Processing Plant Costing
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23534238.xls Finishing Plant Cost Analysis Proposed 10,000 Singeing, Desizing, Scouring & Bleaching {Can be one machine or split into two} Machine Cost Speed/minute 120.00 mtr/min Efficiency 80% Fabric undergoing this process 100% Capacity of Machine 138,240.00 mtr/day Chemical cost per mtr Remarks: It is assumed that the weight range will not vary a lot so there are no major changes from one run to another. Morever, the 30,000 run size for one color would mean bigger run size for bleaching.
Mercerizing Machine Cost Speed/minute Efficiency Capacity of Machine Fabric undergoing this process Capacity of plant for overall fabric Chemical cost {mercerized fabric} Chemical cost {overall}
50.00
mtr/min 80% 57,600.00 mtr/day 37% 155,520.00 mtr/day per mtr per mtr
45,000 Dyeing with mercerizing 45,000 Dyeing without mercerizing 5,000 Printing with mercerizing 40,000 Printing without mercerizing 135,000
Remarks:
Thermosol Speed/minute Production time for one run Set up time Total time for a run Calculated Efficiency Miscellaneous Efficiency losses Net Efficiency
50.00 200.00
mtr/min min 90 min
30 Average Cleaning in minutes 60 Average preparation and matching 90
290.00 69% 10% 59% 1 Machines
Machine Cost Speed/minute Efficiency Capacity of Machine Capacity Adjusted for double pass Fabric undergoing this process Capacity of plant for overall fabric Chemical cost other than dye cost Chemical cost Light Medium Dark
50.00
mtr/min
59% 42,455.17 mtr/day 34,000 mtr/day
42,455 Thermosol Dyeing 21,228 PC 50% 10,614 Double thermosol & washing on pad steam 21,228 Single Pass 10,614 Double Pass 31,841 34,000 Reiterations 8500 Double Pass
per mtr per mtr per mtr
Remarks: 3,000 yards minimum run, for bigger run size chemical cost will also be lower
Pad Steam Speed/minute Production time for one run Set up time Total time for a run Calculated Efficiency Miscellaneous Efficiency losses Net Efficiency
70.00 142.86
mtr/min min 70 min
30 Average Cleaning in minutes 40 Average preparation and matching 70
212.86 67% 10% 57% 1 Machines
Machine Cost Speed/minute Efficiency Capacity of Machine Capacity Adjusted for double pass Fabric undergoing this process Capacity of plant for overall fabric Chemical cost other than dye cost Chemical cost Light Medium Dark Continous Capacity Batch Capacity
70.00
mtr/min 57% 57,571.01 mtr/day 46,000 mtr/day
57,571 Dyeing+Washing 28,786 PC 50% 14,393 Double thermosol & washing on pad steam 28,786 Single Pass 14,393 Double Pass 43,178 46,000 Reiterations 11500 Double Pass 57,500
per mtr per mtr per mtr 34,000 mtr/day 10,000 mtr/day 44,000 mtr/day
Stentor for Dyeing Speed/minute Production time for one run Set up time Total time for a run Calculated Efficiency Miscellaneous Efficiency losses Net Efficiency
50.00 200.00
mtr/min min 90 min
30 Average Cleaning in minutes 60 Average preparation and matching 90
290.00 69% 10% 59%
Page 1 of 2
23534238.xls
1 Machines Machine Cost Speed/minute Efficiency Capacity of Machine Capacity Adjusted for double pass Fabric undergoing this process Capacity of plant for overall fabric Chemical cost other than dye cost Chemical cost Light Medium Dark
50.00
mtr/min
59% 42,455.17 mtr/day 34,000 mtr/day
42,455 Thermosol Dyeing 21,228 PC 50% 10,614 Double thermosol & washing on pad steam 21,228 Single Pass 10,614 Double Pass 31,841 34,000 Reiterations 8500 Double Pass
per mtr per mtr per mtr
Stentor for Setting & Finishing Machine Cost Speed/minute Efficiency Capacity of Machine Capacity Adjusted for double pass Fabric undergoing this process Chemical cost
2 Machines 100% double pass for all non-stentor dye fabric 90.00 mtr/min1 for setting and 1 for finishing 80% and sometimes after mercerizing so divide by 2.25 207,360.00 mtr/day 92,160 per mtr
Remarks: 75% efficiency assumed for longer runs
Printing Speed/minute Production time for one run Set up time Total time for a run Calculated Efficiency Miscellaneous Efficiency losses Net Efficiency
50.00 200.00
mtr/min min 60 min
260.00 77% 10% 67%
60 Average set up Less for color change High for design change
1 Machines Machine Cost Speed/minute Efficiency Capacity of Machine Fabric undergoing this process Capacity of plant for overall fabric Chemical cost other than dye cost Chemical cost Light Medium Dark
50.00
mtr/min 67% 48,184.62 mtr/day mtr/day
per mtr per mtr per mtr
Calendering Machine Cost Speed/minute Efficiency Capacity of Machine Fabric undergoing this process Capacity of plant for overall fabric Chemical cost {Calendered fabric} Chemical cost {overall}
70.00
mtr/min 80% 80,640.00 mtr/day 40% 201,600.00 mtr/day per mtr per mtr
Remarks:
Sanforizing Machine Cost Speed/minute Efficiency Capacity of Machine Fabric undergoing this process Capacity of plant for overall fabric Chemical cost {sanforized fabric} Chemical cost {overall}
70.00
mtr/min 80% 80,640.00 mtr/day 50% 161,280.00 mtr/day per mtr per mtr
