TRIBHUVAN UNIVERSITY

INSTITUTE OF ENGINEERING
THAPATHALI CAMPUS

A project report on
COTTON FABRIC MANUFACTURING

Prepared by
Bishal Adhikari (076BIE011)
Garima Joshi (076BIE015)
Rojit Shrestha(076BIE033)
Sizal Gaire(076BIE044)
Santosh Pokharel(076BIE042)

SUBMITTED TO
THE DEPARTMENT OF INDUSTRIAL ENGINEERING
THAPATHALI, KATHMANDU
DECEMBER 2022
 ABSTRACT

The purpose of this report is to assess the technical feasibility of establishing a cotton fabric
manufacturing industry in Nepal. The report begins by reviewing relevant literature on cotton
fabric manufacturing, including industry reports and academic articles, to gain a better
understanding of the industry and identify key issues and challenges that may be faced when
establishing a factory in Nepal. The report then assesses the feasibility of establishing a
cotton fabric manufacturing industry in different regions of Nepal, including conducting a
market analysis to identify the regions in Nepal that are most suitable for cotton production
and assessing the availability of infrastructure and utilities, such as electricity and water, at
potential sites. The report also includes a detailed analysis of the equipment and technology
required for cotton fabric manufacturing, including research and comparison of different
models and brands of cotton ginning, spinning, weaving, dyeing, and finishing machines.
Based on the equipment and technology selected, the report develops a layout and design for
the factory. Finally, the report assesses the legal and regulatory requirements for establishing
a cotton fabric manufacturing industry in Nepal, including obtaining the necessary business
licenses and permits, and complying with labour and environmental regulations. This report
does not consider any financial or cost-related aspects of establishing a cotton fabric
manufacturing industry in Nepal. Overall, the report provides a comprehensive assessment of
the technical feasibility of establishing a cotton fabric manufacturing industry in Nepal,
taking into account the various technical, economic, and legal considerations involved.

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 ACKNOWLEDGEMENT

We would like to express our sincere thanks to Er. Bishwaram Parajuli (The Head of the
department of Industrial Engineering, IOE, Thapathali Campus), for his assistance during the
entire work. We also want to convey our special thanks to all our teachers of the Department
of Industrial Engineering, IOE, and Thapathali campus.
We are very much indebted to the management team of Cotton Fabric Industries for making
all the arrangements and our visit in the industry very fruitful and enjoyable. We are also very
grateful for co-operation by providing the valuable information and encouragement during
the preparation of this report. We are also very much thankful all the staff of industry who
made our visit a remarkable one.
Lastly, we are thankful to all the fellow friends and people who have helped and encouraged
us to prepare this report.

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 TABLE OF CONTENTS

ABSTRACT ................................................................................................................................ i
ACKNOWLEDGEMENT .........................................................................................................ii
TABLE OF CONTENTS ......................................................................................................... iii
LIST OF FIGURES ................................................................................................................... v
LIST OF TABLES .................................................................................................................... vi
CHAPTER ONE: INTRODUCTION ....................................................................................... 1
1.1 Background of study ........................................................................................................ 1
1.2 Research Objectives ......................................................................................................... 1
1.2.1 General Objective ................................................................................................ 1
1.2.2 Specific Objective ................................................................................................ 1
1.3 Limitations of study ......................................................................................................... 1
CHAPTER TWO: RESEARCH METHOLODOLOGY .......................................................... 2
2.1 Research Design .......................................................................................................... 2
2.2 Selection of Study Area.................................................................................................... 2
2.3 Data Collection ................................................................................................................. 2
2.4 Data Analysis ................................................................................................................... 2
CHAPTER 3: PRODUCTION PROCESS ................................................................................ 3
3.1 Description ....................................................................................................................... 3
3.1.1 Spinning ............................................................................................................... 3
3.1.2 Weaving or knitting ............................................................................................. 3
3.1.3 Dyeing and printing ............................................................................................. 3
3.1.4 Finishing .............................................................................................................. 3
3.1.5 Inspecting and sorting .......................................................................................... 3
3.1.6 Packaging ............................................................................................................. 3
3.1.7 Warehousing and distribution .............................................................................. 3
3.2 Equipment and Technology ............................................................................................. 4
3.2.1 Equipment and Technology in Fiber Preparation ...................................................... 4
3.2.2 Equipment and Technology in Spinning ................................................................... 7
3.1.3 Equipment and Technology in Weaving ................................................................. 10
3.1.4 Equipment and Technology in Dyeing .................................................................... 12
3.1.5 Equipment and Technology in Finishing................................................................. 13
3.1.6 Equipment and Technology in Packaging and Warehousing .................................. 14
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 3.2 Raw materials and Inputs ............................................................................................... 15
CHAPTER 4: LABOUR AND TRAINING ........................................................................... 17
4.1 Workforce Needs............................................................................................................ 17
4.2 Training and Skill Development .................................................................................... 17
4.2.1 Onboarding .............................................................................................................. 17
4.2.4 Quality control ......................................................................................................... 18
4.2.5 Leadership development .......................................................................................... 18
4.3 Recruitment and Retention ............................................................................................. 18
CHAPTER 5: ENVIRONMENTAL SUSTAINABILITY ...................................................... 19
5.1 Environmental Impacts .................................................................................................. 19
5.2 Sustainability Goals........................................................................................................ 19
5.3 Certification and Standards ............................................................................................ 20
5.4 Monitoring and Reporting .............................................................................................. 20
CHAPTER 6: INFRASTRUCTURE AND FACILITIES ...................................................... 22
6.1 Details of Production Facility ................................................................................... 22
6.2 Details of Utilities ..................................................................................................... 24
6.3 Details of Location, Transportation and Logistics .................................................... 27
6.4 Details on Offices and Amenities.............................................................................. 28
CHAPTER 7: LEGAL REGULATORIES AND ISSUES ..................................................... 29
7.1 Regulatory Environment ................................................................................................ 29
7.2 International Trade .................................................................................................... 29
CHAPTER EIGHT: RESULTS AND CONCLUSIONS ........................................................ 31
BIBLIOGRAPHY .................................................................................................................... 32

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 LIST OF FIGURES

Figure 1 Cotton Bale .................................................................................................................. 3

