Abdur Rahman Corporation

Processing Charges Pricing Model

Days in year
Gas days
Non gas holidays
Dec Jan

365
185
52
50

Electricty consumption per day

Average load shedding
Total hours per day
Rented Diesel Power Dec-Jan %

Energy Used Jan-Oct 2012

Fuel
Gas
Gas
LPG
Coal
Gas
LDO
Saw Dust
Wood
Gas
LPG
Gas
Wood

Energy Prices
Gas
LPG
Wood
Diesel
Cost of Electricty
Purchased FESCO
Rented Diesel Power
Grams/ton
Inches/M
Production Tons per day
Grey
Bleaching
Kier PFD/PFP
Jumbo Bleaching

18,500 kWh
7 hrs/non gas day
24
33%

Department
Canteen
Canteen Total
IR
IR
IR Total
Oil Heater
Oil Heater
Oil Heater
Oil Heater
Oil Heater
Oil Heater Total
Singeing
Singeing
Singeing Total
Steam Boiler
Steam Boiler
Steam Boiler Total
Grand Total

MMBTU

Unit
MMBTU
kg
kg
Liter

Price

Per gas day

259
259
2,673
174
2,847
135
40,871
6,087
106
29,137
76,335
3,990
1,777
5,767
40,304
30,778
71,082
156,291

1,000,000.00
39.37

25
25
16
7

25.00

300.00

25.00

246.00
597.10
Factor

560
125
8
110

Rs./kWh
12.00
30.00

1.10

1.00
0.04730
0.01293

Kier Bleaching
Jigger Dyeing
IR Dyeing
Engraving
Design Studio
Printing
Printing Store
Finishing
Folding/Packing

2
1
1
14
14
14
14
25
25

Rotary set up (screens per hour)

Mill Investment Rs
Desired Return %
Desired Return Rs.
Working days
Return/ton

6
1,100,000,000
20%
220,000,000
237
37,130.80

Steam Consumption 01 Nov to 30 Nov

Machine Name
Consumed (tons)
Fabric tons
Singeing
83
Transfer to Kiers
(59)
Transfer to Jumbos
(24)
Kier Bleach
Transfer from singeing
Soaper (main)
Soaper Drying
Kiers
Sub-total Kiers

59
451
434
494
1,438

Sub-total Jumbos

24
411
68
97
106
706

Sub-total Dyeing

248
54
16
26
344

Sub-total Finishing

155
155

Jumbo Bleach
Transfer from singeing
Bleaching Drying
Jumbo Jigger #1
Jumbo Jigger # 2
Jumbo Jigger # 3

Dyeing
Dyeing Drying
Causticize
Open jigger
Pressure Jigger

Mandi

Total

2,643

Cost of Oil Heater on Gas days

Gas
Working days
mmbtu/day
Cost/mmbtu
Cost/day

MMBTU 1-13 Nov

2,582.00
8.00
322.75
560.00
180,740.00

Distribution:
Stenters
Rotary
Curing
Total

3.00
1.00
0.50
4.50

120,493
40,164
20,082
180,740

Per pass
40,164.44
40,164.44
20,082.22

Cost of Oil Heater on Non Gas days

Wood
Working days
mmbtu/day
Cost/mmbtu
Cost/day
Distribution:
Stenters
Rotary
Curing
Total

MMBTU 1-13 Nov

4,180.00
9.00
464.44
580.05
269,399.33
3.00
1.00
0.50
4.50

179,600
59,867
29,933
269,399

Per pass
59,866.52
59,866.52
29,933.26

Avg Rs/day
Tons/day
Batch
Stretch
Print
Finish

Cost of Self Generated Electricity

Guascor
Gas per hour
Maintenance
Hours
Output

Rate
5.83 MMBTU
2,500,000 Rs
25,000
660 kW

Waukesha
Gas per hour
Maintenance
Hours
Output

Rate
3.75 MMBTU
1,200,000 Rs
20,000
350 kW

CAT Diesel
Diesel
Maintenance
Hours
Output

Rate
123 Liters
600,000 Rs
5,000
660 kW

Cost

120.00

Cummins Diesel
Diesel
Maintenance
Hours
Output

Rate
77 Liters
450,000 Rs
5,000
350 kW

Average Daily Electricity Consumption in kWh

Department
Gas day
Bleaching
Kier bleach
PFD/PFP
Jumbo Bleach
Dyeing
Printing
Finishing
Folding
Total

