PROJECT REPORT

ON

PROCESSING UNIT OF TEXTILE

IN NAME OF

M/S BALAJI PROCESSORS

TO BE SETUP IN

GIDA, GORAKHPUR
TEXTILE DYEING INDUSTRIES IN INDIA

Textile dyeing industries need huge quantity of water for textile dyeing, which they

normally pump out repeatedly from the ground or natural water sources resulting i

n depletion of groundwater level.In the dyeing process textile industries generate

huge quantity of toxic effluent containing colors,sodium sulphate, sodium chloride,

sodium hydroxide and traces of other salts. These aregenerated after dyeing and

after washing of garments / fabrics. After dyeing the waste

water produced is called Dye Bath water and after washing the waste water generat

ed is called washwater. Dye Bath contains higher solids in the range 4-5% whereas

wash water contains only 0.5-1% solids.

Based on the above mentioned fact “SSP” has developed a technology which can

process suchharmful toxic effluent water and transform it into reusable water. Thus

the textile industries willhave the advantage of using the same water in the dying

process repeatedly; also the salt used fordyeing can be reused or sold in the

market.The technology offered by SSP can overcome all problems pertaining to

environmental pollutionin respect to textile dying industries.The basic thrust of the

technology is to convert entire quantity of effluent to zero level byseparating water

and salt using evaporation and separation technology.The concept and the

treatment are based on the removal of the entire COD/BOD and thecondensate

coming out to meet the fresh water quality requirement in the process
TEXTILE BLEACHING, DYEING, PRINTING AND FINISHING,

TEXTILEAUXILIARIES

Textile processing is one of the important industries related with textile

manufacturing operations. Textile processing is a general term that covers right

from singeing (protruding fiber removal) to finishing and printing of fabric. The

various steps a fabric goes into are singeing,

desizing, bleaching, dyeing, and finishing. Bleaching is a process

to make the fabric or yarn look brighterand whiter. Dyeing is a process of applying

coloring matter directly on fiber without anyadditives.Finishing is the final process

to impart the required end use finishes to the fabric andlastly the printing process

on fabric which is a science as well as an art. Textile auxiliaries such aschemicals

are used for all stages of the textile manufacturing process that is from pre-

treatmentto dyeing and printing and finishing.The textile industry occupies a

leading position in the hierarchy of the Indian manufacturingindustry. It has

witnessed several new directions in the era of liberalization. While textile

exportsare increasing and India has become the largest exporter in world trade in

cotton yarn and is an important player of readymade garments, country’s

international textile trade constitutes a mere 3% of the total world textile

trade. Several mills have opted for modernization and expansionand are going in
for export-oriented units (EOUs) focused on production of cotton yarn.

It has passed through cyclical oscillations and at present, it is witnessing a recovery

after a downturn.Of the entire industry volume of about 5 million tonnes, polyester

and polyester filament yarnaccount for about 1.7 million tonnes, and acrylic, nylon,

and viscose taken together for 300,000tonnes. The balance is represented by cotton

textiles. A majority - some three fourths - of thetextile mills are in the private

sector. A few of the units are in the co-operative sector with the public sector

(Central and State) accounting for about 15% of the total.The textile industry is

classified into (i) textile mills comprising composite and spinning mills inthe

organized segment, (ii) small powerloom and handloom units in the decentralized

segment,(iii) khadi-based units, (iv)manmade and synthetic fibre and spinning

units, v) knitting units, and(vi) made-ups (garments). Besides, the industry has

a large number of small units scattered allover the country which are engaged

in processing, dyeing and printing of yarn, fabrics and forconversion. The

processing units include sizing, desizing, kiering, bleaching, mercerizing,dyeing,

printing and finishing.

The country’s per capita consumption of woven cotton fabrics is estimated at

around 16.5 meters. This has remained almost constant for quite some time with

the increased productionabsorbed by the expansion in population. Yarn is produced

by the mills in the organized segment but is consumed by powerloom and

handloom segments as well. The production of cotton yarnis divided into three

categories, namely, coarse counts below 20s, medium counts between 20sand 40s,

and fine counts above 40s. The average count spun has increased from about 25 in

early1960s to about 34 in 1990s. This indicates a change in product-mix in favour

of finer textiles andhigh value items.

The pattern of production of cloth in the textile industry is amazingly wide with

regard to typesof fabrics produced with different mono and mixed materials.In the

conventional ring spinning system, increasing spindle speed beyond a level

wastechnologically difficult and economically non-feasible. The search for an

alternative method ofyarn manufacture led to the development of three new

technologies, namely, rotor open-end,friction and air jet spinning. The spinning

limits of the four technologies are 6-12, upto 30, 6-18,and 20-80, respectively.A

major improvement in weaving efficiency has been brought about by

developments inspinning technology which has enabled production of yarn of

higher quality. A major share ofthe looms installed in composite mills is now of

automatic looms. However, autolooms installedin the decentralized and

powerloom segments are small in number. Shuttleless technology, directwrapping,

use of splicing technology, automatic doffing and knotting systems, help to

increasemill productivity. Speed of the auto looms or shuttleless looms is 60%

higher than that of non-autolooms.The textile industry has managed to modernise

the spinning sector but there is a long way to goon the weaving front. India's power

loom sector has over 10,000 shuttleless looms as comparedto 150,000 in China. It

may be recalled that India today is the third largest producer of cotton,second

largest producer of cotton yarn and the largest exporter of cotton yarn in the world.

