1) Flat woven cloth bag prescribed bag size.

This is done FILE: 81

The woven cloth is run through continually. The bottom of the ISIC 3212
a flexo printing machine and wound heat-cut tube is folded and sewn to
off. get the finished woven bag.
How To Start Manufacturing Industries
The printed cloth is put on the

Woven Bag Making Plant

bag making machine. It is folded Note;
into a tubular shape and centre- When packaging moisture-absorbing
sealed by hot melting; then, it is substance such as fertilizer, lamina-
heat-cut into the prescribed bag tion by polypropylene should be
size. The bottom of the heat-cut done on the woven cloth before
tube is folded and sewn with a bag making, or thin polyethylene
The kinds of heavy duty bags which and paper has been developed in Japan.
sewing machine. The result is a inner bag should be inserted in the
are being used in Japan at the present The strength, compared with papers so
WO'Ten bag.
time
2) are paper bags, woven
Circular polyethylene
cloth bagbags, far, woven bag as agreat.
is exceedingly liner bag.
The bag will Circular weaving loom
and woven cloth bags. These bags are not break or tear during transport.
PolypropyleneExample
The seamless woven tube cloth is
respectively being used in the proper
of
cloth is laminated with a
put through the printing and cutting Woven Bag Making Plant making plant for flat weaving and
places. film of resin; therefore, the moisture-
machines. Flexo printing is done circular weaving would be as the at-
proof property is excellent, and the
on onebags,
Paper face which
of the seamless
usually havetube;the tached tables.
quality of the
Planned cement can
designing of abe prevented
woven bag
then, of
capacity thepackaging
tube is heat-cut
20 - 30tokg
the from degeneration. Also, filling and
are used for feed, £lour, sugar, rice packing can be handled the same way Table 1: Production Scheme
and wheat (30 kg), and PVC Tableresin,
2; Required Machinery asand Equipment
ordinary paper bag because of the
or
1) for cement weaving is heavy (40 -
Flat which special structure of the bag. It is
50 kg) but which packed in paper
Yarn extrusiOIl and' stretching rrlachine being used for packaging export cement.
Take-up winder. ........•.
bags to avoid the inconvenience during By making use of the good features
Creel stand and beaming machine.
filling and handling. Loom. . ..............••.. of the bag, it is predicted that woven stretched yarn will shrink; therefore,
Printing machine ............................................... cloth bag will be used for packaging annealing is done. The annealed yarn
Polyethylene bagsTubing 20 - 30 kg
for machine various sorts of substance. is wound on a bobbin in a fixed length.
Sewing machine
capacity are used for [Link]
machine. che~i-
cal fertilizer and industnal chemical
Testing machine Process Description 2. Weaving
which must be protected from
Forklift truck. moisture. There are two kinds of weaving
The production of woven cloth bag loom: one is a flat loom which weaves
FOB price of machinery and equipment. . (appeax.) $US 1,914,000
Woven cloth bags are used for export begins with the production of yarn Table
in a flat 3: Required
state, RawisMaterials
and the other a circular
chemical fertilizer,2) rice and wheat Circular weaving (raw material yarn), gdes on to weav- loom which weaves in a tubular state. bags
ing, and ends in bag making. PE or PP pellet. 156 kg/1,000
(60 kg), and productsYarn by extrusion
the combine
and stretching machine. 3 sets Both are copless type weaving machine.
Take-up winder. 6 sets Ink and solvent. 3 kg/1,000 bags
agriculture, which require packaging of which docs not require a cop Winder.
more than 50 kg. 1. Production 29 sets
of yarn [Link]
The . . .types
. . . . of weaving 2will
kg/1be,Oex-
OO bags
Circular and
Printing loom.
cutting machine. 1 set
Sewing machine . Polypropylene or polyethylene
1 set pellet plained below.
Woven cloth bag, Packingcompared [Link] is charged in the hopper1 set of the extruder,
paper bag and polyethylene Testing machine
bag, is heated, passed through11aset die and made
set 1) Flat weaving
Forklift truck.
strong and is suitable for packing and into a tubular film. The tubular mm The yarn wound on the bobbin is
carrying heavy goods. It will
FOB price not tear
of machinery and equipment. is cooled,
... {approx.) $USslit1,462,000
into a fixed width, then set on a creel stand and wound off
or break easily by rough handling and4: Required Manpower delivered continually to the stretching onto the beam as warp yarn by the
Table
bad transporting. Also, since the raw equipment. 'the slit tape-film is heated beaming machine.
material for woven The cloth baglabour
following is not force would be required. Oneby chiefthe hotisplate
engineer requiredof
for the stretching equip-
either flat weaving or circular weaving.
natural fibre as in jute bag and since ment, stretched by the high-speed re- The warp yarn wound on the beam
the raw material is manufactured in No. of Engineer volving Skilled roll and formed
Ordinary into a stretched
Required and the pick yarn wound on the
various parts of the world, it can be shift yarn. When left in amanpower
worker free state, the bobbin are set on the loom. The
worker
obtained at allY1)place and Flat at any time. loom automatically begins moving
weaving
Yarn making
the pick through the warp with a
Recently, a cement Woven Bag Manufacturing Process 9
shuttle to weave a cloth in a sheet
Weavin~ bag consisting of o 45
a combination of polypropylene cloth
Printing state. The woven cloth is wound
Bag forming
I. Flow Diagram Sewing
for Flat W~aving Bag size: o 570 mm width x 1,050 3
2 off by the winder.
3
se mm length3 2) Circular weaving
6tssets Creel
1,000stand and 1
denier 69
Packing and inspecting
The yarn wound on bobbin is set on
1 set
59 sets
Total Beaming
12 x 12/sq. in. 8
1machine
Loom the creel stand arranged at both
2) Circular 4
• This information has been prepared •
1 set
1 set
2 sets
weaving
Yarn making
Output;
Working hours:
~6,000,000 bags/year
8 hours/day
b 27
sides of the circular 100m. The
: byyarn
the Japan
drawnConsulting
out from the Institute:
creel stands
1 set Weaving : (JCI) and
is set onreproduced
the loom inby UNIDOshape
a circular :
o
1 set Printing and cutting
b
Printing machine Tu ing machine
Sewing
Sewing machine
300 days/year All. 6 Packing machine : with
andspecial
is usedpermission
as the warp. The1pick
from CL •
• Further reproduction of which
this docu-
are :
c=> ~~J~tt~O~~5~n~~~a~~~_~~~~=-_ is set on four shuttles
1 set (one shift) 1 54
Packing and inspecting
3 : ment without
inside permission
the loom, and when of lCI
the is :
Totdl Table 5: Required Plant Site Area loom is operated
: prohibited. : the shuttles rotate
in [Link]
: Any circularabout
[Link] pick moves
information :
II. Flow Diagram for Circular
Buildings area of either Weaving
methods of bag making. 40 m x 100 m = 4,000 m2 through the
• contamed warp
should beinsent
a circular
to:. shape,
Required land drea , .. , . " ...
90 m x 120 m = 10,800 m2 and a seamless tube
: IO/COOP, Registry fileisNo.
woven.
10/ The:
Extruder Note: Take-up
~alc~ldtion winder
on the Circular
plant has been based on average figuresloom
of normal opera- woven UNIDO,
: 562112, seamlessP.O.
tubeBox is wound
300,: off

