Rotor Spinning Mill Plan

Contents [show]

Introduction
Here Rotor spinning is the production potential as compared to that of ring
spinning. Here this article contains spinning mill plan for the plants which
are consist of 10 rotors spinning daily 3 tons/day production. So the total
cost of the project is around 2167.5316 RS in lac.

Here total 95 workers should be required to run the origination. The 365
days the mill is running. But in that 365 days, first-year utilization is about
75%, second-year utilization is 85%, & 3rd,4th,5th the utilization is about
95%. So following is the detail of the project spin plan.

Nowadays everyday change in technology, but here in the case of the

spinning change in technology but the ring is also king. Only one thing
about that limited spindle speed, less production, complex into that of auto-
doffing, more no of the process involved like speed frame, autoconer
winding machine.

Due to that more no of worker & floor space is required. So due to that
cost of production increased. To avoid all these related problem new
spinning technology is coming which is known as ROTOR SPINNING.

In rotor spinning only card sliver or draw frame, the sliver is to be feed and
directly yarn wound on the cone or cheese due there is no extra process is
required.

Due to that less cost of production, 10 times more production than ring
spinning. So that rotor spinning is economically viable technology.

So following are the process flow chart of Rotor spinning technology

Process Flow For Rotor Spinning
So Following Are The Advantages Of Rotor Spinning:

1. Lower power consumption per unit quantity of yarn produced.

2. The Higher speed of twist insertion resulting in very high yarn delivery
speed.
3. A significant resulting increase in productivity.
4. Larger delivered package size.
5. Elimination of some processes such as roving and winding more
uniform yarns.

Here rotor spinning plan about 10 rotor spinning machine. Production

capacity 3041 kg/day with 65:35 p/v blend propagation.

Yarn Production Particulars

Sr.no Particulars Data
1 Blend ration (p/v) 65:35

2 Avg count 16 ‘s Ne OE

3 TPI 20

4 Waste 0.5%

5 Total/pro/day 3041.0666 kg/day

6 amount of polyester required 1976.6933 kg/day

7 Amount of viscose required 1064.3733 kg/day

Technical Specification Of Machine

Reiter BT 923 Rotor Spinning
rotor spinning
Material Cotton, man-made fibres

Fibre length Up to 60 mm

Feed weight 8 – 2.2 ktex

Yarn count Ne 3 – 40, 200 – 14,5 tex

Draft 30 – 300
Twist 180 – 2200 T/m

Winding helix Adjustable between 30º and 40º

Package weight Up to 4 kg

Rotors 31, 33, 36, 38, 41, 44, 48, 50, 54 mm

Opening rollers 65 mm in various designs

Insert 1 insert type with 3 exchangeable caps

Spinning elements for specific applications

Draw Frame Finisher Reiter E-75

 Delivery speed [m/min] – up to 800.

 Production per delivery [kg/h] – up to 400.
 Deliveries per machine – 1 or 2.
 Doublings – 4 to 8.
 Draft – up to 12.
 Delivery hank [ktex] – 1.25 to 7.
 Waste [%] – 0.1 to 1.

Draw Frame Breaker SB-2

 Input material: card sliver.

  Total no of cans: 6×2=12.
 of doublings: 6.
 No of coiling head: 2.
 Output: sliver.
 Drafting system 3/3.
 Total draft range 4.24-12.15.
 Delivery speed 650- 800m/min.
 Length of delivery 10750m/min.

Technical Specification Of DK803 CARD

 Feed roll diameter – 100 mm.

 1st l-in diameter – 172.5 mm.
 2nd l-in diameter – 172.5 mm.
 3rd l-in diameter – 172.5 mm.
 Cylinder diameter – 1287 mm.
 Doffer diameter – 700 mm.
 Cylinder speed – (494-604)rpm.
 Licker-in speed:
 1ST- 945-1230
 2ND – 1467-1909
 3RD – 1922-2502
 Doffer speed – (120-180)rpm
 Draft – 60-250fold (120fold)
 Flat speed – 320mm/min
 Dfk pressure – 0-999pa (300pa)
 Fineness – 0.066-0.197Ne (0.135Ne)
 Points/sq. inch of cylinder roller – 860
 Points/sq. inch of doffer – 360
 Production – 41-52.5kg/h

Production Details
For the production capacity of daily 3 tons/days and 10 rotor spinning so
that here consideration of 10 rotor spinning m/c following no of m/c are
requireduired.