Figure 2 Cotton Yarn ................................................................................................................. 4
Figure 3 Cotton Fabric ............................................................................................................... 4
Figure 4 Cotton Ginning Machine ............................................................................................. 5
Figure 5 Cotton Bale Opener ..................................................................................................... 6
Figure 6 Cotton Carding Machine ............................................................................................. 8
Figure 7 Cotton Carding Fiber Passing Schematic .................................................................... 8
Figure 8 Spinning Machine ...................................................................................................... 10
Figure 9 Cotton Fabric Weaving Machine............................................................................... 12
Figure 10 Cotton Fabric Dyeing Machine ............................................................................... 13
Figure 11 Cotton Fabric Shrinking and Finishing Machine .................................................... 14
Figure 12 Cotton Production in Nepal by Fiscal Year ............................................................. 16
Figure 13 Conceptual Plant Layout ........................................................................................ 23
Figure 14 Yearly Cotton Import of Nepal................................................................................ 29

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 LIST OF TABLES

Table 1 Cotton Ginning Machine Specifications ....................................................................... 5

Table 2 Bale Opening Machine Specifications .......................................................................... 6
Table 3 Carding Machine Specification .................................................................................... 8
Table 4 Cotton Spinning Machine Specifications ................................................................... 10
Table 5 Cotton Fabric Weaving Machine Specifications ........................................................ 11
Table 6 Fabric Dyeing Machine Specifications ....................................................................... 13
Table 7 Cotton Fabric Shrinking and Finishing Machine Specifications ................................ 14
Table 8 Estimation of number and type of workers according to the department ................... 17
Table 9 List of training programs with their wages and incentives ......................................... 18
Table 10 Quantity and Area Estimation for Machines and Amenities .................................... 24
Table 11 Estimation of Power Requirement ............................................................................ 25
Table 12 List of Electrical Equipment ..................................................................................... 26
Table 13 District-wise Production and Yield of Cotton for the fiscal year 2020/21 ............... 27

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 CHAPTER ONE: INTRODUCTION

1.1 Background of study

The production of cotton fabrics is a key sector within the global textile industry, with a long
history dating back to ancient civilizations. Cotton is a natural fiber that is prized for its
softness, absorbency, and durability, and is widely used in a variety of applications, including
clothing, home furnishings, and other end products. The cotton fabric manufacturing industry
involves a range of production processes, including spinning, weaving, knitting, dyeing,
printing, and finishing. These processes are typically carried out using specialized equipment
and machinery, such as cotton gin machines, spinning machines, looms, knitting machines,
and dyeing and finishing equipment. In recent years, the cotton fabric manufacturing
industry has undergone significant changes, with advances in materials and production
technologies driving innovation and growth. The industry has also faced challenges,
including competition from synthetic fibers, environmental concerns, and changes in
consumer preferences.
This research aims to provide a detailed overview of the cotton fabric manufacturing
industry, with a focus on the production processes, equipment and technology, and key
challenges and opportunities facing the sector. The research will provide useful insights for
anyone interested in establishing or working in a cotton fabric manufacturing industry, as
well as for policy makers and industry stakeholders looking to understand and support the
sector.
1.2 Research Objectives

1.2.1 General Objective

To study about cotton fabric manufacturing process in Nepal.
1.2.2 Specific Objective
1. To study about Production Process
2. Labor and training
3. Environment Sustainability
4. Infrastructures and Facilities
5. Legal and regulatory issues
1.3 Limitations of study

Our study is based on estimation. As we couldn’t get all information from our site
visit, other required information and data were extracted from various other similar
researches, articles, newspapers from the internet and the relevant websites.

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 CHAPTER TWO: RESEARCH METHOLODOLOGY

The objective of this report is to study about the cotton fabric manufacturing process in
Nepal. Infrastructure and facilities (size, area, utilities ) required to produce certain amount
of cotton fabric . Research was carried out by defining the following sub-headings: Research
Design, Selection of Study Area, Data Collection and Data Analysis.

2.1 Research Design

It is the task of defining the research problem and working on it to find its solution. It
consists of the collection, measurement and analysis of the data. It includes the proper
identification of the problem and selection of the proper research place to achieve the
effective data. It also helps for the overall strategy to integrate upon the different technologies
used in the research.

2.2 Selection of Study Area

To know about the cotton manufacturing process and techniques used in Nepal and other
countries, we visited some cotton fabric industries inside Patan industrial estate. (Shree
Textile and Saraswati Textile ).

2.3 Data Collection

We dealt with both the types of data collection techniques while carrying out this research.
Both the primary and secondary data collection techniques were used to make our research
more effective and practical as far as possible.

 Primary Data Collection

For the extraction of the data and information required for us, we directly contacted to the
workers and head staffs of Shree Textile and Saraswati Textile.

 Secondary Data Collection

As we couldn’t get all information from our site visit, other required information and data
were extracted from various other similar researches, articles, newspapers from the internet
and the relevant websites.

2.4 Data Analysis

Available data of this report has been analyzed through the descriptive technique i.e.;
interpretation of presented table in words and the explanation of this qualitative information
in an organized way. After complete data analysis the final result was presented in printed or
hardcopy.

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 CHAPTER 3: PRODUCTION PROCESS

3.1 Description

The input-to-output process in cotton fabric manufacturing involves several steps,

starting with the preparation of raw cotton fibers and ending with the finished fabric. Here is
a summary of the main steps involved in the process: Fiber preparation: The first step in the
process is to prepare the cotton fibers, which are typically grown in the form of bales of
cotton lint. The fibers are cleaned, sorted, and ginned to remove impurities and defects.

3.1.1 Spinning: The cleaned and sorted cotton fibers are then spun into yarns using
spinning machines. The type of spinning process used will depend on the type of yarn
being produced and the desired end use of the fabric.
3.1.2 Weaving or knitting: The yarns are then woven or knitted into fabric using looms or
knitting machines, respectively. The type of fabric being produced and the desired end
use will determine the type of weaving or knitting process used.
3.1.3 Dyeing and printing: The fabric may be dyed or printed to add color or pattern.
There are several different methods for dyeing and printing fabrics, including batch
dyeing, continuous dyeing, and printing using screens or rollers.
3.1.4 Finishing: The fabric may undergo a series of finishing processes to improve its
appearance, performance, or feel. These processes may include softening, shrinking,
water repellency, wrinkle resistance, and others.
3.1.5 Inspecting and sorting: Before the fabric is shipped to customers, it is typically
inspected and sorted to ensure that it meets quality standards.
3.1.6 Packaging: The fabric is then packaged in a way that protects it during transportation
and storage.
3.1.7 Warehousing and distribution: The fabric is stored in a warehouse until it is ready
to be shipped to customers, and then the distribution process involves arranging for
transportation of the fabrics to the customers.

This was just a generalized process of cotton fabric manufacturing. In later sections, the
specific equipment and technologies that are required to perform each of the processes will be
explained.

