Cotton Yarn Dyeing

Introduction

The art of dyeing is a branch of applied chemistry in which a use of both physical and chemical principle is made in order to bring about a permanent Union between the dyes and the textile material. For dyeing the cotton yarn in various shades, the art lies in colouring the textiles in such a manner that the colour may be fast or may not ordinarily be removed by such operations as working, rubbing, sunlight etc. to which the textiles are usually subjected. The dyeing can only take place when the dyeing is in solution/or finely divided or dispersed condition and the fibres are subjected to this dye in solution condition and then this dye being rendered insoluble or fixed by same means. There must exist same marked physico-chemical affinity between the fibres and the dye, which would naturally depend upon the respective properties of both. The dyed cotton yarn is used in the following fields.

1. Ready-made garments
2. Hosiery industries
3. Bag closing industry
4. Sports goods
5. Umbrella and carpet making
6. Book binding
7. Handloom textiles
8. Furnishing textiles

Market Potential

Despite the marked inroads of synthetic fibres into the textile industry, cotton continues as a major textile fibre. At present, cotton constitutes 78 percent of the total fibre consumed by the textile industries. There is demand for cotton dyeing units as the consumption of cotton textiles has increased. The proposed purchase grey yarn from the mills and can be dyed and sold in the market. There is also possibility to take up the job work from the mills and dye the yarn on as per their requirement. Since there are large number of textile mills in Maharashtra state there would not be any problem in getting sufficient work for such type of units. Besides this there is good scope for exporting the dyed yarn to foreign countries.

Basis and Presumptions

1. The project profile has been prepared on the basis of single shift of 8 hours each day, 25 days in a month and at 75% efficiency.

2. It is presumed that in the 1st year the capacity utilisation will be 70% followed by 85% in the next year and 100% in the subsequent years.

3. The rates quoted in respect of salaries and wages for skilled workers and others are the minimum rates in the State/ neighbouring states.

4. Interest rate for fixed and working capital has been taken @ 14% on an average, whether financed by bankers or by financial corporation.

5. Margin money required is minimum 30% of the projected investment.

6. Pay Back period of the project : After the initial gestation period of one and a half years, it will require 5 years to pay back the loans.

7. The building/workshed is considered of its own

8. The rates quoted in respect of machines, equipment and raw materials are those prevailing at the time of preparation of this project profile, and are likely to vary from supplier to supplier and place to place. When a tailor made project profile is prepared necessary changes are to be made.

9. Working capital for 2 months has been taken into consideration for smooth running of the project.

Implementation Schedule

Technical Aspects
Process of Manufacture

The most popularly used colours for cotton dyeing are Aurammic G. victoria blue, brilliant green crystals, rhodamine yellow G, rhodamine dye blue, melachite green etc. The class of dye used depends on the end use, colour and shade required, quality desired and the process adopted. However direct, reactive and mordant dyes are the most common classes of dyes used in the industry. The grey yarn which may be in the form of hand or solution to penetrate in the yarn. These soft cheeses are creeled on to stand and then loaded in to the machine chamber. Then the dye bath is prepared containing the requisite amount of dyestuff and other chemicals like alum, soda etc. The yarn packages are subjected to high temperature high pressure dyeing for 30 minutes to 1½ hour. The packages are removed from the chamber, excess dye solution is washed and finally dried. The different methods practiced in the industry are given below:

Quality Control and Standards

The cotton yarn is dyed as per the requirements of the owner. The quality of the dyeing depends on the class of dye, process, method and the condition of the machines used and also on the hardness of the water used. If the water is hard it is to be treated using salt which will dissolve the Calcium and Magnesium salt present in the water. The following BIS specifications are available.

1. IS 1670 : 1970
2. IS 1671 : 1977
3. IS 8014 : 1983

Production Capacity (per annum)

Motive Power

A total of 50 kW or 70 HP power is required to run at full capacity and this can be drawn from state electricity boards.

Pollution Control

In the textile dyeing industry, considerable amount of polluted water is discharged from which harmful chemicals should be neutralised before leaving them into the drainage system. The use of various toxic chemicals and chemical based dyes may be avoided/reduced. The units should not use rice-husk and rubberised material as a fuel in dyeing unit. The smoke of this is very harmful for the human beings. This type of unit should only be started in an area where the common effluent plant facilities are available or the unit installed this type of facilities in the unit's premises to avoid any health hazards.

Energy Conservation

Another important international aspect of the recent period is energy conservation. The energy conservation will make the industries to reduce their production costs and thereby stay more competitive in the market. This matter should be the concern of every person involved in the day to day operations of any industry. Idle running of various machines, heaters, boilers, lights, fans, air conditioners etc. Should be completely avoided. Suitable capacitors and energy saving devices should be incorporated wherever possible to minimise the wastage of energy. Steam should not be wasted and sufficient insulation should be provided to the dye chamber.

Financial Aspects
A. Fixed Capital

(ii) Machinery and Equipments

B. Working Capital (per month)
(i) Salaries and Wages

(ii) Raw Materials

C. Total Capital Investment

Financial Aspects

(6) Break Even Point

Addresses of Machinery Suppliers

1. M/s. Baltex Engineering Pvt. Ltd.
13th Floor, Jolly Maker Chambers
No. II, Nariman Point,
Mumbai-400021

2. M/s. Paramount Instruments P. Ltd.
B-3/45, Paschim Vihar,
New Delhi-110063

3. M/s. Erhardt Leimer India Ltd.
43, Dr. V. B. Gandhi Road,
Mumbai-400023

4. M/s. Eastern Engineering Co.
Jeevan Udyog, II Floor, 278,
Dr. D. N. Road, Fort,
Mumbai

5. M/s. Srirang Equipment Company
472, Kamarajar Road,
Coimbatore-641004

6. M/s. Ludhiana Dyeing Machinery Work
Link Road, Ludhiana

7. M/s. Kiran Dyeing Machinery Works
Partap Nagar,
Ludhiana

8. M/s. Electronic and Engineering Co.
EEC House, Plot No. C-7,
Dalia Estate, Andheri (E),
Mumbai-400058

9. M/s. Venkatapathy Foundry
445, Kamarajar Road,
Peelamedu,
Coimbatore-641004

Raw Material Suppliers

1. M/s. ABC Dyes and Chemicals
2282, Gali Hinga Beg, Tilak Bazar,
Delhi-110006

2. M/s. Basf India Ltd.
No. 7, Basant Lok, Vasant Vihar,
New Delhi-110052

3. M/s. Arora Tex Dyes Corporation
Plot No. 108, Sector-24,
Faridabad-110005 (Haryana)

4. M/s. Indokem Ltd.
3/4, Asaf Ali Road
New Delhi-110002

5. M/s. Andhra Sugars Ltd.
Venkatrayapuram, P. O. No. 2
Tanuku-534211 (AP)

6. M/s. Sarocevan Dyes Mfr. Co.
Industrial Area ‘A”,
Ludhiana

7. M/s. Rashmi Dyes and Chemicals
Focal Point,
Ludhiana

Contact for more information:

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