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COTTON TO READYMADE GARMENTS
Dr.R.B.CHAVAN
FORMER PROFESSOR, I I T DELHI
CONSULTANT
MAHATMA GANDHI INSTITUTE OF RURAL INDUSTRIALIZATION
WARDHA
COTTON CULTIVATION STATISICS
STATUS OF COTTON GROWING FARMERS AND COTTON USING INDUSTRIALISTS
ORGANIC AND NON-ORGANIC CULTIVATION
Non ORGANIC COTTON CULTIVATION
HIGHEST CONSUMPTION OF PESTICIDES (33%)
MOST EXPENSIVE CROP
HARMFUL TO SOIL
HARMFUL TO HUMAN LIFE AND OTHER LIVING ORGANISMS
ENVIRONMENT POLLUTION
ORGANIC
LESS EXPENSIVE
NON-HAZARDOUS TO SOIL, HUMAN LIFE, OTHER LIVING ORGANISMS
ENVIRONMENT FRIENDLY
NO EFFECT ON PHYSICAL AND CHEMICAL PROPERTIES OF COTTON FIBRE
LONG RELATION OF HUMAN BEING AND CLOTH
RIGHT FROM BIRTH TO DEATH
MODERN CIVILIZATION CAN NOT THINK OF LIVING WITHOUT CLOTHS EXCEPT JAIN MUNIs
WHEN A PERSON DIES EVERY THING IS RMOVED FROM HIS/HER BODY EXCEPT CLOTHES
PROBABLY FIRST FIBRE DISCOVED WAS COTTON
RECORDS INDICATE DISCOVERY OF COTTON FIBRE 8OOO YEARS B C
RECORDS AND MYTHOLOGY ALSO INDICATE THAT COTTON PLANT WAS DISCOVERED BY BRIHANMAD RISHI AT KALAMB A VILLAGE NEAR YEOTMAL
DIFFERENT FIBRES FOR CLOTH MAKING
NATURAL
COTTON
WOOL
SILK
SYNTHETIC
NYLON
POLYESTER
ACRYLIC
BLENDS OF NATURAL AND SYNTHETIC FIBRES
COTTON KING FIBRE
COTTON CONSIDERED TO BE KING FIBRE
SILK QUEEN FIBRE
COTTON
ROBUST TO DAY TO DAY WEARING
COMFORTABLE IN TROPICAL COUNTRY LIKE INDIA
CHEAP
ABUNDANT AVAILABILITY COMPARED TO WOOL AND SILK
BIODEGRADABLE
ENVIRONMENT FRIENDLY
UNFORTUNATE VIDARBHA FARMERS
LARGE SCALE CULTIVATION OF COTTON IN VIDARBHA
COTTON GROWING FARMERS ARE POOREST AND IN DEBT
PRONE TO SUICIDES BECAUSE OF DEBT DUE TO PURCHASE OF EXPENSIVE AND LARGE SCALE USE PETICIDES
MANY TIMES NO EXPENSES INCURRED ARE MORE THAN EARNING
IS IT POSSIBLE TO CHANGE THE EQUATION BETWEEN EXPENSES AND EARNING?
WAY OUT
CONVERT THE RAW COTTON INTO FINISHED PRODUCT LIKE
YARN
GREY FABRIC
FINSIHED FABRIC
READYMADE GARMENTS
PHASEWISE CONVERSION SUGGESTED
IT WILL BE INTERESTING TO UNDERSTAND HOW PROFIT MARGIN INCREASES AS ONE MOVES FROM RAW COTTON ►YARN ►GREY FABRIC ►FINISHED FABRIC ►GARMENTS
STEPS INVOLVED
PRE-SPINNING
SPINNING
PRE-WEAVING
WEAVING
CHEMICAL PROCESSING
GARMENT MAKING
STEPS INVOLVED
PRE-SPINNING
1. RAW COTTON
2. GINNING
3. BALE FORMATION
4. FIBRE OPENING
5. LAP MAKING
6. CARDING
7. SLIVER MAKING
8. ROVING MAKING
SPINNING
9. YARN
PRE-WEAVING
10. SIZING
11.LOOM PREPARATION
12. WEAVING
GREY FABRIC
CHEMICAL PROCESSING
13. DESIZING
14. SCOURING
15. BLEACHING
16. DYEING
17. PRINTING
18. FINISHING
19. GARMENT MAKING
CAPITAL INVESTMENT
ESTABLISHING A TEXTILE MILL
MOST CAPITAL AND LABOUR INTENSIVE
CAPITAL INVESTMENT FEW CRORES RUPEES
MOST EXPENSIVE PROPOSAL FOR MARGINAL FARMERS OR GROUP OF FARMERS
WAY OUT
