BLEND & / OR DYED FIBRE BALES PROJECT

Yarn Manufacturers’ Problem

- Require more yarn preparatory which

o Occupy more space for production as well as storage
o Lower utilization & flexibility
o More manpower & conversion cost due to lower utilization
- Invest in all business / unit actually increase capital & operational cost
- Manual work create quality related problems
- Not possible to have multi-fibre blend or fibre dyeing facility in-house
- Either higher fibre inventory or delay in order completion which affect business profitability
- If same capital & resources invested in final product i.e. yarn, will increase their profitability
- Small units cannot afford higher capital cost & associated risk.

Opportunity / Justification

- Arvind (Denim, woven & AMD) alone is procuring average 8 – 1o tones per day of Blend yarn
- Due to fibre dyeing facility, possible to produce either Dyed yarn or Melange yarn in-house
- Multi-fibre blending possible
- Small spinning units (Ring as well as open end spinning) are the potential customers
- Due to higher utilization, economies of scale & flexibility cost of production is less. Even yarn
manufacturers’ cost remain same if they’ve this facility in-house (See Payback calculation)
- Customer can also have net increase in yarn conversion capacity, flexibility & profitability

Project Cost

Section Item Quantity Source Cost In Lac Rs

BDT 1 RS3
AFC 1 RS3
MPM 1 RS3
25
Blow Room ASTA 1 RS3
CVT4 1 RS3
DUSTEX 1 RS3
CC CLEANER 1 New 27.5
Carding CARD 12 RS3 50
Draw Frame DRAW FRAME 3 RS3 5
UNILAP 1 New 42.5
Combing
COMBER 5 New 202.5
GBR - 2 / MBO - 1 / BOA - 1 4 Intex / CC Plant  
BLENDER (5 COMPONENT) 1 New 150
Blending
MPM / Unimix 2 RS3
25
BALE PRESS 2 CC Plant
Dyeing Fibre Dyeing Facility with dryer 1 Woven + AMD 75
WCS + H – PLANT 1 New 50
Laboratory     50
Engineering,
Shifting - Loading - Unloading Etc     7.5
Utility & Other
Waste Collection - H Plant & Duct     100
Cable + Lighting + Compressor etc     40
Total 850
GST 153
Grand Total 1003
Price, Profitability & Payback Period
Category Particulars Quantity Rate Total Cost Cost / Kg Selling Price Profit / Day 10s Ne @ 90% YR & 3 Rs Conversion Cost
Electricity 10000 8.3 83000 6.92
Mapower 100 500 50000 4.17
Tech / Mgnt Staff 8 1833 14666.67 1.22
Maintenance Cost 12000 0.75 9000 0.75
Common
Packing 12000 0.75 9000 0.75
Facility
Rent 50000 0.45 22500 1.9
Transport 12000 1 12000 1.0
Administratve 12000 0.5 6000 0.50
206167 17.18
Dyeing 2000 45 90000 40
Fibre (Cotton) 2857 116 331429 166
Dyed
286 15 4286 2.14
Fibre Waste Credit (less)
571 85 48571 24.29
368571 179.29 196 214 35364 280
Blend (50/50, Combed) 2500
Tencel 1275 205 261375 104.55
Tencel Fibre (Cotton) 1786 116 207143 82.86
Blend 179 15 2679 1.07
Waste Credit (less)
357 85 30357 12.14
435482 174.19 191 205 33490 255
Blend (50/50, Combed) 2500
Polyester (Recycle) 1275 80 102000 40.80
Polyester Fibre (Cotton) 1786 116 207143 82.86
Blend 179 15 2679 1.07
Waste Credit (less)
357 85 30357 12.14
276107 110.44 110 118 19328 158
Blend (50/50, Carded) 5000
Viscose 2550 135
344250 68.85
Viscose
Fibre (Cotton) 2778 116
322222 64.44
Blend
Waste Credit (less) 278 154167 0.83
662306 132.46 132 139 33115 182
Payback Period In Month 23.36

Tentative Layout

Waste Collection, H - Plant, Raw Material Storage

AUTOMATIC WEIGHING BLENDER

FINISHED MATERIAL STORAGE & DISPATCH FACILITY

BOA / GBR

Blendomat BOA / GBR

BOA / GBR
Blowroom
BOA / GBR
Card

Card

Card

Card

Card

Card

Card

Card

Fibre Dyeing
Office & other amenities
Draw Frame

Draw Frame

Draw Frame
Card

Card

Card

Card

MPM

MPM
Comber

Comber

Comber
Comber

Comber

Balepress

Balepress

Unilap

REMARK - Tentative implementation time / commencing commercial production is 3 to 4 months.