Apparel Merchandising

(08.03.05)

Introduction to apparel Merchandising:-

Merchandising -Merchandising involved with trade (buy & sale).

Apparel Merchandising – Apparel merchandising involved in garments trade (goods are
bought and apparel sold).
Definition of Merchandising – Merchandising may be defined as: - Person who
merchandises the goods, specifically for export purposes. Term Apparel Merchandising
means:-

 Order confirmation by negotiation

 Buying raw materials and accessories
 Producing garments
 Maintaining required quality level
 Exporting the garments with in schedule time

From the above definitions, we can say that a person who involved in apparel
merchandising needs a wide range of knowledge and skills to perform his/ her job
successfully. The job itself is Technical and general as well.

# Basic qualifications should have the Merchandisers:-

 Good command in English and adequate knowledge of technical terms for
accurate and efficient communication.
 Good knowledge of fiber, yarn, fabric, dyeing, printing, finishing, dyes,
colorfastness and garments production etc.
 Clear conception of the usual potential quality problem in apparel merchandising.
 Good knowledge of the usual raw materials, raw materials inspection system and
apparel inspection system.
 Knowledge of the buyer’s compliance and various standards.
 Knowledge of the quota system, free-trade, shipping and banking documentation.

# Main function of a Merchandiser to execute an order perfectly on time (schedule):-

 Fabric requirement calculation (consumption, YPD).
 Accessories requirement, calculation.
 Sourcing of fabrics.
 Sourcing of accessories.
 Possible date of arrival of fabrics and accessories.
 Costing.
 Garment analysis and production planning.
 Performa making, swatch making and distribution to the production unit and
quality concern people.
 Pre-shipment inspection schedule.
  Arranging shipping documents and final inspection.

15.03.05

For woven –
Before placing a “fabric purchase order”

# What points should be considered in preparation the “contract sheet”?

Ans. Four basic categories of information are identified by the AAMA to purchase fabric
1. Physical characteristics of the fabric
2. Performance characteristic of the fabric
3. Visual defect characteristic of the fabric
4. Shade specification of the fabric

Physical characteristic of the fabric –

Composition or fabric content –

1. Fibers ( cotton, polyester)
2. Yarns, kinds of yarns, like- [carded yarn, combed yarn)for woven, {for knit
fabric,(ring spun yarn, open end yarn)].
3. Fabric construction 108(warp / inch) × 56 ( weft / inch)
20(warp count) × 16(weft count)
4. Finishing treatment ( washed, pre-shrink)
5. Finished width ( 45 inch for shirt, 54 inch for women shirt, 58 inch for trouser)
6. Acceptable tolerances (±1 inch)

Performance characteristic of the fabric

1. Shrinkage - ±1/ ( woven ), ±5/ (knit)

2. Color fastness to light and wash ( 4 to 5)
3. Strength ( warp way, weft way)
4. Fabric weight ( woven 16 OZS/YDS, knit 120GSM)
5. Piece length with no seam 75% of the fabric longer than 80 yards maximum 25%
of the between 30 and 79 yard.
6. Specials tests such as shower fastness or flammability etc.( wind proof)

Visual defect characteristic of the fabric

The grading system to be used should be specified together with the level of acceptance
Shade specification of the fabric

The colors of the purchased materials should be specified together with tolerances
between batches to batch (pantone book, swatch book)

Other information’s are

1. Test method ( ASTM 9507, ISO, BS)

2. Packaging details-
- type ( role or flat format)
- size {weight (length / width)}
- ticket information (how much)
- bar code position etc ( computer)

For knit

Should additionally specify the following –

1. Type of knit
2. Tubular or open width
3. Yarn count, type and gsm ( 20, 24, 26 & 30s cotton combed)
4. Shrinkage

# How merchandiser can achieve success in building career as a “ Merchandiser” ?

1. He / she should be hard worker
2. He / she should be responsible for the job
3. He / she should be not bureaucratic
4. He / she should be must have knowledge in
- computer literacy
- e- mail website
- windows, ms
5. He / she should be able work intelligently
6. He / she should have ability to improve public relation
7. He / she should be well behaved personality
8. He / she should be pleasant behavior to motivate people
9. He / she should be good knowledge on calculation
10. He / she should be goal achiever
11. He / she should be international marketing

Others –
- performs given who those to have knowledge about production, quality, machine and
its operations.
29.03.05

“Quick Response”
&
“Sample Development”

