PROJECT PROFILE ON

AUTOMATIC CONE WINDING UNIT

1. INTRODUCTION:

The textile industry has witnessed stringent requirements on quality and

economic efficiency over a period of time and this has been subject to
continuous change. Newer types of materials, suitable performance
characteristics and fashion have assumed increasingly important role. Parallely
growing with this is the importance of the yarn package winding as a quality
filter in the textile production chain.

The factors such as conservation of the specific quality of the yarn,

further optimization of the structure and build of the yarn packages and the
production of yarn like spliced joints for gentle handling and undisturbed
processing of yarn and packages in the production processes downstream of
winding, are still considered vital in the yarn winding process. In addition to
these, advanced monitoring and operating systems, proven automation
solutions, energy and raw material saving technologies constitute the other
performance features of the modern winding machines.

The autoconers provide the textile industry with mature, state-of-the-art

technology capable of efficiently winding yarn for any specific application.
Flexible and innovative modular technologies are the platform for textile
technological progress and outstanding economic efficiency in automatic yarn
package winding. In the automatic package winding, high performance
functional units and intelligent closed-loop control systems form the integral
part. High standards of quality and economy can thus be achieved in the modern
winding machines due to the mature winding concepts.
IMPORTANT FEATURES OF THE AUTOCONER WINDING
MACHINE
Auto cone is a modern yarn winding machine. It is use to prepare bigger
package from ring bobbin. It is just not only has a winding machined, there also
some extra specification of this machine. There are several features of the
autoconer. However the essential ones are being discussed.

These are as follows:

1. Automated spinning bobbin feed

2. Linkage with the ring spinning machine

3. Yarn package rewinding with automatic feed package change

4. Manual filling of the feed bobbins into the feed magazines

5. Rewinding of manually creeled yarn packages

6. Rewinding of residual yarn packages

7. Predefined package density

8. Continuous online measuring of the yarn tension

9. Easy operation and maintenance

10.Highest accuracy and reproducibility of the yarn tension

11.Increase in productivity

12.Compensation of yarn tension variation

13.Flexible splicing principle

14.Systematic data analysis and targeted process control

2. MARKET POTENTIAL:

The world cotton cultivation area and cotton production are estimated at
around 30-31 million hectares and 20 million tons respectively. The biggest
cultivators of cotton are America, India, China, Egypt, Pakistan, Sudan and
Eastern Europe. India is the third largest producers of cotton after USA and
China. USA has a considerable share in world exports. India and China both fall
short of their domestic requirement and are net importers. Andhra Pradesh is
3rd largest state in India which grows cotton. Among the consumers China
leads the way being followed by India, Pakistan, USA and Turkey.

Indian Textile Industry contributes 4% to the GDP of the country; it

contributes 14% to Industrial Production, 9% of excise collections, 18% of
employment in industrial sector, and has 16 % share in country’s export. Textile
industry provides employment to 35 million people in India. Winding, being
one of the most important part of the spinning mills, it provides a wide market
demand and job opportunities.
3. BASIS & PRESUMPTIONS:

1. This project is based on one and half shift basis and 300 working days in
a year.
2. Since this industry is labour-intensive, the working efficiency is
considered at 75%.
3. Costs of machinery and equipment/ material indicated refer to a particular
make and approximately to those prevailing at the time of preparation of
this project.
4. Installation and electrification cost is taken @ 10% of cost of machinery
and equipment.
5. Non-refundable deposits, project report cost, trial production, security
deposits with Electricity Board are taken under pre-operative expenses.
6. Depreciation has been considered:
(a) On Building @ 5%
(b) On plant and machinery @ 10%
(c) On office furniture and fixtures @ 15%
(d) On other fixed assets @ 15%.
7. Interest on capital investment has been taken @ 12% per annum.
8. Minimum 5% of total investment is required as margin money.
9. The project is eligible for a maximum of 35% subsidy under central
government’s PMEGP scheme
4. TECHNICAL ASPECTS

Winding is one of the most important operation, which is mainly occurred

in spinning section. Besides, it is also important in fabric manufacturing. In
fabric manufacturing, directly winding is not so much important, but rewinding
is so important. The creation of large yarn packages that can be easily unwound,
is called winding. This makes using the yarn on subsequent machines both
easier and more economical.

After warping, some packages contain just a few grams of yarn which is
unsuitable for the efficiency of further processing, such as warping, twisting,
and quelling. This necessitates the preparation of a dense and uniform yarn
package of sufficiently large size from unsuitable packages which can unwind
in the subsequent operations without interruptions, is called rewinding.

