Detailed Project Report on microfiber terry towels

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Description
How to Start Business

MICROFIBER TERRY TOWELS

[CODE NO.4003]

Microfiber or microfiber is synthetic fiber finer than one or 1.3 denier or decitex/thread. This is 1/100th the diameter of a human hair and 1/20th the diameter of a strand of silk. The most common types of microfibers are made from polyesters, polyamides (e.g., nylon, Kevlar, Nomex, trogamide), or a conjugation of polyester, polyamide, and polypropylene (Prolen).

Microfiber combines two basic fibers, Polyester and Polyamide (a Nylon by-product). These fibers are usually “split” and formed into a woven fabric of 80% Polyester (the scrubbing and cleaning fiber), and 20% Polyamide (the absorbing and quick drying fiber).

These threads are very small in diameter making them super soft. Rated in denier, the unit for measuring fineness of fabric, a strand of cotton has a rating of 200. A human hair has a denier of 20 and a strand of silk has a denier of 8. Microfiber has a denier of 0.01 to 0.02! At minimum, 100 times finer than a human hair. Softer than silk, yet bull-dog tough, split Microfiber cloth attracts dust, grime, oily films and salt residues like a magnet.

The unique surface structure of split Microfiber cloth contains hundreds of thousands of micro fiber “hooks” per square inch! These micro-hooks grab, lift, and hold dust and grime without the need for cleaning solutions. Microfiber cloth can be used damp or dry. Used dry, Microfiber cloth works like a chamois. The super absorbent weaves holds up to seven times its weight in fluid and will not scratch paint, glass, acrylics or plastic window tint films.

COST ESTIMATION

Plant Capacity 6 Ton/Day

Land & Building (12000 sq.mt.) Rs. 8.80 Cr

Plant & Machinery Rs. 9.50 Cr

Working Capital for 1 Month Rs. 4.35 Cr

Total Capital Investment Rs. 23.13 Cr

Rate of Return 42%

Break Even Point 44%

INTRODUCTION

MICROFIBER

RELATIONSHIP BETWEEN FIBER LINEAR DENSITY AND CLASSIFICATION

BENEFITS AND END USER OF MICRO FIBER

BENEFITS OF MICROFIBER

1. EFFECTIVE AT CAPTURING MICROBES:

2. PREVENTS CROSS-CONTAMINATION:

3. REDUCES CHEMICAL AND WATER USE MORE EFFECTIVELY:

MAIN PRODUCTS FOR WHICH MICROFIBER ARE IDEALLY SUITED:

PROPERTIES OF MICROFIBER

GENERAL PROPERTIES OF MICROFIBERS

B.I.S. SPECIFICATION

COMPARISON BETWEEN FIBER OF STANDARD LINEAR DENSITY

AND MICROFIBER

PHYSICAL PROPERTIES OF POLYESTER AND ACRYLIC MICROFIBERS

WITH DIFFERENT LINEAR DENSITIES

PROPERTIES OF TERRY TOWELS

PHYSICAL PROPERTIES OF A TOWEL

ABSORBENCY

HEAT INSULATION

CREASE RESISTANCE

DULLNESS

CLARIFICATION OF TERRY TOWEL

TABLE: CLASSIFICATION OF TERRY TOWELS ACCORDING TO WEIGHT,

PRODUCTION STYLE, FINISHING, WEFT COUNT PER PILELOOP AND

PILE PRESENCE ON FABRIC SURFACES.

MARKET POSITION

THE ROAD AHEAD

TABLE STRUCTURAL CHANGE: ASIAN DOMINANCE IN HOME TEXTILES

TABLE: STRUCTURAL CHANGE: NON INDIA PLAYERS FACING CHALLENGES

MANUFACTURE OF MICROFIBER

DISSOLVED TYPE:

SPLIT TYPE:

DIRECT SPUN TYPE:

SUPER-DRAWING TECHNIQUE:

SHEATH-CORE SPINNING METHOD:

DETAILS TO PRODUCE MICROFIBER

THERE ARE TWO WAYS TO PRODUCE MICRO FIBERS:

TEXTURING MACHINES FOR MICRO FIBERS:

PROCESSING OF MICROFIBER

CARDING

WINDING AND WARPING

SIZING

WEAVING/KNITTING

METHOD OF MICROFIBER MANUFACTURING

A) DISSOLVED TYPE

B) SPLIT TYPE

C) DIRECT SPUN TYPE

(D) SUPER-DRAWING TECHNIQUE

(E) SHEATH-CORE SPINNING METHOD.

(F) SOME OTHER METHODS;

FIBERS FOR MICROFIBER:

FIG 1: BI-COMPONENT FIBERS

SPECIALTY CROSS-SECTIONS

FIG 2: SPECIALTY CROSS-SECTIONS

MELT SPINNING PROCESS DIAGRAM

PROCESSING DETAILS OF MICROFIBER TOWELS

MICROFIBER YARN EXTRUSION

TESTING OF THE MICROFIBER YARN

CONVERSION OF POY INTO FDY

CONVERSION OF POY INTO DTY

SPOOLING

WEAVING/KNITTING

VISUAL QUALITY CHECK

MICROFIBER SPLITTING

DYEING

DRYING AND TENSIONING

CUTTING

SEWING

PIGTAILS REMOVAL

FINAL INSPECTION

DYEING OF MICROFIBER MADE FABRIC

DYEING OF POLYESTER MICROFIBERS:

THE PROBLEMS IN WET PROCESSING OF MICRO FIBERS CAN BE

OVERCOME BY:

PROPER DYE SELECTION FOR MICROFIBER DYEING:

OPTIMIZING THE DYEBATH CONDITIONS AND DYEING CYCLE:

PROPER SELECTION OF DYEING MACHINERY:

PROPER SELECTION OF DYE BATH ADDITIVES SUCH AS:

RECOMMENDED DYEING CYCLE FOR POLYESTER MICROFIBERS:

PROCEDURE:

DYESTUFF USED

DISPERSE DYESTUFF

THE FOLLOWING ARE EXAMPLES OF RECOMMENDED ITEMS:

DYEING AUXILIARY USED CARRIER

SOME EXAMPLES OF GENERAL AND SPECTACULAR APPLICATIONS

OF MICROFIBERS:

APPLICATION OF MICROFIBER DYED GOODS

IN TEXTILES,

OTHER MAIN PRODUCTS FOR WHICH MICROFIBER ARE IDEALLY SUITED:

PROCESS FLOW DIAGRAM

QUALITY CONTROL MANAGEMENT IN TOWEL MANUFACTURE

QUALITY

QUALITY CONTROL

QUALITY CONTROL AND PRODUCTIVITY

QUALITY CONTROL AND COST REDUCTION

TOTAL QUALITY CONTROL

TOOLS OF TOTAL QUALITY CONTROL

COST REDUCTION

QUALITY CONTROL IN THE JUTE INDUSTRY

RAW FIBRE DEVELOPMENT

IN-COMING MATERIAL CONTROL

STATISTICAL QUALITY CONTROL

QUALITY CONTROL UNIT

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

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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