[Link]£JOO
non m japan. by a winder.
• A-1400 Vienna, Austria. •
~ Stretching unit
~FlI!I Fl !tC--j!'rin!H",~••. ::mur;cmHlf!'
2
~
3. Bag making
Printing & Cutting machine Sewi hi The method of bag making using
ewmg mac me Packing machine
flat woven cloth as raw material and
~ ivgvJL~ 14 fil circular woven seamless tube as raw
material will be explained below.
How To Start Manufacturing lndustries FILE: B2
ISle 3215
~-_ .~:lP-" •.••. , !.;.> \' ' ••.... : .!
-

Plast:ic Fila:rnent: ·T~ine and

Rope Making Plant:
Twine and rope have so far been b) Below 5 mme (Twine) various kinds of net, agricultural
made of natural fibers for the purpose Hand craft material, material for material
of fisheries, agriculture, ships, land
transportation, etc. c) 5 ~ 10 mmo (Rope)
Agricultural material, packing and
However, the demand for twine and transportation materials, fishing
rope made of natural fibers has decreas- material
ed because of the reasons that they are
liable to rot, injure hands while handling d) 0 ~ 22 mm¢ (Rope)
them, they must be dried in the sun Packing and transportation mate-
when they got wet and the supply of rials, material for fixed fishing net
natural fibers is on the decrease. In e) Above 20 mm¢ (Rope)
addition, the recent rapid development Fishing material, transportation
of petrochemistry has caused the twine material
and rope to be made from such plastic
matters as nylon, polyethylene, poly- 2) Manufacturing of ropes
propylene and the like. In contrast with
One hundred and fifty pieces of
natural fibers, these chemical products
monofilament, which are extruded in
have conspicuously reduced the liability
1-1) are cooled and solidified in the
to rot and improved various other
quenching bath, and go in order from
defects. As a result, light, strong and
No. 1 roller stand, stretching bath,
handy plastic filament twine and rope
No. 2 roller bath, and to No.2 roller
have come to be produced both in
stand, and are heated in the stretching
Japan and in other countries.
bath, and are stretched to the length
Process Description seven to ten times between No.1 roller
stand and No. 2 roller stand.
1) Manufacturing of plastic The stretched mono filaments are
monofilament annealed in the subsequent annealing
bath, and become 400 denier mono-
The plastic filament twine and rope filaments. Each filament is wound
are made from such plastic resins as round the winder bobbin. The thickness
nylon, polyethylene and polypropylene. of a monofilament is decided on accord-
They are extruded in the form of a ing to its use, and is also controlled by
filament by an extruder, and are the extruding rate of the extruder and
stretched to the length three to thirteen by the stretching ratio.
times, and the filaments having 200 to The monofilament bobbin is set on
6,000 denier are extruded, and are the 4-spindle strander S-type creel stand,
wound round the monofilament bobbin. and a fixed number of monofilaments
In the case of a polyethylene fila- are twisted by -l-spindlc strander. In this
ment, one having 300 to 800 denier is way 1 to 2.5 mm diameter strands are
usually extruded. The tensile strength of produced. These strands are wound
a 3,000 denier polypropylene filament round the flange bobbin, and 3 flange
is 5 to 7.5 g/denier. With these filaments bobbins are set on the twine layer to
as basic materials, fishing net, fishing produce 2 to 5 mm diameter twines.
string, rope, casting net, spoon net, The twines are then rewound round the
brush, etc. are manufactured. balling machine, and become products.