ROTOR SPINNING MACHINE

 No of m/c-10
 No of rotor/machine-50
 rotor RPM-100000
 Avg count-16
 TPI-20
  Efficiency-0.9
 Waste-0.5%

FRD (front roller Del):

= Rotor RPM/TPI

=100000/20

=5000

Production/Day/Machine:

= (FRD*60*8*3*EFFI*No of rotor)/(840*36*2.202*count)

= (5000*60*8*3*0.9*50)/(840*36*2.202*16)

=304.1067 kg/day/machine

Total production/day:

=304.1067*No of m/c

=304.1067*10

=3041.0666 kg/day

Required Material For Draw Frame Finisher:

=(Total production of rotor/day)*waste%

=3041.0666*(0.5+100/100)

=3056.2719

DRAW FRAME FINISHER

 Delivery speed – 400 mpm
 Hank – 0.12
  Efficiency – 0.9
 Waste – 0.25%

Production/Day/Machine:

= (0.283*delivery speed* Efficiency*3)/Hank

=(0.283*400*0.9*3)/0.12

=2547 kg/day/machine

No Of Draw Frame Finisher required:

=(required material for draw frame finisher)/(Draw frame finisher

production/day/machine)

= 3056.2719/2547

=1.2011

Required Material For Draw Frame Breaker:

=required material for draw frame finisher*waste%

=3056.2719*(0.25+100/100)

=3063.9126 Kg

DRAW FRAME BREAKER

 Delivery speed-300 mpm
 Hank-0.12
 Efficiency-0.9
 Waste-0.25%

Production/DAY/machine:

=(0.283*delivery speed* Efficiency*3)/Hank

=(0.283*300*0.9*3)/0.12

=1910.25 kg/day/machine

No Of Draw Frame Breaker Required:

=(required material for draw frame breaker)/(Draw frame breaker

production/day/machine)

=3063.9126/1910.25

=1.60

Required Material For Carding:

=required material for draw frame breaker*waste%

=3063.9126*(0.25+100/100)

=3071.5724 Kg

CARDING
 Delivery speed-140 mpm
 Hank-0.12
 Efficiency-0.9
 Waste-2%

Production/DAY/machine:

= (0.283*delivery speed* Efficiency*3)/Hank

=(0.283*140*0.9*3)/0.12

=891.45 kg/day

No Of Carding Required:

=(required material for carding)/(Carding production/day/machine)

=3071.5724/891.45

=3.4456

MIXING DEPARTMENT
Material required for Mixing Department:

=requireduired material for carding*waste%

=3071.5724*1.02

=3132.9426

Total Amount Of Polyester required For Mixing:

=Material required.for mixing department*(65/100)

=2036.4127

Total Amount Of Viscose required For Mixing:

=Material required.for mixing department*(35/100 )

=1096.5299

Raw Material Cost Particulars

Sr.no Particulars Data

1 Polyester required/day in kg 1976.6933 kg/day

2 Polyester required/year in kg 721493.0545 kg/year

3 Cost of polyester 85

4 Cost of polyester/day in Rs 168018.9305 RS/day

5 Cost of polyester/year in Rs 61326309.63 RS/year

6 Viscous required/day in kg 1064.3733 kg/day

7 Viscous required/year in kg 388496.2545 kg/year

8 Cost of viscous 75

9 Cost of viscous/day in Rs 79827.9975 RS/day

10 Cost of viscous/year in Rs 29137219.09 RS/year

11 Total cost/day 247846.9280 RS/day

12 Total cost/year 90463528.72 RS/day

Total Area Required For Spinning

Organization
Rotor Spinning Machine
Dimension

 Length – 15 m
 Width – 4 m
 M/c alley – 3 m
 Spinner alley – 5m

Area required. for one m/c

=[(Length*width) +m/c alley +side alley]*2

= [(15*4) +3+5]*2

=136 meter. Square

Total area required for 10 rotor m/c

=Area required. for one m/c *No of m/c

=136*10

=1360 meter.square

Draw Frame Sections

Dimensions

 Length – 8.5 m
 Width -3 m
 M/c alley -1 m
 Spinner alley – 3 m
Area required for one m/c

