How to Start Denim Fabric Manufacturing Business | Best Business Idea

Summary

This video explores the business of Denim Fabric Manufacturing, highlighting its historical roots in Nimes, France, and its evolution into a global fashion staple. It covers the raw materials like cotton and synthetic yarns, essential machinery, and the detailed production process from yarn preparation to fabric finishing. The video also addresses the plant's area and power requirements, manpower, investment, profitability, and necessary licenses. It concludes with guidance on government schemes and how to start the business, offering resources for further information and support.

Takeaways

• 👖 The origin of 'Denim' fabric traces back to 'Serge De Nimes', first manufactured in Nimes, France in the 19th century.
• 🌐 Denim fabric, initially made from 100% cotton, has evolved to include synthetic fibers for enhanced convenience and performance.
• 🔁 The Twill Weave technique is a crucial part of the Denim fabric production process, contributing to its distinctive texture and appearance.
• 👷 Denim was initially used for laborers due to its strength and durability but has since become a fashion staple across all social classes.
• 🌟 Denim is now a global fashion icon, especially favored by the youth for its versatility in clothing like jeans, jackets, and shirts.
• 🏭 The raw materials for Denim fabric manufacturing include cotton yarn, polyester yarn, blended yarn, indigo dye, and various chemicals.
• 🔧 Key machinery and equipment in Denim production include Ball Warping Machines, Rope Dyeing Machines, Weaving Machines, and Sanforizing Machines.
• 📈 The production process involves several steps such as yarn preparation, dyeing, weaving, and finishing, each critical for the final product's quality.
• 🏢 A plant with a monthly production capacity of 20 lakh meters requires an area of approximately 35000 - 40000 Sq mtr. for operations.
• ⚡ Power consumption for such a plant is substantial, estimated at around 4000 kW, influenced by the level of automation in the machinery used.
• 👥 A workforce of 550-600 employees, including skilled, unskilled, and various managerial roles, is necessary to operate a Denim fabric manufacturing plant at this scale.
• 💼 The investment for setting up a Denim fabric manufacturing plant is substantial, around Rs. 6 crore - Rs. 7 crore, with a potential profit margin of 8% - 10%.
• 📄 To start a Denim fabric manufacturing business, obtaining necessary licenses and permits, such as GST, UDYAM, NOC, and Factory License, is mandatory.
• 💼 Entrepreneurs can benefit from government subsidies and grant schemes to support their Denim fabric manufacturing ventures.

Q & A

What is the origin of the term 'Denim'?

The term 'Denim' originates from 'Serge De Nimes,' a fabric first manufactured in Nimes, France, in the 19th century.

What is the primary material used in making Denim?

Denim is traditionally made entirely of cotton threads, but synthetic fibers are also blended in for added strength and convenience.

What weaving technique is used in the production of Denim?

The Twill Weave technique is used in the production of Denim fabric.

Why was Denim initially popular among laborers?

Denim was initially popular among laborers due to its strength and durability, making it suitable for heavy-duty use.

How has the use of Denim evolved over time?

Over time, Denim has evolved from being a fabric for laborers to a fashion and style statement, especially among the youth, and is now popular across all classes.

What are the raw materials needed for Denim fabric manufacturing?

The raw materials needed for Denim fabric manufacturing include cotton yarn, polyester yarn, blended yarn, indigo dye, finishing dyes, and various chemicals.

What are the key machines and equipment required for Denim fabric manufacturing?

Key machines and equipment required include Ball Warping Machine, Rope Dyeing Machine, Sizing Machine, Weaving Machine, Singing Machine, Fabric Mercerizing Machine, Stenter, Sanforizing Machine, Oil Tanks, Chemical Tanks, Bins, Trolleys, Water Pumps, and other handling equipment.

Can you describe the process of yarn dyeing in Denim manufacturing?

In Denim manufacturing, yarn dyeing is done using the Rope Dyeing machine after scouring and washing the threads, where they are dyed before proceeding to the weaving process.

What is the purpose of the singeing process in Denim fabric production?

