Bleaching and Dyeing of Cotton Knitted Fabric
| Product Code | 248100009 |
| Quality and Standards | As per IS 689:1956, IS 763:1957, IS 786:1957, IS 687:1966, IS 3417:1966 |
| Uploaded on | January 2006 |
Introduction
Bleaching of textile grey fabrics is generally carried out to impart whiteness to textile fabrics by removing natural colouring matter. The process of dyeing is carried out to improve the marketability of textile products and also to suit the customer needs by adding colour. These two processes are generally carried out in open tank, kier machines, jet dyeing machines, jiggers, soft flow dyeing machines etc. For hosiery goods, it is carried out with winch machines, since it imparts very less tension during operation. Viable processing units can be set up as most of the fabric manufacturing units do not have their own processing units. In this report, details are provided for setting up the unit for bleaching and dyeing of cotton knitted fabrics.
Market Potential
The demand for hosiery garments is increasing due to its popularity in domestic and export market. There are number of units engaged in manufacturing of knitted cloth and most of these units are not having their own captive processing units. Bleaching and dyeing of knitted fabric produced by these units are normally carried out from outside on paying requisite processing charges. It is, therefore, presumed that setting up of textile processing units is economically viable.
Basis and Presumptions
This project is based on single shift basis with 300 working days in a year. Time period for achieving maximum capacity utilisation is considered from 3rd year from the date on which production is started. Rental value of the building is taken at Rs. 2 per sq. ft. Costs of machinery and equipments/materials indicated refer to a particular make and approximately to those prevailing at the time of preparation of this project.
Cost of installation and electrification is taken @ 10% of cost of machinery and equipment. Non-refundable deposits, project report cost, trial production, security deposit with Electricity Board are classified under pre-operative expenses.
Depreciation has been considered at 10% on plant and machinery, 15% on office furniture, fixtures, vehicle and 20% on testing equipments. Interest rate on capital loan has been taken @ 12% per annum.
Implementation Schedule
The implementation period required for executing this project right from selection of site to starting the trial run production will be 6 months.
Technical Aspects
Process of Manufacture
The knitted fabric to be bleached is thoroughly wet in a soap solution of 2% and piled in kier boiling pan containing 1.5% caustic soda, 2% soda ash and 1% lisapol etc. and allowed to boil for 6-8 hours. The cloth is washed well and taken to SS winches for bleaching using 2% bleaching powder and then washed thoroughly. This bleached cloth is scoured using hydrochloric acid of 1.5% concentration. After sometime, cloth is washed thoroughly to neutralise the traces of acid. In case of only bleaching the cloth is treated with optical whitening agent, thereafter, it is hydro-extracted, dried and calendered as final operations.
In case of dyeing, about 15-20% salts, 2% brightol C paste, 2-4% dyes as per shade are mixed and fabric is treated with the solution in winches. The cloth is allowed to run for several times in order to maintain uniform shade, thereafter, washed, hydro-extracted, dried and calendered.
Production Capacity (per annum)
Quantity (Kg.) |
Quantity (Pc.) |
|
| Bleaching Charges | 4,50,000 | 1,15,86,000 |
Motive Power
Total power requirement will be 22 HP.
Pollution Control
There is no generation of pollution in this type of industry.
Energy conservation
Although power consumption is very low, wastage of energy can be minimised by proper housekeeping.
