Cotton Knitted Undergarments (Briefs, Panties, Vests)

Introduction

This project profile is for the setting up of unit for the manufacture of cotton undergarments such as vests, briefs and panties. Knitted undergarments are used and liked by the people because of its good drapability, stretchability, softness and absorbency of sweat characteristics. In this report, guidelines for setting up of unit for the manufacture of gents briefs, vests, ladies panties are given. Machinery and raw material required to set up this industry are indigenously available.

Market Potential

Hosiery industry is an ancient industry in the field of textile industry having very good potential in domestic market and also in the export market. There is increasing market demand for hosiery undergarments for its various advantages. Cotton undergarments are widely used by all classes of people because of its good absorbency, cheaper prices and ready availability. These foundation garments are used by the people throughout the year under different climatic conditions. It is presumed that there will be no problem in marketing of knitted undergarments of good quality.

Basis and Presumptions

This project is based on single shift basis with 8 hours and 300 working days in a year. The unit is proposed to be started in own building. Costs of machinery, equipment, raw material indicated in this report refer to a particular make and approximately to those prevailing at the time of preparation of this project and it is presumed that these rates are likely to vary from supplier to supplier and place to place. Cost of installation and electrification of plant and machinery is taken @ 10% of its cost.

Non-refundable deposits, project report cost, trial production cost, security deposit with Electricity Board are taken under pre-operative expenses. Depreciation has been considered at 5% on building, 10% on plant and machinery, 15% on furniture and 15% on workshop accessories. Interest rate for the loan has been considered at 14% per annum.

Implementation Schedule

Time period required for executing the project from preparation of project report to starting the trial run production will be 7 months period approximately. Considering that some of the many activities may be overlapping, the project implementation will take a total period of five months approximately for starting the actual production.

Technical Aspects
Process of Manufacture

The manufacturing process involves the following steps :

1. Procurement of Knitted Fabric

Dyed/bleached cotton knitted fabrics are to be procured from the open market. The fabric will be inspected by laying the fabric on the inspection table against light before cutting so that unevenness in colour/shades or any other fault if any visible in the fabric can be eliminated.

2. Cutting and Stitching

The inspected fabric is placed on the cutting table in layers and then the different parts of the respective garments are demarked by a chalk as per different sizes. Cutting of fabric layer is carried out by fabric cutting machine in order to have accurate dimensions.

Stitching of whole garment is carried out by the skilled workers with the help of overlock, sewing machines etc.

3. Washing, Checking, Pressing and Packing

Garments obtained from the sewing section will normally have some dirt/ stains which are to be eliminated by treating them with mild soap solution in garment washing machine. Excess water is to be removed from the garments by charging in hydro-extractor and dried in garments drying tumbler.

Final checking is done by placing individual pieces on the checking table so that any fault and protruding thread in the piece may be removed. The individual pieces are pressed by pressing man to remove the wrinkle marks in the piece and packed in the paper board boxes specifically available for the purpose.

Quality Control and Standards

Necessary quality checking must be followed in each stage of manufacturing process in order to maintain the quality. BIS standards applicable for undergarments are given below:

Production Capacity (per annum)

Motive Power

Total power of 22 HP is required to run this unit with proposed installed capacity. The above requirement of power is proposed to be obtained from State Electricity Board.

Pollution Control

Although not required, entrepreneurs are to contact State Pollution Control Board as a precautionary measure.

Energy Conservation

Wastage of energy should be minimised by proper house-keeping methods in order to keep the unit more competitive in the market.

Financial Aspects
A. Fixed Capital

(ii) Machinery and Equipments

B. Working Capital (per month)
(i) Staff and Labour Wages

(ii) Raw Material

Machinery Utilization

Capacity utilisation of plant and machinery is considered as 70% of installed capacity. However, this can be improved to 80% during 3rd year of production.

Financial Analysis

(2) Turnover (per year) by Sales

(6) Break-even Point

Addresses of Machinery and Equipment Suppliers

1. M/s. Paras Special Machine Co.
Madhopur Kucha No. 7,
Rohan Road, Ludhiana.

2. M/s. Vijay Sewing (P) Ltd.
17-D, Everest House, 46-C,
Chowringhee Road, Kolkata.

3. M/s. Industrial Machines Pvt. Ltd.
1/23 B, Asaf Ali Road,
New Delhi-110002.

4. M/s. Apparel and Leather Techniques Pvt. Ltd.
Kaikondanahalli,
Sarjapur Road,
Near Bellaandur Gate,
Bangalore-560035.

5. M/s. Industrial Sewing Systems
30, Ramakrishna Street,
North Usman Road,
T. Nagar, Chennai.

Raw Material Suppliers

1. M/s. Vardhman Threads, Mahavir Spinning Mills Ltd.
Chandigarh Road,
Ludhiana-141001.

2. M/s. Powerloom Cloth Manufacturing Centre Erode, Bhiwandi, Mumbai, Surat etc.

Contact for more information:

Information Manager
TIMEIS Project
E-mail: timeis@ficci.com