COSTS, OPERATIONAL PERFORMANCE

AND YARN QUALITY :

INTER - MILL STUDY OF KEY FACTORS

th
34 CPQ
STUDY REPORT
(OCTOBER - DECEMBER 2018)

SITRA

THE SOUTH INDIA TEXTILE RESEARCH ASSOCIATION

COIMBATORE - 641 014
 Contents

Chapter Page no.

1 Introduction 1

2 Method of study 2

3 Method of comparison 2

4 Summary of individual mills performance 8

- Techno-commercial performance (Figure A) 10

- Contribution, sale value and SWC (Table A) 10

- Productivity particulars (Table B) 11

- Product diversification (Table C) 11

5 Comparison with last study (October - December 2017) 8

- Relative changes in the costs and operational performance of individual mills in 12

comparision with the last study (October - December 2017) (Table D)

- Comparison of costs and operational parameters between the 13

two studies (83 common mills) (Table E)

- Count-wise yarn selling price, raw material cost and NOV 14

in the two studies (Table F )

- Count-wise raw material cost relative to yarn selling price 15

in the two studies (Table G)

Acknowledgement 15

Table Mill-wise and count-wise tables

no.

1 Indices of yarn selling price, raw material cost, commercial - Mill-wise 16

performance, technical performance and
techno-commercial performance

2 Contribution, sale value and cost factors - Mill-wise 20

3 Average count vs. yarn sale value and contribution - Mill-wise 24

4 Power consumption particulars - Mill-wise 27

5 Captive power generation particulars - Mill-wise 31

6 Average count vs. power cost and power consumption - Mill-wise 34

7 Labour productivity - Mill-wise 37

 C o n t e n t s (contd...)
Table Mill-wise and count-wise tables Page no.
no.

8 Machine productivity - Mill-wise 41

9 Product diversification - Mill-wise 45

10 Yarn selling price, raw material cost, NOV and yarn quality - Count-wise 49

11 Yarn realisation & wastes and raw material quality - Count-wise 80

12 Production parameters of spinning - Count-wise 113

13 Production parameters of automatic cone winding - Count-wise 144

14 Production parameters of two-for-one twisting - Count-wise 170

15 Comparison of 83 common mills data - Mill-wise 178

16 Contribution, sale value and cost factors - Yarn type-wise 183

17 Major counts spun by the mills - Mill-wise 186

18 Installed capacity - spinning and post spinning - Mill-wise 192

Soft copy of the 34th CPQ study report

A soft copy of the study report was also uploaded in SITRA's web portal
'www.sitra.org.in' . User ID and password to download/view the 34th CPQ
study report have been sent to all the participants through E-mail.
 ***** 34th CPQ study

It is interesting to note that four groups had contributed for about 35% of the total mills, while 2 mills
groups had contributed for about 25% of the mills (Figure 1). The groups with multiple units have been utilising the
CPQ study results for comparing the performance of their units not only among themselves but also with other
competing mills and initiate necessary measures to improve their performance. A consolidated report (for groups
having 3 mills and above) have been sent to various groups along with a hard copy of the report.
 
4%
5%

9% F
E
A: Single mills
D
40% B: 2 mills group
C: 19 mills group
A
D: 9 mills group
C
18% E: 5 mills group
F: 4 mills group

24%
Figure 1 Pattern of participation in the 34th CPQ study
(As a % of the total mills)
2. Method of study
Data relating to various costs and operational parameters which affect the profitability like salaries
and wages, power and raw material costs, yarn selling price, power consumption, productivity and product-mix
were obtained from the mills for the fourth quarter of 2018 (October - December). Requisite data were collected from
the mills through a well designed questionnaire in MS Excel format.

In this report, more than 250 different counts and varieties of yarns have been covered. The overall
ratings with respect to raw material cost, yarn selling price and techno-commercial index (TCI) are based on up to
6 major counts spun in each mill. Count-wise figures for each mill are also tabulated to enable them to make detailed
comparisons. All other data relating to contribution, labour and machine productivity, power consumption, power
cost, salaries and wages cost and product diversification cover the entire production of the mills.

Necessary care has been taken to ensure that the figures obtained from the mills are reliable and
accurate. Salaries and wages cost figures were verified against those expected for HOK, wage rate and production
pattern of the mills. In the case of other items, in addition to giving clear guidelines to avoid ambiguity, wherever
the individual figures deviated widely, clarifications were obtained from the mills.

3. Method of comparison
3.1. Ranking of mills

The mills have been ranked based on contribution, i.e. yarn sale value less the sum of clean raw
material cost, salaries and wages cost and power cost which ultimately decides the profitability (contribution minus
overheads and stores costs = operating profit). Tables 2, 3 and 16 give the mill-wise contribution, sale value and
cost particulars.

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3.2. Raw material cost, yarn selling price, net out-put value and production rate

Rating of a mill's performance is based on the average values that prevailed in the participant mills. In
each mill, data for up to six major counts have been considered. As these counts account, on an average, for about
three-fourths of the total yarn production, the rating can be expected to reflect more or less a mill’s entire production.
The overall cost for each mill, summing up all the six counts, is computed as follows:

Yarn selling price index (YSPI) has been arrived at by expressing the overall price realised by a mill in
the six counts (sum of yarn selling price/kg multiplied by the corresponding yarn production of the 6 counts) as a
percentage of the survey average yarn selling price (sum of average yarn selling price/kg multiplied by the
corresponding yarn production of the 6 counts). A similar procedure has been followed to compute the raw material
cost index (RMCI), commercial performance index (CI), technical performance index (TI), speed index (SI), TPI index
(TPII) and machine efficiency index (EI).

