ABSORBENT COTTON WOOL MANUFACTURING PREFEASIBILITY REPORT

1. 1
We introduce ourselves as turnkey or technical project consultant for manufacturing Absorbent cotton wool and
all related items. We are sending detailed prefeasibility report for your reference. Please go through the report
and analyze the project. All products described here are interlinked with the project. A complete absorbent
cotton wool project represents following products….
1. Absorbent cotton wool roll
2. Absorbent cotton wool pleat
3. Absorbent cotton wool in loose form
4. Absorbent cotton wool sliver or string or coil or neck wool
5. Absorbent cotton ball white and coloured
6. Cotton ear buds
7. Absorbent cotton gumji
8. Absorbent cotton facial pad and eye pads
9. Boric cotton wool or medicated cotton wool
10. Non absorbent cotton roll
11. Non absorbent cotton sliver or string or coil
12. Non absorbent cotton ball
13. Coloured cotton sliver or string or coil
14. Dental cotton roll
Some special machine is required to produce
• Cotton ball
• Cotton buds
• Cotton pads
• Dental cotton roll
Otherwise all remaining products will be manufactured in same plant and machines with very minor
modification.

2. 2
Absorbent Cotton also known as Surgical Cotton or Cotton Wool all related products are mainly used for
medical purposes in hospitals, nursing homes, dispensaries etc., Because of high fluid absorbency power,
it is better known as absorbent cotton. The absorbent cotton should be chemically inert and soft to give
maximum protection and should not cause irritation. These properties can be achieved by manufacturing
the product as per standard method of manufacture. The raw cotton is processed by series of steps
which render the cotton hydro-phillic in character and free from external impurities needed to be fit for
use in surgical dressings and personal hygiene. Absorbent Cotton is also used for making conventional
type of Sanitary napkins or pads besides medical purposes. And fairly good quality of cotton wool is
consumed in beauty parlours for removing make up and dirt etc., With the development of medical
facilities and growing awareness towards personal hygiene, the absorbent cotton industry registered
steady growth rate in past .
Non absorbent cotton used in pathological laboratories, medicine/drug packing for bulk drug
manufacturing unit, microbiological industry, biotechnology based industry etc..
Filter batting or gumji is used for filtering bulk drug liquid, rayon manufacturing and also used for
animal dressing.
Cotton sliver:
1. Non absorbent cotton sliver is used for pharmaceutical packing, tablet packing etc.
2. Absorbent cotton sliver is used for manufacturing cotton buds, swabs, cotton ball for pharmaceuticals.
3. Coloured cotton sliver is used for manufacturing coloured cotton ball for cosmetic use.
Cotton Buds used for ear cleaning and misc. purpose
Cotton Balls used in cosmetics cleaning and also drug grade
Cotton Pads used normally for eye pad and facial cleaning
Cotton dental roll used for dental purpose and ciggerate filter
Boric cotton roll used as medicated cotton

3. 3
Demand for absorbent cotton depends on various factors. The demand of this product is directly related
with the increase in population and expansion of Public Health Services. The consumption of Surgical
cotton or cotton wool increases with the increase in population and number of hospitals, dispensaries,
health care centers, nursing homes etc. Progressive increase in health amenities offered by government
and coming up of new hospitals and health care centers in private sector even at small towns are
contributing to the growth of absorbent cotton industry. Govt. hospitals and big nursing homes are the
largest consumers for cotton wool. Absorbent cotton has good export market potential. Exporting option
to the countries like Japan, Australia and several European countries. The export of surgical cotton can be
done provided it is made according to standards and specifications of international market. All other
related products also have a very good potential market.
Only the latest technology will be used so that the product conforms to international standards.The most
economical process known as “ ” by hydrogen
peroxide will be used for manufacturing surgical cotton, Non absorbent cotton and coloured cotton.
1.It is a single stage scouring and bleaching process. Step for bleaching and / OR de-chlorination after boiling is
omitted in this process. It is peroxide based modern process in which scouring and bleaching process run
simultaneously and continuous process.
2. Less manpower involvement for production than chlorine bleach or two stage peroxide bleach process.
3. Water consumption will be less up to 50 % than conventional process.
4. Higher rate of production with same infrastructure than conventional process.
5. Electric consumption will be 20% less.
6. Fuel cost will be less BY 40% than old process.
7.Temperature requirement for this process is 950
C for 10 mints which is much less than old process (120 0
C).
8. It works even at atmospheric pressure that is at normal pressure old process works at 40lb pressure.
9. Chemical cost will be less BY 30% than old process
10. Less production space requirement than conventional process due to not requirement of bleaching tank
11. Batch Process time is atleast 50% less than conventional process.
12. Non absorbent cotton will be produced at room temperature process…without heating

