Transcript Product Technology Jute ``Futuristic Approach for

``Futuristic Approach for
Product
and
Technology
Jute,
Development for
A Survival Route``
This Raw Jute
Needs Up gradation
Ranges of Stitchbonding Fabric where Jute
can go in the weft and stitch the nonwoven layer by
stitching with cotton or polyester yarns
Presented
by
Subimal Palit
Jute Textile Consultant
Associate, INDICON, Kolkata, India
E mail [email protected]
Mobile 09109433178548
About the author
•
•
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He spent in jute mills for 7 years
Next joined R&D , IJIRA. Spent 35 years
After retirement in 1994
Spent with
– IJMA 8 years
– Lagan 7 years
• He witnessed for 50 years ups and
down of an industry of 178 years old.
Jute, one of the major and important
natural
fiber industry is in existence for
more than 178
years.
Its products and the processing
technologies
were designed at
Dundee, the seat of
British jute industry that
started in 1830
Later, in 1856
colonial rulers started
parallel jute
production in
Calcutta
With the independence of India
in
1947
the jute industry passed
through crucial
period
Jute mills remained in India
Raw jute production was left
with East Pakistan
Within two decades realigned
its position
East Pakistan built-up jute mills
Became competitor to Indian jute
mills in export market
India made itself self sufficient
in fiber supply.
But lost 70% of its export market
Lost export market was regained
•
Green revolution in India brought
fortune to Indian jute industry
• About 60% of Indian jute mill production
was engaged in grain packing and storing.
• It has made the Indian jute mills too much
dependent on MOT/GOI.
• This retarded progress of the
mills.
What happened in Bangladesh?
• 1972 East Pakistan became independent
Bangladesh
• It has taken two decades to realign
structure.
• But emerged new generations
entrepreneurs
• Worked hard to dent in export
market.
Captains of both the country
had no time for advancement
•
•
•
•
To tide over the time
To look for new products.
To develop innovative products.
Rather, became too much dependent on
Country Govt.
• On subsidy,
• On R&D
• On market development.
Now time has come to halt and
think to see in the darkness.
• Is there future.?
• Yes
• Best alternative is to adopt value added products
where jute can occupy its sound footing.
• Products are --– Woven fabrics-Home furnishing, an
area occupied by Cotton textile.
– Non woven – Technical
Textiles.
Woven jute fabric have limitations
• Due to fiber coarseness [14 Tex ]
• Can't spin yarn below 2 lb
• Present 41/4`` flyer spinning can't spin
below 5 lb. It has limited application.
• Spinning 2 lb needs Ring spinning. Which is not
available in the industry in large scale.
•
Limited second hand ring spinning are
available. Its potential has not been
explored fully.
Jute Yarn in Handloom
• GOI/UNDP Project 1992 brought awareness in
the handloom sector in India.
• Handlooms showed path for use of jute in Home
Textiles using jute yarn in weft as substitute to
coarse cotton yarns. It caught market
acceptance.
• Unfortunately Indian jute mills declined to meet
this demand directly.
• Hence MOT/ GOI had to open yarn bank all over
the country to reach yarn at the door step of
handloom weavers.
Now what jute mills can do?
• Weave Home Textiles in its own
infrastructure and reap benefit of
value addition.
• It has to change the processing
technology to Spin fine and Weave
light.
Technology Required for Producing
Textile Grade Fabrics
• Upto Finisher Card. It is acceptable.
• Add Draw head with Autoleveler
• Add Intersecting Gill Drawing
• 1st Passage with autoleveler
• 2nd Passage
• 3rd Passage
•
•
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•
•
Ring Spinning [ Compact]
Prebeaming
Shuttleless looms
Wet processing
Plant has to be air conditioned for achieving optimum
operating efficiency.
Compact Ring Spinning
Reduces Yarn Hairiness
General Specification
Compact Spinning
Drafting Zone: Russian type : top floating rollers over apron
Draft Range :20 – 40
Building zone :
Lift 406 mm
Ring dia 110 mm
HP 30 + 2 = 32 including pneumafill
Spindles: Basic 120 can tailor made up to 200
Capability :
2lb – 6,000 rpm
8 lb --- 6,5000 rpm
12 lb …5,5000 rpm
Compact; Specially designed condensers
Compact Ring Spinning
•What is Compact Spinning?
