Detailed Project Report on polyester yarn texturing, circular knitting and dyeing of knitted fabric
Detailed Project Report on polyester yarn texturing, circular knitting and dyeing of knitted fabric
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POLYESTER YARN TEXTURING, CIRCULAR KNITTING AND DYEING OF KNITTED FABRIC
[CODE NO.3956]
India is the largest producers and exporters of Polyester Yarn which has contributed a significant change in Indian economy growth. There are many textiles and garment manufacturing industries which have excelled in providing superior quality of materials. Hardik Textiles are one of the best Polyester Yarn Manufacturers in India which provides finest quality of yarn products in diverse requirements for the customers.
The textile industry in India is varied and extremely used in various applications according to different products and its specialized features.
Polyester began as a group of polymers in W.H. Carothers’ laboratory. Carothers was working for DuPoint at the time when he discovered that alcohols and carboxyl acids could be successfully combined to form fibers. Polyester was put on the back burner, however, once Carothers discovered nylon. A group of British scientists J.R. Whinfield. J.T. Dickson, W.K. Birtwhistle and C.G. Ritchie took up Carothers’ work in 1939. In 1941 they created the first polyester fiber called Terylene. In 1946 DuPont bouth all legal rights from the Brits and came up with another polyester fiber which they named Dacron.
Today, polyester is still widely regarded as a “cheap, uncomfortable” fiber, but even now this image is slowly beginning to change with the emergence of polyester luxury fibers such as polyester micro fiber.
Polyester is currently defined as Long chain polymers chemically composed of at least 85 percent by weight of an ester and a di-hydric alcohol and a terephthalic acid. The name polyester refers to the linkage of several monomers (esters) within the fiber. Esters are formed when alcohol reacts with a carboxylic acid.
COST ESTIMATION
Plant Capacity : 8 Ton/day
Land & Building (500 Sq.MT) : Rs. 3.40 Cr
Plant & Machinery : Rs. 6.50 Cr
Working Capital for 2 Month : Rs. 4.91 Cr
Total Capital Investment : Rs. 14.97 Cr
Rate of Return : 40%
Break Even Point : 44%
INTRODUCTION
BLENDS
THE RANGE TAKES ACCOUNT OF THE FOLLOWING:
PROPERTIES OF POLYESTER
CLASSIFICATION OF TEXTURED YARN
1. STRETCH YARNS:
2. MODIFIED STRETCH YARNS:
3. BULK YARN:
POLYESTER TEXTURED YARN
TEXTURING AND ITS PRINCIPLE
TEXTURING:
OBJECT:
PRINCIPLE OF TEXTURING
TEXTURED YARNS EXHIBIT THE FOLLOWING ADVANTAGE
AND DISADVANTAGE PROPERTIES:
ADVANTAGES:
DISADVANTAGES:
POLYESTER TEXTURED YARN SPECIFICATION
1. SCOPE
2. REFERENCES
3. TERMINOLOGY
4. REQUIREMENTS OF PTY
TABLE-4.1: CONSTRUCTIONAL & PERFORMANCE REQUIREMENTS OF PTY
TABLE-4.2: REQUIREMENTS OF BRIGHTNESS OF PTY
5. SAMPLING AND CRITERIA FOR CONFORMITY
TABLE 5.1 SAMPLE SIZE
TYPES OF YARN
FILAMENT VS STAPLE FIBRE
MARKET SCENARIO OF KNITTED FABRIC
INITIATIVES TAKEN BY GOVERNMENT OF INDIA ARE:
FOLLOWING ARE THE ACHIEVEMENTS OF THE GOVERNMENT IN
THE PAST FOUR YEARS:
THE KEY DRIVERS OF THE KNITTED FABRICS MARKET INCLUDE:
GROWTH IN THE APPAREL MANUFACTURING INDUSTRY
THE KEY RESTRAINTS ON THE KNITTED FABRICS MARKET INCLUDE:
RISE IN COTTON PRICES
MAJOR TRENDS INFLUENCING THE KNITTED FABRICS MARKET INCLUDE:
ECO-FRIENDLY FABRICS
OPPORTUNITIES AND RECOMMENDATIONS IN THE KNITTED
FABRICS MARKET
KNITTED FABRICS MARKET SEGMENTATION
BY GEOGRAPHY- THE KNITTED FABRICS MARKET IS SEGMENTED INTO
KNITTED FABRICS COMPETITIVE LANDSCAPE
MAJOR COMPETITORS ARE:
OTHER COMPETITORS INCLUDE:
MARKET OF TEXTILE INDUSTRY IN INDIA
OVERVIEW OF TEXTILE INDUSTRY IN INDIA
SOME OF THE MAJOR INVESTMENTS IN THE INDIAN TEXTILES
INDUSTRY ARE AS FOLLOWS:
INITIATIVE WILL BE TAKEN INTO CONSIDERATION BY GOVERNMENT
OF INDIA.
