Detailed Project Report on denim garments (denim cloth will be purchased from market and converted to garments with 50 machines)

DENIM GARMENTS
(DENIM CLOTH WILL BE PURCHASED FROM MARKET AND CONVERTED TO GARMENTS WITH 50 MACHINES)
[CODE NO.3245]  


The word `DENIM' is almost synonymously used for high fashion garments. `DENIM' has become so popular throughout the world today that the moment this magic word is heard, it conjures up in one's mind visions of a blue garment with unique and elegant appearance. This classic fabric has been in use aross the world for a long time. However, the appearance of this fabric is continuously being modified to appeal to the varied fashion trends of different generations. In many respects fashion trends have dictated how the fabrics and garments should look and accoordingly the processing techniques have been changed. Today, the consumer literally has numerous choices of unwashed and pre-washed garments suit individual tastes.

What is Denim?

Denim fabric can be defined as a warp faced twill fabric made from yarn dyed warp and undyed weft yarn. The count of the yarn used varies between 6 and 12. In general, indigo-vat dye is used for colouring the warp yarn. More than 5000 years before the development of synthetic dyes, before the development of synthetic dyes, natural indigo dye was being used. Evidence for this ha sbeen obtained by the presence of indigo dyed garments and blankets form ancient tombs and graves. The indigo plant is cultivated in India, China, Japan and South America. Indigo is structurally a vat class of dye, which in its pigment state is insoluble in water, alkali or acid. Like other vat dyes, this dye must be vatted to apply it to cellulosic fibre. This reduced dye has moderate affinity for cellulose. The basic steps involved in the application of indigo dye to cellulosic fibres are:


1.    Conversion of the insoluble dye molecules into the soluble leuco form by alkaline reducing conditions.

2.    Absorption of the leuco compound by the fibre.

3.    Conversion of solubilised dye back to the insoluble form by oxidation.

4.    After treatment of the dyed material by washing to remove unfixed loose dye particles.


Indigo dye is generally applied to cotton, either in fibre form or yarn form. The actual indigo shade on the yarn is developed by controlled impregnation and oxidation steps. In a continuous indigo dyeing operation, multiple dips and air oxidation of the substrate and sufficient washing to remove loosely held particles, if followed. The indigo dye molecule is very large and it does not penetrate deeply into the fibre, resulting in ring dyeing. It is this white cetre and dyed oouter ring that results in the characteristic abrasion patterns on garments made form indigo dyed fabric.

    
COST ESTIMATION

Plant  Capacity                                                             :    350.00 Pieces/day  
land & Building (4000 sq.Yard                                  :    Rs. 2.70 Cr
Plant & Machinery                                                        :    Rs. 53.05 Lacs
Working Capital for 2 Months                                    :    Rs  92.70 Lacs
Total Capital Investment                                             :    Rs. 4.25  Cr
Rate of Return                                                               :    34%
Break Even Point                                                          :    54%


INTRODUCTION    
WHAT IS DENIM?    
B.I.S. SPECIFICATION    
FOR BLEACHING AND DYEING:    
FOR PACKING MATERIALS:    
PROPERTIES OF DENIM FABRIC    
TYPES OF DENIM FABRIC    
ALL THE ABOVE
THE MENSWEAR MARKET    
MARKET SIZE AND GROWTH PROJECTIONS    
HIGH GROWTH CATEGORIES    
MARKET TRENDS    
THE WOMENS WEAR MARKET    
MARKET SIZE AND GROWTH PROJECTIONS    
HIGH GROWTH CATEGORIES    
MARKET TRENDS    
THE INNERWEAR CATEGORY    
THE MEN’S INNERWEAR MARKET    
THE WOMEN’S INNERWEAR MARKET    
PRICE-BASED MARKET SEGMENTATION    
LOOKING TO THE FUTURE    
DENIM MARKET IN INDIA    
SOME OF THE KEY DRIVING FACTORS FOR THE DENIM MARKET
  IN INDIA ARE:    
SOME OF THE KEY TRENDS IN DENIM MARKET ARE:    
IMPACT OF MAKE IN INDIA    
ON THE DENIM MANUFACTURING INDUSTRY    
MAKE IN INDIA FOR THE TEXTILE SECTOR    
INDIA’S DENIM POTENTIAL
MANUFACTURING PROCESS OF DENIM GARMENTS    
PROCESS FLOW DIAGRAM    
DETAILS OF DENIM GARMENTS MANUFACTURE    
DENIM GARMENT DESIGN PROCESS    
DENIM CLOTHING MANUFACTURE    
TAGGING AND DISTRIBUTION    
PROCESS OF DENIM FABRIC GARMENT WASHING    
YARN FOR DENIM:    
DYEING AND SIZING PROCESS OF DENIM YARN:    
WEAVING PROCESS OF DENIM FABRIC:    
FINISHING PROCESS OF DENIM FABRICS:    
DENIM FABRIC DYEING:    
DENIM WASHING PROCESS:    
POPULAR WASHING OF DENIM FABRIC:    
GARMENT WASHING:    
STONE WASH:    
ACID WASH:    
ENZYME WASH:    
BLEACHING WASH:    
FINISHING PROCESS OF DENIM GARMENTS:    
DENIM WASHING AND FINISHING PROCEDURE    
DENIM FINISHING AND PROCEDURES:    
STONE WASHING:    
ENZYME WASHING    
BLEACH WASHING    
ICE OR SNOW WASHING    
SAND BLASTING    
DETAILS OF DYEING & BLEACHING    
PREPARATION OF STOCK VAT:-    
IN THE DYEING OPERATING THERE ARE THREE CLASSES OF DYE STUFFS    
CONDITIONS REQUIRED IN DYEING:-    
DYEING BY JIGGER METHOD    
BLEACHING:    
BLEACHING PROCESS    
BLEACHING OR CHEMICKING:    
PREPARATION OF THE BLEACHING SOLUTION:    
METHOD OF BLEACHING:    
BLEACHING:    
WASHING:    
RINSING OR WASHING:    
WASHING MACHINES:    
DETAILS OF DRYING PROCESS    
MECHANICAL REMOVAL:    
DRYING:    
FORMULATIONS OF INDIGO STOCK VAT    
INTERNATIONAL STANDARDS FOR DENIM EXPORTS    
FORMULATION FOR STOCK VAT:-    
PROCESS:-    
OUTLINE OF THE PROCESS (JIGGER PROCESS)    
JIGGER MACHINE:    
FINISHING:-    
FINISHING PROCESS    
THE CREASE RESISTING FINISH     
STITCHING OF GARMENTS    
IN CONCLUSION, A FEW SPECIAL TIPS ON STITCHING JEANS:    
PROCESS FLOW SHEET FOR MANUFACTURE OF JEANS OPERATIONAL
  FLOW IN JEANS MANUFACTURING: CHAIN SYSTEM    
OPERATIONAL FLOW IN JACKETS MANUFACTURING: SINGLE TAILOR
  SYSTEM    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    
HYDRO EXTRACTOR    
BOILERS    

            
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET