My First year MTech (Project Mgmt) students from Mumbai's Premier Technical Institute VJTI were tasked to submit a Project as a part of their Supply Chain Management - they chose a very socially pertinent topic covering environmental and a human issue affecting the country. Here it is.

1. From Loom
To Bloom
Under the guidance of
Prof. Balaji Ramadurai
Anupriya Mitra
(162201004)
anupriya.mitravjti18@gmail.com
9403761513
Mrinmayi Tamboskar
(162201002)
mrinmayi.tamboskarvjti18@
gmail.com
9920329105
Ansari Aadil
(162200008)
aadil.ansarivjti18@gmail.com
8976434598
Jeet Trivedi
(162200021)
jeet.trivedivjti18@gmail.com
9714368522
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2. Defining the Problem
➢ India is one of the largest producers of textiles and
garments – employing the second largest labor force
after agriculture, - 25 million workers, according to the
2015 annual report of the textile ministry.
➢ The second largest component in the textile industry-
decentralized power looms and knitting contributes to
2% of India’s GDP.
➢ Maharashtra, with over 1.1 million power looms, is one
of the largest power loom hubs in the country.
Malegaon, directly employs 3,86,000.and accounts for 4
lakhs looms.
➢ The Indian textile industry is challenged by falling
exports, low productivity and rising
prices, IndiaSpend reported in July 2016.
➢ This industry uses 10,000 different dyes & pigments
and accounts for huge requirement for water.
➢ Major portion of the chemicals are lost to effluents
during the dyeing & finishing operations
➢ Unfortunately, most of these dyes escape conventional
wastewater treatment processes and are hazardous.
➢ Action by Environmental groups and statutory
regulations accounted for closure of several units and
resultant huge unemployment
0
50
100
150
200
250
2009 2010 2011 2017E 2023E
India’s textile market size (USD
billion)
70
225
145
89
78
India’s Textile Market Share ($ billion)
Textile
Apparel
69%
31%
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3. ➢ Textiles were the largest creator of Indian
formal-sector jobs, with 4,99,000 added over
the last three years, IndiaSpend
reported in July 2016.
➢ There is strong international evidence that
exports help create additional jobs and push
up wage and income growth.
Export comparison with other countries
Current Textile Supply Chain Network
Export Comparison & Current SCM Network
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4. Garment Supply Chain Structure
Fiber
Production
Natural
Fibers
Synthetic
Fibers
Blended
Fibers
Plant
Fibers
Animal
Fibers
Acrylic
Polyester
Nylon
Cotton Production stage
Fancy
Yarns
Regular
Yarns
Spinning
Spinning stage
Fabric manufacturing stage
Garment
Producti
on
Regular
Yarns
Regular
Yarns
Regular
Yarns
Regular
Yarns
Regular
Yarns
Retailing
Regular
Yarns
Regular
Yarns
Regular
Yarns
Regular
Yarns
Regular
Yarns
Market
Customers
Product Flow
Information Flow
Garment
Manufact-
uring stage
Regular
Yarns
Regular
Yarns
Regular
Yarns
Fabric
Producti
on
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5. Flow Process Chart
Cotton
Seeds
Cotton
Cultivation
Blow
Room
Ginning Spinning Packaging Warp
Sizing
Warping
Weaving Looming Draw-in
Shuttle
Pin -
winding
Washing
Folding
Quality
check
Batch
removal
BleachingScorning
Dyed
Fabric
Printing
CustomersDistribution
Piece
Dying
*CSP>1800
*CSP<1800
YES
NO
Byproduct
Cotton Bales
*Count Strength Product
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6. Flow Process Chart
Cotton
Seeds
Cotton
Cultivation
Blow
Room
Ginning Spinning Packaging Warp
Sizing
Warping
Weaving Looming Draw-in
Shuttle
Pin -
winding
Washing
Folding
Quality
check
Batch
removal
BleachingScouring
Dyed
Fabric
Printing
CustomersDistribution
Piece
Dying
*CSP>1800
*CSP<1800
YES
NO
Byproduct
Cotton Bales
*Count Strength Product
Problems in the stage:
• Excessive water use
• Harmful chemicals used in dyes
• Use of non-biodegradable
substances
• No proper disposal of effluents
• Operation and maintenance of
Effluent treatment plant (ETP)
Solutions:
• Combining