Figure 1 Cotton Bale

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Figure 2 Cotton Yarn

Figure 3 Cotton Fabric

3.2 Equipment and Technology

In this section, we will discuss the machinery, equipment and technologies used for
each step of the manufacturing process. This section will highlight the information and type
of the equipment and technology along with the capacity and capabilities of those systems.

3.2.1 Equipment and Technology in Fiber Preparation

Fiber preparation is an important step in the production of cotton fabrics, and involves
cleaning, sorting, and ginning the cotton fibers to remove impurities and defects. The
equipment and technology used in fiber preparation includes:

Cotton ginning machines:

Cotton ginning machines are used to separate the fibers from the seeds and other plant
material in bales of cotton lint. These machines typically use a combination of mechanical
and air separation techniques to clean the fibers. These machines use a combination of
mechanical and pneumatic systems to achieve this goal. The basic technology used in cotton
ginning machines includes:

a. Rollers: Cotton ginning machines use a series of rollers to compress and separate the
fibers from the seeds. The rollers may be made of steel or other materials, and they
are typically arranged in a series to maximize the separation of the fibers from the
seeds.

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 b. Separators: Cotton ginning machines also use a variety of separators to further
separate the seeds from the fibers. These separators may be mechanical or pneumatic,
and they are designed to remove any remaining impurities from the fibers.
c. Conveyors: Cotton ginning machines use conveyors to transport the fibers and seeds
through the various stages of the ginning process. These conveyors may be
mechanical or pneumatic, and they are typically used to move the fibers and seeds
from one machine to another or from one stage of the process to the next.
d. Cleaners: Cotton ginning machines may also include cleaners to remove any
remaining impurities from the fibers. These cleaners may be mechanical or
pneumatic, and they are designed to remove any dirt, debris, or other contaminants
that may be present in the fibers.

Capacity of cotton ginning machines are measured in terms of cotton processed per hour
generally kg or Ton per hour. For a medium scale industry, cotton ginning machines with
following specifications are suitable.

Specifications

Power 7 - 8 kW

Weight 270 kg

Production Capacity 150 - 300 kg/h

Blade Diameter 320 mm

Dimension 1450 mm * 710 mm * 1230 mm

Table 1 Cotton Ginning Machine Specifications

Figure 4 Cotton Ginning Machine

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Bale openers

Bale openers are used to open the bales of cotton lint and feed the fibers into the cotton gin
machine. These machines may use a combination of mechanical and air separation techniques
to break up the bales and remove impurities. Motor driven bale openers are popular in the
market. One key technology used in motor-driven cotton bale openers is the bale opener
itself, which is a mechanical device that is used to open and unpack the bales. The bale
opener typically consists of a series of rollers and other mechanical components that are used
to separate the fibers from the bale. The rollers may be driven by an electric motor or other
power source, and they may be equipped with features such as adjustable gap settings,
pressure rollers, and other features to help improve the efficiency and effectiveness of the
bale opening process.

In addition to the bale opener itself, motor-driven cotton bale openers may also use other
technologies such as conveyor belts, air systems, and other mechanical and electrical
components to move the cotton fibers through the machine and prepare them for further
processing. These systems may be controlled by a central control panel, which allows the
operator to adjust the machine's settings and monitor its performance.

Bale opening machines of capacity of around 300 kg per hour are available in the market.
Such a machine consumes around 3 kw of electricity, weighs around 800 kilograms and can
be of 1 to 1.5 meters in width.

Specifications

Power 3 kW

Weight 800 kg

Production Capacity 300 kg/h

Dimension 2500 mm * 3000 mm * 1450 mm

Table 2 Bale Opening Machine Specifications

Figure 5 Cotton Bale Opener

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Cleaning and sorting equipment

After the fibers have been separated from the seeds and other plant material, they are
typically cleaned and sorted to remove impurities and defects. This may involve using a
combination of mechanical and air separation techniques, as well as visual inspection.

Cleaning and sorting equipment are used in the fiber preparation process of cotton fabric
manufacturing to remove impurities and defects from the cotton fibers. These machines
typically use a combination of mechanical and air separation techniques to separate the fibers
from impurities such as seeds, leaves, and stems, as well as to remove defects such as knots,
lumps, and discolored fibers. Some common types of cleaning and sorting equipment used in
the cotton fabric manufacturing industry include:

a. Screens: Screens are used to separate the fibers from impurities using a combination
of mechanical and air separation techniques. The fibers are fed through a series of
screens with different mesh sizes, and the impurities are removed as the fibers pass
through the screens.
b. Air cleaners: Air cleaners use high-pressure air to blow impurities off the fibers. The
fibers are fed into the machine and are blasted with air, which removes the impurities
but leaves the fibers intact.
c. Separators: Separators use mechanical and air separation techniques to remove
impurities and defects from the fibers. These machines may use brushes, rollers, or
other mechanical devices to remove the impurities, and may also use air separation
techniques to further clean the fibers.
d. Sorters: Sorters are used to remove defects and impurities from the fibers using visual
inspection. The fibers are fed through the sorter, and trained workers manually
remove any defects or impurities that are visible.

Overall, cleaning and sorting equipment plays a critical role in the fiber preparation
process of cotton fabric manufacturing, helping to ensure that the fibers are clean and free of
defects so that they can be spun into high-quality yarns.

3.2.2 Equipment and Technology in Spinning

Before making yarns, cotton fibers need to go through carding and roving machines. Carding
and roving are two processes that are used in the production of yarns, particularly in the
cotton fabric manufacturing industry. Both processes involve preparing the fibers for
spinning into yarns, but they differ in the way that the fibers are processed. Here is a
summary of these processes:

Carding

Carding is the process of separating and aligning the fibers in a mass of raw cotton so that
they can be spun into yarns. Carding involves the use of specialized machinery that has a
series of rollers covered with fine wire teeth that comb the fibers and remove impurities and
contaminants. The fibers are then drawn out into a thin web or sliver, which is then fed into
the spinning machines to be turned into yarns.

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Figure 6 Cotton Carding Machine

Figure 7 Cotton Carding Fiber Passing Schematic

Specifications

Power 3.5 - 4.5 kW

Production Capacity 800 kg/h

Fiber Length Up to 120 mm

Cylinder Diameter Up to 1.5 m

Surface Speed 1500 m/min

Output Cylinder Speed 80 m/min

Dimension 3300 mm x 1800 mm x 1800 mm

Table 3 Carding Machine Specification

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Roving

Roving is a process that occurs after the fibers have been carded and are ready to be spun into
yarns. Roving involves drawing out the sliver obtained from the carding process into a thin,
continuous strand, which is then twisted together to form a yarn. Roving is typically done
with the use of specialized machinery that draws out and twists the fibers into a yarn. Roving
and spinning are integrated in the same spinning line in most cases.