Thegovernment has, under its new textile policy set an ambitious export target of

$50 billion to beachieved by 2010.While the Indian textile industry is a premier

industry in India with a large domestic market andsizable exports (considering

India's export earnings), it is still a small player in the global textilemarket. The

global market is expanding (estimated to grow from $ 309 billion to $856

billion by 2014). India has several positive competitive strengths and can benefit fr

om the globalexpansion. However, India will have to catch up with modernization

by restructuring andupgrading its operations. It is an imperative and urgent need

for the industry to focus on valueadded products. With the end of the Multi-fibre

Agreement at the end of 2004, the potential isunlimited, if only the industry gets

fully geared up to adopt global standards

Polymer Processing- Spinning Process of Polymers

According to Concorde, polymer processing are the "operations carried out on

polymericmaterials or systems to increase their utility." Therefore, polymer

processing is done to increasethe value of a polymer in order to obtain the desired

shape, properties, and performance for a polymer article. As far as textile

industry is concerned, polymer processing can be explained asthe spinning process

for manufacturing polymer fibers that are commonly known as syntheticfibers.

Spinning of polymers

The polymers of synthetic fibers are almost always derived from by-products of

petroleum andnatural gas which include nylon, polyethylene terephthalate, as well

as other compounds likeacrylics, polyurethanes and polypropylene. Synthetic

fibers, which are produced from

these polymers, are used for making various consumer and industrial textile produc

ts ranging fromclothing, home furnishings to conveyor belts. Most of thecellulosic

yarnsmanufactured fromsynthetic fibers are produced by extrusion of a thick,

viscous liquid through the tiny holes ofequipment called spinneret which forms

continuous filaments of semi-solid polymer.The polymer is at first converted into a

fluid state. If it is a thermoplastic polymer then it is justmelted otherwise it has to

be dissolved in a solvent or has to be chemically treated in order toform soluble or

thermoplastic derivatives. The fluid polymer is then forced through the

spinneret.The polymer here cools to a rubbery state, and then finally solidifies. For

making specialty yarn,certain polymers have been technologically developed that

do not melt, dissolve, or formappropriate derivatives. In such cases, the small fluid

molecules are mixed and reacted to formthe otherwise intractable polymers during

the process of extrusion. There are typically four typesof spinning for polymers-

wet spinning, dry spinning, melt spinning, and gel spinning.

However, before proceeding to know the actual processes of all these four types of

spinning, one mustknow about the basic process of extrusion and the spinneret

used for it.

Types of Polymer Spinning Processes

As stated earlier, There are four types of spinning for polymers- wet spinning, dry

spinning, meltspinning, and gel spinning.

Wet Spinning:

Of all the four processes, wet spinning is the oldest process. It is used for polymers

that need to be dissolved in a solvent to be spun. The spinneret remains submerged

in achemical bath that leads the fiber to precipitate, and then solidify, as it emerges

out of thespinneret holes. The name of the process i.e. wet spinning has got its
name from this "wet" bathonly. Acrylic fiber, rayon fiber, aramid fiber, modacrylic

fiber, and spandex fibers, all aremanufactured through wet spinning.

Dry Spinning:

It is also used for polymers that have to bedissolved in a solvent.

However,solidification results from evaporation of the solvent. After dissolving the

polymer in a volatilesolvent, the solution is pumped through a spinneret. As

the fibersemerge from the spinneret, airor inert gas is used to evaporate the solvent

which results in solidification of the fibers that can be collected on a take-up

wheel. The fibers are stretched which provides for orientation of the polymer

chainsalong the fiber axis. This technique is used only for polymers which cannot

bemelt spun because of the safety and environmental concerns concerned with

solvent handling.Dry spinning may be used for manufacturing acetate fiber,

triacetate fiber, acrylic fiber,modacrylic fiber, PBI, spandex fiber, and vinyon.

Melt Spinning:

is used for the polymeric fibers or the polymers that can be melted. The polymeris

melted and then pumped through a spinneret. The cooled and solidified molten

fibers getcollected on a take-up wheel. The fibers, when stretched in both,

the molten and solid states,facilitate orientation of the polymer chains along the

fiber axis. Melt spun fibers can be forcedthrough the spinneret in different cross-

sectional shapes such as round, trilobal, pentagonal,octagonal among others.

Trilobal-shaped fibers are capable of reflecting more light which give asparkle to

the fabrics. Pentagonal-shaped and hollow fibersare soil and dirt resistant and as

suchare used for making carpets and rugs. Octagonal-shaped fibers offer glitter-

free effects whereashollow fibers trap air, creating insulation. Polymers like

polyethylene terephthalate and nylon 6,6are melt spun in high volumes. Nylon

fiber, olefin fiber, polyester fiber, saran fiber, etc. are alsomanufactured through

melt spinning.

Gel spinning:

It is also known as dry-wet spinning because the filaments first pass through airand

then are cooled further in a liquid bath. Gel spinning is used to make very strong

and otherfibers having special characteristics. The polymer here is partially liquid

or in a "gel" state,which keeps the polymer chains somewhat bound together at

various points in liquid crystalform.This bond further results into strong inter-chain

forces in the fiber increasing its tensile strength.The polymer chains within the

fibers also have a large degree of orientation, which increases itsstrength. The

filaments come out with an unusual high degree of orientation relative to

eachother, further enhancing strength. The high strength polyethylene fiberand

aramid fibers aremanufactured through this process.Whatever spinning process is

applied, the fibers are finally drawn to increase strength andorientation. This may
be done while the polymer is still in the process of solidifying or after ithas

completely cooled down. Drawing pulls the molecular chains together and orients

themalong the fiber axis, resulting in a considerably stronger yarn.