CLUSTER ACTIVITY IN A GROUP
OF MINIMUM OF 10 FARMERS
EQUIPMENTS
MINI-SLIVER PLANT
AMBER CHARKHA
HANDLOOM
INVESTMENT
3-5 LAKH RUPEES
PHOTO
Ginning machine
Lap making machine Sliver making machine
Carding machine
VALUE ADDITION
RAW MATERIAL
COTTON WITH SEED COST Rs.3200 PER QUINTAL i.e. 100 Kg
COST PER Kg Rs.32
3 Kg COTTON WITH SEED = 1 Kg COTTON WITHOUT SEED
COST OF 1 KG GINNED COTTON = 32x3 = Rs.96
GINNING
COST OF GINNING Rs. 1.5 PER Kg
GINNING COST 1.5x3 = Rs. 4.5 PER Kg
COST OF COVERSION OF 1Kg OF GINNED COTTON TO 1 Kg ROVING = Rs.30
ASSUMPTION ALL OPERATIONS CARRIED OUT INHOUSE
NO TRANSPORTATION COST INVOLVED
COST OF CONVERSION OF 1 Kg ROVING INTO 1 Kg YARN = Rs.60
(30 HANKS OF 30s COUNT IN 1 Kg. Rs. 2 PER HANK SPINNING WAGES)
TOTAL COST OF CONVERSION OF 1 KG YARN
COST OF GINNED COTTON + GINNING COST + ROVING CONVERSION COST + YARN CONVERSION COST
Rs. 96 + 4.5 + 30 + 60 = 190.5 i.e 190
YARN SELLING COST Rs. 240 PER Kg.
PROFIT ON 1 Kg YARN Rs. 240 – 190 = 50
THIS MEANS PROFIT ON 3 Kg UNGINNED COTTON = Rs.50
PROFIT ON 1 Kg UNGINNED COTTON = 50/3 = 16
SALE PRICE OF UNGINNED COTTON 32 + 16 = 48
COST OF 1 QUINTAL COTTON INCREASE TO 48x100 = 4800
CONVERSION OF YARN TO GREY FABRIC
FROM 1 KG YARN IT IS POSSIBLE TO WEAVE 8 METERS OF GREY FABRIC
WEAVING CHARGES
Rs. 10 PER METER
CHARGES FOR WEAVING 8 METER FABRIC 10x8 = Rs.80
SELLING COST OF GREY FABRIC Rs. 50 PER METER
TOTAL COST OF FABRIC 8x50 = Rs 400
PROFIT ON 8 METER FABRIC
SELLING COST OF GREY FABRIC – (YARN CONVERSION COST + FABRIC CONVERSION COST)
400 – (190+80) = 130
PROFIT ON 3 Kg UNGINNED COTTON = Rs.130
PROFIT ON 1 Kg UNGINNED COTTON = 130/3 = 43
SALE PRICE OF 1Kg COTTON AFTER CONVERSION TO GREY FABRIC 32 + 43 = 75
SALE PRICE OF 1 QUINTAL COTTON 75x100 = 7500
CONVERSION OF GREY FABRIC TO FINISHED WHITE FABRIC
COST OF DESIZING, SCOURING AND BLEACHING Rs. 5 PER METER
TOTAL PROCESSING COST 8x5 = 40
SELLING PRICE OF WHITE FINISHED FABRIC Rs. 70 PER METER
PRICE OF 8 METERS WHITE FABRIC 70x8 = Rs 560
PROFIT ON WHITE FABRIC 560 – 40 = 520
COST OF 3 Kg UNGINNED COTTON = Rs.520
COST OF 1 Kg UNGINNED COTTON 520/3 = Rs. 173
SELL PRICE OF 1 Kg UNGINNED COTTON 32 + 173 = 205
SELL PRICE OF 1 QUINTAL COTTON = Rs.20,500
CONVERSION OF WHITE FABRIC TO GARMENTS
FROM 8 METERS FABRIC ONE CAN STITCH 4 HALF SHIRTS
STITCHING CHARGES Rs. 70 PER GARMENT
STITCHING CHARGES OF 4 GARMENTS = 4x60 = Rs.240
SELLING PRICE OF EACH GARMENT Rs. 225
TOTAL SELLING PRICE 225x4 = 900
PROFIT ON 4 GARMENTS 900 – 240 = Rs.660
PRICE OF 3 Kg. UNGINNED COTTON INCREASED TO RS. 660
PRICE OF 1 Kg UNGINNED COTTON 660/3 = 220
SELL PRICE OF 1 Kg. COTTON BECOMES 32 + 220 = 252
SELL PRICE OF 1 QUINTAL COTTON 252x100 = 25200
PRICE APPRECIATION SUMMARY
SELLING PRICE PER QUINTAL (Rs.)
