State-of-the-Art Knitting & Garment project KSTCL

PROJECT PROFILE
ON
KNITTING AND GARMENT PROJECT

Kerala State Textile Corporation Limited

State-of-the-Art Knitting & Garment project KSTCL

PROJECT PROFILE FOR APPAREL AND KNITTING PROJECT

INTRODUCTION:

The Indian textile industry is one of the largest and oldest sectors in the country and among
the most important in the economy in terms of output, investment and employment. The
sector employs nearly 35 million people and after agriculture, is the second highest employer
in the country. Its importance is underlined by the fact that it accounts for around 4% of Gross
Domestic Product, 14% of industrial production, 9% of excise collections, 18% of
employment in the industrial sector, and 16% of the countrys total export earnings.

In the Textile industry, the Apparel industry is one of the important value chains of the vertical
and is Indias second largest industry after IT. At present, it is amongst the fastest growing
industry segment and is also the second largest foreign exchange earner for the country.
Also the retail segment in India is booming up at a very fast phase.

MARKET:

Apparel is one of the basic necessities of human civilization along with food, water and
shelter. The Apparel Industry reflects peoples lifestyles and shows their social and economic
status. The concept of purchasing fabric & get it sewn by our traditional tailors has receded
and the current generation prefers for readymade garment and there is an ever-growing
demand for the same. With the advent of new shopping malls coming up every other day &
looking into the demand, one can infer that this industry can definitely survive in the years to
come.





State-of-the-Art Knitting & Garment project KSTCL

Market size estimates
USD bn
55
Exports
Domestic

40
60
22

33
Drivers of exports
- Outsourcing by retail
giants
- Transition from
Converters to vendor
partners of global buyers.
- Capacity building to
lower per unit cost
and become more
competitive
Drivers of domestic market
- Growing young
population
- Rising household income
levels
- Growth of organized
retail


Trends in Domestic Market
Domestic apparel market growing at 10% per annum
Home textiles demand growing at 12-15% per annum
Urban consumers increasingly seeking branded and lifestyle products
Modern retailing environment (organized retailing) a driver for increased consumption.
Semi-urban and rural Indian markets are growing faster than expected.
Helpful demographic profile and increase in working female population.

2015 2009
100
State-of-the-Art Knitting & Garment project KSTCL

MANUFACTURING PROCESS:
1. Raw material : Grey yarn 100% cotton,Blends, Melanges, etc to outsource.

2. Circular Knitting : Grey fabric, various structures: viz, Single J ersey,Pique, Rib,
Interlock,Waffle, etc can be converted at the inhouse facility.

3. Processing : To be outsourced (Includes: Heat setting,Washing, Scouring,
Mercerising, Dyeing,Slit opening Brushing,Raising, Rotary
printing,Transfer printing, finishing, etc).

4. Finished Fabric : After processing finished fabric is received in roll form or flat
folded which will be issued to Apparel Industry.

5. Fabric Inspection : Checking for fabric paramenters, color matching & visual quality.

6. Cutting : Cutting of fabric into different parts of a garment based on the
styling with a computerised cutting machine.

7. Bundling : Bundling together all the parts of a garment into a bundle of 30 to
40 garments to avoid mix-up of different rolls & lots in a color.
8. Placement print /
Embroidery : If the motif of the print / embroidery is large, the same is done in
panel form.

9. Sewing : Stitching together all the fabric cut panels to form a garment in the
required styling with the respective accessories / trims.
10. Printing /
Embroidery : Small motifs are printed / embroidered on to the garment.

