Bleaching and Dyeing of Cotton Knitted Fabric Project report Introduction Bleaching of textile grey fabrics is generally carried

out to impart whiteness to textile fabrics by removing natural colouring matter. The process of dyeing is carried out to improve the marketability of textile products and also to suit the customer needs by adding colour. These two processes are generally carried out in open tank, kier machines, jet dyeing machines, jiggers, soft flow dyeing machines etc. For hosiery goods, it is carried out with winch machines, since it imparts very less tension during operation. Viable processing units can be set up as most of the fabric manufacturing units do not have their own processing units. In this report, details are provided for setting up the unit for bleaching and dyeing of cotton knitted fabrics. Market Potential The demand for hosiery garments is increasing due to its popularity in domestic and export market. There are number of units engaged in manufacturing of knitted cloth and most of these units are not having their own captive processing units. Bleaching and dyeing of knitted fabric produced by these units are normally carried out from outside on paying requisite processing charges. It is, therefore, presumed that setting up of textile processing units is economically very much viable. Basis and Presumptions This project is based on single shift basis with 300 working days in a year. Time period for achieving maximum capacity utilisation is considered from 3rd year from the date on which production is started. Rental value of the building is taken at Rs. 2 per sq. ft. Costs of machinery and equipments/materials indicated refer to a particular make and approximately to those prevailing at the time of preparation of this project. Cost of installation and electrification is taken @ 10% of cost of machinery and equipment. Nonrefundable deposits, project report cost, trial production, security deposit with Electricity Board are classified under pre-operative expenses. Depreciation has been considered at 10% on plant and machinery, 15% on office furniture, fixtures, vehicle and 20% on testing equipments. Interest rate on capital loan has been taken @ 12% per annum. Implementation Schedule The implementation period required for executing this project right from selection of site to starting the trial run production will be 6 months. Technical Aspects Process of Manufacture The knitted fabric to be bleached is thoroughly wet in a soap solution of 2% and piled in kier boiling pan containing 1.5% caustic soda, 2% soda ash and 1% lisapol etc. and allowed to boil for 6-8 hours.

The cloth is washed well and taken to SS winches for bleaching using 2% bleaching powder and then washed thoroughly. This bleached cloth is scoured using hydrochloric acid of 1.5% concentration. After sometime, cloth is washed thoroughly to neutralise the traces of acid. In case of only bleaching the cloth is treated with optical whitening agent, thereafter, it is hydro-extracted, dried and calendered as final operations. In case of dyeing, about 15-20% salts, 2% brightol C paste, 2-4% dyes as per shade are mixed and fabric is treated with the solution in winches. The cloth is allowed to run for several times in order to maintain uniform shade, thereafter, washed, hydro-extracted, dried and calendered. Production Capacity (per annum) Quantity (Kg.) 1. Bleaching Charges 2. Dyeing Charges Total Motive Power 50 HP is required to run the unit and proposed to be obtained from State Electricity Board. Pollution Control As this process involves treatment of chemicals, entrepreneurs are required to obtain NOC from State Pollution Control Board. Energy Conservation Energy can be conserved by proper house-keeping i.e. unnecessary running of boilers, heaters and fans are to be monitored in order to reduce the excess energy consumption. Technical Aspects A. Fixed Capital (i) Land and Building (i) Land 4000 Mtrs. @ Rs. 3000 per Sq. Mtr Boundary wall and gates Factory shed 400 Sq. Mtr, @ Rs. 6000 / Sq. Mtr Raw Material & finished goods storage 500 Sq. Mtr@ Rs. 6000 / Sq. mtr. Rs.1,20,00,000 Rs. 5,00,000 Rs. 24,00,000 4,50,000 4,50,000 9,00,000 Value (Rs.) 1,15,86,000 1,48,05,000 2,63,91,000

Rs. 30,00,000

Office Building 300 Sq. Mtr @ 750 / Sq. Mtr Workers sitting hall 500 Sq.Mtr @ Rs.6000/Mtr

Rs. 22,50,000 Rs. 30,00,000 Rs.1,18.00,000

Utility plants area e.g., bore well, raw water storage, boiler, generator and effluent treatment plant 200 Sq. Rs. 12,00,000 Mtr @ Rs. 6000/Sq. Mtr Total (ii) Machinery and Equipments Sl. Description No. 1. 2. 3. SS Winch m/c of 6-4 86 200kg. SS Winch m/c 6-4' 66 size 150kg. MS Kier wall thick 1/4' bottom 8' Steam callendering m/c roller sizes 51/21 Hydro-extractor 40-45 kg capacity No. Rate (Rs.) Amount (Rs.) Rs 2,43,00,000

1 3 2

4,00,000 2,00,000 1,50,000

4,00,000 6,00,000 3,00,000

4.

3,00,000

3,00,000

5.

2,50,000

5,00,000

6.

4 cylinder drier with motor and gear 1 box S.S. Conveyors with ball bearing Baby boiler with storage tank chimney, water softening plant Water softening plant (cap. 6kl/hr), with storage tank pumps and S.S. piping 4

7,00,000

7,00,000

7.

50,000

2,00,000

8.

8,00,000

8,00,000

9.

7,00,000

7,00,000

10. Effuent treatment plant 11. Steam pipeline and other

1 LS

5,00,000 3,00,000

500,000 300,000

accessories Deep tube well with submersible 12. pump with storage tank, pumping and distribution system 13. Mini transport vehicle (3 Wheelers) 14. Fire extinguisher 5 kg capacity 15. Testing equipments Computer colour matching equipment (optional)

5,00,00

5,00,000

1 2 LS

3,00,000 20,000

3,00,000 40,000 2,00,000

16.

25,00,000

25,00,000

Total

88,40,000

(iii) Other Fixed Assets (a) Erection and installation (b) Office furniture (c) Pre-operative expenses Total Total Fixed Capital (i) + (ii) + (iii) B. Working Capital (i) Staff and Labour Wages Sl. Designation No. 1. 2. 3. G. Manager Finance and Accountant Computer Operator Nos.

(Rs.) 8,84,000 5,00,000 3,00,000 16,84,000 3,48,24,000

Rate (Rs.) 30000

Amount (Rs.) 30,000 15,000

1 2 1

20,000 20,000

4. 5. 6.

Sales, marketing, administrative and Peon Watchman

6 2 4 3500 3500

50,000 7,000 14,000 1,26,000

Total (i) (ii) Production Staff Dyeing Master 01 no. and shift supervisors 03 nos. Skilled Workers Semi-skilled Workers Lab. Chemists and Attendant Boiler Attendant Electrician 12 15 6 4 3 4000 4000 5,000 3,000

7.

36,000

8. 9. 10. 11. 12. Total

60,000 45,000 30,000 16,000 12,000 1,99,000 3,25,000 72,000 3,97,000

Total (i) + (ii) Perquisites@ 22% G. Total (iii) Raw Material (per month) Sl. Description No. Rate/ unit (Rs.) 35 20 10

Unit

Qty.

Amount (Rs.)

1. 2. 3.

Caustic Soda Soda ash Sodium silicate

Kgs. Kgs. Kgs.

1500 5500 2500

53,000 1,10,000 25,000

4. 5. 6. 7. 8. 9.

Lisopal Bleaching Powder Hydrochloric acid Glabour's salt Common salt Optical whitening agent

Kgs. Kgs. Kgs. Kgs. Kgs. Lit. Lit. Lit. Lit. Kgs. Lumpsum

750 3,000 8,000 800 1000 225 1200 2500 750 750

150 20 8 10 3 140 20 10 75 150

1,13,000 60,000 64,000 8,000 3,000 32,000 24,000 25,000 56,000 1,13,000

10. Hydrogen peroxide 11. Sulphuric acid 12. Acetic acid 13. Dye fixing agent

14. Dyes of different shades

1,00,000

Total

7,86,000

(iv) Utilities Electricity bill 37.5 x 25 x 4 x 0.8 x 24 Water charges Fuel Coal/furnace oil Fuel for vehicle Total

(Rs.) 72,000 10,000 100,000 8,000 1,90,000

(v) Other Contingent Expenses

(Rs.)

(a) Rent (b) Postage/stationery (c) Repair and maintenance (d) Transport/travelling charges (e) Insurance (f) Telephone bills (g) Miscellaneous Total (vi) Total Recurring Expenses (per month) (vii) Total Working Capital for 3 months C. Total Capital Investment (i) Machinery and equipment (ii) Working capital for 3 months Total Machinery Utilisation Capacity utilisation is considered as 75% of installed capacity. Financial Analysis (1) Cost of Production (per year) Recurring expenses Depreciation on machinery @ 10% Depreciation on office furniture, computor and testing equipments @ 20% Depreciation on civil construction @ 5%

5,000 22,000 30,000 19,000 10,000 50,000 1,34,000 11,10,000 33,30,000

Rs. 3,48,24,000 Rs. 33,30,000 Rs. 4,81,54,000

(Rs.) 1,33,20,000 6,14,000

6,40,000

5,90,000

Interest on total investment @ 12% Total (2) Turnover (per year) Processing Charges Bleaching Charges Dyeing charges Total Qty. Kgs. 4,50,000 4,50,000 Rate/Kg. 25.75 32.90

57,78,000 2,03,02,000

Amount (Rs.) 1,15,86,000 1,48,05,000 2,63,91,000

(3) Net Profit (per year) (4) Net profit ratio (Net profit/Turnover (per year) (5) Rate of return on investment (Net profit/Total capital investment) (6) Break-even Point Fixed Cost Depreciation Rent Interest on capital investment 40% of wages of staff and labour 40% of other expenses Insurance Total (Rs.) 18,44,000 57,78,000 19,05,000 6,43,000 2,28,000

60,89,000 23.07%

12.64%

1,03,98,000

B.E.P.

= Fixed Cost 100

-------------------Fixed cost + Profit

1,03,98,000 100 ---------------------1,03,98,000 + 60,89,000

= 63.07%