BANDAGES & SURGICAL COTTON PROJECT REPORT

SURGICAL COTTON AND BANDAGES

CONTENTS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

INTRODUCTION PROPERTIES PROPERTIES: (SURGICAL COTTON) USES AND APPLICATIONS CERTIFIED SPECIFICATION MARKET SURVEY EXPORT ORIENTED UNITS MANUFACTURERS/SUPPLIERS OF SURGICAL COTTON & BANDAGES PROCESS OF MANUFACTURE FLOW SHEET FOR THE MANUFACTURE OF SURGICAL COTTON PROCESS OF MANUFACTURE FOR BANDAGES PLANT LAYOUT PRINCIPLES OF PLANT LAYOUT PLANT LOCATION FACTORS COMPLETE PLANT SUPPLIERS SUPPLIERS OF PLANT AND MACHINERY MACHINERY FOR SURGICAL COTTON & BANDAGE

APPENDIX - A 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

COST OF PLANT ECONOMICS LAND & BUILDING PLANT AND MACHINERY FIXED CAPITAL INVESTMENT RAW MATERIAL SALARY AND WAGES UTILITIES AND OVERHEADS TOTAL WORKING CAPITAL COST OF PRODUCTION PROFITABILITY ANALYSIS BREAK EVEN POINT RESOURCES OF FINANCE INTEREST CHART DEPRECIATION CHART CASH FLOW STATMENT PROJECTED BALANCE SHEET

A 1 A 2 A 3 A 5 A 6 A 7 A 8 A 9 A11 A12 A13 A14 A15 A16 A17 A18

SURGICAL COTTON AND BANDAGES INTRODUCTION Absorbent Cotton also known as Surgical Cotton or Cotton Wool is mainly used for medical purposes in hospitals, nursing homes, dispensaries etc., Because of high fluid absorbency power, it is better known as absorbent cotton. The absorbent cotton should be chemically inert and soft to give maximum protection and should not cause irritation. These properties can be achieved by manufacturing the product as per standard method of manufacture. The raw cotton is processed by series of steps which render the cotton hydro-phillic in character and free from external impurities needed to be fit for use in surgical dressings and personal hygiene. Absorbent Cotton is also used for making conventional type of Sanitary napkins or pads besides medical purposes. And fairly good quality of cotton wool is consumed in beauty parlours for removing make up and dirt etc., With the development of medical facilities and growing awareness towards personal hygiene, the absorbent cotton industry registered steady growth rate in past and is picking up pace with the spread of education and upward economic growth of towns and villages. Surgical Bandages are the products manufactured from White Bleached Cotton gauge Cloth of suitable quality. These are availble in various width of running from 2.5 cm to 15 cms and of length from 3 meters or 4 metres. These are packed in a unit of doz. for sale. These are mainly used in hospital/Dispensaries for tying the woundes after dressing. Surgical Cotton is mainly used for cleaning and dressing the wounds by Doctor and Jauhrus's. It is also used by Tailors for putting pads in Woollen Suits etc. and making Novalties items by artists. Of course the Doctors consume the maximim quantity of Surgical Cotton produced in India. In present much advanced time the numbers of doctors are increasing drastically thereby increasing demand for surgical cotton at very fast rate. It also carried a good potential. Medium stapple cottons, Bonde was to from cotton Mills or Linters from spinning Mills are used as raw materials for the manufacture of this product. To manufacture surgical cotton anyone of these three materials may be used separately or farely economical blend produce good quality surgical cotton.

Cotton Raw material is cleaned and washed and bleached and sterilized properly by undergoing through a series of processes and render Hydrophile in character by sides rendering it petty free from external organic impurities.

Doctors, Vaidyas, and other medical practioners require surgical cotton and bandage for dressing ulcers and wounds etc. Surgical cotton and bandage are extensively used in hospitals, dispensaries and other institutions where treatment facilities are provided. With the spread and increase of health services in rural and urban areas as well as in the standard of living the demand for this product is increasing year after year. The present policy of the government is to reserve its manufacture for small scale. The small scale unit does not require a licence for its production. Lint Cotton (gined virgin cotton), Cotton Linters, comber cotton and various processed cottons generally available in India are the materials used to make surgical cotton or absorbent cotton and bandage. Lint cotton and comber cotton are used for high quality and long fibre cotton and bandages. Processed cotton materials and cotton linters are used mostly for low cost filler materials in dressings.

The surgical bandages include the manufacture of bandages, rolled bandages, absorbent gauge and medicated gauge. In the field of surgical operations these items are indispensable. These are made of very fine and plain woven cotton cloth. The raw material required for the manufacture of surgical bandages is the bandage cloth is not readily available in the market. According to the needs and requirement for one's own item of manufacture one should arrange with local weavers for the weaving of cotton bandage cloth.

Cotton goods are made soft and absorbent by frequent washing with soap and chemical bleaching or drying in the sun. The processing removes the natural oils and waxes of the cotton fibres so that the water proof quality is lost. Generally about 15% of the raw cotton is removed in the treatment to render it suitable for surgical uses and this treatment is essentially the same for both absorbent cotton and the woven gauge.

PROPERTIES

1.

Surgical Bandage is made of very fine cotton yarn.

2.

It is very soft.

3.

It is quite absorbent the quality being incorporated in it by virture of the frequent washing with soap and chemical bleaching or dyring in the sun.

4.

It is free from natural oils and waxes.

5.

It has little water/proof quality.

PROPERTIES: (SURGICAL COTTON)

1.

Surgical colour.

Cotton

2.

It is completely sterlised by the action of chemicals.

3.

It is very dressings.

4.

Surgical cotton is most absorbent material.

5.

It is free from natural oils and waxes.

6.

It has little water/proof quality.

soft

or absorbent cotton is snow white

and is

quite

suitable

for

in

wound

USES AND APPLICATIONS

Abosrbent Cotton also known as surgical Cotton is used mainly for medical purposes. Raw Cotton is purified by a series of processes and rendered hydrophile in character besides rendering it free from other external organic impurities. There is an increasing demand for this item in India and has good exporting possibility. Medium and short staple Indian Cotton is ideal for this purpose and avialable in large quantity.

Absrobent Cotton or medical Cotton is used by Doctors, Dentists, Industrial safety organisations in Hospitals and for individuals for first aid and home kits. This item is regulated under the Drugs Control Act and a manufacturing licence under the Provisions of the act, has to be acquired from the Drugs Controller of the state concerned.

1.

2.

Surgical cotton and bandages are used in dispensaries and hospitals another places (Where facilities for treatment are provided) for dressing the wounds and the ulcers etc.

Surgical sprain.

cotton

and bandages are used for in case

3.

They are available in the shops of and Surgeon.

vaidyas,

4.

Surgical cotton and bandage are used in first aid boxes.

5.

Good quality surgical cotton and packing is used for export purposes.

doctors,

factories

bandage

of

in

in

good

B. I. S. SPECIFICATION

For B.I.S. Specification refer to I.S.: 2369-1967-77 (Method

for

determination of absorbency

of

absorbent

textile

materials & for surgical Dressings:-

I.S. No. 758 - 1975.

Above Specifications may be obtained from

Bureau of Indian Standards, 9, B.S. Zafar Marg, New Delhi - 110 002.

NOTE :- The use of the ISI Certification Mark is governed by the provisions of the Indian Standards Institution (Certification Marks) Act and the Rules and Regulations made thereunder. The ISI Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well-defined system of

inspection, testing and quality control which is devised and supervised by ISI and operated by the producer. ISI marked products are also continuously checked by ISI for conformity to that standard as a further safeguard. Details of conditions under which a licence for the use of the ISI Certification Mark may be granted to manufacturers or processors, may be obtained from the Indian Standards Institution.

MARKET SURVEY

Demand for absorbent cotton depends on various factors. The demand of this product is directly related with the increase in population and expansion of Public Health Services. The consumption of Surgical cotton or cotton wool increases with the increase in population and number of hospitals, dispensaries, health care centers, nursing homes etc. Progressive increase in health amenities offered by government and coming up of new hospitals and health care centers in private sector even at small towns are contributing to the growth of absorbent cotton industry. Govt. hospitals and big nursing homes are the largest consumers for cotton wool. Absorbent cotton has good export market potential. Presently it is being exported to the countries like Japan, Australia and several European countries. The export of surgical cotton can be done provided it is made according to standards and specifications of international market. BASIS & PRESUMPTIONS : The estimates are drawn for a production capacity generally considered techno-economically viable for model type of manufacturing activity. The cost in respect of land & building, machinery & equipments, raw materials and selling prices of the finished products etc., are those generally obtained at the time of the preparation of the project profile and may vary depending upon various factors. The production capacity is based on single shift per day and 300 working days in a year and 75% working efficiency of plant & machinery. However, Break Even Point in the scheme has been calculated on the full capacity utilization. Whereas some names of manufacturers/suppliers of machinery and equipment, raw materials etc., are indicated at the end of the profile, these are by no means exclusive and

exhaustive. Working capital for 3 months has been taken into consideration and rate of interest on total capital investment has been assumed to be 15%. IMPLEMENTATION SCHEDULE : Preparation of details Project Report

11/2 Months.

