Detailed Project Report (DPR) on powder enzyme [stone free]

POWDER ENZYME [STONE FREE]

[CODE NO.4369]  

Enzymes have been used in textile processing and finishing since a very long time to get rid of starch-based sizing, but it’s in the past two decades that a serious attention has been given to enzymes for a wide range in textile applications. Jeans which is manufactured from denim fabric is one of the world’s most popular clothing items. The famous “stonewash look” has been traditionally achieved by removing the indigo dye using a local process in which a pumice stone is added to the washing drum for the abrasion of the garment. This stone-washed finish on denim fabric virtually damages the machinery items and also cause a lot of water pollution. The concept of biotechnology in this process can be utilized for the removal of indigo dye from the yarn or fabric surface. The new eco-friendly process which is known as bio-stoning, uses enzymes to wash/bio-stone the denim material. This produces a distressed appearance, without harming any machinery items or the environment. The bio-stoning method has benefitted in cost saving and has also improved the quality of denim.

Denim jeans which are dyed with natural or synthetic indigo, are one of the most popular garments among all the age groups and approximately one billion pairs of jeans are being produced in one year. Traditionally, denim is woven with cotton in twill weave (warp face), in which the warp is blue, and the weft is white. Dyeing of denims is usually performed with pure indigo, or indigo dye mixed with a sulphur dye to decrease the costs which is caused by the expensive indigo dye. Indigo dye is quite popular because it washes down to bright blue shades without staining any of the white weft yarns.

Most of the denim jeans or other denim materials are subjected to a wash treatment to get a slightly worn look. In the traditional stonewashing technique, which is done by pumice stone, the blue denim is faded out by an abrasive action of the stones on the garment surface. This process removes some of the indigo dye. Stonewashing whereas added a whole new dimension to the denim garments in the late 1970s: the process facilitated the artificial ageing of denim fabrics which imparted a fashionably aged look. As the name ‘stonewashing’ suggests, the blue jeans were washed with pumice stones to give a faded look. However, the usage of pumice stones has many limitations, like damage of the machine parts, blockage of the drainage system and difficulty in removal of the residues. Moreover, too much abrasion can damage the fabric, particularly the hems, seams, and waistbands.

The finishing process of denim fabric and garments has been revolutionized by the application of enzymes as an alternative to pumice stonewashing process. Currently the cellulolytic enzymes are applied in textile processes where mechanical action is always present like in jets or rotating drum washers. Cellulase treatment of cotton/denim fabrics is an eco-friendly way of improving their property. It is already recognized that cellulases with strong EG activity is preferred for achieving the worn-out look of denims and this effect is best obtained in machines that provide fast beating action. It is an obvious advantage in letting out pumice stone and the possibility of significantly increasing the capacity of the laundry, that convince people to use biostoning. These advantages are obtained at a lower or similar cost per unit compared to the traditional stonewashing methods.

Cellulase enzymes were introduced in the 80s to assist denim washing to get a faded and abraded look different from what is traditionally provided by pumice stones. Cellulase enzyme fastens the abrasion by a process known as ‘bio stone washing’. The use of these enzymes allows the denim garment washing procedure to be carried out under mild conditions without the use of pumice stones and other harsh chemical agents. As a result of this process, different visual effects may also be fused on fabrics. A small amount of enzyme can replace several kgs of pumice stones. It is now feasible to fade a denim fabric to a greater degree without any possibility of damaging the garment. Productivity can also be increased because the laundry machines contain lesser stones and more garments. There is also no sediment in the wastewater so there will be reduced block drains.

Enzymes are proteins in which amino acids are linked to each other through peptide bonds in a particular sequence. Enzymes are universally present in all living systems either in animals or plants.

Enzyme used for Denim cloth and garment washing prevalent in the market is of SWGR cognis/ Hankel compouny.

Enzyme for Denim washing is gaining immense eminence is modern times which is water soluble. The specialty of this Enzyme is that while washing denim pant with it Denim colour does not come on the pocket lining i.e. there is no back staining on the pocket lining of Denim cloth.