The singeing process in Denim fabric production is used to clean and clear the fabric surface by separating projecting fiber and yarn ends, often using gas flame or heated copper plates.

How is the structure of the fabric set in Denim manufacturing?

The structure of the fabric is set using the Sanforizing machine, where the fabric passes through guide rolls, control rolls, pressure rolls, and dryers, reducing the chances of shrinkage during garment making.

What is the approximate production area required for a Denim fabric manufacturing plant with a monthly capacity of 20 lakh meters?

A Denim fabric manufacturing plant with a monthly capacity of 20 lakh meters requires approximately 35000 - 40000 Sq mtr. of area, including production, raw material storage, finished goods storage, and administrative areas.

What is the estimated manpower needed to run a Denim fabric manufacturing plant with the mentioned capacity?

To run a Denim fabric manufacturing plant with a monthly capacity of 20 lakh meters, approximately 550-600 workers are needed, including skilled, unskilled, supervisors, technical staff, plant heads, production managers, and accountants.

What are the potential profits from Denim fabric manufacturing business?

The Denim fabric manufacturing business can yield a profit of about 8% - 10%.

What are the necessary licenses and schemes required to start a Denim Fabric Manufacturing Business?

To start a Denim Fabric Manufacturing Business, one needs licenses such as GST, UDYAM, NOC from Fire & Pollution Control Board, and Factory License. Additionally, one can avail of benefits from Central and State Government's subsidy and grant schemes.

Outlines

00:00

👖 Introduction to Denim Fabric Manufacturing

The script introduces the history and evolution of 'Serge De Nimes,' which became known as 'Denim.' Originating in Nimes, France, this cotton fabric is now a global fashion staple. Initially used for its strength by laborers, it has become a symbol of style, particularly among the youth. The video promises to provide a comprehensive guide to starting a denim fabric manufacturing business, including details on raw materials, machinery, the production process, and market insights.

05:07

🏭 Setting Up a Denim Fabric Manufacturing Plant

This section delves into the specifics of establishing a denim fabric manufacturing plant. It outlines the necessary raw materials such as cotton and polyester yarns, dyes, and chemicals. The machinery and equipment required for the process are listed, including Ball Warping Machines and Weaving Machines. The production process is detailed, from yarn preparation and dyeing to weaving and finishing. The script also covers the area and power requirements, manpower needed, and the potential profitability of the business. Lastly, it mentions the importance of obtaining necessary licenses and government schemes that can support the venture.

Keywords

💡Denim

Denim is a durable fabric initially made entirely of cotton threads. Originating from 'Serge De Nimes' in France, denim has become a globally popular material. The video highlights how denim, once used mainly for laborers due to its strength, is now a fashion statement, especially among the youth.

💡Twill Weave

Twill Weave is a textile weaving technique characterized by a diagonal pattern. It is used in the production of denim to enhance the fabric's durability. The video mentions various types of twill designs like 2/1 twill, broken twill, and zig-zag twill, which contribute to the fabric's aesthetic and functional qualities.

💡Warp and Weft

Warp and Weft refer to the two sets of threads used in weaving. Warp threads run lengthwise, while weft threads run crosswise. In denim manufacturing, specific counts of yarn are used for the warp and weft to create the desired fabric strength and texture, as mentioned in the warping and weaving processes in the video.

💡Sanforizing

Sanforizing is a fabric treatment process that stabilizes and pre-shrinks the fabric. The video explains that this process reduces shrinkage in denim garments, ensuring a better fit for the final product. It is a crucial step in producing high-quality denim fabric.

💡Indigo Dye

Indigo Dye is a natural dye traditionally used to color denim fabric. The video discusses how the yarn is dyed using indigo during the rope dyeing process, giving denim its characteristic blue color. The dyeing process is crucial for the final appearance of denim products.

💡Ball Warping Machine

A Ball Warping Machine is used in the initial stage of denim manufacturing to prepare yarns for dyeing. The machine wraps warp threads in specified quantities on a beam, which is then used in subsequent processes. This machine is essential for ensuring that the yarn is properly prepared for the dyeing stage.

