Detailed Project Report (DPR) on yarn dyeing

YARN DYEING [CODE NO.3512]  


The fact that dyes in solution in the dye bath leave the bath and are sobned by the fibre/yarn material during the dyeing process has been of interest to chemist and physicists for many years.   Theories  of  dyeing  the  describe  the  Sorption   (or desorption) process and the resulting dye-fiber bonds using the tools of thermodynamics have increased in  complexity  over  the year. Further more, it must be recognized that the dyeing process in dynamic in nature. It normally entails changes in the dyeing temperature the dye concentration the bath composition  and  the fiber structure.

Affinity and diffusion are fundamental aspect of the dyeing process. The former describes the force by which the dye is attracted by the fiber and the latter describes the speed with which it travels within the fiber/yarn a from areas  of  higher concentration to areas of lower concentration. Alone or together with fiber characteristics, affinity and diffusion determine the speed of dyeing, its temperature  dependency,  the  equilibrium exhaustion of the dye, and some of its fastness properties.

Two fundamental dyeing processes have been distinguished, the  nonionic and the ionic dyeing  process.  The former refers to the dyeing of synthetic fibers  such   as polyester, nylon and triocetate by disperse dye.


COST ESTIMATION

Plant Capacity                                           4.00 MT/day       
Land & Building (3000 sq.mt)                Rs. 2.01 Cr
Plant & Machinery                                     Rs. 2.50 Cr
Working Capital for 1 Month                   Rs. 2.38 Cr
Total Capital Investment                         Rs. 7.04 Cr
Rate of Return                                          22%
Break Even Point                                      61%


INTRODUCTION    
PROPERTIES OF POLYESTER FIBRES    
PHYSICAL PROPERTIES    
CHEMICAL PROPERTIES    
PROPERTIES OF DISPERSE DYES    
DISPERSE DYES AND ITS CLASSIFICATION    
DISPERSE DYES    
CLASSIFICATION    
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    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
MARKET SURVEY    
MARKET SIZE    
INVESTMENT    
SOME OF THE MAJOR INVESTMENTS IN THE INDIAN TEXTILES
   INDUSTRY ARE AS FOLLOWS:    
GOVERNMENT INITIATIVES    
INITIATIVE WILL BE TAKEN INTO CONSIDERATION BY GOVERNMENT
    OF INDIA.    
SOME OF INITIATIVES TAKEN BY THE GOVERNMENT TO FURTHER
    PROMOTE THE INDUSTRY ARE AS UNDER:    
TEXTILES EXPORT    
THE BREAK-UP OF OUR CURRENT EXPORTS ARE AS FOLLOWS:    
PROJECTIONS FOR INDIA IN WORLD EXPORTS    
PROJECTIONS FOR DOMESTIC TEXTILES INDUSTRY    
MARKET POSTION OF TEXTILE YARN    
MAJOR PLAYERS IN TEXTILE INDUSTRY    
MAJOR PLAYERS IN THE INDUSTRY    
PROFILE OF MAJOR PLAYERS IN INDIA    
WELSPUN INDIA LTD.    
VARDHMAN GROUP    
PRODUCTS    
MANUFACTURERS/SUPPLIERS OF YARN DYEING (DYED YARNS)    
DYES USED IN POLYESTER YARN DYEING    
FASTNESS PROPERTIES:-    
PROCESS OUTLINE FOR YARN DYEING   
SOFT WINDING    
BATCHING    
DYEING    
HYDROEXTRACTOR    
DRYER    
PACKAGING    
PROCESS FLOW DIAGRAM    
PROCESS OF MANUFACTURE    
OF POLYESTER YARN DYEING    
PREPARATION FOR DYEING OF POLYESTER YARN    
PROCESSING DETAILS AND MECHANISM OF POLYESTER DYEING    
EFFECT OF VARIOUS CONDITIONS ON DISPERSE DYEING:    
EFFECT OF TEMPERATURE:    
EFFECT OF PH:    
CARRIER DYEING METHOD:    
PROCEDURE:    
HIGH TEMPERATURE DYEING METHOD:    
PROCEDURE:    
METHED 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    
STAGES AND PARAMETERS IN    
POLYESTER YARN DYEING    
IMPORTANT PARAMETERS IN POLYESTERS YARN DYEING    
SEQUENCES IN POLYESTER YARN DYEING    
PROCESS FLOW DIAGRAM    
METHOD OF NYLON YARN DYEING    
PRETREATMENT & DYEING:    
PROCESS FLOW DIAGRAM    
METHODS FOR DYEING (COTTON YARN DYEING)    
PREPARATION FOR DYEING    
RAW STOCK    
COTTON YARN    
AN EXAMPLE OF SUCH A TREATMENT FOR 100 LB (POUNDS) OF YARN
   IS THE FOLLOWING:    
DYEING MEDIUM    
DETAILS OF DYESTUFF, STORAGE & HANDLING    
DIRECT DYES    
DETAILS OF YARN CONDITIONING    
CONDITIONING PROCESS FOR VARIOUS YARNS:    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT & MACHINERY    
VERTICAL YARN DYEING MACHINE    
SAMPLING DYEING MACHINE    
AIR COMPRESSORS    
HYDRO EXTRACTOR    
BOILERS    

     
        
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