Illustration:- Calculation of YSPI :

Mill ref. no.: 46
Yarn selling price Yarn
(Rs/kg) production
Count Mill Survey during the
figure average quarter (kg)
40s K 218.0 207.5 3,36,947
40s C 240.7 232.6 1,04,210
60s C 289.5 288.6 2,15,303
40s C-Comp. 244.1 249.4 1,40,572
60s C-Comp. 298.4 314.3 27,775
Total 8,24,807
Total yarn sale value (Rs) :

Mill =(218.0x 3,36,947)+(240.7x1,04,210)+(289.5x 2,15,303)+(244.1x1,40,572)+(298.4x 27,775)

=20,34,57,455

Survey=(207.5x 3,36,947)+(232.6x1,04,210)+(288.6x 2,15,303)+(249.4x1,40,572)+(314.3x 27,775)

=20,00,92,904

Overall yarn selling price (Rs/kg) :

20,34,57,455
Mill average = = 246.7
8,24,807
20,00,92,904
Survey average = = 242.6
8,24,807
246.7
Yarn selling price index = x 100 = 102
242.6
Overall yarn selling price of the mill, based on the 5 major counts, is 2% higher than the survey average.

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Yarn selling price is one of the most important parameters that decides a mill’s overall performance
interms of profitability. However, as yarn selling price and yarn quality are to a large extent influenced by the cost
and quality of cotton, while judging yarn selling price, a mill’s rating of the raw material cost should also be taken
into consideration.

3.3. Techno-commercial Index (TCI)

TCI is a combined measure of YSP, RMC and production rate in relation to survey average. It is an
useful tool for mills to quickly assess the techno-commercial performance of various counts, either individually or
along with the comparison with the survey average. This information would also be helpful for mills to prioritise
corrective actions either in the commercial parameters or in the operational parameters.

NOVM x PRM CI x TI
TCI = x 100 (or)
NOVS x PRS 100
Where,
NOV = Net out-put value (Rs/kg of yarn).
PR = Production per spindle (rotor) per 8 hours in grams.

NOVM
CI = Commercial performance index, i.e. x 100
NOVS
PRM SI x EI
TI = Technical performance index, i.e. x 100 or
PRS TPII
M and S = Mill average and Survey average.

Calculation of techno-commercial index (TCI)

Illustration
Mill ref. no.: 46
NOVM NOVS PR M PR S Yarn prodn.
Count (Rs/kg of (Rs/kg of (g) (g) during the
yarn) yarn) quarter (kg)
40s K 64.9 55.1 119 102 3,36,947
40s C 64.7 55.8 129 124 1,04,210
60s C 113.5 111.4 64 62 2,15,303
40s C-Comp. 68.1 76.7 136 129 1,40,572
60s C-Comp. 122.4 126.5 66 67 27,775
Weighted avg. 80.0 76.0 107 98 -
Index CI = 105 TI = 109 TCI = 114

NOVM x PRM CI x TI
TCI = x 100 (or)
NOVS x PRS 100

80.0 x 107 105 x 109

= x 100 (or) => 114
76.0 x 98 100

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3.4. How to analyse techno-commercial performance of a mill ?

Illustration
Mill ref. no.: 46

Techno-commercial index (TCI = 114)

Commercial performance Index Technical performance Index

(CI = 105 ) (TI = 109)

Yarn selling Raw material Speed TPI Efficiency

price index cost index index index index
(YSPI = 102) (RMCI = 100) (SI = 106) (TPII = 99) (EI = 102)

The TCI of the mill, based on the 5 major counts, is 14% more than its competitors manufacturing the
same counts. The good performance of the mill is mainly due to better technical performance (TI = 109) and also
due to higher commercial performance (CI=105) when compared with its competitors.

From the above analysis, it can be deduced that the mill has been exercising a good control over
both technical and commercial performances when compared with its competitors' performance.

Mill-wise data with respect to YSPI , RMCI, CI, SI, TPII, EI, TI and TCI are presented in Table 1.
Count-wise figures for each mill which form the basis for computing the overall rating are given in Tables 10 and 12.
The major counts that were considered in each mill for estimating mill-wise indices are furnished in Table 17.

3.5. Salaries and wages cost (SWC)

Salaries and wages cost (SWC), expressed as a percentage of sale value, is generally independent of
the counts spun by the mills. However, the type of yarn has an important bearing on the SWC. In mills manufacturing
hosiery yarns, combed yarns, compact yarns, doubled yarns, processed yarns, fancy yarns, etc., the SWC tends
to be low. The wage levels prevailing in the mills also influence the SWC in direct proportion.

The SWC is thus primarily determined by three parameters, labour productivity, operative wage level
and type of yarn. It will be lower in mills achieving higher levels of labour productivity, paying lower wages and
producing high value yarns. The reduction in the SWC will be compounded, if more than one of these operating
conditions are present in the same mill. For example, in a mill with 20% higher labour productivity, 30% lower wages
and fetching 25% higher yarn sales realisation, the SWC will be lower by 53% [100 - (70 x 1002 / 120 x 125)]. On the
other hand, a high SWC largely stems from low labour productivity.

A SWC value of 8% or more should be viewed with concern and calls for both short-term and long-
term planning to increase labour and machine productivity. Percentile rankings of the SWC based on 103 mills are
given in Figure 2.

