Cotton Yarn Dyeing
PRODUCT CODE QUALITY AND STANDARDS : N.A. : As per IS 1670 :1970 IS 1671:1977 IS 8014 :1983 : May, 2003 : Small Industries Service Institute Government of India, Ministry of SSI, Andheri-Kurla Road, Sakinaka, Mumbai-400072 Tel. : 022-28576090/3091/7166 Fax : 022-28578092 Website : www.sisimumbai.com E-mail : firstname.lastname@example.org
MONTH AND YEAR OF PREPARATION PREPARED BY
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. 1. Ready-made garments 2. Hosiery industries 3. Bag closing industry 4. Sports goods 5. Umbrella and carpet making 6. Book binding 7. Handloom textiles 8. Furnishing textiles
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
4. victoria blue. colour and shade required. 9. 6. 2. Margin money required is minimum 30% of the projected investment. rhodamine dye blue. whether financed by bankers or by financial corporation. 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. equipment and raw materials are those prevailing at the time of preparation of this project profile. Recruitment of staff 1 month and workers. melachite green etc.
Sl. Financial arrangements 3 months 4. However direct. Activity Period
Process of Manufacture The most popularly used colours for cotton dyeing are Aurammic G. The rates quoted in respect of salaries and wages for skilled workers and others are the minimum rates in the State/ neighbouring states. Working capital for 3 months has been taken into consideration for smooth running of the project. reactive and mordant dyes are the most common classes of dyes used in the
. and are likely to vary from supplier to supplier and place to place. The rates quoted in respect of machines.C OTTON YARN DYEING
proposed purchase grey yarn from the mills and can be dyed and sold in the market. 5. There is also possibility to take up the job work from the mills and dye the yarn on as per their requirement. When a tailor made project profile is prepared necessary changes are to be made. 25 days in a month and at 75% efficiency. Interest rate for fixed and working capital has been taken @ 14% on an average.No. The project profile has been prepared on the basis of single shift of 8 hours each day. The class of dye used depends on the end use.
B ASIS AND PRESUMPTIONS
1. Besides this there is good scope for exporting the dyed yarn to foreign countries. Purchase and 2 months procurement of machinery 5. 3. Preparation of the Project Report: (a) Calling quotations 1 month (b) Preparation 2 weeks 2. Provisional Registration 1 week as SSI 3. rhodamine yellow G. it will require 5 years to pay back the loans. Electrification 1 month 7. 20 per square meter. 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. quality desired and the process adopted. The rental value of the workshed and other built up/covered area has been taken at the rate of Rs.
8. brilliant green crystals. Pay Back period of the project : After the initial gestation period of one and a half years. Installation of machine 1 month 6. 7.
These soft cheeses are creeled on to stand and then loaded in to the machine chamber. process. IS 8014 : 1983 Production Capacity (per annum) Quantity : 2000 Kgs. The grey yarn which may be in the form of hand or solution to penetrate in the yarn. The units should not use rice-husk and rubberised material as a fuel in dyeing unit. The packages are removed from the chamber.00. per day or 6.
Process flow diagram for Dyed cotton yarn
Cotton Yarn ↓ Winding on soft package ↓ Dyeing ↓ Drying ↓ Winding or reeling ↓ Quality control ↓ Packing ↓ Storage ↓ Market Quality Control and Standards The cotton yarn is dyed as per the requirements of the owner.000 Kgs. Pollution Control In the textile dyeing industry. excess dye solution is washed and finally dried. The different methods practiced in the industry are given below:
dye. The use of various toxic chemicals and chemical based dyes may be avoided/reduced. Then the dye bath is prepared containing the requisite amount of dyestuff and other chemicals like alum. 1. IS 1670 : 1970 2. The following BIS specifications are available. 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. If the water is hard it is to be treated using salt which will dissolve the Calcium and Magnesium salt present in the water. IS 1671 : 1977 3. method and the condition of the machines used and also on the hardness of the water used. 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.36
C OTTON YARN DYEING
industry. Value : Rs. considerable amount of polluted water is discharged from which har mful chemicals should be neutralised before leaving them into the drainage system. The quality of the dyeing depends on the class of
. soda etc. 270 lakhs processing charges. The yarn packages are subjected to high temperature high pressure dyeing for 30 minutes to 1½ hour.