Remarks:
Overall Capacity Dyeing & Printing Continuous + Batch Stentor Dyed Fabric Printing
Finishing Stentor Dyed Fabric Stentor for Setting + Finishing
44,000 mtr/day 34,000 mtr/day 48,185 mtr/day 126,185
34,000 mtr/day 92,160 mtr/day 126,160 mtr/day
Page 2 of 2
Mercerizing Machine Cost Speed/minute Efficiency Capacity of Machine Fabric undergoing this process Capacity of plant for overall fabric Chemical cost {mercerized fabric} Chemical cost {overall}
50.00
mtr/min 80% 57,600.00 mtr/day 37% 155,520.00 mtr/day per mtr per mtr
45,000 Dyeing with mercerizing 45,000 Dyeing without mercerizing 5,000 Printing with mercerizing 40,000 Printing without mercerizing 135,000
Remarks:
Thermosol Speed/minute Production time for one run Set up time Total time for a run Calculated Efficiency Miscellaneous Efficiency losses Net Efficiency
50.00 200.00
mtr/min min 90 min
30 Average Cleaning in minutes 60 Average preparation and matching 90
290.00 69% 10% 59% 1 Machines
Machine Cost Speed/minute Efficiency Capacity of Machine Capacity Adjusted for double pass Fabric undergoing this process Capacity of plant for overall fabric Chemical cost other than dye cost Chemical cost Light Medium Dark
50.00
mtr/min
59% 42,455.17 mtr/day 34,000 mtr/day
42,455 Thermosol Dyeing 21,228 PC 50% 10,614 Double thermosol & washing on pad steam 21,228 Single Pass 10,614 Double Pass 31,841 34,000 Reiterations 8500 Double Pass
per mtr per mtr per mtr
Remarks: 3,000 yards minimum run, for bigger run size chemical cost will also be lower
Pad Steam Speed/minute Production time for one run Set up time Total time for a run Calculated Efficiency Miscellaneous Efficiency losses Net Efficiency
70.00 142.86
mtr/min min 70 min
30 Average Cleaning in minutes 40 Average preparation and matching 70
212.86 67% 10% 57% 1 Machines
Machine Cost Speed/minute Efficiency Capacity of Machine Capacity Adjusted for double pass Fabric undergoing this process Capacity of plant for overall fabric Chemical cost other than dye cost Chemical cost Light Medium Dark Continous Capacity Batch Capacity
70.00
mtr/min 57% 57,571.01 mtr/day 46,000 mtr/day
57,571 Dyeing+Washing 28,786 PC 50% 14,393 Double thermosol & washing on pad steam 28,786 Single Pass 14,393 Double Pass 43,178 46,000 Reiterations 11500 Double Pass 57,500
per mtr per mtr per mtr 34,000 mtr/day 10,000 mtr/day 44,000 mtr/day
Stentor for Dyeing Speed/minute Production time for one run Set up time Total time for a run Calculated Efficiency Miscellaneous Efficiency losses Net Efficiency
50.00 200.00
mtr/min min 90 min
30 Average Cleaning in minutes 60 Average preparation and matching 90
290.00 69% 10% 59%
Page 1 of 2
23534238.xls
1 Machines Machine Cost Speed/minute Efficiency Capacity of Machine Capacity Adjusted for double pass Fabric undergoing this process Capacity of plant for overall fabric Chemical cost other than dye cost Chemical cost Light Medium Dark
50.00
mtr/min
59% 42,455.17 mtr/day 34,000 mtr/day
42,455 Thermosol Dyeing 21,228 PC 50% 10,614 Double thermosol & washing on pad steam 21,228 Single Pass 10,614 Double Pass 31,841 34,000 Reiterations 8500 Double Pass
per mtr per mtr per mtr
Stentor for Setting & Finishing Machine Cost Speed/minute Efficiency Capacity of Machine Capacity Adjusted for double pass Fabric undergoing this process Chemical cost
2 Machines 100% double pass for all non-stentor dye fabric 90.00 mtr/min1 for setting and 1 for finishing 80% and sometimes after mercerizing so divide by 2.25 207,360.00 mtr/day 92,160 per mtr
Remarks: 75% efficiency assumed for longer runs
Printing Speed/minute Production time for one run Set up time Total time for a run Calculated Efficiency Miscellaneous Efficiency losses Net Efficiency
50.00 200.00
mtr/min min 60 min
260.00 77% 10% 67%
60 Average set up Less for color change High for design change
1 Machines Machine Cost Speed/minute Efficiency Capacity of Machine Fabric undergoing this process Capacity of plant for overall fabric Chemical cost other than dye cost Chemical cost Light Medium Dark
50.00
mtr/min 67% 48,184.62 mtr/day mtr/day
per mtr per mtr per mtr
Calendering Machine Cost Speed/minute Efficiency Capacity of Machine Fabric undergoing this process Capacity of plant for overall fabric Chemical cost {Calendered fabric} Chemical cost {overall}
70.00
mtr/min 80% 80,640.00 mtr/day 40% 201,600.00 mtr/day per mtr per mtr
Remarks:
Sanforizing Machine Cost Speed/minute Efficiency Capacity of Machine Fabric undergoing this process Capacity of plant for overall fabric Chemical cost {sanforized fabric} Chemical cost {overall}
70.00
mtr/min 80% 80,640.00 mtr/day 50% 161,280.00 mtr/day per mtr per mtr
Remarks:
Overall Capacity Dyeing & Printing Continuous + Batch Stentor Dyed Fabric Printing
Finishing Stentor Dyed Fabric Stentor for Setting + Finishing
44,000 mtr/day 34,000 mtr/day 48,185 mtr/day 126,185
34,000 mtr/day 92,160 mtr/day 126,160 mtr/day
Page 2 of 2
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