Detailed Project Report (DPR) on footwear manufacturing

FOOTWEAR MANUFACTURING
[CODE NO.3357 ]


Poly Urethane (PU) is a plastic material or polymer consisting of organic units linked by carbamate links. Main sources of its formation include di-isocyanates, tri- isocyanates and polyols, along with these amine catalyst, bio derived material, hydroxyl and amine terminated compounds are used in its formation. Foam and non-foam PU are further modified by using surfactants. Hydrogen bonding also determines the properties of final PU product. The product does not melt when heated, which are known as thermosetting polymers. They are also available as thermoplastic PU.TPU (Thermo Plastic Urethane), for highquality footwear, into the country. This material has better properties than PVC or TPR (conventional materials used for footwear).
Footwear is the product to protect human feet from effects of all biological damages. Footwear industry is age old traditional industry in India and it has been changed structurally into different segments like casual-wears, dress-wears and sportswear. New segment is emerging for medical purposes as medical-wear like diabetic footwear. Many companies use to concentrate different segment like men’s-wear, women’s-wear and children’s-wear separately.
Footwear industry has been giving considerable amount of employment to the nation especially weaker sections and minority sections of society in India. Population growth, exports, domestic markets are the factors of expansion of footwear industry and creation of employment opportunities in this sector. This case study reveals the production capacities, structure of industry, exports growth, global imports, per capita consumption and estimates of future requirements of human resources in footwear industry in India.
CONCENTRATION OF FOOTWEAR INDUSTRY IN INDIA:

The major production of footwear manufacturing concentrated in these centers.

•    Tamil Nadu - Chennai, Ambur, Ranipet, Vaniyambadi, Trichy, Dindigul
•    Maharashtra - Mumbai
•    West Bengal - Kolkata
•    Uttar Pradesh - Kanpur, Agra & Noida
•    Punjab –Jallandhar, Ludhiana
•    Karnataka - Bangalore
•    Andhra Pradesh - Hyderabad
•    Haryana - Ambala, Gurgaon, Panchkula and Karnal
•    Delhi and Surroundings


The left and right footwear were identical and hence could be worn on either foot. Only prolonged usage shaped them into right and left boots. The right and left shoes were invented by a fashionable boot maker, William Young from Philadelphia in 1800. The first crafted footwear is the Sandals, which are known to be the successors to these wrappings.
The Indian Footwear sector is a promising one with tremendous opportunity for growth both in the international and domestic market. With low production cost, abundant supply of raw material, evolving retail system, buying patterns and huge consumption market, this sector is posed to grow to great heights.
How the Polyurathane is made :-

A variety of raw materials are used to produce polyurethanes.These include monomers, prepolymers, stabilizers which protect the integrity of the polymer, and colorants.
Isocyanates

One of the key reactive materials required to produce polyurethanes are diisocyanates.These compounds are characterized by a (NCO) group, which are highly reactive alcohols. The most widely used isocyanates employed in polyurethane production are toluene diisocyanate (TDI) and polymeric isocyanate (PMDI). TDI is produced by chemically adding nitrogen (/knowledge/Nitrogen.html) groups on toluene, reacting these with hydrogen to produce a diamine, and separating the undesired isomers. PMDI is derived by a phosgenation reaction of aniline formaldehyde polyamines. In addition to these isocyanates, higher end materials are also available.
These include materials like 1,5-naphthalene diisocyanate and bitolylenediisocyanate. These more expensive materials can provide higher melting, harder segments in polyurethane elastomers.
Polyols

The other reacting species required to produce polyurethanes are compounds that contain multiple alcohol groups (OH), called polyols. Materials often used for this purpose are polyether polyols, which are polymers formed from cyclic ethers. They are typically produced through an alkylene oxide polymerization process. They are high molecular weight polymers that have a wide range of viscosity. Various polyether polyols that are used include polyethylene (/knowledge/Polyethylene.html) glycol, polypropylene glycol, and polytetramethylene glycol. These materials are generally utilized when the desired polyurethane is going to be used to make flexible foams or thermoset elastomers.
Polyester polyols may also be used as a reacting species in the production of polyurethanes.They can be obtained as a by-product of terephthalic acid production. They are typically based on saturated aromatic carboxylic acids and diols. Branched polyester polyols are used for polyurethane foams and coatings. Polyester polyols were the most used reacting species for the production of polyurethanes. However, polyether polyols became significantly less expense and have supplanted polyester polyols.

COST ESTIMATION

Plant  Capacity                                      :       11500.00 PAIR/day
land & Building  (800 sq.Mtr               :    Rs. 63.37 Lacs
Plant & Machinery                                 :    Rs. 39.20 Lacs
Working Capital for 1 Month               :    Rs. 5.95 Cr
Total Capital Investment                      :    Rs. 7.12 Cr
Rate of Return                                       :    70%
Break Even Point                                   :    26%

INTRODUCTION                                        
PLANT LOCATION    
THE PURPOSE OF FOOTWEAR    
FORMULATE YOUR POLYETHER PU FOOTWEAR SYSTEMS    
METHODS OF CONSTRUCTION    
FASHION    
SIZES AND FITTINGS    
PATTERN CUTTING    
MANUFACTURING PROCESS    
POLYURETHANE SYSTEMS FOR SOLING
PU SOLING PROCESS    
PU SOLE FOOTWEAR    
2NDWAY:-    
PU POURING TECHNOLOGY    
MACHINES WITH SPECIFICATION    
STANDARDS AND SECTIONS    
STITCHING AND PROCESSES    
STITCHING THREADS USED IN THE CLOSINGDEPARTMENT    
FLOWCHART    
EDUCATION AND TRAINING    
MARKET SURVEY    
INDIA WILL HAVE STRONG FOOTHOLD IN GLOBALFOOTWEAR MARKETPRODUCTION LINE    
SUPPLIERS OF PLANT AND MACHINERIES    
SUPPLIERS OF RAW MATERIALS    
MACHINERY PHOTOGRAPHS    
PRODUCT PHOTOGRAPHS    

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