POLYESTER YARN TEXTURING, CIRCULAR KNITTING AND DYEING OF KNITTED FABRIC

[CODE NO.3956]

India is the largest producers and exporters of Polyester Yarn which has contributed a significant change in Indian economy growth. There are many textiles and garment manufacturing industries which have excelled in providing superior quality of materials. Hardik Textiles are one of the best Polyester Yarn Manufacturers in India which provides finest quality of yarn products in diverse requirements for the customers.

The textile industry in India is varied and extremely used in various applications according to different products and its specialized features.

Polyester began as a group of polymers in W.H. Carothers’ laboratory. Carothers was working for DuPoint at the time when he discovered that alcohols and carboxyl acids could be successfully combined to form fibers. Polyester was put on the back burner, however, once Carothers discovered nylon. A group of British scientists J.R. Whinfield. J.T. Dickson, W.K. Birtwhistle and C.G. Ritchie took up Carothers’ work in 1939. In 1941 they created the first polyester fiber called Terylene. In 1946 DuPont bouth all legal rights from the Brits and came up with another polyester fiber which they named Dacron.

Today, polyester is still widely regarded as a “cheap, uncomfortable” fiber, but even now this image is slowly beginning to change with the emergence of polyester luxury fibers such as polyester micro fiber.

Polyester is currently defined as Long chain polymers chemically composed of at least 85 percent by weight of an ester and a di-hydric alcohol and a terephthalic acid. The name polyester refers to the linkage of several monomers (esters) within the fiber. Esters are formed when alcohol reacts with a carboxylic acid.

COST ESTIMATION

Plant Capacity : 8 Ton/day

Land & Building (500 Sq.MT) : Rs. 3.40 Cr

Plant & Machinery : Rs. 6.50 Cr

Working Capital for 2 Month : Rs. 4.91 Cr

Total Capital Investment : Rs. 14.97 Cr

Rate of Return : 40%

Break Even Point : 44%

INTRODUCTION

BLENDS

THE RANGE TAKES ACCOUNT OF THE FOLLOWING:

PROPERTIES OF POLYESTER

CLASSIFICATION OF TEXTURED YARN

1. STRETCH YARNS:

2. MODIFIED STRETCH YARNS:

3. BULK YARN:

POLYESTER TEXTURED YARN

TEXTURING AND ITS PRINCIPLE

TEXTURING:

OBJECT:

PRINCIPLE OF TEXTURING

TEXTURED YARNS EXHIBIT THE FOLLOWING ADVANTAGE

AND DISADVANTAGE PROPERTIES:

ADVANTAGES:

DISADVANTAGES:

POLYESTER TEXTURED YARN SPECIFICATION

1. SCOPE

2. REFERENCES

3. TERMINOLOGY

4. REQUIREMENTS OF PTY

TABLE-4.1: CONSTRUCTIONAL & PERFORMANCE REQUIREMENTS OF PTY

TABLE-4.2: REQUIREMENTS OF BRIGHTNESS OF PTY

5. SAMPLING AND CRITERIA FOR CONFORMITY

TABLE 5.1 SAMPLE SIZE

TYPES OF YARN

FILAMENT VS STAPLE FIBRE

MARKET SCENARIO OF KNITTED FABRIC

INITIATIVES TAKEN BY GOVERNMENT OF INDIA ARE:

FOLLOWING ARE THE ACHIEVEMENTS OF THE GOVERNMENT IN

THE PAST FOUR YEARS:

THE KEY DRIVERS OF THE KNITTED FABRICS MARKET INCLUDE:

GROWTH IN THE APPAREL MANUFACTURING INDUSTRY

THE KEY RESTRAINTS ON THE KNITTED FABRICS MARKET INCLUDE:

RISE IN COTTON PRICES

MAJOR TRENDS INFLUENCING THE KNITTED FABRICS MARKET INCLUDE:

ECO-FRIENDLY FABRICS

OPPORTUNITIES AND RECOMMENDATIONS IN THE KNITTED

FABRICS MARKET

KNITTED FABRICS MARKET SEGMENTATION

BY GEOGRAPHY- THE KNITTED FABRICS MARKET IS SEGMENTED INTO

KNITTED FABRICS COMPETITIVE LANDSCAPE

MAJOR COMPETITORS ARE:

OTHER COMPETITORS INCLUDE:

MARKET OF TEXTILE INDUSTRY IN INDIA

OVERVIEW OF TEXTILE INDUSTRY IN INDIA

SOME OF THE MAJOR INVESTMENTS IN THE INDIAN TEXTILES

INDUSTRY ARE AS FOLLOWS:

INITIATIVE WILL BE TAKEN INTO CONSIDERATION BY GOVERNMENT

OF INDIA.