The twine and rope, which are made A fixed number of monofilaments
by twisting many filaments are em- are twisted by the ring doubling .flame
ployed for the following purposes: on the creel stand. As the first yarns
thus produced are still thin, a fixed
Examples: number of yar~s are set on the dies
twister creel and are twisted to become
a) Monofilament
the second yarns. The second yarns are
Nylon: Materials for fishing line,
set on the strander, and strands are
casting net and spoon net, brush
produced by twisting a fixed number of
Polyethylene:
the second yarns. Three strand bobbins
Materials for insect net, fishing are set on the rope layer, and 5 to 12
mm diameter ropes are produced by
net
twisting the three strands. The ropes are
then rewound by the coiling machine to become products.
Strands are produced by setting the
second yarns on the cylindrical strander
and by twisting a fixed number of rope
yarns. The strand bobbins are set on the
cylindrical tandem lead machine, and
ropes are produced by twisting the three
strands. As this machine coils the ropes,
no coiling machine is required.
Rope yarns are set on the closer-type
strander, and strands are produced by
twisting a fixed number of rope yarns,
and ropes are produced by twisting the
strands by the tandem lead machine.
This does not require the coiling ma-
chine either. Thus, coiled ropes having
12 to 32 mm diameter are produced.
The above yarns are set on the closer-
type strander, and a fixed number of
rope yarns are twisted, and the pro-
duced three strands are twisted by the
closer. Thus, ropes having more than a
32 mm diameter are produced. These
being produced in the shape of coiled
ropes, no coiling machine is required.

Example of Plastic Filament

Rope Making Plant
1) production Capacity

Monofilament .. 5,000 kg/24 hrs.

(as rope yarn ... 4,500 kg/16 hrs.)

Breakdown of Final Products

a) Rope. 2 - 5 mm dia. 195 kg/8 hr s.
b) Rope. 5 - 8 mm dia. 580 kg/8 hrs.
c) Rope, 8 - 12 mm dia. 420 kg/8 hrs.
d) Rope. 10 -18 mm dia. 600 kg/8 hrs.
e) Rope. 13 - 26 mm dia . 1,130 kg/8 hrs.
f) Rope. 20 - 32 mm dia. l,680 kg/8 hrs.
g) Rope. 28 - 36 mm dia. 1.215 kg/8 hrs,
h) Rope, 38 - 65 mrn dia , 3,360 kg/8 hrs.

2) [Link] Raw Materials and

Utilities
Polypropylene and/or HDPE

· ..... total 5,000 kg/24 hrs.

Electric power
· ..... 840 kw x 24 '" 20,160 kwh
Cooling water

· . . . .. 120 tons/24 hrs.

3) Required Manpower

Engineer ..... " 2

Worker
9 x 2 shifts= 18
14 x 3 shifts= 42
Clerical worker. . . 8

Total ........................68
 Outline of Rope Making Process and Machinery
Daily Capacity: 5,000 kg
2.
P.E A.' P.P
MUIlUfil<llllcn
t 4-Spindles
Resin srrunder
DIT 75E type S - type 3.
extruder
3 lines 6 sets 195 kg/8 Ius.
5,000 kg/24 hrs .
-t-Spindlcs
strandcr
M - type
3 sets 580 kg/8 hrs.

Ring doubling frame

100 spindles

5 sets

8" dies twister

18 - F

5 sets 4,500 kg/16 hrs.

4) FOB Price of Machinery and

Equip-
ment ... (approx.) $US 2,500,000
including monofilament, twine and
rope manufacturing machinery and
equipment.
5) Required Area for Plant Site
Building ..................(approx.) 2,800 m2
Land ........................(approx.) 8,500 m2

Note: It is possible to construct a plant

having a smaller capacity than
that. In this case, pertinent data
must be prepared according' to
the kind of product and the
production capacity if req uire.d ,

2
 FILE: B3
4.
ISIC 3215

How To Start Manufacturing Industries 2 - 5 mm dia rope

2 - 5 mm dia
Balling

Polypropylene Soft Rope and String Making Plant

3·Piy twine
machine
195 kg/8 1m.

[Link] 5 - 8 rnm dirt

Rope coiling
rope layer 3·Ply <ope
machine
M - type 580 kg/B hrs.
2 sets 580 kg/8 hrs. 2 sets
Up to now, ropes and strings have Fig. 1 Process Flow Sheet for Soft Rope Making plant
been made of hemp, jute, cotton, straw, 2-Spindles
I-Spindles Rope coiling
8-12 rom dia
f----I strander 3·Ply rope
paper and the like which are called a For mammoth layer
mammoth layer
Stretching unit machine
420 kg/8 hrs.
natural fiber. However, they have had 3 sets 420 kg/8 hrs. 2 sets(2)
420 kg/8 hrs. 2 sets
4,650 kg/16 lus .
some troubles of injuring fingers or
hands in binding and deterioration by High speed cy linder
High speed cylinder 10 - 18 mm dia
soaking up water in binding, transport- type s t ra nd er T-20 type
type tandem lead machine
3-Ply rope
T·20 type
ing or storing. 1 set
2 sets
With the advance of the development
of petrochemical technology, ropes and 13 - 26 mm dia rope
High speed cylinder High speed cylinder
13 - 26 mm dia
type strander type tandem lead machine
strings are being made of synthetic T·30 type
3-Ply rope
T·30 type
fibers like nylon, polyethylene or poly- 3 sets 1 set
propylene and troubles mentioned 20 - 32 mm dia rope
before have being solved. It is described High speed cylinder High speed cylinder
type str andcr type tandem lead machine
that the string is made by stretching of TAO type TAO type 20 - 32 mm dia
3·Ply rope
polypropylene tubular film and the 2 sets 1 set
rope is made by twisting of three pieces 28 -- 36 mm dia rope
of the string described above. The string 810 mm dia.
28 - 36 mm dia
3·Ply rope
is used for both mechanical and manual 810 mm dia. Bobbin closer 600 kg/8 hrs.
Bobbin srr andcr
operation for binding of consumer 2 sees 600 kg/8 hrs. 1 set 600 kg/8 hrs.
goods and for binding of agricultural
products and others, too. 915 mm dia. 38 - 65 mm dia
3-Ply rope
Rope is chemically and physically 915 mm dia. Bobbin closer
3,360 kg/8 hrs.
Bobbin strander
stable and strong but very soft and it 2 sets 3,360 kg/8 hrs. 38 - 65 mm dia rope
can be widely utilized for general pur- 1 set 3,360 kg/8 hrs.

pose.