ABOUT THE COMPANY

M/s BALAJI PROCESSORS belongs to Shri Himanshu Khetan, Shri Atul Kumar

Poddar and Shri Ankush Nathani steers his companies toward success., the

company has emerged as a successful and vibrant enterprise. Target to Employ

more than 50 people, M/s BALAJI PROCESSORS has a projected sales turnover

of Rs. 4.50 crores in first year itself. It is almost a year since we drew up our

vision, mission and values for the company. A recent random survey indicated that

most of us have imbibed these values to perform better at the

work place. Speed of response will enhance our individual performance and give th

e company a winning outlook. It must be our endeavor to always seek ways and

means to do better by the day. M/s BALAJI PROCESSORS business plans and

budgets have been finalized and their short and long term actions plans are taking

shape. All of them have an immense variety of strength sand zeal at various levels.

They have seen these emerge through their various teams that overcame challenges

and accomplished the impossible.

COMPANY MISSION
M/s BALAJI PROCESSORS mission is to achieve leadership in growth rate.

They will leverage their effective R & D, registration, manufacturing and

marketing competencies through their committed and proficient team. They will

strive to make their customers successful by providing high quality products,

services and solutions in domestic and global markets. To expedite growth, we will

user collaborations, acquisitions and manufacturing proximity to the market in the

segment of crop care, specialty and performance chemicals.

COMPANY VALUES

Customer Success - Believing that success lies in the success of existing and

potential customers.On this foundation, doing all possible to understand, fulful and

exceed that customers stated andunstated needs, thus enabling them to succeed on

a continual basis.Knowledge - Continuously ungrade skills and knowledge about

technology, markets, products,customers, regulations and business process.

Encourage new ideas and their implementationaccross the company for

commercial benefit.Prosperity - Winning done better than other through exploiting

new opportunities and enhaucingthe interests of every employee, share holder and

stake holder. To be recognized and perceivedamoungst the leaders in the segment

of operations.Teamwork - Employees and channel partners thinking and working

together across functions, business and geographies, leveraging the available

resources to achieve common goals.Velocity - Responding to internal and external

customers with a sense of urgency by consistent,focussed and accelerated growth

of the organisation with timely and optimal utilisation of allresources.

COMPANY PRODUCTS

M/s BALAJI PROCESSORS range of products is known for excellence in

product quality. Our team always working for betterment of farmers, operating in

Indian Market for more than 4decades. The range of specialty chemicals that they

have is used for different set of textile industry. Some of the products include
DEPARTMENTS

Purchase Department

The first function of textile mills is purchasing the raw materials. Raw materials

include purchasing of cotton. Before purchasing the samples of cottons are

received after checking

t the purchasing order is sent. The purchase is done through the brokers, commissio

n agents or through the direct dealing of the polymer chemical industries. While

receiving the polymers the manager has to check for the quality. Then after

receiving the polymers the density of the agentsare checked. They are purchasing

verities of Polymer Chemicals.

Mode of payment

Cash purchase

Cash purchase means purchasing raw materials for ready cash. The payments are

made duringthe purchase because while purchasing large quantity there will be a

cash discount. The direct payments are made through cashes and cheques.

Credit purchase

Credit purchases means buying the yarns on the credit basis. When the credit

purchase is madethe rate of the raw materials will be high and there will be no

discount on the purchase of the rawmaterials. Credit purchases are made due to the

in sufficient of cash. There will a specific timefor payment of cash from the

purchased day.

Thickening Agent

Acryprint series is a synthetic thickener designed especially for providing viscosity

in pigment printing system of textile printing. It is easy to handle and relatively

low usage levels yield highviscosity upon neutralization.It forms smooth swelling
as well as homogenous blend of all additives in the textile printing. Itmakes stock

paste preparation simple with excellent cost reduction. It is compatible with

most pigment concentrate, neutralizers, binders and printing system and hence pro

vides excellentcolor value.Some advantages of ACRYPRINT K100 are mentioned

below:

➢ Excellent uniformity & reproducibility

➢ Eco-friendly and users friendly

➢ Sharp printing & smooth appearance

➢ No clogging or chocking of screen

➢ Simplicity in stock paste preparation

➢ High color value with uniform leveling

➢ Good salt resistance

➢ Low quantity gives higher viscosity

➢ High speed printing

➢ Compatible with all additives

➢ Easy to wash equipments

➢ Excellent reduction in production cost

➢ No back penetration

➢ Good stock paste storage

➢ Reduce effluent emissions

This product improves the wet fastness of reactive dyeing and prints. It also

improves the storagestability of reactive dyeing, which under humid conditions

tend to undergo hydrolysis, adverselyaffecting the wet fastness properties.This

product acts by combining with the reactive dye hydrolysates that have not been

washed offand would have otherwise reduced the fastness of the dyeing. The extent

of improvement in thefastness properties depends on the specific dyes present.This

product does not significantly affect the shade of reactive dyeings nor does

treatment withthis product affect the fabric handle. The rub fastness is not impaired

as long as the dyeings arewell soaped and rinsed.

