DENIM FABRIC MANUFACTURING
[EIRI/EDPR/4467]
Denim is a firm durable twill cotton fabric which woven with colored warp and white filling threads. Technically speaking, denim is a warp faced twill weave fabric. Here coarse and lower yarn count is used. So it is heavy fabric.
Denim is one of the oldest types of work cloths that is available in the fashion world. It is used for its durability and comfort. Denim comes from the French phrase “Serge de Nimes”. The 17th century “Serge de Nimes” was introduced in French. Those fabrics were produced by using a mixture of cotton and wool. Some historians believe that it was first worn by sailors of Portugal. Initially it was worn by mechanics and miners. In the 21st century denim comes in many different styles including carpenters, sportswear, khakis, chinos and combat. Now it is true that the millions of people around the world favorite choice is denim cloth.
Cloth food and shelter are the basic needs of every human being. In the early years of human existence human beings covered themselves with leaves and other such raw Products so as to protect themselves against the natural conditions with the passage of time man began in search for an alternative and a much better way to protect himself and thus developed hand woven cloth slowly and gradually the technique of cloth making gained momentum as a result of which a fine variety of clothes come into existence. Today with the rapid industrialization. There have been new innovations in the technique of clothe manufacturing. In India cotton has been the most popular and most widely used cloth amongst the other varieties of cloth. But with fashion at its peak. Denim cloth came into existence which consists of a fairly large percentage of cotton. Denim cloth was more popular in the western countries since the early 60's while India was manufacturing Khadi cloth. But today as all set with fashion catching up, Denim Jeans, Jackets etc. have become a dream of every youth Denim cloth is thick and keeps the body warms. Most of the Denim cloth is utilized in the manufacture of Jeans and Jackets. There are a variety of shades Blues, Blacks etc.
COST ESTIMATION
Plant Capacity 25,000 Mtrs./Day
Land & Building (6000 sq.mt.) Rs. 3.80 Cr
Plant & Machinery Rs. 29.10 Cr
Working Capital for 2 Months Rs. 12.93 Cr
Total Capital Investment Rs. 46.46 Cr
Rate of Return 29%
Break Even Point 53%
CONTENTS
INTRODUCTION
TYPES OF DENIM FABRIC
1. DRY DENIM:
2. SELVEDGE DENIM:
3. STRETCH DENIM:
4. COLOR DENIM:
5. REVERSE DENIM:
6. VINTAGE DENIM:
USES AND APPLICATION
PROPERTIES
DETAILS OF DENIM YARN
FIGURE: PROCESS FLOW FOR WARP YARN IN DENIM MANUFACTURING
COMMON YARN SIZES FOR DENIM
YARN SPINNING SYSTEMS
SPECIALTY YARNS
STRUCTURED DENIM YARNS
ELASTIC DENIM YARNS
MARKET OVERVIEW OF DENIM FABRIC
DENIM MARKET IN INDIA
KIDS’ DENIM SEGMENT:
COMPARISON WITH DENIM CONSUMPTION OF SOME OTHER COUNTRIES
CITY-WISE DISTRIBUTION OF DENIM MARKET
PRESENCE OF BRANDS
DRIVING FACTORS FOR DENIM MARKET
DENIM VALUE CHAIN IN INDIA
SELECT TRENDS IN DENIM MARKET
ISSUES AND CHALLENGES FOR DENIM MARKET
FUTURE PROSPECTS OF DENIM INDUSTRY IN INDIA
EMERGING PLAYERS
LEADING DENIM MILLS AND THEIR CAPACITY
DENIM WEAR MARKET IN INDIA
GROWTH DRIVERS AND TRENDS IN DENIM WEAR IN INDIA
YOUTH AS A GROWTH DRIVER:
INFLUENCE OF INTERNATIONAL BRANDS:
INCREASED RURAL SPENDING:
CASUALIZATION OF FASHION:
ALTERNATIVE RETAIL CHANNEL:
RISE OF PRIVATE LABEL:
SUPER PREMIUM JEANS HAS EMERGED AS THE BEST PERFORMING
CATEGORY:
CROPPED OR FOLDED HEMS CONTINUE TO BE FASHIONABLE AMONG