Features of Products

1) String
Denier: 3,000 - 20,000
Tensile strength: 3 - 4 g/denier
Type of hunk:
Non bobbin wind-
ing coil

Uncoiling from the

center of hunk 2-spindles 810 mm dia bobbin closer
Winding length: Can be adjusted as Rope Layer M type
2) Soft rope ordered
Diameter of twisted rope:
3 -10 mm • This information has been prepared •
Tensile strength: 3 - 4 g/denier : by the Japan Consulting Institute:
Type of hunk: Non bobbin wind- : (JCI) and reproduced by UNIDO :
ing in coil • with special permission from J CI. •
Uncoiling from the : Further reproduction of this docu- :
: ment without permission of JCI is :
center of hunk
: prohibited. :
Winding length: Can be adjusted as
: Any inquiry about the information :
ordered • contained should be sent to:.
: IO/COOP, Registry file No. ID/ :
Process Description (Fig. 1) : 562/12, UNIDO, P.O. Box 300,:
• A-1400 Vienna, Austria. •
1) Raw material A (polypropylene) is
fed to extruder of Tubular Film Unit 915 mm dia bobbin closer
(1). Polypropylene is melted in ex-
truder and extruded in a tubular
form and it is blown up by the air to
make a tubular film which is slit at
the center of film tube into two
 Tape rewinder 2 sets
Rope twister
Rope rewinder 4 sets
Tape rewinder
2 sets
Total ... (approx.) $US 238,000

1 set
The cost of machinery and equip-
ment is estimated at FOB price, Japan
but the erection cost is not included in.
5.

Production Capacity

Strings of 3,000 denier to 20,000

denier can be produced by this plant
and Iurther soft ropes of diameter
1 [Link] 6 m.m. can also be made.
Their production capacity varies de-
pending upon varieties of products. In
case, 15,000 denier string and 45,000
denier soft rope are manufactured, the
manufacturing capacity of a soft rope is
30 kg/h and the capacity of a small
Soft Rope (C)
hunk string and a large hunk string is Tape rewinder
t----Small hunk string (D)
15 kg/h of each. (7)

L- ______________________Large hunk string (B)

1) Annual production fo soft rope
and
strings
The production of the plant designed sheets of flat film and then they are Screw: 50 m.m.e, 45 - 135
in this project is as follows under the transferred to Stretching Unit (2). r.p.m.
n ext conditions: Film is heated on hot plate and Motor: 15 kw.
stretched 3 to 6 times successively Capacity: 12 - 35 kg/h
a. Two shift-operation in 16 hours according to aimed usage and wound b. Film take-up equipment
a day by Tape Winder (3). The procedure Layflat width of film:
from Extruder to Tape Winder is 300 - 500 m.m.
a. 330 days operation a year
conducted by a continuous method.
Soft rope ........................................... 2) Stretching Unit. . . . . . . . .. 2 sets
The wound string has a shape of large
158At 31,680 km 45,000 denier Type; Hot plate type
hunk (wound long length string in
Small hunk string ................................ Stretching ratio:
79.2t 47,520 krn 15,000 denier other word) and it can be marketed
2) LargeRaw hunkmaterial requirement
string ................................... to large users. The large hunk string
is rewound by a bobbin for exclusive 2.5 - 6.0
79.2t 47,520 km 15,000 denier Denier of tape:
Tape grade polypropylene pellet is use for it after rewinding by Tape
required. 3,000 - 20,000
Rewinder (4) in order to send to
Consumption of p.p. pellet 3) Tape Winder 4 sets
Rope Twister (5) and three pieces of
I Type: Two bobbin type, auto
Loss 5 strings are twisted into a rope, there.
960 kg x 330 = 316.8 t/y winding
Total The twisted rope is rewound by
15.84 t/y
Rope Rewinder (6) for the unit to be
332.7 t/y 4) Tape Rewinder . . . . . . . . .. 2 sets
3) Utility requirement sold, and the rewinder is equipped with
Utility the length meter by which rope is cut Tape width; 1 to 3 m.m.
Electric power ..................................... automatically after winding the length Capacity: 15 kg tape/h
. 101.6 kw x 16 hours x 330 days desired by means of setting the adjust-
= 536,448 kwh ment of the length. 5) Rope Twister. . . . . . . . . .. 4 sets
Cooling water ...................................... Large hunk string (B) is too long for Capacity: 7.5 kg rope/h
1.0 m3 x 16 hours x 330 days general use and so it is sold as a product
= 5,280 m3 for general use after rewinding by Tape 6) Rope Winder . 2 sets
Rewinder (7) in the small hunk (short Capacity: 15 kg/h
4) Manpower length string in other word). Tape Re-
Engineer ....................... winder is equipped with a lengthmeter 7) Tape Rewinder
Shift operator .....................5 x 2 shifts by which string is cut automatically Capacity: 15 kg/h
Routine operator .. 3 after winding the length desired by
means of setting the adjustment of the . Machinery and Equipment Cost
Total ........................14 man-day
length.
Stretched Tape Unit (approx.) $US 205,000
Required Machinery and Tubular film unit 2 sets
2 Stretching unit 2 sets
Equipment
Tape winder 4 sets
1) Tubul
ar Film Unit ..... 2 sets Soft Rope Twister and Rewinder •....
a. Extruder. . . . . . . . . . .. 2 sets . . . . . . . . . .. (approx.) $US 33,000
 FILE: B4

n
, ,
ISle 3213

--,..;: '.:----.