Wetting Agents

They are providing the most powerful wetting agent which is best suited for the

most efficientwetting processes of grey yarns and fabrics of all types of fibers

either in the cold or hotResidual. Their wetting agents on the material impart a very

high degree of absorbency to thetextile material.General

Characteristics:Physical Appearance : Colorless to pale yellow liquidIonic Nature :

Anionic pH of 1% solution : 6.5 - 7.5Miscibility :Miscible with hot water and also

soluble in most of the

polarsolvents.Stability to hard water : Very goodApplications:Being a powerful

wetting agent, it has many applications. Grey yarn may be made absorbent

bywetting with wetting agent solution prior to dyeing.Excellent for wool

particularly in top dyeing and fabric dyeingToweling material may be treated with

wetting agent solution to improve its water absorbency.Application on cotton

fabrics prior to subjecting them to compressive shrinkage process.In addition, it

has excellent deareation properties. Because of deareation action, the

bubbleformations are prevented resulting into a high degree of absorbency to the

textile material.Depending on the requirements 0.5 - 1 gpl of it may be used for

different purposes.

Dyeing Chemicals

Textile dyeing chemicals are known for their excellent foam suppressing and

wetting properties,and are suitable for various stages of textile processing. These

textile dyeing chemicals

are procured from the reliable manufacturers of the industry to ensure superior qual

ity andaccurately composed formulations to the clients.Antimussol D-AIR liq :

Silicon Based De Aerating agent with excellent Foam Suppressing &wetting

properties, suitable for various stages of textile processing , especially suitable

formachine like Package, Soft Flow & Beam Dyeing machineAntimussol FKI liq :

Silicone based antifoaming agent stable to JET dyeing application.Antimussol

HT2S liq : Stable, silicone-free antifoaming agent especially for the wet treatment

ofPES and PES in blends with other types of fibre.Antimussol SDF liq : Silicone
based antifoaming agent stable to JET dyeing application.Dilatin ENI.IN liq : Low

foaming diffusion accelerant with levelling action for dyeing of polyester & its

blends.Dilatin POE liq : Diresul Antioxidant PRS liq : An Antioxidant for better

dyebath stabilityduring Sulphur DyeingDiresul Oxidant BRI.IN liq : Stabilized

Oxidizing agent for Sulphur DyeingsDiresul Oxidant PRB liq : Drimagen ALK.IN

liq : Alkaline pH buffering agent for dyeing ofcellulosic fibres with reactives.

Printing Chemicals

These cotton printing chemicals are suitable for printing with pigment emulsions

on all types ofcellulosics and their blends with polyester. These cotton printing

chemicals are accuratelyformulated using the best quality raw materials.Printing

chemicals are safe to use and eco-friendly.Arostit BLNDP.IN p: Discharging agent

for Cellulosic material and its blends.Hostapal EPP liq : Emulsifier for pigment

printingMinerprint Finish S liq : Additive for improving the softness and fastness

of prints & pasterunnabilityMinerprint Transparent Elastil FG pa : Ready-to-Print

paste for lacquered and glossy elasticeffectsMinerprint White Elastil FG pa :

Ready-to-Print paste for elastic effects MinerprintMatt Lacquer NT liq : Paste for

printing on dark groundsPrintofix Binder 1912 PLUS : Eco friendly binder for

aqueous printing
Dyeing DepartmentDyeing

is the process of adding color to textile products like fibers, yarns, and fabrics.

Dyeing isnormally done in a special solution containing dyes and particular

chemical material. Afterdyeing, dye molecules have uncut chemical bond with

fiber molecules. The temperature and timecontrolling are two key factors in

dyeing. There are mainly two classes of dye, natural and man-made.

Acrylic fibers

are dyed with basic dyes; while nylon and protein fibers such as wool and silk

aredyed with acid dyes, and polyester yarn is dyed with disperse dyes. Cotton is

dyed with a rangeof dye types, including vat dyes, and modern synthetic reactive

and direct dyes. The common dyeing process of cotton yarn with reactive dyes at

package form is as follows:

1.The raw yarn is wound on a spring tube to achieve a package suitable for dye

penetration.

2. These softened packages are loaded on a dyeing carrier's spindle one on another.

3.The packages are pressed up to a desired height to achieve suitable density of

packing.

4.The carrier is loaded on the dyeing machine and the yarn is dyed.

5.After dyeing, the packages are unloaded from the carrier into a trolly.

6. Now the trolly is taken to hydro extractor where water is removed.

7.The packages are hydro extracted to remove the maximum amount of water

leaving thedesired color into raw yarn

8.The packages are then dried to achieve the final dyed package.

After this process, the dyed yarn packages are packed and delivered
Dyeing Methods

Direct Dyeing

When a dye is applied directly to the fabric without the aid of an affixing agent, it

is called directdyeing. In this method the dyestuff is either fermented (for natural

dye) or chemically reduced(for synthetic vat and sulfur dyes) before being applied.

The direct dyes, which are largely usedfor dyeing cotton, are water soluble and can

be applied directly to the fiber from an aqueoussolution. Most other classes of

synthetic dye, other than vat and sulfur dyes, are also applied inthis way.

Yarn Dyeing

When dyeing is done after the fiber has been spun into yarn, it is called Yarn

dyeing. There aremany forms of yarn dyeing- Skein (Hank) Dyeing, Package

Dyeing, Warp-beam Dyeing, andSpace Dyeing.

Skein (Hank) Dyeing

The yarns are loosely arranged in skeins or hanks. These are then hung over a rung

andimmersed in a dyebath in a large container. In this method, the colour

penetration is the best andthe yarns retain a softer, loftier feel.