💡Rope Dyeing Machine

The Rope Dyeing Machine is used to dye yarn in the denim manufacturing process. The video describes how yarn is scoured, washed, and dyed in this machine, which is crucial for achieving the desired color and quality of the denim fabric. This process ensures even and consistent dyeing of the threads.

💡Singeing

Singeing is a process that removes projecting fibers from the fabric's surface using a gas flame or heated plates. This step, as mentioned in the video, helps create a clean and smooth surface on the denim fabric, improving its appearance and quality before further processing.

💡Power Requirement

Power Requirement refers to the electrical energy needed to operate the machinery and equipment in the denim manufacturing plant. The video specifies that around 4000 kW is required, depending on whether the machines are fully automatic or semi-automatic. This is a critical factor in the operational planning of the factory.

💡Investment & Profitability

Investment & Profitability covers the financial aspects of setting up and running a denim manufacturing business. The video outlines an initial investment of Rs. 6-7 crore and potential profits of 8-10%. Understanding these figures is vital for entrepreneurs considering entering the denim production industry.

Highlights

In the 19th century, 'Serge De Nimes' fabric from Nimes, France, later known as 'Denim', became globally popular.

Denim is traditionally made from cotton threads, with synthetic fibers now sometimes blended for convenience.

The Twill Weave technique is used in the production of denim for its distinct texture.

Initially used for laborers due to its strength and durability, denim has since become a fashion staple across all classes.

Denim is currently the most popular fabric worldwide, especially among the youth, for jeans, jackets, and shirts.

IID presents a business idea for denim fabric manufacturing, covering all aspects from raw materials to the final product.

Raw materials for denim manufacturing include cotton yarn, polyester yarn, blended yarn, indigo dye, and various chemicals.

Key machines and equipment for denim production include Ball Warping, Rope Dyeing, Sizing, Weaving, Singing, Mercerizing, and Sanforizing machines.

The denim manufacturing process starts with yarn preparation, dyeing, weaving, and finishing to produce the fabric.

Different weave designs like 2/1 Twill, Broken twill, and Zig-Zag twill are used to create various denim patterns.

Singeing and heat setting processes are used to refine the fabric's surface and control shrinkage.

The Sanforizing machine is crucial for the final finishing, setting the fabric's structure and reducing garment shrinkage.

A plant with a monthly production capacity of 20 lakh meters requires an area of 35000 - 40000 Sq mtr.

Power requirement for such a plant is approximately 4000 kW, depending on the automation level of the machinery.

A workforce of 550-600 workers is needed to operate a denim manufacturing plant at the described capacity.

Investment in machinery and fixed assets for a denim plant is estimated to be around Rs. 6 crore - Rs. 7 crore.

Profit margins for the denim fabric manufacturing business are expected to be between 8% - 10%.

Licenses required for starting a denim fabric manufacturing business include GST, UDYAM, NOC from Fire & Pollution Control Board, and Factory License.

Government subsidies and grant schemes can be availed to start a denim fabric manufacturing business.

IID offers membership for access to industrial documentaries, detailed project reports, and expert episodes.

For more business ideas, IID suggests downloading their app 'Entrepreneur India Live' and subscribing to 'Entrepreneur India TV'.

Transcripts

In the 19th century, for the first time in Nimes, a city in France,

a fabric called "Serge De Nimes" was manufactured.

It later became popular all over the world by the name of 'Denim.'

Denim is a fabric which is made entirely of cotton threads.

But now as per requirement & convenience, synthetic fibers are blended in it as well.

Twill Weave technique is used in its production.

Pertaining to its strength and durability, initially, it was used for laborers.

But with time it was adopted by every class.

Currently, it has become a fashion & style statement especially for the youth.

At present, it is considered as the most popular fabric not only in India but all over the world.

The craze of denim jeans, jackets and shirts is continuously increasing.

So today, IID has brought for you a great business idea in the form of denim fabric manufacturing.

In this video, we will provide all the information related to this business.

Raw material

In the business of Denim fabric manufacturing, the raw materials needed are-

Cotton yarn, Polyester Yarn, Blended yarn, Indigo Dye, Finishing Dyes, Chemicals etc.