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23.0%
90

80 15.0 %

Percentile ranking
70 12.5 %

60 11.2 %

50 9.9 %

40 8.1 %
Avg. of 103 mills: 11.6%
(excluding 100% OE mills)
30 7.1 %

20 6.3 %

10 4.7 %

0 5 10 15 20

SWC

Figure 2 Salaries & wages cost (SWC) as a % of sales revenue

If a mill achieves 20 percentile ranking (6.3%), it means that 20% of the mills are having SWC lower
than this mill and 80% are with higher SWC.

3.6. Power consumption and cost

Power cost per spindle per year (PCY) is a function of the type of yarn and to a lesser degree the
counts spun. PCY is also determined by the power tariff, that is, primarily the location of the mill. Thus, a
comparatively high PCY does not necessarily mean that there is a loss of power and a scope for conservation. This
measure nevertheless indicates how a mill ranks in relation to others and this is important in the context of overall
and comparative profitability of the mills as power cost has become the largest component of conversion costs
incurred by them.

Vital information pertaining to the power consumption are given in Tables 4, 5, and 6. The consumption
particulars include units per kg of yarn (UKG), units per 1000 spindle shifts (USS), cost per unit, extent of use of
captive power, captive power generator details such as number of generators, age and capacity, type and cost of fuel
used, units of power generated per litre of fuel, etc.

3.7. How the cost figures given in Table 2 have been calculated?
Illustration:
Mill ref.no.46

Data furnished by the mill for October - December 2018:

A. Total yarn production (kg) : 8,69,679
B. Total estimated yarn sale value (Rs) : 21,33,80,179
C. Net raw material cost (Rs) : 14,15,61,145
D. Total salaries and wages cost (Rs) : 1,71,77,368
E. Total power cost (Rs) : 2,19,48,382
F. No.of working days : 90
G. Installed capacity (spindles) : 34,128
H. Total spindle shifts worked : 87,08,681

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Table 1
Indices of yarn selling price, raw material cost, commercial performance, technical performance
and techno-commercial performance
Yarn Raw Commercial Technical Techno-
Sl. Mill selling material performance Speed TPI Efficiency performance commercial
no. ref. price cost index index index index index index
no. index index (CI) (SI) (TPII) (EI) (TI) (TCI)
(YSPI) (RMCI)
1 30 116 114 119 107 98 103 112 133
2 15 99 91 115 109 100 98 107 123
3 22 99 96 108 110 98 102 114 123
4 13 99 94 113 106 102 101 105 119
5 18 104 102 108 104 97 103 110 119
6 91 104 100 111 104 100 102 106 118
7 46 102 100 105 106 99 102 109 114
8 61 99 96 112 105 101 98 102 114
9 8 101 95 109 104 101 101 104 113
10 26 106 101 113 96 99 100 97 110
11 32 100 96 106 102 101 103 104 110
12 41 99 94 107 103 98 98 103 110
13 51 104 105 102 105 100 102 107 109
14 72 102 101 107 99 98 101 102 109
15 73 101 98 106 101 101 103 103 109
16 12 99 99 98 108 101 103 110 108
17 5 101 97 110 99 102 100 97 107
18 10 103 102 104 99 97 101 103 107
19 9 101 99 104 101 101 102 102 106
20 49 101 99 104 106 100 96 102 106
21 76 103 100 107 99 99 99 99 106
22 4 101 99 104 100 100 101 101 105
23 14 100 99 102 - 99 - 103 105
24 44 101 97 105 99 101 102 100 105
25 50 109 112 102 103 100 99 102 104
26 100 103 102 104 98 98 100 100 104
27 37 102 98 106 96 100 101 97 103
28 57 99 99 99 103 100 101 104 103
29 1 96 98 93 107 97 100 110 102
30 6 97 98 96 106 100 100 106 102
31 7 101 100 102 100 100 100 100 102
32 31 101 100 102 100 100 100 100 102

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Table 2
Contribution, sale value and cost factors - mill-wise
Mill Selling Sale RMC/ As % of sales Power cost Contribution#
rank price value kg of Avg.
and /kg of /spl. yarn as /spl. /spl. /kg as count
ref. yarn /year (Rs) RMC SWC % of /year /year of yarn % of (Ne)
no. (Rs) (Rs)@ sales (Rs)@ (Rs)@ (Rs) sales