Provisional Registration as SSI unit

1 Week

Finance Arrangements

3 Months

Procurement of Machinery & Equipments

3 Months

Installation of Machinery & Equipments

1 Month

NOC from Pollution Control Board

1 Month

Recruitment of Staff & Labour

3 Weeks

Trial run of plant

1 Week

The Surgical Cotton Industry is mainly limited to small and cottage scale units. These units are engaged in the manufacture of absorbent cotton, boric gauge, absorbent lint, dressing and bandages. In the small sector, a number of units are manufacturing absorbent cotton which are distributed in Andhra Pradesh, Punjab, Maharashtra, Madhya Pradesh, Rajasthan, Tamil Nadu, Uttar Pradesh, and West Bengal.

EXPORT & IMPORTS

Wedding articles of which absorbent cotton forms the bulk, are being exported to Sri Lanka, Hong Kong, Kuwait, Nalasia, Singapore & Thailand. The imports of absorbent cotton have been banned since 1957.

The government is making vigerous efforts to build new industries in state and Central. Atractive incentive a e provided to entrepreneurs from outside that state to establish industries. Scientific research is gathering momentum in different parts of the country, it has been carried out under the suspicious of the central and state Governments. Several private organisation including industry are also doing private research.

In the Industrial field too, scientific research has come to play an important part in the improvement of goods.

The Central promote research.

Government has offered several

incentives

to

PRESENT STRUCTURE At present the industry consists of 136 units in the organised sector 5 Govt. run units and bout 2,600 units in the small scale sector, besides 8 units in the non organised sector. There are 35 foreign companies with direct foreign equity above 40 per cent of which 28 are in the 'organised sector' and 7 in the (Non organised' sector). 28 out of these 35 have a direct foreign equity exceeding 50 per cent, 21 in the organised sector of the 35 foreign companies with direct foreing equity above 40 per cent. 5 branches of companies two of which are in the organised sector and three in the non organised sector.

100% EXPORT ORIENTED UNITS (100% EOU)

A

100% export oriented unit would imply :-

i) An industrial unit offering for exports its entire production excluding permitted level of rejects. An agreed time phasing for achieving 100% exports will be permissible on merits of each case.

ii) Such unit belong to an industry in respect of which export potential and export targets have been considered by concerned EP Council.

the the

iii) It would not produce an item which is subject to export control guota ceilings which can be reached by existing units in the country. The intention being that a 100% export oriented unit would create capacity to get additionality of exports and not mere substitution there of .

SIA The secretariat for Industrial Approval Ministry of Industry, Department of Industrial Development, Udyog Bhawan, New Delhi, will continue to act as the secretariat for 100% EOU as well.

Application

Applications for setting up of such units will be sent on the prescribed form `IL' (15 Copies) superimposed with words " 100% export oriented industry " alongwith a demand draft for Rs. 2500/Rs. 1000/as applicable, to the above mentioned secretariat . These applications will be considered by a Board headed by the Commerce Secretary.

If the proposal involves foreign collaboration , should be sent simultaneously .

EXIM Bank's Facilities to

Form

FC

100% EOUs

The EXIM bank provides term finance to EOUs to meet capital cost of new projects/expansion and modernisation of those units. Finance is provided on attractive terms to the units in association with the Commercial bank/Financial institutions.

Export Promotion (Other than EPCs/

1.

Organisation Commodity Boards)

State Trading Corporation of India Ltd.,

Jawahar Vyapar Bhawan, Tolstoy Marg, New Delhi - 110 001.

2.

Minerals and Metal Trading Corpn. of India Ltd., CGO Complex, Lodhi Road, New Delhi - 110 003.

3.

Project & Equipment Corpn. of India

Ltd.,

Hansalaya , 15, Barakhamba Road, New Delhi -

4.

National

110 001.

Textile Corpn. of India

Surya Kiran Bldg, 19, Kasturba Gandhi Marg, New Delhi

5.

- 110 001.

Indian Institute of Foreign Trade, B

- 21, Institutional Area,

South

of IIT. ,

New Delhi- 110 016.

Ltd.,

6.

Export Credit Guarantee Corpn, Express Towers

(13th Floor),

Nariman Point, Mumbai -

21.

Guidance/Clarifications

For any further clarifications /guidance on the use of the standardised Pre-Shipment Export Documents, entrepreneurs may please approach :-

1.

The Export Commissioner o/o the CCI& E, Udyog Bhawan,

New Delhi - 110011.

2.

The Indian Institute B- 20,

of Foreign Trade,

Institutional Area, South of

IIT Compus, New Delhi - 110 016.

3.

The Federation of Indian Export Organisations, PHD House, Hauz khas, New Delhi

-

110 016.

MANUFACTURERS/SUPPLIERS OF SURGICAL COTTON & BANDAGES

Mr. Anil Gulati ALFA - SYNTH CHEMICALS PVT LTD 201, B. D. Chamber, 10/54, D. B. Gupta Road, Karol Bagh

New Delhi-110005 Phone:011-23637628/23550878 Manufacturers Of Cotton (Surgical) Surgical Dressings & Disposable

Mg. Director BRISK GROUP OF COMPANIES R.O.: 62, G.I.D.C., Kalol Gandhinagar-382725, Gujarat Phone:02764-23497, 25560 [email protected]

Mfg. & Expts. Of Surgical & Cosmetic Cotton, Surgical Cotton M Bleached Uncarded, Absorbent & Rolled Gauze Cosmetic Cotton (Roll & Zig Zag) Cotton Balls (Medical & Cosmetic) Sliver (Strings For Making Buds & Balls) Cosmetics

Kirit Chauhan, Director GOLDEN INDOVEN EXIM PVT LTD 15, Contractor Building, Vaju Kotak Road Mumbai-400001, Maharashtra Phone:+91 22 226 50053,22650 [email protected]

Exporter of Absorbent Cotton Wool B.P, Coveralls (Overalls), P.P. Products (Plastic Products), Ayurvedic Hair Oil, Industrial Garments and Pilfer Proof Plastic Seal / Sleeves.

Purshottam Das Agarwal, Chairman JAYCOT INDUSTRIES C-7 & C-8, Industrial Estate, Chandulal Baradari Hyderabad-500064, Andhra Pradesh

Phone:+91 40 24462720, 24466 [email protected]

Manufacturer of Absorbet Cotton Wool, Surgical Dressing, Cotton Balls, Cotton Buds, Bandage Cloth, Gauze Cloth.

Mg. Director KASHYAP SURGICALS PVT LTD 23, Ramyakunj Society, Opp. Galaxy Cinema, Naroda Ahmedabad-382325, Gujarat Phone:079-3847185/6, 2810239 [email protected] Manufacturers & Exporters Of Surgical Dressing, Absorbent Gauze, Gauze Swab Rolled Bandage, P.O.P. Bandages, Uncarded Cotton, Absorbent Cotton Rolls, Zig-Zag, Cotton Balls, Adhesive Tape. Medical, Diagnostic & Hospital Supplies

M/s. A.R. Enterprises 2653, Roshanpura, Nai Sarak Delhi - 110 006 Ph. : 326 5319 E-mail : [email protected]

M/s. Florance Surgical Cotton Industry 1892/13, 1st Floor, Hari Ram Market, Bhagirath Place, Delhi - 110 006 Ph. : 2968337

M/s. Care Surgicals F-37, Site - B, Surajpur Indl. Area, Greater Noida Ph. : 4560401

M/s. Datt Medi Products Ltd. 53,54, Roz-ka Meo Indl. Area Sohna, Distt. Gurgaon Ph. : 6362144

Bleached

M/s. Divya Deep Surgicals (P) Ltd. 2138,39 M.I.E. Bahadurgarh - 124 507 Ph. : 312915/0118-315002 M/s. Gitanjali Ir. & Imp. Co. Pvt. Ltd. C-31, Surajpur, Site - C, Greater Noida Ph. : 4560138

M/s. Gurunanak Surgical Pvt.Ltd. Delhi Road, Rithani, Meerut Ph. : 513188, 510388

M/s. Jajo Surgical Pvt. Ltd. 64/66 Princess St. Ranvir Building 27, 3rd Flr M2 Ph. : 2012061

M/s. Sai Enterprises 201B/Cyac Nagar R.K. Marg Marol Andheri (E) Mumbai - 110 059 Ph. : 837520

M/s. Surgical Dressing Company 52/53, Ratnajyot Ind. Estate Vile Parle W Mumbai - 110 056 Ph. : 6712068 Fax : 6714191

PROCESS OF MANUFACTURE

The process of manufacture of surgical cotton consists of the following steps:-

1)

Mechanical cleaning of Raw cotton.

