T-SHIRT MAKING BUSINESS

Executive Summary

Manufacturing of sportswear t-shirt under the category of readymade Garment industry. Readymade
garment industry has occupied a unique place in the industrial scenario of our country by generating
substantial export earnings and creating lot of employment. Its contribution to industrial production,
employment and export earnings are very significant. This industry provides one of the basic
necessities of life. The employment provided by it is a source of livelihood for millions of people. It
also provides maximum employment with minimum capital investment. Since this industry is highly
labour-intensive, it is ideally suited to Indian condition. This project report is prepared for the
manufacture of sportswear dry fit t-shirts as they find wide acceptance in local and international
markets.

The purpose of the project is to create a B-plan for for RAP (t-shirt manufacturing company)

The propose is to create yarn and fabric from the wastage of corn (corn husk)We will set up our
manufacturing unit in Andhra Pradesh as it is the biggest producers of corn in India. We will also be
able to benefit from these two states since they operate SEZ’s especially for uplifting textile sector in
India. The plan to create yarn and weave it into fabric and after some time starts exporting our product
as well. We have planned to create sport wear as well as casual t-shirts using the fabric. Our produce
is environment friendly and benefit the society in dealing with the wastages incurred during the
produce of corn. We plan to employ physically disabled for unskilled job work and for stitching. We
are targeting 20-40 years of age group having a disposable income of 40-60k per month.

Technical Aspects: Process of Manufacturing:

1) Making of Fabric: The propose is to create yarn and fabric from the wastage of corn (corn
husk) procured from the open market. The fabric will be made & then inspected by laying on
the inspection table against light before cutting so that unevenness in colour/shade or any
other fault, if any visible in the fabric are eliminated.

Process in manufacturing Fabric:

a) Retting: Retting is the process for separation of fibres from the husks, as it provides easy
observation and monitoring of corn husk during retting. Corn husks are washed
thoroughly to remove all dust and dirt particles deposited on the surface of corn husk.
Then all the husks were immersed in to water filled in a plastic tank. Due to its lower
density corn husks keeps floating on the water surface so one has to provide some dead
weight to plunge corn husks in to water. To avoid contamination from dirt and dust, the
tank was closed with lid and little air passage was provided. Approximately 20 litres of
water was used for retting process for 1 kg of cornhusks. Degradation of corn husks start
within a day, bacteria and other micro-organism start degrading the materials which act
as binder in the husk. This separates fibres from other materials. Day by day changes
taking place in corn husks were observed. When continues loss in tensile strength
observed retting process was stopped and remaining husks were washed thoroughly to
get it clean. Then these husks were dried to make it free from water.
 b) Fibre Separation: The 2nd step is fibre separation in which the dried corn husk,
still have some of binding material which is difficult to remove during retting. To
get individual fibers it is very important first to remove the extra binding
material. These rings were then fasted on mounting shaft with help of three
screws.Mounting shaft was constructed in such a manner that it facilities driving
pulley on one side of shaft itself.. Pedestals with ball bearing were used for
mounting of roller with the frame of machine. Now after setting up all necessary
parameter of opening roller, machine was run for actual production of individual
fibers. Open up fibers were collected from delivery side of the machine where
they fall from the surface of last roller. Dust from the husks falls beneath the
roller which was cleaned at regular interval. All dried husks were converted into
fiber by this procedure.

c) Yarn Production: The 3rd step is after obtaining opened and individualized fibers
the further focus was on converting fibers in to yarn.The fibres are rolled in to
Flyer twister where the fibres are rolled and then converted in to yarns.

2) Cutting and Stitching: The inspected fabric is placed on the cutting table in layers and then the
different parts of the respective t-shirts are demarked by a chalk as per different sizes. Cutting is
carried out by the cutting machine. Stitching is carried out for individual portion of the garments by
skilled workers with the help of over-lock, lock stitch machines etc.

3) Washing, Checking, Pressing and Packing: All t-shirts are charged into washing machine
containing mild detergent and washed for 4 hours in order to remove dirt and stains acquired during
the manufacturing process. After washing, the garments are hydro extracted to remove excess water
and after this, these garments are dried in tumbler dryer. Final checking is done before pressing and
packing on the checking table so that any fault in the piece may be removed and protruding threads
eliminated. The individual pieces are pressed by steam presses to remove any wrinkle marks and
packed in the carton boxes.

Opportunities in Industry

• With consumerism and disposable income on rise, the retail sector has experienced rapid
growth in past decade and the same trends are expected for the future.
• The organised apparel sector has a CAGR of 13% in last ten years.
• The Indian textile sector is set for strong growth, both through a strong domestic consumption
and export demand.
• The sector is expected to reach US $226 billion by FY2023.
• Population is expected to reach 1.34 billion by FY2019.
• India has received maize production equal to 26 Mn MT during 2018 and would require 45
Mn MT by the year 2022.
• As per demand estimates, the Indian Maize Production is expected to grow at a CAGR of
15% in next 4-5 years.