1 207 56720 140 67.9 3.6 8.2 4630 11540 42 20.3 30

2 391 26590 173 44.4 9.9 4.4 1180 10980 161 41.3 52
3 226 45460 147 64.8 6.3 4.9 2210 10890 54 24.0 27
4 242 39830 153 63.0 6.6 4.3 1700 10400 63 26.1 34
5 235 48010 151 64.1 3.6 10.9 5230 10240 50 21.4 31
6 287 35500 155 54.2 5.4 11.7 4150 10190 82 28.7 45
7 283 32830 142 49.9 9.1 10.5 3440 10020 86 30.5 35 *
8 390 32090 216 55.2 5.5 9.4 3000 9610 117 29.9 55
9 229 49470 157 68.3 5.6 7.9 3900 9020 42 18.2 30
10 235 37610 162 69.0 4.2 3.4 1300 8800 55 23.4 32
11 249 30640 155 62.5 6.4 2.8 860 8680 70 28.3 44
12 219 47480 147 66.9 4.8 10.2 4830 8600 40 18.1 30
13 252 42500 159 62.8 7.2 9.9 4210 8530 51 20.1 33
14 206 52290 141 68.3 6.1 9.4 4930 8480 33 16.2 25
15 217 42720 138 63.6 3.6 13.1 5610 8400 43 19.7 31
16 209 57470 155 74.3 3.0 8.3 4800 8290 30 14.4 29
17 233 36390 159 68.1 4.8 6.1 2230 7630 49 21.0 37
18 285 32440 180 63.2 6.7 7.4 2390 7360 65 22.7 47
19 250 27810 149 59.6 6.6 7.5 2080 7310 66 26.3 41 *
20 199 50310 138 69.7 8.5 8.6 4310 6680 26 13.2 29
21 518 15910 227 43.7 10.9 3.8 600 6610 215 41.6 91
22 165 65460 125 75.6 4.3 10.1 6590 6590 17 10.0 18 *
23 410 18050 200 48.7 7.6 7.2 1290 6590 150 36.5 74 *
24 230 37310 160 69.5 7.1 5.9 2190 6560 40 17.5 31 *
25 337 22470 159 47.2 9.6 14.1 3170 6530 98 29.1 66
26 326 28420 183 56.2 7.2 13.9 3960 6440 74 22.7 49
27 282 51280 197 69.9 8.2 9.5 4860 6350 35 12.4 30
28 297 36130 190 63.8 7.1 12.1 4360 6160 51 17.0 41
29 239 33810 144 60.3 10.3 11.8 3980 5940 42 17.6 39
30 536 17820 244 45.5 7.8 13.8 2450 5870 176 32.9 107
31 182 57930 121 66.5 9.8 13.6 7890 5830 18 10.1 22
32 289 24540 169 58.6 8.0 10.0 2460 5730 67 23.4 48
33 236 26950 133 56.5 8.5 14.7 3960 5480 48 20.3 36 *

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Table 4
Power consumption particulars - mill-wise
UKG Overall
Avg.cnt.

Mill Power consumption (%) Power cost per unit (Rs) power State
(Ne)

doubling
Without
Overall

ref. USS cost per code

no. EB HSD HFO Pvt. Oth. EB HSD HFO Pvt. Oth. unit (Rs)

1 30 2.58 - 690 100 - - - - 6.5 - - - - 6.5 GJ

#
2 52 7.88 5.68 555 98.74 1.26 - - - 2.0 15.5 - - - 2.2 TN
3 27 1.75 - 350 99.67 0.33 - - - 6.2 17.6 - - - 6.3 PB
#$
4 34 3.72 3.51 605 76.94 0.06 0.20 22.80 - 2.0 17.0 9.2 5.3 - 2.8 TN
5 31 3.96 - 780 100 - - - - 6.5 - - - - 6.5 MP
6 45 5.76 - 685 98.95 1.05 - - - 5.8 11.5 - - - 5.8 HP
#
7 35 * 6.27 4.23 715 46.57 0.15 0.78 52.50 - 3.6 20.9 11.2 5.6 - 4.7 TN
#
8 55 7.08 - 570 49.48 1.21 - 49.31 - 4.3 21.6 - 5.6 - 5.2 TN
#
9 30 3.29 - 700 30.61 0.16 - 69.23 - 5.4 23.6 - 5.5 - 5.5 TN
#
10 32 3.69 - 625 99.19 0.81 - - - 2.0 21.7 - - - 2.2 TN
#
11 44 4.39 4.14 520 98.67 1.33 - - - 1.4 16.8 - - - 1.6 TN
12 30 3.82 - 805 99.27 0.73 - - - 5.7 17.4 - - - 5.8 HP
13 33 4.33 - 715 99.32 0.68 - - - 5.7 16.1 - - - 5.8 HP
$
14 25 2.74 2.50 670 99.97 0.03 - - - 7.1 37.5 - - - 7.1 HR
15 31 3.97 3.81 755 21.62 0.03 - - 78.35 8.2 16.4 - - 6.9 7.2 MP
16 29 2.64 - 710 100 - - - - 6.6 - - - - 6.6 GJ
#
17 37 3.66 - 560 89.08 0.85 - 10.07 - 3.6 13.3 - 5.5 - 3.9 TN
#
18 47 5.53 - 605 56.66 0.56 - 42.78 - 1.5 22.2 - 6.6 - 3.8 TN
#
19 41 * 4.65 - 500 52.36 0.62 - 47.02 - 1.5 22.2 - 6.6 - 4.0 TN
20 29 2.81 2.67 700 99.97 0.03 - - - 6.1 19.6 - - - 6.1 PB
#
21 91 12.18 8.96 360 99.87 0.13 - - - 1.6 35.2 - - - 1.6 TN
$
22 18 * 2.19 2.07 840 100 - - - - 7.6 - - - - 7.6 RJ
#
23 74 * 8.01 7.89 345 59.73 1.23 - 39.04 - 2.1 20.3 - 5.6 - 3.7 TN
#$
24 31 * 3.20 3.16 525 43.90 - 0.74 55.36 - 2.2 - 13.5 5.8 - 4.2 TN
25 66 7.76 7.41 530 2.23 0.86 - 96.91 - @ 20.2 - 5.4 - 6.1 TN
26 49 6.41 6.03 555 98.41 1.59 - - - 6.8 25.2 - - - 7.1 TN
27 30 4.42 4.17 830 99.61 0.14 0.24 - - 6.0 21.8 10.5 - - 6.0 PB
28 41 5.84 5.21 695 0.26 - - 99.73 - 7.5 22.7 - 6.1 - 6.1 TN
29 39 3.71 - 505 99.52 0.48 - - - 7.6 13.9 - - - 7.6 MH
30 107 11.06 - 365 2.91 1.56 - 95.53 - 7.8 21.3 - 6.4 - 6.7 TN
31 22 3.19 2.46 1000 - - - - 100 - - - - 7.8 7.8 RJ
#$
32 48 5.41 5.35 450 48.88 0.54 - 50.58 - 4.5 20.5 - 6.1 - 5.4 TN
33 36 * 4.33 - 485 100 - - - - 8.0 - - - - 8.0 MH
34 23 2.58 2.49 685 100 - - - - 5.0 - - - - 5.0 MP