The yarn unwound from the package passes through yarn tensioned and
control systems, and with the help of a grooved cylinder, is wound evenly
around the package; the yarn enters the recess in the cylinder, thus the rotary
movement of the cylinder corresponds to the translation of the yarn. Winding
machines currently have independent heads with individually adjustable motors.

A modern winding machine can process yarns ranging from a count of

No.2 to finer ones, at a winding speed of 400 to 2000 m/min. Winding is more
than just transferring yarn from one package to another. Further functions of
winding are to check the yarn and to eliminate any faults found.
Materials Processed:

Input - Yam (spinning bobbins)

Output - Yarn (large cones, tubes, etc.)
Objectives of the Process:

 Inspect the yarn

 Clearing of defects
 Lubricate the yarn
 Package the yarn

A basic diagram of winding machine:

Yarn Winding
Elements of Winding:

1. Yarn withdrawal
2. Yarn tensioner
3. Yarn clearing
4. Stop motion 
5. Take up

Importance of winding:

Unevenness in traditionally spun staple yarns is a natural phenomenon

usually induced by the process of manufacturing (spinning). Although with
modern process controls and machines many imperfections in the spun yarns
can be controlled, some still remain in the final yarns. Most common of all
imperfections are thin or weak places, thick places, slubs, neps, and wild fibers,
as shown schematically.

During the subsequent processes of winding, warping, and slashing, not

all but some of these imperfections create obstacles to steady and smooth
working. Therefore, it is important to classify, quantify, and remove those
imperfections which may cause the interruption of the operation. In other
words, only ‘‘objectionable’’ faults need to be removed for trouble-free
processing of the yarns. The ring-spinning operation produces a ring bobbin
containing just a few grams of yarn which is unsuitable for the efficiency of
further processing, such as warping, twisting, and quelling. This necessitates the
preparation of a dense and uniform yarn package of sufficiently large size which
can unwind in the subsequent operations without interruptions.

The packages prepared for warping are normally cross-wound, containing

several kilograms of yarns. This implies that a number of knots or splices are
introduced within each final package. Bear in mind, each knot or splice itself is
an artificially introduced imperfection; therefore, the size of this knot or splice
must be precisely controlled to avoid an unacceptable fault in the final fabric.

In modern winding machines, knots and splices are tested

photoelectrically for size, and only acceptable knots and splices are allowed to
pass on to the winding package. In modern spinning processes, such as open
end, friction and air jet, the spinning process itself produces a large cross-wound
package, thus eliminating the winding operation.

Functions of the Winding Operation:

Important functions of the winding operation are

1. Clearing of yarn faults

2. Making larger wound packages
3. Preparing soft packages for dyeing 

5. ABOUT THE PROMOTER

Name :

Sex : Male

Permanent Address : Sathyamangalam(Tk), Erode (Dt)-638451.

Nationality : Indian

Working Experience : 12 years in various industries as supervisor

6. PRODUCTION CAPACITY (Per year):

Products Quantity Value (Rs.)

18 tones
Winding cones 28,80,000/-
(as job orders)

7. MOTIVE POWER REQUIRED:

Total 15 kW is required to run this unit at installed capacity.

8. POLLUTION CONTROL:

The process of manufacture does not generate pollution. However,

entrepreneurs are to contact State Pollution Control Board for necessary
guidance.

9. ENERGY CONSERVATION:

Maximum care should be taken while selecting the machinery and other
electrical equipments so as to ensure minimum power consumption.

10. MACHINERY UTILISATION:

Capacity utilization of plant and machinery is considered as 75% of

installed capacity. However, this can be improved to 80% during 3rd year of
production.
11. FINANCIAL ASPECTS:
(A) Fixed Capital

(i) Land & Building:

Land: 1000 sq. ft. @ Rs. 10 per sq. ft.

Building Area

Factory Shed : 700 sq. ft.

Store (Raw Material) : 150 sq. ft.

Store (Finished Goods) : 150 sq. ft.

Total Covered Area : 1000 sq. ft.

Rent : Rs. 10,000/-

(ii) Machinery & Equipments

Sl. Rate Qty Value

Machinery Description
No. (Rs.) Nos. (In Rs.)