Machines & Equipment-

Ball Warping Machine, Rope Dyeing Machine, Sizing Machine, Weaving Machine,

Singing Machine, Fabric Mercerizing Machine, Stenter, Sanforizing Machine,

Oil Tanks, Chemical Tanks, Bins, Trolleys, Water Pumps & Other Handling Equipment.

Process-

Firstly, the raw material i.e yarn is bought, according to the requirement of denim fabric.

For Denim manufacturing, after procuring the threads,

the main process which is followed sequentially, is as follows–

Firstly the yarns are prepared for dyeing,

for which it is fed into the Ball Warping Machine.

In Denim fabric, yarns of 7- 20 counts are used in warp and 10- 15 counts are used in weft

In the process of warping,

the threads used in the warp are wrapped in a specified quantity on a beam,

so that they can be used in the next process.

After this, the process of yarn dyeing is started.

For which it is fed into the Rope Dyeing machine.

In this process after scouring & washing, the threads are dyed

After this, weaving process is done, in which fabric is produced with the help of looms.

Different types of weave designs are used in this

like 2/1 Twill weave, Broken twill, Reverse twill or Zig-Zag twill etc.

Sometimes to make special fancy fabric, other fancy designs are also used.

Now, in order to make the surface of the fabric clean and clear, singeing process is adopted.

In the process of singeing,

to separate the projecting fiber & yarn ends above the fabric,

gas flame or heated copper plates are also used.

Then to set the yarn and fibers as well as control the shrinkage of the fabric,

heat setting or equalizing process is required.

This thermal process can be done in steam atmosphere or dry heat environment.

Then for the final finishing of the fabric it is fed into the Sanforizing machine.

In this process the fabric is passed through guide rolls, control rolls, pressure rolls and dryers

This process sets the structure of the fabric

and while making denim garment, the chances of shrinkage is also reduced.

Now your denim fabric is ready.

After this, the fabric is inspected and after final inspection,

folding and packaging of denim fabric is done, after which it is sent for selling.

Area-

The production capacity of the plant shown in this video is 20 lakh meters per month.

To set up a plant of this production capacity,

About 35000 - 40000 Sq mtr. area will be required.

In which production area 20000-22000 sq mtr.

raw material storage area 4000-5000 sq mtr, finished goods area 5000-8000 sq mtr

and administrative area is included.

Power Requirement-

To run all the machines, equipment & office setup of the plant shown in this video,

you will need an electricity load connection of about 4000 kW power consumption.

Power consumption

depends on whether the machines used in production are fully automatic or semi automatic.

Manpower-

To run a plant at this production capacity, you will need 550-600 workers,

which includes 120-150 skilled, 200-250 unskilled,

supervisor, technical staff, plant head, production manager & accountant.

All the mentioned figures, depend on the size, type of business & your investment

and it may increase or decrease accordingly.

Investment & Profitability-

Now let's talk about the investment and profit involved in this business.

The production capacity of the plant shown in the video is about 20 lakhs meters cloth/month.

In which machinery & fixed asset investment is approx. Rs. 6 crore - Rs. 7 crore.

Talking about the profits, you can earn a profit of about 8% - 10% from this business.

Licenses & Schemes-

To start any business, it is necessary to get license from the government.

For the Denim Fabric Manufacturing Business you will need

GST, UDYAM, NOC from Fire & Pollution Control Board

and Factory License.

To start this business,

you can avail the benefits of Central & State Government's other subsidy & grant schemes.

So today you have learned about the 'Denim Fabric Manufacturing Business.'

Hope you have got every information related to this business & the answer to all your questions.

If you have any query regarding this business or any other business,

then you can contact us by calling on the phone numbers given on the screen.

MSME Helpline- 7408733333 | 7607655555 Email: [email protected]

You can become our valuable member, with the help of IID's membership registration

and get access to industrial documentaries, detailed project reports,

expert episodes & many other valuable services.

To get new business ideas download our app 'Entrepreneur India Live'

and subscribe our channel 'Entrepreneur India TV.'

For more information visit our website at www.iid.org.in