Power House Labor

Total Direct Labor per month
Average working days
Labor per day
Hours per day
Labor cost Rs. per hour
CAT/Guascor %
Cummins/Waukesha %
CAT/Guascor Rs/hr
Cummins/Waukesha Rs/hr

Non-Gas day
2650

580
3170
9723
1080
18100

480
2400
8370
900
14800

24,850
25
994.00
24
41.42
65%
35%
-

Department wise Store Consumption

M/O Nov-2012
Department
Grey Depart
Bleaching Depart
Dyeing
Printing
Engraving Screen etc.
Finishing
Folding

Direct
17,982
15,871
2,698
57,483
1,192,475
17,432
14,570
1,318,511
Total

90.00

3547

25
24
65%
35%
117,481.00
63,259.00

Power House Stores/month

Average working days
Stores per day
Hours per day
Labor cost Rs. per hour
CAT/Guascor %
Cummins/Waukesha %
CAT/Guascor Rs/hr
Cummins/Waukesha Rs/hr

Cost

type
1
2
3
4
5
6
7

Electric
Mechanical
PPC
HR Department & Admin.
Information Technology
Lab
Main Store
Purchase
Quality Assurance
Sub Store
Utility
Waste store
Sub-total

418,001
505,230
110
38,031
11,670
65,298
1,257
173
152
1,842
133,734
89
1,175,587

P-House
Grand Total

24,850
2,518,948

Salary Data For M/o November-2012

Direct Labor
Grey
Bleaching
Dyeing
Engraving
Design Studio
Printing
Printing Store
Finishing
Folding/Packing
Sub-total Direct Labor

Headcount

Indirect Labor Cost Estimates

Production
Civil
Commercial Marketing
Costing
Electrical
HR & Administration
House Keeping
Information Technology
Laboratory
Main Store
Management & Finance
Mechanical
PPC
Purchase
Quality Assurance
Security
Sub-Store
Sub-total Indirect Labor

Headcount

Utility
Power House

Pay/mth
14
51
20
12
8
49
2
53
76
285

170,550
558,140
289,855
152,450
161,800
654,250
20,950
607,600
803,300
3,418,895
Pay/mth

Overtime
4,569
187,435
76,734
52,164
18,631
190,465
9,645
243,244
244,736
1,027,623
Overtime

1
10
2
9
16
15
20
3
10
4
1
19
5
4
10
20
4
153

55,000
117,600
85,000
154,400
248,350
229,150
193,200
80,000
133,900
77,900
10,500
299,050
109,800
95,000
146,900
203,000
51,250
2,290,000

41,699
63,426
16,899
314,594

16
6

285,200
116,300

53,975
39,328

3,549
20,404
43,897
11,223
6,726
25,463
3,578
77,272
458

Sub-total Heat, Steam and Power

22

401,500

93,303

Total Labor

460

6,110,395

1,435,520

Permanent
Temporary

375
85
460

5,252,045
858,350
6,110,395

1,271,667
163,853
1,435,520

Total
Contract Utility Labor per day
Steam consumption per day

15000
100 tons

Per Non Gas day

-

21.00

464.00

25.00

319.00
829.00
Rs./MMBTU
560.00
2,642.71
580.05

Batch/Stretch
Finish
Print
40,164.44
80,328.89

40,164.44
22.22%

80,328.89
0.44

Batch/Stretch
Finish
Print
59,866.52
119,733.04

59,866.52 119,733.04
22.22%
44.44%

Cure

Total
120,493
40,164.44
40,164
20,082.22
20,082
40,164.44 20,082.22
180,740
22.22%
11.11%
100.00%
Days
185
Annual
33,436,900

Cure

Total
179,600
59,866.52
59,867
29,933.26
29,933
59,866.52 29,933.26
269,399
22.22%
11.11%
100.00%
Days
52
Annual
14,008,765