WOMEN:
B.I.S. SPECIFICATION
TECHNOLOGY OF DENIM PRODUCTION
MANUFACTURE OF DENIM
SPINNING
OPEN END SPINNING
RING SPINNING
FABRIC WEAVING
A. GREY YARN ON CONES
B. WARPING ON SECTIONAL/ DIRECT WARPING
C. SIZING OF YARN IN SET/ BEAM TO BEAM POSITION
D. DRAWING–IN
E. BEAM GAITING OR KNOTTING ON LOOM
F. WEAVING
AIRJET LOOMS
FINISHING
A. GREY FABRIC
B. DENIM FABRIC
C. SHEET DYEING PROCESS
D. MAKING-UP
DISPATCH
WARP PREPARATION - DYEING AND SIZING PROCESSES
CONTINUOUS INDIGO-ROPE DYEING AND SIZING
CONTINUOUS INDIGO DYEING AND SIZING:
INDIGO-BACK BEAM DYEING AND SIZING
WEAVING
FINISHING
SEQUENCES IN DENIM FABRIC MANUFACTURE
YARN FOR DENIM:
DYEING AND SIZING PROCESS OF DENIM YARN:
1. CONTINUOUS INDIGO ROPE DYEING AND SIZING:
2. CONTINUOUS INDIGO DYEING AND SIZING:
3. INDIGO BACK BEAM DYEING AND SIZING:
WEAVING PROCESS OF DENIM FABRIC:
FINISHING PROCESS OF DENIM FABRICS:
DENIM FABRIC DYEING:
DENIM WASHING PROCESS:
1. MECHANICAL WASH:
2. CHEMICAL WASH:
POPULAR WASHING OF DENIM FABRIC:
GARMENT WASHING:
STONE WASH:
ACID WASH:
ENZYME WASH:
BLEACHING WASH:
FINISHING PROCESS OF DENIM GARMENTS:
PROCESS IN DETAILS FOR DENIM FABRIC MANUFACTURE
WARPING
FIGURE: BEAM WARPING
FIGURE: BALL WARPING (ROPE)
TYPES OF CREELS
TRAVELING PACKAGE CREELS
MAGAZINE CREELS
FIGURE MAGAZINE CREELS
BALL WARPING
BEAM WARPING
FIGURE BEAM WARPING
DYEING AND SLASHING WARP YARNS FOR DENIM
ROPE DYEING
SLASHER DYEING
FIGURE: SLASHER INDIGO DYE RANGE
BEAM DYEING
FIGURE: DYE BEAMS
UNDYED DENIM
RE-BEAMING
FIGURE: ROPE DYED YARN BEING RE-BEAMED
SLASHING (SIZING)
FIGURE: SLASHER CREEL
FIGURE: SIZE BOX
FIGURE: SLASHER (LOOM BEAM AT HEAD-END)
DRAWING-IN AND TYING-IN OF WARP YARNS
FIGURE: WARP DRAWING-IN
WEAVING DENIM FABRICS
STRUCTURE OF DENIM FABRICS
FIGURE: WOVEN FABRIC STRUCTURE
YARN FLOW IN WEAVING
FIGURE:. WEAVING MACHINE ELEMENTS
BASIC WEAVING MOTIONS
SHEDDING
FILLING INSERTION
BEAT UP
WARP LEFT OFF
FABRIC TAKE UP
FIGURE: BASIC WEAVING MOTIONS
TYPICAL DENIM CONSTRUCTIONS, WEAVES, AND WEIGHTS
FIGURE DIAGRAM OF 3/1 RIGHT AND LEFT HAND T WILLS
FIGURE: Z AND S TWIST DIRECTIONS
SEQUENCES IN DENIM FABRIC MANUFACTURE
DETAILS OF DYEING
KIERING (SCOURING)
DETAILS OF SCOURING PROCESS:-
BLEACHING:-
BLEACHING WITH HYDROGEN PEROXIDE:-
FOLLOWING IS TYPICAL FORMULATION OF BLEACH LIQUOR
RECOMMENDED FOR COTTON BLEACHING
DETAILS OF BLEACHING PROCESS
BLEACHING:-
HYPOCHLORITES:-
HYDROGEN PEROXIDE:-
DYEING:-
DYEING MACHINES:-
DYEING OF DENIM CLOTH:-
DYEING OR JIGGERS:-
DETAILS OF DYEING PROCESS:-
DYIENG:-
DRYING:-
DETAILS OF DRYING PROCESS:-
MECHANICAL REMOVAL:-
DRYING:-
PROCESS FLOW DIAGRAM FOR DENIM FABRIC
STEPS & DENIM WASHING
PRE TREATMENT
ENZYME & STONE WASHING
CLEAN UP
BLEACHING
TINTING/DYEING
SOFTENING PROCESS
LIST OF LABORATORY EQUIPMENTS FOR DEMIN CLOTH MANUFACTURING
SUPPLIERS OF PLANT AND MACHINERIES
SUPPLIERS OF DYEING MACHINE
SUPPLIERS OF SCOURING MACHINE
SUPPLIERS OF EFFLUENT TREATMENT PLANT
SUPPLIERS OF BOILERS
SUPPLIERS OF LABORATORY TESTING EQUIPMENTS
SUPPLIERS OF ETP PLANTS
SUPPLIERS OF RAW MATERIALS
STRENGTHS AND WEAKNESSES OF DENIM FABRIC
MANUFACTURERS/SUPPLIERS/EXPORTERS OF DENIM FABRICS
LIST OF TOP DENIM FABRIC MANUFACTURING COMPANY IN THE WORLD
DENIM MILLS IN BANGLADESH:
DENIM MILLS IN CHINA:
DENIM MILLS IN INDIA:
DENIM MILLS IN PAKISTAN:
DENIM MILLS IN HONGKONG:
DENIM MILLS IN JAPAN:
DENIM MILLS IN ITALY:
DENIM MILLS IN TURKEY:
DENIM MILLS IN USA:
DENIM MILLS IN INDONESIA:
DENIM MILLS IN SOUTH AMERICA (BRAZIL, ARGENTINA):
DENIM MILLS IN SPAIN:
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)