GLOBAL KNITTED FABRIC MARKET
MANUFACTURERS/SUPPLIERS OF YARNS
TYPES OF YARN PRODUCTION
FILAMENT
FIGURE: FILAMENT YARNS
STAPLE
FIGURE: STAPLE YARNS
DETAILS OF POLYESTER YARN
AVAILABILITY
POLYESTER YARN FOR TEXTILES
POLYESTER YARN FOR HOME FURNSHING
POLYESTER YARN FOR INDUSTRIAL USE
POLYESTER FDY
FDY PRODUCT FEATURES AND USES
PRODUCT FEATURES AND USES
POLYESTER TEXTURED YARN 68
POLYSTER TEXTURED YARN FEATTURES AND USES
PARTIALLY ORIENTED YARN (POY) AND FULLY ORIENTED YARN (FOY)
METHOD OF TEXTURIZATION
TEXTURED YARNS CAN BE PRODUCED BY FOLLOWING METHODS:
FALSE-TWIST COILING METHOD
STUFFER-BOX CRIMPING METHOD
AIR-JET TEXTURING METHOD
KNIT-DE-KNIT CRINKLING METHOD
GEAR CRIMPING METHOD
INTERMINGLING
OBJECTS:
WAYS OF INTERMINGLING:
HEAT SETTING
OBJECTS OF HEAT SETTING
DISADVANTAGES OF HEAT SETTING
SPIN FINISH
DYEING OF KNIT FABRIC
PRETREATMENT:
RECIPE:
PROCEDURE:
TWO BATH TWO STAGES DYEING
STAGE 1: POLYESTER PART DYEING WITH DISPERSE DYES (HIGH TEMP,
HIGH PRESSURE)
RECIPE:
PROCEDURE:
CARBONIZING:
REDUCTION CLEARING:
RECIPE:
PROCEDURE:
PROCESS CURVE (POLYESTER PART DYEING WITH DISPERSE DYES)
STAGE 2: COTTON PART DYEING WITH REACTIVE DYES
RECIPE:
PROCEDURE:
DYEING OF POLYESTER FABRIC WITH DISPERSES
DYE (CARRIER METHOD)
CARRIERS:
MECHANISM OF CARRIER ACTION:
RECIPE:
DYEING CURVE:
PROCEDURE:
AFTER TREATMENT:
PROPERTIES OF DISPERSE DYES
DISPERSE DYES AND ITS CLASSIFICATION
DISPERSE DYES
CLASSIFICATION
AZO DISPERSE DYES
GENERAL STRUCTURE OF AMINOAZOBENZENE DYES.
SOME TYPICAL AZO DISPERSE DYE STRUCTURES.
ANTHRAQUINONE DISPERSE DYES
ANTHRAQUINONE SYSTEMS OF BASIC FORMULA ; 9,10-ANTHRAQUINONE.
COMMERCIAL ANTHRAQUINONE DISPERSE DYES.
OTHER DISPERSE DYE CLASSES
MANUFACTURING PROCESS OF YARN TEXTURISING
METHOD OF DISPERSE DYEING
BASIC PRINCIPLE
DISPERSE DYEING MECHANISM
THE FOUR STAGES OF THE PROCESS MECHANISM ARE AS FOLLOWS:
THE EFFECTS OF VARIATIONS IN DISPERSE DYEING
CRYSTAL FORM OF THE DISPERSE DYES
DISPERSING AGENT
PARTICLE SIZE IN DISPERSION OF THE DYES
PH OF DYEBATH
SUBSTANTIVITY OF DISPERSE DYES
TEMPERATURE
FIBRE FINENESS
MAIN METHODS OF DISPERSE DYEING
CARRIER DYEING
HIGH TEMPERATURE DYEING
ADSORPTION PHASE
PHASES OF EXHAUST DYEING OF POLYESTER.
DIFFUSION PHASE
CLEARING PHASE
CHEMICAL REACTION DURING REDUCTION CLEARING
POLYESTER DYEING RECIPE
PROCESS FLOW DIAGRAM
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF AIR COMPRESSORS
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
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