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Table 7
Labour productivity - mill-wise
Mill Up to ring frames@
Cone winding HOK@ Ring frame Avg.
ref. Conv. Auto Tenter Doffer count (Ne)
no. HOK OHSAM winding winding assign. assign. (ring
index* index* spinning)
1 - - - - 90 AD 30
2 13.4 1.7 8.3 2.8 129 108 52
3 - - - 1.0 241 AD 27
4 11.6 1.6 - - 126 AD 34
5 - - - - 238 AD 31
6 - - - - 200 AD 45
7 14.6 2.0 - 6.0 100 83 82
8 11.9 1.6 - - 106 AD 55
9 9.7 1.4 - - 119 AD 30
10 20.0 2.7 - - 69 AD 32
11 10.8 1.5 - - 93 100 44
12 - - - - 175 AD 30
13 - - - - 196 AD 33
14 11.0 1.7 - 2.0 88 AD 25
15 - - - - 165 AD 31
16 9.8 1.5 - 1.9 93 AD 29
17 13.0 1.8 - 1.9 - - 37
18 8.8 1.3 - - 175 AD 47
19 9.1 1.3 - - 136 AD 61
20 13.3 1.9 - 2.5 83 87 29
21 15.3 1.9 - 3.7 138 117 91
22 9.2 1.4 - - 204 AD 24
23 18.9 2.5 6.0 4.0 103 92 85
24 11.5 1.6 - 2.1 115 133 40
25 15.3 2.2 - 2.7 88 97 66
26 - - - - 120 122 49
27 - - - - 152 125 30
28 13.8 1.9 - 2.2 116 105 41
29 12.5 1.7 - 2.2 141 101 39
30 18.9 2.5 - - 71 92 107
31 - - - - 74 64 22
32 14.2 1.9 - 2.3 100 108 48
33 17.1 2.1 - 3.4 112 100 52

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Table 8
Machine productivity - mill-wise
Prodn./ Spindle/ % loss in utilisation
Mill spl./ rotor
ref. 8 hrs. utilisation Repairs Labour Power MPI
no. (g)@ (%) & maint- shortage shortage Others# Total
enance
1 145 98.20 1.40 - 0.20 0.20 1.80 132
2 95 91.73 1.04 7.00 0.13 0.10 8.27 80
3 - 95.88 1.20 1.00 0.39 1.53 4.12 -
4 114 96.00 2.01 0.21 1.47 0.31 4.00 102
5 - 98.19 1.27 - 0.08 0.46 1.81 -
6 - 99.09 0.78 - 0.05 0.08 0.91 -
7 110 97.40 1.55 - 0.15 0.90 2.60 99
7* - 92.94 0.54 - 0.06 6.46 7.06 -
8 111 97.19 1.83 - 0.09 0.89 2.81 100
9 123 96.88 0.75 0.06 1.52 0.79 3.12 111
10 109 90.13 3.31 0.25 2.00 4.31 9.87 91
11 112 99.15 0.60 - 0.08 0.17 0.85 103
12 - 97.98 1.72 - 0.04 0.26 2.02 -
13 - 97.08 0.62 0.02 0.12 2.16 2.92 -
14 136 98.50 0.72 0.12 0.26 0.40 1.50 124
15 - 98.92 0.79 - 0.01 0.28 1.08 -
16 137 97.55 1.44 - 0.60 0.41 2.45 124
17 113 96.96 1.00 0.15 0.87 1.02 3.04 102
18 118 98.82 0.69 - 0.42 0.07 1.18 108
19 120 98.86 0.52 - 0.39 0.23 1.14 110
19 * - 97.10 0.72 - 1.98 0.20 2.90 -
20 114 96.94 1.09 0.04 0.12 1.81 3.06 103
21 96 99.35 0.49 0.13 - 0.03 0.65 89
22 131 98.01 0.63 1.04 0.32 - 1.99 119
22 * - 98.10 0.79 - 0.68 0.43 1.90 -
23 103 97.15 0.80 0.80 0.68 0.57 2.85 93
23 * - 97.56 1.74 - 0.61 0.09 2.44 -
24 110 93.83 1.70 0.36 1.64 2.47 6.17 96
24 * - 94.57 1.23 - 2.03 2.17 5.43 -
25 118 93.22 2.83 0.86 2.04 1.05 6.78 102
26 106 96.21 1.79 0.03 0.28 1.69 3.79 94
27 129 92.33 4.17 0.20 1.20 2.10 7.67 111
28 108 97.07 1.29 0.05 0.36 1.23 2.93 97

