri (E),
Mumbai-400058 - M/s. Venkatapathy Foundry
445, Kamarajar Road,
Peelamedu,
Coimbatore-641004
Raw Material Suppliers
- M/s. ABC Dyes and Chemicals
2282, Gali Hinga Beg, Tilak Bazar,
Delhi-110006 - M/s. Basf India Ltd.
No. 7, Basant Lok, Vasant Vihar,
New Delhi-110052 - M/s. Arora Tex Dyes Corporation
Plot No. 108, Sector-24,
Faridabad-110005 (Haryana) - M/s. Indokem Ltd.
3/4, Asaf Ali Road
New Delhi-110002 - M/s. Andhra Sugars Ltd.
Venkatrayapuram, P. O. No. 2
Tanuku-534211 (AP) - M/s. Sarocevan Dyes Mfr. Co.
Industrial Area "A",
Ludhiana - M/s. Rashmi Dyes and Chemicals
Focal Point,
Ludhiana
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
