Detailed Project Report (DPR) on manufacturing silk yarn from raw silk cocoon

MANUFACTURING SILK YARN FROM RAW SILK COCOON
[CODE NO.3879]


Silk is the most prized of all the textile fibres. It is the continuous filament exuded by silk worm at the end of its larval period through a small opening under the jaws called the spinneret. The silk worm generates within itself a protein like viscons substance (fibroin) which on passing through two serefic glands near the mouth forms two separate fine filaments (brins) and these are cemented together in the spinneret into a single thread (save) by a gummy substance (sericin or silk gum). The extruded thread is used by the silkworm to spin a Cocoon, a protective oxal shell By a continuous motion of its head in arcs of circles the worms adds layer after layer of silk thread around itself in the form of figuse eight in this may a continuous thread is spcin, the web grows closer and the Cocoon is completed in 2-3 days, after which the enclosed silkworm passed from the Caterpillar stage into an inert Chrysalis or pupa.

For utilizing this thread, the Cocoon is steamed or heated by hot air to kill the inside pupa, soaked in hot water to soften the outer layer brushed to remove the outer floss and the thread recovered from the Cocoon by unwinding (reeling). The fibre so obtained constitutes the raw silk of Commerce.

The his tory of the culture of silk according to a Chinese lagend dates back to 2640 B.C when the Empress Si-Lang-Chi of China learned how to rear the silkworm and to unwind the filament that that formed their Cocoona. The Chinese monopolized the art of Seri Culture-reering of silk worm for Cocoon production-for over 3000 year after which the silk Culture spread clandestinely to Japan and India in the beginning of Christian Era. Between the ganges and Brahmaputra, the Indian silk industry soon become established. From India, it is believed to have gradually spread throughout central Asia to Persia Turkey and Arabia. In the 8th Century, it was carried into the countries influenced by the Moorish rule including Spain, Sicily and the African Cost.



COST ESTIMATION


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%            


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 – 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)