Process Flow Chart for making Cement and Fertiliser Bag

PP / HDPE (Raw Material)

Tape Stretching Line (Extruder)

Tapes
Cheese Winders
Bobbins
Circular Weaving Machines

Fabric Roll

Cutting Table Lamination M/c

Cut Lengths Fabric Roll

Sewing M/c Cutting Table

Sewed Sacks Cut Lengths

Reversing
Printing M/c

Cut Lengths
Printed Sacks Sewing M/c
Bailing Press
Sewed Sacks
Baled Sacks
Printing M/c
Despatch
Printed Sacks

Bailing Press

Baled Sacks

Despatch

Cement Bag Fertiliser Bag

Lohia Starlinger Limited, Kolkata

Lohia Starlinger Limited

Project Profilr for 50 Kg Cement Bags

BAG SPECIFICATIONS
Length of bag cm 70
Width of bag cm 48
Cut off length cm 83
Fabric construction
Warp tapes/10cm 40
Weft tapes/10cm 40
Denier 850
Fabric weight gsm 76
Weight of bag gm 60
CAPACITY REQUIRED
Bags per annum million 60

OPERATING PARAMETERS
Efficiency,Waste,Running hours per annum
Number of working days per annum 300

EQUIPMENT EFFICIENCY WASTE HOURS

Tape line with winder 92% 1% 7200
Circular looms 85% 1% 6600
Lamination line 85% 3% 7200
Cutting and stitching 80% 1.5% 6600
Printing 70% 1.5% 6600

STAGEWISE MATERIAL THROUGHPUT

Printing
Number of finished bags million 60
Fabric weight of finished bags mt 3590
Fabric weight from cutting mt 3645
Weight of material wasted mt 55

Cutting and stitching

Fabric weight for printing mt 3645
Fabric weight in from weaving mt 3701
Weight of material wasted mt 56

Weaving
Fabric weight for cutting mt 3701
Tape input from extrusion mt 3738
Weight of material wasted mt 37

Tape production
Weight of tape for weaving mt 3738
Weight of tape,including waste mt 3776
Weight of material wasted mt 38

Total material waste mt 185

1 12 Tonne/day
Lohia Starlinger Limited

STAGEWISE CAPACITY ESTIMATION AND LINE BALANCING

Tape extrusion
Finished sacks million 60
Gross equivalent oftapes to
be produced million 63
Fabric weight per sack gm 60
Tape throughput required mt 3776
Tape throughput per hour kg 524
Extruder capacity per hour kg 570
Suggested tape line 450Kg/Hr no 0
Suggested tape line PP 600Kg/Hr no 1

Circular weaving
Finished sacks million 60
Cut off length cm 83
Length to weave million mtr 50
Length including waste million mtr 52
Loom capacity reqd million mtr 61
Loom capacity reqd/hour mtr 9186
Suggested loom LSL6 no 68

Cutting and stitching

Finished sacks million 60
Quantity to cut incl waste million 62
Quantity to cut incl waste/hour no 9370
Cutting capacity reqd per minute no 195
Suggested cutting machines no 7
Suggested stitching machines no 32

Printing
Finished sacks required no 60
Quantity to print incl waste no 61
Quantity to print incl waste/hr no 9229
Printing capacity reqd/hour no 13185
Suggested printing machines no 8

Baling
Finished sacks required million 60
Sacks per bale no 700
Number of bales required no 85714
Number of bales required/hour no 13
Suggested baling machines no 2

2 12 Tonne/day
Lohia Starlinger Limited

UTILITIES(ESTIMATE)

POWER
EQUIPMENT QTY CONN KW CONSUMED KW AIR M3/HR CL LOAD TR WATER M3/HR

LOAD DATA
TL600Kg/Hr+LTW200C 1 490.0 269.5 128.0 20.0 0.15
TL450Kg/Hr+LTW200C 1 465.0 325.5 128.0 15.0 0.15
Loom LSL6 1 3.2 2.7
Cutting machine 1 3.2 2.1
Stitch.machine 1 0.4 0.3
Print.machine 1 2.4 1.7
Baling press 1 8.0 5.6
UNIT REQUIREMENT
TL600Kg/Hr+WINDER 1 490.0 269.5 128.0 20.0 0.15
Loom LSL6 68 217.6 185.0
Cutting machine 7 22.4 14.6
Stitch.machine 32 12.8 9.0
Print.machine 8 19.2 13.4
Baling press 2 16.0 11.2

