Industry Overview
Silk is one of the most prized textile fibres and is produced as a continuous filament by the silkworm during the final stage of its larval development. The filament consists primarily of fibroin, a protein-like substance, and is bonded by sericin, commonly known as silk gum. The silkworm continuously spins this filament around itself to form a protective cocoon over a period of approximately 2–3 days.
Raw silk is obtained by steaming or heating the cocoons to kill the pupa, soaking them in hot water to soften the sericin, removing the outer floss, and subsequently unwinding the filament through reeling. The report covers the production of silk yarn from raw silk cocoons, including cocoon sorting, sericin softening, reeling, throwing, degumming, twisting, dyeing, finishing, and packaging.
The history of sericulture is traditionally traced to China around 2640 B.C., when Empress Si-Ling-Chi is credited with learning silkworm rearing and silk filament unwinding. China maintained a long-standing monopoly over sericulture before the practice spread to Japan and India around the beginning of the Christian Era. The Indian silk industry subsequently became established between the Ganges and Brahmaputra regions and later spread toward Central Asia, Persia, Turkey, Arabia, and territories influenced by Moorish rule.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 140.00 Kg./day |
| Land & Building (1500 sq.mt.) | Rs. 1.96 Cr |
| Plant & Machinery | Rs. 2.30 Cr |
| Working Capital for 1 Month | Rs. 95.85 Lacs |
| Total Capital Investment | Rs. 5.39 Cr |
| Rate of Return | 27% |
| Break Even Point | 57% |
Content Index
- INTRODUCTION
- PROPERTIES OF RAW SILK FIBRE
- SILK DEGUMMED
- USES OR APPLICATION
- GRADING OF RAW SILK
- DISEASES OF SILK WORMS & PREVENTIVE MEASURE
- SERICULTURE
- B.I.S. SPECIFICATION
- MARKET OVERVIEW OF SILK IN INDIA
- EXPORT EARNINGS FROM SILK DURING 2016-17 TO 2018-19
- COUNTRY WISE EXPORT EARNINGS FROM SILK GOODS DURING 2016-17 TO 2018-19
- RAW MATERIALS
- MANUFACTURING PROCESS OF SILK YARN FROM RAW SILK CACOON
- SORTING COCOON
- SOFTENING THE SERICIN
- REELING
- THROWING
- PROCESS FLOW DIAGRAM
- STEP IN SILK YARN MAKING
- 1. HARVESTING
- 2. STIFLING & SORTING
- 3. BOILING
- 4. DEFLOSSING
- 5. REELING
- 6. TWISTING & DYING
- DETAILED PROCESS TO MANUFACTURE SILK YARN
- CULTIVATION OF COCOONS:
- BOILING OF COCOONS
- FILATURE OPERATIONS:
- 1. SORTING COCOONS:
- 2. SOFTENING THE SERICIN:
- 3. REELING THE FILAMENT:
- THROWING:
- DEGUMMING OF THROWN SILK:
- SERICULTURE
- BREEDING SILKWORMS
- FEEDING THE LARVA
- SPINNING THE COCOON
- STOVING THE CHRYSALIS
- THE FILATURE
- SORTING AND SOFTENING THE COCOONS
- REELING THE FILAMENT
- PACKAGING THE SKEINS
- FORMING SILK YARN
- DEGUMMING THROWN YARN
- FINISHING SILK FABRICS
- REELING OF NON MULBERRY COCOON
- A) TASAR COCOON REELING
- TABLE: REELING EFFICIENCY OF DOUPION SILK BY THE SIZES OF THREAD
- TABLE: A TRIAL OF TASAR COCOON REELING
- B) ERI COCOON SPINNING
- TABLE: A SURVEY OF CHARACTERISTICS OF ERI COCOON BAVE
- MANUFACTURE OF FLOSS SILK
- DEGUMMING
- OPENING-UP
- FINISHING
- TABLE: YIELD OF FLOSS SILK AND SPUN SILK BY DIFFERENT COCOON RAW MATERIALS
- PRINCIPLES OF PLANT LAYOUT
- PLANT LOCATION FACTORS
- PRIMARY FACTORS8
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- SPECIFIC FACTORS
- 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. TERM LOANS:
- 8. TOTAL LOAD:
- 9. 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
- BUYERS OF SILK YARN
Appendix
- 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)
Frequently Asked Questions
Silk yarn manufacturing generally involves harvesting, stifling and sorting cocoons, boiling, deflossing, reeling, twisting and dyeing. The process begins with suitable cocoons, from which the silk filament is softened and unwound. Reeling converts the continuous cocoon filament into raw silk, while subsequent throwing, degumming, twisting, dyeing and finishing operations can produce yarn with the required characteristics for textile applications.
Raw silk is obtained by treating the cocoon and unwinding its filament through a reeling operation. The cocoon is first heated or steamed to kill the enclosed pupa, then soaked in hot water to soften the sericin that binds the filaments. After the outer floss is removed, the continuous filament is located and unwound. Several filaments may be combined during reeling to obtain a usable raw silk thread with the desired size and uniformity.
Sericin is the gummy protein that binds the silk fibroin filaments together and can be removed during degumming. During cocoon formation, sericin acts as a natural adhesive that holds the filament layers together. In silk processing, controlled degumming reduces or removes this gum to expose the fibroin, improving the handle, appearance and processing characteristics of the silk. The extent and method of degumming depend on the intended end use and the required properties of the finished silk.
The report covers both conventional silk processing and non-mulberry silk operations. It specifically discusses Tasar cocoon reeling and Eri cocoon spinning in addition to the processing of raw silk and floss silk. These different raw materials require appropriate processing methods because cocoon characteristics and filament structure can vary. The report also addresses the manufacture of floss silk, including degumming, opening-up and finishing operations.
A silk yarn plant should be located after considering raw-material availability, markets, power and fuel, water, climate, transportation, waste disposal and labour. Other factors include regulatory requirements, taxes, site characteristics, community considerations, flood and fire control, and overall site vulnerability. Reliable access to cocoons and supporting utilities is particularly important because interruptions in material supply or processing services can affect production continuity, product quality and operating efficiency.
Reeling converts the softened filament from silk cocoons into continuous raw silk. After the sericin has been softened, the filament is located and unwound from the cocoon, with suitable filaments combined to form the required thread. Reeling efficiency and the characteristics of the cocoon influence the quality and productivity of the operation. The report therefore includes detailed coverage of cocoon sorting, sericin softening and reeling, along with reeling operations for non-mulberry cocoons.
The project report includes capital investment, working capital, plant and machinery, land and building, rate of return and break-even information. It also provides an appendix covering plant economics, fixed capital, raw materials, salary and wages, utilities and overheads, cost of production, turnover, financing resources, instalments, depreciation, profit analysis and projected balance sheets. These sections are intended to provide a structured basis for evaluating the technical and financial aspects of a silk yarn manufacturing project.
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