T-SHIRT PRINTING

INTRODUCTION

T-Shirt printing refers to the production of designs of any kind that could not be made

on textile fabrics by normal weaving/knitting techniques. Before the printing process, the cloth

should be thoroughly prepared by different wet process namely designing, scouring and

bleaching. Printing is mainly done on finished fabrics, curtain clothes, ladies dress materials,

bed sheets, bed covers, fabric for children’s garments, gents’ shirts etc. to improve its

attractiveness, marketability etc. Screen printing can be done in single colour or in combination

of different colours as per end use requirement Colour combination is an important area by

which the appearance of an ordinary fabric can be improved to a maximum extent. It is,

therefore, necessary that the quality printing material, chemicals and printing screen should be

good so that printed items are fully accepted in the market.

MARKET POTENTIAL

With regard to marketability of the product in general, printed items have good market

potential both in domestic and export market. In populated country like India, there is no

problem of marketing printed fabrics as the requirement tends to increase and also these items

will satisfy individual customer's needs and requirements in terms of colour combination,

design requirements etc.

The growth of the T-Shirt Printing Market can be credited to customized t-shirts being

used across educational institutions and corporate organizations to increase engagement

practices. A consumer preference shift towards customized t-shirts due to the influence of

trending movies and reality shows, coupled with a rise in disposable income also contributes

to the growth of the market. The Global T-shirt Printing Market report provides a holistic

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evaluation of the market. The report offers a comprehensive analysis of key segments, trends,

drivers, restraints, competitive landscape, and factors that are playing a substantial role in the

market.

MANUFACTURING PROCESS

Method used for this T-Shirt Printing project is Screen Printing. Screen or silkscreen

printing is a stencil-based printing technique where ink is applied to the t-shirt through a mesh

screen. It’s the most popular printing method and has been around for decades – first done by

hand and now by printing machines.

It uses special screen-printing inks that are thicker than those used for other printing

methods, resulting in very vibrant, longer-lasting prints. As opposed to DTG printing, screen

printing is better suited for designs with fewer colours.

Silkscreen printing is ideal for large orders up to 500 t-shirts, as it is relatively quick

and easy to set up. However, it can be more expensive for smaller orders, as there is a setup

cost involved.

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Pros:

• Screen printing ink is deeply absorbed into fibres, which results in stunning vibrant

prints

• Fast printing process for large amounts of t-shirts

• Can be used on most materials – cotton, polyester, and various blends

• Screen-printed t-shirts can withstand countless wash cycles without fading

Cons:

• Limited printing area – this printing method won't be suitable for covering the whole

t-shirt

• If you're thinking of doing this at home, keep in mind that screen printing ink tends to

spill all over, and it's pretty messy

• Limited colours – you won't be able to achieve an extremely colourful design or print

a super vivid photograph on your t-shirt

BASIS AND PRESUMPTIONS

This project is based on single shift basis and 300 working days in a year and time

period for achieving maximum capacity utilisation is considered from 3rd year from the date

on which production is started. The rental value for the proposed building of the project is taken

as Rs. 20 per sq. mt. The costs of machinery and equipment/material indicated refer to a

particular make and approximate to those prevailing at the time of preparation of this project.

The cost of installation and electrification is taken @ 10% of cost of machinery and equipment.

Nonrefundable deposits, project report cost, trial production, security deposit with State

Electricity Board is taken under pre-operative expenses.

Depreciation has been considered at 10% on plant and machinery, 15% on office

furniture. Interest rate on capital loan has been considered as 14% per annum.
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IMPLEMENTATION SCHEDULE

The implementation period for executing different types of work right from selection

of site/working shed and forming of company to selection of market channel and miscellaneous

work will take a total period of 5 months. However, on considering that some of the activities

may be overlapping, the actual project implementation may hardly take 3 months.

TECHNICAL ASPECTS

Process of Manufacture

The various steps involved in printing process are preparation of printing paste, printing

of fabric, fixation of dye stuff by curing/steaming, washing off, calendaring, folding and

packing. Scoured and bleached cotton fabric as obtained from dealers is inspected to remove

any objectionable faults and stretched evenly on printing table. Screens containing the designs

is placed over the table and the dye paste is pressed over the screen by means of rubber

squeezer. The selection of dyes and gums depends on the construction of basic cloth to be

printed and their end use. After printing, the printed clothes are cured or steamed for the fixation

of the colour. Later, the printed material is thoroughly washed to remove loose dye stuffs. Then,

it is calendared, folded and packed for the delivery.

Quality Control and Standards

A quality printed item should have good fastness to washing, rubbing and light. This

can be achieved by properly fixing the print on the cloth by curing or steaming. Dyes to be

used should be of good quality and capable of giving bright shades. Printing quality is not

covered by any specifications.

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Production Capacity (per annum)

S.No. Product Qty. (Nos.) Value (Rs.)