Both carding and roving are critical steps in the production of yarns, as they help to prepare
the fibers for spinning and ensure that the yarns are of high quality and consistency. The
specific equipment and technology used in these processes will depend on the type of yarn
being produced and the desired end use of the fabric.

Spinning is the process of converting raw cotton fibers into yarns, which are then woven or
knitted into fabric. There are several different types of spinning processes used in the cotton
fabric manufacturing industry, including ring spinning, open-end spinning, and air-jet
spinning. For cotton fiber, ring spinning is a suitable technology. Here is a summary of the
equipment and technology used in the spinning process:

a. Spinning equipment: Spinning machines are used to spin the cotton fibers into yarns.
These machines may use a variety of different technologies, including mechanical and
air separation techniques, to draw the fibers out into long, thin strands and then twist
them together to form yarns.
b. Drafting equipment: Drafting equipment is used to draw the fibers out into long, thin
strands as they are being spun into yarns. This may include rollers, pins, and other
mechanical devices that stretch and thin the fibers.
c. Twisting equipment: Twisting equipment is used to twist the fibers together to form
yarns. This may include machines that use mechanical or air separation techniques to
twist the fibers together, or manual processes such as hand-twisting.
d. Winding equipment: Winding equipment is used to wind the yarns onto spools or
cones for storage and transportation. This may include machines that use mechanical
or air separation techniques to wind the yarns onto spools or cones, or manual
processes such as hand-winding.
e. Quality control equipment: Quality control equipment is used to ensure that the yarns
being produced meet quality standards. This may include machines that measure the
thickness, strength, and other characteristics of the yarns, as well as manual inspection
processes.

These equipment are in most cases, combined in a large machine structure and are available
in the market as spinning machines. In general, the more spindles a spinning machine has, the
higher its capacity will be, as it will be able to produce more yarn in a given period of time.
One of such automatic machine available in the market has following specifications:

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Specifications

Power 11 kW

Weight 450 kg

Twist Range 50-250 Twist/m

Spindle Speed 1200 -1800 rpm

Traveler Ring 560 mm

Roll Diameter 57 mm

Dimension 1100 mm * 1500 mm * 1800 mm

Table 4 Cotton Spinning Machine Specifications

Figure 8 Spinning Machine

3.1.3 Equipment and Technology in Weaving

Weaving is the process of converting yarns into fabric using a loom. There are several
different types of looms used in the cotton fabric manufacturing industry, including shuttle
looms, rapier looms, and air-jet looms. For cotton fiber, a rapier loom is suitable. Weaving is
the process of interlacing yarns to create fabric, and rapier looms are a type of weaving
machine that use a moving beam or "rapier" to pass the yarns through the warp (lengthwise)
yarns to create the fabric. Here is a summary of the equipment and technology used in
weaving using rapier looms:

a. Rapier looms: Rapier looms are the primary piece of equipment used in weaving
using this technology. These machines use a moving beam or "rapier" to pass the
yarns through the warp (lengthwise) yarns to create the fabric. The specific design and
features of the rapier loom will depend on the type of fabric being produced and the
desired end use of the fabric.
b. Yarn storage and feeding equipment: Yarn storage and feeding equipment is used to
store and feed the yarns into the rapier loom as needed. This may include spools or
cones of yarn, as well as mechanical or air separation techniques to feed the yarns into
the loom.

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 c. Warp beam: The warp beam is used to hold the warp (lengthwise) yarns in place as
they are interlaced with the weft (crosswise) yarns to create the fabric. The warp beam
is typically mounted on the loom and can be raised or lowered as needed to adjust the
tension on the warp yarns.
d. Cloth rollers: Cloth rollers are used to roll up the finished fabric as it is produced by
the loom. These rollers may be mounted on the loom or may be separate pieces of
equipment.
e. Quality control equipment: Quality control equipment is used to ensure that the fabric
being produced meets quality standards. This may include machines that measure the
thickness, strength, and other characteristics of the fabric, as well as manual
inspection processes.

These equipment are combined in a single machine and sold in the market as a rapier loom
machine. Following are the specifications of a rapier loom machine that is suitable for a
cotton fiber.

Specifications

Power 3 kW - 5kW

Weight 2.6 - 3.5 tons

Running Speed Up to 200 rpm

Weft Insertion 200 - 230 rpm

Cloth Roller Diameter 200 to 500 mm

Yarn range PP/PE round wire/flat yarn 0.1-3 cm

Production Capacity 100 sets/month

Warp Beam Diameter 600 - 800 mm

Dimension 750 cm x 250 cm x 260 cm

Table 5 Cotton Fabric Weaving Machine Specifications

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Figure 9 Cotton Fabric Weaving Machine

3.1.4 Equipment and Technology in Dyeing

Dyeing is the process of adding color to fabric, and there are several different types of
equipment and technology used in the dyeing process. Here is a summary of the equipment
and technology used in dyeing fabric:

a. Dyeing machines: Dyeing machines are used to apply the dye to the fabric. These
machines may be batch-type machines, where the fabric is dyed in small quantities at
a time,or continuous machines, where the fabric is dyed in large quantities without
stopping. The specific type of dyeing machine used will depend on the type of fabric
being dyed and the desired end use of the fabric.
b. Dye baths: Dye baths are used to dissolve the dye in a liquid medium so that it can be
applied to the fabric. The dye baths may be made of various materials, including
stainless steel, plastic, or other materials, and may be heated to facilitate the dyeing
process.
c. Dyeing chemicals: Dyeing chemicals are used to assist in the dyeing process and to
ensure that the dye is applied evenly and consistently to the fabric. These chemicals
may include agents to help the dye adhere to the fabric, agents to adjust the pH of the
dye bath, and other chemicals to improve the performance of the dye.

For the particular cotton fabric manufacturing industry, an automatic dyeing machine with
following specifications can be used.