4. 4
Vergin Raw cotton or coumber/TEXTILE WASTE
Caustic soda flakes or lye
Soda ash
Anionic or Nonionic detergent
Hydrogen peroxide
Stabiliser for hydrogen peroxide
Softening agent
Acid slurry
Urea
All the above raw materials are easily available in local market .
Total water requirement is 1: 8 that means to produce 100 Kgs of finished cotton water requirement will be 800
Ltrs.
Detailed Motor HP against each machine already given in our offer details. Extra requirement will be for light,
fan, AC , Laboratories and related appliances as per your requirement.

5. 5
HEAT
RAW COTTON CLEANER PRESSURE KIER I.T.O.HEATER MACHINE
MACHINE FOR SCOURING & BLEACHING FOR HEATING
SEEDS,HUSKS.SHORT FIBRE BLEACHED COTTON WATER
WASTE ABSORBENT REMOVED BY
HYDROEXTRACTOR
MACHINE
OPENED BY
HUMID OPENER MACHINE
HEAT
COTTON IS THEN DRYED IN CONTINEOUS CONVEYOR DRYER HOT AIR
GENERATOR
BLEACHED AND DRYED BLEACHED AND DRYED COTTON FEED INTO
COTTON , BALE PRESSED
BY BALE PRESS MACHINE
LAP FORMER
MACHINE
SALE TO MARKET
CARDING WITH CONVEYOR CARDING WITH COILER CARDING WITH CROSS LAPPER
ATTACHMENT ATTACHMENT ATTACHMENT
PRODUCT: CARDED LAP PRODUCT: COTTON SLIVER PRODUCT: COTTON JUMBOO LAP
ROLLED IN ROLLING BUDS BALLS
MACHINE MACHINE MACHINE JUMBOO SHEET CUTTED INTO 200MM
WIDTH FOR PAD MAKING BY
SLITTER MACHINE
PRODUCT: COTTON PRODUCT: PRODUCT: CUTTED SHEET FEED INTO
BIG ROLL COTTON BUDS COTTON BALLS PAD MAKING MACHINE
PRODUCT: COTTON PAD
CUTTED INTO SMALL PCS SALE TO MARKET
BY CUTTER MACHINE
SALE TO MARKET SALE TO MARKET
*** COTTON PLEAT,COTTON DENTAL ROLL ETC.. WILL BE MANUFACTURED FROM COTTON WAVE.

6. 6
Cotton Bales
Bleached cotton conforming to Japanese, European, British and US pharmacopoeial
standards.
Standard Bale Weight :
150 kgs.+/- 10%
20' FCL - 9.6 MT, 40' FCL - 19.2 MT
Dimensions :
46" X 22" X 28"
Packing :
Wrapped in laminated fabric neatly bound by self locking straps
Cotton Laps
Ensuring firm bonding of fibres and good multi-dimensional strength.
Width :
80 cms. or cuts thereof to specifications
Weight :
150 to 300 gsm +/- 10%
Packing :
HMHDPE Bags
Sliver
Cotton is also processed into sliver form for cotton ball and tip manufacture.
Weight of product offered :
from 1.5 gms/m (+/- 10%) and upwards
Weight of each coil :
7 to 10 kgs.
Packing :
HMHDPE Bags further packed in corrugated cartons
Cosmetic Balls
Specifications
Weight per 100 balls : 100 / 50 / 40 gms
or as required by the customer.

