Dyeing And Finishing of Textile Cloth [Synthetic Shirting And Suiting] (Cap: 1,50,000 Mtr/Day)

DYEING AND FINISHING OF TEXTILE CLOTH [SYNTHETIC SHIRTING AND SUITING] (CAP: 1,50,000 MTR/DAY)

[EIRI/EDPR/4492] J.C.: 2708XL

The art of dyeing is a branch of applied chemistry in which a severe use of both physical and chemical principle is made in order to bring about a permanent union between the dyes and the fibres.

True dyeing  can  only take place when  the  dyeing  is  in solution and /or finally divided or dispersed colloidal  condition and  the fibers are subjected to this dye in solution condition and  then  this  dye being rendered insoluble or  fixed  by some means, when absorbed upon or within the fibers, or can be direct contact  with the fibers. There must exist some marked physico-chemical affinity between the fibers and the dye which would naturally depend upon the respective properties of both.

The local application of colour is carried out by some form of printing, and the greater part of textile printing concerns woven  cotton piece goods, the process is sometimes called calico printing, at the same time it must be released  that  very considerable quantities of rayon’s are printed as well as small amounts of silk and wool.

The resist style, as its name implies, comes from printing the material with a substance which will resist dyeing later and hence produce a pattern on a coloured ground. The discharge style depends on dyeing the fabric first and then removing the colour in selected areas i.e. descharging it is the discharging medium may also contain another colour which does not discharge, and in this manner it replaces, the colour originally situated on the fabric.

The object of finishing is to improve the attractiveness and /or serviceability of the fabric. A more restricted view of finishing is that of the third and final stage of the treatment of woven or knitted fabrics to prepare them for the consumer, bleaching a colouring from the fist and seconds stages.

Even this definition, however, is open to criticism for some  fabrics are  not bleached and others are not dyed or printed again,  many finishing operations, such as the creeping of silk and rayon, the mercerizing of cotton the crabbing of wool and the  cutting of velvets,  from part of the first phase of fabric treatment. Subject of these corrections, finishing, is best regarded as  the final stage is the embellishing of the fabrics.

The textile dyeing industry consumes large quantities of water and produces large volumes of wastewater from different steps in the dyeing and finishing processes. Wastewater from printing and dyeing units is often rich in color, containing residues of reactive dyes and chemicals, and requires proper treatment before being released into the environment. The toxic effects of dyestuffs and other organic compounds, as well as acidic and alkaline contaminants, from industrial establishments on the general public are widely accepted. Increasing public concern about environmental issues has led to closure of several small-scale industries.

In dyeing textiles, ecological standards are strictly applied throughout processing from raw material selection to the final product. This has become more critical since the German environmental standards regarding dye effluents became effective. The main challenge for the textile industry today is to modify production methods, so they are more ecologically friendly at a competitive price, by using safer dyes and chemicals and by reducing cost of effluent treatment/disposal. Recycling has become a necessary element, not because of the shortage of any item, but because of the need to control pollution. There are three ways to reduce pollution: (1) use of new, less polluting technologies; (2) effective treatment of effluent so that it conforms to specified discharge requirements; and (3) recycling waste several times over before discharge, which is considered the most practical solution.

COST ESTIMATION

Plant Capacity            1,50,000 Mtr/Day  

Land & Building (76,000 sq.ft.)    Rs. 7.75 Cr    

Plant & Machinery                    Rs. 5.80 Cr 

Working Capital for 1 Month    Rs. 1.64 Cr 

Total Capital Investment          Rs. 15.85 Cr 

Rate of Return                          42%

Break Even Point                      57%

CONTENTS

INTRODUCTION

NEED OF THE FINISHING OF FABRIC

(1) PHYSICAL

(2) CHEMICAL FINISHING METHODS

B.I.S. SPECIFICATION

MARKET OVERVIEW OF TEXTILE INDUSTRY IN INDIA

MARKET SIZE

INVESTMENT AND KEY DEVELOPMENT

GOVERNMENT INITIATIVES

ROAD AHEAD

TEXTILE INDUSTRY IN INDIA

MAJOR TEXTILE’S HUBS IN INDIA

MAJOR PLAYERS IN TEXTILE INDUSTRY

MAJOR PLAYERS IN THE INDUSTRY

GLOBAL TEXTILE MARKET

KEY COMPANIES & MARKET SHARE INSIGHTS

CATEGORIES OF DYES

THERE ARE THREE CATEGORIES:

THERE ARE MANY CLASS OF DYE IN THE FOLLOWING:

REACTIVE DYE:

DISPERSE DYE

DIRECT DYE

BASIC DYE

ACID DYE

SULPHUR DYE

VAT DYE

AZOIC DYE

OXIDATION DYE

OPTICAL DYE OR FLUORESCENT

SOLVENT DYE

DETAILS OF DYEING

DYEING METHODS:

TYPE OF TEXTILE MATERIAL TO BE PROCESSED:

PROCESSING METHODS:

OPERATING PRINCIPLES:

PROCESS CONDITIONS:

CLASSIFICATION OF DYEING METHODS/DYEING TECHNIQUES/DYEING PROCESS:

A. EXHAUST DYEING:

B. PAD DYEING:

FABRIC DYEING METHOD

BALE DYEING

BATIK DYEING

BEAM DYEING

SPECK DYEING

CHAIN DYEING

CROSS DYEING

JIG DYEING

PIECE DYEING

SOLUTION DYEING

TECHNICAL DETAILS OF TEXTILE PROCESSING

BLEACHING:-

HYDROGEN PEROXIDE:

DETAILS OF DRYING PROCESS

MECHANICAL REMOVAL:

DRYING:

DETAILS OF DYEING PROCESS

DYEING

DYEING MACHINES

MORDANT DYESTUFFS

DIRECT DYESTUFFS

VAT DYESTUFFS

FINISHING OF CLOTH

SOFTENING:

SOFTENING AGENTS MAY BE DIVIDED INTO THE FOLLOWING CLASSES:

OILS, FATS AND WAXES:

APPLICATION OF SYNTHETIC RESINS

VISCOSITY

SOLUBLE STARCH

DEXTRIN:

WATER REPELLENT FINISHING

ALUMINIUM ACETATE:

SYNTHETIC COMPOUNDS:

SILICONES:

HYDROPHOBIC FIBRES:

FIRE PROOF FINISHING

SOLUBLE COMPOUNDS:

DETAILS OF DIFFERENT TEXTILE OPERATION

TABLE: POSSIBLE TREATMENTS FOR COTTON TEXTILE WASTES AND THEIR ASSOCIATED ADVANTAGES AND DISADVANTAGES

EFFLUENT TREATMENT IN TEXTILE

TABLE: COMPOSITION OF COTTON TEXTILE MILL WASTE

FIGURE: ELECTROCHEMICAL TREATMENT AND RECOVERY OF CHEMICALS FROM THE TEXTILE EFFLUENT

MEMBRANE PROCESSES

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

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:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

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:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

ADDRESSES OF PLANT AND MACHINERY SUPPLIER

SUPPLIERS OF HYDRO EXTRACTOR

SUPPLIERS OF BOILERS

SUPPLIERS OF WATER SOFTENING PLANT

SUPPLIERS OF RAW MATERILS

SUPPLIERS OF CAUSTIC SODA

SUPPLIERS OF SODA ASH

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)