•Sliver passes through
specially designed condensers
a. Based on the ring principle the
compact spinning ensures 20% less
hairiness by adopting special
condensing system in the drafting
zone.
b. It also helps reduction in ends down
rate.
You are to add red circled
portion in your new frame
Top self weighted
rollers
Sliver and
yarn
passage.
Ring Spinning with DOUBLE DRAFTING ZONE
Ring Dia 95,Tube 450 mm, Spindles 200,Price EURO 23,000, Year1980
1
2
Compact
Ring
Spinning
Drafting Zone
Bottom Apron, Top
floating rollers
Spindle with Crown at
the tip
Jute Compact Ring Spinning
Woolen Ring Spinning
Adoptable for Jute
Woolen Ring Spinning, Ring Dia 110
Spindles 160, Tube 500 mm
Auto Doffing
Price EURO
38,000
Year 1986
Crown
Auto Doffing
Process Flow – Spinning
Spin 2 lb
Intersecting Drawing
with autoleveler
1st Spreader
2nd Spreader
Doubling 6:1
Breaker Card
Finisher Card
Draw Head with
Autolever
Doubling 6:1
2nd Passage
Intersecting
Doubling 4:1
3rd Passage
Intersecting
Doubling 3:1
Compact Ring
Spinning -2lb, 6000
rpm
Roll winding
Process flow – Weaving
& Wet treatment
Prebeaming
Jiggers
Dressing
Stanter
Shuttless looms
Dryer
With Jacquards
Inspection
Calendar
Rollup
Singing
Market ---Home textiles
Advanced Jute Card
• Adopted woolen system of
transferring fiber from 1st Card to
2nd Card.
• Designed rotary Intersecting
drawing with instant auto leveling
• Our put wt. CV% below 2%
Gentle fiber
transfer system
Auto leveler
Intersecting Gill Drawing
Fibera are
kept in
control
Draw Head with
Auto leveler
Composite Jute Card with Intersecting
Draw head and Auto leveler
Intersecting Gill
Drawing with
Autoleveler
Intersecting Gill
Drawing
Dornier loom
Dornier
Dornier
PICANOL
DORNIER With Jacquard
PICANOL
PICANOL
Roll up
Batch take
up
PICANOL
Batch take
up
Vamatex
320 CM, Bonas Double
Jacquard
Somet
Selvedge
Cutter
Sulzer Gripper Loom
Warp Stop Motion
Shuttless Looms
with 6 colour
selectors
Investment required for 12 TPD
Textile Grade Fabric
•INR 840 lakhs
•Sales price INR 2,00,000
•Considering INR 60/sqm/300gsm
fabric.
Stitchbonded
Fabric
Prospect
of Textile
Grade
Fabric
lies here.
Stitchbonded
Curtains
Non Woven Jute
Textiles
•Stitchbonding
•Needle Punch
This is the area
completely
untouched
•It has immense
possibility
Stitch bonding Process
1 Fiber stage bleaching
/ Dying
2 Stapling
3 Blending
4 Hopper feeding
5 Carding
6 Cross Lapping
7 Stitchbonding
8 Printing
9 Roll up
Here is the market
Carding for Nonwoven : It is
up striker
Non Woven line with Cross lapper
Stitchbonding Technology
Stitchbonding
Features:
1) Working width (mm): 1,600, 2,400
2) Speed (r/min): 10 - 800
3) Gauges: 3.5, 5, 7
4) Stitch length variable: 0.5 - 5.0mm
5) Let-off mechanism: roller
6) Warp beam support: 30 or 21 feet
free-standing floor creel
7) Fabric take-up: electronic
8) Needle type: slot needle
9) Pattern drive: 1 bar
Delivery End of
Stitchbonding Machine
Maliwatt lines
consisting of 3
FOR cards
2.2m wide
3 cross
lappers of lay
down 4m
and 2
Maliwatt 3.7m
machines.