7. 7
Pharma grade Balls
Specifications
Weight per 100 balls : 100 / 50 / 40 gms
or as required by the customer.
Rectangular pads
Specifications
Rectangles of 30 mm to 100 mm side.
gsm : 120 to 300 +/- 10%
Weight and Packing as per customer's specifications
Rounds
Specifications
Diameter : 57 mm
gsm : 200 to 300 +/- 10%
Ovals
Specifications
Dimensions : 90 mm X 70 mm
gsm : 200 to 300 +/- 10%

8. 8
Tips Ear buds
Tips in multiples of 25 in round cans and also in rectangular boxes
of 200's from paper or poly propylene sticks.
Boric cotton wool roll
Absorbent Cotton Wool impregnated with Boric Acid is termed as Boric Cotton. It has anti-bacterial & anti-fungal
properties. It can be supplied with/without interleaf in sizes ranging from 15gms to 2500gms.
Absorbent uncarded bleached cotton white and coloured
Absorbent cotton woll roll
• Bleached to a good white and free from neps, leaf & shell.
• Conforms to International Standards.
• Single and uniform lap without joints.
• Suitable for cleaning and swabbing wounds.
• The sizes of rolls varies from 20 gms to 2500 gms and the width varies from 8 cms to 45 cms
• Economical and convenient for clinic,dental,nurshing home and hospital

9. 9
Cotton Wool Pleats (Zigzag)
Packed in printed poly bags with string and gusset
• Quick Absorbency
• Free from leaf & shell
• Folded neatly to required width & length.
• Sterile or Non Sterile
• 25g, 50g, 100g & 200gms. packing
Non absorbent cotton wool roll
• Used for pharmaceutical packing
• Microbial laboratories
• Tissue cultural laboratory
• Pathological laboratory
• University and institutes etc
Absorbent cotton gumji
Highly absorbent, hospital quality cotton wool enclosed in a non-woven cover in either 30cm or 45cm lengths. Soft, low-
adherent medical grade wound interface minimises wound disruption and provides a fibre and particle barrier.
Non-woven Veterinary Gamgee cushions and protects wounds from external trauma. Can be autoclave sterilised.
SIZE : 12” X 500GM AND 18” x 500GM

10. 10
NAME OF MACHINE USED FOR
Verticle or Horizontal Opener Opening and cleaning pressed raw cotton
Stamping Machine Cotton pressing in carrier
Fibre carrier For boiling in kier
Pressure kier Boiling raw cotton
Over head crain for transporting material
Centrifuge/Hydroextractor Removing excess water
humid opener/Wet opener Fluppying hydro extracted cotton
Conveyor/Tray/R.F. Dryer Drying wet cotton
Lap former Lap formation
Carding with conveyor attachment carded the lap cotton
Carding with Coiler attachment For sliver or coil making
Carding with cross lapper wave formation for pad
Rolling Machine Rolling the carded cotton
Cutting Machine Cutting as per packet size
Zig zag/Pleat machine For pleat formation
Cotton ball machine For cotton ball making
Cotton buds machine For buds manufacturing
Cotton pad machine cotton pad manufacturing
Dental cotton roll machine Making dental cotton/cigarette filter
Bale press machine Making bleached cotton in pressed bale
Hot air generator For heating dryer machine
Iso Thermal fluid heater Heat Source Boiling of raw cotton
Platform type weigh scale and weigh balances
Laboratory equipment and accessories
Water tube well, over head tank and pipe line for water
Dust collector
Leathe, welding machine, grinder etc..
Electrical work
Effluent Treatment Plant
1. Equalization Tank
2. Zig Zag channel
3. Alum dozing tank
4. Lime dozing tank
5. Polyelectrolyte dozing tank
6. Primary clarifier
7. Secondary clarifier
8. Aeration tank/aerator
9. Sludge collection tank

11. 11
Plant and machineries
Erection Charge
Electrical equipment and installation
Transportation charge
Other fixed assets
Effluent treatment plant
Technical know how and engineering fees
Preliminary and pre operative cost
Provisions for contingencies
Margin money for working capital for three months
1. Preperation of Project reports and all necessary documents(Exceptt collection and
submission of licence form and getting approval) for
Inspector of factories
Drug department
Pollution control board
Weights and measures
Fire licence
As per WHO/GMP rule
2. Supply of plant and machineries including repairing, erectioning, commissioning and
running
3. Technical supervision and guidance during civil construction and platform construction,
electrical wiring and cable line installation, installation of control panel board for each
machine.
4. Technical supervision and assistance in successful start-up/commissioning of the plant.
5. successful production charge and training of manpower (technical and non technical)