Quick Response

[Management] – (in apparel management)

It is divided in the three classes. They are in the following:-
1. Production Management

2. Merchandisers & Designers

3. Quality Management

“Production Management”
1. Organization must now be added “ QR” ( quick response)
2. Current demand for “ QR”
- Modular Manufacturing (developed by japans Toyota com.)
- The unit production system (develop system of progressive bundle
system)
- Tailoring ( it is not essential for quick response)

Features of Modular manufacturing

- A team concept that involve the “cross training” of operators (multi skills)
- Each team member works on “more than one operation”
- “Operation stand to work”
- M/c’s are raised to correct height and laid out in a shape
- Small teams of 4 to 17 (usually 8 to 10)
- A supervisor is available to help “technical information”
- The team works on only “1 bundle at a time”
- Production managers provide continuous “feed back” through display
(showing target output of the day.)
 - Labor turnover is considerably reduced motivation of member is very
strongly
- All m/c’s manual control. This result is less m/c down time improved
stitch quality and fervor maintenance requirements.(all m/c should be high
performance)
- Team meetings are held regularly to promote exchange of information
- Advantages, shorter cycle times and higher morale because the work is
less boring

Sample development
This is response of merchandiser and designer

Designer
1. The origin of style
- market research ( fashion show, fashion journal, idea from retail store)
- design concept
- proto type pattern (sample development)

2. The development of sample

Merchandiser
Merchandising chronological processes:-
-1st pattern (first sample)

-2nd pattern (second sample)

-Approved sample and counter sample (three pace)

- Sales man sample (for sale every chain store can take 20)

- Photo / proto type sample (original fabric & accessories are made)

- Size set sample

- Pre-production sample (production running in that time merchandiser take)

- Production sample

 Shipping sample (before shipping merchandiser takes some sample)

05.04.05

Fabric consumption for woven fabric:-

The quality of fabric which is required to produce a garment is called consumption.
System of fabric consumption:-
There are two type of fabric consumption:-
 Marker planning system (actual)
 Mathematical system / estimation

Basic principle of marker planning:-

# Pattern set (small, medium, large & XL)
# Place it on marker paper
# Measure marker paper to length wise
# Find a consumption/ dz from the calculation

Basic principle of mathematical system:-

# Rough estimation
# Consumption calculation by following a sample or size sheet
**# Measuring the area of each part for each piece of garment
# Find consumption /dz from the calculation

Example:-
For a long sleeve shirt:-
Spec. sheet:-
Collar = 16"
Chest = 48"
Center back length = 31"
Sleeve length = 34.5"
Drop shoulder = 21"(yoke)
Arm hole depth (1/2) = 10.5"
Cuff = 9"
Pocket = 6" × 5.5"
Yoke is all time = 4"
[Area means- L× W]

Back part
Formula:-
(Center back length + allowance) × (½ chest + allowance) / 36
{L} {W}
44
= (31" + 2") × (24" + 2" ) /36
44
= 0.541yds
Yoke
Formula:-
(Yoke length + allowance) × (yoke width + allowance) / 36
44
= (21" + 4") × (4"+ 1") / 36
44
= 0.079 ydz

Front part
Formula:-
(Body length + allowance) × (¼ chest + allowance) × 2 /36
44
= [{31"- 1 ¼" + 1"} ×{ 12" + 2 ½" }] 2" /36
44
= 0.562 yds

Sleeve
Formula:-
(Sleeve length + allowance) × (arm hole depth full + allowance) ×2 / 36
44
= {sleeve length – (½ drop shoulder + ½") × (arm hole depth + allowance)} ×2 /36
44
= [{34 ½" - 11"} +1"] × {21" +1"} × 2 /36
44
= 0.68yds

Cuff
Formula:-
(Cuff length + allowance) × (cuff width + allowance) ×2 / 36
44
= (9" + 3") × (2 ½" + ½" ) ×2 /36
44
= 0.05yds

Collar
Formula:-
(Collar length + allowance)× (collar width + allowance) × 2 /36
44
= (collar length + allowance) × (collar width + allowance) ×4 / 36
44
= (16" + 5") × (2" +1") × 4/36
44
= 0.159yds
Pocket
Formula:-
(Pocket length + allowance) × (pocket width +allowance) / 36
44
= (6" +2") (5½" +1") /36
44
= 0.032yds
Total consumption for one garment = 0.541+0.079+0.562+0.68+0.05+0.159+0.032
= 2.100 yds/ per garment
Per dz = 2.100 ×12
= 25.20/dz (ypd) + 5%
= {25.20 ×5 / 100} + 25.20
= 1.26 + 25.20
= 26.46

19.04.05

Consumption calculation for trouser:-

Measurements:-
Out seam = 42"
In seam = 32"
Waist = 36"
Hip = 40"
Bottom = 20"
Find out fabric consumption / dz if fabric width = 58"

Formula:-

Out seam × thigh × 4 / 36"

57"
= (42" + 2" + 2") × (Hip/4 + 1.5" + 1.5" ) × 4 / 36"
57"
= 46" × (40"/4 + 3") × 4 / 36"
57"
= 46" × 13" × 4 / 36"
57"
= 1.165 yd / per trouser
1.165 yd / per trouser + zipper fly (2) + pocket facing (4) + back pocket bone + belt loop
= 1.165 × 5% (for regular trouser)
{= 0.058}
1.165 + 0.058 = 1.21
1.21 + 5%
=1.21 +0.060 = 1.270 × 12 (per dz) =15.24 ypd
Knit Fabric
For, T-shirt {(s/j) 30/1 combed yarn}

Measurement:-
Length = 70 cm
½ chest = 60 cm / dia
Sleeve length = 25 cm
Arm hole width = 40 cm
GSM = 145
Find out consumption / dz in kg?
Formula:-

(Back length + sleeve length) × ½ chest × 2 × GSM ×12

10000000

= {(70 +5) + (25 +5)} × 60 × 2 ×145 ×12 {B.L + S.L × chest × GSM ×12}
10000000 100 100 1000
= 2.28 kg + 7%
= 2.28 kg +0.159
= 2.439 kg [neck and sleeve are made rib so add 0.10]
All time collar in rib = (350-400)

26.04.05 last mid

Cost calculation
Cost is divided in to:-
1. Pre- cost------- merchandiser
2. Final costing -------- merchandiser + import section

Garment: - $ 5.00 = cost

Garment costing: - $ 5.00 + profit = costing

Question. – Briefly describe the costing function of a garment?

Ans. –
Pre- cost:-
1. It is an estimate made before the garment is adopted in to the line
2. Fabric, trim and labour costs for each garment is calculated
3. The merchandiser / designer usually keep a record of all materials costs on a
work sheet.
4. Then the costing department can roughly estimate the cost and price
structure. (Normally over head cost is 30-40%)
Final costing

1. It is an exact calculation by the costing or import department

2. Using actual figures for fabric,, accessories and labour cost
3. Costing department uses-
a. merchandiser work sheet
b. A proto type garment
c. Production pattern

4. A detailed cost analysis is made for each garment the final cost is plotted
on a “cost sheet”.

Ques. - Analysis a cost sheet for a garment order?

Ans. –
1. Materials:- total amount of material × @ ($ 1) / yd = total price
2. Trimming :- button(BTN), thread(THD), interlining(int), level & packing
3. Production pattern making, grading, marking, spreading and cutting
4. Assembly and finishing:- calculated the average time of operations
5. Over head cost :- salary, rent, utilities > (30- 40%)
6. Freigh :- air freight / sea freight
7. Quota change

Ques. – Pre pare price quotation for buyers?

Ans. - There are following process for fixation price:-

1. FOB ( free on board) :-
a. Exporter does not bear the cost of freight of ship or air
b. It is buyer who him self bear the freight

2. C & F ( cost & freight)

a. Free on board + freight = c & f
b. In this case ship or air freight is carried by the exporter while quoting
price.
c. This price a bit higher than FOB

3. CIF ( cost, insurance & freight)

a. c& f + insurance = CIF
b. In this case in addition to the bearing of freight, the cost of insurance is
also borne by the exporter

4. CM ( cost of making / manufacturing)

a. manufacturing or exporter will get only making charge of that garment
b. fabric, trimming and other materials is supplied by the buyer
 5. CMT (cost of manufacturing and trimming)
c. manufacture or exporter will get the making charge and at the same
time will get the trimming cost
d. fabric is supplied by the buyer

Ques. Quote a price of one dozen long sleeve shirts?

