DPR
DPR
DPR
REPORT
G MUNIRATNAM
33-127/5-1, Gadduru road
Palamaner, Chittoor
Andhra Pradesh – 517408
+91-9492662740
Introduction
Silk reeling is the process by which a number of cocoon baves are reeled together to produce a
single thread. This is achieved by unwinding filaments collectively from a group of cooked
cocoons at one end in a warm water bath and winding the resultant thread onto a fast moving
reel. Raw silk reeling may be classified by direct reeling method on a standard sized reel,
indirect method of reeling on small reels, and the transfer of reeled silk from small reels onto
standard sized reels on a re-reeling machine. The last technique is primarily applied in modern
silk reeling processes.
There are many types of silk reeling machines in use. The major structural features of the
Sitting Type Reeling Machine, the Multi-ends Reeling Machine and the Automatic Reeling
Machine are shown in Table 20.
This primitive spinning apparatus is operated by two hands – one to drive the wheel and the
other to feed in cocoons. One end of the reeling thread is wound onto each wheel, while
cocoons are boiled in a separate pot.
The Charka type is in use in India. This machine is operated with separate work motions in reel
driving and cocoon feeding to reeling ends by two men per machine. Each machine has 3 ends
or more to a reel, which is the same size as the large wheel of the Re-reeling machine in order
to save the re-reeling process (direct reeling method).
There are two kinds of sitting type reeling machines, foot operated and motor-driven (see
Appendix, Figure 17). The motor-driven reeling machine is not equipped with the stop motion
attachment (see appendix, Figure 18). There are obstacles to the production of good quality raw
silk as the raw silk thread is wound too rapidly to maintain good quality control.
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Comparisons of structural features of various reeling machines
An automatic ten-brush unit brushes cocoons with independent arms rotating in reverse motion
on an axis in circular basins.
Picking frames rotating in one direction pick off the brushed cocoon filaments when a cam
during the operation raises the brushes. Selective picking is completed in the most effective
manner by this equipment. To maintain the exact number of cocoons at each reeling end, a
control device is attached which detects the amount of cocoons in the cocoon suppliers and
automatically supplements deficiencies in the number of cocoons.
2. Reeling section
In these devices, the yarn constantly passes through the denier indicator and detector, which are
set to a given size. The size of thread being reeled is detected through the balance between the
friction of the running thread and an eccentric weight fitted on the denier indicator.
The velocity of cocoon reeling affects the raw silk yield, reeling efficiency and raw silk quality
(see Table 21 and 22). Optimum reeling velocity should be maintained for the best possible
product.
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b) Groping ends
The high water temperature of the groping ends section dissolves sericin to a great extent and
improves the reelability of the cocoon. However, it is apt to reduce raw silk percentage of the
cocoon. Alternatively, too low water temperature in this process can reduce the groping end
efficiency, the reelability percentage and the reeling efficiency.
When the thread becomes thinner than the fixed limit, the denier indicator indicates the
necessity of feeding-ends. This indicator is composed of two gauge glass plates with other
pieces of gauge plate which have a slit between them corresponding to the given size of thread
to be reeled. The size of yarn may be adjusted to the required sizes by varying the irregular
weight with the denier-adjusting device; if a wider range of adjustment is required the denier
indicators have to be replaced.
The fixed end feeding system is employed together with a conveyor system to carry cocoon
supplies and feed cocoons to the reeling section whenever required.
Cocoons are supplied to the conveyor, which rotates constantly around the reeling section. The
feeding lever fixed to the detecting mechanism will trigger the driving lever on the cocoon
supplier only when the size of yarn becomes thinner than the required denier during reeling
operation.
Stop motion
If there is a defect in the reeling, the reel is automatically stopped by a brake, which is activated
by contact pressure from operation of the detector level.
The apparatus gathers baskets that have collected all cocoons dropped during end feeding.
These are carried to the dropped cocoon separator. These baskets travel intermittently between
the cocoon suppliers.
The device accurately distinguishes and separates pupae, dropped middle layer cocoons and
thick layer dropped cocoons.
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6. Semi-automatic reeling machine
This is a mixed-mode or hybrid machine between the automatic and multi-ends reeling
machines. As an application, this type is better for improved reeling efficiency and raw silk
quality than the multi-ends reeling machine. The semi automatic reeling machine can be
operated with poor quality cocoons, but relies on more labour than the automatic reeling
machine.
The cooked cocoons are carried into the groping end part (10) and the end-groped cocoons are
removed to the picking end part (11). The correctly picked end cocoons go through the cocoon
supplying basket (9) and then to the arranging basin (8). When the size detector of the reeling
thread indicates the feeding motion, the picked end cocoons on standby are fed to the reeling
thread by a feeding spoon. The reeling thread passes through the jetboute, silk button, first
guider, second guider, third guider, fourth guider, size detector, fifth guider and traverse guide,
and then it is finally wound onto small reels (4) (Figure 16).
The end dropped cocoons are collected by the cocoon buckets (13) and removed to the cropped
cocoon basin, where more reelable cocoons are separated and then poured into the groping end
part (10). The principal difference between a semi-automatic reeling machine and an automatic
reeling machine is that the cocoon end groping, cocoon end picking and cocoon carrying are
manual.
Reeling velocity is defined as the winding speed of raw silk on the reel. The reeling velocity is
measured as the length of raw silk reeled during 1 minute or as the revolution number of the
reel per minute. It is usually calculated by the following formulas.
Where formula (1) applies to the automatic type, formula (2) applies to the multi-ends type.
Effect of various reeling velocities on silk yield and quality with different grades of
reelability cocoon (Choe, et al. 1971)
Relationship between reeling velocity and evenness of raw silk quality (S.