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Table 9
Product diversification - mill-wise
(as a % of total yarn production)

processed
Chemical
Compact
Combed
Mill Doubled 100% 100% Cotton/

Hosiery
Export

ref. Gassed cotton non- MMF

no. Ring TFO Eli-twist cotton blended

1 100 100 100 - - - 100 - - 100 - -

2 100 100 - 54 40 - - - 31 100 - -
3 52 80 98 - 11 - - - - 27 7 66
4 98 30 98 - - - 93 - - 32 - 68
5 80 100 78 - - 5 - - - 100 - -
6 12 100 40 - - - 67 - - 100 - -
7 41 100 - - 47 - 100 - 10 100 - -
7* 6 - 6 - - - - - - 100 - -
8 - 100 - - - - 100 - - 100 - -
9 4 - 100 - - - 42 - - 27 - 73
10 - 80 100 - - - - - - 100 - -
11 81 100 81 - 10 - 72 - - 100 - -
12 18 19 65 - 8 - 15 - - 43 - 57
13 74 83 76 - - - 18 - - 74 9 17
14 72 45 73 1 19 - 1 - - 100 - -
15 6 66 6 - - - 55 - - 71 - 29
16 50 100 100 - - 8 100 - - 100 - -
17 60 75 100 - - - 100 - - 100 - -
18 - 100 11 - - 1 100 - - 100 - -
19 - 100 44 - 34 - 100 - - 100 - -
19 * - - - - - - - - - 100 - -
20 16 63 - - 28 - - - - - 37 63
21 52 95 6 6 40 - 21 - 15 100 - -
22 62 13 64 - 25 - - - - 100 - -
22 * 55 - - - - - - - - 68 - 32
23 - 92 - - 2 5 83 - 2 83 4 13
23 * - - - - - - - - - 100 - -
24 90 91 54 - - - 99 - - 40 - 60
24 * - - - - - - - - - 100 - -
25 - 100 - - 5 - 100 - - 100 - -
26 - 100 10 - 15 - 100 - - 100 - -
27 34 1 43 - 18 - 3 - - 30 16 54
28 62 100 39 - 19 - 16 - - 100 - -

45 _____SITRA
 ***** 34 th CPQ study

Table 10
Yarn selling price, raw material cost,
net out-put value and yarn quality - count-wise

Yarn Raw Net out-put value Ring yarn quality

Mill selling material Hairi-

Strength
ref. price cost (Rs/ (Rs/ Count Imperfections/1000 m ness

CV%
no. (Rs/ (Rs/kg kg of spl./ CV% CSP@ U% index
kg) of yarn) yarn) shift)* Thin Thick Neps Total

Ring spun yarn

Cotton carded yarn

Domestic market

12s K
86 160.0 147.4 12.6 5.0 1.4 2580 3.3 10.2 0 80 94 174 -

16s K
32 173.0 138.0 35.0 11.8 1.3 2340 4.7 13.1 19 290 289 598 9.2

20s K
15 195.0 132.9 62.1 19.9 1.0 2600 3.1 11.0 1 90 127 218 7.2
22 188.6 138.7 49.9 15.6 1.0 2750 3.2 11.0 1 95 57 153 6.9
101 196.0 157.0 39.0 8.6 - - - - - - - - -
Avg. 193.2 142.9 50.3 14.3 1.0 2670 3.1 11.0 1 93 92 186 7.1

24s K
69 204.8 150.7 54.1 12.2 1.2 - 3.5 10.8 2 91 220 313 -
22 185.6 138.7 46.9 12.1 0.9 2700 3.3 11.5 2 149 108 259 6.5

29s K
77 189.4 155.0 34.4 6.0 2.1 2190 4.5 13.1 50 711 991 1752 -

32s K
72 201.0 151.0 50.0 7.3 1.6 2630 4.1 12.6 7 363 702 1072 -
67 182.1 145.5 36.6 5.3 1.2 2610 5.0 11.9 5 246 657 908 -

34s K
67 197.0 145.5 51.5 6.6 1.4 2600 4.5 12.2 9 288 760 1057 -
85 198.2 149.5 48.7 6.2 1.0 2420 3.7 14.3 53 693 2272 3018 -
102 197.1 151.2 45.9 4.7 2.1 2210 5.3 14.0 41 632 645 1318 -
Avg. 197.4 148.7 48.7 5.8 1.5 2410 4.5 13.5 34 538 1226 1798 -

49 _____SITRA
 ***** 34 th CPQ study

Table 11
Yarn realisation & wastes and raw material quality - count-wise
Yarn realisation and wastes Average cotton quality
Mill Yarn Hard Sweep Invisible Proportion of 2.5% Unifor- Fine- Trash
Blow room

waste(%)

Strength
(g/tex)
& card

ref. reali- waste waste loss cotton(s) in span mity ness in

no. sation (%)* (%)* (%)* the mixing** length ratio (µg/ mixing
(%) (mm) (%) inch) (%)

Ring spun yarn

Cotton carded yarn

Domestic market

12s K
86 84.5 12.3 0.7 1.0 0.5 B1 (100%) - - - 3.7 4.0

16s K
32 83.3 14.8 0.5 0.6 0.5 S6 (75%)+V (25%) 25.9 47.7 19.0 3.8 7.2

20s K
22 87.8 10.7 0.5 0.1 0.9 - - - - 4.5 3.2
15 86.9 10.5 0.6 0.2 1.4 - - - - 4.0 2.6
101 84.9 11.8 0.8 1.8 0.7 B2 (100%) 29.6 46.1 21.6 - 3.9
Avg. 86.5 11.0 0.6 0.7 1.0 - - - - 4.3 3.2

24s K
22 87.8 10.7 0.5 0.1 0.9 - - - - 4.5 3.2
69 84.2 11.8 0.6 0.9 (+) 0.1 M2 (100%) - - - 4.3 3.4

29s K
77 86.1 11.0 0.8 1.2 1.0 B2+H 29.7 46.5 24.6 - 3.4

32s K
67 86.9 11.4 0.4 0.7 0.5 M1 (100%) 29.9 47.3 24.6 4.6 2.5
72 86.1 11.2 0.5 0.7 1.6 B1 (100%) 30.0 48.0 - 4.1 3.0

