Detailed Project Report on Coated Yarn

COATED YARN

[EIRI/EDPR/1624] J.C.427

INTRODUCTION

The textile industry is one of the largest industries in global commerce. With many hundreds of years of technological development, today’s industry provides an almost unlimited variety of products, many of which are carefully optimized fr specific applications. Even high-volume commodity products use a sophisticated understanding of the properties and behavior of fibres to provide the performance and functionality that is required.

One aspect of the technology routinely utilized is the use of liquid coatings to control and modify the behavior of Yarn. These liquid coatings are applied at a variety of stages in the manufacturing process.

The name used depends partly on application, and partly on geography. To encompass all these variants, the terms liquid coating will be used here.

Whatever name is preferred, these liquid coatings are carefully formulated products, often combining many components. Liquid coatings may be oil-or aqueous based, and may include many substances, such as oils, soaps, surfactants, waxes, anti statics, and others.

They may be true liquids, emulsions, or suspensions. They are designed to perform a number of functions, particularly control of inter fibre friction, static charge, inter fibre cohesion, heat generation and heat dissipation. They may also be used to control appearance, feel, and texture.

Application of the correct amount of liquid coating is critical for both performance and economic reasons. Too much coating can lead to insufficient inter fibre cohesion, buildup on downstream machinery, uncontrolled fibre behavior, problems with downstream processes such as dyeing, and , of course too much coating is an unnecessary increase in cost in a very cost sensitive industry.

Conversely, too little coating leads to problems from excessive friction, likely to cause yarn breakage, excessive static charge build up, causing erratic fibre behavior, and uncontrolled performance in downstream process.

For these reasons, constant attention to ensuring the application of the correct amount of liquid coating is essential to efficient and profitable fibre, yarn, and fabric process. This constant attention means that in a busy manufacturing facility, many tens or hundreds of samples should be measured each day.

COST ESTIMATION

Plant Capacity            2 MT/Day  

Land & Building (1000 sq.mt.)    Rs. 68.00 Lac    

Plant & Machinery                    Rs. 62.00 Lac 

Working Capital for 3 Months    Rs. 3.09 Cr 

Total Capital Investment          Rs. 4.54 Cr 

Rate of Return                          40%

Break Even Point                      38%

CONTENTS

INTRODUCTION

END USER MARKETS OF COATED YARN

MATERIALS SELECTION FOR COATING YARN

MARKET SURVEY

MARKET SIZE STATISTICS MARKET FORECAST - FIBER, YARN & THREAD MILLS]

TYPES OF FIBRE

MANUFACTURING PROCESS OF COATED YARN

PROCESS FLOW DIAGRAM

DETAIS AND PROCESS OF SUPER ABSORBENT COATED YARN WITH TESTING

METHOD OF COATING OF CORE YARN

MANUFACTURING PROCESS OF PVC AND PTFE COATED YARN

YARN COATING ASSEMBLY AND APPLICATOR

METALLIC YARN FOR TEXTILE APPLICATION

MEASUREMENT APPROACHES AND NMR METHOD

MEASUREMENT OF LIQUID COATING BY NMR

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

SUPPLIERS OF PLANT AND MACHINERIES

SUPPLIERS OF YARN COATING MACHINE (IMPORTED)

SUPPLIERS OF RAW MATERIALS

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)