RAW COTTON 3200
YARN 4800
GREY FABRIC 7500
WHITE FABRIC 20,500
GARMENT 25,200
PROFIT MARGIN
THE PROFIT MARGIN SHOWN AS GUIDELINE
THERE IS LIKELY TO BE VARIATION DEPENDING ON VARIOUS FACTORS
ONE THING IS CERTAIN
CONSIDERABLE VALUE ADDITION AS ONE MOVES FROM
RAW COTTON
YARN
GREY FABRIC
FINISHED FABRIC
GARMENTS
ORGANIC COTTON WILL HAVE BETTER PROFIT MARGIN COMPARED TO NON-ORGANIC COTTON
NO DOUBT ALL BIG BUSINESSMEN IN INDIA LIKE TATA, BIRLA, AMBANI ETC BUILD UP THEIR EMPIRE STARTING FROM TEXTILE BUSINESS
THE FARMERS CAN ALSO DREAM OF BECOMING TATA, BIRLA, AMBANI
YOU HAVE TO HAVE HIGH DREAMS AND GET TOGETHER, PLAN AND WORK HARD TO CONVERT THE DREAM INTO REALITY
MGIRI’S ROLE
KHADI GROUP AT MGIRI IS VERY ACTIVE IN PROVIDING TECHNICAL SUPPORT TO FARMERS
PLANNED TO DESIGN AND FABRICATE LOW COST PRE-SPINNING MACHINES FOR SMALL SCALE PRODUCTION 20 Kg YARN PER DAY
COST OF SUCH DOWSIZED MACHINES WILL BE IN THE RANGE OF Rs. 2-3 LAKH AGAINST FEW CRORES FOR LARGE SCALE MACHINES
THIS PRODUCTION CAPACITY USES THE MAH’ATMA GANDHI’S PRINCIPLE OF PRODUCTION BY MASSES
FARMERS IN A GROUP OF 10 CAN DO YARN AND FABRIC PRODUCTION IN THE FORM OF CLUSTER
IT IS STRONGLY BELIEVED THAT SUCH A EXPERIMENT BASED ON GANDHIAN PHILOSOPHY WILL GO A LONG WAY FOR THE BENEFIT OF FARMERS AND WILL PROVIDE A TECHNOLOGY SOLUTION TO SUICIDE PRONE FARMERS.
REMEMBERING GANDHI
WHEN ONE TALKS OF SMALL SCALE PRODUCTION IT IS OBVIOUS TO REMEMBER GANDHI
MAHATMA GANDHI STARTED HIS FREEDOM STRUGGLE PROPAGATING THE PRODUCTION OF KHADI
THEREFORE KHADI SYMBOLISES THE FABRIC OF FREEDOM STRUGGLE
GANDHI FIRM BELIEVED AND WAS CONVINCED THAT SMALL SCALE MANUFCTURING BASED ON THE PRINCIPLE OF PRODUCTION BY MASSES IS THE ONLY WAY TO FIGHT WITH THE EVIL OF UNEMPLOYMENT AND THE MISERABLE PLIGHT OF FARMERS AND VILLAGES IN GENERAL
I
KHADI A FABRIC FOR EMPLOYMENT GENERATION
KHADI MANUFACTURING INVOLVES LONG CHAIN OF PROCESSES
MOST IMPORTANT ACTIVITY FOR EMPLOYMENT GENERATION
GANDHI DREAMT THAT EVERY HOUSE SHOULD BECOME A TEXTILE MILL
THE DOWN SIZED TECHNOLOGY DEVELOPED AT MGIRI CAN HELP TO FULFILL THE DREAM OF GANDHI
GANDHI ALSO BELIEVED THAT KHADI IS PHILOSOPHY AND NOT A COMMERCIAL FABRIC
HE USE TO SAY
EVERY REVOLUTION OF CHARKHA SPINS LOVE AND PEACE
TIME IS OPPRTUNE TO REVOLVE CHARKHA TO BRING CHEERS ON THE FACE OF FARMERS AND LOVE AND PEACE IN THIR FAMILIES.
NEED OF COLLECTIVE EFFORTS
TO FULFILL MAHATMA GANDHI’S DREAM THERE IS NEED FOR COLLECTIVE EFFORTS, HARD WORK WITH PATIENCE.
FARMERS ARE BORN WITH THE QUALITY OF HARD WORK AND PATIENCE
WHAT IS NEEDED IS THE NEED OF COLLECTIVE EFFORTS
IT IS HOPED THAT FARMERS WILL MAKE USE OF GOLDEN OPPORTUNITY OF COMING TOGETHER PALN TO WORK UPLIFTING THEMSELVES
MGIRI WILL PROVIDE ALL POSSIBLE TECHNICAL SUPPORT IN THIS ENDEAVOR