=[(Length*width)+m/c alley +side alley]*2

= [(8.5*3) +1+3]*2

=59 meter. Square

Total Area required For Draw Frame M/C

=Area required. for one m/c*No of m/c

= 59*4

=236 meter. Square

Carding Section
Dimensions

 Length – 8 m
 Width – 4 m
 M/c alley – 0.5 m
 Spinner alley – 2 m

Area required. for one m/c

=[(Length*width) +m/c alley +side alley]*2

= [(8*4) +0.5+2]*2

=69 meter. Square

Total area required for carding m/c

= Area required. for one m/c*No of m/c

=69*4
=276 meter. Square

Mixing Department
Mixing Bale Opener
Length -7 m

Width -4 m

Side alley -5 m

M/c alley – 2 m

Area required for MBO

= [(length*width) +side alley+ m/c alley]*2

= [(7*4) +5+2]*2

= 70 meter. Square

Unimix
 Length -7 m
 Width -4 m
 Side alley -5 m
 M/c alley -2 m

Area required for unimix

= [(length*width) +side alley+ m/c alley]*2

= [(7*4) +5+2]*2

= 70 meter. Square

Other Required Area

Raw material storage department – 300 meter. Square
Go down and packing department -3 00 meter. Square

Office and staff – 300 meter. Square

Maintenance room

 rotor maintenance room – 50 meter. Square

 Draw frame maintenance room – 50 meter. Square
 Carding maintenance room – 50 meter. Square

Total working area = 2200 meter. Square

For future expansions consider 10 times more area of that total

working area

So total area

=10*total working area

=10*2200

=22000 meter. Square

1 meter. Square=10.78 square. Feet

Total area in square. Feet

=22000*10.78

=231760 square. Feet

Cost Of Land And Side Development

Sr.no Particulars Data
1 Total land requireduired in the square. Feet 231760 square. Feet

2 Land cost for square. Feet 300 RS/square. Feet

3 Total land cost in cr. 7.1148 RS in cr.

4 Side development cost 10 RS in lac

5 Total cost of land and site development 7.2148 RS in cr.

Estimated Cost Of Factory And Non-Factory Building

Sr.no Particulars Data

Factory building

20683.36 Square.
A- area required of total machinery set up
Feet

1 B- Construction cost/ square. Feet 800

c- total construction cost of machinery 1.65 RS in cr.

D- maintenance construction area 1617 square. Feet

E- Construction cost/ square. Feet 600

 F- total construction cost of maintenance dept. 9.7020 RS in lac

G-area required for raw material and yarn go down 6168 square. Feet

H- Construction cost/ square. Feet 600

I- total construction cost raw material and yarn go

37 RS In lac
down debt.

Other construction

A-Office and staff 3048 square. Feet

B-Construction cost/ square. Feet 500

2
C- total construction cost office and store dept. 15.42 RS in lac

D-miscellaneous construction 10 RS in lac

GRAND TOTAL OF CONSTRUCTION COST 2.4284 RS in cr.

Estimated Cost Of Plant And Machinery

No of Cost of Total cost Total RS
Sr.no Particulars Incident expenses
m/c m/c of m/c in lac

1 Reiter BT 923 Rotor 10 35 lac 350 lac 63 lac 413

2
2 25 lac 50 lac 9 lac 59

Draw frame finisher Reiter

 E-75

Draw frame breaker SB-2

3 2 20 lac 40 lac 7.2 lac 47.2

Technical specification of

DK803 CARD
4 4 30 120 lac 21.6 lac 141.6

5 MBO 1 35 35 6.3 41.3

6 Unimix 1 35 35 6.3 41.3

GRAND TOTAL 743.4

Estimated Cost Of Miscellaneous Fixed Assets

Sr.no Particulars RS in lac

1 Humidification +5% other taxes 25 lac

2 Compressor + 5% other taxes 50 lac

3 Office equipment 8 lac

4 Electrical installation 20 lac

5 Material handling equipment 10 lac

6 Accessories 10 lac

7 Tools and gauges 10 lac

8 miscellaneous equipment 5 lac

9 Yarn packing equipment 2 lac

GRAND TOTAL 140 lac

Pre-Operative Expenses
Sr.no Particulars Rs. in lac
1 Communication expenses 0.5 lac