11. Snap/Button hole/
Buttoning : Attaching the snaps / buttons onto the garment.

12. Trimming/
Checking : Cutting of extra & unwanted threads) / Checking of garments for
any defects.

13. Ironing : Steam pressing of Garment for better finish & appearance.

14. Inspection : Final inspection of garments for measurements, visual appreance,
etc.

15. Folding : Folding the garment as per customers requirements.

16. Metal detector : Passing the garments thru a metal detector for any metal parts
viz, broken needles, etc).

17. Packing : Pack the garment with required materials into cartons, seal the
cartons & store it in a secured ware house.
State-of-the-Art Knitting & Garment project KSTCL

PROJECT PARAMETERS:
Capacity :

Knitting Production of 4.30 Tons grey fabric per day (Circular knitting)
Garment industry Production of approximately 10,000 garments a day (5000
pieces of Round neck & 5,000 pieces of Polo T-Shirt)

Land:

Knitting unit : Approximately 1 acre of land
Garment unit : Approximately 1 acre of land
Totally : 2 acres of land

Raw material & utilities:

Yarn : Requirement would be approximately 4.5 tons per day
(based on garment unit requirement), this is to be
oursourced.
The knitting of fabric will be done in the proposed knitting unit.
Finished Fabric : Approximate requirement is 4 Tons per day, the knitted
greige fabric need to be sent to the respective processing
units for processing & to be got back as finished fabric for
the consumption of garment unit.
Water for Humidification - 24 kl per day

PLANT & MACHINERY:
The plant & machinery proposed for the Knitting & Garment industry are as follows:
a) Knitting unit machinery:
1) Single J ersey - 10 nos
2) Single J ersey with 6 color Autostriper - 2 nos
3) Interlock machine - 2 nos
4) Rib Machine - 2 nos
5) Collar / Cuff machine - 8 nos
6) Winding machine - 1 no.
7) Compressors - 3 nos
8) Humidification plant - 1 no.

State-of-the-Art Knitting & Garment project KSTCL

Vendors:
a. Mayer and Cie, Germany.
b. Pai lung Machinery Mill Co., Ltd., Taiwan
c. Orizio s.r.l., Italy
d. Khaoheng, China

b) Garment unit machinery:

1. Cutting department - 9 nos
2. Sewing machines - 286 nos
3. Finishing department machines - 31 nos
4. Embroidery machines - 2 nos
5. Compressors - 3 nos
6. Placement Printing machines - 4 nos
7. Humidification plant - 1 no.

Vendors:
Sewing machines:

a. M/s. J uki Pvt Ltd. J apan.
b. Brother International , USA
c. Pegasus Sewing Machine Pte Ltd., J apan

Embroidery Machines:

a. Barudan Asia Pte. Ltd. J apan.
b. Tajima Embroidery machines, J apan.
c. Brother Embroidery machines, USA



State-of-the-Art Knitting & Garment project KSTCL

MANPOWER:
Knitting unit: Approximately 52 persons / day of 3 shifts



Garment Industry: Approximately 587persons

Designation No. of persons
Administration staff 19
Managerial / Technical staff 28
Operators / Technicians /
Out house / Helpers
536
Others 8
Total 591


COST OF THE PROJECT:

INR (In Crore)
Knitting Garments Total
15.30 33.50 49.00

SALES TURNOVER (PER YEAR):
The sales turn over of INR 65.16 Cr. per year

NET PROFIT:
Designation No. of persons
Administration 8
Operators / Technicians 37
Others 7
Total 52
State-of-the-Art Knitting & Garment project KSTCL

INR 3.26 crore per annum (averaged out for five years)



CONCLUSION:

The state has to depend on other states for all its ready made garments requirement. In spite
of having world class shopping malls in the state, all the garment requirement is met by
outsourcing. By setting up this fully advanced project we can attract the major players in the
retailing business. The location being in the same state, reduces their transit cost, is easily
accessable which gives them a confidence to place orders & saves their transit time.

So, this project, if implemented would be economically and financially viable and feasible.

Conatact Kerala State Textile Corporation Limited for further details

Disclaimer:
The findings contained in this project profile are based on the initial information collated through primary and secondary study, which is
only indicative and may not reflect the realities of an actual project. Reference herein to any specific commercial product, process,
service by trade mark, trademark, manufacturer, or otherwise, does not constitute or imply its endorsement, recommendation, or
favouring by KSTCL or any entities thereof.