Detailed Project Report on denim fabric manufacturing

DENIM FABRIC MANUFACTURING [3542]

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. With Denim coming enormously in vigil with fashion conscious seat of society. This area possesses a high Potential and has a great demand, which needs to be exploited. The use of Denim Cloth for multifarious purposes makes it most versatile demandable item. The  use of Denim cloth also attributes to its long  lasting quantity of the fabric i.e. the span of the usages of Denim items is  elongated  making  it  move popular  in the modern fashion conscious society where apparel also attributes a new  dimensions to human personality.

COST ESTIMATION

Plant Capacity                                                      25000 Mtr/Day  
Land & Building (12000 sq.mt)                        Rs. 11.38 Cr
Plant & Machinery                                               Rs. 22 Cr
Working Capital for 2 Months                          Rs. 11.83 Cr
Total Capital Investment                                  Rs. 46.22 Cr
Rate of Return                                                  20%
Break Even Point                                             61%


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    
COMMON YARN SIZES FOR DENIM    
YARN SPINNING SYSTEMS    
SPECIALTY YARNS    
STRUCTURED DENIM YARNS    
ELASTIC DENIM YARNS    
OVERVIEW OF THE DENIM MARKET (INDIAN & GLOBAL)    
INDIA’S DENIM MARKET    
INDIA’S DENIM STORY    
DEMAND DRIVERS AND POPULARITY    
GROWTH PROSPECTS AND TRIGGERS    
DENIM EXPORTS    
MARKET SURVEY    
FEW POSITIVE FACTORS ENCOURAGING THE DENIM MARKETS IN INDIA    
MARKET SIZE AND GROWTH    
COMPARISON WITH DENIM CONSUMPTION OF SOME OTHER COUNTRIES    
CITY-WISE DISTRIBUTION OF DENIM MARKET    
PRESENCE OF BRANDS    
DRIVING FACTORS FOR DENIM MARKET    
SOME OF THE KEY DRIVING FACTORS FOR THE DENIM MARKET IN INDIA ARE    
DENIM VALUE CHAIN IN INDIA    
SELECT TRENDS IN DENIM MARKET    
SOME OF THE KEY TRENDS IN DENIM MARKET ARE    
ISSUES & CHALLENGES FOR DENIM MARKET    
CONCLUSION    
MARKET POSITION OF DENIM WEAR OF GST STRUCTURE    
DENIM MARKET SIZE AND GROWTH    
INCREASING DENIM AFFINITY    
PRICE SEGMENTATION    
KEY TRENDS AND GROWTH DRIVERS    
CONCLUSION    
B.I.S. SPECIFICATION    
TYPES OF STONE WASH & THEIR EFFECTS ON THE DENIM FABRIC    
PUMICE STONE USAGE IN STONE WASH    
DISADVANTAGES OF PUMICE STONE USAGE    
ALTERNATE METHODS FOR STONEWASHING    
CELLULOSE METHOD    
DISADVANTAGES OF CELLULOSE TREATMENT    
LATEST PROCESS OF STONE WASH – PERLITE    
MODERN STONE-WASHED JEANS, BIOSTONEING TECHNIQUE    
RINSE (WATER) WASH    
STONE WASH    
OVERYDYE    
DIRTY WASH    
DESTROYED/DAMAGED/USED/WHISKERS
LASER MARKING/SPRAY PAINTING, ETC    
OBJECTS OF INVENTION    
FOAMING AGENTS    
FOAM STABILISERS    
THE INVENTION IS FURTHER DESCRIBED IN THE FOLLOWING EXAMPLES    
DENIM GARMENT PROCESSING THE ECO-FRIENDLY WAY    
ADVANTAGES OF GARMENT PROCESSING    
DESIZING    
ADVANTAGES OF ENZYMATIC DESIZING OVER TRADITIONAL DESIZING    
STONE WASH EFFECT    
ENZYME WASH    
CELLULOSE ENZYME IS CLASSIFIED INTO TWO CLASSES    
ADVANTAGE OF ENZYME WASHING    
DENIM BLEACHING    
LIMITATIONS    
3-E BLEACHING CONCEPT FOR DENIM    
ADVANTAGES    
LIMITATIONS    
ENZYMATIC ANTI-BACK STAINING AGENT-PROTEASE    
SELECTION OF DENIM FABRIC    
ADVANTAGES OF SAND BLASTING PROCESS    
MECHANICAL ABRASION    
ADVANTAGES OF THESE PROCESSES    
OZONE FADING    
WATERJET FADING    
SINGLE-BATH STONE-WASHING AND TINTING TECHNIQUE    
ALTERNATE TO PUMICE STONE    
THE ADVANTAGE OF USING SUCH TYPE OF PRODUCTS ARE    
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    77
TYPES OF CREELS    
TRAVELING PACKAGE CREELS    
MAGAZINE CREELS    
BALL WARPING    
BEAM WARPING    
DYEING AND SLASHING WARP YARNS FOR DENIM    
ROPE DYEING    
SLASHER DYEING    
BEAM DYEING    
UNDYED DENIM    
RE-BEAMING    
SLASHING (SIZING)    
DRAWING-IN AND TYING-IN OF WARP YARNS    
WEAVING DENIM FABRICS    
STRUCTURE OF DENIM FABRICS    
YARN FLOW IN WEAVING    
BASIC WEAVING MOTIONS    
SHEDDING    
FILLING INSERTION    
BEAT UP    
WARP LEFT OFF    
FABRIC TAKE UP    
TYPICAL DENIM CONSTRUCTIONS, WEAVES, AND WEIGHTS    
YARN TWIST DIRECTION AND TWILL LINE DIRECTION    
DETAILS OF DYEING    
KIERING (SCOURING)    
DETAILS OF SCOURING PROCESS    
BLEACHING    
BLEACHING WITH HYDROGEN PEROXIDE    
DETAILS OF BLEACHING PROCESS    
BLEACHING    
HYPOCHLORITES    
HYDROGEN PEROXIDE    
DYEING    
DYEING MACHINES    
DYEING OF DENIM CLOTH    
DYEING OR JIGGERS    
DETAILS OF DYEING PROCESS    
DYIENG    
DYEING MACHINES    
MORDANT DYESTUFFS    
DIRECT DYESTUFFS    
VAT DYESTUFFS    
DRYING    
DETAILS OF DRYING PROCESS    
MECHANICAL REMOVAL    
DRYING     
PRINTING OF COTTON FABRIC    
FINISHING    
FINISHING    
PROCESS FLOW DIAGRAM FOR DENIM FABRIC MANUFACTURE    
STEPS & DENIM WASHING    
PRE TREATMENT    
ENZYME & STORE WASHING    
CLEAN UP    
BLEACHING    
TINTING/DYEING    
SOFTENING PROCESS    
FLOW CHART OF DENIM PRODUCTION    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERIES    
DYEING MACHINE    
SCOURING MACHINE    
EFFLUENT TREATMENT PLANT    
BOILERS    
LABORATORY TESTING EQUIPMENT    
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       

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)