DENIM GARMENTS
(DENIM CLOTH WILL BE PURCHASED FROM MARKET AND CONVERTED TO GARMENTS WITH 50 MACHINES)
[CODE NO.3245]
The word `DENIM' is almost synonymously used for high fashion garments. `DENIM' has become so popular throughout the world today that the moment this magic word is heard, it conjures up in one's mind visions of a blue garment with unique and elegant appearance. This classic fabric has been in use aross the world for a long time. However, the appearance of this fabric is continuously being modified to appeal to the varied fashion trends of different generations. In many respects fashion trends have dictated how the fabrics and garments should look and accoordingly the processing techniques have been changed. Today, the consumer literally has numerous choices of unwashed and pre-washed garments suit individual tastes.
What is Denim?
Denim fabric can be defined as a warp faced twill fabric made from yarn dyed warp and undyed weft yarn. The count of the yarn used varies between 6 and 12. In general, indigo-vat dye is used for colouring the warp yarn. More than 5000 years before the development of synthetic dyes, before the development of synthetic dyes, natural indigo dye was being used. Evidence for this ha sbeen obtained by the presence of indigo dyed garments and blankets form ancient tombs and graves. The indigo plant is cultivated in India, China, Japan and South America. Indigo is structurally a vat class of dye, which in its pigment state is insoluble in water, alkali or acid. Like other vat dyes, this dye must be vatted to apply it to cellulosic fibre. This reduced dye has moderate affinity for cellulose. The basic steps involved in the application of indigo dye to cellulosic fibres are:
1. Conversion of the insoluble dye molecules into the soluble leuco form by alkaline reducing conditions.
2. Absorption of the leuco compound by the fibre.
3. Conversion of solubilised dye back to the insoluble form by oxidation.
4. After treatment of the dyed material by washing to remove unfixed loose dye particles.
Indigo dye is generally applied to cotton, either in fibre form or yarn form. The actual indigo shade on the yarn is developed by controlled impregnation and oxidation steps. In a continuous indigo dyeing operation, multiple dips and air oxidation of the substrate and sufficient washing to remove loosely held particles, if followed. The indigo dye molecule is very large and it does not penetrate deeply into the fibre, resulting in ring dyeing. It is this white cetre and dyed oouter ring that results in the characteristic abrasion patterns on garments made form indigo dyed fabric.
COST ESTIMATION
Plant Capacity : 350.00 Pieces/day
land & Building (4000 sq.Yard : Rs. 2.70 Cr
Plant & Machinery : Rs. 53.05 Lacs
Working Capital for 2 Months : Rs 92.70 Lacs
Total Capital Investment : Rs. 4.25 Cr
Rate of Return : 34%
Break Even Point : 54%
INTRODUCTION
WHAT IS DENIM?
B.I.S. SPECIFICATION
FOR BLEACHING AND DYEING:
FOR PACKING MATERIALS:
PROPERTIES OF DENIM FABRIC
TYPES OF DENIM FABRIC
ALL THE ABOVE
THE MENSWEAR MARKET
MARKET SIZE AND GROWTH PROJECTIONS
HIGH GROWTH CATEGORIES
MARKET TRENDS
THE WOMENS WEAR MARKET
MARKET SIZE AND GROWTH PROJECTIONS
HIGH GROWTH CATEGORIES
MARKET TRENDS
THE INNERWEAR CATEGORY
THE MEN’S INNERWEAR MARKET
THE WOMEN’S INNERWEAR MARKET
PRICE-BASED MARKET SEGMENTATION
LOOKING TO THE FUTURE
DENIM MARKET IN INDIA
SOME OF THE KEY DRIVING FACTORS FOR THE DENIM MARKET
IN INDIA ARE:
SOME OF THE KEY TRENDS IN DENIM MARKET ARE:
IMPACT OF MAKE IN INDIA
ON THE DENIM MANUFACTURING INDUSTRY
MAKE IN INDIA FOR THE TEXTILE SECTOR
INDIA’S DENIM POTENTIAL
MANUFACTURING PROCESS OF DENIM GARMENTS
PROCESS FLOW DIAGRAM
DETAILS OF DENIM GARMENTS MANUFACTURE
DENIM GARMENT DESIGN PROCESS
DENIM CLOTHING MANUFACTURE
TAGGING AND DISTRIBUTION
PROCESS OF DENIM FABRIC GARMENT WASHING
YARN FOR DENIM:
DYEING AND SIZING PROCESS OF DENIM YARN:
WEAVING PROCESS OF DENIM FABRIC:
FINISHING PROCESS OF DENIM FABRICS:
DENIM FABRIC DYEING:
DENIM WASHING PROCESS:
POPULAR WASHING OF DENIM FABRIC:
GARMENT WASHING:
STONE WASH:
ACID WASH:
ENZYME WASH:
BLEACHING WASH:
FINISHING PROCESS OF DENIM GARMENTS:
DENIM WASHING AND FINISHING PROCEDURE
DENIM FINISHING AND PROCEDURES:
STONE WASHING:
ENZYME WASHING
BLEACH WASHING
ICE OR SNOW WASHING
SAND BLASTING
DETAILS OF DYEING & BLEACHING
PREPARATION OF STOCK VAT:-
IN THE DYEING OPERATING THERE ARE THREE CLASSES OF DYE STUFFS
CONDITIONS REQUIRED IN DYEING:-
DYEING BY JIGGER METHOD
BLEACHING:
BLEACHING PROCESS
BLEACHING OR CHEMICKING:
PREPARATION OF THE BLEACHING SOLUTION:
METHOD OF BLEACHING:
BLEACHING:
WASHING:
RINSING OR WASHING:
WASHING MACHINES:
DETAILS OF DRYING PROCESS
MECHANICAL REMOVAL:
DRYING:
FORMULATIONS OF INDIGO STOCK VAT
INTERNATIONAL STANDARDS FOR DENIM EXPORTS
FORMULATION FOR STOCK VAT:-
PROCESS:-
OUTLINE OF THE PROCESS (JIGGER PROCESS)
JIGGER MACHINE:
FINISHING:-
FINISHING PROCESS
THE CREASE RESISTING FINISH
STITCHING OF GARMENTS
IN CONCLUSION, A FEW SPECIAL TIPS ON STITCHING JEANS:
PROCESS FLOW SHEET FOR MANUFACTURE OF JEANS OPERATIONAL
FLOW IN JEANS MANUFACTURING: CHAIN SYSTEM
OPERATIONAL FLOW IN JACKETS MANUFACTURING: SINGLE TAILOR
SYSTEM
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERY
HYDRO EXTRACTOR
BOILERS
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