Financial Aspects
Financial Aspects
| Land and Building | |
| Land 4000 Mtrs. @ Rs. 3000 per Sq. Mtr | Rs.1,20,00,000 |
| Boundary wall and gates | Rs. 5,00,000 |
| Factory shed 400 Sq. Mtr, @ Rs. 6000 / Sq. Mtr | Rs. 24,00,000 |
| Raw Material & finished goods storage 500 Sq. Mtr@ Rs. 6000 / Sq. mtr. | Rs. 30,00,000 |
| Office Building 300 Sq. Mtr @ 750 / Sq. Mtr | Rs. 22,50,000 |
| Workers sitting hall 500 Sq.Mtr @ Rs.6000/Mtr | Rs. 30,00,000 |
| Rs.1,18.00,000 | |
| Utility plants area e.g., bore well, raw water storage, boiler, generator and effluent treatment plant 200 Sq. Mtr @ Rs. 6000/Sq. Mtr | Rs. 12,00,000 |
| Total | Rs 2,43,00,000 |
Machinery and Equipments
Description |
No. |
Rate (Rs.) |
Amount (Rs.) |
| SS Winch m/c of 6-4× 8×6 200kg. | 1 | 4,00,000 | 4,00,000 |
| SS Winch m/c 6-4'× 6×6 size 150kg. | 3 | 2,00,000 | 6,00,000 |
| MS Kier wall thick 1/4' bottom 8' | 2 | 1,50,000 | 3,00,000 |
| Steam callendering m/c roller sizes 51/21 | 1 | 3,00,000 | 3,00,000 |
| Hydro-extractor 40-45 kg capacity | 2 | 2,50,000 | 5,00,000 |
| 4 cylinder drier with motor and gear box | 1 | 7,00,000 | 7,00,000 |
| S.S. Conveyors with ball bearing | 4 | 50,000 | 2,00,000 |
| Baby boiler with storage tank chimney, water softening plant | 1 | 8,00,000 | 8,00,000 |
| Water softening plant (cap. 6kl/hr), with storage tank pumps and S.S. piping | 1 | 7,00,000 | 7,00,000 |
| Effuent treatment plant | 1 | 5,00,000 | 5,00,000 |
| Steam pipeline and other accessories | LS | 3,00,000 | 3,00,000 |
| Deep tube well with submersible pump with storage tank, pumping and distribution system | 1 | 5,00,00 | 5,00,00 |
| Mini transport vehicle (3 Wheelers) | 1 | 3,00,000 | 3,00,000 |
| Fire extinguisher 5 kg capacity | 2 | 20,000 | 40,000 |
| Testing equipments | LS | 2,00,000 | |
| Computer colour matching equipment (optional) | 1 | 25,00,000 | 25,00,000 |
| Total | 88,40,000 | ||
Other Fixed Assets |
(Rs.) |
| Erection and installation | 8,84,000 |
| Office furniture | 5,00,000 |
| Pre-operative expenses | 3,00,000 |
| Total | 16,84,000 |
| Total Fixed Capital | 16,84,000 |
Working Capital (per month)
Staff and labour Wages
Designation |
Nos. |
Rate (Rs.) |
Amount (Rs.) |
| G. Manager | 1 | 30000 | 30000 |
| Finance and Accountant | 2 | 15,000 | |
| Computer Operator | 1 | 20,000 | 20,000 |
| Sales, marketing, administrative and | 6 | 50,000 | |
| Peon | 2 | 3500 | 7,000 |
| Watchman | 4 | 3500 | 14,000 |
| Total (i) | 1,26,000 | ||
Production Staff |
|||
| Dyeing Master 01 no. and shift supervisors 03 nos. | 36,000 | ||
| Skilled Workers | 12 | 5,000 | 60,000 |
| Semi-skilled Workers | 15 | 3,000 | 45,000 |
| Lab. Chemists and Attendant | 6 | 30,000 | |
| Boiler Attendant | 4 | 4000 | 16,000 |
| Electrician | 3 | 4000 | 12,000 |
| Total | 1,99,000 | ||
| Total (i) + (ii) | 3,25,000 | ||
| Perquisites@ 22% | 72,000 | ||
| G. Total | 3,97,000 | ||
Raw Material (per month)
Description |
Unit |
Qty. |
Rate/ unit (Rs.) |
Amount (Rs.) |
| Caustic Soda | Kgs. | 1500 | 35 | 53,000 |
| Soda ash | Kgs. | 5500 | 20 | 1,10,000 |
| Sodium silicate | Kgs. | 2500 | 10 | 25,000 |
| Lisopal | Kgs. | 750 | 150 | 1,13,000 |
| Bleaching Powder | Kgs. | 3,000 | 20 | 60,000 |
