Detailed Project Report (DPR) on gunny bags manufacturing plant

GUNNY BAGS MANUFACTURING PLANT

[CODE NO.3999] 

Jute is a naturally occurring, inexpensive fiber that is biodegradable and environmentally friendly. Because of its natural golden shine, jute is also known as "the golden fiber." Jute is most commonly used to make consumer goods such as bags and rugs. When the jute industry started in India, one of the earlier developments was the manufacture of jute sacks. The bulk of jute sack production is used for all types of jute bags. Sacking bags, woven wholly from jute fabrics, are available as plain and twill bags. Jute bags, the other name for sacking bags are mainly used to pack cement, sugar and other bulky articles, which are packed in weight range from 50 to 100kgs. These are tailored as per customer’s specifications in terms of size and to meet the ever increasing demand of jute bags in the farm sector, agro‐based industries and cement industries. The Jute Textiles Industry occupies and important place in the national economy. It is one of the major industries in the eastern region, particularly in West Bengal. It supports nearly 4 million farm families, besides providing direct employment to about 2.6 lac industrial workers.

 The jute industry is labor intensive and contributes about Rs.1,200 crores annually to the export earnings.

Indian Jute Industry

    Jute, the Golden Fiber as it is called, is a plant that yields a fiber used for sacking and cordage. Known as the raw material for sacks the world over, jute is truly one of the most versatile fibers gifted to man by nature that finds various uses in the form of Handicrafts. Next to cotton, jute is the cheapest and most important of all textile fibers. Jute is being cultivated in India for centuries. The landmark in the history of jute industry in India dates back to 1854 when the first jute mill as set up by George Auckland at Rishra in Hoogly district of West Bengal. Jute is predominantly a crop of eastern India.

The production process in the jute industry goes through a variety of activities, which include cultivation of raw jute, processing of jute fibers, spinning, weaving, bleaching, dyeing, finishing and marketing of both raw jute and its finished products. Currently the production of the fibre in India is around 100 lakh bales and about 73 jute mills are operating in the country at present. Besides, there are several small scale industries in the decentralized sector producing handicrafts, decoratives, twines, pulp & paper from jute and allied fibers and particle board from jute stick.

India: Industry Milestones  

• The largest producer of raw jute in the world.

• The biggest manufacturer of jute goods in the world.

• The capacity to manufacture the widest range of products, tailored to customers requirements.

• Comprehensive and world class research and development facilities in the area of jute agriculture, product development and machinery design.

• Highly quality conscious employing most modern facilities for TQC.

• Export history of raw jute and jute manufactures dates back to over 100 years.

• Highly developed infrastructure like ports, shipping facilities etc.

• A vibrant jute industry oriented to provide maximum customer satisfaction.

• Indian Jute Industry has the capacity to produce and meet the International demand for food grade Jute bags and cloth.

• Food grade Jute Bags and cloth manufactured in India ‐ are a boon in the context of global environmental and ecological concern. Indian food grade jute bags have a twin edged advantage: preservation of food in the most natural way.

Jute is a rainy season crop and hence sown from March to May according to rainfall and type of land, and harvested from June to September depending on whether the sowings are early or late.

Jute fiber, extracted from the plants of corchorus-spp., is at present principally used in the manufacture of hessian and sacking cloth and bags, ropes and cords, and miscellaneous fabrics. India and Bangladesh are the principal producers of jute and together they account for nearly 90 per cent of the world production.

India is present the biggest manufacture of jute goods. Producers of jute goods outside India are Pakistan Bangladesh, U.K., West Germany, France, Belgium and Japan. U.S.A. Producer jute yarn and bagging for cotton balls.

Three qualities of gunny cloth were produced prior to the introduction of the mill-industry. These were goon (finely woven fabric resembling hessian,  occasionally containing cotton) used as wearing apparel and sleeping mats by  poor classes, and goon chat (coarse and loosely woven fabric) used for packing agricultural produce and bulkier articles.

About 98% of the jute produced in India is utilized by jute mills for the manufacture of jute goods. From the point of view of its sized and place in national economy, the jute industry is one of the most important in the country as an earner of foreign exchange.

About 95% of the production conforms to qualities for which there is a world demand. The goods produced are:-

1.   Hessian

It is plain woven fabric made from white jute of good quality and weighing 12 OZ/Yd with a normal basic with of 40".