the processes
• Reuse of
water
• Eco-friendly
dyeing
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7. Water utlisation at various stagesDoNotCop

8. Cotton
Oil,
Natural
Gas
Yarn
(Spinning)
Petrochemicals Synthetic
Fibres
Weaving Washing
ScouringBleaching
Dyeing Printing
Garment
Factories
Brand-
named
Apparel
companies
Overseas
buying
offices
Trading
companies
Department
Stores
Specialty Stores
Mass Merchandise
Chains
Discount Chains
Off-Price, Factory outlet,
Mail order, other
Proposed Distribution Structure
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9. Cotton
Oil,
Natural
Gas
Yarn
(Spinning)
Petrochemicals Synthetic
Fibres
Weaving Washing
ScouringBleaching
Dyeing Printing
Garment
Factories
Brand-
named
Apparel
companies
Overseas
buying
offices
Trading
companies
Department
Stores
Specialty Stores
Mass Merchandise
Chains
Discount Chains
Off-Price, Factory outlet,
Mail order, other
Proposed Distribution Structure
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10. Cotton
Oil,
Natural
Gas
Yarn
(Spinning)
Petrochemicals Synthetic
Fibres
Weaving Washing
ScouringBleaching
Dyeing Printing
Garment
Factories
Brand-
named
Apparel
companies
Overseas
buying
offices
Trading
companies
Department
Stores
Specialty Stores
Mass Merchandise
Chains
Discount Chains
Off-Price, Factory outlet,
Mail order, other
Proposed Distribution Structure
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11. SURAT
50 mn metres of
fabric a day
35 dyeing and
printing mills
closed in 2012
BHIWANDI
26 mn metres of
fabric a day
TIRUPUR
4000 knitwear pieces a day
MALEGAON
30 mn metres of
fabric a day
ICHALKARANJI
10 mn metres of
fabric a day
SALEM
75000
handloom units
ERODE
500000 power looms and 25000
handlooms
LUDHIANA
10000
knitwear units Garment
manufacturers
Leading raw
Cotton
producers
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12. Scouring and Bleaching
Fiber
opening and
cleaning
Alkali
scouring
application
Alkali
reaction
stage
Rinsing
Alkaline
agents: NaOH,
KOH,Na2CO3
Saponification,
emulsification,
solubilization
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13. Scouring and Bleaching
Bleach
application
Bleach
reaction
stage
Rinsing
Finish
application
Drying
Opening
and bale
formation
Bleaching
agents: NaOCl,
NaCLO2, H2O2
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14. Scouring and Bleaching
Fiber
opening and
cleaning
Alkali
scouring
application
Alkali
reaction
stage
Rinsing
Bleach
application
Bleach
reaction
stage
Rinsing
Finish
application
Drying
Opening
and bale
formation
Alkaline
agents: NaOH,
KOH,Na2CO3
Saponification,
emulsification,
solubilization
Bleaching
agents: NaOCl,
NaCLO2, H2O2
Consumption
of
water:80L/Kg
of cloth
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15. One step de-sizing, scouring, bleaching
Sodium
Perborate(SP
B,
NaBO34H2O)
Cost
Effective
Non-
Toxic
Breaks
down
easily
Better
Stability
No
Additives Reduction
in time :
From 2-
3hrs to 1hr
Higher
Whiteness
index
Reduced
temperature
requirement
: 500c-600c
Reduced
water usage
& Drying time
Less Space
utilization
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16. Before Dyeing Rinse(BDR) Wash Water
Reuse
Micro-filters
• Remove suspended solids
• Reduce Chemical Oxygen Demand
• Remove colour
Saves 8000 litres of water for
dyeing 1 ton fabric
Saving 200000 lit/day
Reduces the
load on the
Effluent
Treatment
Plant(ETP)
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17. Drawbacks of conventional dyeing
Water consumption
: 80-100L/kg of
cloth
Time required:
7-8 hours
Unsafe chemicals
use Need for
effluent
treatment plant
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18. Waterless dyeing process
❖ The technology uses reclaimed
CO₂ as the dyeing medium in
a closed loop process.
❖ When pressurized, CO₂
becomes supercritical , a phase
between a liquid and a gas.
❖ In this state CO₂ has a very
high solvent power, allowing
the dye to dissolve easily.
❖ Due to the high permeability,
the dyes are transported easily
and deeply into fibres, creating
vibrant colours.