Package Dyeing

The yarns are wound on spools, cones or similar units and these packages of yarn

are stacked on perforated rods in a rack and then immersed in a tank. In the tank,

the dye is forced outward fromthe rods under pressure through the spools and then
back to the packages towards the center to penetrate the entire yarn as thoroughly

as possible.

Warp-beam Dyeing

It is similar to package dyeing but more economical. Here, yarn is wound on to a

perforated warp beam, immersed in a tank and dyed under pressure.

Space Dyeing

In this method, the yarn is dyed at intervals along its length. For these two

procedures- knit-deknit method and OPI Space-Dye Applicator- are adopted. In the

first method, the yarn isknitted on either a circular or flat-bed knitting machine and

the knitted cloth is then dyed andsubsequently it is deknitted. Since the dye does

not readily penetrate the areas of the yarn whereit crosses itself, alternated dyed

and undyed spaces appear. The OPI Space-Dye Applicatortechnique produces

multi coloured space- dyed yarns. The yarns are dyed intermittently as theyrun at

high speeds of upto 1000 yards (900 m) per minute through spaced dyebaths

withcontinuous subjection to shock waves produced by compressed air assuming

supersonicvelocities.

Problems in Dyeing and remedies

The art of processing of textiles today is well known to all processors. In the

past the organizedsector dominated the textile scene; whereas today the

decentralized process houses are predominant. There is a shift in emphasis from

the requirements related to finished products toenvironment related requirements.

Requirements related to the finished product fastness &

other properties of dyestuffs & chemicals, processing etc. shift of emphasis environ

ment relatedrequirements, cost reduction, security, energy & water saving,

toxicology, hygiene legalregulations, and competitiveness.Reduction in costs and

utilities are achieved by the trend to telescope processes. In order to becompetitive

processors would have to give equal if not better quality then the existing material

atthe same price. Considering the energy and labour costs, the only means of

maintaining acompetitive edge is to lay emphasis on 'Quality'. Good quality does

not necessarily meanincreased prices, but in fact would mean "Doing it right the

first time" thereby reduce the costs.Thus with this theme in mind of "Doing it right

the first time" we would have to first understandthe problems in the process of

dyeing. So, this paper mainly discusses "Problems in Dyeing & itsremedies".The

ultimate law of accuracy states, "when working towards a solution of a problem, it

alwayshelps if you know the answer provided, of course you know there is

problem".Every manufacturing unit has a number of problems, however problem

solving cannot beconsidered to be astrology or palmistry, but it needs the fullest

knowledge of basic facts.The stages in the processing of textiles are:

Remedies:

➢ By ensuring proper pretreatment.

➢ Proper dosing of dyes and chemicals.

➢ Heat should be same throughout the dye liquor.

➢ Proper salt addition

➢ GREY CLOTHPRETREATMENTDYEINGFINISHING

There is sample evidence of their harmful effects. Triple primary cancers

involvingkidney, urinary bladder and liver of dye workers have been reported.

Most of the dyes,used in the textile industry are known only by their trade name,

while their chemicalnature and biological hazards are not known. Mathur et. al.

studied the mutagenicity oftextile dyes (known only by their trade name, used in

Pali, identified as one of the most polluted cities in India) and the

effluents containing these dyes, and the influence on thehealth of textile dyeing

workers and the environment. The dyes were used in their crudeform and no

following purification was attempted, because they wanted to test the potential

danger that dyes represent in actual use. The results clearly indicated that mostof

the used dyes are highly mutagenic. Brow net. al, published an article, to show it

is possible to predict the toxicity of new azo dyes. The systematic backtracking of

the flowsof wastewater from textile-finishing companies led to the identification of

textile dyes asa cause of strongly mutagenic effects. The textile dyes used in the

textile-finishingcompanies in the European Union were examined for

mutagenicity. According to theobtained results the dyes that proved to be

mutagenic have been replaced with lessharmful substances.The degradation

product of dyes could be carcinogenic. The formation of Discolorationof Textile

Wastewaters 177 carcinogenic aromatic amine o-to lidine from the dye DirectBlue

14 by skin bacteria has been established.

Textile dyes can cause allergies such as contact dermatitis and respiratory

diseases,allergic reaction in eyes, skin irritation, and irritation to mucous

membrane and the upperrespiratory tract. Reactive dyes form covalent bonds with

cellulose, woollen and PAfibres.

Accounts Department

Accounts department also plays a vital role in the businesses by monitoring the

income andexpenditure, regulating receipts and payments the financial strength as

otherwise of the unit atany time. Accounts helps to know whether the businesses

are in running progress or not. Sohence every business needs to maintain the

accounts as per the rule of the government and wantto pay the tax according to the

profit of business. Accounts help to know the current

financial position of businesses when ever needed. Further it will help him to know

the level of theinvestment in the fixed assets, working capital, fixed expenses etc.
Balaji Processors maintainall the account with the help of well experienced

accountants. They maintain all the accounts like

journal, ledger, and trail balance etc…, for every transaction the entr

ies and the accounts areentered. All the accounts related to the other departments

are also handled and kept in control.While purchasing and selling the yarn and the

other items they will receive the bills they use tofile all the bills in the separate

books of accounts. They have the separate beam stock book forrecording the

stocks. By using separate book all the personal expenses are entered. Auditing

iseasy because of maintaining the accounts properly. They are paying the tax

regularly every year.Before auditing all the accounts are checked by the auditor

and then it is submitted. Hence theaccounts departments are maintained strictly and

properly in order to maintain the stable high profit

Marketing Department

Marketing is the main function because without the market the goods cannot be

sold out. But inthe field of textile the role of the marketing department is not much

necessary, because the

entire produced good are not the finished goods and it should take away for the furt

her process. InConcorde Polymers they are marketing the two varieties of yarn as

40and 30 based on theirthickness. The 40 is used for making shirts and 60 are used
for making pants. In Concorde polymers the manager directly deals with the other

nearby buyers. So the marketing departmentis not done in full effort.

