PROJECT

REPORT

SILK REELING AND TWISTING UNIT

G MUNIRATNAM
33-127/5-1, Gadduru road
Palamaner, Chittoor
Andhra Pradesh – 517408
+91-9492662740
Introduction

Silk reeling is the process by which a number of cocoon baves are reeled together to produce a
single thread. This is achieved by unwinding filaments collectively from a group of cooked
cocoons at one end in a warm water bath and winding the resultant thread onto a fast moving
reel. Raw silk reeling may be classified by direct reeling method on a standard sized reel,
indirect method of reeling on small reels, and the transfer of reeled silk from small reels onto
standard sized reels on a re-reeling machine. The last technique is primarily applied in modern
silk reeling processes.

Various silk reeling devices

There are many types of silk reeling machines in use. The major structural features of the
Sitting Type Reeling Machine, the Multi-ends Reeling Machine and the Automatic Reeling
Machine are shown in Table 20.

1. Hand spinning wheel

This primitive spinning apparatus is operated by two hands – one to drive the wheel and the
other to feed in cocoons. One end of the reeling thread is wound onto each wheel, while
cocoons are boiled in a separate pot.

2. Charka type reeling machine

The Charka type is in use in India. This machine is operated with separate work motions in reel
driving and cocoon feeding to reeling ends by two men per machine. Each machine has 3 ends
or more to a reel, which is the same size as the large wheel of the Re-reeling machine in order
to save the re-reeling process (direct reeling method).

3. Sitting type reeling machine

There are two kinds of sitting type reeling machines, foot operated and motor-driven (see
Appendix, Figure 17). The motor-driven reeling machine is not equipped with the stop motion
attachment (see appendix, Figure 18). There are obstacles to the production of good quality raw
silk as the raw silk thread is wound too rapidly to maintain good quality control.

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Comparisons of structural features of various reeling machines

Kinds of machine Sitting type Multi-ends Automatic reeling

reeling (m/c) reeling (m/c) (m/c)

No. of reeling ends per basin 4 (2 to 8) 20 (10 to 40) 20

End-groping apparatus Hand-driven Semi-automatic Automatic

End-picking apparatus Hand-driven Hand-driven Automatic

Cocoon supplying apparatus None None Equipped

End-feeding apparatus None Equipped (hand Equipped

feeding) (machine feeding)

Stop motion None Equipped Equipped

Traverse guider Equipped Equipped Equipped

Temperature of reeling bath 65-80 C 30-45 C 30-45 C

Reeling velocity (meter per 180-250 50-80 120-200

minute)

Brushing and picking section

An automatic ten-brush unit brushes cocoons with independent arms rotating in reverse motion
on an axis in circular basins.

Picking frames rotating in one direction pick off the brushed cocoon filaments when a cam
during the operation raises the brushes. Selective picking is completed in the most effective
manner by this equipment. To maintain the exact number of cocoons at each reeling end, a
control device is attached which detects the amount of cocoons in the cocoon suppliers and
automatically supplements deficiencies in the number of cocoons.

2. Reeling section

In these devices, the yarn constantly passes through the denier indicator and detector, which are
set to a given size. The size of thread being reeled is detected through the balance between the
friction of the running thread and an eccentric weight fitted on the denier indicator.

The velocity of cocoon reeling affects the raw silk yield, reeling efficiency and raw silk quality
(see Table 21 and 22). Optimum reeling velocity should be maintained for the best possible
product.

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b) Groping ends

The high water temperature of the groping ends section dissolves sericin to a great extent and
improves the reelability of the cocoon. However, it is apt to reduce raw silk percentage of the
cocoon. Alternatively, too low water temperature in this process can reduce the groping end
efficiency, the reelability percentage and the reeling efficiency.

When the thread becomes thinner than the fixed limit, the denier indicator indicates the
necessity of feeding-ends. This indicator is composed of two gauge glass plates with other
pieces of gauge plate which have a slit between them corresponding to the given size of thread
to be reeled. The size of yarn may be adjusted to the required sizes by varying the irregular
weight with the denier-adjusting device; if a wider range of adjustment is required the denier
indicators have to be replaced.