How To Start Manufacturing Industries

Socks Making Plant

There are two impressive things The stripping function, the spiral machine. There is keen competition in
about socks (half hose): 1) socks most function, and general Jacquard are pat- the pattern function of links Jacquard
frankly exhibit elasticity and plasticity tern functions of the single cylinder and links wrapping Jacquard of the
which are essentially characteristic of double cylinder machine. As for the
knit; 2) the first step taken in mechaniz- matter of quality improvement, the
ing the knitting industry began from the trend is toward fine gauge. All kinds of
development of the socks making ma- Soft rope string manufacturing machine (General view)
chine (hosiery machine).
fine gauge machine have been develop-
The history of present-day (knit) ed. As for the matter of speed-up, the
mechanization began when the English single cylinder machine now runs at
curate William Lee designed a manually 5) Plant site area
operated socks making machine in Floor area of factory building
1589. Functioning as a protective wear · ........................, .................400 m2
for the feet and playing the role of Floor area of warehouse .
beautifying the leg lines, and after · ............................................100 m2
undergoing many changes, socks knit- Floor area of office building ....
ting industry gradually developed to the ·............... 50 m2
present state. Especially after World Total ..............................550 m2
War II, the socks knitting industry made
rapid progress. The reasons have been
as follows:

(1) The change in everyday clothing

pushed socks up to the realm of
fashion.
(2) New synthetic fibre which con-
Winder of string
secutively appeared after World
War II markedly improved knit- 200 - 240 r.p.m. The double cylinder
ting performance and quality of machine runs at 150 - 200 r.p.m. The
knitted goods. number of feeders of both machines
(3) The appearance of all sorts of has increased to 2 - 3, and the trend is
new high speed, high perform- toward multi feeders.
ance knitting machines.
Spun yarn of natural fibre (cotton,
In socks milking, small diameter circu-
wool), textured yarn of nylon, mixed
lar knitting machine is used to form the
heel and toe by making a half rotation • This information has been prepared •
round trip. The other parts of the socks : by the Japan Consulting Institute:
are formed by full rotation. : (JCI) and reproduced by UNIOO :
: with special permission from J CL •
The standard size socks knitting • Further reproduction of this docu- :
machine has a cylinder diameter of 3 : ment without permission of ]CI is :
- 4 inches. Generally, there are 350 : prohibited. :
needles or less. : Any inquiry about the information :
• contained should be sent to:.
The classification of socks knitting : IO/COOP, Registry file No. ID/ :
machines is shown in Fig. 1. They are : 562/12, UNIOO, P.O. Box 300,:
the single cylinder machine (plain stitch • A-1400 Vienna, Austria. •
type) and the double cylinder machine spun yarn of synthetic fibre and natural
(rib and links type). Recently, the fibre, and mixed knit of synthetic fila-
double cylinder socks knitting machine ment textured yarn and spun yarn of
is used widely. As for the single cylinder natural fibre are used as raw materials
socks knitting machine, the double welt for socks.
socks knitting machine is used mainly,
Process Description
Improvement in pattern function and
production of high quality goods are 1) Arrival of raw materials
advancements made in socks knitting
machine. Also, productivity has been The raw material yarn comes in
improved. various forms: cheese, cone, pirn. The
raw material yarns can also be classified socks" There fore , socks will continuous- 6) Second inspection and mending
by yarn count and denier, which are ly run through the knitting machine in
Inspection of the socks is done again
sizes of yarn. Classification can also be a cylindrical shape. Accordingly, the
after linking is completed, and socks
made by colours. These raw material chain of socks which come out from the
with knitting damage are mended.
are arranged neatly and kept in the raw knitting machine is separated into indi-
Mending is done so that the damage
materials storeroom. vidual piece of socks by removing the
would be unrecognizable. Socks which
yarn by hand from the drawn thread
pass the inspection will go to the next
2) Winding course. Recently a separating device has
process.
been developed, and this device will
The raw material yarn which has separate each piece while knitting. 7) Soaping and dyeing
been delivered is wound onto cones that
are most suitable for knitting. The yarn The knitting order will be as follows: Socks which have gone through the
is oiled while being wound onto the (see Fig. 2) various processes will have oil stains and
cone. Oiling of the yarn will make the will be soiled with dust. Soaping is done
yarn slide easily, and will prevent knit- Welt knitting -+ Leg knitting -+ to remove the oil stains and dust; then,
,-ing damage and will improve knitting the socks are dyed.
efficiency. Winding is half of knitting. Heel formation -+ Knitting instep and
sale -+ Knitting the toe 8) Setting and finishing
3) Knitting
4) First inspection Shaping of socks is done in this
The yarn wound on the cone" is set process. The most suitable finishing is
Knitted socks are inspected for knit-
on the designated socks knitting ma- done, depending on the sort of raw
ting damage and other flaws, and faulty
chine and knitted into the shape of material used and the characteristics of
goods are eliminated.
socks. the finished product, so that the quality
5) Linking the toe of the product will be heightened and
In the single cylinder socks knitting the product will have a good look.
machine, the completed socks come out This is the linking of the open part Generally, finishing of the socks is done
separately one foot (piece) at a time. of the toe of the knitted socks. Linking by steam setting.
This is called the separate method. is done with the socks turned inside out.
After linking is completed, the drawn
In the double cylinder knitting ma-
yarn of the drawn thread stitch is
chine one piece of the socks is com-
drawn out, and one piece of socks is
pleted; then, a drawn thread makes its
completed.
entry and knitting begins continuously
from the welt of the next piece of

