Detailed Project Report on leather processing unit

LEATHER PROCESSING UNIT
[CODE NO.3923]  


Leather is a material created through the tanning of hides and skins of animals, primarily cattle hide. The tanning process converts the putrescible skin into a durable, long-lasting and versatile natural material for various uses.

Leather is an important material with many uses. Together with wood, leather formed the basis of much ancient technology. The leather industry and the fur industry are distinct industries that are differentiated by the importance of their raw materials. In the leather industry the raw materials are by-products of the meat industry, with the meat having higher value than the skin. The fur industry uses raw materials that are higher in value than the meat and hence the meat is classified as a by-product. Taxidermy also makes use of the skin of animals, but generally the head and part of the back are used. Hides and skins are also used in the manufacture of glue and gelatin.

Tanning is effected by treating the conditioned hides and skins with organic, inorganic or synthetic tanning agents, the most important among them being vegetable tanning materials and basic chromium sulphate. Basic salt of aluminium, Zirconium, and iron, formaldehyde, quinone, aliphatic sulphonyl chlorides, fish oils, and synthetic polymerized materials (Syntans) are used for the production of special leathers. Tanning is an ancient art practiced in India since long before the Christian era. Up to about 1857, the Indian leather industry remained a cottage industry confined mostly to the villages. The production of semi-finished leather for export was started in South India at about that time. In 1867, the Government established the Government Harness & Saddlery Factory at Kanpur to produce vegetable tanned leather by process followed in England. In 1881, another factory, cooper, Allen and Co. was set up at Kanpur to produce vegetable tanned leather required for military footwear. Experimented trials on the production. One of chrome tanned leather were started at Madras towards the beginning of the present Century and a course of instruction in chrome tanning was introduced in the Government School of Arts, Madras. Students trained in this institution started chrome tanneries in Chennai, Kolkata and Kanpur.



COST ESTIMATION


Plant Capacity                    200 SQ.MTR/DAY         
Land & Building (2000 sq.ft.)      Rs. 2.70 Cr                          
Plant & Machinery               Rs. 3.00 Cr                            
Working Capital for 2 Month     Rs. 77.96 Lac       
Total Capital Investment        Rs. 6.65 Cr
Rate of Return                    22%                   
Break Even Point             59%            


