Denim Fabric Manufacturing (25000 Meters per day)

DENIM FABRIC MANUFACTURING

[EIRI/EDPR/4467]

Denim is a firm durable twill cotton fabric which woven with colored warp and white filling threads. Technically speaking, denim is a warp faced twill weave fabric. Here coarse and lower yarn count is used. So it is heavy fabric. 

 Denim is one of the oldest types of work cloths that is available in the fashion world. It is used for its durability and comfort. Denim comes from the French phrase “Serge de Nimes”. The 17th century “Serge de Nimes” was introduced in French. Those fabrics were produced by using a mixture of cotton and wool. Some historians believe that it was first worn by sailors of Portugal. Initially it was worn by mechanics and miners. In the 21st century denim comes in many different styles including carpenters, sportswear, khakis, chinos and combat. Now it is true that the millions of people around the world favorite choice is denim cloth. 

Cloth food and shelter are the basic needs of every human being. In the early years of human existence human beings covered themselves  with  leaves and other such raw Products so as to protect themselves against the natural  conditions  with  the passage  of  time man began in search for an  alternative  and  a much better way to protect himself and thus developed hand  woven cloth  slowly and gradually the technique of cloth making  gained momentum as a result of which a fine variety of clothes come into existence. Today with the rapid industrialization. There have been new innovations in the technique of clothe manufacturing. In India cotton has been the most popular and most widely used cloth amongst the other varieties of cloth. But with fashion at its peak.  Denim cloth came into existence which consists of a fairly large percentage of cotton. Denim cloth was more popular in the western countries since the early 60's while India  was manufacturing  Khadi  cloth. But today as all set with fashion catching up,  Denim Jeans, Jackets etc. have become a  dream  of every  youth Denim cloth is thick and keeps the body warms.  Most of the Denim cloth is utilized in the manufacture of Jeans and Jackets. There are a variety of shades Blues, Blacks etc.

COST ESTIMATION

Plant Capacity            25,000 Mtrs./Day  

Land & Building (6000 sq.mt.)    Rs. 3.80 Cr    

Plant & Machinery                    Rs. 29.10 Cr 

Working Capital for 2 Months    Rs. 12.93 Cr 

Total Capital Investment          Rs. 46.46 Cr 

Rate of Return                          29%

Break Even Point                      53%

CONTENTS

INTRODUCTION

TYPES OF DENIM FABRIC

1. DRY DENIM:

2. SELVEDGE DENIM:

3. STRETCH DENIM:

4. COLOR DENIM:

5. REVERSE DENIM:

6. VINTAGE DENIM:

USES AND APPLICATION

PROPERTIES

DETAILS OF DENIM YARN

FIGURE: PROCESS FLOW FOR WARP YARN IN DENIM MANUFACTURING

COMMON YARN SIZES FOR DENIM

YARN SPINNING SYSTEMS

SPECIALTY YARNS

STRUCTURED DENIM YARNS

ELASTIC DENIM YARNS

MARKET OVERVIEW OF DENIM FABRIC

DENIM MARKET IN INDIA

KIDS’ DENIM SEGMENT:

COMPARISON WITH DENIM CONSUMPTION OF SOME OTHER COUNTRIES

CITY-WISE DISTRIBUTION OF DENIM MARKET

PRESENCE OF BRANDS

DRIVING FACTORS FOR DENIM MARKET

DENIM VALUE CHAIN IN INDIA

SELECT TRENDS IN DENIM MARKET

ISSUES AND CHALLENGES FOR DENIM MARKET

FUTURE PROSPECTS OF DENIM INDUSTRY IN INDIA

EMERGING PLAYERS

LEADING DENIM MILLS AND THEIR CAPACITY

DENIM WEAR MARKET IN INDIA

GROWTH DRIVERS AND TRENDS IN DENIM WEAR IN INDIA

YOUTH AS A GROWTH DRIVER:

INFLUENCE OF INTERNATIONAL BRANDS:

INCREASED RURAL SPENDING:

CASUALIZATION OF FASHION:

ALTERNATIVE RETAIL CHANNEL:

RISE OF PRIVATE LABEL:

SUPER PREMIUM JEANS HAS EMERGED AS THE BEST PERFORMING

CATEGORY:

CROPPED OR FOLDED HEMS CONTINUE TO BE FASHIONABLE AMONG

WOMEN:

B.I.S. SPECIFICATION

TECHNOLOGY OF DENIM PRODUCTION

MANUFACTURE OF DENIM

SPINNING

OPEN END SPINNING

RING SPINNING

FABRIC WEAVING

A. GREY YARN ON CONES

B. WARPING ON SECTIONAL/ DIRECT WARPING

C. SIZING OF YARN IN SET/ BEAM TO BEAM POSITION

D. DRAWING–IN

E. BEAM GAITING OR KNOTTING ON LOOM

F. WEAVING

AIRJET LOOMS

FINISHING

A. GREY FABRIC

B. DENIM FABRIC

C. SHEET DYEING PROCESS

D. MAKING-UP

DISPATCH

WARP PREPARATION - DYEING AND SIZING PROCESSES

CONTINUOUS INDIGO-ROPE DYEING AND SIZING

CONTINUOUS INDIGO DYEING AND SIZING:

INDIGO-BACK BEAM DYEING AND SIZING

WEAVING

FINISHING

SEQUENCES IN DENIM FABRIC MANUFACTURE

YARN FOR DENIM:

DYEING AND SIZING PROCESS OF DENIM YARN:

1. CONTINUOUS INDIGO ROPE DYEING AND SIZING:

2. CONTINUOUS INDIGO DYEING AND SIZING:

3. INDIGO BACK BEAM DYEING AND SIZING:

WEAVING PROCESS OF DENIM FABRIC:

FINISHING PROCESS OF DENIM FABRICS:

DENIM FABRIC DYEING:

DENIM WASHING PROCESS:

1. MECHANICAL WASH:

2. CHEMICAL WASH:

POPULAR WASHING OF DENIM FABRIC:

GARMENT WASHING:

STONE WASH:

ACID WASH:

ENZYME WASH:

BLEACHING WASH:

FINISHING PROCESS OF DENIM GARMENTS:

PROCESS IN DETAILS FOR DENIM FABRIC MANUFACTURE

WARPING

FIGURE: BEAM WARPING       

FIGURE: BALL WARPING (ROPE)

TYPES OF CREELS

TRAVELING PACKAGE CREELS

MAGAZINE CREELS

FIGURE MAGAZINE CREELS

BALL WARPING

BEAM WARPING

FIGURE BEAM WARPING

DYEING AND SLASHING WARP YARNS FOR DENIM

ROPE DYEING

SLASHER DYEING

FIGURE: SLASHER INDIGO DYE RANGE

BEAM DYEING

FIGURE: DYE BEAMS

UNDYED DENIM

RE-BEAMING

FIGURE: ROPE DYED YARN BEING RE-BEAMED

SLASHING (SIZING)

FIGURE: SLASHER CREEL

FIGURE: SIZE BOX

FIGURE: SLASHER (LOOM BEAM AT HEAD-END)

DRAWING-IN AND TYING-IN OF WARP YARNS

FIGURE: WARP DRAWING-IN

WEAVING DENIM FABRICS

STRUCTURE OF DENIM FABRICS

FIGURE: WOVEN FABRIC STRUCTURE

YARN FLOW IN WEAVING

FIGURE:. WEAVING MACHINE ELEMENTS

BASIC WEAVING MOTIONS

SHEDDING

FILLING INSERTION

BEAT UP

WARP LEFT OFF

FABRIC TAKE UP

FIGURE: BASIC WEAVING MOTIONS

TYPICAL DENIM CONSTRUCTIONS, WEAVES, AND WEIGHTS

FIGURE DIAGRAM OF 3/1 RIGHT AND LEFT HAND T WILLS

FIGURE: Z AND S TWIST DIRECTIONS

SEQUENCES IN DENIM FABRIC MANUFACTURE

DETAILS OF DYEING

KIERING (SCOURING)

DETAILS OF SCOURING PROCESS:-

BLEACHING:-

BLEACHING WITH HYDROGEN PEROXIDE:-

FOLLOWING IS TYPICAL FORMULATION OF BLEACH LIQUOR

RECOMMENDED FOR COTTON BLEACHING

DETAILS OF BLEACHING PROCESS

BLEACHING:-

HYPOCHLORITES:-

HYDROGEN PEROXIDE:-

DYEING:-

DYEING MACHINES:-

DYEING OF DENIM CLOTH:-

DYEING OR JIGGERS:-

DETAILS OF DYEING PROCESS:-

DYIENG:-

DRYING:-

DETAILS OF DRYING PROCESS:-

MECHANICAL REMOVAL:-

DRYING:-

PROCESS FLOW DIAGRAM FOR DENIM FABRIC

STEPS & DENIM WASHING

PRE TREATMENT

ENZYME & STONE WASHING

CLEAN UP

BLEACHING

TINTING/DYEING

SOFTENING PROCESS

LIST OF LABORATORY EQUIPMENTS FOR DEMIN CLOTH MANUFACTURING

SUPPLIERS OF PLANT AND MACHINERIES

SUPPLIERS OF DYEING MACHINE

SUPPLIERS OF SCOURING MACHINE

SUPPLIERS OF EFFLUENT TREATMENT PLANT

SUPPLIERS OF BOILERS

SUPPLIERS OF LABORATORY TESTING EQUIPMENTS

SUPPLIERS OF ETP PLANTS

SUPPLIERS OF RAW MATERIALS

STRENGTHS AND WEAKNESSES OF DENIM FABRIC

MANUFACTURERS/SUPPLIERS/EXPORTERS OF DENIM FABRICS

LIST OF TOP DENIM FABRIC MANUFACTURING COMPANY IN THE WORLD

DENIM MILLS IN BANGLADESH:

DENIM MILLS IN CHINA:

DENIM MILLS IN INDIA:

DENIM MILLS IN PAKISTAN:

DENIM MILLS IN HONGKONG:

DENIM MILLS IN JAPAN:

DENIM MILLS IN ITALY:

DENIM MILLS IN TURKEY:

DENIM MILLS IN USA:

DENIM MILLS IN INDONESIA:

DENIM MILLS IN SOUTH AMERICA (BRAZIL, ARGENTINA):

DENIM MILLS IN SPAIN:

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)