34s K
67 86.9 11.4 0.4 0.7 0.5 M1 (100%) 29.9 47.3 24.6 4.6 2.5
85 85.3 10.4 0.6 1.0 0.1 M2 (100%) - - - 4.2 3.5
102 85.1 11.0 1.0 - 2.9 B2 (100%) 29.5 47.2 23.5 - -
Avg. 85.8 10.9 0.7 0.9 1.2 - 29.7 47.3 24.0 4.4 3.0

38s K
72 86.1 11.2 0.5 0.7 1.6 B1 (100%) 30.5 48.0 - 3.9 3.0
102 85.1 11.0 1.0 - 2.9 B2 (100%) 29.5 47.2 23.5 - -

80 _____SITRA
 ***** 34 th CPQ study
Table 12
Production parameters of spinning - count-wise
Mill Actual Prodn./ Spindle End Pneumafil Lift (mm) Tenter* Doffer*
ref. count @ spl./ speed Tpi breaks/ waste & ring assign. assign.
no. (Ne) 8 hrs.(g) (rpm) 100 spindle (%) dia. (mm) (spls.) (spl.
hours doffs)

Ring spun yarn

Cotton carded yarn

Domestic market

12s K
86 12.2 398 10500 13.7 5.0 3.0 180x42 3024 6000

16s K
32 16.0 337 14250 17.8 4.8 1.1 180x40 1440 AD

20s K
15 20.2 320 18000 18.7 4.3 1.0 170x38 3600 AD
22 20.2 312 17700 18.8 3.6 0.8 185x40 3360 AD
101 20.0 221 14200 20.6 8.8 4.0 178x40 1080 3200
Avg. 20.1 284 16630 19.3 5.6 1.9 - 2680 -

24s K
22 24.2 257 19150 20.7 3.4 0.8 185x40 3360 AD
69 23.7 225 16000 19.9 4.7 2.3 170x38 1632 AD

29s K
77 29.5 175 18000 24.2 4.6 2.2 - 1008 AD

32s K
72 32.8 145 17230 24.0 7.0 2.7 152x36 3200 6000
67 32.5 144 17100 24.5 7.2 3.4 170x38 1800 4800

34s K
67 34.5 128 - 26.3 7.8 3.5 170x38 1800 4800
85 34.5 128 16800 25.7 6.8 2.4 180x40 1656 4200
102 34.5 102 14200 26.7 10.0 3.5 170x38 1512 3200
Avg. 34.5 119 15500 26.3 8.2 3.1 - 1656 4067

38s K
72 38.5 113 16450 26.0 7.0 2.7 152x36 3200 6000
102 38.5 90 14800 29.0 12.5 3.5 170x38 1512 3200

113 _____SITRA
 ***** 34 th CPQ study

Table 13
Production parameters of automatic cone winding - count-wise
Mill Production/ Average Drums Clearer Cop Delivery
ref. tenter/ winding- assigned Efficiency cuts/one content cone wt.
no. 8 hours on speed per (%)+ lakh (g) (kg)
(kg) (mpm) tenter metres

Ring spun yarn

Cotton carded yarn

Domestic market

12s K
86 500 1300 30 54 - 70 1.89

16s K
32 521 1200 35 70 35 55 2.00

20s K
15 - 1500 300 # - 90 50 2.50
68 308 1100 30 66 32 45 1.50
101 287 900 30 75 60 60 1.50
Avg. 298 1170 120 71 61 52 1.83

24s K
14 1883 1577 146 # 69 30 61 2.80
69 1894 1400 151 # 76 27 50 1.89

29s K
77 275 1100 30 85 - 45 1.50

30s K
68 - 1100 30 - 32 45 1.50

32s K
67 378 1550 40 69 75 50 2.00
72 215 1450 20 84 60 38 1.89

34s K
67 352 1550 40 68 75 50 2.00
85 368 1400 40 79 22 62 1.89
102 184 1000 30 74 41 40 1.50
Avg. 301 1320 37 74 46 51 1.80

144 _____SITRA
 ***** 34 th CPQ study

Table 14
Production parameters of two-for-one twisting - count-wise
Mill Production/ Average Breaks/ Feed Delivery
ref. spindle/ spindle Tpi Efficiency 100 weight weight Spindles/
@
no. 8 hours speed (%) spindle (g) (g) tenter
(g) (rpm) hours

Ring spun yarn

Cotton carded yarn

Domestic market
2/20s K
15 838 9500 13.6 83 0.3 945 1890 1584
68 1250 10500 11.0 91 5.0 600 1500 240

2/24s K
14 1214 9200 8.6 95 1.9 833 2500 245

2/30s K
19 468 9000 17.1 93 0.5 945 1890 960

2/60s K
90 158 10000 25.0 82 1.9 300 1500 432

2/40s K-Comp.
79 243 7000 19.5 94 - 500 1500 480

2/60s K-Comp.
79 131 8500 25.5 82 - 500 1500 480

Export market

2/20s K-Ex.
22 1552 7000 5.5 85 0.5 1000 2000 2160

2/24s K-Ex.
22 1202 8000 7.0 88 0.5 1000 2000 2160

2/30s K-Ex.
57 518 10270 17.9 94 1.0 830 2520 456

170 _____SITRA
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Table 17
Major counts spun by the mills
Prodn. Counts
Mill of major spun during the quarter*
ref. Major counts counts as Total
no. % of total Min. Max. Range per
prodn. 30000
spls.

