23534238.

xls

Finishing Plant Cost Analysis

Proposed
10,000
Singeing, Desizing, Scouring & Bleaching
{Can be one machine or split into two}
Machine Cost
Speed/minute 120.00 mtr/min
Efficiency 80%
Fabric undergoing this process 100%
Capacity of Machine 138,240.00 mtr/day
Chemical cost per mtr
Remarks: It is assumed that the weight range will not vary a lot so there are no major changes from one run to another.
Morever, the 30,000 run size for one color would mean bigger run size for bleaching.

Mercerizing 45,000 Dyeing with mercerizing

45,000 Dyeing without mercerizing
Machine Cost 5,000 Printing with mercerizing
Speed/minute 50.00 mtr/min 40,000 Printing without mercerizing
Efficiency 80% 135,000
Capacity of Machine 57,600.00 mtr/day
Fabric undergoing this process 37%
Capacity of plant for overall fabric 155,520.00 mtr/day
Chemical cost {mercerized fabric} per mtr
Chemical cost {overall} per mtr
Remarks:

Thermosol

Speed/minute 50.00 mtr/min 30 Average Cleaning in minutes

Production time for one run 200.00 min 60 Average preparation and matching
Set up time 90 min 90
Total time for a run 290.00
Calculated Efficiency 69%
Miscellaneous Efficiency losses 10%
Net Efficiency 59%

1 Machines
Machine Cost 42,455 Thermosol Dyeing
Speed/minute 50.00 mtr/min 21,228 PC 50%
Efficiency 59% 10,614 Double thermosol & washing on pad steam
Capacity of Machine 42,455.17 mtr/day 21,228 Single Pass
Capacity Adjusted for double pass 34,000 10,614 Double Pass
Fabric undergoing this process 31,841
Capacity of plant for overall fabric mtr/day 34,000 Reiterations
Chemical cost other than dye cost 8500 Double Pass
Chemical cost
Light per mtr
Medium per mtr
Dark per mtr
Remarks: 3,000 yards minimum run, for bigger run size chemical cost will also be lower

Pad Steam

Speed/minute 70.00 mtr/min 30 Average Cleaning in minutes

Production time for one run 142.86 min 40 Average preparation and matching
Set up time 70 min 70
Total time for a run 212.86
Calculated Efficiency 67%
Miscellaneous Efficiency losses 10%
Net Efficiency 57%

1 Machines
Machine Cost 57,571 Dyeing+Washing
Speed/minute 70.00 mtr/min 28,786 PC 50%
Efficiency 57% 14,393 Double thermosol & washing on pad steam
Capacity of Machine 57,571.01 mtr/day 28,786 Single Pass
Capacity Adjusted for double pass 46,000 14,393 Double Pass
Fabric undergoing this process 43,178
Capacity of plant for overall fabric mtr/day 46,000 Reiterations
Chemical cost other than dye cost 11500 Double Pass
Chemical cost 57,500
Light per mtr
Medium per mtr
Dark per mtr

Continous Capacity 34,000 mtr/day

Batch Capacity 10,000 mtr/day
44,000 mtr/day

Stentor for Dyeing

Speed/minute 50.00 mtr/min 30 Average Cleaning in minutes

Production time for one run 200.00 min 60 Average preparation and matching
Set up time 90 min 90
Total time for a run 290.00
Calculated Efficiency 69%
Miscellaneous Efficiency losses 10%
Net Efficiency 59%

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 23534238.xls

1 Machines
Machine Cost 42,455 Thermosol Dyeing
Speed/minute 50.00 mtr/min 21,228 PC 50%
Efficiency 59% 10,614 Double thermosol & washing on pad steam
Capacity of Machine 42,455.17 mtr/day 21,228 Single Pass
Capacity Adjusted for double pass 34,000 10,614 Double Pass
Fabric undergoing this process 31,841
Capacity of plant for overall fabric mtr/day 34,000 Reiterations
Chemical cost other than dye cost 8500 Double Pass
Chemical cost
Light per mtr
Medium per mtr
Dark per mtr

Stentor for Setting & Finishing

2 Machines
Machine Cost 100% double pass for all non-stentor dye fabric
Speed/minute 90.00 mtr/min1 for setting and 1 for finishing
Efficiency 80% and sometimes after mercerizing so divide by 2.25
Capacity of Machine 207,360.00 mtr/day
Capacity Adjusted for double pass 92,160
Fabric undergoing this process
Chemical cost per mtr
Remarks: 75% efficiency assumed for longer runs

Printing

Speed/minute 50.00 mtr/min

Production time for one run 200.00 min
Set up time 60 min 60 Average set up
Total time for a run 260.00 Less for color change
Calculated Efficiency 77% High for design change
Miscellaneous Efficiency losses 10%
Net Efficiency 67%

1 Machines
Machine Cost
Speed/minute 50.00 mtr/min
Efficiency 67%
Capacity of Machine 48,184.62 mtr/day
Fabric undergoing this process
Capacity of plant for overall fabric mtr/day
Chemical cost other than dye cost
Chemical cost
Light per mtr
Medium per mtr
Dark per mtr

Calendering

Machine Cost
Speed/minute 70.00 mtr/min
Efficiency 80%
Capacity of Machine 80,640.00 mtr/day
Fabric undergoing this process 40%
Capacity of plant for overall fabric 201,600.00 mtr/day
Chemical cost {Calendered fabric} per mtr
Chemical cost {overall} per mtr
Remarks:

Sanforizing

Machine Cost
Speed/minute 70.00 mtr/min
Efficiency 80%
Capacity of Machine 80,640.00 mtr/day
Fabric undergoing this process 50%
Capacity of plant for overall fabric 161,280.00 mtr/day
Chemical cost {sanforized fabric} per mtr
Chemical cost {overall} per mtr
Remarks:

Overall Capacity

Dyeing & Printing

Continuous + Batch 44,000 mtr/day
Stentor Dyed Fabric 34,000 mtr/day
Printing 48,185 mtr/day
126,185

Finishing
Stentor Dyed Fabric 34,000 mtr/day
Stentor for Setting + Finishing 92,160 mtr/day
126,160 mtr/day

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