2)

Boiling

3)

Bleaching

4)

Hydroextraction

5)

Drying

6)

Carding.

7)

Sterlization.

1.

MECHANICAL CLEANING OPF RAW COTTON:-

The first and foremost step in the manufacture of surgical cotton is the mechanical cleaning of raw cotton. Raw cotton contains dirt, leaves, seed hulls and sometimes sticks, stones and other foreign matter. The raw cotton is passed through a machine provided with rollers and a toothed drum or cylinder. It tears the entangled masses part. An air blast picks up the fibres and drives them against the meshes of a revolving cylinderical screen. The impurities and foreign matter pass through the meshes while the cotton sticks to the screen and is rolled with it. This mechanical operation is separated and carried on till the mechanical cleaning of the raw cotton is complete. This type of mechanical cleaning machine is the one used for cleaning cotton for filling the quilts etc. Whatever be the raw material the cotton has to go through the steps of opening and cleaning. After opening and cleaning the cotton is further cleaned by pickering and lapping. Cotton is cleaned and made into laps so that it can be conveniently handled in kiering, bleaching and washing.

2.

BOILING:

The cleaned cotton is then boiled and by controlled chemical processing cotton laps prepared in the earlier step are charged into a large stainless steel basket or nets and lowered into the kier which is merely a cast iron cylinder with a lid and having steam heating arrangement. The cotton laps are treated with dilute casutic lye generally 1 - 2%. Sodium hydroxide solution containing soaps and detergents and also a sequenstering agent like tertrasodium pyrophosphate. The boiling with alkali is carried out at 90 - 125oC for 2 - 3 hours.

This process of boiling and bleaching removes nearly all waxy and fatty matter from the cotton under treatment. It softens and is integrates any kind of foreign matter that may have remained after the mechanical cleaning operation. After complete boiling abd bleaching dark coloured alkaline solution is removed from the tank bottom. Thus it separates from the cotton mass in the tank bottom. This operation requires a large volume of demineralised water.

3

BLEACHING:

The boiled and dilute alkali treated cotton obtained from the boiling operation is of absorbent type but it does not have good colour. For improving its colour it is bleached. A bleaching solution is run into the tank and circulated by pump for quite sometimes enough to decolourize the cotton. The bleaching agent used is sodium hypochlorite or Hydrogen peroxide.

The process of bleaching of not only decolourized the cotton under treatment byt also it improves its wetting properties and further helsp to destroy any impurities present.

4.

HYDROEXTRACTION:-

The bleached cotton is washed throughly and calculated amount of dilute sulphuric acid is added to neutralize any excess alkali. The cotton is again washed with water and fed through hydroextractor to remove as much water as possible. This process neutralizes the chemicals adhering to the cotton and the final washing step complete the purification of cotton. It is then dried.

5.

DRYING:-

After Boiling, bleaching and hydroextraction the purified cotton much be dried, in comparement driers. Drying is usually accomplished by placing the wet lumps wire screens which are fitted above radiators containing steam under high pressure. The wet cotton laps are placed over the wire screens, dried and picked up. Further more, wet cotton laps are charged to the compartment driers for drying purpose.

6.

CARDING:-

The dired cotton is picked and carded, roll cotton is prepared by gathering together and packing the webs from various cards to give a product of desired bulk weight.

7.

STERLIZATION:-

The absorbent cotton rolls obtained above are sterlized before packing. Generally the purified cotton is subjected to dry steam or formaldehyde vapours, in heated vacuum chambers. If it is expected that the cotton may be damaged or injured by steam, formaldehyde vapour alone may be used. After sterlization the cotton is not touched by basic hand.

8.

PACKING:-

After sterlization the rolls of the absorbent packed into card board boxes, or paper board boxes. sent for marketing.

cotton are It is then

FLOW SHEET FOR THE MANUFACTURE OF SURGICAL COTTON

+------------------------+ | Raw - Cotton | | | +------------------------+ V +------------------------+ | Mechanical Cleaning | | | +------------------------+ V +------------------------+ | Boiling | | | +------------------------+ V +------------------------+ | Bleaching | | | +------------------------+ V +------------------------+ | Hydro Extraction | | | +------------------------+ V +------------------------+ | Drying | | | +------------------------+ V +------------------------+ | Carding | | | +------------------------+ V +------------------------+ | Sterlization | | | +------------------------+

V +------------------------+ | Packing | | | +------------------------+ V Surgical Cotton for Marketing

PROCESS OF MANUFACTURE FOR BANDAGES

The manufacture of bandages starting from cotton as the raw material consists of the following process steps:-

1.

Mechanical cleaning.

2.

Drawing

3.

Combing.

4.

Spinning to make cotton yarn.

5.

Weaving into bandage cloth.

6.

Washing and bleaching.

7.

Starching and natural drying.

8.

Cutting cloth into bandages.

9.

Packing.

1.

MECHANICAL CLEANING:

Mechanical cleaning of cotton is most essential as it contains dirt, leaves, seed hulls, sticks and sometimes stones etc. The cotton is passed through a machine provided with rollers and toothed drum or cylinder. The cotton fibres are picked up by an air blast. This operation is repeated till the cotton is throughly cleaned. The process of mechanical cleaning is also called carding. In the carding machine use is made of card clothing which consists of leather or composite fabric in which are anchored densily packed fine painted wires. Their pointed ends being bent over. At the end of the carding process the cotton has passed through the first stage of its conversion into - Yarn.

2.

DRWING:-

The cotton sliver is now ready to pass through a drawing process which has for its object a further mixing of the fibres and also making them more paralleled. This objected is attained by leading several of the sliver through a machine known as a draw frame which comprises three or four pairs of rollers in line and suitably spaced, each succeeding pair of rollers is driven at a higher speed than the preccding pair. Thus on leading a sliver through these rollers it becomes drawn out or attenuated and made much more longer.

3.

COMBING:-

When the cotton is to be made into very fine yarns is advisable to subject the material from th drawing process combing operations.

4.

it to

SPINNING:-

After passing through all the processes enumerated above the cotton is fully purified and thoroughly blended so as to have uniform compsotion and it has its individual fibres alinged parallel to each other. The roving is ready for spinning into yarn. The spinning is in fact the manufacture of yarn (or fibres) from cotton. This yarn is used for the production of fabric by weaving.

5.

fine

WEAVING:-

The bandage

fine cotton yarn obtained above is converted into cloth by the process of weaving on a handloom.

Weaving is an art and the weavers do it. manufactured is further processed as murder.

6.

The

bandage

cloth

WASHING AND BLEACHING:-

Washing and Bleaching operations are carried out in a washing tank. Generally the boiling tank used in the preparation of absorbent cotton can be used for the purpose of treatment with dilute alkali. Bleaching is carried out with sodium hypochlorite or hydrogen peroxide. The process of alkali washing and bleaching removes all waxy and fatty materials from the bandage cloth. The stuff is further washed in the hydroextractor with enough water to remove all the chemical used earlier for washing and bleaching.

7.

STARCHING & NATURAL DRYING:-

After washing the bandage cloth is dipped into very dilute solution of starch in water. Then it is spread in an open space ( On hangers) for sun drying. After drying the fine bandage cloth is cut into bandags.

8.

CUTTING THE BANDAGES CLOTH INTO BANDAGE:-

The starched and sun dried bandage cloth is then made into the form of a roll. It is done by spreading it over a table and then rolling into a roll with a rolling machine. One rolling machine take up 2400 yards of cloth per day in one stuff of 8 hours. The roll is marked with pencil according to the width of the bandage required. A cutting machine is used for cutting roll into bandages. A cutting add is used for this purpose.