9) Final inspection and packaging can also be ~sed for non Jacquard), and pairs per 10 hours. The cost of one
the price of one machine is approxi- machine is $US 1,566. Six sets of
Final inspection before shipping mately: $US 10,500. machine would be $US 9,400.
must be done carefully of the finished One double cylinder machine is
goods for each process. Goods which approximately $US 7,600.
have passed inspection are arranged into A setup of 12 single cylinder ma- (3) Setting machine
pairs by matching the size, colour, and chines and 12 double cylinder machines,
pattern; they are packed in boxes and a total of 24 machines, would be Socks are fit on a mould, and the
shipped out. $US 217,200. machine sets and forms the socks by
heat of steam. One machine will set
Example of Socks Making Plant 2,400 pairs per 10 hours. The cost of a
3) Auxiliary Machinery and Equipment
machine of this capacity would be
1) Production Capacity (1) Winding machine $US 19,000 for semi-automatic and
The kinds of socks knitting machines $US 3,300 for fully automatic. One
A cone winder of about 24 drums is of either machines would be sufficient.
for an economically minimum scale
used. The speed of yarn winding on
plant would be as follows:
cone is 200 meters per minute per (4) Dyeing machine
Single cylinder double welt socks drum .. [Link] of a machine with 24
knitting machine .....................12 sets drums is $US 9,500. The paddle dyeing machine is re-
Double cylinder socks knitting commended for dyeing knitted socks.
machine . . . . . . . , . . . . 12 sets (2) Linking machine One machine has a capacity of dyeing
Total ..................................24 sets and soaping approximately 50 kilograms
The toe of knitted socks is open, so a
As to productivity one single cylin- of socks per operation. The cost would
liJlking machine is used to link the open-
der machine will knit 40 - 140 pairs per be approximately $US 9,500. One machine
ing. This is called the linking process.
10 hours, and one double cylinder would be sufficient.
This work requires skill. One person
machine will knit 40 - 80 pairs per 10
operates one linking machine, and a
hours. The margin in productivity is due (5) Steam iron
skilled worker would link 200 - 300
to the difference in gauge, the knitted
Two steam irons would be required.
structure, and the type of machine.
They are used for finishing the socks.
Let us say that approximately 50 2
The cost of one steam iron would be
pairs of socks are produced by a socks
$US 38, so 2 x $US 38 = $US 76.
knitting machine operating 10 hrs/day.
If 24 machines are put in operation, the (6) Boiler for steam
production would be 50 x 24 = 1200
pairs/day. One set of boiler for steam would be
required for the setting machine and the
2) Required Machinery and dyeing machine. The pressure should be
Equipment 8 kg/cm2 and the volume of steam
generation should be about 500 kg per
The single cylinder machine is a high
hour. The cost would be approximately
class double welt type Jacquard (which
$US 14,300. aforementioned case of nylon 100 is dyestuff is used for dyeing. The quan-
to be produced. Then, the yarn required tity required for either would be 3 of
4) Required Raw Materials and Utilities would be 1,2007 10 x 500 = 60,000 g the weight of cotton socks to be dyed
= 60 kg/day. for winter wear, and 1 - 1.5 for
(1) Yarn
summer wear. That is, for winter wear
When making nylon 100 socks,
(2) Latex rubber yarn the quantity would be 60 kg x 0.03 =
stretch nylon 110/2 denier yarn would 1.8 kg/day, and for summer wear the
To bring out stretch in the welt of
be suitable. The weight of the yarn will quantity would be 60 kg x 0.01 - 0.015
socks the welt is knit with different
be 400 grams per 10 pairs. Let us say yarn, and latex rubber yarn is inserted = 0.6 - 0.9 kg/day.
that approximately 50 pairs of socks are in the welt. The latex yarn is made by
(4) Water
produced by a socks knitting machine covering cotton yarn or nylon yarn over
operating 10 hrs/day. If 24 machines latex rubber. The quantity required, for The total amount of water required
are put in operation, the production the plant described above, is approxi- would be approximately 9 - 10 tons/
would be 50 x 24 = 1,200 pairs/day. mately 3 kg/day. day.
Therefore, the yarn required would be
1,200 7 10 x 400 = 48,000 g = 48 kg/ (3) Dyestuff (5) Electric power
day.
If only nylon socks are to be pro- The total consumption of electric
When making socks with a mixture
duced in the plant, the production, as al- power is approximately 40 kWh.
of 80 cotton yarn and 20 nylon
ready stated in (1), would be 48 kg/day.
yarn, 40/2 yarn count cotton and 70/1 5) Required Manpower
Acid dyestuff is used for dyeing. Since
denier stretch nylon are used. The face
most winter wear are dark coloured, 3
should be cotton and the back should The layout of hosiery plant will be as
of the weight of the socks to be dyed
be stretch nylon, and the knitting shown in Fig. 3. The distribution of
would be required; that is, 48 kg x 0.03
should be plating structure. The weight
= 1.44 kg/day. Most summer wear are personnel in the plant will be two
of the yarn in this case would be 500 persons for winding section, three or
light coloured, so the dyestuff required
grams per 10 pairs. Let us say that the four persons for knitting section (one
would be 1 - 1.5 of the weight of the
same number of pairs of socks as in the person can operate and run 7 to 12
socks to be dyed; that is, 48 kg x 0.01
- 0.Q15 = 0.48 - 0.72 kg/day. socks knitting machines), six persons for
If only cotton socks are to be pro- linking section, two persons for check-
duced in the plant, the production, as al- ing shop, two persons for setting ma-
ready stated in (1), would be 60 kg/day. chine, two persons for dyeing room, one
In this case, reactive dyestuff or direct person for office, and one person for