GLOBAL KNITTED FABRIC MARKET

MANUFACTURERS/SUPPLIERS OF YARNS

TYPES OF YARN PRODUCTION

FILAMENT

FIGURE: FILAMENT YARNS

STAPLE

FIGURE: STAPLE YARNS

DETAILS OF POLYESTER YARN

AVAILABILITY

POLYESTER YARN FOR TEXTILES

POLYESTER YARN FOR HOME FURNSHING

POLYESTER YARN FOR INDUSTRIAL USE

POLYESTER FDY

FDY PRODUCT FEATURES AND USES

PRODUCT FEATURES AND USES

POLYESTER TEXTURED YARN 68

POLYSTER TEXTURED YARN FEATTURES AND USES

PARTIALLY ORIENTED YARN (POY) AND FULLY ORIENTED YARN (FOY)

METHOD OF TEXTURIZATION

TEXTURED YARNS CAN BE PRODUCED BY FOLLOWING METHODS:

FALSE-TWIST COILING METHOD

STUFFER-BOX CRIMPING METHOD

AIR-JET TEXTURING METHOD

KNIT-DE-KNIT CRINKLING METHOD

GEAR CRIMPING METHOD

INTERMINGLING

OBJECTS:

WAYS OF INTERMINGLING:

HEAT SETTING

OBJECTS OF HEAT SETTING

DISADVANTAGES OF HEAT SETTING

SPIN FINISH

DYEING OF KNIT FABRIC

PRETREATMENT:

RECIPE:

PROCEDURE:

TWO BATH TWO STAGES DYEING

STAGE 1: POLYESTER PART DYEING WITH DISPERSE DYES (HIGH TEMP,

HIGH PRESSURE)

RECIPE:

PROCEDURE:

CARBONIZING:

REDUCTION CLEARING:

RECIPE:

PROCEDURE:

PROCESS CURVE (POLYESTER PART DYEING WITH DISPERSE DYES)

STAGE 2: COTTON PART DYEING WITH REACTIVE DYES

RECIPE:

PROCEDURE:

DYEING OF POLYESTER FABRIC WITH DISPERSES

DYE (CARRIER METHOD)

CARRIERS:

MECHANISM OF CARRIER ACTION:

RECIPE:

DYEING CURVE:

PROCEDURE:

AFTER TREATMENT:

PROPERTIES OF DISPERSE DYES

DISPERSE DYES AND ITS CLASSIFICATION

DISPERSE DYES

CLASSIFICATION

AZO DISPERSE DYES

GENERAL STRUCTURE OF AMINOAZOBENZENE DYES.

SOME TYPICAL AZO DISPERSE DYE STRUCTURES.

ANTHRAQUINONE DISPERSE DYES

ANTHRAQUINONE SYSTEMS OF BASIC FORMULA ; 9,10-ANTHRAQUINONE.

COMMERCIAL ANTHRAQUINONE DISPERSE DYES.

OTHER DISPERSE DYE CLASSES

MANUFACTURING PROCESS OF YARN TEXTURISING

METHOD OF DISPERSE DYEING

BASIC PRINCIPLE

DISPERSE DYEING MECHANISM

THE FOUR STAGES OF THE PROCESS MECHANISM ARE AS FOLLOWS:

THE EFFECTS OF VARIATIONS IN DISPERSE DYEING

CRYSTAL FORM OF THE DISPERSE DYES

DISPERSING AGENT

PARTICLE SIZE IN DISPERSION OF THE DYES

PH OF DYEBATH

SUBSTANTIVITY OF DISPERSE DYES

TEMPERATURE

FIBRE FINENESS

MAIN METHODS OF DISPERSE DYEING

CARRIER DYEING

HIGH TEMPERATURE DYEING

ADSORPTION PHASE

PHASES OF EXHAUST DYEING OF POLYESTER.

DIFFUSION PHASE

CLEARING PHASE

CHEMICAL REACTION DURING REDUCTION CLEARING

POLYESTER DYEING RECIPE

PROCESS FLOW DIAGRAM

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:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF AIR COMPRESSORS

APPENDIX – A:

1. COST OF PLANT ECONOMICS

2. LAND & BUILDING

3. PLANT AND MACHINERY

4. FIXED CAPITAL INVESTMENT

5. RAW MATERIAL

6. SALARY AND WAGES

7. UTILITIES AND OVERHEADS

8. TOTAL WORKING CAPITAL

9. COST OF PRODUCTION

10. PROFITABILITY ANALYSIS

11. BREAK EVEN POINT

12. RESOURCES OF FINANCE

13. INTEREST CHART

14. DEPRECIATION CHART

15. CASH FLOW STATEMENT

16. PROJECTED BALANCE SHEET

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