9.

PACKING:-

These bandages prepared above are unsterlized bandages. They may be sterlized (if required) with dry steam or formaldehyde vapour. The cut bandages are taken out carefully and packed according to the demand in the market or the hospitals as the case may be.

PROCESS FLOW SHEET FOR THE MANUFACTURE OF SURGICAL BANDAGE

+------------------------+ | Raw - Cotton | | | +------------------------+ V +------------------------+ | Mechanical Cleaning | | | +------------------------+ V +------------------------+ | Drawing | | | +------------------------+ V +------------------------+ | Combing | | | +------------------------+ V +------------------------+ | Spinning | | | +------------------------+ V +------------------------+ | Weaving Bandage Clothes| | | +------------------------+ V

+------------------------+ | Washing & Bleaching | | | +------------------------+ V +----------------------------+ | Starching & Natural Drying | | | +----------------------------+ V +------------------------+ | Cutting | | | +------------------------+ V +------------------------+ | Packing | | | +------------------------+ V Surgical Bandage for Marketing

PLANT LAYOUT

+--------------------------------------------------------------+ | | | | | | | ADMINISTRATIVE | |PARK| | | BUILDING | |ING | | | | | | | | | +----.G | +---------.-------.-----------+ |A | GATE |T | .E | | | GATE | | +---------.-------.--------------------------+ | | | | | | | | | | | | | | SITE | | | | | WORKSHOP | | | | | | | | | P R O C E S S +--------------| | | | E Q U I P M E N T | | | | | | | | .G | | | |A | | | WORKING SHED |T | | | .E | | | | |

| | | | | | | | | | | | | +--------.-------.---------------------------+ | | GATE | | | | | | +--------------------------------------------+ | | | | | | | | FINISHED | RAW MATERIAL | | | | GOODS | STORE | | | | STORE | | | | | | | | | +--------------------------------------------+ | | | +--------------------------------------------------------------+

PRINCIPLES OF PLANT LAYOUT

Some of the guiding principles for detailed plant layout will be discussed for the benefit of those making layout decisions for the first time.

Storage Layout: Storage facilities for raw materials and intermediate and finished products may be located in isolated areas or in adjoining areas. Hazardous materials become a decided menace to life and property when stored in large quantities and should consequently be isolated. Storage in adjoining areas to reduce materials handling may introduce an obstacle toward future expansion of the plant. Arranging storage of materials so as to facilitate or simplify handling is also a point to be considered to design. Where it is possible to pump a single material to an elevation so that subsequent handling can be accomplished by gravity into intermediate reaction and storage units, costs may be reduced. Liquids can be stored in small containers, barrels,s horizontal or vertical tanks and vats, either indoors or out of doors.

Equipment Layout: In making a layout, ample space should assigned to each piece of equipment; accessibility is important factors for maintenance.

be an

It is extremely poor economy to fit the equipment layout too closely into a building. A slightly larger building than appears necessary will cost little more than one that is crowded. The extra cost will indeed be small in comparison with the penalties that will be extracted if, in order to iron out the kinks, the building must be expanded.

The operations that constitute a process are essentially a series of unit operations that may be carried on simultaneously. These include filtration, evaporation, crystallization, separation, and drying. Since these operations are repeated several times in the flow of materials,k it should be possible to arrange the necessary equipment into groups of the same kinds possible to arrange the necessary equipment into groups of the same kinds. This sort of layour will make possible a division of operation labor so that one or two operators can be detailed to tend all equipment of a like nature.

The relative levels of the several pieces of equipment and their accessories determine their placement. Although gravity flow is usually preferable, it is not altogether necessary because liquids can be transported by blowing or by pumping, and solids can be moved by mechanical means. Gravity flow may be siad to acost nothing to operate, whereas the various mechanical means of transportation involve the first cost of the necessary equipment and the cost of operation and maintenance. But material must be elevated to a level where gravity flow must start. However, gravity flow usually means a multistory layout, whereas the factors favoring a single-story plant may largely, if not entirely, compensate for the cost of mechanical transportation.

Access for intial construction and maintenance is a necessary part of planning. for example, overhead equipment must have space for lowering into place, and heat-exchange equipment should be located near access areas where trucks or hoist can be placed for pulling and replacing tube bundles. Thus, space should be provided for repair and replacement equipment, such as cranes and forked trucks, as well as access way around doors and underground hatches.

Safety: A great deal of planning is governed by local and national safety and fire code requirements. Fire protection consisting of reservoirs, mains, hydrant, hose houses, fire

pumps, reservoirs, sprinklers in building, explosion barriers and directional routing of explosion forces to clear areas, and dikes for combvustible-product storage tanks must be incorporated to protect costly plant investment and reduce insurance rates.

Plant Expansion: Expansion must always be kept in mind. The question of multiplying the number of units or increasing the size of the prevailing unit merits more study than it can be given here. Suffice it to say that one must exercise engineering judgement; that as a penalty for bad judgement, scrapping of present serviceable equipment constitutes but one phase, for shutdown due to remodeling may involve a greater loss of money than that due to rejected equipment. Nevertheless, the cost of change must sometimes be borne, for the economies of larger units may, in the end, make replacement imperative. Floor Space: Floor space may or may not be a major factor in the design of a particular plant. The value of land may be a considerable item. The engineers however, follow the rule of practicing economy of floor space, consistent with good housekeeping in the plant land with proper consideration given to line flow of materials, access to equipment, space to permit working on parts of equipment that need frequent servicing, and safety and comfort of the operators.

Utilities Servicing: The distribution of gas, air, water, steam, power, and electricity is not always a major item, inasmuch as the flexibility of distribution of these serivces permits designing to meet almost any condition. But a little regard for the proper placement of each of these services, practicing good design, aids in ease of operation, orderliness, and reduction in costs of maintenance. No pipes should be laid on the floor or between the floor and the 7-ft level, where the operator must pass or work. Chaotic arrangement of piping invites chaotic operation of the plant. The flexibility of standard pipe fittings and power-transmission mechanisms renders this problem one of minor diffculty.

Building: After a complete study of quantitative factors, the seletion of of the building or buildings must be considered. Standard factory buildings are to be desired, but, if none can be found satisfactory to handle the space and process requirements of the chemical engineer, then a competent architect should be consulted to design a building around the process - not a beautiful structure into which a process must fit. It is fundamental in chemical engineering industries that the buildings should be built arount the process, instead of the process being made to fit building of conventional design.

with

In many cases only the control area requires housing, the process equipment eracted outdoors. This is known as

outdoor consturction and such layouts should be considered for many types of plants. What consideration must be given to buildings depends upon conditions. If the designer must adapt his design to fit an old building or building space already erected, his problem is cut out for him and he was limiting conditions. However, the selection of the design of a new building to meet the requirements of the process is more scientific. In this case, one finds before him practically all types of standard building, built in units, interlocking or otherwise, ready for shipment and erection. Throughout chemical industry, much thought must be given to the disposal of waste liquors, fumes, dusts, and gases. Ventilation, fume elimination, and drainage may require the installation of extra equipment. This may involve the design of the individual pieces of operating equipment, or it may require the installation of isolated equipment. If the latter be the case, the location of such equipment where it will be interfere with the flow of materials in process should be practiced. The selection of the proper piece of equipment for doing this service is also an important point; the less attention the ventilating, fume, or waste-elimination systems require, the better service they may render. Sometimes air conditioning of the plant is called for an may required an elaborate setup. But the installation of such equipment, when needed, pays in better service from operators, less discomfort, greater production, and a better morale than when such conditions are left to nature.

It must be recognized that there is not only one solution to the problem of layout of the equipment. There are many rational designs. Which plant to adopt must be decided upon after exercise of engineering judgement and after striking a balance job the advantages and disadvantages of each possible choice.

Material-handling Equipment: Consideration of equipment for materials handling is only a minor factor in most cases of arrangement, owing to the multiplicity of available materialshandling devices. But where this operation is paramount in a process, serious thought must be given to it. Again it should be said that engineering judgement must be exercised. Whenever possible, one should take advantage of the topography of the site location, one should take advantage in the process.

Railroads and Roads: Existing or possible future railroads and highways adjacent to the plant must be known in order to plan rail siding and access roads within the plant. Railroad spurs and roadways of the correct capacity and at the right location should be provided for in a traffic study and over-all master track and road plan of the plant area. Some of the factors in rail-track planning are:

1.

Existing and future off-site main rail facilities

2.