Annual Gas + Non Gas

44,487.26

88,974.52

11.00
1.00
11.00
24.00

Cost/ton
3,707.27
3,707.27
6,066.44
3,707.27

Avge/day
44,487.26 22,243.63

47,445,665
200,193
200,192.68

Total cost/month
175,119
745,575
366,589
204,614
180,431
844,715
30,595
850,844
1,048,036
4,446,518
Total cost/month
55,000
121,149
85,000
174,804
292,247
240,373
199,926
105,463
133,900
81,478
10,500
376,322
110,258
95,000
188,599
266,426
68,149
2,604,594
339,175
155,628

494,803

7,545,915
6,523,712
1,022,203
7,545,915

Abdur Rahman Corporation

Processing Charges Pricing Model
Days in year
Gas days
Non gas days
Non gas holidays
Non gas working days
Dec Jan
Feb-Nov

365
185
180
52
128
50
78

Electricty consumption per day

Avergae load shedding
Total hours per day
Energy Used Jan-Oct 20112
Fuel
Gas
Gas
LPG
Coal
Gas
LDO
Saw Dust
Wood
Gas
LPG
Gas
Wood

Energy Prices
Gas
LPG
Wood
Diesel
Cost of Electricty
Purchased FESCO
Diesel Power

Grams/ton
Inches/M
Production Tons per day
Grey
Bleaching
Kier PFD/PFP
Jumbo Bleaching

18,500 kWh
7 hrs/non gas day
24

Department
Canteen
Canteen Total
IR
IR
IR Total
Oil Heater
Oil Heater
Oil Heater
Oil Heater
Oil Heater
Oil Heater Total
Singeing
Singeing
Singeing Total
Steam Boiler
Steam Boiler
Steam Boiler Total
Grand Total

MMBTU

Unit
MMBTU
kg
kg
Liter

Price

Per gas day

259
259
2,673
174
2,847
135
40,871
6,087
106
29,137
76,335
3,990
1,777
5,767
40,304
30,778
71,082
156,291

17
7
24
Cost/kWh Non gas Feb-Nov

1,000,000.00
39.37

25
25
16
7

25.00

300.00

25.00

246.00
597.10
Factor

560
125
8
110

Rs./kWh
hrs/non gas day
12.00
22.07

1.10

1.00
0.04730
0.01293

Weighted
204.56
153.46
358.02
14.92

Kier Bleaching
Jigger Dyeing
IR Dyeing
Engraving
Design Studio
Printing
Printing Store
Finishing
Folding/Packing
Rotary set up (screens per hour)
Mill Investment Rs
Desired Return %
Desired Return Rs.
Working days
Return/day

2
1
1
14
14
14
14
25
25
6
1,100,000,000
20%
220,000,000
237
37,130.80

Steam Consumption 01 Nov to 30 Nov

Machine Name
Consumed (tons)
% of total
Soaper (main)
451
Soaper Drying
434
Singeing
83
Kiers
494
Sub-total Bleaching
Dyeing
248
Dyeing Drying
54
Open jigger
16
Pressure Jigger
26
Causticize
0
Sub-total Dyeing
Jumbo Jigger #1
68
Jumbo Jigger # 2
97
Jumbo Jigger # 3
106
Bleaching Drying
411
Sub-total Jigger Bleach
Finishing
Mandi
155

Total

2077

0
0
0
0

Fabric tons
367.00
367.00
613.00
487.00

0
0
0
0

31.00
32.00
31.00
8.00
9.60

0
0
0
0

141.67
141.67
141.67
282.00

613.00

Cost of Oil Heater on Gas days

Gas
Working days
mmbtu/day
Cost/mmbtu
Cost/day
Distribution:
Stenters
Rotary
Curing
Total

MMBTU 1-13 Nov

2582
8
322.75
560
180,740
3.0
1.0
0.5
4.5

120,493
40,164
20,082
180,740

Per pass
40,164.44
40,164.44
20,082.22

Cost of Oil Heater on Non Gas days

Wood
Working days
mmbtu/day
Cost/mmbtu
Cost/day
Distribution:
Stenters
Rotary
Curing
Total