Duties & responsibilities of marketing officer:

Dealing with the buyer & convince the buyer is the main duty of marketing

officer. A marketingofficer also has some other duties. The main duties &

responsibilities of marketing officer aregiven bellow-

1) To prepare cost sheet by dealing with the buyer.2) To make different steps by di

scussing with the high officials & merchandiser.3) To maintain a regular & good re

lationship between commercial officer & merchandiser.4) To maintain a communi

cation with the buyers and buying house.5) Communicate with better criteria of the

products.Actually the responsibilities & duties of marketing officer begin from

getting order of buyer &end after receiving goods by buyer. So, he should be

always smart, energetic & sincere

Store Department

The purchased raw materials are stored in stores room for the production

processes. In thestorage department they are having a large area of godown for

storing their purchase of rawmaterial and they are keeping safe from destruction

until they used for production process. Themain function of the storage is due to

avoid un necessary accidents like fire, theft etc the stocklevel can be identified by
maintaining the proper ledger accounts. This department is under thecontrol store

man

TEXTILE DYEING & PRINTING MILL

The bleaching of the textile is done to bring the whiteness finishing in the fabric

where as dyeingfor various shades. The art lies in colouring the textiles in such a

manner that the colour may befast or may not ordinarily be removed by such

operations as washing, rubbing, sunlight etc.The art of dyeing is a branch of

applied chemistry in which a severe use of both physical andchemical principle is

made in order to bring about a permanent union between dyes and thefibres. The

local application of colour is carried out by some form of printing and the greater

partof textile printing concerns woven cotton piece goods, the process is some

times called

calico printing, at the same time it must be released that very considerable quantitie

s of rayons are printed as well as small amount of silk and wools.Cotton textile

industry by large occupies a unique place in the industrial map of the

country.These are single large organized industries as well as a large number of

auxiliary industriesdepending upon the sector.Textile dyeing and printing is the

one of the main part of the industry which gets it done from theout side by the

small textile mills. Large mills have their own dyeing and printing sections.

Sothere is very good scope for new entrants

Dyeing on Rayon in Hanks Form & Cone Form

These dyes are so powerful that very small amounts, comparatively, are needed to

colour a largeamount of material. The dyestuff should never be shaken out, but

carefully dipped out in anarrow-bowled teaspoon from the tin or glass container,

and placed in a small-sized agatesaucepan.Then a few drops of acetic acid are

added, and the dyestuff is rubbed in the acid with the spoonuntil every particle has

been wet down. In this condition the dye is readily soluble in hot (not boiling)

water, which should be poured on it stirred well and allowed to settle,

before decantingthe solution into the dye-bath, preferably through a strainer

covered with a piece of wet muslin ordoubled cheesecloth, to be sure and strain out

any particles of undissolved colour.Some of the dyes, notably Methylene Blue,

when wetted, have a way of making a sticky paste,which is hard to dissolve, but by

keeping it wet with acid each time, before adding more warmwater, it will sooner

or later make a good clear solution. It is used to making nonwoven fabrics.It is

used to make coated fabrics.It is best to begin with the dye-bath at a very moderate

temperature, and to heat it gently, keepingwell below the boiling point. According

to observation in India it is found that there is negativegrowth of rayon grade

fibers. In all new production of rayon grade fibre is 227000 MT/Annum.It is better

to start dyeing unit of other textile fabric with rayon grade threads.
Wetting Oil (Textile Yarn Wetting Agent)

Wetting oils are wetting agents having oily consistency. Wetting agents are surface

active agentswhich when added to water causes it to penetrate more easily into, or

to spread over the surface,another material by reducing surface tension of

the water. Wetting oils because of their growinguses in various industries are

having ever increasing demand.The prospect of the industry is very well

linked with soaps, detergents, allied products, paints,varnishes any lacquers,

leather, paper cosmetics, textiles and various other industries which arefast

developing. These industries have very bright future. A new entrepreneur can

confidentlyventure into this field and he will find it highly profitable.