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19. Benefits of Dry Dyeing
Particulars Conventional
process
CO2dyeing
process
Oil 121 Liters 7 Liters
Water(per
1kg of cloth)
100-150 Liters 0 Liters
Energy 120KW 107KW
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20. Machinery and Equipment cost comparison
Description No.
Rate
(Rs.)
Amount
(Rs.)
SS Winch m/c of 6-4× 8×6 200kg. 1 4,00,000 4,00,000
SS Winch m/c 6-4'× 6×6 size 150kg. 3 2,00,000 6,00,000
MS Kier wall thick 1/4' bottom 8' 2 1,50,000 3,00,000
Steam callendering m/c roller sizes 51/21 1 3,00,000 3,00,000
Hydro-extractor 40-45 kg capacity 2 2,50,000 5,00,000
4 cylinder drier with motor and gear box 1 7,00,000 7,00,000
S.S. Conveyors with ball bearing 4 50,000 2,00,000
Baby boiler with storage tank chimney,
water softening plant
1 8,00,000 8,00,000
Water softening plant (cap. 6kl/hr), with
storage tank pumps and S.S. piping
1 7,00,000 7,00,000
Effuent treatment plant 1 5,00,000 5,00,000
Steam pipeline and other accessories LS 3,00,000 3,00,000
Deep tube well with submersible pump
with storage tank, pumping and
distribution system
1 5,00,00 5,00,00
Mini transport vehicle (3 Wheelers) 1 3,00,000 3,00,000
Fire extinguisher 5 kg capacity 2 20,000 40,000
Testing equipments LS 2,00,000
Computer colour matching equipment
(optional)
1
25,00,00
0
25,00,000
Total 88,40,000
Description No.
Rate
(Rs.)
Amount
(Rs.)
CO2 dyeing
machine
1 50,00,000 50,00,000
S.S. Conveyors
with ball
bearing
4 50,000 2,00,000
Mini transport
vehicle (3
Wheelers)
1 3,00,000 3,00,000
Fire extinguisher
5 kg capacity
2 20,000 40,000
Testing
equipments
LS 2,00,000
Computer
colour matching
equipment
(optional)
1 25,00,000 25,00,000
Total 82,40,000
Conventional dyeing process One-step+BDR+CO2dyeing process
*Capacity utilisation is considered
as 75% of installed capacity
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21. Raw material(per month) cost comaprison
Description Unit Qty.
Rate/
unit
(Rs.)
Amount
(Rs.)
Caustic Soda Kgs. 1500 35 53,000
Soda ash Kgs. 5500 20 1,10,000
Sodium silicate Kgs. 2500 10 25,000
Lisopal Kgs. 750 150 1,13,000
Bleaching Powder Kgs. 3,000 20 60,000
Hydrochloric acid Kgs. 8,000 8 64,000
Glabour's salt Kgs. 800 10 8,000
Common salt Kgs. 1000 3 3,000
Optical whitening agent Lit. 225 140 32,000
Hydrogen peroxide Lit. 1200 20 24,000
Sulphuric acid Lit. 2500 10 25,000
Acetic acid Lit. 750 75 56,000
Dye fixing agent Kgs. 750 150 1,13,000
Dyes of different shades
Lump-
sum
20,000 40,000
Testing equipments LS 1,00,000
Total 7,86,000
Description Unit Qty.
Rate/
unit
(Rs.)
Amount
(Rs.)
SPB Kgs. 1500 120 1,80,000
TAED Kgs 120 550 66,000
Dyes of different shades
Lump-
sum
40,000 80,000
Testing equipments LS 1,00,000
Total 4,26,000
Conventional dyeing process One-step+BDR+CO2dyeing process
*Average daily capacity considered as 4000kg
of cloth
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22. Utilities cost comparison
Utilities (Rs.)
Electricity bill 37.5 x 25 x 4 x 0.8 x 24 72,000
Water charges 10,000
Fuel Coal/furnace oil 100,000
Fuel for vehicle 8,000
Total 1,90,000
Utilities (Rs.)
Electricity bill 37.5 x 25 x 4 x 0.8 x 24 72,000
Water charges 5,000
Fuel for vehicle 8,000
Total 85,000
Conventional dyeing process
One-step+BDR+CO2dyeing process
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23. Thank You
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