INTRODUCTION    
USES AND APPLICATION    
TANNED AND HALF-TANNED LEATHER ARE USED FOR:    
TYPES OF LEATHER    
LEATHER TYPES    
IN GENERAL, LEATHER IS SOLD IN THREE FORMS:    
OTHER LESS-COMMON LEATHERS INCLUDE:    
THE FOLLOWING ARE NOT 'TRUE' LEATHERS, BUT CONTAIN LEATHER
   MATERIAL.    
B.I.S. SPECIFICIFICATION    
RAW MATERIALS    
CLASSIFICATION OF HIDES AND SKINS    
IN THE CASE OF CATTLE HIDES:    
MARKET OVERVIEW OF LEATHER INDUSTRY IN INDIA    
STRENGTHS OF INDIAN LEATHER SECTOR    
EMERGING STRENGTHS    
HIGHLIGHTS OF PRODUCT SEGMENTS OF INDIAN LEATHER
    AND FOOTWEAR INDUSTRY    
INDIA’S EXPORT OF LEATHER & LEATHER PRODUCTS FOR 5 YEARS    
% SHARE OF LEATHER & LEATHER PRODUCTS FY 2018-19    
MAJOR MARKETS:    
% SHARE OF INDIA’S EXPORTS OF LEATHER & LEATHER PRODUCTS
     IN TOP 12 COUNTRIES IN US $ MN FY 2018-19    
INDIA’S EXPORT OF LEATHER & LEATHER PRODUCTS TO VARIOUS
     COUNTRIES FOR LAST 5 YEARS.    
FUTURE OUTLOOK:-    
SEQUENCES IN LEATHER PROCESSING    
CURING    
SOAKING    
PAINTING    
LIMING    
FLESHING    
DELIMING    
BATING    
PICKLING    
DEGREASING    
TANNING    
MINERAL TANNAGES    
ALDEHYDE AND OIL TANNAGES    
VEGETABLE TANNAGES    
SPLITTING    
SHAVING    
NEUTRALISATION    
DYEING    
FATLIQUORING    
SAMMING    
SETTING OUT    
FINAL DRYING    
STAKING AND DRY DRUMMING    
BUFFING AND BRUSHING    41
FINISHING    41
FINAL GRADING    
MEASUREMENT    
UNIT OPERATION IN LEATHER PROCESSING    
LEATHER PROCESS FLOW DIAGRAM    
PRE-TANNING OPERATIONS    
SOAKING    
LIMING    
DELIMING    
BATING    
PICKLING    
DEGREASING    
TANNING PROCESS    
CHROME TANNING    
VEGETABLE TANNING PROCESS    
POST-TANNING OPERATIONS    
RECHROMING OF WET BLUE LEATHERS    
NEUTRALISATION    
RETANNING    
DYEING    
FATLIQUORING    
FINISHING    
STEPS IN LEATHER TANNING AND DRY FINISHING PLANT    
LIMING-    
DELIMING:    
BATING:    
PICKLING:    
TANNING:    
NEUTRALIZATION    
RETAINING:    
DYEING:    
FAT LIQUORING:    
DRYING:    
FINISHING:    
LEATHER TANNING AND FINISHING PROCESS    
HIDE AND SKIN PRESTORAGE / STORAGE, AND BEAMHOUSE OPERATIONS    
SORTING AND TRIMMING    
CURING AND STORING    
SOAKING    
DEHAIRING AND LIMING OF BOVINE HIDES    
PAINTING AND LIMING OF SHEEPSKINS    
FLESHING    
TANYARD OPERATIONS    
DELIMING    
BATING    
DEGREASING    
PICKLING    
WET-WHITE PRETANNING    
TANNING    
DRAINING, SAMMING, AND SETTING    
SPLITTING    
SHAVING    
POST-TANNING OPERATIONS    
NEUTRALIZATION    
BLEACHING    
RETANNING    
DYEING    
FATLIQUORING    
DRYING    
FINISHING OPERATIONS    
MECHANICAL FINISHING PROCESSES    
SURFACE COAT APPLICATION    
DIFFERENT STAGES IN LEATHER TANNING    
PREPARATORY STAGES    
TANNING    
CRUSTING    
SURFACE COATING    
PROCESS FLOW DIAGRAM FOR LEATHER PROCESSING    
WASTE CHARACTERISTICS, POLLUTION PREVENTION AND CONTROL    
THE TANNING AND FINISHING PROCESS GENERALLY CONSISTS OF:    
WASTE CHARACTERISTICS    
POLLUTION PREVENTION AND CONTROL    
TARGET POLLUTION LOADS    
TABLE. TARGET LOADS PER UNIT OF PRODUCTION    
TREATMENT TECHNOLOGIES    