Ans.
Fabric- Ging ham (Tc fabric):-
1. Fabric: - 30yds × $ 0.95 = us $ 28.50
2. Accessories: - cost / dz × = us $ 6.00 (1 piece all time $ .15)
3. Cm / dz = us $ 10.00
Sub total = $ 44.50
4. Transport cost from factory to sea or air port (.5%) = us $ 0.25
5. Clearing and fording cost (2%) = us $ 0.90
6. Over head cost (.5%) = us $ 0.20
Net cost price = us $ 45.85
7. Profit (10%) = us $ 4.50
Net FOB price = us $ 50.90
8. Freight (4%) = us $ 2.00
Net C & F price = us $ 52.90
9. Insurance (1%) = us $ 0.52
Net CIF price = us $ 53.42
 For final semester
03.05.05

Documentation:-
(a) Order confirmation documentation:-
1. Copy of master L/C > or received of this documentation from the buyer, the
exporters become sure that they would obtain foreign currency after the perches
shipment.

2. Contract sheet > Sing by buyer and vender (2 page)

> Style number
> Shipment date
> Mode of shipment (sea / air)
> Order quantity and size ratio….xl xxl sml
> Fabric description
> Labels etc

3. Product package >

> 10- 15 page
> Spec sheet
> Stitch & seam type (button gap-2.5" to 3.5")
> Position of levels, taken tag, price ticker
> Sketches partly of each garment
4. Trim card with approval > swatch card

(b) Import documentation:-

1. Proforma invoice > Total requirement: - how many fabric, trims = 1 sheet
2. Commercial invoice > Fab: Unit price, trim unit price
3. Packing list > how many roles Break down each fabric roles
4. UP (utilization permission) > given from the government
5. PSI certificate/ pre-shipment inspection {if necessary}

(c) Documentation: - on receipt of the material at the factory.

1. Inventory report – collection store manager.

SL. NO Item o/q p/lq Recive status of aim

2. Fabric and accessories swatch (actual)

(d) Documentation: - during production

1. Daily production report
2. Daily quality report
 3. Daily production report DUPRO

(e) Export documentation:-

1. Packing list
2. IC (inspection certificate) Buyer qc team
3. Bill at leading {(B/L) sea}Collect from ship
4. Air way bill (air)
5. Certificate of origin Collect from custom

(f) Documentation for opening L/C (for opening L/C the bank will provide the following
things:-
1. L/C application form
2. IMP form (import permission form)
3. Agreement form
4. Guarantee form

Have to fill up the forms mentioned above and after verifying and signing the following
documents should be submitted to the bank:-
1. Trade license (valid)
2. IRC (import Registration certificate)
3. Membership certificate
4. Memorandum of association
5. Income tax declaration
6. A photograph

17.05.05

Question: - Who is making a knitting Proforma by following buyer order?

Ans. Proforma making in knit merchandiser:-
An order of 5 tons single jersey finished fabric as per following data to be supplied:-

Dia 18" = 500kg}

Dia 19" = 500 kg
Dia 20" = 500 kg
Dia 21" = 500 kg} white [used yarn count = 30/1 combed, finished GSM, 135-140]
Dia 25" = 1000 kg}
Dia 28" = 1000kg
Dia 30" = 1000 kg} color

For proforma making, we can follow the knitting m/c dia, knitting m/c gauge. Single m/c
gauge most of the time = 24 and 28.
M/c selection = yarn count-30s = m/c dia equal to fabric dia or more ½ ". (When
gauge=24)

M/c dia Grey Finished Finished Quantity to be

(white=5,color= dia GSM knit(kg)
15)
18 =24 130-132 18" 135-140 500 kg
19 =24 130-132 19" 135-140 = 525
(18=28)
20 =24 130-132 20" 135-140 Kg.
21 =24 130-132 21" 135-140 5%more
25 =24 120-122 25" 135-140 All time
28 =24 120-122 28" 135-140
30 =24 120-122 30" 135-140

Yarn count =30s when gauge =28, {more1" or 1 ½"}

M/c dia Grey Finished Finished Quantity to be knit

GSM dia GSM

17=28 130-132 18" 135-140 500kg=

18=28 130-132 19" 135-140 525kg
19=28 130-132 20" 135-140 5%more
20=28 130-132 21" 135-140 All time
24=28 120-122 25" 135-140
27=28 120-122 28" 135-140
29=28 120-122 30" 135-140

