State-of-the-Art Knitting & Garment project

KSTCL

PROJECT PROFILE ON KNITTING AND GARMENT PROJECT

Kerala State Textile Corporation Limited

State-of-the-Art Knitting & Garment project

KSTCL

PROJECT PROFILE FOR APPAREL AND KNITTING PROJECT

INTRODUCTION:

The Indian textile industry is one of the largest and oldest sectors in the country and among the most important in the economy in terms of output, investment and employment. The sector employs nearly 35 million people and after agriculture, is the second highest employer in the country. Its importance is underlined by the fact that it accounts for around 4% of Gross Domestic Product, 14% of industrial production, 9% of excise collections, 18% of employment in the industrial sector, and 16% of the countrys total export earnings.

In the Textile industry, the Apparel industry is one of the important value chains of the vertical and is Indias second largest industry after IT. At present, it is amongst the fastest growing industry segment and is also the second largest foreign exchange earner for the country. Also the retail segment in India is booming up at a very fast phase. MARKET: Apparel is one of the basic necessities of human civilization along with food, water and shelter. The Apparel Industry reflects peoples lifestyles and shows their social and economic status. The concept of purchasing fabric & get it sewn by our traditional tailors has receded and the current generation prefers for readymade garment and there is an ever-growing demand for the same. With the advent of new shopping malls coming up every other day & looking into the demand, one can infer that this industry can definitely survive in the years to come.

State-of-the-Art Knitting & Garment project

KSTCL

Market size estimates USD bn 55 Exports Domestic

100

22 33 2009

40 60

2015

Drivers of exports - Outsourcing by retail giants - Transition from Converters to vendor partners of global buyers. - Capacity building to lower per unit cost and become more competitive Drivers of domestic market - Growing young population - Rising household income levels - Growth of organized retail

Trends in Domestic Market

Domestic apparel market growing at 10% per annum Home textiles demand growing at 12-15% per annum Urban consumers increasingly seeking branded and lifestyle products Modern retailing environment (organized retailing) a driver for increased consumption. Semi-urban and rural Indian markets are growing faster than expected. Helpful demographic profile and increase in working female population.

State-of-the-Art Knitting & Garment project

KSTCL

MANUFACTURING PROCESS:
1. Raw material : Grey yarn 100% cotton,Blends, Melanges, etc to outsource. Grey fabric, various structures: viz, Single Jersey,Pique, Rib, Interlock,Waffle, etc can be converted at the inhouse facility. To be outsourced (Includes: Heat setting,Washing, Scouring, Mercerising, Dyeing,Slit opening Brushing,Raising, Rotary printing,Transfer printing, finishing, etc). After processing finished fabric is received in roll form or flat folded which will be issued to Apparel Industry. Checking for fabric paramenters, color matching & visual quality. Cutting of fabric into different parts of a garment based on the styling with a computerised cutting machine. Bundling together all the parts of a garment into a bundle of 30 to 40 garments to avoid mix-up of different rolls & lots in a color. If the motif of the print / embroidery is large, the same is done in panel form. Stitching together all the fabric cut panels to form a garment in the required styling with the respective accessories / trims. Small motifs are printed / embroidered on to the garment.

2. Circular Knitting :

3. Processing

4. Finished Fabric

5. Fabric Inspection : 6. Cutting :

7. Bundling

8. Placement print / Embroidery :

9. Sewing 10. Printing / Embroidery

11. Snap/Button hole/ Buttoning : 12. Trimming/ Checking

Attaching the snaps / buttons onto the garment.

Cutting of extra & unwanted threads) / Checking of garments for any defects. Steam pressing of Garment for better finish & appearance. Final inspection of garments for measurements, visual appreance, etc. Folding the garment as per customers requirements. Passing the garments thru a metal detector for any metal parts viz, broken needles, etc). Pack the garment with required materials into cartons, seal the cartons & store it in a secured ware house.

13. Ironing 14. Inspection

: :

15. Folding 16. Metal detector

: :

17. Packing

State-of-the-Art Knitting & Garment project

KSTCL

PROJECT PARAMETERS:
Capacity : Knitting Garment industry Production of 4.30 Tons grey fabric per day (Circular knitting) Production of approximately 10,000 garments a day (5000 pieces of Round neck & 5,000 pieces of Polo T-Shirt)

Land: Knitting unit : Garment unit : Totally : Raw material & utilities: Yarn : Approximately 1 acre of land Approximately 1 acre of land 2 acres of land

Requirement would be approximately 4.5 tons per day (based on garment unit requirement), this is to be oursourced. The knitting of fabric will be done in the proposed knitting unit. Finished Fabric : Approximate requirement is 4 Tons per day, the knitted greige fabric need to be sent to the respective processing units for processing & to be got back as finished fabric for the consumption of garment unit. Water for Humidification - 24 kl per day

PLANT & MACHINERY: The plant & machinery proposed for the Knitting & Garment industry are as follows: a) Knitting unit machinery: 1) Single Jersey 2) Single Jersey with 6 color Autostriper 3) Interlock machine 4) Rib Machine 5) Collar / Cuff machine 6) Winding machine 7) Compressors 8) Humidification plant 10 nos 2 nos 2 nos 2 nos 8 nos 1 no. 3 nos 1 no.

State-of-the-Art Knitting & Garment project

KSTCL

Vendors: a. Mayer and Cie, Germany. b. Pai lung Machinery Mill Co., Ltd., Taiwan c. Orizio s.r.l., Italy d. Khaoheng, China

b) Garment unit machinery:

1. Cutting department 2. Sewing machines 3. Finishing department machines 4. Embroidery machines 5. Compressors 6. Placement Printing machines 7. Humidification plant

9 nos 286 nos 31 nos 2 nos 3 nos 4 nos 1 no.

Vendors: Sewing machines: a. M/s. Juki Pvt Ltd. Japan. b. Brother International , USA c. Pegasus Sewing Machine Pte Ltd., Japan Embroidery Machines: a. Barudan Asia Pte. Ltd. Japan. b. Tajima Embroidery machines, Japan. c. Brother Embroidery machines, USA

State-of-the-Art Knitting & Garment project

KSTCL

MANPOWER: Knitting unit: Approximately 52 persons / day of 3 shifts Designation Administration Operators / Technicians Others Total No. of persons 8 37 7 52

Garment Industry: Approximately 587persons Designation Administration staff Managerial / Technical staff Operators / Technicians / Out house / Helpers Others Total No. of persons 19 28 536 8 591

COST OF THE PROJECT:

Knitting 15.30 SALES TURNOVER (PER YEAR):

INR (In Crore) Garments 33.50

Total 49.00

The sales turn over of INR 65.16 Cr. per year

NET PROFIT:

State-of-the-Art Knitting & Garment project

KSTCL

INR 3.26 crore per annum (averaged out for five years)

CONCLUSION:

The state has to depend on other states for all its ready made garments requirement. In spite of having world class shopping malls in the state, all the garment requirement is met by outsourcing. By setting up this fully advanced project we can attract the major players in the retailing business. The location being in the same state, reduces their transit cost, is easily accessable which gives them a confidence to place orders & saves their transit time.

So, this project, if implemented would be economically and financially viable and feasible.

Conatact Kerala State Textile Corporation Limited for further details

Disclaimer: The findings contained in this project profile are based on the initial information collated through primary and secondary study, which is only indicative and may not reflect the realities of an actual project. Reference herein to any specific commercial product, process, service by trade mark, trademark, manufacturer, or otherwise, does not constitute or imply its endorsement, recommendation, or favouring by KSTCL or any entities thereof.