12. 12
RAW COTTON IN PRESSED BALE FORM,IT MAY BE COMBER (TEXTILE WASTE) OR PURE RAW COTTON,COTTON
BALE IS OPENED AND FEED TO STEP CLEANER OR CRYTON MACHINE TO REMOVE LEAVES, HUSKS,SEEDS
AND OTHER FOREIGN MATERIAL.
THIS IS CLEANER MACHINE AND USED TO REMOVE LEAVES,HUSKS,SEEDS ETC.. TO CLEAN COTTON
THIS IS SEEDS,HUSKS,LEAVES AND FOREIGN PARTICALS REMOVED FROM CLEANER MACHINE.IT IS USED
FOR MUSHROOM CULTIVATION.
THIS IS CLEANED COTTON HAVING TRACES OF FOREIGN MATERIAL. THIS FORM OF COTTON IS NOW BOILED
WITH CHEMICALS TO SCOURE AND BLEACH
SIMULTANEOUSLY BY SCOURING AGENT AND HYDROGEN PEROXIDE. M.S. or S.S. PRESSURE KIER(REACTOR)
IS USED FOR THIS PURPOSE.
CLEANED COTTON SCOURING AND BLEACHING FLOOR
COTTON IS BOILED HERE TO MAKE IT ABSORBENT AT 100 DEGREE CENTIGRADE FOR 15 MINUTES THEN
WASH THE BOILED COTTON WITH FRESH WATER TILL THE MATERIALS BECOME NEUTRAL.AFTER REACHING
NEUTRAL pH COTTON IS THEN FEED INTO HYDROEXTRACTOR TO REMOVE EXCESS WATER FROM COTTON.
BLEACHED, ABSORBENT, NEUTRAL COTTON. MATERIAL IS READY FOR HYDROEXTRACTION
THIS IS CENTRIFUGE AND USED TO REMOVE EXCESS WATER FROM BOILED COTTON.

13. 13
HYDROEXTRACTED COTTON.THIS FORM OF COTTON IS THEN FEED INTO WET OPNER MACHINE TO OPEN UP
PRESSED HYDROEXTRACTED COTTON.
HYDROEXTRACTED PRESSED COTTON OPNER AND DRYER MACHINE.THIS IS CONTINEOUS CONVEYOR DRYER
USED TO DRY HYDROEXTRACTED WET COTTON.TRAY DRYER ALSO USED FOR THIS PURPOSE.
DRYED UNCARDED COTTON. THIS IS ONE OF YOUR SELLING PRODUCT.THIS IS GENERALY MARKETED IN
PRESSED BALE FORM. OTHERWISE THIS FORM OF COTTON IS THEN FED INTO BLOW ROOM
BLEACHED,DRYED,UNCARDED COTTON BALING PRESS
MACHINE USED TO PRESS AND FORM UNCARDED ABSORBENT COTTON BALE.
DRYED COTTON FEED INTO THIS LAP FORMER AND SCUTCHER MACHINE TO FORM SCUTCHER LAP.WHICH
IS THEN FEED INTO CARDING MACHINE
CARDING MACHINE BUT IS USED ONLY FOR MANUFACTURING SLIVER COTTON BY USING SCUTCHER LAP
COTTON SLIVER IS READY TO MARKET.SLIVER WILL BE ABSORBENT, NONABSORBENT, COLOURED ETC..
CARDING MACHINE used mainly for sliver

14. 14
CARDED LAP ROLLING MACHINE
CARDED COTTON IN ROLLED CONDITION
MANUFACTURED BY ROLLING MACHINE
BAND SAW TYPE CUTTING MACHINE
ISO THERMAL OIL HEATER
COTTON PAD MAKING MACHINE
COTTON BALLS MAKING MACHINE
COTTON BUDS MAKING MACHINE