Permissible radius of curvature for spurs rail authorities.

3.

Provision for traffic handling - arrangement of ladder track and switching.

4.

Adequate spur facilities

consult

spurs

a.

Loading and unloading facilities for initial construction and subsequent operations.

b.

Rack stations for liquid handling

c.

Storage space for full and empty cars

d.

Space for cleaning and car repairs.

Major

local

provisions in road planning for multipurpose

and

plant

service

are:

1.

A means of interplant movement pedestrian and vehicular

for

road

traffic,

2.

Heavier and wider roads for large-scale traffic

both

3.

Routing of heavy traffic outside the operational areas

4.

Roadways for access to initial

construction,

maintenance,

and repair points 5.

Roadways to isolated points, storage equipment, such as fire hydrants.

tanks,

and

safety

PLANT LOCATION FACTORS

Factors which generally apply to the economic and operability aspect of plant site location are classified into two major groups. The primary factors listed apply to choice of a region, whereas the specific factors looked at in choosing an exact site location within the region. All factors are important in making a site location selection.

Primary Factors

1.

Raw-material supply:

2.

3.

4.

5.

a.

Availability form existing or future suppliers

b.

Use of substitute materials

c.

Distance

Markets: a.

Demand versus distance

b.

Growth or decline

c.

Inventory storage requirements

d.

Competition - present and future.

Power and fuel supply: a.

Availability of electricity and various type of fuel

b.

Future reservers

c.

Costs

Water supply:

a.

Quality - temperature, mineral content, bacteriological content

b.

Quantity

c.

Dependability - may involve reservoir construction

d.

Costs

Climate: a.

Investment required for construction

b.

Humidity and temperature conditions

c.

Hurricane,a tornado, and earthquake history

Specific Factors

6.

Transportation: a.

7.

8.

9.

Availability of various services and projected rates 1.

Rail - dependable for over all distances

light and

heavy

shipping

2.

Highways - regularly used for short distance generally small quantities

3.

Water - cheaper, but may be slow and irregular

4.

Pipeline - for gases and liquids, particularly for petroleum products

5.

Air - for business transportation of personnel

Waste disposal: a.

Regulations laws

b.

Stream carry-off possibilities

c.

Air-pollution possibilities

Labor: 1.

Availability of skills

2.

Labor relations - history and stability in area

3.

Stability of labor rates

Regulatory laws: a.

Building codes

b.

Zoning ordinances

c.

Highway restrictions

d.

Waste-disposal codes

and

10.

Texes: a.

b.

11.

12.

State and local taxes 1.

Income

2.

Unemployment insurance

3.

Franchise

4.

Use

5.

Property

Low assessment or limited term exemptions industry

to

attract

present

Site characteristics: a.

Contour of site

b.

Soil structure

c.

Access to rail, highway, and water

d.

Room for expansion

e.

Cost of site

f.

Site and facilities available by expansion on company-owned property

Community factors: a.

Rural or Urban

b.

Housing costs

13.

14.

C.

Cultural aspects - churches, libra ries, theaters

d.

School system

e.

Recreation facilities

f.

Medical facilities - hospitals, doctors

Vulnerability to wartime attack: a.

Distance form important facilitics

b.

General industry concentration

Flood and fire control: a.

Fire hazards in surrounding area

b.

Floor history and control

COMPLETE PLANT SUPPLIERS

Impex International Corporation, Mr. I.J. Sehgal 13, Crystal Apatment, Gulmohar Cross Road, No. 11, JVPD Scheme, Mumbai - 400 049 Ph: 022-26232810 TeleFax: 022-26201914 E-mail: ijsehgal2bom5.vsnl.net.in

Swastik Group of Companies Swastik Premises, Near Indira Nagar, Amraiwadi, Ahmedabad - 380 026 Gujarat Ph: 079-22748551, 22743553

R-Tex Spin Mac Pvt. Ltd. Regd Off: 10, Devang Park, Near Polytechnic, AHMEDABAD (INDIA) E-Mail: [email protected] [email protected] [email protected] [email protected] [email protected] [email protected]

Corporate Office :- FF/46, Krishna Gopal Estate, Near Fruit Market, Naroda Road, Ahmedabad.(Gujarat) PIN-380 025, Phone: 91- 079- 32416898, 32416897 Fax No.: 91079-22205499,

KB Corporation Jaldarshan Building, Near: H. K. Arts College, Ashram Road, Ahmedabad, Gujarat, India Contact Person: Mr. Parth J. Panchal Mob : +91-94279-54669 Phone : +91-79-2658 8818 Fax : +91-79-2658 0354 Email : [email protected] Url : www.kbcorporation.com

SUPPLIERS OF PLANT AND MACHINERY

HYDRO EXTRACTOR

MR. SUNIL KUMAR BABACARE F-80, UAJINDER NAGAR INDL. AREA, MOHAN NAGAR, GHAZIABAD-201007, UTTAR PRADESH Email: [email protected]

MR. JITENDRA ARYA(PROP) FABCARE EQUIPMENTS A-81, GH-10, SUNDER APPARTMENTS, OUTER RING ROAD, PASCHIM VIHAR NEW DELHI-110087 Phone: 011-25180277, 25964735, 25180018, 25475569, 25 Email: [email protected]

MR. ALOK CHAWLA GLOBAL TECHNOLOGIES A-14, ASHOKA ENCLAVE-II, SECTOR-37, FARIDABAD-121003, HARYANA Phone:911292277862 Email: [email protected]

MR. SUKHWINDER SINGH GURUSON INTERNATIONAL 2512/10 (9B/3), INDUSTRIAL AREA A EXTENSION, BACKSIDE R.K. MACHINE TOOLS, LUDHIANA-141003, PUNJAB Phone: 911615056246/5015297/5034667 Email: [email protected]

K B CORPORATION 2, JALDARSHAN BUILDING, NR. H K ARTS COLLEGE, ASHRAM ROAD, AHMEDABAD-380009, GUJARAT Phone: 917926588818/26576635 Email: [email protected], [email protected]

Mg. Director

KLEEN RITE ENTERPRISES 22, INDL AREA, ANAND PARBAT, NEW ROHTAK, NEW DELHI-110005 Phone: 011-45475244, 9312289281, 9810622250 Email: [email protected]

MR. JOGINDER MAHAJAN PIONEER UDYOG 24/11, STREET NO.1, MASTER MOHALLA, JIWAN PARK ROAD, LIBASPUR, DELHI-110042 Phone: 911127291383 Email: [email protected]

RAMSONS GARMENT FINISHING EQUIPMENTS PVT LTD H.O. 320, MYSORE ROAD, BANGALORE-560026, KARNATAKA Phone: 918026749238/26746983/26743737/26745885 Email: [email protected], [email protected]

MR. SANJIT MEHTA, MR. AMIT MEHTA SWASTIK GROUP OF COMPANIES SWASTIK PREMISES, NEAR INDIRA NAGAR AMRAIWADI, AHMEDABAD-380026, GUJARAT Phone: 917922743553/22748551/22749068 Email: [email protected]

MR. B. KANNAN U K ENGINEERING WORKS 550, CHINAMUTHU STREET, PRABHA THEATRE ROAD, ERODE-638011, TAMIL NADU Phone:914242269712/2250712 Email: [email protected]

Mg. Director UNITED ENGG ENTERPRISES 15 PRAGATI INDL. ESTATE, N M JOSHI MARG, LOWER MARG MUMBAI-400011, MAHARASHTRA Phone: 022-23094450 Email: [email protected]

ROLLING MACHINE

Mg. Director BUSINESS HAR KRSH & MANUFACTURERS 173, Subramaniam Road, R.S. Puram Coimbatore-641002, Tamil Nadu Phone:2471552 Email: [email protected]

Mg. Director CHIRAG ENGINEERING WORKS 23/28, Amrapali Ind. Est., Ram Mandir Rd., Goregaon (W) Mumbai-400104, Maharashtra Phone: 022-28727346

Mg. Director PIYUSH ENGG WORKS Shanker Tekri, Opp. Paresh Engg. Works, Udyognagar, Jamnagar-361004, Gujarat Phone: 0288-2561009 Email: [email protected]

Mg. Director ARMECH ENGINEERS PVT LTD C-10, Sec-63 Noida, Uttar Pradesh Phone:2403772-73/0120-2581263

Mr.R.K. Mahajan ROLLMILL INDUSTRIES LTD E-30,31,Sector-11 Noida-201301, Uttar Pradesh Phone: 0120-4521123/4557589 Email: [email protected]