Idle running of various machines. Steam should not be wasted and sufficient insulation should be provided to the dye chamber. Accountant/Cashier 5.400 sq. This matter should be the concern of every person involved in the day to day operations of any industry.000
2 No. lights.00. 2 No.00. Sales Officers 3.38.500 2. Insurance. erection cost of pipelines and cables etc. Tanks Cap: 4 MT.000 11. Stainless Steal Dye and springs (1500 Nos.000 1. mt.S. Pre-operative expenses Total Fixed Capital
B. 1No.00.000 5. Transport.00. 2.
Sl.000 5. Clerks/Typists 6.000 97. Rewinding machine 8.S.80.) 8. Water storage tanks (Civil construction) Cap.000 1. 48. mtrs. M.000 1.) 1 2 2 1 2 1 2 8.10. mtrs. mt.
8. Fixed Capital
(i) Land and Building (Rented) (per month) (a) Builtup / Covered area (b) Open/Un-covered area Total area required Average rental charges @ 20 sq. cheese carries 2. Set 200 kVA 12.S. Description No. 1No. Designation No. Store Keeper Nos.000
4. Process water softening plant and effluent treatment plant 7.) 48. 1No. Package winding machine 1No.000 3. Rs.00.000
1. boilers. Electric Hoist 2 tonne capacity 1No. fans. 4. Laboratory Beaker Dyeing plant 5.000 litres each 11.) 9.500 sq.000 2. Office furniture 4.
6. Peon 7. 900 sq. 2.) 1. Lab and testing equipment 13. Should be completely avoided.000 1. Steam Boiler 2 tonnes 1No.000 (Rs.000
A.00. stock tank 200 kgs capacity open machine type Rapid ADLT Driver and 4 S. capacity with water softening plant for boiler 3.C OTTON YARN DYEING
Energy Conservation Another important international aspect of the recent period is energy conservation. Process control and instrumentation equipment 14. 1. (ii) Machinery and Equipments Sl.000 3.G. heaters. air conditioners etc.000 6. D.10.00.000
10. Salary (Rs. Marketing manager 2.000 10.500 2250 2250 Total (Rs.00. Suitable capacitors and energy saving devices should be incorporated wherever possible to minimise the wastage of energy.000 1.
Amount (In Rs. Qty.000 2.40. Electrification and wiring 3.
12.38.60. Working Capital (per month)
(i) Salaries and Wages Sl.000 1. The energy conservation will make the industries to reduce their production costs and thereby stay more competitive in the market. 80.000 1.00.000 2250 4500
1. Amount (In Rs.000 2.000 5.000 Total 92. 200 Kgs Cap HTHP 1No. Yarn Dyeing machine with automation S.000 Total
1.00.00.00.) 35. Description No. Miscellaneous equipment (iii) Other Fixed Assets
Technical Manager 2. card board boxes etc.76. Helpers 9. polythene sheet wrapping. LS LS LS 3. 25200000 – 21924000 = Rs. Salaries and wages ii.) Amount (In Rs.000 25. Boiler operator
(v) Total Working Capital (per month) i. Raw Materials iii. Fitter 7. Fabric checkers 5.000 kWh @3/unit 2. Transportation and Cartage 4.000 2.250 3000 97. Dyes and chemicals 2. @ Rs.23.000 15. LS LS
10.000 2500 2500 3000 3000 2250 3000 Amount (In Rs.000 5.000 (Rs. Fuel.000 (iv) Other Contingent Expenses 5. Miscellaneous expenses Total (Rs.000 1.000 10. Water charges 4.000 90.50.980 21923780 21924000 (Rs.000 R s . Working capital for 3 months Total Rs. Other expenses Total
1.000 9700 Total Say (ii) Raw Materials Sl. Steam consumption 5. Supervisor 4.000 1. (3) Net Profit (per year) = Turnover – cost of production = Rs.000 15. Electricity bill10.)