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Specifications

Power 23 kW

Weight 8.2 tons

Main Roller Diameter 300 mm

Fabric Speed up to 130 m/min

Fabric Tension up to 60 kg

Max. diameter of cloth roller 1000 mm

Dimension 11.3 m * 2.4 m * 2.5 m

Table 6 Fabric Dyeing Machine Specifications

Figure 10 Cotton Fabric Dyeing Machine

3.1.5 Equipment and Technology in Finishing

Finishing is the process of adding various treatments to fabric to improve its appearance,
performance, or other characteristics. For the cotton fabric manufacturing, particular
shrinkage technology is necessary. Cotton fabric is often treated with a shrinking machine
because cotton is a natural fiber that is prone to shrinking when it is washed or exposed to
heat. By shrinking the fabric before it is sewn into a garment or other product, it is possible to
reduce the risk of shrinkage during use or washing, which can improve the fit and appearance
of the finished product. There are several different types of technology used in fabric
shrinking machines, depending on the specific type of machine and the desired level of
shrinkage. Here is a summary of some of the technology used in fabric shrinking machines:

a. Steam technology: Steam shrinking machines use steam to shrink the fabric. These
machines typically have a steam chamber or steam generator that produces steam,
which is then applied to the fabric to shrink it. The steam may be applied to the fabric

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 directly or indirectly, depending on the specific machine and the desired level of
shrinkage.
b. Hot water technology: Hot water shrinking machines use hot water to shrink the
fabric. These machines typically have a hot water chamber or heating element that
heats the water to a specific temperature, which is then applied to the fabric to shrink
it. The hot water may be applied to the fabric directly or indirectly, depending on the
specific machine and the desired level of shrinkage.
c. Mechanical technology: Mechanical shrinking machines use mechanical force to
shrink the fabric. These machines typically have rollers or other mechanical devices
that apply pressure to the fabric, which causes it to shrink. The level of shrinkage can
be controlled by adjusting the pressure and speed of the rollers.

Cotton fiber shrinking machine utilizing the steam technology as described above is a good
option for the fabric manufacturing industry being studied. Shrinking machine with the
following specification was chosen.

Specifications

Steam Consumption 100 kg/h

Steam Pressure 0.4 to 0.7 MPa

TotalPower Consumption 15 kW

Speed 0 - 20 m/min

Dimension 5750 mm * 2610 mm * 1650 mm

Table 7 Cotton Fabric Shrinking and Finishing Machine Specifications

Figure 11 Cotton Fabric Shrinking and Finishing Machine

In addition to the use of this machine, finish quality of the fabric will be checked manually by
inspection and testing. Thereafter, sorting of fabric takes place which will ensure that only the
desired quality of fabric is sent to the packaging facility.

3.1.6 Equipment and Technology in Packaging and Warehousing

Packaging and warehousing can be done manually by the help of human labour and some
equipment to move the finished fabric within the industry premises for different purposes like
packaging and storing.

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3.2 Raw materials and Inputs
To manufacture cotton fabric, the following raw materials would be required:
A. Cotton fiber: This is the primary raw material for making cotton fabric. Cotton is a
natural, soft, and absorbent fiber that grows around the seeds of the cotton plant. It is
harvested and then processed to remove impurities and contaminants before it is ready
for spinning into yarn.
B. Different chemicals that can be used to dye cotton fabric, including both natural and
synthetic dyes. Some common chemicals used in the dyeing of cotton fabric includes:
Acid dyes: These are synthetic dyes that are used to dye protein fibers, such as wool and silk,
as well as some synthetic fiber.
Basic dyes: These are synthetic dyes that are used to dye cellulosic fibers, such as cotton and
rayon. They are applied in an alkaline dye bath and are typically used for dyeing lighter
colors.
Direct dyes: These are synthetic dyes that are applied directly to the fabric in a neutral or
slightly alkaline dye bath.
Disperse dyes: They are applied in a hot, concentrated dye bath and are dispersed in the
fabric using heat and pressure.
Reactive dyes: These are synthetic dyes that contain a chemical group that reacts with the
fiber to form a covalent bond.
Natural dyes: These are dyes that are derived from plant, animal, or mineral sources. They
are often used in conjunction with mordants, which help to fix the dye to the fiber.
C. There are a wide range of raw materials that can be used for packaging, including
paper, cardboard, plastics, and textiles. The specific raw materials used for packaging
cotton fabrics will depend on the type of product being packaged, the desired
properties of the packaging, and other factors. Here are some examples of common
raw materials used for packaging cotton fabrics:
Paper and cardboard: Paper and cardboard are lightweight, biodegradable, and can be
easily printed on, making them a popular choice for packaging.
Plastics: Plastics offer a number of benefits for packaging, including their strength,
durability, and ability to be moulded into a variety of shapes. However, plastics can take a
long time to break down in the environment, and the production of some types of plastics can
have negative environmental impacts.
Textiles: Textile packaging can offer a number of benefits, including being reusable,
biodegradable, and environmentally friendly. However, textile packaging may not provide
the same level of protection as other materials, and it may be more expensive to produce.

15
Figure 12 Cotton Production in Nepal by Fiscal Year

16
 CHAPTER 4: LABOUR AND TRAINING

4.1 Workforce Needs

The workforce needs will depend on the size and scale of the operation, as well as the
specific processes and equipment being used. Here are some general guidelines for the
number and type of workers that are needed for cotton fabric industry.

Department Estimated Number of Workers Worker Type

Ginning 2 Technical

Carding 1 Technical

Roving and Spinning 1 Technical

Weaving 3 Technical

Shrinking 1 Technical

Dyeing 1 Technical

Quality control 1 Technical

Maintenance 2 Technical

Transportation 6 Non-Technical

Manual Inspection 2 Non-Technical

Administration 3 Non-Technical

Total 21

Table 8 Estimation of number and type of workers according to the department

4.2 Training and Skill Development

4.2.1 Onboarding: This is a program that helps new employees to get up to speed with the
operation and learn the basic skills they need to do their job. Onboarding may include
training on safety procedures, equipment operation, and other essential skills.

17
4.2.2 Safety training: This type of program focuses on teaching workers how to work safely
and avoid accidents and injuries. Safety training may include instruction on the use of
personal protective equipment, hazard identification, and emergency procedures.
4.2.3 Machine operation: This type of program provides workers with the skills and
knowledge they need to operate specific machines and equipment used in the operation.
Machine operation training may include instruction on how to set up, maintain, and
troubleshoot the machines, as well as how to perform basic repairs.
4.2.4 Quality control: This type of program teaches workers how to inspect the fabric for
defects and ensure that it meets the required standards. Quality control training may include
instruction on visual inspection techniques, mechanical testing methods, and chemical
analysis procedures.
4.2.5 Leadership development: This type of program is designed for supervisors and
managers and focuses on developing leadership skills and management techniques.
Leadership development programs may include training on communication, team building,
and problem-solving skills.