Conveyor system for cocoon suppliers

The fixed end feeding system is employed together with a conveyor system to carry cocoon
supplies and feed cocoons to the reeling section whenever required.

End feeding for cocoons suppliers

Cocoons are supplied to the conveyor, which rotates constantly around the reeling section. The
feeding lever fixed to the detecting mechanism will trigger the driving lever on the cocoon
supplier only when the size of yarn becomes thinner than the required denier during reeling
operation.

Stop motion

If there is a defect in the reeling, the reel is automatically stopped by a brake, which is activated
by contact pressure from operation of the detector level.

Dropped cocoon gatherers

The apparatus gathers baskets that have collected all cocoons dropped during end feeding.
These are carried to the dropped cocoon separator. These baskets travel intermittently between
the cocoon suppliers.

Separator of dropped cocoons

The device accurately distinguishes and separates pupae, dropped middle layer cocoons and
thick layer dropped cocoons.

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6. Semi-automatic reeling machine

This is a mixed-mode or hybrid machine between the automatic and multi-ends reeling
machines. As an application, this type is better for improved reeling efficiency and raw silk
quality than the multi-ends reeling machine. The semi automatic reeling machine can be
operated with poor quality cocoons, but relies on more labour than the automatic reeling
machine.

The cooked cocoons are carried into the groping end part (10) and the end-groped cocoons are
removed to the picking end part (11). The correctly picked end cocoons go through the cocoon
supplying basket (9) and then to the arranging basin (8). When the size detector of the reeling
thread indicates the feeding motion, the picked end cocoons on standby are fed to the reeling
thread by a feeding spoon. The reeling thread passes through the jetboute, silk button, first
guider, second guider, third guider, fourth guider, size detector, fifth guider and traverse guide,
and then it is finally wound onto small reels (4) (Figure 16).

The end dropped cocoons are collected by the cocoon buckets (13) and removed to the cropped
cocoon basin, where more reelable cocoons are separated and then poured into the groping end
part (10). The principal difference between a semi-automatic reeling machine and an automatic
reeling machine is that the cocoon end groping, cocoon end picking and cocoon carrying are
manual.

6.3 Methods of silk reeling

a) Reeling velocity (R.V.)

Reeling velocity is defined as the winding speed of raw silk on the reel. The reeling velocity is
measured as the length of raw silk reeled during 1 minute or as the revolution number of the
reel per minute. It is usually calculated by the following formulas.

Where formula (1) applies to the automatic type, formula (2) applies to the multi-ends type.

Number of end feeding : Automatic type - 1.2-1.5 pc/min./reel

Multi-ends type - 12-14 pc/min./man
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None breaking reelable bave = length of cocoon filament (m)
x cocoon reelability (percent)

Effect of various reeling velocities on silk yield and quality with different grades of
reelability cocoon (Choe, et al. 1971)

Cocoon Reeling Raw silk Percentage Raw silk quality

reelability velocity percent of of cocoon
(m/min.) cocoon reelability Neatness Cleanness
(%) (%)

Good 90 16.87 72 96.2 96.8

Group
120 16.80 71 95.2 96.8

150 16.73 71 93.4 94.5

Fair
Group 90 16.36 58 91.9 93.7

120 16.32 57 90.9 93.8

Poor 150 16.21 55 90.5 93.0

Group
90 16.17 50 91.0 92.3

120 16.07 49 89.5 90.8

150 15.70 46 89.0 90.6

Relationship between reeling velocity and evenness of raw silk quality (S.
Kimura, et al. 1964)

Reeling velocity (m/min.) Average evenness (%) Low evenness (5)

50 93.5 86.0

80 98.0 82.0

110 88.5 80.2

140 87.3 80.0

170 85.5 78.4

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Quality control during raw silk reeling

The purpose of reeling process is not only to raise the raw silk yield of cocoons and reeling
efficiency, but also to improve raw silk quality.