2.   Sacking

It is a heavy woven fabric, either plain or twill, weighing 12-20 OZ/Yd of different widths and ordinarily made lowest grades of fiber.

3.   Canvas

It is closely woven cloth of fine texture 36" in width, weighing 14-240 OZ/Yd and made from white and toassa jute of good spinning quality and yarn and twine.

Hessian is used for a variety of purpose, such as linoleum and floor cloth  backing, cable wrapping, brattice cloth for roads, cement cleavage fabrics for the building trade, thinning for clothing, meat scrappers etc. It is exported in finished lengths or cuts to overseas markets. Hessian bags - wheat pockets, grass and seed bags, sugar pockets, onion pockets, cotton packs, sand bags etc. are also made for Indian market and export.

COST ESTIMATION

Plant Capacity                                    10,000 Nos/Day

Land & Building (2000 sq.mt.)           Rs.  85 Lac

Plant & Machinery                               Rs.  35 Lac

Working Capital for 1 Month          Rs. 1.47 Cr

Total Capital Investment                    Rs. 2.78 Cr

Rate of Return                                     36%

Break Even Point                                55%

• INTRODUCTION
  
• INDIAN JUTE INDUSTRY
• INDIA: INDUSTRY MILESTONES
• 1.   HESSIAN
• 2.   SACKING
• 3.   CANVAS
• PRODUCT DESCRIPTION
• JUTE SACKING BAGS & THEIR USAGE
• USAGES:
• DESIGNS:
• TYPES OF JUTE SACKS
• DIFFERENT CATEGORIES OF SACKING ARE:
• USES AND APPLICATION
• TABLE: - I APPLICATION OR GUNNY BAGS
• 1.   GOOD GRAINS
• 2.   SUGAR
• 3.   CEMENT
• 4.   FERTILIZERS
• 5.   CHEMICALS
• B.I.S. SPECIFICATIONS
• 1 SCOPE
• 2 REFERENCES
• 3 TERMINOLOGY
• 4 MANUFACTURE
• 4.2 SEAM
• 4.3 SAFETY STITCH
• 4.4 HEMMING AT THE MOUTH
• 4.5 FREEDOM FROM DEFECTS
• 5 SPECIFIC REQUIREMENTS
• 6 PACKING
• 7 MARKING
• 8 SAMPLING AND CRITERIA FOR CONFORMITY
• FOR MORE INFORMATION CONTACT AT:
• MARKET AND SCOPE
• PROCUREMENT OF GUNNY BAGS FOR PACKAGING OF FOOD GRAINS
• CURRENT POLICY ON USE OF ONCE USED GUNNY BAGS
• DETAILED EXPORT DATA OF EMPTY GUNNY BAGS
• OVERVIEW OF INDIA’S FOOD GRAIN
• THE COUNTRY HAD REPORTED THE MONSOON (RAINFALL) 
•     DEFICIT OF 12% LAST YEAR.
• MANUFACTURERS/EXPORTERS OF GUNNY BAGS
• MANUFACTURING PROCESS
• INSPECTION OF HESSIAN CLOTH
• SET MAKING
• MARKING
• CUTTING
• STITCHING
• INSPECTION OF THE BAGS
• PACKAGING
• PROCESS FLOW DIAGRAM
• DETAILS OF AUTOMATIC JUTE BAG MAKING MACHINE
• MECHANICAL SYSTEMS
• FIG. 3 D VIEW OF AUTOMATIC JUTE BAG MAKING MACHINE
• DRIVES AND CONTROL SYSTEMS
• SPECIFICATION OF THE MACHINE
• MANUFACTURING PROCESS OF GUNNY BAGS FROM YARN
• RAW JUTE
• SELECTION OF RAW JUTE
• SOFTNING PROCESS
• CARDING
• DRAWING
• WINDING
• BEAMING
• WEAVING
• DAMPING
• CALENDERING
• SEWING
• PRESS AND PACKING
• PROCESS FLOW CHART
• PRINCIPLES OF PLANT LAYOUT
• 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:
• 6.   TRANSPORTATION:
• 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
• PLANT LAYOUT
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF PLANT AND MACHINERY

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)