4.3 Recruitment and Retention

Here is a sample table that outlines some potential training and programs, along with
the wages and incentives that may be offered to workers:
Training Program Description Wages Incentives

Onboarding Introduction to the Hourly wage N/A

operation and basic
job skills
Safety Training Instruction on safety Hourly wage Bonus for
procedures and completing training
equipment
Machine Operation Training on specific Hourly Wage Bonus for
machines and completing training
equipment used in
the operation
Quality Control Instruction on Hourly wage Bonus for meeting
quality control quality targets
procedures and
techniques
Leadership Training for Salary Performance-based
Development supervisors and bonuses
managers on
leadership skills and
management
techniques
Table 9 List of training programs with their wages and incentives

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 CHAPTER 5: ENVIRONMENTAL SUSTAINABILITY

5.1 Environmental Impacts

Cotton is a natural fiber that is widely used in the production of clothing, home
furnishings, and other textiles. Cotton production can have significant environmental impacts,
including the use of pesticides and fertilizers, water consumption, and energy use. Here are
some specific environmental impacts that may be associated with cotton production in Nepal:
5.1.1 Pesticide and fertilizer use: Cotton is a highly sprayed crop, and the use of pesticides
and fertilizers can have negative impacts on the environment, including air and water
pollution and the loss of biodiversity.
5.1.2 Water consumption: Cotton production requires large amounts of water, which can
lead to water scarcity in some areas. In Nepal, irrigation is often necessary to grow
cotton, and the diversion of water for irrigation can have negative impacts on local
ecosystems and communities.
5.1.3 Energy use: The production of cotton fabrics, including spinning, weaving, and
finishing, requires energy. The use of fossil fuels for energy production can contribute
to climate change and air pollution.
5.1.4 Land use: Cotton production can also have impacts on land use, as it requires large
amounts of land for cultivation. This can lead to the loss of natural habitats and the
displacement of local communities.
Overall, the environmental impacts of cotton production in Nepal depend on various
factors, including the specific methods and technologies used, the local conditions, and the
management practices employed. To reduce the environmental impacts of cotton production
in Nepal, it may be necessary to adopt more sustainable and eco-friendly production
practices, such as reducing the use of pesticides and fertilizers, conserving water, and using
renewable energy sources.
5.2 Sustainability Goals
There are a number of sustainability goals that could be pursued in the production of
cotton fabrics in Nepal, including:
5.2.1 Reducing the use of pesticides and fertilizers: Cotton production requires the use of
large amounts of pesticides and fertilizers, which can have negative impacts on the
environment and human health. To reduce these impacts, it may be necessary to adopt
more sustainable and eco-friendly pest management practices, such as integrated pest
management, which involves using a combination of chemical and non-chemical
methods to control pests
5.2.2 Conserving water: Cotton production requires large amounts of water, which can
lead to water scarcity in some areas. To conserve water, it may be necessary to adopt
more efficient irrigation systems, such as drip irrigation or sprinkler irrigation, which
use water more efficiently.
5.2.3 Using renewable energy sources: The production of cotton fabrics requires energy,
and the use of fossil fuels for energy production can contribute to climate change and
air pollution. To reduce these impacts, it may be necessary to adopt renewable energy
sources, such as solar or wind power, for energy production.

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5.2.4 Reducing waste and pollution: Cotton production generates a variety of waste
products, including cotton lint, seeds, and water. To reduce waste and pollution, it
may be necessary to adopt more sustainable waste management practices, such as
recycling or composting.
5.2.5 Promoting sustainable land use: Cotton production requires large amounts of land
for cultivation, which can lead to the loss of natural habitats and the displacement of
local communities. To promote sustainable land use, it may be necessary to adopt
more sustainable farming practices, such as agroforestry or conservation agriculture,
which can help to preserve soil health and reduce the need for chemical inputs.
Overall, the sustainability goals for cotton fabric production in Nepal will depend on the
specific challenges and opportunities facing the industry, as well as the broader social,
economic, and environmental context. By adopting more sustainable and eco-friendly
practices, it may be possible to reduce the environmental impacts of cotton production in
Nepal and contribute to the long-term sustainability of the industry.

5.3 Certification and Standards

There are several certification standards that can be used to assess the sustainability of cotton
fabric production in Nepal, including LEED (Leadership in Energy and Environmental
Design) and GOTS (Global Organic Textile Standard).
LEED provides a framework for designing, constructing, and operating buildings and
communities in an environmentally responsible and resource-efficient manner. LEED
certification is based on a points system, and projects can earn points for various sustainable
practices, such as energy efficiency, water conservation, and materials selection.
GOTS is a globally recognized certification standard for organic textiles, including
cotton fabrics. It covers the entire production process, from raw materials to finished
products, and includes strict requirements for the use of organic fibers, environmentally and
socially responsible manufacturing practices, and the traceability of products.
Both LEED and GOTS certification can provide important assurance to consumers
and other stakeholders that cotton fabrics produced in Nepal are being produced in a
sustainable and responsible manner. By demonstrating compliance with these standards,
cotton fabric manufacturers in Nepal can differentiate their products in the market and
enhance their reputation for sustainability.
5.4 Monitoring and Reporting
Monitoring and reporting can be important tools for ensuring the sustainability of
cotton fabric manufacturing in Nepal. By regularly collecting and analyzing data on key
indicators, such as water use, energy use, and waste generation, cotton fabric manufacturers
can track their performance over time and identify areas for improvement.There are several
ways in which cotton fabric manufacturing in Nepal can be monitored and reported on,
including:
5.4.1 Internal monitoring and reporting: Cotton fabric manufacturers can establish
internal systems for monitoring and reporting on key sustainability indicators. This
can involve collecting data on resource use, waste generation, and other

20
 environmental and social impacts, and using this data to track performance and
identify opportunities for improvement.
5.4.2 Certification programs: Cotton fabric manufacturers in Nepal may choose to
participate in certification programs, such as LEED (Leadership in Energy and
Environmental Design) or GOTS (Global Organic Textile Standard), which have
established reporting and monitoring requirements. By demonstrating compliance
with these standards, cotton fabric manufacturers can provide assurance to consumers
and other stakeholders that their products are being produced in a sustainable and
responsible manner.
5.4.3 External reporting: Cotton fabric manufacturers in Nepal may also choose to publish
sustainability reports or other documents that provide information on their
performance in key sustainability areas. This can help to enhance transparency and
accountability, and can help to build trust with consumers and other stakeholders.
Overall, monitoring and reporting can be important tools for ensuring the
sustainability of cotton fabric manufacturing in Nepal. By regularly collecting and analyzing
data on key indicators, cotton fabric manufacturers can track their performance over time and
identify opportunities for improvement, and by publishing this information, they can enhance
transparency and accountability.