a. Size development and evenness - To maintain reeling thread in the required size, the
average cocoon number per thread must be adjusted by a check to produce silk thread in
the same size throughout all ends during reeling. If the size is different from the required
size it should be readjusted by the group size controller. This will reduce size deviation.
By improving the accuracy of cocoon supplying each silk thread becomes uniform in
size and different skein sizes are reduced. It can also improve the size deviation and
evenness of raw silk quality through accuracy of cocoon supplying work and the
improvement of cocoon reelability.
b. Defects – Defects in raw silk are divided into super major defects, major defects and
neatness defects. Defects occur based on reeling conditions. Types of defects and
remedies are explained in Table 23.
c. Cohesion – Good cohesion raw silk is needed for the warp of silk fabric. Factors that
improve the cohesion are temperature, amount of reeling tension, sufficient croissure
and good drying of raw silk.
d. Colour – The water consistency and temperature of groping end part and reeling part
affect the colour of raw silk. Therefore, the temperature control and water supply in the
reeling machine should be constantly monitored to obtain a uniform colour of raw silk.

Prevention method against various types of cleanness defects

Types of defects Prevention methods

Waste 1. Control of over or uneven cooking.

2. Prevention of carry over cocoons by remaining in
basins during reeling process.
3. Reducing the number of standby cocoons in the
reeling basin.
4. Preventing the over swelling of cooked cocoons in the
reeling process by controlling the temperature of grope
end and picking end bath as well as maintaining a
constant temperatur

1. To 4) are same as above.

2. Avoid low temperature cocoon drying
Large slug 3. Controlling the excessive increase of reeling speed and
reeling thread

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 Bad casts 1. Keep the extra end of cocoon filament short when the
correct end picked cocoons are fed to the reeling
thread.

Long knots 1. When the broken thread are tied and knotted during
the reeling or re-reeling process, the end of the tied
and knotted thread must be cut off, leaving only 2 mm.

1. When the reeler has to eliminate a reeled out or bad

cocoon during reeling, he should not use force to pull
Cork screws it out but should snip it out with his fingers as quickly
as possible.

Split ends 1. Reduce friction effect on silk thread. Pulleys with

cracks and splits on the surface should be removed.
All pulleys should be perfectly polished to reduce split
ends in the reeled yarn.

Long loops 1. Prevention of over or uneven cooking.

COST OF PROJECT

A. Fixed Capital Investment

a. Land : 339 SQM Own

b. Workshed Area Sq.ft Rate in Rs. Amt. In Rs.

LAND 339 850.00 288150.00
BUILDING 150 5000.00 750000.00
STORAGE 100 3000.00 300000.00
Shelters & Parking 40 2000.00 80000.00
SPACE FOR GREENARY 57 500.00 28500.00
Total 1446650.00

C. Machinery Qty. Rate Amount in Rs.

REELING MACHINE 1 950000.00 950000.00
DRYER AND HEATER 1 4000.00 4000.00
SILK THREAD TWISTING MACHINE 1 500000.00 500000.00
Total 1454000.00

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d. Preliminary & Pre-operative Cost : Rs. 150000.00

e. Furniture & Fixtures : Rs. 30000.00

f. Contingency/Others/Miscellaneous Rs. 20000.00

Total Capital Expenditure : Rs. 3100650.00

Working Capital : Rs. 394650.00

Total Cost Project : Rs. 3495300.00

Means of Financing :

Own Contribution 5% Rs. 174765.00

Bank Finance : 95%

Term Loan Rs. 2945618.00

Working Capital Rs. 374918.00

Total Rs. 3320536.00

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 WORKING CAPITAL
STATEMENT SHOWING THE REPAYMENT OF TERM LOAN & WORKING CAPITAL :
TERM LOAN

Opening Closing Interest @

Year Installment
Balance Balance 13.00%
1st 2945618 0 2945618 382930
2nd 2945618 589124 2356494 382930
3rd 2356494 589124 1767371 306344
4th 1767371 589124 1178247 229758
5th 1178247 589124 589124 153172
6th 589124 589124 0 76586

Opening Closing Interest @

Year Installment
Balance Balance 13.00%
1st 374918 0 374918 48739
2nd 374918 74984 299934 48739
3rd 299934 74984 224951 38991
4th 224951 74984 149967 29244
5th 149967 74984 74984 19496
6th 74984 74984 0 9748

STATEMENT SHOWING THE DEPRECIATION ON FIXED ASSETS:

WORKSHED @ 5.00%
Particulars 1st Year 2nd Year 3rd Year 4th Year 5th Year
Opening Balance 1446650 1374318 1305602 1240322 1178305
Depreciation 72333 68716 65280 62016 58915
Closing Balance 1374318 1305602 1240322 1178305 1119390
MACHINERY @ 10.00%
Opening Balance 1454000 1308600 1177740 1059966 953969
Depreciation 145400 130860 117774 105997 95397
Closing Balance 1308600 1177740 1059966 953969 858572
TOTAL DEPRECIATION
Workshed 72333 68716 65280 62016 58915
Machinery 145400 130860 117774 105997 95397
Total 217733 199576 183054 168013 154312

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Schedule of Sales Realization :
Details of Sales

Rate/ No. of Amount in Rs.

Particulars of Product
Pair/Unit Pair/Unit

EXTRACTED AND REELED SILK 800.00 5000 4000000.00

Total 4000000.00

Capacity Utilization of Sales

3rd
Particulars 1st Year 2nd Year Year 4th Year 5th Year

Capacity Utilization 70% 80% 90% 90% 90%

Sales / Receipts 2800000 3200000 3600000 3600000 3600000

Rawmaterials :

Particulars Unit Rate/unit Reqd.Unit Amount in Rs.

COCOONS KGS 350.00 500 175000.00
CASES Nos 500.00 15 7500.00
Total 182500.00

Wages
:
No. of Wages Amount in Rs.
Particulars
Worker Per Month (Per Annum)
WORKERS 9 5000.00 540000.00
Superviser 2 7000.00 168000.00
Total 11 708000.00

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Repairs and Maintenance : Rs. 30000.00

Power and Fuel : Rs. 15000.00

Other Overhead Expenses : Rs. 15000.00

Administrative Expenses :

Salary
Accounts & Stores 1 8000.00 96000.00
Master 1 9000.00 108000.00
Manager 1 12000.00 144000.00
0 0.00 0.00
0 0.00 0.00
Total 3 348000.00

Telephone Expenses 5000.00

Stationery & Postage 5000.00

Advertisement & Publicity 30000.00

Workshed Rent 0.00

Other Miscellaneous Expenses 50000.00

Total 438000.00

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Capacity Utilization of Manufacturing & Administrative Expenses :

3rd 4th
Particulars 1st Year 2nd Year Year Year 5th Year
Capacity Utilization 70% 80% 90% 90% 90%
Manufacturing Expenses
Rawmaterials 127750 146000 164250 164250 164250
Wages 495600 566400 637200 637200 637200
Repairs & Maintenance 21000 24000 27000 27000 27000
Power & Fuel 10500 12000 13500 13500 13500
Other Overhead Expenses 10500 12000 13500 13500 13500
Administrative Expenses
Salary 348000 348000 348000 348000 348000
Postage Telephone Expenses 3500 4000 4500 4500 4500
Stationery & Postage 3500 4000 4500 4500 4500
Advertisement & Publicity 21000 24000 27000 27000 27000
Workshed Rent 0 0 0 0 0
Other Miscellaneous Expenses 35000 40000 45000 45000 45000
Total: 1076350 1180400 1284450 1284450 1284450

Assessment of Working Capital :

Particulars Amount in Rs.
Sale 4000000.00

Manufacturing Expenses
Raw Material 182500.00
Wages 708000.00
Repair & Maintenance 30000.00
Power & Fuel 15000.00
Other Overhead Expenses 15000.00
Production Cost 950500.00
Administrative Cost 438000.00
Manufacturing Cost 1388500.00

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Working Capital Estimate :

