Detailed Project Report (DPR) on pigment binder for textile printing

Pigment printed textiles represent the highest percentage of all printed textiles.  This is primarily due to the uncomplicated process  and low cost of importing colored patterns  to  textiles with pigment system.      The water insoluble pigment used in most cases as an aqueous dispersion, has no affinity to textile fibres and is not able  to enter  into chemical or physical reactions with the  fibre.   For the bonding of pigments to textile a bonding agent generally of a synthetic  latex type, is incorporated in the print paste,  which through  its film forming properties holds the  embedded  pigment firmly or fibre surface. Due  to  the  possibility of fixing,  pigments  to  textiles without  interaction  with  the  fibre  material  this  class  of colorants can be applied to a greater variety of fibres than  any other  coloring  matter this advantage largely accounts  for  the popularity  of pigments in textile printing especially  on  fibre blends. The binding agent or "low crock" is a dispersion or solution of such polymers as poly(acrylic acid) derivatives and butadiene-styrene  copolymers.   In  most cases a crass  linking  agent  is applied  in the same print paste, consisting of  synthetic  rosin types melamine- formaldehyde derivatives for added wash and crock fasteners. Both pigment dispersion and binding agents cross linking are incorporated  into  a  clear  emulse,  or  synthetic   thickening solution.   The  clear  concentration form  which  the  clear is prepared   contains   such  necessary  auxiliary   chemicals   as dispersing   agents   emulsifiers,   acid   dovors,   lubricants, protective  colloid  and  synthetic  thickening  agents  of   the poly(acrylic acid) and maleic acid anhydride copolymer type.  For emulsion clear printing mostly oil in water emulsions are used. Pigment print systems have a number of inherent  limitations most  notably the effect of the binding agent and  cross  linking chemicals  on  the hand and feel of the textile  materials, also sometimes  insufficient fastness to cracking,  abrasion,  washing and  dry  cleaning noticed especially in heavier  shades  and  on large  coverage  and  the  sometimes  objectionable  property  of pigments  to camouflage fiber texture and luster pigments  prints are  fixed  by  heat  treatment at 150-200oC  in  1-5  min  after coursing is generally not necessary. Synthetic lattices may be defined as aqueous dispersions  of polymers  particles  produced by the process  known  as  emulsion polymerization.  Interest in these materials arose initially from the  use  of natural rubber latex and the prospect of  making  by synthetic  means,  a  latex similar to  the  naturally  occurring product. The earliest references to synthetic lattices probably  date back  to pre-1920 with the work originating in Germany.   It  has been  noted by several reviewers that all the essential  elements of  emulsion polymerization were almost certainly  known  before World War 1. During the period 1930-35 emulsion polymerization was  being established  as a method of producing synthetic rubber  lattices.  Considerable  advances were made during World war II  in  Germany and  U.S.A.  when  continuous  processes  for  synthetic   rubber production   were  developed  for  styrene-butadiene  (SBR)   and acrylonitrile-butadiene  copolymers to alleviate the shortage  of natural rubber.  Since then, many other types have come onto  the market  with  polyvinyl  acetate and  copolymers,  acrylics,  and carboxylic - SBR types being the major products. Today,  the annual consumption of synthetic lattices of all types is estimated at about 800 000 dry tonnes for Western Europe and a further 900 000 dry tonnes for U.S.A.

PIGMENTS BINDERS FOR TEXTILE PRINTING (EIRI-0993) 
Cost Estimation
Plant Capacity                                                            5 Ton/Day
Land and Building (Area 1000 sq.mt.)                  Rs. 88 Lacs
Plant & Machinery                                                      Rs. 27 Lacs        
W.C. for 3 Months                                                      Rs. 1.51 Cr.          
Total Capital Investment                                           Rs. 2.73 Cr.             
Rate of Return                                                            64%  
Break Even Point                                                       29%

•    EIRI can modify the Capacity of the Project and Total Capital Investment as per your requirement.
•    Note: The project investment cost and capacity are subject to change without any notice. Future projects may have different values of project cost and capacity.
 

MARKET  SURVEY CUM  DETAILED  TECHNO 
ECONOMIC FEASIBILITY  REPORT covers
 

Introduction
Uses and  Applications
Properties
Market   Survey  with   future   aspects 
Present Manufacturers 
Detailed  Process of  Manufacture 
Formulations
B.I.S. Specifications
Process Flow Sheet Diagram, Plant  Layout,
Cost  Economics  with Profitability Analysis 
Capacity 
Land  & Building  Requirements with Rates
List & Details  of  Plant  and Machinery with their Costs
Raw Materials Details/List and Costs
Power & Water Requirements
Labour/Staff Requirements
Utilities and  Overheads
Total  Capital  Investment
Turnover
Cost  of Production
Break  Even Point
Profitability
Land  Man  Ratio
Suppliers  of  Plant & Machineries and Raw Materials
Cash  Flow Statement
Repayment  Schedule
Interest  Chart
Depreciation Chart
Projected Balance Sheet for 5 Years etc.