M/c selection= yarn count-26s (24) =1" more than m/c dia, 26s (28) = 2"more

M/c dia Grey Finished Finished Quantity to be knit

GSM dia GSM
18"=17=16" 130-132 18" 135-140
19"=18=17" 130-132 19" 135-140
20"=19=18" 130-132 20" 135-140 5%more
21"=20=19" 130-132 21" 135-140 All time
25"=24=23" 120-122 25" 135-140
28"=27=26" 120-122 28" 135-140
30"=29=27" 120-122 30" 135-140
M/c selection= yarn count-26s (24) =1" more than m/c dia, 26s (28) = 2"more

M/c dia Grey Finished Finished Quantity to be knit

GSM dia GSM
130-132 18" 135-140
18"=17=16
19"=18=17 130-132 19" 135-140
20"=19=18 130-132 20" 135-140 5%more
21"=20=19 130-132 21" 135-140 All time
25"=24=23 120-122 25" 135-140
28"=27=26 120-122 28" 135-140
30"=29=28 120-122 30" 135-140

M/c selection, yarn count 20s (24) = 2" more than m/c dia, 24s (28) = 3"more

M/c dia Grey Finished Finished Quantity to be knit

GSM dia GSM
16=15 Grey 18" 135-140
GSM
17=16 130-132 19" 135-140
18=17 130-132 20" 135-140 5%more
19=18 130-132 21" 135-140 All time
23=22 130-132 25" 135-140
26=25 120-122 28" 135-140
28=27 120-122 30" 135-140

24.05.05

# Briefly describe about the Operations Management in Apparel Manufacturing?

Ans. Operation Management:- The steps involved in garment assembly are called
operation in apparel manufacturing:
1. Cutting room management
2. Sewing room management

Cutting Room Management

Function: - Material control > Fabric wastage control and proper utilization

@ Material control ≤ Material control in the cutting room begins with establishing
material estimates. This will include a standard usage for a certain garment.
@ Material control ≤ Material control in the cutting room may take place in three areas
1. Fabric issue:-
* The storekeeper knows the length and width of pieces in store and issue cloth against a
copy of the cutting sheet.
* Control consists of compring expected usage (material estimate × no of garments cut)
with actual usage (issued fabric minus returned fabric)
2. Marker Making
* Control may involve checking that a copy marker is the same length as the original i.e.
master marker length = 25 yds 04"
Copy marker length = 25 yds 04"
3. Spreading
* Control of end losses, edge alignment damages which affects material utilization and
control (material width 43", fabric width 44" not allow 45")

Sewing Room Management

Function:-
1. Labour cost control (pm= 40 worker, M= 35 worker)
2. Line balancing (smooth)

Line Balancing
 Good line balancing increases the rate of production
 Systematic work procedure is the pre-condition for smooth production
 By good line balancing we can determine the exact number of machine and types
of machine required for a new style
 Line balancing also helps in the determination of labour requirement

Disadvantage:-
1. Labour cost high
2. production hamper/ rate of production low
3. proper work can be hamper

Labour Cost Control

1. Worked time record
2. Standard hours record
3. Performance of the work > standard hours are divided by worked hours and
multiplied by hundred (i.e. performance = standard hours / worked house × 100)

# What do mean by production planning and production control?

Ans.
Production planning:-
1. production planning involves planning of men & women, machine, material
2. production planning is carried out before starting production
3. production planning ensure that production can be started smooth

Production planning requirement

1. Daily production estimates (shipment)
 2. plain consists of date for completion work(shipment date)
3. draw up a production budget setting
4. correct scheduling to the sewing room and cutting room

Production control
Production control is concerned with production documents.
Aim: - To produce the right garment in the right quantity of the right quality and at the
eight times.
Objective: - Maximum production efficiency at minimum cost

Production control function: - will keep the cutting room and sewing room running
smooth. I.e. - organizes the flow of manufacturing process as per-production planning.

04.06.05

# Make a opining (before production) and closing (after shipment) summery for a
production style which is assigned to a merchandiser?