CONCLUSION
A polymer processing and dyeing business is a relatively simple one to start,
although there areupfront costs for equipment and inventory. We can create
designs with easy to use process andallow machines to create sophisticated and
high quality products for printings the fabrics. Ensurethat w have planned business
carefully and that we can reach specific customers with our products and we will
be able to run a profitable business from home on our own schedule.It is difficult
to separate the development of art of dyeing and the development of the
syntheticdyestuff industry. Indigo and Alizarine also their methods of application
were known the introduction of synthetic equivalents added nothing to the dyer’s
technique. Similarly the development of a range of derivatives or the introduction
of synthetic reducing agent
merely provided the dyers with new tools. Whether this be true or not, it is an excel
lent illustration of innumerable instances of progress achieved by the chemist’s
intelligent development of the dyer’s natural opportunism. It seems clear the
chemists explanation of many phenomena is no longer tenable, and it is hoped that
the physicists recently acquired interest in textile mattersgenerally may soon give
rise to the establishment of a working hypothesis. The physics has brought
new methods, such as X-ray analysis to bear upon textile problems and this has
alreadyresulted in a considerable clarification of the general theory of dyeing
although uncertainty still persists in many aspects. Blended yarn production which
comprises mostlypolyester cottonand partly polyester viscose is only about 350 mil
lion kg. Exports of cotton yarn have traditionally been regulated within a
quantitative ceiling fixed on a year to year. Balaji processors has given a change to
perform the industrial attachment in ONE COMPOSITE MILLS. This training, act
as a bridge to minimize the gap between theoretical
and practical knowledge. Undoubtedly, this training taught us more about textile te
chnology,industrial management & production process. Besides it gave us the first
opportunity to work inan industry. We believe that, the experience of this industrial
training will help us in our futurecareer as textile technologist/engineer
 BALAJI PROCESSORS
PROJECT COST & MEANS OF FINANCE

PROJECT COST
Particulars Rs in Lacs Allocation of interest Total(Rs in
during construction Lakhs)
period &
contingencies

Land 1200.00 1200.00

Building 700.00 26.27 726.27
Plant & Machinery and Furniture & Fixtures 1455.00 54.60 1509.60
Other Fixed Assets 50.00 1.88 51.88
Contingencies @ !% of P&M, OFA & 3% of 40.00 0.00
Building
Preliminary & Preoperative expenses 12.25 12.25
Intersest during construction period 42.75 0.00
Working Capital 500.00 500.00
Total Project Cost 4000.00 82.75 4000.00

MEANS OF FINANCE
Particulars Rs in Lacs Total(Rs in Lakhs)

Promoters Contribution 1,975.00

Term Loan 2,025.00
Working Capital 375.00
Total Means of Finance 4,000.00
 BALAJI PROCESSORS

DETAIL OF COST OF PRELIMINARY AND PRE-

OPERATIVE EXPENSES

Sr. No. Particulars Estimated cost (Rs.

In lacs)

A Preliminary Expenses 2.00

B Pre-operative Expenses

(i) Interest during Construction 42.75

(ii) Establishment and other Exps 6.00

(iii) Consultants & other Fee 15.00

(iv) Other Misc Expenses 2.50

Sub Total - B 66.25

Total - (A+B) 68.25

 BALAJI PROCESSORS
BALANCE SHEET

(Rs in Lacs)
Particulars 2025-26 2026-27 2027-28 2028-29 2029-30 2030-31 2031-32 2032-33 2033-34

Liabilities
Promoters contribution 1975.00 1975.00 1975.00 1975.00 1975.00 1975.00 1975.00 1975.00 1975.00
Reserves and Suplus Less Drawings 166.18 394.56 692.10 984.41 1269.17 1544.40 1828.19 2089.93 2338.71
Secured Term Loans 1735.71 1446.43 1157.14 867.86 578.57 289.29 0.00 0.00 0.00
Secured Working Capital Loans 375.00 375.00 375.00 375.00 375.00 375.00 375.00 375.00 375.00

TOTAL 4251.90 4190.98 4199.24 4202.27 4197.74 4183.69 4178.19 4439.93 4688.71

Assets
Gross Block 3487.75 3512.75 3562.75 3612.75 3662.75 3712.75 3762.75 3812.75 3862.75
Less : Depreciation 267.94 502.08 709.91 895.41 1061.97 1212.44 1349.25 1474.43 1589.74
Net Block 3219.81 3010.67 2852.84 2717.34 2600.78 2500.31 2413.50 2338.32 2273.01

Receivables 126.58 144.66 162.74 162.74 162.74 162.74 162.74 162.74 162.74
Inventory of Consumables and stores 63.29 72.33 81.37 81.37 81.37 81.37 81.37 81.37 81.37
Misc Assets 124.64 295.92 519.08 738.31 951.88 1158.30 1371.14 1567.45 1754.03
Cash & Bank Balance 706.56 657.61 574.64 495.17 394.85 276.07 145.76 287.61 416.34
Preliminary Expenses 11.03 9.80 8.58 7.35 6.13 4.90 3.68 2.45 1.23

TOTAL 4251.90 4190.98 4199.24 4202.27 4197.74 4183.69 4178.19 4439.93 4688.71
 BALAJI PROCESSORS
PROFITABILITY STATEMENT

(Rs in Lacs)
Particulars 2025-26 2026-27 2027-28 2028-29 2029-30 2030-31 2031-32 2032-33 2033-34

SALES
Capacity of Mill
Suiting (Meters in Lakhs ) 360.00 360.00 360.00 360.00 360.00 360.00 360.00 360.00 360.00
Shirting (Meters in Lakhs ) 240.00 240.00 240.00 240.00 240.00 240.00 240.00 240.00 240.00

Running Capacity 70% 80% 90% 90% 90% 90% 90% 90% 90%

Per meter rate (Suiting) 14.00 14.00 14.00 14.00 14.00 14.00 14.00 14.00 14.00
Per meter rate (Shirting) 6.50 6.50 6.50 6.50 6.50 6.50 6.50 6.50 6.50

From Suiting 3,528.00 4,032.00 4,536.00 4,536.00 4,536.00 4,536.00 4,536.00 4,536.00 4,536.00
From Shirting 1,092.00 1,248.00 1,404.00 1,404.00 1,404.00 1,404.00 1,404.00 1,404.00 1,404.00
Receipts 4,620.00 5,280.00 5,940.00 5,940.00 5,940.00 5,940.00 5,940.00 5,940.00 5,940.00