TABLE. EFFLUENTS FROM TANNING AND LEATHER FINISHING PROCESSES    
LEATHER PRODUCTION PROCESSES    
ROLE OF ENZYMES IN LEATHER PRODUCTION    
PRESERVATION AND CONDITIONING OF LEATHER    
MANUFACTURING PROCESS OF FINISHED LEATHER    
PROCESS IN DETAILS    
PHYSICAL CHECK UP OF THE STOCK    
2. SOAKING    
B) SOAKING OF COW-SKINS:    
B) SOAKING OF HEAVY HIDES:    
C) SOAKING OF DRIED SKIN:    
3. UNHAIRING    
A) UNHAIRING OF COW SKINS:    
B) UNHAIRING OF GOAT SKINS:    
C) HEAVY HIDES:    
4. BATING    
5. PICKLING    
6. THE TANNING PROCESS    
7. FINISHING:    
A) PRESSING:    
B) COLOURING:    
DYEING:-    
ACID & DIRECT DYES    
PRACTICAL PROCESSES    
(1) GLAZED KID SKINS    
(2) SEMI-CHROME GLAZED SKINS    
(3) CLOTHING SUEDES    
CHEMICALS & THEIR COMPOSITIONS USED IN DIFFERENT SECTIONS
   & OTHER OPERATIONS IN BRIEF    
1. SOAKING    
2. LIMING    
3. RELIMING    
4. DELIMING
5. PICKLING    
6. CHROME TANNING    
7. TREATMENT WITH LADDER  LINK :-    
8. RETANNING    
9. NEUTRILIZATION    
10. DYEING AND FATLIQUORING    
SEASON IS PREPARED WITH -    
NOW THESE ARE AGAIN SPRAYED WITH FOLLOWING SOLUTION    
TANNING AND OTHER OPERATION FOR FINISHED LEATHER    
THE TANNING PROCESS    
PREPARATION OF THE RAW PELT FOR TANNING    
SOAKING    105
UNHAIRING AND LIMING    
DELIMING AND BATING    
PICKLING    
PRETANNING, TANNING AND RETANNING    
TANNING    
MECHANICAL OPERATIONS    
NEUTRALISATION    
RETANNING    
DYEING, FATLIQUORING AND DRYING    
DYEING    
FATLIQUORING    
DRYING    
FINISHING    
DIFFERENT TREATMENT OF HIDES FOR FINISHED LEATHER    
POLLUTION EFFECTS    
TABLE - VOLUME & CHARACTERISTICS OF WASTES    
TABLE- CHARACTERISTIC OF COMPOSITE EFFLUENTS ALL VALUES IN
    MG/LITRE EXCEPT FOR PH    
EFFLUENT    
TREATMENT METHODS    
A. RECOVERY MATERIALS:    
B. PROCESS CHANGES    
C. FINAL TREATMENT:    
OPERATING CONDITIONS FOR CHROMETANNING    
SOAKING    
LIMING:    
DELIMING:    
SAVING IN CHEMICALS AND WATER IN DELIMING    
CHROME TANNING    
EFFLUENT TREATMENT IN TANNERY    
EFFLUENT TREATMENT    
FIGURE. TANNERY EFFLUENT TREATMENT SYSTEM    
SOURCES: CENTRAL LEATHER RESEARCH INSTITUTE, CHENNAI.
AIR EMISSIONS    
TABLE : SOURCES OF AIR EMISSIONS AND PREVENTIVE METHODS    
TABLE ODOUR  EMISSIONS TO AIR    
SOLID WASTE    
HAZARDOUS MATERIALS    
FLOW DIAGRAM OF COMPLETE TANNING PROCESS    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF RAW HIDES    132
SUPPLIERS OF SODIUM SULPHIDE    
SUPPLIERS OF SODIUM CHLORIDE    
SUPPLIERS OF AMMONIUM CHLORIDE    
SUPPLIERS OF BASIC CHROMIUM SULPHATE    
SUPPLIERS OF ANIONIC WETTING AGENT    
SUPPLIERS OF SULPHURIC ACID    
SUPPLIERS OF PLANT AND MACHINERIES    
SUPPLIERS OF SOAKING DRUMS    
SUPPLIERS OF LEATHER PRESSING MACHINE    
SUPPLIERS OF TRIMMING MACHINE    
SUPPLIERS OF BUFFING MACHINE    
SUPPLIERS OF BOILERS    
SUPPLIERS OF EFFLUENT TREATMENT PLANT    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF MEASURING & TESTING EQUIPMENTS    
SUPPLIERS OF EMBOSSING MACHINE    
PLANT AND MACHINERY SUPPLIERS (IMPORTED)    



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)