TextileScreen  Printing
Q		quality and Standards	No standard available for Textile Printing
Uploaded on	August 2007

Introduction

Textile printing refers to the production of designs of any kind that could not be made on textile fabrics by normal weaving/knitting techniques. Before the printing process, the cloth should be thoroughly prepared by different wet process namely designing, scouring and bleaching. Printing is mainly done on finished fabrics, curtain clothes, ladies dress materials, bed sheets, bed covers, fabric for children garments, gents shirts etc. to improve its attractiveness, marketability etc. Screen printing can be done in single colour or in combination of different colours as per end use requirement. Colour combination is an important area by which the appearance of an ordinary fabric can be improved to a maximum extent. It is, therefore, necessary that the quality printing material, chemicals and printing screen should be good so that printed items are fully accepted in the market.

Market Potential

With regard to marketability of the product in general, printed items have good market potential both in domestic and export market. In populated country like India, there is no problem of marketing printed fabrics as the requirement tends to increase and also these items will satisfy individual customer's needs and requirements in terms of colour combination, design requirements etc.

Basis and Presumptions

This project is based on single shift basis and 300 working days in a year and time period for achieving maximum capacity utilisation is considered from 3rd year from the date on which production is started. The Building is of own . The costs of machinery and equipment/material indicated refer to a particular make and approximate to those prevailing at the time of preparation of this project. The cost of installation and electrification is taken @ 10% of cost of machinery and equipment. Nonrefundable deposits, project report cost, trial production, security deposit with State Electricity Board are taken under pre-operative expenses.
Depreciation has been considered at 10% on plant and machinery, 20% on office furniture. Interest rate on capital loan has been considered as 13% p er annum.

Implementation Schedule

The implementation period for executing different types of work right from selection of site/working shed and forming of company to selection of market channel and miscellaneous work will take a total period of 5 months. However, on considering that some of the activities may be overlapping, the actual project implementation may hardly take 3 months.

Technical Aspects

Process of Manufacture

The various steps involved in printing process are preparation of printing paste, printing of fabric, fixation of dye stuff by curing/steaming, washing off, calendering, folding and packing. Scoured and bleached cotton fabric as obtained from dealers is inspected to remove any objectionable faults and stretched evenly on printing table. Screens containing the designs is placed over the table and the dye paste is pressed over the screen by means of rubber squeezer. The selection of dyes and gums depends on the construction of basic cloth to be printed and their end use. After printing, the printed clothes are cured or steamed for the fixation of the colour. Later, the printed material is thoroughly washed to remove loose dye stuffs. Then, it is calendered, folded and packed for the delivery.

Quality Control and Standards

A quality printed item should have good fastness to washing, rubbing and light. This can be achieved by properly fixing the print on the cloth by curing or steaming. Dyes to be used should be of good quality and capable of giving bright shades. Printing quality is not covered by any specifications.

Production Capacity (per annum)

Product	Qty. (Nos.)
Printed Sarees (Pcs.)	25,000
Printed fabric (Mts.)	12,500
Total	150000

Motive Power

Most of the processes in printing are carried by manual operations as such the requirement of power will be only for running the washing machine, drying heater, fans and lightings. Therefore, 13 HP power will be required to run the unit.

Pollution Control

Textile printing does not necessarily produce sufficient effluents (except washing section) so as to create pollution problems. However, a no objection certificate from the State Pollution Control Board is required before setting up of the project.

Energy Conservation

Wastage of energy should be minimised as much as possible so that the unit can withstand competition with similar unit.

Financial Aspects

Fixed Capital

Land and Building
Land 400sq.mt. @ Rs. 3000p.s.m. Amounting Rs 1200000.00
Building Area
Factory shed	200 sq. mt.
Store (Raw material)	50 sq. mt.
Store (Finished goods)	50 sq. mt.
Office etc.	25 sq. mt.
Total Covered Area	325 sq. mt.
Total Construction Cost @ Rs. 4000/sq.mt.	1300000
Total Investment in land and Building	2500000

Machinery and Equipments

Description	No.	Rate (Rs.)	Amount (Rs.)
Printing Table with AC Top 20'×15'×3'	1	20000	80000
Rubber squeezers 30 cms.	15	500	7500
Cottage steamer	1	75000	75000
Open width jigger	1	150000	150000
Cylinder drying machine	1	300000	300000
Baby boiler	1	160000	160000
Wash room trolleys	3	9000	27000
Dye paste stirrer	3	3000	9000
Weighing balance (Dial model)	1	35000	35000
Water Storage Tank, Bore well		100000	100000
Total			943500

Other Fixed Assets	(Rs.)
Erection and installation	40000
Office furniture	80000
Pre-operative expenses	30000
Total	150000
Total Fixed Capital	3593500

Working Capital (per month)

Staff and Labour Wages

Designation	Nos.	Salary (Rs.)	Amount (Rs.)
Manager	1	16000	16000
Accountant/Casher	1	6000	6000
Store-keeper	8	4000	4000
Peon	6	3000	3000
Watchman	1	3500	3500
Total			32500
Production Staff	1	4000	4000
Skilled workers	8	5000	40000
Artist-cum-stencil maker	1	7000	7000
Total			96500
Production Staff	1	4000	4000
Pre-requisite 20%			19300
Pre-requisite 20%			19300
G. Total			115800

Raw Material

Description	Unit	Rate/ Unit (Rs.)	Amount (Rs.)
Mull Mull cloth bleached 5.5 mtr.×130cm. (mts.)	11460	25	286500
Dyes (Kgs.)	13	180	2340
Gums (Kgs.)	46	25	1150
Chemical and Auxiliaries	LS		8000
Thickener (Kgs.) Thickener (Kgs.)	50	18	900
Total			298890

Utilities	(Rs.)
Electricity	7500
Coal and fire wood	2000
Total	9500

Other Contingent Expenses (per month)	(Rs.)
Postage/stationery	1000
Repair and replacement	2000
Transport/travelling charges	5000
Insurance	300
Miscellaneous expenses	3000
Screens	5000
Total	16300

Total Recurring Expenses (per month)	440490
Total Working Capital for 2 months	880980

Total Capital Investment

Land , Machinery and equipment	3593500
Working capital for 2 months	880980
Total	4474480

Machinery Utilisation

Capacity utilisation is considered as 75% of installed capacity as the utilisation mainly depends on the skill of the labour force employed.

Financial Analysis

Cost of Production (per year)	(Rs.)
Recurring expenses	5285880
Depreciation on Building @ 5 %	125000
Depreciation on machinery @ 10%	94350
Depreciation on office furniture @ 20%	16000
Interest on total investment @ 13 %	581682.4
Total	6102912.4

Turnover (per year) (Sales)

Turnover (per year) (Sales)	Turnover (per year) (Sales)	Rate (Rs.)	Amount (Rs.)
Sarees	25000	220	5500000
Printed fabric (mts.) (on job work)	12500	78	975000
Total			6475000

Net Profit (per year)	372087.6
Net Profit Ratio (Net profit/Turnover per year)	5.75
Rate of Return on Investment (Net profit/Total Capital Investment)	8.32

Break-even Point

Fixed Cost	(Rs.)
Depreciation	235350
Interest on capital investment	581682.4
40% of wages of staff and labour	555840
40% of other contingent expenses	76800
Insurance	3600
Total	1453272

B.E.P.

FC ×100 --------------- FC+Profit = 79.62%