1. Auto Cone Winding Machine 50,000 10 5,00,000/-

Total 5,00,000/-

(iii) Other Fixed Assets

i. Erection and installation 50,000/-

ii. Office Furniture 5,000/-
iii. Pre-operative expenses 5,000/-
Total: 60,000/-
Total Fixed Capital: 5,60,000/-
(B) Working Capital (per month)
(i) Staff & Labour (Per Month):

Sl. Rate Amount

Personnel No.
No. (In Rs.) (In Rs.)

1. Marketing Manager 1 10000 10,000/-

Accounts Officer cum
2. 1 6000 6,000/-
Store-Keeper
3. Electrician 1 3500 4,000/-
4. Production Supervisor 1 8000 8,000/-
5. Skilled Workers 5 6000 30,000/-
6. Unskilled Workers 2 3000 6,000/-
Total: 64,000/-
Perquisites @ 20% on the total salary 12,800/-
Grand Total 76,800/-

(ii) Raw Material (Per month):

Sl. Qty. Rate Value

Item description
No. Unit (Rs.) (In Rs.)
1. Plastic winding cone 1500 kg 45/- 67,500/-

2. Lubricating oil 125 lit 180/- 22,500/-

Total: 90,000/-

(iii) Utilities: (Per Month)

1. Electricity 18,000/-
2. Water charges 2,000/-
Total: - 20,000/-
(iv) Other Contingent Expense (Per Month):
 1. Rent 10,000/-
2. Advertisement & Publicity 1,000/-
3. Postage & Stationery 500/-
4. Repair and maintenance 2,000/-
5. Transport /Traveling charges 1,000/-
6. Telephone Bills 800/-
7. Miscellaneous Expenses 700/-
Total: 16,000/-

(v) Total Recurring expenses (Per month):

i. Staff & Labour 76,800/-

ii. Raw Material 90,000/-
iii. Utilities 20,000/-
iv. Other contingent expenses 16,000/-
Total: 2,02,800/-

(C) TOTAL CAPITAL INVESTMENT:

1. Machinery & Equipment 5,60,000/-
2. Working Capital for 1½ months 3,04,200/-
Total: 8,64,200/-

(D) MEANS OF FINANCE:

Total Project Cost 8,64,200/-
Promoter contribution 1,04,200/-
Finance required from the Bank 7,60,000/-

12. INCOME ASSESSMENT:

(1) Cost of Production (Per Annum)

1. Recurring Expenses 22,80,000/-

2. Depreciation on Machinery @ 10% 50,000/-

Depreciation on Office Furniture &
3. 1,000/-
other fixed assets @ 20%
4. Interest on Total Investment @ 12% 1,03,704/-

Total: 24,34,704/-

Say 24,34,700/-

(2) Turn Over (per year) by Sales

Products Quantity Rate/Tone (Rs.) Value (Rs.)

18 tones
Cone winding 1,60,000/- 28,80,000/-
(plastic cones)

(3) Net Profit (per year)

Sales Value (-) Cost of Production

28,80,000/- (-) 24,34,700/- = Rs.4,45,300/-

(4) Net Profit Ratio:

Net profit X 100 4,45,300 X 100 = 15.46%

Turn Over/Annum 28,80,000

(5) Rate of Return on Investment:

(Net Profit/Total Capital Investment)

Annual Profit X 100 4,45,300 X 100 = 51.53%

Total Capital Investment 8,64,200

(6) Break Even Point/Analysis:

Fixed Cost (Per Annum):

1. Rent Rs. 1,20,000/-

2. Depreciation Rs. 51,000/-

3. Interest on Capital Investment Rs. 1,03,704/-

4. 40% of Wages of Staff & Labour Rs. 3,07,200/-

5. 40% of other contingent expenses Rs. 1,24,800/-

Total Fixed Cost: Rs. 7,06,704/-

Total Fixed Cost: (say) Rs. 7,06,700/-

Break Even Point:

Fixed Cost X 100 7,06,700/- X 100 = 61.35%

Fixed Cost + Annual Profit 7,06,700/- + 4,45,300/-
13. REPAYMENT SCHEDULE

Repayment of loan Rs.8.00 lakhs (Rs.7.60 lakh) will be repayable in 5

years with 60 instalments. The rate of interest has been calculated @ 12.5% per
annum however the rate of interest may vary while implementing the project.

(Rs. in lakhs)

Total Total
Year Months Principle Instalment Interest
Interest repayment

1 12 1.17 2.05 0.88 0.88 1.17

2 12 1.32 2.05 0.73 1.61 2.49

3 12 1.50 2.05 0.55 2.16 3.99

4 12 1.69 2.05 0.36 2.52 5.68

5 12 1.92 2.05 0.13 2.65 7.60