2 Travelling expenses 5 lac

3 Project consistency charges

(A) civil 5 lac

(B) electrical consentient 1 lac

(c) finance consentient 2.5 lac

(D) textile consentient 2.5 lac

5 Project report and project report particulars 0.5 lac

6 Bank expenses 2.25 lac

7 Electrical connections & various deposit 2 lac

8 Expenses of various permeations 0.5 lac

9 Regiestion charges 0.2 lac

10 Insurances 1 lac

11 Trial production expenses 0.5 lac

12 Training expenses 0.3 lac

13 *Interest during project implications 75.07

14 Grand total of project 23.75 lac

Estimated Cost Of Project

Sr.no Particulars Rs in lac

1 COST OF LAND & SIDE DEVELOPMENT 705.28

 COST OF FACTORY & NON FACTORY
2 237.4209
BUILDING

3 COST OF PLANT OF MACHINERY 743

4 COST OF MISLENOUS ASSETS 140

5 PRE-OPERATIVE EXPENSES 98.82

6 MARGIN MONEY FOR WORKING CAPITAL

7 CONTINGENCY PROVISION

(A) LAND & BUILDING 47.15

(B) MACHINE 55.7250

8 GRAND TOTAL OF PROJECT 2027.3959

Interest During Project Implementations

During your project bank will give you about 70% of that total cost and 30%
is your money. First, your money is used for that project and then after you
use bank money. Suppose first 4 mounts your money is over.

After that, you utilize bank money e.g. in the 5-month bank gives money
then the bank will start to the interest that 7 months. After that 8-month
bank gives you money then the bank will start to an interest of that 4
months. Addition of this interest which is known as interest during project
implementations.

RS in lac on interest
Sr.no Particulars Data (RS in lac)
with 12%

1 Total cost of project 1952.3259

2 Your money 585.6978

3 Bank money 1366.6281

4 1-3 month –

5 3-6 month with 12% interest 341.6576 27.28

6 6-9 month with 12% interest 341.6576 20.46

7 9-12 month with 12% interest 683.3152 27.33

GRAND TOTAL OF INTEREST

8 75.07
DURING PROJECT IMPLECTIONS

Cost Of Production And Working Capital

The estimated cost of staff salaries and labor wages.

Total

salary of
Sr.no Particulars No of worker/day Salary/month
year RS in

lac

A-staff
Spinning manager 1 40000 4.8
details

Supervisor 15 12000 21.6

Office assistance 1 10000 1.2

Watchman and peon 3 8000 2.88

 GRAND TOTAL 30.48

B-labor Workers for m/c

50 8000 48
details operating

Main technician 2 25000 6

Workers for maintenance 10 12000 14.4

Store and go down 8 8000 7.68

Miscellaneous workers 5 8000 4.8

GRAND TOTAL 95 80.8

Details Of Fringe Benefits To Staff And Labor

Annual labor Fringe benefits Annual staff salary Fringe benefits
GRAND
Year salary to be to labors at to be increased by to labors at
TOTAL
increased by 5% 26.17% first 3 5% 20.17% first 3

years & 34.5% years & 28.5%

 their after their after

1 80.8 21.14 30.48 6.14 138.56

2 84.8 22.19 32.00 6.45 145.44

3 89.08 23.31 33.60 6.77 152.76

4 93.53 32.26 35.28 10.05 171.12

5 98.21 33.88 37.04 10.55 179.68

Estimated Cost Of Electrical Power Charges

No of Total
Sr.no Items Kwh Efficiency Kwh/day Kwh/year
m/c kwh

1 rotor 10 25 250 0.9 5400 1971000

2 Draw frame finisher 2 12 24 0.9 518.4 181440

3 Draw frame breaker 2 10 20 0.9 432 157680

4 Carding 4 10 40 0.9 864 315360

5 MBO 1 38 38 0.9 820 299592

6 UNIMIX 1 35 35 0.9 756 275940

7 Humidification 1 25 25 0.9 540 197100

8 Compressor 1 10 10 0.9 216 78840

9 Lighting 10 10 0.9 216 78840

10 Other 10 10 0.9 216 78840

11 GRAND TOTAL 9978 3634632

1 UNIT=1 Kwh so price of 1 unit is 5RS

Total cost of kwh/year

=3634632*5
=181.7316 lac RS/year

Project Profitability And Cash Flow

Sr.no Particulars 1st year 2nd year 3rd year 4th year 5th year

Assumption of
A
profitability

1 Utilization 75% 85% 95% 95% 95%

2 Yarn pro/tons/year 876.2882 993.1266 1109.6950 1109.9650 1109.9650

Estimated cost of
B
production

Raw material
1 714.4158 809.4105 904.6359 904.6359 904.6353
cost(RS in lac)