Stitchbonded Fabric
Stitchbonded
Fabric
Stitchbonded
Fabric
Ranges of Stitchbonding Fabric where Jute
can go in the weft and stitch the nonwoven layer by
stitching with cotton or polyester yarns
Printed
Stitchbond
Fabric
Automotive headliner fabric
Stitchbonded fabric printed and raised for use as
blanket
Stitchbond
Printed
Fabric
Product out of
Stitchbonding
Technology
Made up bags for Export.
Note: Hemp fiber almost similar to
jute is Stitchbond and made up as
shopping bags.
Price arrange USD0.28USD0.45 This is FOB Songhai
price.
Shopping Bag
Garment
99701
99703
99705
99707
PP non woven Grocery Tote
Flat tote bag
Gusset Tote Bag
Trade show tote
$0.35
$0.15
$0.23
$0.46
67*35*45cm/200pcs
40*49*50CM/10PCS
53*43*45cm/100pcs
37*33*45cm/100pcs
99709
99801
99803
99805
string bag w/reflective
PP non woven Grocery tote
PP non woven Grocery tote
$0.43
$0.35
$0.60
$0.23
42x35x30CM/25PCS
67*35*45cm/200pcs
Packing :68*40*45/200
53*43*45cm/100pcs
99807
99803
1489
1490
Zipper tote bag
PP non woven cooler bag
6 Pack Lunch bag
Lunch Bag
$0.36
$0.98
$0.48
$0.48
43*40*45cm/200pcs
Packing：40*68*65/100
37*36*50CM/100PCS
37*36*50CM/100PCS
Exposure Suits
40gsm Fabrics PP.
Such suits can be
made out of Jute
Stitchbonded fabrics
The fabrics of
Fragrant series
adopted micro
capsule technique
to conceal
fragrances, and will
release the
fragrances at a
proper temperature
or pressure in the
environment.
Non Woven Packaging
Spunlace Fabric.
MINMUM QTY
ITEM
NAME
THB-SXH
SIZE
MATERIAL
60"X90"
+18"
100%
polyester，
jacquard
curtain
fabric with
taffta lining
PRICE/BA PACKIN
G
G
$5.9/bag
two pics
in one
bag
24BAG/
CTN
100ctns
Stitchbonding
• Application area Home
Textiles
•Realization :
INR 1,80,000/MT
•Process is simple
Stitch bonding Process
1 Fiber stage bleaching
/ Dying
2 Stapling
3 Blending
4 Hopper feeding
5 Carding
6 Cross Lapping
7 Stitchbonding
8 Printing
9 Roll up
Here is the market
Water Jet Punching
DILO
Jute Non Woven
Mat
Shortcut to jute nonwoven 1.lnk
Needle Punching
Product
Technology
Count Range
Required
[lb]
Flyer
Spinning
Ring
Spinning
Stitch
bonding
Non
woven
Fiber
Grade
Tossa
Fiber
Grade
White
Price range
INR/MT
1 Sacking
10 – 35
*
5-8
2 Hessian
5- 15
*
3- 6
3- 6
40,000
3 Yarn
5- 30
*
1- 4
1- 4
33,000
4 Coarse fabric
Secondary CBC
7--12
*
3- 6
5 Home textiles
Woven / Utility items
2-30
35,000
35,000
1-6
80,000 –
2,00,000
1- 8
1- 8
80,000 –
2,00,000
1- 8
40,000 –
80,0000
*
]6 Home textiles
Non wovenStitchbonding
100 – 1000 gsm
7 Home TextilesNon woven
100 – 1000 gsm
*
1- 8
8 Technical TextilesNonwoven
100 – 1000 gsm
*
1- 8
40,000 –
80,0000
9 Technical Textiles –
Woven
100 – 1000 gsm
1- 8
40,000 –
80,0000
Investment require/MT/ INR]
In Lakhs
*
*
100
100
80,000
Other Possibility
•Use Cotton system
•50:50 :: Jute : Cotton blends
•Investment INR 100 lakhs/ 1
MTD
•Woven fabric price INR 2,00,000
/ MT
Technology available with
SITRA
• Cotton mill owner is preferred
Author and INDICON is
grateful to IJSG for
opportunity given to
present this paper
Thank you