Detailed Project Report on NON WOVEN CARPET [NEEDLE PUNCHED] AND PAINTED NON WOVEN CARPETS

Nonwovens are not made by weaving or knitting and do not require converting the fibres to yarn. Nonwoven fabrics are engineered fabrics that may be single-use disposable or a very durable fabric. They are used in numerous applications, including; baby diapers, adult incontinence products, wet wipes, surgical drapes and covers, liquid cartridge and bag filters, face masks, air-conditioning filters,soil stabilizers and roadway underlayment, erosion control, drainage systems, insulation (fiberglass batting), pillows, cushions, and upholstery padding,carpet backing, automotive headliners and upholstery, house wraps, anddisposable clothing (foot coverings, coveralls).

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



NON WOVEN CARPET [NEEDLE PUNCHED] AND
PAINTED NON WOVEN CARPETS
[EIRI/EDPR/4731] J.C.: 2951XL

Nonwovens are not made by weaving or knitting and do not require converting the
fibres to yarn. Nonwoven fabrics are engineered fabrics that may be single-use
disposable or a very durable fabric. They are used in numerous applications,
including; baby diapers, adult incontinence products, wet wipes, surgical drapes
and covers, liquid cartridge and bag filters, face masks, air-conditioning filters,soil
stabilizers and roadway underlayment, erosion control, drainage systems,
insulation (fiberglass batting), pillows, cushions, and upholstery padding,carpet
backing, automotive headliners and upholstery, house wraps, anddisposable
clothing (foot coverings, coveralls).

The characteristics of the fibrous web are a key determinant of the physical
properties of the final product. The choice of methods for forming webs is
determined by fibre length. Initially, the methods for the formation of webs from
staple-length fibres were based on the textile carding process, whereas web
formation from short fibres was based on a wet laid process similar papermaking.
These technologies are still in use, but methods based forming a web directly from
filaments immediately they exit an extruder (Spun laid) have also been developed.

Fibrous webs have little mechanical strength and a further manufacturing process
is necessary to form a fabric with useful properties. There are number of
processes which are used to accomplish this as described in next section.

Needle punching is a process of bonding nonwoven web structures mechanically
interlocking the fibers through the web. Barbed needles, mounted on a board,
punch fibers into the web and then are withdrawn leaving fibers entangled. The
needles are spaced in a non-aligned arrangement are designed to release the fiber
as the needle board is withdrawn.

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CONTENTS

INTRODUCTION

WEB FORMATION

WEB BONDING

B.I.S. SPECIFICATION

FOR MORE INFORMATION CONTACT AT:

MARKET OVERVIEW OF NON WOVEN CARPET

MANUFACTURERS/EXPORTERS OF CARPETS

MANUFACTURING PROCESS OF NEEDLE PUNCHED CARPET

CARDING

CROSSLAPPING

NEEDLING

FINISHING

PADDING AND SECURING

QUALITY ASSURANCE

TIPS FOR PUTTING IN CARPET WITH NEEDLE PUNCHING

PREPARE THE SUBFLOOR:

MEASURE THE SPACE:

CUT THE CARPET:

TACK STRIPS:

CARPET LAYING:

TRIM THE EXTRA CARPET:

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PUT THE TRANSITION STRIPS IN PLACE:

CARPET CLEANING:

NEEDLE PUNCHING MACHINE

NEEDLE PUNCHED

THE MAIN COMPONENTS OF A BASIC FELT TATTOO NEEDLE ARE AS
FOLLOWS:

MACHINE TRANSFORMATION:

PROCESS FLOW DIAGRAM

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

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2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

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7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

SUPPLIERS OF RAW MATERIALS

ADDRESSES OF PLANT AND MACHINERIES SUPPLIERS



APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

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11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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COST ESTIMATION

Plant Capacity 16,000 sq.mt./Day

Land & Building (8000 sq.mt.) Rs. 4.30 Cr

Plant & Machinery Rs. 6.00 Cr

Working Capital for 1 Month Rs. 3.24 Cr

Total Capital Investment Rs. 14.32 Cr

Rate of Return 27%

Break Even Point 54%