Detailed Project Report on yarn manufacturing (polyester & nylon)

YARN MANUFACTURING (POLYESTER & NYLON) [3523]

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. Because of their many desirable qualities, polyester fibers and fabrics have many uses. Polyester is often used in outerwear because of its high tencity and durability. It is a strong fiber and consequently can withstand strong and repetitive movements. Its hydrophobic property makes it ideal for garments and jackets that are to be used in wef or damp environments-coating the fabric with a water resistant finish intensifies this effect. Many jackets and quilted garments are made of polyester, Since polyester can be molded into almost any shape, certain insulating properties can be built in to the fiber. One method is to create hollow fibers. This process traps air inside the fiber which is then heated by the body. The warm air stays inside and helps warm the body in good weather. A second method is to use crimped polyester in a fiberfill product. The crimp helps to keep in warm air. Polyester is an ideal fiber to use for this since it will retain its shape, unlike its cotton and wool counterparts that lend to flatten out over time, significantly reducing their ability to trap warm air. Polyester is used in pants, shirts suits, and bed sheets either by itself or as a blend, because of its wrinkle resistant property and its ability its shape . Since these garments are frequently worm and washed, its stain resistance and durability are also desirable. After the fiber itself is created, it is made into a yarn. There are two types of polyester yarns filament and spun. Filament yarns are made by taking the single polyester filaments, grouping them together and then twisting or air entangling therm to make them workable. A monofilament yarn has just one. Single polyester fiber that is usually not twisted. Spun yarns are produced in much, the name way as a cotton or wool yarn is produced. The longfilaments are fist cut into short pieces called staple. These are then combined tighter and spun to create ayarn made up of thousands of short filaments. At this stage, polyester can also be combined with other fibers to produce a variety of effect. Polyester and cotton is probably the most famous and popular blend. The polyester helps the fabric retain its shape and resist stains and wrinkles. The cotton makes the fabric more absorbent and comfortable. Polyester is combined with wool to give it wrinkle-resistance and shaps retention in all kinds of weather. Since polyester is stronger than wood, it increases the durability and life of the fabric. The wood contributes good draping characteristics and elasticity. Polyester and rayon is another popular blend fabric. Here again the polyester makes the fabric more resilient and durable, and helps it keep its shape. The rayon adds a different texture, has a good hand, is good for draping and is more absorbent. Polyester and nylon produce a strong fabric because of nylon’s strength and abrasion resistance and polyester’s wrinkle free properties. This combination produces a yarn that is strong, durable, stable, easy to launder, and resistant to  mildew and insects. Problems with this blend, however, are that pilling may occur, and  it does not have a very nice hand, Furthermore, since neither nylon nor polyester is very absorbent, the fabric may feel wet and clammy in warm or humid weather.

COST ESTIMATION

Plant Capacity                                                1600 Kg/Day  
Land & Building (800 sq.mt)                       Rs. 1.17 Cr
Plant & Machinery                                          Rs. 1.45 Cr
Working Capital for 2 Months                     Rs. 1.44 Cr
Total Capital Investment                             Rs. 4.22 Cr
Rate of Return                                              24%
Break Even Point                                         58%


INTRODUCTION    
BLENDS    
PROPERTIES OF POLYESTER    
TYPES OF YARN    
FILAMENT VS STAPLE FIBRE    
MARKET SURVEY    
PRODUCTION OF YARN 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.    
MANUFACTURERS/SUPPLIERS OF YARNS    
TYPES OF YARN PRODUCTION    
FILAMENT    
STAPLE    
USES AND APPLICATION    
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    
POLYSTER TEXTURED YARN FEATTURES AND USES    
PARTIALLY ORIENTED YARN (POY) AND FULLY ORIENTED YARN (FOY)    
MANUFACTURING PROCESS OF YARN TEXTURISING    
PROCESS FLOW DIAGRAM    
PROCESSING DETAILS OF POLYESTERED NYLON YARN    
TWIST IN FILAMENT YARNS    
TEXTURING OF FILAMENT YARNS    
STEPS IN MAKING FIBERS INTO YARNS    
FILAMENTS    
STAPLE    
BLOWROOM    
CARDING    
COMBING    
DRAWING    
ROVING    
GENERAL COMPARISON BETWEEN FILAMENT AND STAPLE YARNS PERFORMANCE    
TENACITY & ELONGATION    
MANUFACTURING PROCESS OF POLYESTER FILAMENT YARN    
POLYMERIZATION    
DRYING    
MELT SPINNING    
DRAWING THE FIBER    
WINDING    
MANUFACTURING STAPLE FIBER    
DRAWING TOW    
CRIMPING    
SETTING    
CUTTING    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    
AIR COMPRESSORS    


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)