BLEACHING MACHINE

MR. RAJIV JAIN GEE AAR INDUSTRIES A-9/3, WAZIR PUR INDL. AREA, DELHI-110052 Phone: 911127373066/42474134 Email: [email protected]

MR. J. R. PANCHAL K B CORPORATION 2, JALDARSHAN BUILDING, NR. H K ARTS COLLEGE, ASHRAM ROAD, AHMEDABAD-380009, GUJARAT Phone: 917926588818/26576635 Email: [email protected], [email protected]

MR. ATUL PANCHAL BHARATBAHI RAMNLAL PANCHAL K B SONS 432-B, OPP. SHARDA ESTATE, ANIL ROAD, AHMEDABAD-380025, GUJARAT Phone: 917922201668/22200977/26747158 Email: [email protected]

CARDING ENGINES

SHOBHANA BHARTIA, DIRECTOR BIRLA TEXTILE MILLS TEXMACO LTD BELGHARIA KOLKATA-700056, WEST BENGAL Phone: +91 33 25392388, 25391631

BOILER

D. N. Reddy, MD A P MOTRONIX PVT LTD 3-18-3, Pragathi Nagar, Ramanthapur, Hyderabad-500013, Andhra Pradesh Fax:Phone:040-27038560/27031929 Email: [email protected]

K. C. Rana, MD A V U ENGINEERS PVT LTD A-15, A.P.I.E., Balanagar, Hyderabad-500037, Andhra Pradesh Fax:Phone:+91 40 237 73235, +91 40 237 72343 Email: [email protected]

J. K. Bhattacharya, Director & CE ABB ABL PROJECTS LTD II ACI House, 1 & 3, Brabourne Road, Kolkata-700001, West Bengal Fax:Phone:+91 33 222 05401

Mr. M. G. Patel ACCU TECH ENGINEERING CO 34, P. D. Estate, Near Revabhai Estate, C.T.M. Amraiwadi, Ahmedabad-380026, Gujarat Fax:Phone:079-5856596 Email: [email protected]

M. Sekar, Director AISHWARYA BOILERS LTD 231, New Tiny Sector, Ambattur Industrial Estate, Chennai-600058, Tamil Nadu Fax:Phone:+91 44 28264935, 28229458

Mr.Subhash Rana AKSENGNIEERING CO 468, SIDCO Industrial Estate, Ambattur, Chennai-600098, Tamil Nadu Fax:Phone:044-26250052

Mr. Kailash Magolra ALBATRON FINE CHEM LTD 40, Dlf Industrial Area, Alishan Building, Kirti Nagar, New Delhi-110015 Fax:Phone:011-25161151/25114789/25100768 Email: [email protected]

Mg. Director ALFA ENTECH (GUJ) PVT LTD 504, Suyojan Hotel President Lane, Off C G Road, Navrangpura, Ahmedabad-380009, Gujarat Fax:Phone:079-26426555 Email: [email protected]

Mr. Lalit ALIDHRA MACHINES PVT LTD 179-B Road No 6 G, New Estate, Udhna Surat, Gujarat Fax:Phone:0261-28677564/28679725 Email: [email protected]

A. N. Rathod, Partner AMBICA ENGG WORKS 16/A, 1st Main, Modi Hospital Road, W.D.C. Road, 2nd Stage, Bangalore-560086, Karnataka

Fax:Phone:+91 80 349 5370 Email: [email protected]

Mg. Director ALLIED ALLOY PRODUCTS E-51, Industrial Area, Yamuna Nagar-135001, Haryana Fax:Phone:01732-251378/221370/228770 Email: [email protected]

AIR COMPRESSORS

Mr. Vishnubhai Patel ASHISH MFG CO Kankuba Estate, Nr. Swaminarayan Temple, B/H. Wonder Point, Nr,. C.T.M. Char Rasta, Amrawadi, Ahmedabad, Gujarat Phone: 079-2877698

Mg. Director BOROMILL INDUSTRIES National Highway No. 8, Near Ankur Society, Post Saijpur Bogha Ahmedabad-380045, Gujarat Phone: 079-22821206 Email: [email protected] Mr. M.G. Puri CHICAGO PENUMATIC SALES A-57/2, Okhla Industrial Area, Phase-II, New Delhi-110020 Phone:51615087-95 Email: [email protected] Mg. Director COIMBATORE COMPRESSOR ENGG CO PVT LTD S F No. 429, Thruviram Coimbatore-641004, Tamil Nadu Phone: 0422-2570323 Email: [email protected]

Mr Soundararejan COIMBATORE ENGINEERING CORPN 25, Perumal Kovil Thottam, P.N. Palayam Road, Ganapathy

Coimbatore-641006, Tamil Nadu Phone: 0422-2532940

Nehal Roy, General Manager DINT-TECH CONTROL PVT LTD 89/1, Panchvati Industrial Estate, Near Memco AMC Office, Naroda Road, Saijpur Ahmedabad-382345, Gujarat Phone: +91 79 282 1471 Email: [email protected]; [email protected]

WEIGHING SCALES/MACHINES Lalit Kumar Dhauper, Proprietor ACI MARKETING A-3, Shop (1st Floor), Inder Puri, New Delhi-110012 Phone: +91 11 25831297, 25835053 Email: [email protected]

Mg. Director ALFA SYSTEMS Mehta Estate, M V Road, Chakala Andheri (E) Mumbai-400093, Maharashtra Phone: 022-28368889 Email: [email protected]

J. S. Pal, Director ATCOM TECHNOLOGIES LTD No. 45, 1st Main Roadrial Estate, C. I. T. Nagar, Nand Danam Chennai-600035, Tamil Nadu Phone: +91 44 282 61112 Email: [email protected]

Krishna Kumar Gupta, Whole Time Director ATCOM TECHNOLOGIES LTD 116, Sant Nagar, East of Kailash New Delhi-110065 Phone: +91 11 262 22134, +91 11 264 72598 Email: [email protected]

Jatin Aggarwal, Partner BANSAL TRADING COMPANY 1st Floor, 4753/23,

Ansari Road, Daryaganj New Delhi-110002 Phone: +91 11 232 85383, +91 11 232 85849 Email: [email protected]; [email protected]

Mg. Director DELMER PRODUCTS LTD 101 Alkapuri Shopping Centre, Vishwas Colony Vadodara-390005, Gujarat Phone: 0265- 2353971, 2357934 Email: [email protected]

SURGICAL COTTON AND BANDAGES J.C. 7964 J.C. 7964

Page A-

PLANT ECONOMICS

Rated Plant capacity

= =

1.00 MT./day 300.00 MT./annum SURGICAL COTTON AND BANDAGES

No. of working days

= =

25 days/month 300 days/annum

No. of shifts

=

One shift

=

Basis

1

per day

8 hours

1 MT./Day SURGICAL COTTON 800000 NOS. BANDAGES/Annum

Currency - Rs.

1


Page A-

2

LAND & BUILDING

1.

2.

3.

Land Area 1500 sq.mt. @ Rs. 2000/- per sq.mt.

Rs.

30,00,000.00

Builtup Area for Production Shed, Godown and Office 1000 sq.mt. @ Rs. 6000/- per sq.mt.

Rs.

60,00,000.00

Boundary wall and Gate

Rs.

4,50,000.00

TOTAL

-----------------------Rs. 94,50,000.00 ------------------------


Page A-

PLANT & MACHINERY

1.

2.

FOR SURGICAL COTTON:High pressure Keir (MS) with inside coated with acid resistant epoxy coating fitted with pump for circulation of reagents steam pipe for heating, capacity 2000 kgs. Charges of cotton fitted with all accessories.

1 No.

Rs.

1,60,000.00

MMC Revolving flat high production carading machine 1016 mm width with dust extractor, electronic stop motion, brush rolls stripping brush rools, filet grinder and other accessories.

2 No.

Rs.

7,30,000.00

3

3.

Two compartment continuous cotton dryer with steam heating arrangements, at 100 psi Cap.100 kg chamber of drying loose open cotton per hour provided with trolley elec electrical heaters and electric control panel.

2 No.

Rs.

6,30,000.00

Porcupine cleaner 1200 mm working width 406 mm diprcupine type cylinder with strikers, each striker having two striking edges, centrally adjustable grid bars and reduction gear, electric motor 5 HP for materials transport with accessories.

2 No.

Rs.

2,40,000.00

Centrifugal hydro extractor with S.S. basket dia 1000 mm fitted with Motor and other accessories.