COTTON YARN DYEING
50.06. 97. Electrician 8.000 =
Processing charges dyeing 2.77.) 48.) 1 1 2 2 8 1 1 5 1 Total 8. Nos.46.000 75. Telephone bills 6. 47.700 1.000 50.000 5. Packing material.000 20/ kg kgs.07.000 Rs. Dyeing master 3.) 8. Insurance 7. Repair and maintenance 3.000 20.70.07. 14.23. Total Capital Investment
i. Fixed capital ii.00000 yarn of 6.31.000 10.000 1.000 20.000 6. Effluent treatment charges Total (iv) Other Contingent Expenses 1.000 2.38.000 5.00.000
Add perquisites @10%
(1) Cost of Production (i) Total recurring expenditure (iii) Depreciation on other fixed assets @ 20% (iv) Interest on total capital investment @14% Total Say (2) Turnover (per year) (ii) Depreciation on machinery @ 10% (Rs.000 10.00.000 kgs. Designation No.50.000 20. (iii) Utilities 1.70.00.000 9.52. Rate (In Rs. Salary (In Rs.000 (Rs. Utilities iv.800 10.50.000 17.50. coal and furnace oil Qty. 3276000 (4) Net Profit Ratio = Net profit (per year)× 100 Turnover (per year) 3276000 × 100 25200000
. Postage and Stationery 9000/ ltrs.000 3000 3000 11. Skilled workers 6.000 8. Building rent 2. Description No.) 1.000 16.) 80. 42/kg.) 8.) 10. Sales and advertisement 8.000 4.
Sarocevan Dyes Mfr. M/s. Kamarajar Road. Andheri (E). Interest on total capital investment vi. 7. Kiran Dyeing Machinery Works Partap Nagar. M/s. M/s. Annual building rent ii.) 5. P. Mumbai-400023 4. Tanuku-534211 (AP) 6.23.P. Indokem Ltd. Asaf Ali Road.800 2023980 204000 60. Fort. Ludhiana 7. Dr. 3/4. Gandhi Road. V. Road. 40% of salaries and wages iii. Dr. II.
. Mumbai-400021 2. Insurance Total B. Ludhiana Dyeing Machinery Work Link Road. Nariman Point. M/s. Baltex Engineering Pvt. 43. N. Sector-24. New Delhi-110052 3. Basant Lok. Co. Tilak Bazar. Vasant Vihar. Peelamedu. (Rs. Kamarajar Road. Coimbatore-641004
Raw Material Suppliers 1. II Floor. 2. Jeevan Udyog. Depreciation on fixed assets v. Andhra Sugars Ltd.000 494400 1704000 10. 8. M/s. Jolly Maker Chambers No. Plot No. Srirang Equipment Company 472. Faridabad-110005 (Haryana) 4. M/s. M/s. Basf India Ltd. M/s.180 Where as the fixed cost is calculated as below :
6. New Delhi-110002 5.76. 13th Floor. M/s. Ludhiana
= Fixed cost × 100 Fixed cost + Profit = 6026180 × 100 6026180 + 3276000 = 64%
Addresses of Machinery Suppliers 1. Electronic and Engineering Co. Gali Hinga Beg. M/s. B. Industrial Area ‘A”. Mumbai 5. O. M/s.
9. 40% of utilities and other expenses iv. 278. New Delhi-110063 3. Ltd. Erhardt Leimer India Ltd. Ludhiana M/s.
Coimbatore-641004 M/s. Ludhiana M/s. EEC House. M/s. Eastern Engineering Co. 7. Dalia Estate. B-3/45. Mumbai-400058 M/s. Paschim Vihar. Ltd. Rashmi Dyes and Chemicals Focal Point.E.COTTON YARN DYEING
(5) Percent of Profit on Total Investment Net profit (per year) × 100 = Total Investment = 3276000 × 100 14457000 = 23% (6) Break Even Point Fixed Cost i. C-7. No. Venkatrayapuram. No. ABC Dyes and Chemicals 2282. D. Delhi-110006 2.26. Venkatapathy Foundry 445. Arora Tex Dyes Corporation Plot No. Paramount Instruments P. 108.