MMBTU 1-13 Nov

4180
9
464
580.05
269,399
3.0
1.0
0.5
4.5

179,600
59,867
29,933
269,399

Per pass
59,866.52
59,866.52
29,933.26

Avg Rs/day
Tons/day
Batch
Stretch
Print
Finish

Per Non Gas day

-

21.00

464.00

25.00

319.00
829.00
Rs./MMBTU
560.00
2,642.71
580.05

Steam/ton of fabric
1.23
1.18
0.14
1.01
3.56
8.00
1.69
0.52
3.25
13.45
0.48
0.68
0.75
1.46
3.37
0.25

0.25

Batch/Stretch
Finish
Print
40,164.44
80,328.89

Cure
40,164.44

40,164.44

80,328.89

40,164.44

Total
120,493
40,164
20,082.22
20,082
20,082.22
180,740

22.22%

0.44

22.22%

Batch/Stretch
Finish
Print
59,866.52
119,733.04

59,866.52 119,733.04
22.22%
44.44%

11.11%
Days
Annual

Cure

Total
179,600
59,866.52
59,867
29,933.26
29,933
59,866.52 29,933.26
269,399
22.22%
11.11%
100.00%
Days
52
Annual
14,008,765

Annual Gas + Non Gas

44,487.26

88,974.52

11.00
1.00
11.00
24.00

Cost/ton
3,707.27
3,707.27
6,066.44
3,707.27

100.00%
185
33,436,900

Avge/day
44,487.26 22,243.63

47,445,665
200,193
200,192.68

Salary Cost Redistribution

Direct Labor
Grey
Bleaching
Jumbo Bleaching
Kier Bleaching
PFD/PFP
Dyeing
Engraving
Design Studio
Printing
Printing Store
Finishing
Folding/Packing

Cost Rs.
175,119
745,575

Total

366,589
204,614
180,431
844,715
30,595
850,844
1,048,036
4,446,518

Working days/month
Indirect Dir + Ind.
Tons/day
102,578
277,697
25
436,728
1,182,303
25
331,045
7
94,584
2
756,674
16
214,733
581,322
2
119,855
324,469
14
105,689
286,120
14
494,801
1,339,516
14
17,921
48,516
14
498,391
1,349,235
25
613,898
1,661,934
25
2,604,594 7,051,112

26
Tons/mth
Rs/ton
650
427
650
1,819
182
1,819
52
1,819
416
1,819
52
11,179
364
891
364
786
364
3,680
364
133
650
2,076
650
2,557

Department wise Store Consumption

M/O Nov-2012
type
1
2
3
4
5
6
7

Department
Grey Depart
Bleaching Depart
Dyeing
Printing
Engraving Screen etc.
Finishing
Folding

Electric
Mechanical
PPC
HR Department & Admin.
Information Technology
Lab
Main Store
Purchase
Quality Assurance
Sub Store
Utility
Waste store
Sub-total
P-House
Grand Total

Dir + Ind
Tons/day
Indirect
17,982
9,178.84
27,160.84
15,871
8,101.29
23,972.29
2,698
1,377.18
4,075.18
57,483
29,341.98
86,824.98
1,192,475
608,694.40
583,780.60
17,432
8,898.10
26,330.10
14,570
7,437.20
22,007.20
1,318,511
673,029.00
1,991,540.00
Total
Capital
Expense
418,001
246,806.00
171,195.00
505,230
161,049.00
344,181.00
110
110.00
38,031
38,031.00
11,670
11,670.00
65,298
65,298.00
1,257
1,257.00

Direct

173
152
1,842
133,734
89
1,175,587
24,850
2,518,948

94,703.00

173.00
152.00
1,842.00
39,031.00

502,558.00

673,029.00
24,850.00

25
25
2
14
14
25
25

26
Tons/mth
Rs/ton
650
42
650
37
52
78
364
239
364
1,604
650
41
650
34

Cost of Self Generated Electricity

Guascor
Gas per hour
Price
Maintenance
Hours
Spares and Lubes
Labor
Total Cost/hr
Output
Cost per kWh
Waukesha
Gas per hour
Price
Maintenance
Hours
Spares and Lubes
Labor
Total Cost/hr
Output
Cost per kWh
Average (Guascor + Waukesha)