| Hydrochloric acid | Kgs. | 8,000 | 8 | 64,000 |
| Glabour's salt | Kgs. | 800 | 10 | 8,000 |
| Common salt | Kgs. | 1000 | 3 | 3,000 |
| Optical whitening agent | Lit. | 225 | 140 | 32,000 |
| Hydrogen peroxide | Lit. | 1200 | 20 | 24,000 |
| Sulphuric acid | Lit. | 2500 | 10 | 25,000 |
| Acetic acid | Lit. | 750 | 75 | 56,000 |
| Dye fixing agent | Kgs. | 750 | 150 | 1,13,000 |
| Dyes of different shades | Lump-sum | 20,000 | 40,000 | |
| Testing equipments | LS | 1,00,000 | ||
| Total | 7,86,000 | |||
Utilities |
(Rs.) |
| Electricity bill 37.5 x 25 x 4 x 0.8 x 24 | 72,000 |
| Water charges | 10,000 |
| Fuel Coal/furnace oil | 100,000 |
| Fuel for vehicle | 8,000 |
| Total | 1,90,000 |
Other Contingent Expenses |
(Rs.) |
| Rent | - |
| Postage/stationery | 5,000 |
| Repair and maintenance | 22,000 |
| Transport/travelling charges | 30,000 |
| Insurance | 19,000 |
| Telephone bills | 10,000 |
| Miscellaneou | 50,000 |
| Total | 1,34,000 |
| Total Recurring Expenses (per month) | 11,10,000 |
| Total Working Capital for 3 months | 33,30,000 |
Total Capital Investment
| Machinery and equipment | Rs. 3,48,24,000 |
| Working capital for 3 months | Rs. 33,30,000 |
| Total | Rs. 4,81,54,000 |
Machinery Utilisation
Capacity utilisation is considered as 75% of installed capacity.
Financial Analysis
Cost of Production (per year) |
(Rs.) |
| Recurring expenses | 1,33,20,000 |
| Depreciation on machinery @ 10% | 6,14,000 |
| Depreciation on office furniture, computor and testing equipments @ 20% | 6,40,000 |
| Depreciation on civil construction @ 5% | 5,90,000 |
| Interest on total investment @ 12% | 57,78,000 |
| Total | 2,03,02,000 |
Turnover (per year)
Processing Charges |
Qty. Kgs. |
Rate/Kg. |
Amount (Rs.) |
| Bleaching Charges | 4,50,000 | 25.75 | 1,15,86,000 |
| Dyeing charges | 4,50,000 | 4,50,000 | 1,48,05,000 |
| Total | 2,63,91,000 |
| Net Profit (per year) | 60,89,000 |
| Net profit ratio (Net profit/Turnover (per year) | 23.07% |
| Rate of return on investment (Net profit/Total capital investment) | 12.64% |
Break-even Point
Fixed Cost |
(Rs.) |
| Depreciation | 18,44,000 |
| Rent | - |
| Interest on capital investment | 57,78,000 |
| 40% of wages of staff and labour | 19,05,000 |
| 40% of other expenses | 6,43,000 |
| Insurance | 2,28,000 |
| Total | 1,03,98,000 |
| B.E.P. | Fixed Cost × 100 ----------------------- Fixed Cost × 100 1,03,98,000 × 100 ------------------------- 1,03,98,000 × 100 = 63.07% |
Addresses of Machinery and Equipment Suppliers
- M/s. Gangan Mech. Works
28-B, Industrial Area,
Ludhiana-141003. - M/s. Ludhiana Dyeing Machinery Works
3064, St. No. 3, Ganesh Nagar,
Ludhiana-141003. - M/s. Paradise Engg. Corpn.
302, Industrial Area-A,
Ludhiana-141003. - M/s. Dynamic Engg. Corpn.
Dionic Chambers,
50, Rani Jhansi Road,
New Delhi-110055 - M/s. Data Colour
3061/4, Lucky Lanes,
Andheri East,
Mumbai.
Raw Material Suppliers
- M/s. Rangila Dyes Co.
Chauri Sarak,
Ludhiana. - M/s. Crescent Dye Industries
Chauri Sarak,
Ludhiana. - M/s. Sarjeevan Dyes Mfr. Co.
Industrial Area-A,
Ludhiana-141003. - M/s. ICI (India) Ltd.
P. B. No. 107,
Himaltane House,
New Delhi-110001.
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
