DENIM FABRIC MANUFACTURING [3542]
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. With Denim coming enormously in vigil with fashion conscious seat of society. This area possesses a high Potential and has a great demand, which needs to be exploited. The use of Denim Cloth for multifarious purposes makes it most versatile demandable item. The use of Denim cloth also attributes to its long lasting quantity of the fabric i.e. the span of the usages of Denim items is elongated making it move popular in the modern fashion conscious society where apparel also attributes a new dimensions to human personality.
COST ESTIMATION
Plant Capacity 25000 Mtr/Day
Land & Building (12000 sq.mt) Rs. 11.38 Cr
Plant & Machinery Rs. 22 Cr
Working Capital for 2 Months Rs. 11.83 Cr
Total Capital Investment Rs. 46.22 Cr
Rate of Return 20%
Break Even Point 61%
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
COMMON YARN SIZES FOR DENIM
YARN SPINNING SYSTEMS
SPECIALTY YARNS
STRUCTURED DENIM YARNS
ELASTIC DENIM YARNS
OVERVIEW OF THE DENIM MARKET (INDIAN & GLOBAL)
INDIA’S DENIM MARKET
INDIA’S DENIM STORY
DEMAND DRIVERS AND POPULARITY
GROWTH PROSPECTS AND TRIGGERS
DENIM EXPORTS
MARKET SURVEY
FEW POSITIVE FACTORS ENCOURAGING THE DENIM MARKETS IN INDIA
MARKET SIZE AND GROWTH
COMPARISON WITH DENIM CONSUMPTION OF SOME OTHER COUNTRIES
CITY-WISE DISTRIBUTION OF DENIM MARKET
PRESENCE OF BRANDS
DRIVING FACTORS FOR DENIM MARKET
SOME OF THE KEY DRIVING FACTORS FOR THE DENIM MARKET IN INDIA ARE
DENIM VALUE CHAIN IN INDIA
SELECT TRENDS IN DENIM MARKET
SOME OF THE KEY TRENDS IN DENIM MARKET ARE
ISSUES & CHALLENGES FOR DENIM MARKET
CONCLUSION
MARKET POSITION OF DENIM WEAR OF GST STRUCTURE
DENIM MARKET SIZE AND GROWTH
INCREASING DENIM AFFINITY
PRICE SEGMENTATION
KEY TRENDS AND GROWTH DRIVERS
CONCLUSION
B.I.S. SPECIFICATION
TYPES OF STONE WASH & THEIR EFFECTS ON THE DENIM FABRIC
PUMICE STONE USAGE IN STONE WASH
DISADVANTAGES OF PUMICE STONE USAGE
ALTERNATE METHODS FOR STONEWASHING
CELLULOSE METHOD
DISADVANTAGES OF CELLULOSE TREATMENT
LATEST PROCESS OF STONE WASH – PERLITE
MODERN STONE-WASHED JEANS, BIOSTONEING TECHNIQUE
RINSE (WATER) WASH
STONE WASH
OVERYDYE
DIRTY WASH
DESTROYED/DAMAGED/USED/WHISKERS
LASER MARKING/SPRAY PAINTING, ETC
OBJECTS OF INVENTION
FOAMING AGENTS
FOAM STABILISERS
THE INVENTION IS FURTHER DESCRIBED IN THE FOLLOWING EXAMPLES
DENIM GARMENT PROCESSING THE ECO-FRIENDLY WAY
ADVANTAGES OF GARMENT PROCESSING
DESIZING
ADVANTAGES OF ENZYMATIC DESIZING OVER TRADITIONAL DESIZING
STONE WASH EFFECT
ENZYME WASH
CELLULOSE ENZYME IS CLASSIFIED INTO TWO CLASSES
ADVANTAGE OF ENZYME WASHING
DENIM BLEACHING
LIMITATIONS
3-E BLEACHING CONCEPT FOR DENIM
ADVANTAGES
LIMITATIONS
ENZYMATIC ANTI-BACK STAINING AGENT-PROTEASE
SELECTION OF DENIM FABRIC
ADVANTAGES OF SAND BLASTING PROCESS
MECHANICAL ABRASION
ADVANTAGES OF THESE PROCESSES
OZONE FADING
WATERJET FADING
SINGLE-BATH STONE-WASHING AND TINTING TECHNIQUE
ALTERNATE TO PUMICE STONE
THE ADVANTAGE OF USING SUCH TYPE OF PRODUCTS ARE
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 77
TYPES OF CREELS
TRAVELING PACKAGE CREELS
MAGAZINE CREELS
BALL WARPING
BEAM WARPING
DYEING AND SLASHING WARP YARNS FOR DENIM
ROPE DYEING
SLASHER DYEING
BEAM DYEING
UNDYED DENIM
RE-BEAMING
SLASHING (SIZING)
DRAWING-IN AND TYING-IN OF WARP YARNS
WEAVING DENIM FABRICS
STRUCTURE OF DENIM FABRICS
YARN FLOW IN WEAVING
BASIC WEAVING MOTIONS
SHEDDING
FILLING INSERTION
BEAT UP
WARP LEFT OFF
FABRIC TAKE UP
TYPICAL DENIM CONSTRUCTIONS, WEAVES, AND WEIGHTS
YARN TWIST DIRECTION AND TWILL LINE DIRECTION
DETAILS OF DYEING
KIERING (SCOURING)
DETAILS OF SCOURING PROCESS
BLEACHING
BLEACHING WITH HYDROGEN PEROXIDE
DETAILS OF BLEACHING PROCESS
BLEACHING
HYPOCHLORITES
HYDROGEN PEROXIDE
DYEING
DYEING MACHINES
DYEING OF DENIM CLOTH
DYEING OR JIGGERS
DETAILS OF DYEING PROCESS
DYIENG
DYEING MACHINES
MORDANT DYESTUFFS
DIRECT DYESTUFFS
VAT DYESTUFFS
DRYING
DETAILS OF DRYING PROCESS
MECHANICAL REMOVAL
DRYING
PRINTING OF COTTON FABRIC
FINISHING
FINISHING
PROCESS FLOW DIAGRAM FOR DENIM FABRIC MANUFACTURE
STEPS & DENIM WASHING
PRE TREATMENT
ENZYME & STORE WASHING
CLEAN UP
BLEACHING
TINTING/DYEING
SOFTENING PROCESS
FLOW CHART OF DENIM PRODUCTION
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERIES
DYEING MACHINE
SCOURING MACHINE
EFFLUENT TREATMENT PLANT
BOILERS
LABORATORY TESTING EQUIPMENT
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
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)