COST ESTIMATION

Plant Capacity                             3 Ton/Day

Land & Building (700 sq.mt.)  Rs. 1.02 Cr

Plant & Machinery                      Rs. 22 Lac

Working Capital for 2 Months   Rs. 2.59 Cr

Total Capital Investment            Rs. 3.90 Cr

Rate of Return                              49%

Break Even Point                         38%

• INTRODUCTION
  
• PROPERTIES & CHARACTERISTICS OF ENZYME
• STONE ENZYMES WASH
• IN STONE WASH, THE FOLLOWING POINTS SHOULD BE 
•   CAREFULLY CHECKED:
• A) SIZE OF THE STONES:
• B) GARMENT-STONE RATIO:
• YOU MAY ALSO LIKE: STONE WASHING PROCESS OF DENIM FABRIC
• C) WASHING TIME:
• D) QUANTITY OF THE BLEACH:
• OBJECTS OF STONE ENZYME WASH:
• PROCESS OF STONE ENZYME WASH:
• FIRST STEP: PRETREATMENT/DESIZING
• SECOND STEP: HOT WASH
• THIRD STEP: ENZYME STONE WASHING
• YOU MAY ALSO LIKE: STONE WASH PROCESS OF GARMENT STONEWASH WITH CHLORINE
• FOURTH STEP: BLEACHING
• FIFTH STEP: NEUTRAL WASH
• SIXTH STEP: SOFT WASH
• SEVENTH STEP: HYDRO-EXTRACTOR MACHINE
• EIGHTH STEP: DRYING MACHINE
• B.I.S. SPECIFICATION
• OVERVIEW OF TEXTILE AND GARMENT INDUSTRY IN BANGLADESH
• CURRENT SCENARIO OF DENIM MARKET OF BANGLADESH
• TOP FOREIGN DENIM BUYER OF BANGLADESH
• SWOT ANALYSIS OF DENIM SECTOR OF BANGLADESH
• STRENGTH OF BANGLADESH DENIM INDUSTRY
• WEAKNESS OF BANGLADESH DENIM INDUSTRY
• OPPORTUNITIES OF BANGLADESH DENIM INDUSTRY:
• THREATS OF BANGLADESH DENIM INDUSTRY
• TEXTILE ENZYMES MARKET
• GLOBAL TEXTILE ENZYMES MARKET SEGMENTATION ANALYSIS
• TEXTILE ENZYMES MARKET, BY TYPE
• TEXTILE ENZYMES MARKET, BY APPLICATION
• TEXTILE ENZYMES MARKET, BY GEOGRAPHY
• KEY PLAYERS
• PRESENT MANUFACTURE OF STONE FREE ENZYMES
• INDUSTRIAL APPLICATIONS OF ENZYMES IN TEXTILES
• TEXTILES PROCESSING
• STONEWASHED JEANS WITHOUT STONES
• YARN TREATMENT
• RAW MATERIALS DETAILS
• PROTEOLYTIC ENZYMES
• ANIONIC SURFACTANTS
• SODIUM LAURYL SULPHATE
• OTHERS IN THIS GROUP ARE:-
• NON-IONIC SURFACTANT
• SESQUESTRANT
• SODIUM SESQUISILICATE
• ENZYMES CLASSIFICATION FOR TEXTILE PROCESSING
• HYDROLASES
• AMYLASES
• PECTINASES
• PECTIN ESTERASES:
• POLYGALACTURONASES:
• PECTIN LYASES:
• PROTEASES
• LIPASES/ESTERASES
• OXIDOREDUCTASES
• PEROXIDASE/GLUCOSE OXIDASE
• FORMULATION OF POWDER ENZYMES [STONE FREE]
• MANUFACTURING PROCESS OF POWDER ENZYMES (STONE FREE)
• PROCESS FLOW DIAGRAM
• FORMULATION OF ENZYMES USED FOR DENIM CLOTH AND GARMENT WASHING (POWDER FORM)
• PROCESS FLOW DIAGRAM
• PRINCIPLES OF PLANT LAYOUT
• STORAGE LAYOUT:
• EQUIPMENT LAYOUT:
• SAFETY:
• PLANT EXPANSION:
• FLOOR SPACE:
• UTILITIES SERVICING:
• BUILDING:
• MATERIAL-HANDLING EQUIPMENT:
• RAILROADS AND ROADS:
• 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:
• SPECIFIC FACTORS
• 6. TRANSPORTATION:
• A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
• 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. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• ADDRESSES OF RAW MATERIAL SUPPLIERS
• SUPPLIERS OF ALKALINE PROTEASES
• SUPPLIERS OF ACETAMIDE
• SUPPLIERS OF SODIUM LAURYL SULPHATE
• SUPPLIERS OF SEQUESTRANT
• SUPPLIERS OF SODIUM SILICATE
• SUPPLIERS OF SODIUM SULPHATE
• ADDRESSES OF PLANT AND MACHINERY
• SUPPLIERS OF PULVERISER
• SUPPLIERS OF MIXERS
• SUPPLIERS OF STORAGE TANKS
• SUPPLIERS OF VIBRATORY SCREEN
• RAW MATERIALS CALCULATION/MONTH

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)