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Fabtech Textile

Introduction

The Indian Textile industry is growing at the rate of 20% and accounts for 4% of India’s GDP. Textile exports are targeted to reach $50 billion by 2010. The Industry requires 5 million spindles every year up to the year 2012, translating into 30 million spindles over the next five years. Fabtech Textiles a division of Fabtech Projects & engineers Ltd. India’s leading Lumpsum turnkey Projects & Fabrication Company was formed to cater to this growing market demand.

Infrastructure

With a vision to create state-of-the-art cotton yarn spinning unit, Fabtech group initiated the project development during the financial year 2006-07. Fabtech textiles is situated in Sangola, district Solapur around 5 hours drive from Pune. The factory with ultramodern equipment for Cotton Yarn manufacturing spans over 11 acres of land. The total built up area consisting of the Production unit, ancillary block, administration block, training lab and guest rooms is spread over 20,000 Square meters

The company’s executive director is Mr. Bausaheb Rupnar and Vice President is Mr. Patil.

The Textile project is divided into two phases.

Phase 1: The first phase of 15,600 spindles is already installed and commissioned. Production activity in Phase 1 has also been started. The cost of Total Plant & Machinery installed till date is Rs. 200 Million.

Phase II: The phase II of the project is already underway and will cater to a capacity of 14,400 spindles. Estimated Cost of Plant and Machinery for Phase II is expected at Rs.225 Million

Uniqueness of the project

The setup of the project is planned very scientifically and systematically with due importance to facilitate smooth flow of material and ease of production
Energy conservation and saving is given topmost priority, in selection of machinery vis-a- vis productivity
Selection of state of the art and latest technology machines with low electric consumption and high production ratio, will give better cost effective production.
Combination of machinery is planned systematically, to keep the managements hands free to use flexible product mix of production line
From day one, an ERP software is installed for production and management reporting.
Ultramodern testing equipments such as “Uster” and “Premier” make equipment will definitely help in producing high quality yarn.

Production Highlights

Timeline	Spindles Installed	Count Pattern	Annual Production	Status
PHASE - I	15,600	30’s to 40’s KRD.	2,660 MT.	Commissioned & Production active
PHASE - II	14,400	40’s to 60’s CBD.	1,500 MT	Under installation, expected production Sept. 2010

Particulars	2009-10	2010-11	2011-12
CAPACITY(SPINDLES)	15,600	30,000	30,000
UTILIZATION (%)	25%	85%	90%

Manufacturing Process of Cotton Yarn

The basic procedure in cotton yarn spinning is the raw cotton is converted into a thread of required quality and of a required count. The manufacturing process and value addition/function of each stage of continuous process is explained as under.

Sr. No.	Department	Type of Activity Carrieout
	Raw Cotton receipt and storage in godown	Raw & un cleaned cotton is stored in the godown.
1	BLOWROOM	Raw & un-cleaned cotton is fed into the blow room unit and impurities of cotton such as trash, foreign particles and other impurities are removed from cotton. The fire diversion system diverts to a wet pond outside the factory, any cotton that might catch fire due to friction of the impurities. The Premier contamination clearer system results in highly cleaned cotton and this is directly fed to carding machines through chut feed method.
2	CARDING	The cleaned cotton fed through chut from blowroom is further cleaned though lickerin wires and fine cleaned cotton is converted into sliver using LMW carding Machines. The cotton sliver/noil is stored in cans.
3	COMBING	The carding sliver is further passed though combing unit and short fiber contents of the cotton is further removed from the sliver and cotton sliver/noil of very fine quality is manufactured.
4	DRAWFRAME	Multi slivers drawn from combers are fed into this units and single sliver of these multi slivers is manufactured. The draw frame finisher further enhances the slivers before the spinning operation
5	SPEED FRAME	This is the beginning of real spinning of the yarn. The sliver is spun into primary stage of yarn, at a speed of 1,000-1,200 rpm and the sliver is winded on to pre-primary bobbin
6	RINGFRAME	The speed frame bobbins are loaded to the ring frame machines and final yarn is manufactured. The ring frame machine hasa speed of 16,000 to 22,000 rpm and it is the final stage of yarn manufacturing. The yarn is winded on plastic bobbins.
7	AUTOCONNING	We have specialized Auto conning machinery imported from Germany that is used to wind the yarn on bobbins onto cones of required quantity say, 1.00kg, 1.50kg, 1.89kg or say 3.00 kgs, as per requirement.
8	YARN CONDITIONING	The yarn cone of required size, manufactured on auto coning machine is loaded on trollies and the trollies are loaded into high pressure steam vessel. The high-pressure vessel of steam is carrying out the process of yarn conditioning and improves the strength value of the yarn
9	CHECKING & PACKING	The yarn taken out from the yarn conditioning machine is checked in ultraviolet light for contamination in yarn and finally yarn is packed in HDPE Bag or Cartoon as per requirement.