Detailed Project Report on denim fabric manufacturing (cap: 5000 meter per day)
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DENIM FABRIC MANUFACTURING (CAP: 5000 METER PER DAY) [CODE NO.3674]
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.
COST ESTIMATION
Plant Capacity 5000 MTR/Day
Land & Building (3000 sq.mt.) Rs. 2.93 Cr
Plant & Machinery Rs. 8.59 Cr
Working Capital for 1 Month Rs. 1.30 Cr
Total Capital Investment Rs. 13.08 Cr
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
DENIM MARKET 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
DENIM VALUE CHAIN IN INDIA
SELECT TRENDS IN DENIM MARKET
ISSUES & CHALLENGES FOR DENIM MARKET
CONCLUSION
INDIAN DENIM TEXTILE INDUSTRY
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
DENIM VALUE CHAIN IN INDIA
SELECT TRENDS IN DENIM MARKET
ISSUES & CHALLENGES FOR DENIM MARKET
CONCLUSION
MARKET POSITION OF DENIM WEAR AND GST STRUCTURE
DENIM MARKET SIZE AND GROWTH
INCREASING DENIM AFFINITY
PRICE SEGMENTATION
KEY TRENDS AND GROWTH DRIVERS
CONCLUSION
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
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
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
FLOW CHART OF DENIM PRODUCTION
LIST OF LABORATORY EQUIPMENTS FOR DEMIN CLOTH MANUFACTURING
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)
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