Ans:-
1. Buyer = JC penny
2. Style = 7153
3. Order quantity = 100000 piece (ladies blouse)
4. Delivery / shipment date = 03 / 09 / 05

Opening summery

Particular Required quantity Order Received Status Remarks

quantity quantity ETA/ ETD
Fabric 65/35 250,000 yds 25,0000 150,000 yds
Button 18 L 1200 G G 1200 G G 1200 G G ETA on fab: 100000 yds on
14 L 100 G G 100 G G 100 G G pipe line
ok ok
Labels: Main: 105000 105000 piec Ok
Main = 105000 Size:-
Size level:- XL= 30000 XL=40000 XL excess To be order
L = 40,000 L=40000 Same L=30000 = 10000 pie locally
M = 25000 M=25000 M=25000 L= short
S = 10,000 S=10000 S=10000 M = ok
S = ok

Thread:
60/2 White =4000 cone ETA on On pipe line
Black =2000 cone Nile Fab:-
same 11/06/05
50/2 White =6000 cone Nile
Black =3000 cone

ETA = Expected Time Arrival

GG = Great Gross, 0.635 mm = L line
12 piece = 1 DZ
12 DZ = 1 gross
12 gross = 1GG
Carton = Local
Poly bag = Local (7 to 10% more)

Buyer: - JC penny
Style no: - 7153
Order / quantity: - 100000 piece
Shipment date: - 03/09/05
Shipment quantity = 98,000 piece
Closing summery

Particulars Order Issued Actual used Returned Remark

quantity quantity quantity quantity
Fabric 250,000yds 250,000yds 240,000yds 10,000yds Reject fabric
due to
shading

# Over view of textile materials processing which is essential for a merchandiser?

 Animals (wool, silk)
Natural
Vegetable (cotton, linen)
(1)Fibers

Mineral (asbestos)
 Man-made Regular (viscose)

Synthetic (polyamide)
Regular (single,
combed)
(2)Yarn

Fancy (slab yarn, crepe)

 Plain/tappet

Dobby loom

Woven
Jacquard
(3) Fabric Knit S/j
weft
Bonded

Non-woven Rib

Felled Warp
Inter
Knotted
Purl
Preparatory
Singing
Tricot
Dyeing Scouring
4.Applied Printing mercering
Rascal

Finishing

Appearance enhance

Performance
enhance
Men’s
(5) Apparel
Ladies

Kids
processing

Reactive, acid, direct dye

Roller

Screen

Block

Transfer

Water proof (anti shrinking)

07.06.05

# Button Measurement:-
Line number:
Formula:-
1 line = 0.025"
1 line = 0.635 mm
So, 40 L = 1"
20 L = 0.5"
10 L = 0.25"
Garment washing
Washing (after wearing):- Removal of impurities (oil, stain and dust etc)
Garment wash (before wearing):- it is divided in two class:-
1. Fashion aspects
2. Functional purpose

Type of wash:-
1. Normal wash > Detergent 1% - 2% / hot wash up to 60° / time 20 min.
2. Pigment wash
3. Bleach wash
4. Stone wash with bleach or without bleach
5. Acid wash
6. Enzyme wash ( individual fiber hit & break)
7. Garment wash
8. Whitening
Stone wash:-
Stone wash – pumice stone
 A light weight stone, it is lighter than water. It means when used in liquor, it is floating or
surface.
 Produces from “LAVA”
 When lava is cooled then it from a “stone”
 This stone is perforated form
 It is costly
Role of peumic stone:-
 Play major roll in stone wash & acid wash
 When fading effect required in jeans or denim garment it is used
 Not only fashion but also to reduce “Hardness of fashion”
 It changes the “out look” of garment
 Help to introduce a new “Trend of fashion”

Stone washing process:-

M / C: - Washing machine
Lot size: - 100 kg (65 piece)
1st step:-
Pretreatment (de-sizing)
 Enter the garment in the machine
 Add water:-ML > 1:5 > 500 liter
 Start m/c running
 Add detergent, 1.5 % > 1.5 kg
 Steam supply up to 60°
 Continues 20 minute
 Remove water
 Hot wash for washing

2nd step:-
Stone wash step –
 Enter the garment in m/c and add water 500 liter
 Start the m/c
 Add bleaching agent:- 4% =kg
 Punic stone :- total weight / 2 = 50 kg(half volume of total fabric)
 Add soda ash:- 8% = 8kg
 Continue the process for:- it depend on the sample
 Remove the water
 Again hot wash

3rd step:-
Neutralization:-
 Water 500 liter
 Acetic acid :-1% = 1 liter
 Continue :- 5-10 min
 Cold water
 Remove water

4th step:-
Softening:-
 Add 500 liter water
 Add softening : 0.3% = 300gm
 Whitening agent :- 0.5% = 500 gm ( it depend)
 Continue 20 min
 Remove water

Step 5th
Unloading

Step 6th:-
Excess water removal (hydo-extractor)
Step 7th:-
Drying, pressing and finishing.