Element of Working No of
Capital Days Basis Amount in Rs.
0 0 Material Cost 0.00

Stock in process 15 Production Cost 47525.00

Finished goods 30 Manufacturing Cost 138850.00

Receivable by 45 Manufacturing Cost 208275.00

Total Working Capital Requirement Per Cycle 394650.00

Financial Analysis
Projected Profit & Loss Account :
0 2nd
Particulars Year 1st Year Year 3rd Year 4th Year
Sales / Receipts 2800000 3200000 3600000 3600000
2800000 3200000 3600000 3600000
Manufacturing Expenses
Rawmaterials 127750 146000 164250 164250
Wages 495600 566400 637200 637200
Repairs & Maintenance 21000 24000 27000 27000
Power & Fuel 10500 12000 13500 13500
Other Overhead Expenses 10500 12000 13500 13500
Depreciation 217733 199576 183054 168013
Production Cost 883083 959976 1038504 1023463
Administrative Expenses
Salary 348000 365400 383670 402854
Postage Telephone Expenses 3500 4000 4500 4500
Stationery & Postage 3500 4000 4500 4500
Advertisement & Publicity 21000 24000 27000 27000
Workshed Rent 0 0 0 0
Other Miscellaneous Expenses 35000 40000 45000 45000
Administrative Cost 411000 437400 464670 483854
Interest on Bank credit @ 13%
Term Loan 382930 382930 306344 229758
Working Capital Loan 48739 48739 38991 29244
Cost of Sale 1725752 1829046 1848510 1766318
Net Profit Before Tax 1074248 1370954 1751490 1833682
Less Tax 0.00 0.00 0.00 0.00
Net Profit 1074248 1370954 1751490 1833682
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CALCULATION OF DEBT SERVICE CREDIT RATIO (D.S.C.R) :

Particulars 0 Year 1st Year 2nd Year 3rd Year 4th Year
Net Profit 1074248 1370954 1751490 1833682
Add :
Depreciation 217733 199576 183054 168013
TOTAL - A 1291980 1570530 1934544 2001694
Payments :
On Term Loan :
Interest 382930 382930 306344 229758
Installment 0 589124 589124 589124
On Working Capital
Interest 48739 48739 38991 29244
TOTAL - B 431670 1020793 934459 848125
D.S.C.R = A/B
2.99 1.54 2.07 2.36
Average D.S.C.R

PROJECTED BALANCE SHEET :

0
Particulars Year 1st Year 2nd Year 3rd Year 4th Year
LIABILITIES :
Promoters Capital 174765 174765 174765 174765
Profit 1074248 1370954 1751490 1833682
Term Loan 2945618 2945618 2356494 1767371
Working Capital Loan 374918 374918 299934 224951
Current Liabilities 0 0 0 0
Sundry Creditors 0 0 0 0
4569549 4866255 4582684 4000768
ASSETS :
Gross Fixed Assets : 2930650 2712918 2513342 2330288
Less : Depreciation 217733 199576 183054 168013
Net Fixed Assets 2712918 2513342 2330288 2162275
Preliminary & Pre-Op. Expenses 150000 112500 84375 63281
Current Assets 374918 374918 299934 224951
Cash in Bank/Hand 1481713 1977996 1952462 1613542
Total 4569549 4866255 4582684 4000768

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CASH FLOW STATEMENT :
Particulars 0 Year 1st Year 2nd Year 3rd Year 4th Year
Net Profit 1074248 1370954 1751490 1833682
Add : Depreciation 217733 199576 183054 168013
Term Loan 2945618 2945618 2356494 1767371
Working Capital Loan 374918 374918 299934 224951
Promoters Capital 174765 0 0 0
Total 4787281 4891066 4590973 3994016

Total Fixed Capital Invested 3100650

Repayment of Term Loan 0 589124 589124 589124

Repayment of WC Loan 0 74984 74984 74984
Current Assets 374918 374918 299934 224951
Total 374918 1039025 964042 889058

Opening Balance 0 4412363 8264404 11891336

Surplus 4412363 3852041 3626931 3104958
Closing Balance 4412363 8264404 11891336 14996294

BREAK EVEN POINT AND RATIO ANALYSIS :

Particulars 0 Year 1st Year 2nd Year 3rd Year 4th Year
Fixed Cost 1011663 1019906 954068 881625
Variable Cost 931822 1008715 1077496 1052706
Total Cost 1943485 2028621 2031564 1934331

Sales 2800000 3200000 3600000 3600000

Contribution (Sales-VC) 1868178 2191285 2522504 2547294

B.E.P in % 54.15% 46.54% 37.82% 34.61%

Break Even Sales in Rs. 1516266 1489400 1361602 1245969

Break Even Units 1895 1862 1702 1557

Current Ratio 0.87 0.34 0.30 0.24

Net Profit Ratio 38.37% 42.84% 48.65% 50.94%

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