Detailed Project Report (DPR) on polyester yarn texturing, circular knitting and dyeing of knitted fabric

Industry Overview

India is one of the largest producers and exporters of polyester yarn, and the textile industry has made a significant contribution to the country's economic growth. Polyester yarn is widely used across textile, garment, home furnishing, and industrial applications because of its versatility and specialized performance characteristics.

Polyester originated from early polymer research conducted in W.H. Carothers' laboratory. Although development was initially overshadowed by nylon, British scientists J.R. Whinfield, J.T. Dickson, W.K. Birtwhistle, and C.G. Ritchie continued the work and developed the first polyester fibre, Terylene, in 1941. In 1946, DuPont acquired the legal rights and developed another polyester fibre known as Dacron.

Modern polyester is available in a wide range of forms, including conventional and luxury fibres such as polyester microfibres. Polyester is defined as a long-chain polymer chemically composed of at least 85 percent by weight of an ester and a di-hydric alcohol and a terephthalic acid. Polyester fibres are formed through linkages of monomers, with esters produced when alcohol reacts with carboxylic acid.

Cost Estimation

Content Index

• 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

• 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

Frequently Asked Questions