Detailed Project Report on Yarn Manufacturing (Polyester & Nylon)

YARN MANUFACTURING (POLYESTER & NYLON)

[EIRI/EDPR/3523] J.C.: 1610

INTRODUCTION

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.

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. 4.23 Cr

Rate of Return                          24%

Break Even Point                      58%

CONTENTS

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)