Rate
5.83 MMBTU
560.00
2,500,000 Rs
25,000
27.06 Rs/hr
26.02

Cost
3,264.80
100.00
27.06
26.02
3,417.89

660 kW
5.18
Rate
3.75 MMBTU
560.00
1,200,000 Rs
20,000
14.35 Rs/hr
13.80

Cost
2,100.00
60.00
14.35
13.80
2,188.15

350 kW
6.25
5.55

CAT Diesel
Diesel
Price
Maintenance
Hours
Spares and Lubes
Labor
Total Cost/hr
Output
Cost per kWh

Rate
123 Liters
110.00
600,000 Rs
5,000
27.06 Rs/hr
26.02

Cummins Diesel
Diesel
Price
Maintenance
Hours
Spares and Lubes
Labor
Total Cost/hr
Output
Cost per kWh
Average (CAT + Cummins)

Rate
77 Liters
110.00
450,000 Rs
5,000
14.35 Rs/hr
13.80

Cost
13,530.00
120.00
27.06
26.02
13,703.09

660 kW
20.76
Cost
8,470.00
90.00
14.35
13.80
8,588.15

350 kW
24.54
22.07

Electricity (kWh)
FESCO
Captive
Diesel Rental
Diesel Own

Per gas day

Total
Electricty Cost Rs. per day
FESCO

18,500

Feb-Nov Non Gas

13,140
-

18,500

5,360
18,500

Rate
Per gas day
12.00

Nov-Feb Non Gas

157,683.59

Captive
Diesel Own
Diesel Rental

5.55
22.07
30.00
Total
Working days
Annual Rs.
Average
Average per kWh

Average Daily Electricity Consumption in kWh

Department
Gas day
Bleaching
3547
Kier bleach
PFD/PFP
Jumbo Bleach
Dyeing
Printing
Finishing
Folding
Total

Rs/day

102,684.90
102,684.90
185
18,996,706.15
5.55

Tons/day

160,791.02
318,474.61
78
24,841,019.53
17.21

Rs/ton

42,368.75

25

1,695

0
3,389.50
0
27,116.00
0
11,863.25
580
6,928.07
3170
37,865.50
9723
116,140.79
1080
12,900.55
18100 216,203.67

2
16
7
2
14
25
25

1,695
1,695
1,695
3,464
2,705
4,646
516

Power House Labor

Total Direct Labor per month
Average working days
Labor per day
Hours per day
Labor cost Rs. per hour
CAT/Guascor %
Cummins/Waukesha %
CAT/Guascor Rs/hr
Cummins/Waukesha Rs/hr

24,850
26
955.77
24
39.82
65%
35%
26.02
13.80

Power House Stores/month

Average working days
Stores per day
Hours per day
Spares cost Rs. per hour
CAT/Guascor %
Cummins/Waukesha %
CAT/Guascor Rs/hr
Cummins/Waukesha Rs/hr

24,850
25
994.00
24
41.42
65%
35%
27.06
14.35

Dec-Jan

Total

6,105
12,395
18,500
Dec-Jan
-

134,740.62
371,850.00
506,590.62
50
25,329,530.82
27.38

421,160
313
69,167,256.51
220,981.65
11.94

Cost of Steam
Utility Labor
Contract Labor
Spares
Wood
Gas

Monthly
339,175
390,000
19,516

Utility Stores Cost Apportioned

Stores cost for month
Wood Steam %
DDFC %
Sub- total Steam

Daily Per gas day

13,045
13,045
15,000
781
781
137,760
Total
151,586
Steam (tons)
100
Steam cost/ton
1,516
Days
185
Tons/day
100
Annual
28,043,375
Tons/yr
18,500

39,031.00
25%
25%

2,139
128
100
27,374,159
12,800
Avge Rs/ton

9,757.75
9,757.75
19,515.50

Gas Oil Heater %

Wood Oil Heater %
Sub total Oil Heater

25%
25%

9,757.75
9,757.75
19,515.50

Total

100%

39,031.00

Steam Consumption 01 Nov to 30 Nov

Machine Name
Consumed (tons) %
Singeing
83
Transfer to Kiers
(59)
Transfer to Jumbos
(24)
Sub-total Singeing
Kier Bleach
Transfer from singeing
59
Soaper (main)
451
Soaper Drying
434
Kiers
494
Sub-total Kiers
1,438
Jumbo Bleach
Transfer from singeing
24
Bleaching Drying
411
Jumbo Jigger #1
68
Jumbo Jigger # 2
97
Jumbo Jigger # 3
106
Sub-total Jumbos
706
Dyeing
248
Dyeing Drying
54
Causticize
Open jigger
16
Pressure Jigger
26
Sub-total Dyeing
344
Mandi
155