1. Printed T-Shirts (Pcs.) 25000 4000000

2. Printed Fabric (metres) 12500 562500

TOTAL 4562500

MOTIVE POWER

Most of the processes in printing are carried by manual operations as such the

requirement of power will be only for running the washing machine, drying heater, fans and

lightings. Therefore, 13 HP power will be required to run the unit.

POLLUTION CONTROL

Textile printing does not necessarily produce sufficient effluents (except washing

section) so as to create pollution problems. However, a no objection certificate from the State

Pollution Control Board is required before setting up of the project.

ENERGY CONSERVATION

Wastage of energy should be minimised as much as possible so that the unit can

withstand competition with similar unit.

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FINANCIAL ASPECTS

Fixed Capital

S.No. Land & Building Value

1. Covered Area 250 Sq.mt

2. Uncovered Area 50 Sq.mt

3. Rent per Month 6000

Machinery And Equipment’s

S.No. Description Nos. Rate (Rs.) Amount (Rs.)

1. Printing Table 4 14000 56000

2. Rubber Squeezers 15 450 6750

3. Cottage Steamer 1 65000 65000

4. Open with Jigger 1 120000 120000

5. Cylinder Drying Machine 1 223000 223000

6. Baby Boiler 1 115000 11500

7. Wash Room trolleys 3 8500 25500

8. Dye Paste Stirrer 3 3000 9000

9. Weighing Balance (Dial Model) 1 35000 35000

TOTAL 655250

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Other Fixed Assets

S.No. Description Amount (Rs.)

1. Erection and Installation 25000

2. Office Furniture 20000

3. Pre-operative Expenses 15000

TOTAL 60000

WORKING CAPITAL

Staff and Labour Wages

S.No. Designation Nos. Rate (Rs.) Amount (Rs.)

1. Manager 1 6000 6000

2. Accountant 1 3500 3500

3. Printing Master 1 6000 6000

4. Skilled Worker 8 3000 24000

5. Artist cum Stencil 1 3000 3000

Maker

6. Helpers 2 2250 4500

7. Store Keeper 1 2500 2500

8. Labour 1 1500 1500

9. Watchman 1 2500 2500

TOTAL 52000

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Raw Material

S.No. Description Qty Rate/Unit (Rs.) Amount (Rs.)

1. Cloth in Meter 11460 20 229200
2. Dyes (Kgs) 13 160 2080
3. Gums (Kgs) 46 22 1012
4. Chemical and Auxiliaries LS 5000
5. Thickener (Kgs) 50 15 750
TOTAL 238042

Utilities (per Month)

S.No. Utilities Per month Per 3 Months

1. Electricity 6500 78000
2. Water Charges 1000 12000
3. Cal and Fire Wood 2000 24000
TOTAL 114000

Other Contingent Expenses

S.No. Expenses Per month Per 3 Months

1. Rent 6000 18000

2. Postage/ Stationery 500 1500

3. Repair and Replacement 500 1500

4. Transport 1000 3000

5. Insurance 200 600

6. Miscellaneous Expense 1000 3000

7. Screens 3000 9000

TOTAL 36600

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Total Recurring Expenses = Rs. 322142

Total Working Capital for 3months = Rs.966426

TOTAL CAPITAL INVESTMENT

S.No. Expenses Per 3 Months

1. Machinery and Equipment 715250

2. Working Capital (3months) 966426

TOTAL 1680676

MACHINERY UTILISATION

Capacity Utilisation is considered as 75% of installed capacity as the utilisation mainly

depends on the skill of the labour force employed.

FINANCIAL ANALYSIS

Cost of Production (per Year)

S.No. Description Amount (Rs.)

1. Recurring Expenses 3865704

2. Depreciation on Machinery @10% 58575

3. Depreciation on Office Furniture @20% 4000

4. Interest on Total investment @14% 235435

TOTAL 4163713

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Sales Turn over per year

S.No. Product Nos. Rate (Rs.) Amount (Rs.)

1. Cloths 25000 160 400000

2. Printed Fabric 12500 45 562500

TOTAL 4562500

BREAK EVEN POINT

S.No. Description Amount (Rs.)

1. Depreciation 62575

2. Rent 72000

3. Interest on Capital Investment 235435

4. 40% of Wages of Staff and labour 299520

5. 40% of other contingent Expenses 28800

6. Insurance 2400

TOTAL 700730

Fixed cost X 100

= %

Fixed Cost – Annual Profit

700730 X 100

--------------------------- = 63.7 %

700730 - 398787

Break Even Analysis: 63.7%

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Addresses of Machinery and Equipment Suppliers

1. M/s. Anil Starch Products Ltd. P.B. No. 10009, Anil Road, Ahmedabad-380025.

2. M/s. Supertex (India) Corp. 132, Dr. Annie Besant Road, Mumbai-400018.

3. M/s. KAM Syndicate Suraj Niwas, Tanulane, Santacrus (W), Mumbai-400054.

4. M/s. S. Pritam Singh and Sons A-115, Ground Floor, Wazirpur Industrial Area, New Delhi-
110052.

5. M/s. Amardye Chem Ltd. Sitadevi Temple Road, Mumbai-400016.

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