1 No.

Rs.

85,000.00

* 4.

5.


6.

7.

8.

Page A-

Wet Cotton opener worlding width 1000 mm fitted with motor and all necessary accessories.

1 No.

Rs.

45,000.00

Vertical opener with 7 steel discs and three separate centrally adjustable settings for beater and grid bars fitted with motor 5 HP complete with all accessories.

1 No.

Rs.

95,000.00

Single soutcher and lap machine 1065 mm working width with kirschener beater, centrally adjustable grid bars, High pressure device for loading calendar rollers and lap racks etc. for making lap doffing arrangement with extended

4

lap holder for continuous operation with 10 HP motor starter etc.

2 No.

Rs.

6,20,000.00

Rolling and winding machine 1320 mm on face complete with motor starter and other accessories

2 No.

Rs.

56,000.00

Small band saw type machine with motor for roll cutting machine.

2 No.

Rs.

16,500.00

11.

Air compressor for lapping machine.

1 No.

Rs.

12,500.00

12.

Coal/wood fired boiler 1000 kg/hrs. evaporation cap. 50 psi complete with feed pump and accessories.

1 No.

Rs.

1,85,000.00

Water overhead tank of 10000 liters capacity and tube well fitted with accessories.

1 No.

Rs.

75,000.00

Water Treatment plant for treating process water required for boiler and keir.

1 No.

Rs.

80,000.00

9.

10.

13.

14.


15.

Page A-

Water and pipe connection with insulation, various MS tanks and concrete tanks for washing purpose

1 No.

Rs.

45,000.00

16.

Weighing scale, sealing M/c etc.

1 No.

Rs.

5,000.00

17.

Testing equipments such as chemical balance, PH Meter, Soxhlet extracto rs, crucible, Furnace oven etc.

1 No.

Rs.

1,00,000.00

Electrification and Installation charges

1 No.

Rs.

3,18,000.00

18.

5

19.

Pollution control equipments and energy conservation equipments

1 No.

Rs.

1,25,000.00

FOR SURGICAL BANDAGE:Cloth winding machine, hand operated.

1 No.

Rs.

40,000.00

21.

Rolling & Bandage

1 No.

Rs.

41,000.00

22.

Bandage Rolls cutting machine electrically driven by 1 H.P. motor 3 Phase, 2800 RPM.

1 No.

Rs.

60,000.00

Bandage compressing machine, hand operated

1 No.

Rs.

45,000.00

Sterilizer (Stainless Steel) centri -fugal Dehydrating unit (eletctrica -lly driven by 1HP, 3 Phase, 960RPM

1 No.

Rs.

75,000.00

Rs.

50,000.00

20.

23.

24.

25.

Misc. Tool etc. and other mis. Charges

TOTAL

-----------------------Rs. 39,34,000.00 ------------------------


Page A-

OTHER FIXED ASSETS

1.

2.

Office equipment, furniture plus other equipment & accessories

Rs.

2,00,000.00

Installation costs for water, electricity, fuel etc.

Rs.

1,20,000.00

6

3.

Pre-operative & preliminary expenses

Rs.

1,00,000.00

4.

Project Report Exp.

Rs.

50,000.00

5.

Inplant Study

Rs.

10,000.00

6.

P-4 Computer, Printer and Software

Rs.

75,000.00

TOTAL

-----------------------Rs. 5,55,000.00 ------------------------


Page A-

FIXED CAPITAL

1.

LAND & BUILDING

Rs.

94,50,000.00

7

2.

PLANT & MACHINERY

Rs.

39,34,000.00

3.

OTHER FIXED ASSETS

Rs.

5,55,000.00

TOTAL

-----------------------Rs. 1,39,39,000.00 ------------------------


WORKING CAPITAL REQUIREMENT/MONTH

Page A-

8

RAW MATERIALS

1.

FOR SURGICAL COTTON:Raw Ginned cotton (with 10% wastage appx.) 27500 kg. @ Rs. 33/- per kg.

Rs.

9,07,500.00

Caustic Soda Flakes 850 kg. @ Rs. 18/- per kg.

Rs.

15,300.00

Soda Ash 550 kg. @ Rs. 12/- per kg.

Rs.

6,600.00

Bleaching Powder 550 kg. @ Rs. 7/- pe kg.

Rs.

3,850.00

Misc. Chemicals Packing paper, labels.

Rs.

25,000.00

6.

Gum, PE sheets, sacks etc.

Rs.

48,000.00

7.

FOR SURGICAL BANDAGE:Surgical Bandage good quality cloth bleached gauge cloth width 34" Reed picks 12900 meter @ Rs. 4/- meter

Rs.

51,600.00

2.

3.

4.

5.

TOTAL


-----------------------Rs. 10,57,850.00 ------------------------

Page A-

9

SALARY & WAGES / MONTH

1.

Works Manager

1 No.

Rs.

20,000.00

2.

Technologist/Chemist

1 No.

Rs.

16,000.00

3.

Clerk cum Accountant

1 No.

Rs.

7,600.00

4.

Supervisor

1 No.

Rs.

9,000.00

5.

Store keeper

1 No.

Rs.

6,500.00

6.

Blow Room Operator

1 No.

Rs.

6,000.00

7.

Boiler Attendant

20 No.

Rs.

1,12,000.00

8.

Skilled Workers

20 No.

Rs.

1,30,000.00

9.

Unskilled Workers

34 No.

Rs.

1,53,000.00

10.

Packers

5 No.

Rs.

22,500.00

11.

Peon Cum Chowkidar

1 No.

Rs.

4,200.00

TOTAL

-----------------------Rs. 4,86,800.00 ------------------------

Plus perks @ 33% p.a. Rs.

TOTAL

1,60,644.00

-----------------------Rs. 6,47,444.00 ------------------------


Page A- 10

UTILITIES AND OVERHEADS

1.

2.

Power Consumption of 17000 Kwatt hrs @ Rs. 5.00 per Kwatt hr.

Rs.

85,000.00

Water Consumption of KLs @ Rs. 2.50 per KL

Rs.

500.00

200

3.

Stationery, Postage, Telephone etc.

Rs.

12,000.00

4.

Conveyance & Transportation etc.

Rs.

50,000.00

5.

Insurance

Rs.

7,600.00

6.

Publicity & Sales Promotion

Rs.

75,000.00

7.

Repairs & maintenance

Rs.

10,000.00

8.

Telegraphic Expenses

Rs.

6,500.00

9.

Miscellaneous

Rs.

25,000.00

Coal for boiler 45 MT. @ Rs. 4000/- MT.

Rs.

1,80,000.00

10.

Professional fees

TOTAL

Total load is

94 Kwatts

-----------------------Rs. 4,51,600.00 ------------------------


Page A- 11

TOTAL WORKING CAPITAL/MONTH

1.

RAW MATERIAL

Rs.

10,57,850.00

2.

SALARY & WAGES

Rs.

6,47,444.00

3.

UTILITIES & OVERHEADS

Rs.

4,51,600.00

TOTAL

1.

WORKING CAPITAL FOR

3 MONTHS

2.

MARGIN MONEY FOR W/C LOAN

-----------------------Rs. 21,56,894.00 ------------------------

Rs.

64,70,682.03

Rs.

16,17,670.51

Rs.

1,39,39,000.00

Rs.

16,17,670.51

COST OF PROJECT

TOTAL FIXED CAPITAL MARGIN MONEY

TOTAL

-----------------------Rs. 1,55,56,670.61 ------------------------


Page A- 12

TOTAL CAPITAL INVESTMENT

TOTAL FIXED CAPITAL

Rs. 1,39,39,000.00

TOTAL WORKING CAPITAL FOR 3 MONTHS Rs.

TOTAL

64,70,682.03

-----------------------Rs. 2,04,09,682.13 ------------------------


Page A- 13

COST OF PRODUCTION/ANNUM

1.

Working Capital for 1 year

Rs. 2,58,82,728.12

2.

Interest @ 13.50% on T.C.I

Rs.

27,55,307.09

3.

Depreciation @ 10.00% on buildings

Rs.

6,45,000.00

4.

Depreciation @ 20.00% on Plant and Machinery

Rs.

7,86,800.02

5.

Depreciation @ 20.00% on office equipment & furnitures TOTAL

Rs. 40,000.00 -----------------------Rs. 3,01,09,835.23 ------------------------


Page A- 14

TURN OVER/ANNUM 1.

2.

3.

By sale of 300 MT. Surgical Cotton @ Rs.110000/- per MT.