Per Non Gas day

13,045
15,000
781
185,035
213,861

100
Rs @ 100 ton
Fabric tons
3.14%
-2.22%
-0.92%

2.22%
17.06%
16.42%
18.69%
54.40%

2,545,650.75

468

0.92%
15.55%
2.57%
3.67%
4.01%
26.72%

1,250,361.80

182

9.38%
2.04%
0.61%
0.98%
13.02%

609,061.72

26

5.86%

Sub-total Finishing
Total

Total

155
2,643

5.86%
100.00%

274,431.88

650

Total
313
55,417,534
31,300
1,771

Rs/ton

5,439.42

6,870.12

23,425.45

422.20

Fuel
Coal
Gas
LDO
Saw Dust
Wood

Department
Oil Heater
Oil Heater
Oil Heater
Oil Heater
Oil Heater

MMBTU

Oil Heater Total

Energy Prices
Gas
LPG
Wood
Diesel

Unit
MMBTU
kg
kg
Liter

Utility Stores Cost Apportioned

Stores cost for month
Wood Steam %
DDFC %
Sub- total Steam

Per gas day

135
40,871
6,087
106
29,137

40,871
-

76,335

300

Price

Factor
488.23
125
7.5
110

39,031.00
25%
25%

9,757.75
9,757.75
19,515.50

Gas Oil Heater %

Wood Oil Heater %
Sub total Oil Heater

25%
25%

9,757.75
9,757.75
19,515.50

Total

100%

39,031.00

Labour Cost
Total Utility
Steam 50%
Oil Heater 50%

339,175.00
169,587.50
169,587.50

Cost of Thermal Oil

Gas
Wood
Stores
Labour
Rs/day
Days
Annual

Allocation of cost
Ratio
Rupees/day

Gas day
168,000
750.60
6,523
175,273
185
32,425,540.58

Non-gas day
269,142
751
6,523
276,415
128
35,381,084.62
Avge/day

313
67,806,625.20
216,634.59

Stenter # 1
1
48,141.02

Stenter # 2
1
48,141.02

Stenter # 3
1
48,141.02

Process tons
Kier White
Jumbo Bleach
Dyeing
Printing

0
0
2
14
16

Total
Process cost Rs.

1
0.0473
0.01293

Stenter # 1

Total

2
7
0
0
9
Stenter # 2

0
0
2
14
16
Stenter # 3

Kier White
Jumbo Bleach
Dyeing
Printing
Total

6,017.63
42,123.39
48,141.02

10,698.00
37,443.01
48,141.02

6,017.63
42,123.39
48,141.02

Per Non Gas day

135
6,087
106
29,137
464

Rs./MMBTU
488.23
2,642.71
580.05

Rotary
1
48,141.02

Curing
0.5
24,070.51

0
0
0
14
14
Rotary

Total
4.5
216,634.59

0
0
0
14
14
Curing

2
7
4
56
69
Total

Rs/ton

48,141.02
48,141.02

24,070.51
24,070.51

10,698.00
37,443.01
12,035.25
156,458.31
216,634.59

5,349.00
5,349.00
6,017.63
11,175.59
8,665.38

Department Wise Costs in Rupees per ton

Department
Tons/day
Grey
25
Kier Bleach
2
PFD/PFP
16
Jumbo Bleach
7
Dyeing
2
Printing
14
Finishing
14
Folding/Packing
14

Labor

Stores

427
1,819
1,819
1,819
11,179
5,491
2,076
2,557
27,187

42
37
37
37
78
239
41
34
544

Electricity
1,695
1,695
1,695
3,464
2,705
4,646
516
16,415

*Oil Heater cost includes finishing

Reallocation of Grey, Finish & Folding
Own
14,339
15,770
44,165
19,610

Kier Bleach
Jumbo Bleach
Dyeing
Printing

Jumbo Bleaching
Standard tons
Warp
Weft
Ends
Pick
Width
Grey gsm
Grams
Square Meters
Linear Meters