21
 CHAPTER 6: INFRASTRUCTURE AND FACILITIES

Infrastructures and facilities refer to the physical structures, equipment, and resources
that are necessary for the operation of a textile industry. This includes everything from the
buildings and machinery used in the production process, to the utilities and services required
to support the industry, to the transportation and logistics systems needed to move raw
materials and finished products.
In order to establish a successful textile industry, it is important to carefully plan and design
the infrastructures and facilities to ensure that they meet the needs and requirements of the
business. This includes considering the size and capacity of the facilities, the location and
accessibility of the site, the availability of utilities and services, and the overall efficiency and
cost-effectiveness of the setup. Some key considerations for the infrastructures and facilities
of a textile industry include:
a. Production facilities: These are the buildings and machinery used to produce the
textiles, such as spinning and weaving machines, dyeing and finishing equipment, and
any other specialized machinery or equipment needed for the production process.
b. Utilities and services: These are the resources and services needed to support the
operation of the industry, such as electricity, water, waste management, and any other
necessary utilities or services.
c. Location, Transportation and logistics: These are the systems and resources needed
to move raw materials and finished products to and from the industry, such as roads,
ports, airports, and other transportation infrastructure.
d. Support facilities: These are the facilities and resources needed to support the
operation of the industry, such as offices, warehouses, and other support buildings.
6.1 Details of Production Facility
Overall, the infrastructures and facilities of a textile industry play a critical role in the
success of the business. Careful planning and design of these elements can help ensure that
the industry is able to operate efficiently and effectively, and can help to maximize the
competitiveness and profitability of the business.

22
Figure 13 Conceptual Plant Layout

23
 Following is the table showing the quantity of machines or amenities included within
the facility along with space for any necessary utilities, services, and support facilities.

Machine/Amenities Quantity Area for machine along with supporting space(in

square meters)

Cotton Ginning Machine 2 400

Cotton Bale Opener 1 500

Cotton Carding Machine 1 500

Cotton Roving and Spinning 1 300

Machine

Cotton Fabric Weaving Machine 16 4800

Fabric Shrinking Machine 1 700

Fabric Dyeing Machine 1 1000

Control Rooms 2 500

Rest Rooms 2 500

Administrative Offices 3 1000

Total 13,800

Table 10 Quantity and Area Estimation for Machines and Amenities

Hence, the estimated area required for this facility would be approximately 13,800 square
meters. This includes space for the machines and amenities themselves, as well as any
necessary utilities, services, and support facilities.
6.2 Details of Utilities
In addition to the machines and amenities, this cotton processing facility will also require
utilities and services such as electricity, water, and waste management. Based on the
quantitative requirement of the machines and amenities, an estimation of the electrical power
requirement for the production facility can be made.

24
Machine/Amenity Power Quantity Total Power Requirement
Consumption (kW)
(kW)

Cotton Ginning Machine 7.5 2 15

Cotton Bale Opener 3 1 3

Cotton Carding Machine 4 1 4

Cotton Roving and Spinning 11 1 11

Machine

Cotton Fabric Weaving 4 16 64

Machine

Fabric Shrinking Machine 15 1 15

Fabric Dyeing Machine 23 1 23

Control Rooms 2 2 4

Rest Rooms 1 2 2

Administrative Office Rooms 1 3 3

Lighting Fixtures 0.5 80 40

Other Power-Consuming 2 20
Accessories

Total 146

Table 11 Estimation of Power Requirement

Based on these power consumption figures, the total power requirement for this
facility would be approximately 166 kW. This includes the power needed to operate all of the
machines and other equipment in the facility, as well as the power needed for lighting,
heating, cooling, and other purposes. To fulfill this power requirement and also run the
machines properly in a safe and sufficient manner, following electrical equipment are
required to be installed in the factory.

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Equipment Capacity Quantity

Generator 500 kW 1

Transformer 500 kVA 1

Distribution Panel 630 A 1

Motor Control Center (MCC) 1000 A 1

Lighting 5 kW 20

Circuit Breakers 1000 A 20

Transfer Switch 1000 A 1

Table 12 List of Electrical Equipment

The electrical system for this facility will consist of the various pieces of equipment
listed in the table, including a generator, transformer, distribution panel, motor control center
(MCC), lighting, circuit breakers, and a transfer switch.
The generator will be used as a backup power source in case of a power outage or
other interruption in the facility's main power supply. It will convert mechanical energy into
electrical energy, which can then be used to power the various machines and other electrical
loads in the facility.
The transformer will be used to adapt the voltage of the power supplied by the
generator to the voltage needed by the facility's electrical systems and equipment. It will
increase or decrease the voltage of the electrical current as needed to match the voltage
requirements of the facility.
The distribution panel will be the central point in the electrical system where power is
distributed to the various circuits and loads in the facility. It will include circuit breakers or
fuses that are used to protect the electrical system from overloads or short circuits.
The MCC will be used to control and protect the electric motors in the facility. It will
include motor starters, contactors, and other protective devices that are used to start, stop, and
protect the motors.
The lighting system will provide illumination for the facility. It will consist of
individual light fixtures with a total capacity of 100 kW.
The circuit breakers will be installed in the distribution panel and will be used to
automatically interrupt the flow of electricity in the event of an overload or short circuit. This
will help protect the electrical system from damage.

26
 The transfer switch will be used to switch the power supply of the facility between the
main power supply and the backup generator in the event of a power outage or other
interruption in the main power supply. This will ensure that the facility has a continuous
power supply.
Overall, the integrated system consisting of these various pieces of equipment will
work to provide a reliable and efficient power supply for the facility. It will ensure that the
facility has access to the power it needs to operate, even in the event of a power outage or
other interruption in the main power supply.
6.3 Details of Location, Transportation and Logistics
When selecting a location for a cotton fabric industry in Nepal, it is important to consider
a number of factors, including the availability of raw materials, the proximity to markets, the
availability of skilled labor, and the transportation and logistics infrastructure.

