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Chapter 7
Towel Manufacturing 7.1 Introduction The primary function of a terry towel is to absorb moisture from wet skin. It must,
however, be strong enough to withstand the strain of rubbing and pulling, twisting
and tugging of the user, and of constant laundering. Terry towels are made
either of all-cotton or a combination of cotton and polyester. While polyester
provides increased strength, lighter weight, faster drying after laundering, and
less shrinkage, all-cotton towels provide greater absorbency.
7.2 Manufacturing Process
Doubling Bobin (Weft) Warping / sizing
Plain Weave
Cutting & Stitching
Jacquard Weave
Bleaching Dyeing
Sheering
Printing
Bleaching
Sheering
Finishing/ Packing Ready To Export
Yarn
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The various stages of manufacturing of towel are indicated in the previous flow
chart. The weaving and processing stages of this chart are the same as
discussed in chapter No. 3 and 4. However, these processes are illustrated in
the subsequent figures.
Warping
3
Twisting / Doubling
Bobbing
4
Weaving
Bleaching
5
Dying
Shearing at grey stage
6
Shearing / Polishing after bleaching
7.2 General Types/Categories Of Towels
Towels can be defined in 4 types (i) Plain White Towel (ii) Plain Dyed Towel
(iii) Plain white Jacquard Towel (iv) Partly dyed Jacquard towel. The towels
can also be as per their use i.e. face towel, hand towel, bath towel, beach
towel etc.
7.3 Categories Of Raw Material Used
In the manufacturing of terry towels following raw materials are used;
i. Basic raw materials are cotton / blended / pc yarn of different counts.e.g.
10/s, 20/s, 16/s, 30/s etc.
ii. Starch / PVA are used for sizing.
iii. Chemicals used for bleaching & dyeing are Soap, Caustic soda,
Hydrogen peroxide, Antioxidant, Hypochlorite, Soda Ash, Acetic Acid,
Optical brightner and Softener. In addition for dyeing of towels we
require dyes, Sequestering Agent, Soda Ash, Acetic Acid, Salt &
Softener.
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7.4 Average Conversion Charges Of General Types Of Towels It is difficult to determine conversion charges of different types of towels as it
depend upon their quality. However, normally for medium size & medium
weight towel, conversion charges ranges from Rs.3 per Kg to Rs.8 per Kg.
7.5 Input / Output Ratio
The input output ratio depends upon types of production. Please see the
following chart.
Description Yarn (Kg)
input Fabrics (Kg) Output
Loss (Kg)
White / Dyed Towel 100 80 20 Note: If shearing process is used, add further wastage of 20%.
7.6 Element Of Value Addition At Each Stage
7.6.1 Bleach Towel
S.No. Description Value addition (100 Kg)
%age value
addition 1 Cost of Yarn 7,500
2 Cost of grey towelling
fabrics+wastages
9,750 30%
3 Cost of bleach towelling
fabrics+wastage
11,700 20%
4 Cutting , Stitiching & Packing 12,300 05%
7.6.2 Dyed Towel
S.No. Description Value addition (100 Kg)
%age value
addition 1 Cost of Yarn 7,500
2 Cost of grey towelling 9,750 30%
8
fabrics+wastages
3 Cost of Bleach towelling
fabrics+wastage
11,200 15%
4 Cost of Dyed towelling
fabrics+wastage
12,900 15%
5 Cutting , Stitiching & Packing 13,600 05%
7.6.3 Sheared Towel Bleached
S.No. Description Value addition (100 Kg)
%age value
addition 1 Cost of Yarn 7,500
2 Cost of grey towelling
fabrics+wastages
9,750 30%
3 Cost of Bleach towelling
fabrics+wastage
11,700 20%
4 Cost of Shearing 15,200 30%
4 Cutting , Stitiching & Packing 16,000 05%
7.6.4 Sheared Towel Dyed
S.No. Description Value addition (100 Kg)
%age value
addition 1 Cost of Yarn 7,500
2 Cost of grey towelling
fabrics+wastages
9,750 30%
3 Cost of Bleach towelling
fabrics+wastage
11,200 15%
4 Cost of Dyed toweling
fabrics+wastage
12,900 15%
4 Cost of Shearing 16,800 30%
4 Cutting , Stitiching & Packing 17,700 05%
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7.7 Stage-wise Wastage S.No
. Process Description Wastage
invisible Wastage Visible
1 Yarn Warping / Sizing 1.50% -
2 Yarn Twisting / Doubling 1.00% -
3 Weaving 3.00% -
4 Bleaching / Dying 8.50% -
5 Stitching - 3.00%
6 Cutting - 3.00%
TOTAL 14.00% 6.00%
Notes:
a) If sheering process is used, add another 20% wastage.
b) B grade is 5 to 30% of A grade.
c) B grade is sold between Rs.20/- to Rs.25/- per kg.
d) Wastage of cutting is used for preparation of rags etc.
e) Rags are sold between Rs.10/- to Rs.15/- per kg.
7.9 Relationship Of Energy (Electricity Or Gas) With Production
S.No. Description Cost of Electric Cost of Gas 1 Warping/Doubling/Weaving Rs.5 / Kg Nil
2 Bleaching/Dyeing Rs.1/ Kg Rs.1.5/Kg
3 Shearing Rs.1/Kg Nil