7
40
40
100
80
112
114
7,000,000
61,671
21,679

Grey
469
469
469
469

Finish
7,184
7,184
7,184
7,184

Jigger Dyeing IR Dyeing

1
1
40
40
40
40
100
100
80
80
112
112
114
114
1,000,000
1,000,000
8,810
8,810
3,097
3,097

Fold
3,107
3,107
3,107
3,107

2.84

Cost Including Dyes & Chemicals

Jumbo Bleach
Kier Bleach
IR Dyeing
Dye Light
Dye Medium
Dye Dark
Jigger Dyeing
Medium
Dark
Extra Dark

Printing
Warp
Weft
Ends
Pick
Width
Grey gsm
Full speed
Screens

Process Dye+Chem
Margin
26,529
3,751
37,131
25,099
3,751
37,131

31,089
31,089
31,089

10,418
14,142
18,529

37,131
37,131
37,131

Process Dye+Chem
Margin
63,195
8,828
37,131
63,195
15,899
37,131
63,195
38,105
37,131

30
30
76
66
87
2.21 Meters
119
37 Mtr/minute
8

Total/ton
67,411
65,981

78,637
82,361
86,748
Total/ton
109,154
116,225
138,431

Standard tons
Grams
Square Meters
Linear Meters
25% Coverage
Light-Med
Dark
Extra Dark
50% Coverage
Light-Med
Dark
Extra Dark
75% Coverage
Light-Med
Dark
Extra Dark
100% Coverage
Light-Med
Dark
Extra Dark

14
14,000,000
117,396
53,125
Process
31,089
31,089
31,089

Dye+Chem
10,583
14,111
21,167

Screens
16,829
16,829
16,829

Margin
37,131
37,131
37,131

31,089
31,089
31,089

21,167
28,222
35,278

16,829
16,829
16,829

37,131
37,131
37,131

31,089
31,089
31,089

28,222
35,278
49,389

16,829
16,829
16,829

37,131
37,131
37,131

31,089
31,089
31,089

35,278
42,333
63,500

16,829
16,829
16,829

37,131
37,131
37,131

Average ARC gsm gms/inch

gms/93 inch
120
3.048006096 283.464566929
State
Cost/283gm
Cost/kg
Cost/ton
L-M 25%
3
10.58
10,583
L-M 50%
6
21.17
21,167
L-M 75%
8
28.22
28,222
L-M 100%
10
35.28
35,278
D 25%
4
14.11
14,111
D 50%
8
28.22
28,222
D 75%
10
35.28
35,278
D 100%
12
42.33
42,333
ED 25%
6
21.17
21,167
ED 50%
10
35.28
35,278
ED 75%
14
49.39
49,389
ED 100%
18
63.50
63,500
Also the Screens, Designing and Engraving Cost
Cost of New Screen
7,500
Average Designing Cost
per Rotary position

200

Average Engraving Cost

per Screen

500

Total cost of designed

screen
Scrap Value
Net Cost per screen
Average re-use (times)
Cost/screen
Set up Time
Screens per hour
Set up costs/screen
Total cost/screen

8,200
2,200
6,000
3
2000
25
103.63
2,103.63

Steam
5,439
5,439
6,870
23,425

Oil Heater*
###
5,349
5,349
6,018
11,176

422
41,597

PFD/PFP
8,271
719

27,891

Total
25,099
26,529
63,195
31,089

Meters

Meters/ton
3,097
3,097

Rs/Meter
21.77
21.31

Meters/ton
3,097
3,097
3,097

Rs/Meter
25.39
26.59
28.01

Meters/ton
3,097
3,097
3,097

Rs/Meter
35.25
37.53
44.70

Total
469
14,339
8,990
15,770
44,165
19,610
7,184
3,107
113,633

Hours
24
24
24
24

Cost/hour
1,045.78
1,105.40
2,633.14
1,295.35

Total/ton
95,632
99,159
106,215

Rate/inch
0.29
0.30
0.32

Rate/Mtr
25.20
26.13
27.99

106,215
113,271
120,326

0.32
0.34
0.36

27.99
29.85
31.71

113,271
120,326
134,437

0.34
0.36
0.41

29.85
31.71
35.43

120,326
127,382
148,548

0.36
0.39
0.45

31.71
33.57
39.15