Rs. 3,30,00,000.00

By sale of Cotton Waste 25 MT. @ Rs. 7/- per kg.

Rs.

1,75,000.00

By sale of 800000 Nos. of Different sizes of Bandages @ Rs. 180/- per packet of 120 pcs.

Rs.

12,00,000.00

TOTAL

PROFIT

=

-----------------------Rs. 3,43,75,000.00 ------------------------

RECEIPTS - COST OF PRODUCTION

=

3,43,75,000.00

=

42,65,164.77

-

3,01,09,835.23

PROFIT SALES RATIO =

=

Profit / Sales

100

42,65,164.77 ------------------------------ X 100 3,43,75,000.00

=

RATE OF RETURN =

x

12.41 %

Operating profit / T.C.I

=

x

100

42,65,164.77 ------------------------------ X 100 2,04,09,682.13

=

20.90 %


Page A- 15

BREAK EVEN POINT (B.E.P)

Fixed Costs of the plant are as under -

1.

Interests

Rs.

27,55,307.09

2.

Depreciation

Rs.

14,71,800.02

3.

40.00% of salaries

Rs.

31,07,731.20

4.

40.00% of overheads TOTAL

B.E.P.

=

Rs. 21,67,680.00 -----------------------Rs. 95,02,518.31 ------------------------

FIXED COSTS ------------------------------ X 100 FIXED COSTS + PROFIT

=

=

95,02,518.31 ------------------------------ X 100 95,02,518.31 + 42,65,164.77

69.02 %

LAND MAN RATIO = Total land / Manpower

1500 : 86

::

17 :

1


Page A- 16

RESOURCES FOR FINANCE

1. Term loans from Financial institutions ( 80.00 % of fixed capital ) at @13.50% p.a rate of interest

Rs.

1,11,51,200.08

2. Bank loans for 3 months ( 75.00 % of working capital ) at @ 13.50% p.a rate of interest

Rs.

48,53,011.52

3. Self raised capital from even funds & loans from close ones to meet the margin money needs at a

@ 13.50% p.a rate of interest

Rs.

TOTAL

SURGICAL COTTON AND BANDAGES J.C. 7964

44,05,470.53

-------------------------Rs. 2,04,09,682.13 --------------------------

J.C. 7964 Page A- 17

INSTALMENT PAYABLE IN

5 YEARS

================================================================================ Year To Financial To Commercial To others Total institutions banks (Rs. 11151200) (Rs. 4853012) (Rs. 4405471) ================================================================================ 1 22,30,240.02 9,70,602.30 8,81,094.11 40,81,936.43 2 22,30,240.02 9,70,602.30 8,81,094.11 40,81,936.43 3 22,30,240.02 9,70,602.30 8,81,094.11 40,81,936.43 4 22,30,240.02 9,70,602.30 8,81,094.11 40,81,936.43 5 22,30,240.02 9,70,602.30 8,81,094.11 40,81,936.43 ================================================================================

INTEREST PAYABLE IN

5 YEARS

================================================================================ Year On term loans On bank loans On self loans Total (Rs. 11151200) (Rs. 4853012) (Rs. 4405471) @ 13.50 % P.A. @ 13.50 % P.A. @ 13.50 % P.A. ================================================================================ 1 15,05,412.00 6,55,156.56 5,94,738.52 27,55,307.09 2 12,04,329.61 5,24,125.24 4,75,790.82 22,04,245.67 3 9,03,247.21 3,93,093.93 3,56,843.11 16,53,184.25 4 6,02,164.80 2,62,062.62 2,37,895.41 11,02,122.84 5 3,01,082.40 1,31,031.31 1,18,947.70 5,51,061.42 ================================================================================

TOTAL REPAYMENT SCHEDULE FOR 5 YEARS

================================================================================ Year Interest Instalments Total ================================================================================ 1 27,55,307.09 40,81,936.43 68,37,243.51 2 22,04,245.67 40,81,936.43 62,86,182.00 3 16,53,184.25 40,81,936.43 57,35,120.68 4 11,02,122.84 40,81,936.43 51,84,059.26 5 5,51,061.42 40,81,936.43 46,32,997.84 ================================================================================


DEPRECIATION CHART FOR

J.C. 7964 Page A- 18

5 YEARS

================================================================================

Year

Building costs Plant & Machinery fur. & office equip. Total ( Rs. 6450000.00 ) ( Rs. 3934000.00 ) ( Rs. 200000.00 ) @ 10.00 % P.A. @ 20.00 % P.A. @ 20.00 % P.A. ================================================================================ 1 6,45,000.00 7,86,800.02 40,000.00 14,71,800.02 2 5,80,500.00 6,29,440.02 32,000.00 12,41,940.02 3 5,22,450.00 5,03,552.00 25,600.00 10,51,602.00 4 4,70,205.00 4,02,841.61 20,480.00 8,93,526.61 5 4,23,184.50 3,22,273.29 16,384.00 7,61,841.79 ================================================================================


PROFIT ANALYSIS FOR

J.C. 7964 Page A- 19

5 YEARS

================================================================================================ YR CAP. Sales Mfg. Gross DepreInterest Net profit Net profit UTIL Expenses Profit ciation before tax after tax @ 35.00% ================================================================================================ 1 70% 24062500 18117910 5944590 1471800 2755307 1717483 1116364 2 80% 27500000 20706182 6793818 1241940 2204246 3347632 2175961 3 80% 27500000 20706182 6793818 1051602 1653184 4089031 2657870 4 90% 30937500 23294455 7643045 893527 1102123 5647395 3670807 5 100% 34375000 25882728 8492272 761842 551061 7179369 4666590 ================================================================================================

CASH FLOW STATEMENT FOR

5 YEARS

================================================================================ YR CAP. Net profit DepreCash Repayment of Net surplus UTIL (after tax) ciation in hand Instalment ================================================================================ 1 70% 1116364 1471800 2588164 3200842 -612678 2 80% 2175961 1241940 3417901 3200842 217058 3 80% 2657870 1051602 3709472 3200842 508630 4 90% 3670807 893527 4564334 3200842 1363491 5 100% 4666590 761842 5428431 3200842 2227589 ================================================================================


J.C. 7964

PROJECTED BALANCE SHEET FOR ( 5 YEARS)

LIABILITIES 1. 2.

Promoters Capital Term loans

3.

W/C loan

1. 2. 3. 4.

Promoters capital Net Surplus Term loans W/C loans

ASSETS

44,05,470 1,11,51,200

1. 2.

48,53,011 3. -------------------2,04,09,681 --------------------

Fixed Assets 1,05,84,000 Interest during Construction period @ 13.50 p.a. 10,50,075 Surplus funds 87,75,606 -------------------2,04,09,681 --------------------

1

Year 70 % Capacity 44,05,470 1. Depreciated value -6,12,677 of Fixed Assets 91,12,200 89,20,960 2. Working Capital 45,29,477 38,82,409 3. Surplus funds 29,54,485 --------------------------------------1,65,96,162 1,65,96,162 ---------------------------------------

2

1. 2. 3. 4.


Promoters capital

80

% Capacity

37,92,793 1. 2,17,060 66,90,720 2. 29,11,807 3. -------------------1,36,12,380 --------------------

3 1.

Year

Year

80

40,09,853

Depreciated value of Fixed Assets Working Capital Surplus funds

% Capacity 1.

Depreciated value

78,70,260 51,76,545 5,65,575 -------------------1,36,12,380 --------------------

2. 3. 4.

Net Surplus Term loans W/C loans

5,08,631 44,60,480 2. 19,41,205 3. -------------------1,09,20,169 --------------------

of Fixed Assets Working Capital Surplus funds

68,18,658 51,76,545 -10,75,034 -------------------1,09,20,169 --------------------


4 1. 2. 3. 4.



90

% Capacity

45,18,484 1. 13,63,492 22,30,240 2. 9,70,603 3. -------------------90,82,819 --------------------

5 1. 2. 3. 4.

Year

J.C. 7964

Year

100

Depreciated value of Fixed Assets Working Capital Surplus funds

59,25,132 58,23,613 -26,65,926 -------------------90,82,819 --------------------

% Capacity

58,81,976 1. 22,27,591 0 2. 0 3. -------------------81,09,567 --------------------

Depreciated value of Fixed Assets 51,63,291 Working Capital 64,70,682 Surplus funds -35,24,406 -------------------81,09,567 --------------------

BANDAGES & SURGICAL COTTON PROJECT REPORT

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