TOTAL REQUIREMENTS 778.0 502.6 128.0 20.0 0.15

Auxiliaries(Load Data)
Chilling(TL600Kg/Hr) 1 65.0 48.8
Chilling(TL250Kg/Hr) 1 32.0 24.0
Air compressor 1 7.5 5.6
Air drier 1 4.8 3.6
DM water unit 1 1.0 0.8
UNIT REQUIREMENT
Chilling(TL600Kg/Hr) 1 65.0 48.8
Air compressor 1 7.5 5.6
Air drier 1 4.8 3.6
DM water unit 1 1.0 0.8

TOTAL AUXILIARY 78.3 58.7

TOTAL POWER 856.3 561.3

3 12 Tonne/day
Lohia Starlinger Limited

MANPOWER ESTIMATE

MEN/SHIFT TOTAL ENGR ENGR

S.N EQUIPMENT M/Cs SK UNSK SK UNSK PER/Sh TOTAL

A DIRECT PRODUCTION
1 TAPELINE 600Kg/Hr 1 2 2 6 6 1 3
2 LOOM LSL6 68 17 17 51 51 3 9
3 CUTTING 7 7 7 21 21
4 STITCHING 32 32 16 96 48 1 3
5 PRINTING 8 8 8 24 24
6 BALING 2 2 4 6 12

SUB TOTAL A 68 54 204 162 5 15

B STORAGE AND SUPPORT AREA

RAW MATERIAL STORAGE 1 3
BOBBINS STORAGE 1 3
FABRIC STORAGE 1 3
FINI GOODS STORAGE 1 1 3 3
INSPECTION 3 9 1 3
MECH MAINTENANCE 1 3 1 3
ELEC MAINTENANCE 1 3 1 3
MATERIAL HANDLING 1 2 3 6 1 3
DESPATCH AREA(1 Sh) 1 1 1 1 1 1

SUB TOTAL B 8 7 22 19 5 13

C UTILITY AREA
CHILLING PLANT 1 1 3
AIR COMPRESSOR 1 1 3
WATER TREATMENT 1 1 3

SUB TOTAL C 3 9

TOTAL MANPOWER 79 61 235 181 10 28

TOTAL MEN/SHIFT 150

TOTAL MEN REQUIRED 444

4 12 Tonne/day
Lohia Starlinger Limited

PRICE SCHEDULE (ESTIMATE)

(PRICES IN INDIAN RUPEES)

S.NO EQUIPMENT QTY UNIT PRICE TOTAL PRICE

1 Tapeline 600Kg/Hr (Lorex-E120B.1400HS) 1 16,700,000 16,700,000

2 Take up winders(LTW200C) 264 25,000 6,600,000
3 Circular weaving machine(LSL6) 68 630,000 42,840,000
4 Cutting Table 7 25,000 175,000
5 Stitching machine 32 60,000 1,920,000
6 Printing machine(2 Colour) 8 300,000 2,400,000
7 Baling press 2 300,000 600,000
8 Air compressor 1 190,000 190,000
9 Air drier 1 80,000 80,000
10 DM water unit 1 70,000 70,000
11 Testing Equipments 1 300,000 300,000
(Set)
12 Chilling plant(TL600Kg/Hr)) 1 1,500,000 1,500,000
13 Cheese Tubes( MS ) 90,000 18 1,620,000
14 Electricals i.e. UPS, Genset, Transformer, 1 10,000,000 10,000,000
Distribution Panels, Cables etc. (set)

Total price(ex works packed) 84,995,000

Ps: Price of Lamination machine Rs 40,00,000/-

Our scope of supply includes tapeline, winders & circular looms ie. Items 1 to 4
The prices of conversion & auxilliary equipment are budgetory and subject to
confirmation.

Excise Duty, Sales Tax, Freight, Erection & Commissioning charges are extra.

Estimated factory area required is 7500 sq.mtr.approx.

5 12 Tonne/day