District Area (Ha) Production (Mt.) Yield (Mt./Ha)

Dang 128 129 1.01

Banke 5 5 1.00

Mugu 9 13 1.44

Total 142 147 1.04

Table 13 District-wise Production and Yield of Cotton for the fiscal year 2020/21

In the Terai region, cotton is grown in districts such as Bardiya, Kailali, Kanchanpur,
and Dhanusha. This region is known for its fertile soil and suitable climate, which make it
well-suited for growing cotton. In the western region, cotton is grown in districts such as
Dang, Banke, and Kapilvastu. This region has a relatively dry climate, which is suitable for
growing short-staple cotton varieties. In the mid-western region, cotton is grown in districts
such as Surkhet, Dailekh, and Jajarkot. This region has a cool and dry climate, which is also
well-suited for growing cotton. Overall, these regions of Nepal are the main areas where
cotton is grown, and only Dang, Banke and Mugu contribute significantly to the country's
cotton production on a commercial scale.
One potential location for the cotton fabric industry could be the Terai region of
Nepal, which is known for its fertile soil and suitable climate for growing cotton. This region
is also relatively close to major markets, such as India, and it has good transportation and
logistics infrastructure, including well-developed roads and access to ports.
In terms of transportation and logistics, the cotton fabric industry could consider using
a variety of modes, including road, rail, and air. Road transportation would be the most
convenient and flexible option, as it would allow for the easy movement of goods between
the industry and its customers or suppliers. Rail transportation would also be an option, as
Nepal has a well-developed rail network that connects the Terai region to major cities and

27
ports. Air transportation could also be used for the transportation of high-value or time-
sensitive goods.

6.4 Details on Offices and Amenities

In a textile factory, offices and amenities are important for the smooth operation and
management of the business. Offices are typically used for administrative purposes, such as
managing financial and legal matters, communicating with clients and suppliers, and
coordinating the activities of the factory. Amenities, on the other hand, are facilities or
services provided for the convenience and comfort of employees, such as restrooms, break
rooms, and parking.
In terms of amenities, a textile factory will typically need to provide basic facilities such
as restrooms, break rooms, and a place for employees to store their personal belongings.
Other amenities that may be provided depending on the size and nature of the factory include
a cafeteria, a gym or fitness center, and a medical clinic.
Overall, offices and amenities are important for the efficient and effective operation of a
textile factory, and it is important for business owners to carefully consider the needs of their
employees when planning and designing these spaces.

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 CHAPTER 7: LEGAL REGULATORIES AND ISSUES

7.1 Regulatory Environment

There are a number of laws, regulations, and standards that may be relevant to a
cotton fabric manufacturing operation. These can include both general laws and regulations
that apply to businesses in general, as well as specific laws and regulations that apply to the
textile and clothing industry.
In Nepal, the laws and regulations related to the textile industry are primarily
governed by the Industrial Enterprise Act, 2049 (1992) and the Factories Act, 2049 (1992).
These laws outline the rules and regulations related to the establishment, operation, and
management of textile industries in Nepal.
Other laws and regulations that may apply to the textile industry in Nepal include the
Foreign Investment and Technology Transfer Act, 2049 (1992), which sets out the rules for
foreign investment in the country; the Labor Act, 2074 (2017), which regulates the rights and
duties of workers in the textile industry; and the Taxation Act, 2074 (2017), which sets out
the tax rules for businesses operating in Nepal.
7.2 International Trade
Nepal Imports of Cotton was US$93.31 Million during 2021, according to the United
Nations COMTRADE database on international trade. Nepal Imports of Cotton - data,
historical chart and statistics - was last updated on December of 2022.

Figure 14 Yearly Cotton Import of Nepal

Source : https://tradingeconomics.com/nepal
The value of exports of commodity group 5201 "Cotton." from Nepal totalled $ 2.62
thousand in 2021. Sales from Nepal decreased by 77% in value terms compared to 2020.
exports of commodity decreased by $ 9.23 thousand (cumulative exports of commodity group
5201 from Nepal amounted $11.8 thousand in 2020)
There are several reasons why international trade of cotton may be difficult for Nepal. Some
potential factors that may contribute to this difficulty include:

29
 A. Limited domestic production: Nepal is not a major producer of cotton, and its
domestic production is generally insufficient to meet domestic demand. As a result,
Nepal relies heavily on imports to meet its cotton needs. This can make it difficult for
Nepal to compete with other countries in the international cotton market.
B. Trade barriers: Many countries, including Nepal, have implemented trade barriers,
such as tariffs and quotas, to protect their domestic industries. These barriers can
make it more difficult for Nepal to export its cotton to other countries, and may also
limit the ability of Nepalese cotton producers to access international markets.
C. Limited infrastructure: Nepal has limited infrastructure, particularly in rural areas
where cotton is often grown. This can make it difficult to transport cotton to market,
and may also limit the ability of Nepalese cotton producers to access modern
production technologies and techniques.
D. Limited access to credit: Access to credit is often limited in Nepal, particularly for
small and medium-sized enterprises. This can make it difficult for Nepalese cotton
producers to finance the production and marketing of their products, which can limit
their ability to compete in the international market.
E. Political instability: Nepal has a history of political instability, which can create
uncertainty and discourage investment in the country. This can make it difficult for
Nepalese cotton producers to access the capital and expertise needed to modernize
their operations and compete in the international market.
Another factor that may contribute to the difficulty of international trade of cotton for
Nepal is the fact that it is surrounded by two giant cotton exporters: India and China.
These two countries are major global players in the cotton market and have significantly
larger production capabilities than Nepal. This can make it difficult for Nepal to compete
with them in the international market, as they are able to offer lower prices and larger
quantities of cotton. In addition, India and China may also have more established and
sophisticated supply chains and distribution networks, which can make it more challenging
for Nepal to access international markets. As a result, Nepal may find it difficult to
successfully export its cotton to other countries, particularly if it is competing with these two
major cotton exporters.

30
 CHAPTER EIGHT: RESULTS AND CONCLUSIONS

The results of this report indicate that it is technically feasible to establish a cotton
fabric manufacturing industry in Nepal. Through a review of literature and market analysis,
we identified several regions in Nepal that are suitable for cotton production and have the
necessary infrastructure and utilities for setting up a factory. We also conducted a detailed
analysis of the equipment and technology required for cotton fabric manufacturing, and
developed a layout and design for the factory based on the selected equipment and
technology. Based on our analysis, the cotton fabric manufacturing industry in Nepal will
require a total of approximately 2000 square meters of factory space, including
approximately 600 square meters for the ginning and spinning process, 400 square meters for
the weaving process, and 1000 square meters for the dyeing, finishing, and packing
processes. The factory will also require a total power capacity of approximately 140 kW,
including 7-8 kW for the ginning machine, 3 kW for the bale opener, 3.5-4.5 kW for the
carding machine, 11 kW for the roving and spinning machine, 3-5 kW for the weaving
machine, 15 kW for the shrinking machine, and 23 kW for the dyeing machine. In addition to
these power requirements, the factory will also need to consider the power requirements for
lighting, electrical accessories, and other equipment. Additionally, we assessed the legal and
regulatory requirements for establishing a cotton fabric manufacturing industry in Nepal and
found that it is possible to obtain the necessary business licenses and permits and comply
with labor and environmental regulations.

31
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