MICROFIBER TERRY TOWELS
[CODE NO.4003]
Microfiber or microfiber is synthetic fiber finer than one or 1.3 denier or decitex/thread. This is 1/100th the diameter of a human hair and 1/20th the diameter of a strand of silk. The most common types of microfibers are made from polyesters, polyamides (e.g., nylon, Kevlar, Nomex, trogamide), or a conjugation of polyester, polyamide, and polypropylene (Prolen).
Microfiber combines two basic fibers, Polyester and Polyamide (a Nylon by-product). These fibers are usually “split” and formed into a woven fabric of 80% Polyester (the scrubbing and cleaning fiber), and 20% Polyamide (the absorbing and quick drying fiber).
These threads are very small in diameter making them super soft. Rated in denier, the unit for measuring fineness of fabric, a strand of cotton has a rating of 200. A human hair has a denier of 20 and a strand of silk has a denier of 8. Microfiber has a denier of 0.01 to 0.02! At minimum, 100 times finer than a human hair. Softer than silk, yet bull-dog tough, split Microfiber cloth attracts dust, grime, oily films and salt residues like a magnet.
The unique surface structure of split Microfiber cloth contains hundreds of thousands of micro fiber “hooks” per square inch! These micro-hooks grab, lift, and hold dust and grime without the need for cleaning solutions. Microfiber cloth can be used damp or dry. Used dry, Microfiber cloth works like a chamois. The super absorbent weaves holds up to seven times its weight in fluid and will not scratch paint, glass, acrylics or plastic window tint films.
COST ESTIMATION
Plant Capacity 6 Ton/Day
Land & Building (12000 sq.mt.) Rs. 8.80 Cr
Plant & Machinery Rs. 9.50 Cr
Working Capital for 1 Month Rs. 4.35 Cr
Total Capital Investment Rs. 23.13 Cr
Rate of Return 42%
Break Even Point 44%
INTRODUCTION
MICROFIBER
RELATIONSHIP BETWEEN FIBER LINEAR DENSITY AND CLASSIFICATION
BENEFITS AND END USER OF MICRO FIBER
BENEFITS OF MICROFIBER
1. EFFECTIVE AT CAPTURING MICROBES:
2. PREVENTS CROSS-CONTAMINATION:
3. REDUCES CHEMICAL AND WATER USE MORE EFFECTIVELY:
MAIN PRODUCTS FOR WHICH MICROFIBER ARE IDEALLY SUITED:
PROPERTIES OF MICROFIBER
GENERAL PROPERTIES OF MICROFIBERS
B.I.S. SPECIFICATION
COMPARISON BETWEEN FIBER OF STANDARD LINEAR DENSITY
AND MICROFIBER
PHYSICAL PROPERTIES OF POLYESTER AND ACRYLIC MICROFIBERS
WITH DIFFERENT LINEAR DENSITIES
PROPERTIES OF TERRY TOWELS
PHYSICAL PROPERTIES OF A TOWEL
ABSORBENCY
HEAT INSULATION
CREASE RESISTANCE
DULLNESS
CLARIFICATION OF TERRY TOWEL
TABLE: CLASSIFICATION OF TERRY TOWELS ACCORDING TO WEIGHT,
PRODUCTION STYLE, FINISHING, WEFT COUNT PER PILELOOP AND
PILE PRESENCE ON FABRIC SURFACES.
MARKET POSITION
THE ROAD AHEAD
TABLE STRUCTURAL CHANGE: ASIAN DOMINANCE IN HOME TEXTILES
TABLE: STRUCTURAL CHANGE: NON INDIA PLAYERS FACING CHALLENGES
MANUFACTURE OF MICROFIBER
DISSOLVED TYPE:
SPLIT TYPE:
DIRECT SPUN TYPE:
SUPER-DRAWING TECHNIQUE:
SHEATH-CORE SPINNING METHOD:
DETAILS TO PRODUCE MICROFIBER
THERE ARE TWO WAYS TO PRODUCE MICRO FIBERS:
TEXTURING MACHINES FOR MICRO FIBERS:
PROCESSING OF MICROFIBER
CARDING
WINDING AND WARPING
SIZING
WEAVING/KNITTING
METHOD OF MICROFIBER MANUFACTURING
A) DISSOLVED TYPE
B) SPLIT TYPE
C) DIRECT SPUN TYPE
(D) SUPER-DRAWING TECHNIQUE
(E) SHEATH-CORE SPINNING METHOD.
(F) SOME OTHER METHODS;
FIBERS FOR MICROFIBER:
FIG 1: BI-COMPONENT FIBERS
SPECIALTY CROSS-SECTIONS
FIG 2: SPECIALTY CROSS-SECTIONS
MELT SPINNING PROCESS DIAGRAM
PROCESSING DETAILS OF MICROFIBER TOWELS
MICROFIBER YARN EXTRUSION
TESTING OF THE MICROFIBER YARN
CONVERSION OF POY INTO FDY
CONVERSION OF POY INTO DTY
SPOOLING
WEAVING/KNITTING
VISUAL QUALITY CHECK
MICROFIBER SPLITTING
DYEING
DRYING AND TENSIONING
CUTTING
SEWING
PIGTAILS REMOVAL
FINAL INSPECTION
DYEING OF MICROFIBER MADE FABRIC
DYEING OF POLYESTER MICROFIBERS:
THE PROBLEMS IN WET PROCESSING OF MICRO FIBERS CAN BE
OVERCOME BY:
PROPER DYE SELECTION FOR MICROFIBER DYEING:
OPTIMIZING THE DYEBATH CONDITIONS AND DYEING CYCLE:
PROPER SELECTION OF DYEING MACHINERY:
PROPER SELECTION OF DYE BATH ADDITIVES SUCH AS:
RECOMMENDED DYEING CYCLE FOR POLYESTER MICROFIBERS:
PROCEDURE:
DYESTUFF USED
DISPERSE DYESTUFF
THE FOLLOWING ARE EXAMPLES OF RECOMMENDED ITEMS:
DYEING AUXILIARY USED CARRIER
SOME EXAMPLES OF GENERAL AND SPECTACULAR APPLICATIONS
OF MICROFIBERS:
APPLICATION OF MICROFIBER DYED GOODS
IN TEXTILES,
OTHER MAIN PRODUCTS FOR WHICH MICROFIBER ARE IDEALLY SUITED:
PROCESS FLOW DIAGRAM
QUALITY CONTROL MANAGEMENT IN TOWEL MANUFACTURE
QUALITY
QUALITY CONTROL
QUALITY CONTROL AND PRODUCTIVITY
QUALITY CONTROL AND COST REDUCTION
TOTAL QUALITY CONTROL
TOOLS OF TOTAL QUALITY CONTROL
COST REDUCTION
QUALITY CONTROL IN THE JUTE INDUSTRY
RAW FIBRE DEVELOPMENT
IN-COMING MATERIAL CONTROL
STATISTICAL QUALITY CONTROL
QUALITY CONTROL UNIT
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
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)
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