Total - (A) 4,620.00 5,280.00 5,940.00 5,940.00 5,940.00 5,940.00 5,940.00 5,940.00 5,940.00

COST
Consumables (Chemical and Colour)2,511.65 2,870.46 3,229.26 3,229.26 3,229.26 3,229.26 3,229.26 3,229.26 3,229.26
Power & Fuel 178.87 224.58 252.66 252.66 252.66 252.66 252.66 252.66 252.66
Wages 942.48 1,077.12 1,211.76 1,211.76 1,211.76 1,211.76 1,211.76 1,211.76 1,211.76
Insurance @ 2 % of Gross block 9.24 10.56 11.88 11.88 11.88 11.88 11.88 11.88 11.88
Depreciation 267.94 234.14 207.83 185.50 166.56 150.47 136.80 125.19 115.31
Misc Expenses 138.60 158.40 178.20 178.20 178.20 178.20 178.20 178.20 178.20
Sub Total 4,048.78 4,575.26 5,091.59 5,069.26 5,050.32 5,034.23 5,020.56 5,008.95 4,999.07
ADMINISTRATIVE COST
Administrative Exps. @ 2% of Sales 92.40 105.60 118.80 118.80 118.80 118.80 118.80 118.80 118.80
Sub Total 92.40 105.60 118.80 118.80 118.80 118.80 118.80 118.80 118.80
Prel. Expenses written off 1.23 1.23 1.23 1.23 1.23 1.23 1.23 1.23 1.23
Total Cost - (B) 4,142.41 4,682.09 5,211.61 5,189.29 5,170.34 5,154.26 5,140.59 5,128.97 5,119.09
Profit before Interest - (A-B) 477.59 597.91 728.39 750.71 769.66 785.74 799.41 811.03 820.91
Interest
- Term Loan 178.63 151.15 123.67 96.19 68.71 41.22 13.74 0.00 0.00
- Working Capital 45.00 45.00 45.00 45.00 45.00 45.00 45.00 45.00 45.00
Sub Total 178.63 151.15 123.67 96.19 68.71 41.22 13.74 0.00 0.00
Profit before tax 298.96 446.76 604.72 654.52 700.95 744.52 785.67 811.03 820.91
Tax 93.28 139.39 188.67 204.21 218.70 232.29 245.13 253.04 256.12
Net Profit 205.68 307.37 416.05 450.31 482.26 512.23 540.54 557.99 564.78
Cash Profit 474.85 542.74 625.10 637.04 650.04 663.93 678.57 684.40 681.32
Cumulative Cash Profit 474.85 1,017.59 1,642.69 2,279.73 2,929.77 3,593.69 4,272.26 4,956.66 5,637.98
Dividend Rate 2.00% 4.00% 6.00% 8.00% 10.00% 12.00% 13.00% 15.00% 16.00%
Dividend 39.50 79.00 118.50 158.00 197.50 237.00 256.75 296.25 316.00
Retained Profit 166.18 228.37 297.55 292.31 284.76 275.23 283.79 261.74 248.78
 BALAJI PROCESSORS
Computation of Power and Fuel Cost

Total Requirement of Power

Rs. Lacs
Particulars per month
1 Electricity Bill 8.41
2 Diesel and Other Fuel 6.50

Total per month 14.91

Total Cost per annum 178.92

 BALAJI PROCESSORS

Calculation of Debt Service Coverage Ratio

PARTICULARS 2025-26 2026-27 2027-28 2028-29 2029-30 2030-31 2031-32 2032-33 2033-34 Total
Profit after Tax 205.68 307.37 416.05 450.31 482.26 512.23 540.54 557.99 564.78 4037.21
Depreciation 267.94 234.14 207.83 185.50 166.56 150.47 136.80 125.19 115.31 1589.74
Prel. Exps. Written Off 1.23 1.23 1.23 1.23 1.23 1.23 1.23 1.23 1.23 11.03
Interest 223.63 196.15 168.67 141.19 113.71 86.22 58.74 45.00 45.00 0.00

Total 698.48 738.89 793.77 778.23 763.74 750.15 737.31 729.40 726.32 5637.98

Interest 223.63 196.15 168.67 141.19 113.71 86.22 58.74 45.00 45.00 1078.31
Repayment of Loan 289.29 289.29 289.29 289.29 289.29 289.29 289.29 0.00 0.00 2025.00

Total 512.92 485.44 457.96 430.47 402.99 375.51 348.03 45.00 45.00 3103.31

Ratio (including
interest) 1.36 1.52 1.73 1.81 1.90 2.00 2.12
Average DSCR
(inclduing Interestt) 1.85
 BALAJI PROCESSORS

KEY INDICATORS

Particulars 2025-26 2026-27 2027-28 2028-29 2029-30 2030-31 2031-32 2032-33

Debt Equity Ratio 0.81 0.61 0.43 0.29 0.18 0.08 0.00 0.00

PBDIT/Sales 16% 16% 16% 16% 16% 16% 16% 16%

PBT / Sales 6% 8% 10% 11% 12% 13% 13% 14%
Net Profit/Sales 4% 6% 7% 8% 8% 9% 9% 9%
Interest Coverage 2.67 3.96 5.89 7.80 11.20 19.06 58.18
DSCR (including Interest) 1.36 1.52 1.73 1.81 1.90 2.00 2.12