material and finished goods store. FILE: B4

Besides, a boiler room should be set up,
and one boiler man would be required.
The total number of personnel would
be about 22 or 23.
ml. The floor space of the dyeing room
6) Required Area for Plant Site is 4 m x 5 m = 20 m2• Also, a boiler
room would be required, and the floor
The layout of a minimum scale plant
space is 7 m x 7 m = 49 m2•
is shown in Fig. 3. The floor space of
the main room is 32 m x 12 m = 384 The setting machine room uses
steam, so a heat insulating wall should
be set up between the other rooms.

The building is a steel structure one-

storied building.
 Fig. 1
Non Jacquard machine
{ Jacquard machine
Single welt machine
Non Jacquard machine
Jacquard machine
{{
Double welt machine
{

Single cylinder system machine

Socks knitting machine

Double cylinder system machine

Fig. 2

b
Non Jacquard machine
.

hi
{ Links Jacquard machine
acquar mac me
c .k
.
hi
Lin s wrappmg mac me

a (Welt) • This information has been prepared _

b (Rib top) : by the Japan Consulting Institute:
c (Leg) : (jCI) and reproduced by UN IDa :
d (Instep) : with special permission from J CI. •
e (Heel) - Further reproduction of this docu- :
f (Sale) : ment without permission of lCI is :
g (Toe) : prohibited. :
h (High splicing)
I (Length) : Any inquiry about the information :
s •... (Size) - contained should be sent to:.
: la/COOP, Registry file No. ID/ :
: 562112, UNIDO, P.O. Box 300,:
• A-1400 Vienna, Austria. •

Double welt socks knitting machine

{ J d
 Dimensions Gram/Piece Piece/Year Tons/Year Colour Design Sort FILE: B5
description (em)
ISle 3212
125 x 64 360 97,222 35 Multi colour Plain Bath towel
How To Start
Medium quality Manufacturing
35 x 33 60 Industries
250,000 15 Multi colour Plain Wash towel
terry towels 100 x 50 340 73,530 25 Single colour Hotel! Bath mat

Terry Towel Plant

53 x 40 100 150,000 15 Single colour Restaurant Hand towel
name
125 x 70 540 83,335 45 Multi colour Plain Bath towel
High quality
terry towels 110 x 60 400 75,000 30 Multi colour Embossed Bath towel
115 X 210 560 44,645 25 Single colour
plain Towel sheet
Low quality (White)
terry towels 80 x 40 275 10 Single colour Plain Bath mat
The towel is a fabric which has un- 36,365
Table 2: Required Machinery
(White) and Equipment
cut loops formed from warp yarns while
being woven on either one or both sides. Item No.
Since these loops are called Terry Pile, Main production Machine
this fabric is also called Terry fabric. 1) Winding
High speed cheese winder (Soft winder) ..................•...... 2
2) Cheese Dyeing and Bleaching
High temperature & high pressure cheese dyeing machine. . . . • . . • . . . . .. 2
High pressure rapid drying machine ...............................................................................
3) Rewinding
High speed cone winder ..........•........................ ". 2

.
One side towel 4) Preparating for Weaving
Sectional warping machine ............................................................................................................

D Rewinding machine ........................................................................................................................

Universal warp tying machine ............................................................................................
Reaching-in machine .....................................................................................................
~ 5)
Automatic pirn winder .................................................................................................
Weaving
Cop change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Both sides towel Automatic towel loom
1 xl, RS 96" (RS: Reed Speed)
The towel can be classified into three Dobby 2 cylinders, 24 shafts
groups, namely the figured towel which Cop change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14
has woven figures, the dobby towel Automatic towel loom
1 x I,RS96"
which has small geometrical figures, and
the plain towel which does not have ] acquard 900
figures. All towels are woven from three Cop change .. . . . . . . . . . . • . . . . . . . . . . . . . . . . • . . . . . . . . . . . . .. 10
kinds of yarns, namely ground warp, Towel loom
loop warp, and weft. 1 x 4, RS 74"
Dobby 2 cylinders, 24 shafts
There is another way of classifying 6) Inspecting
towels. One is bleached, dyed, printed, Cloth plaiting inspecting machine ..................................................................................
etc. on the plain towel woven of grey 7) Finishing
cotton yarn and the other is coloured Lock stitch sewing machine ................................................................................................................3
Over lock stitch sewing machine ........................................................................................................3
woven of dyed or bleached yarn.
FOB price of machinery and equipment . _ . . . . . . . .. (approx.) $US 1,267,000
The quality of the towel is largely including spare parts for 1 year's normal operation
dependent upon the density of loops,
Auxiliary Equipment and Accessories for Production Machine
i.e , the denser, the better.
FOB price ............................................................ _ ..........................(approx.) $US 333,000
Loops can be generated either every
Laboratory Equipment
three warps or every four warps. Hence,
FOB price ............................................................................................(approx.) $US 24,000
generally speaking, towels of good
quality have loops on every three warps Total FOB price of production machine and equipment. (approx.) $US 1,624,000
and are consequently of high loop
Note: 1) Erection supervising and technical inscrucring fee are not included in the
density.
above price.
The trade of towels is usually basing
2) Engineering and know-how fee shall be estimated separately.