Kimura, et al. 1964)
50 93.5 86.0
80 98.0 82.0
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Quality control during raw silk reeling
The purpose of reeling process is not only to raise the raw silk yield of cocoons and reeling
efficiency, but also to improve raw silk quality.
a. Size development and evenness - To maintain reeling thread in the required size, the
average cocoon number per thread must be adjusted by a check to produce silk thread in
the same size throughout all ends during reeling. If the size is different from the required
size it should be readjusted by the group size controller. This will reduce size deviation.
By improving the accuracy of cocoon supplying each silk thread becomes uniform in
size and different skein sizes are reduced. It can also improve the size deviation and
evenness of raw silk quality through accuracy of cocoon supplying work and the
improvement of cocoon reelability.
b. Defects – Defects in raw silk are divided into super major defects, major defects and
neatness defects. Defects occur based on reeling conditions. Types of defects and
remedies are explained in Table 23.
c. Cohesion – Good cohesion raw silk is needed for the warp of silk fabric. Factors that
improve the cohesion are temperature, amount of reeling tension, sufficient croissure
and good drying of raw silk.
d. Colour – The water consistency and temperature of groping end part and reeling part
affect the colour of raw silk. Therefore, the temperature control and water supply in the
reeling machine should be constantly monitored to obtain a uniform colour of raw silk.
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Bad casts 1. Keep the extra end of cocoon filament short when the
correct end picked cocoons are fed to the reeling
thread.
Long knots 1. When the broken thread are tied and knotted during
the reeling or re-reeling process, the end of the tied
and knotted thread must be cut off, leaving only 2 mm.
COST OF PROJECT
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d. Preliminary & Pre-operative Cost : Rs. 150000.00
Means of Financing :
9
WORKING CAPITAL
STATEMENT SHOWING THE REPAYMENT OF TERM LOAN & WORKING CAPITAL :
TERM LOAN
10
Schedule of Sales Realization :
Details of Sales
Total 4000000.00
Rawmaterials :
Wages
:
No. of Wages Amount in Rs.
Particulars
Worker Per Month (Per Annum)
WORKERS 9 5000.00 540000.00
Superviser 2 7000.00 168000.00
Total 11 708000.00
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Repairs and Maintenance : Rs. 30000.00
Administrative Expenses :
Salary
Accounts & Stores 1 8000.00 96000.00
Master 1 9000.00 108000.00
Manager 1 12000.00 144000.00
0 0.00 0.00
0 0.00 0.00
Total 3 348000.00
Total 438000.00
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Capacity Utilization of Manufacturing & Administrative Expenses :
3rd 4th
Particulars 1st Year 2nd Year Year Year 5th Year
Capacity Utilization 70% 80% 90% 90% 90%
Manufacturing Expenses
Rawmaterials 127750 146000 164250 164250 164250
Wages 495600 566400 637200 637200 637200
Repairs & Maintenance 21000 24000 27000 27000 27000
Power & Fuel 10500 12000 13500 13500 13500
Other Overhead Expenses 10500 12000 13500 13500 13500
Administrative Expenses
Salary 348000 348000 348000 348000 348000
Postage Telephone Expenses 3500 4000 4500 4500 4500
Stationery & Postage 3500 4000 4500 4500 4500
Advertisement & Publicity 21000 24000 27000 27000 27000
Workshed Rent 0 0 0 0 0
Other Miscellaneous Expenses 35000 40000 45000 45000 45000
Total: 1076350 1180400 1284450 1284450 1284450
Manufacturing Expenses
Raw Material 182500.00
Wages 708000.00
Repair & Maintenance 30000.00
Power & Fuel 15000.00
Other Overhead Expenses 15000.00
Production Cost 950500.00
Administrative Cost 438000.00
Manufacturing Cost 1388500.00
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Working Capital Estimate :
Element of Working No of
Capital Days Basis Amount in Rs.
0 0 Material Cost 0.00
Particulars 0 Year 1st Year 2nd Year 3rd Year 4th Year
Net Profit 1074248 1370954 1751490 1833682
Add :
Depreciation 217733 199576 183054 168013
TOTAL - A 1291980 1570530 1934544 2001694
Payments :
On Term Loan :
Interest 382930 382930 306344 229758
Installment 0 589124 589124 589124
On Working Capital
Interest 48739 48739 38991 29244
TOTAL - B 431670 1020793 934459 848125
D.S.C.R = A/B
2.99 1.54 2.07 2.36
Average D.S.C.R
0
Particulars Year 1st Year 2nd Year 3rd Year 4th Year
LIABILITIES :
Promoters Capital 174765 174765 174765 174765
Profit 1074248 1370954 1751490 1833682
Term Loan 2945618 2945618 2356494 1767371
Working Capital Loan 374918 374918 299934 224951
Current Liabilities 0 0 0 0
Sundry Creditors 0 0 0 0
4569549 4866255 4582684 4000768
ASSETS :
Gross Fixed Assets : 2930650 2712918 2513342 2330288
Less : Depreciation 217733 199576 183054 168013
Net Fixed Assets 2712918 2513342 2330288 2162275
Preliminary & Pre-Op. Expenses 150000 112500 84375 63281
Current Assets 374918 374918 299934 224951
Cash in Bank/Hand 1481713 1977996 1952462 1613542
Total 4569549 4866255 4582684 4000768
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CASH FLOW STATEMENT :
Particulars 0 Year 1st Year 2nd Year 3rd Year 4th Year
Net Profit 1074248 1370954 1751490 1833682
Add : Depreciation 217733 199576 183054 168013
Term Loan 2945618 2945618 2356494 1767371
Working Capital Loan 374918 374918 299934 224951
Promoters Capital 174765 0 0 0
Total 4787281 4891066 4590973 3994016
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