15. 15
1. RAW COTTON CLEANER & OPENER PRESSURE KIER BOILING
2. WASHING WATER REMOVAL BY CENTRIGUGE OPENING BY HUMID OPENER
3. DRYING IN DRYER SCUTCHER LAP BY LAP FORMER MACHINE LAP
4. CARDED COTTON BY CARDING MACHINE ROLLED COTTON BY ROLLING MACHINE
5. ROLLED COTTON CUTTED INTO SMALL PCS BY CUTTING MACHINE SMALL ROLL
6. PACKING BALING SHIPPING
SMALL ROLLED COTTON PCS PLEATING MACHINE COTTON PLEAT
1. FEED THE DRYED COTTON INTO LAP FORMER MACHINE TO FORM SCUTCHER LAP.
2. LAP FEEDED INTO CARDING WITH COILER ATTACHMENT TO FORM COTTON COIL
3. COTTON COIL FEEDED INTO BALL FORMING MACHINE COTTON BALL
1. FEED THE DRYED COTTON INTO LAP FORMER MACHINE TO FORM SCUTCHER LAP.
2. LAP FEEDED INTO CARDING WITH COILER ATTACHMENT TO FORM COTTON COIL.
3. COTTON COIL FEEDED INTO BUDS FORMING MACHINE COTTON BUDS
1. FEED THE COTTON INTO HOPPER FEEDER OF CARDING MACHINE TO FORM LAP
2. CARDED LAP DIRECTLY FEEDED INTO CROSS LAPPER.
3. CROSS LAPPED COTTON JUMBOO ROLLED IN CONTINEOUS ROLLER
4. ROLLED COTTON CUTTED INTO SMALL TAPE BY SLITTING MACHINE.
5. THIS COTTON TAPE IS THEN FEEDED INTO PAD MAKING MACHINE
6. PRODUCT COTTON PADS PACKING AND SHIPPING

16. 16
1. FEED THE DRYED COTTON INTO LAP FORMER MACHINE TO FORM SCUTCHER LAP.
2. LAP FEEDED INTO CARDING WITH COILER ATTACHMENT TO FORM COTTON COIL.
3. PRODUCT :COTTON COIL
1. FLOOR SPACE DESIGN APPROVAL FROM STATE CONTROL DEPARTMENT
2. CONSENT TO ESTABLISH FROM STATE POLLUTION CONTROL BOARD
3. CONSENT TO OPERATE FROM STATE POLLUTION CONTROL BOARD
4. PRODUCT WISE DRUG MANUFACTURING LICENCE FROM STATE CONTROL DEPARTMENT
5. FACTORY LICENCE FROM STATE INDUSTRIAL DEVELOPMENT CORPORATION
6. SSI REGISTRATION FROM DISTRICT INDUSTRIES CENTRE
7. FIRE LICENCE FROM STATE FIRE CONTROL DEPARTMENT
8. PUBLIC AND HEALTH ENGINEERING
9. WEIGHTS AND MEASURES
10. MANUFACTURING AND TRADING LICENCE FROM MUNICIPALITY/PANCHYAT
11. FACTORY INSURANCE
12. OTHERS LIKE: VAT, CST, PTAX, IEC ……
1. MACHINE MAINTAINANCE COST, SPARE PARTS, OIL, GREASES ETC.
2. FUEL COST ( FUEL IS NOT A RAW MATERIAL)
3. ELECTRICITY COST
4. INSURANCE COST
5. POLLUTION CONTROL DEVICES RUNNING COST
6. FACTORY MAINTAINANCE COST
7. LABORATORY EXPENSES
8. FIRE FIGHTING EQUIPMENT AS RUNNING COST.
a. Preparation of project report as described above
b. To extentd100% know how for production of surgical cotton all related items as
described above.
c. To manufacture all the machineries.
d. Complete erection of the plant to realize quality surgical cotton conforming to
relevant international standards.
e. To extend advisory service in getting the approvals from governmental agencies.
f. To extend Warranty for a period of 6 months for all Plant & Machinery and project
as a whole. Any problem(within warranty terms and conditions) that may arise
during warranty period, would be attended free of cost at the cost of the Supplier.
g. In house Manpower Training for Production and laboratory
h. Creation of check point and maintaining procedure for production & quality control

17. 17
i. Total documentation as per ISO, Drug & GMP rule.