Table 1: - Production Sheme

N

Dyestuff and ~- Fig. 2: Required Area for plant

2-Soft winder

chemical storage
0
0
q
!::;
lillillJ

1
f

0 2-Rewinder -
0 U -
I-Pitn winder
0

0 1-Sectional warper
0

o_

r-- r-- r--

1-Inspecting
~
() o machine 1

~ReaChing-in
t--

\-1
t--

V
f

I
ml i
machine

0 0

f PC:_=:J 0
0
0
0
,.: .,;
Laboratory
~f-- ~ cc

I-Rewinding machine
Sanitary ~-1 i

f
~
Softener and [
CJCJ CJ CJ 00
boiler room
CJCJ 0 0 00 0
0
0

DO
-;
DO 0 D
Spare parts storage
DO 0 D 00
48-Loom

Maintenance room
DO 0 D bo
Work shop
DO 0 D PO 0

bD
0

DO 0 0 ,.:

D bo
Electric room

(Distribution)

f----12,500
DO
12,500
0
12,500 12,500~
I
Unit:m

50,000

Operative condition
Working hour: 8 hours/day 1
Working day: 250 days/year
6.
Size (cm)/PC. 125 x 64
Final
Piece/day 388.89
product Fig. 1: Process Flow Sheet for Towel plant
Piece/year 97,222

Cotton Ne 20 Cotton Ne 20/2 Cotton Ne 30/2 Cotton Ne 40/2

413.51 104.67 35.91

1-1 Cheese winder

(Soft winder)
Cheese dyeing
2-
1 machine

2- Drying machine
2

Cone winder
3-
(Rewinder )
1

--, I
I
I

•
I

Building _______________________________________________________________. _ . _ .••...... _ . _ 4,250 m'

Area for main production machine 3,700" m1
Utility service zone 550 m2
Exclusion: Administration office, warehouse. cafeteria and dressing room for labour etc.
Land ..........................................................................................................._ ..............._ ............Approx. 7,000 m'
Classification of yarn

G.W.: Ground warp

P.: Pile
W.: Weft
w.
Sectional warping
4-1 machine

4- Rewinding machine
2
4- Tying machine or
3 Reaching-in machine
4-
44- Pirn winder
5

5- Loom with Dobby

1 1 x 1, RS 96"

5- Loom with Jacquard

2 1 x I, RS 96"

Loom with Dobby

5-3 1 x 4, RS 74"

6- Inspecting machine
1
7-
Sewing machine
1
7-
2 Strapping machine

35 x 33 50x 60 I 115
100 x110 210
53 xx125
BO xx 70
40 40

1,000.00 294.12 17B.58

600.00300.00
145.46
333.34

250,000 73,530 36,365

44,645
83,335
150,000
75,000

- )
 FILE: B5
.-,

on weight which can be adjusted by

loop length, fineness of yarn, loop
density, etc.
Towels can be also classified in ac-
cordance with the usage as follows:
Bath towel, hand towel, wash towel,
guest towel, kitchen towel, dish cloth,
bath sheet,
The bath
plant mat, [Link] produce the
is intended
total capacityExample of 200 tonsofof various
kinds of Terry TerryTowel Towel perPlant
year. All
cotton yarns shall be bleached or dyed
at the mill. The plant is planned to be
operated on one shift basis (250 days x
8 hours per year).
• This information has been prepared.
by However, an increase Institute in production
Automatic cop change capacity : towel theloom Japan Consulting :
: (JCI) andshall be easilybyachieved
reproduced UNIDOby :
: adding more permission
operation hours
fromwithout
Preparation
with special ICI. •
Table 3: Required Utility Quantity creating for MainWeaving
bottlenecks. Production Machine
• Further The1 reproduction
plant shall of&this
be capable
Inspecting packingdocu-
of produc- :
Softening Cooling
: ing
ment any without
types
Laboratory permission
of towels waterwithof lCI
up
ton/hr. isSteam
to
water 4:[Link]/C
Machine
kg/hr.
ton/hr.
Note: Equipments for the above utility consumption shall be required as follows:
: prohibited.
1. Packaged steam boiler . . . . . . . 2. weft
. . . . . colours
:
. . . . . . . . . .and
.........................1,000 . . any
. . . . ..number
. . ...............,
2 15.0
setsCheese ofdyeing
warp
................................20.0
machine
Total actual steam output: 1 colours.
........................1,000
2,000 kg/hr. x 2 ...................- ........•... Drying18.0 machine 26
: Any inquiry about the information :
2. Water softening plant ............................•..•.. 1 set
Capacity:
The
• contained
Dyeing,
tenance
plant shall
25 m'/hL should be sent to:.
Winding & preparanon also l be capable of Total 38.09
2,000
15.0

: producing
IO/COOP,towels
3. Forced draught cooling tower .............•.............. , 1 set with
Registry Storage embossed design 13
file No. IDI :
Circulation water volume: : as 38well
562112,m13/hr. asUNIDO,towelsWeaving bearing
Winding
P.O. &Box the300,:
finishingnames------' [ 68
Table 4: Suggestive
Note:Management and administrationOrganization
•of
InstallUtility
ed
Total M owners
A-1400
staff
otor
Forman Poare
& electricity foin
werVienna,
not and
the
rincluded
M ain M Labour
case
ain
Dyeing
chi neof
Austria.
the Allocation
Hotels.
above • table.
bleaching
& Total 300 kW Worker
Leader378
34