1 30s CH-Comp.-Ex., 26s CH-Comp.-Ex., 29s CH-Comp.-Ex., 100 26 32 6 5

28s CH-Comp.-Ex., 32s CH-Comp.-Ex.
2 2/30s C-Ex., 2/38s C-G-DHCR-Ex., 2/60s C-Ex., 36 30 115 85 9
2/60s C-G-Ex., 2/100s C-G-Ex.
3 30s CH-Slub, 40s Mod./C-CH-Slub (40/60), 20s KH, 10 10 40 30 -
32s C/A-KH (49/51), 18s C/A-KH-Ex. (48/52), 30s C/A-CH-Ex. (48/52)
4 40s CH-Comp.-Ex., 30s P/C-KH-Comp.-Mel.-Ex. (10/90), 74 20 60 40 10
32s P/C-CH-Comp.-Ex. (45/55), 30s P/C-CH-Comp.-Ex. (45/55),
32s P/C-KH-Comp.-Mel.-Ex. (01/99), 40s C-Comp.-Ex.
5 20s CH-Comp.-Ex., 26s CH-Comp.-Org.-Ex., 30s CH-Comp.-Ex., 69 - - - -
2/40s C-ET, 40s CH-Comp.-Org.-Ex., 32s CH-Comp.-Ex.
6 30s CH-Ex., 40s CH-Ex., 40s CH, 50s C-Comp.-Ex., 50s C-Comp., 47 30 80 50 8
60s CH-Comp.-Ex.
7 2/66s C-Comp.-Ex., 2/80s C-Comp., 80s C-Comp., 70s C-Comp., 31 60 160 100 13
2/100s C-Comp.-Ex., 7s OE
8 50s C-Comp., 50s C-Comp.-Ex., 70s C-Comp.-Ex., 30 30 80 50 5
60s C-Comp., 60s C-Comp.-Ex.
9 30s P/C-CH-Comp. (20/80), 24s P/C-CH (40/60), 30s P/C-CH (40/60), 49 10 42 32 52
30s P/C-CH (48/52), 30s CH-Comp., 36s CH-Comp.
10 30s CH-Slub, 30s CH, 34s CH, 36s CH, 40s CH, 30s KH 76 25 40 15 35
11 40s CH-Comp.-Ex., 40s CH-Comp., 50s CH-Ex., 60s C-Comp., 100 40 60 20 5
2/40s C-Ex.
12 20s P/C-CH (48/52), 24s P/C-CH (48/52), 30s P/C-CH (48/52), 62 10 42 32 6
40s P/C-CH (48/52), 20s CH, 40s C-Comp.
13 30s CH-Ex., 24s CH-Ex., 30s CH-Comp., 32s CH-Ex., 30s CH, 57 16 120 104 29
40s CH-Comp.-Ex.
14 26s CH-Ex., 21s KH-Ex., 16s K-Ex., 2/24s K, 32s KH-Ex., 21s CH-Ex. 41 12 40 28 7
15 40s C-Comp., 30s C-Comp., 20s K, 20s P/C-C (65/35), 32 10 45 35 8
30s P/C-C (65/35), 40s P/C-C (65/35)
16 24s CH-Comp.-Ex., 26s CH-Comp.-Ex., 28s CH-Comp., 100 24 34 10 7
30s CH-Comp.-Ex., 34s CH-Comp., 2/40s CH-ET
17 30s CH-Comp., 34s CH-Comp.-Ex., 40s CH-Comp.-Ex., 87 30 44 14 7
40s KH-Comp., 42s CH-Comp.-Ex., 44s CH-Comp.-Ex.

186 _____SITRA
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Table 18
Installed capacity - spinning and post spinning - mill-wise
Mill Year Ring Doubling TFO Auto No.of days
ref. of esta- spindles@ Rotors spindles spindles winder worked
no. blishment drums during the
quarter

1 2017 27500 - - - 660 92

2 1956 57500 - 22544 8160 1096 91
3* 1965 47500 - - 1728 1020 91
4* 1981 62500 - - 2368 1568 91
5* 2012 56500 - - - 1565 91
6* 1998 55500 - - - 1392 91
7* 1956 31000 576 - 10592 620 90
8* 1992 56500 - - - 1244 90
9* 1993 35000 - - - 840 89
10 2014 13000 - - - 324 91
11 * 1994 51000 - - 1920 1064 90
12 * 2002 87500 - 186 3996 2346 91
13 1996 44000 - - - - 91
14 * 1991 115000 - 1760 4428 2413 91
15 * 2007 115000 - - 7920 2842 91
16 2015 27500 - - - 660 92
17 1996 24500 - - - 560 91
18 * 2006 56000 - - - 960 91
19 * 1953 57000 3320 - 5760 972 91
20 * 1995 66000 - - 5036 1440 91
21 * 1947 119000 - 14592 19928 1804 91
22 * 2007 28500 2208 112 2160 617 91
23 * 1990 103500 720 - 3900 1140 91
24 * 1946 41000 1440 - 2124 896 91
25 2006 27500 - - 1824 440 92
26 * 1992 36000 - - 4056 690 91
27 * 1981 108000 - - 8442 3050 91
28 * 2007 62500 - - 6828 1140 91
29 * 1994 55500 - - - 1140 92
30 * 2006 14000 - - - 188 91
31 * 1989 63500 - 8224 17908 1768 91
32 1956 30000 - - - 500 90
33 1995 35000 640 - 2352 660 85

192 _____SITRA