2 Power charges 143.4721 162.6020 181.7316 181.7316 181.7316

3 Salary of wages 138.56 145.44 152.76 171.12 179.68

with fringes
 benefits (RS in lac)

Checking and

packing
4 3.06 3.47 3.88 3.88 3.88
expenses(0.35 RS

of yarn pro/year)

Admistative

5 taxes(0.3% of fixed 5.47 5.47 5.47 5.47 5.47

assets) RS in lac

Insurance and local

6 taxes(0.4% of fixed 7.29 7.29 7.29 7.29 7.29

assets)

Sales expenses

7
1% raw material 7.1419 8.0941 9.0464 9.0464 9.0464

cost

GRAND TOTAL

RS in lac 1019.4098 1141.7766 1264.8139 1283.1739 1291

Estimation Of Maintenance Expenses
No of Maintenance No of machine Total cost/year
Sr.no Particulars
m/c expenses/machine shift/year in lac Rs

1 rotor 10 100 10950 10.95

2 Draw frame 4 50 4380 2.19

3 Carding 4 50 4380 2.19

4 MBO 1 100 1095 1.95

5 Unimix 1 100 1095 1.95

GRAND TOTAL 19.23

Sales Realization
Sr.no Particulars Data

1 Total yarn production kg/year 1109.9650

2 Total manufacturing cost/year Rs in lac 1291

3 Yarn cost/kg RS 215

4 Total sales cost/year RS in lac 2386.4248

Gross Profits
Gross profits = sales cost-manufacturing cost

Sr.no Particulars 1st year 2nd year 3rd year 4th year 5th year

1 Utilization 75% 85% 95% 95% 95%

2386.4248
Total sales RS in
2 1884.0195 2135.2221 2386.428 2386.4248
lakh

Manufacturing
3 1019.4098 1141.7766 1264.1739 1283.1739 1291
cost/year in RS lac

Gross profits RS in
4 864.6097 993.4455 1122.2541 1103.2509 1095.4248
lac

Margin Money For Working Capital

 Amount of
No of Total Margin money
% bank bank finance
Sr.no Particulars month amount RS requireduired
expenses
required in lac RS in lac
RS in lac

Raw material
1 3 226.1588 70 158.3112 67.8476
particulars

Stock of finished
2 3 322.75 70 225.9250 93.8250
material

Stock of

3 material in 3 50 70 35 15

process

4 Other 3 20 0 0 11.54

GRAND

TOTAL OF RS 419.2362 118.2126

in lac

12% interest on working capital=62.88 RS in lac

Total Cost Of Project

Particulars RS in lac
Land 721.48

Building 242.84

Machine cost 743.3

Miscellaneous and fixed assets 140

Pre-operative expenses 98.82

Margin money for working capital 118.2166

Contingency provision 102.8750

GRAND TOTAL COST OF PROJECT RS in lac 2167.5316

Total cost of the project=2167.5316 RS in lac

Equality of own funds=650.2595 RS in lac

Term loan=1517.2721 RS in lac

Financial Expenses
Sr.no 1st-year 2nd-year 3rd-year 4th-year 5th year

Utilization% 75 85 95 95 95

1-interest on bank

borrowing(15% of 93.3257 105.7692 118.2126 118.2126 118.2126

working capital)

2-Interest on term loan 182.06 167.6873 125.1740 79.6616 34.1456

Term loan interest

Details of service amount for 6

Sr.no
repayment months(12%
half Term loan
amount in ½ interest) Interest/year Dead service
year
year

1 1517.2721 0 91.03 182.06 182.06

2 1517.2721 0 91.03

3 1517.2721 189.65 91.03 167.6873 546.9873

4 1327.6221 189.65 76.6573

5 1137.9721 189.65 68.2747 125.1740 504.4740

6 948.3211 189.65 56.8993

7 758.6721 189.65 45.5203 79.6616 458.9616

8 569.0221 189.65 34.1413

9 379.3721 189.65 22.7623 34.1456 413.4456

10 189.7221 189.65 11.3833

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