DETAIL PROJECT REPORT FOR

R&D Project Profile in connection with Design and Development of JDPs under Mini Mission IV of JTM

PROJECT No. 8

TITLE OF THE PROJECT

DEVELOPMENT OF APPROPRIATE COMPUTER AIDED COLOUR MATCHING DATA-BASE AND PRINT DESIGN LIBRARY FOR THE USE IN

PRODUCTION OF JUTE DIVERSIFIED PRODUCTS

Total Project Cost: Rs 48.00 Lakhs

Project Duration- 4years

Submitted to JUTE MANUFACTURES DEVELOPMENT COUNCIL

MINISTRY OF TEXTILES, GOVT OF INDIA

2007NAME OF P I & CO-P I

P I – PROF.(Dr) A. K. SAMANTA , Professor, IJT(To be Carried out by IJT in Association with AJHEEI for Commercialization)

Institute of Jute Technology35, Ballygunge Circular Road, Kolkata. – 700 019.

Tel. No. - 033-2461-5444/5477/5326/5632Tele-Fax No. - 033-2461-5632

e-mail : ijt@cal2.vsnl.net.inWebsite – www.ijtindia.org

Project Profile in connection with Design and Development of JDPs under Mini Mission IV of JTM

PROJECT No. 8

DEVELOPMENT OF APPROPRIATE COMPUTER AIDED COLOUR MATCHING DATA-BASE AND PRINT DESIGN LIBRARY FOR THE USE IN PRODUCTION OF

JUTE DIVERSIFIED PRODUCTS

A. Project Background

International Market demand precission level of colour matching and novel print designs on any

textile products including that for jute decoratives and home textiles. For widening the vistas of

colour matching in jute based home textile products, it is necessary to develop a computer-

aided colour matching data-base and to develop a print design library for utilization of the same

for jute products to create a niche image in this growing sector . Both organized jute sector

(who have bleaching, dyeing printing arrangement) and decentralized jute sectors

manufacturing jute diversified products and consumers may be benefited, if such systems can

be made operating regularly for jute based fabrics, like other textile sector.

In any standard textile dye house, use of these two systems (Computer aided colour matching

and computer aided print designing ) has become common and vital for their regular samples

development and regular production purposes to satisfy colour match results conforming to that

of the order and to attract more and more buyers/ market share providing newrer print designs

at finger tips. There will be noticeable saving of dye-staff inventory and saving of time for colour

matching by use of these computer aided colour matching system , if customized for colouring

of jute products. Similarly , computer aided print design system provides flexibility and time

saved design generation for approval of customer before the actual printing is done. Also ,

preparation of colour wise transparent positives for preparation of individual print design screen

from any given multicolour print design can be generated within few minutes by colour

separation tools besides resizing, colour change , restyling and change of design dimension , as

required.

These systems are still not in use in any jute dyers/chemical processors both in small scale

sector and large scale sctor of jute, probably due to low volumes of dyed / printed variety of jute

goods production and also due to lack of knowledge of relevant Industry personnel on these

aspects with non-availability of standard database and print design library suitable for jute

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products. IJT has installed computer aided colour matching system in 1990 and also installed

computer aided print design system in 2000-2001 for some R&D work as well as making our

students aware of utilization of these systems. An attempt has also been taken earlier to carry

out some preliminary research work on computer aided colour matching for optimization of

colour interaction parameters prior to preparation of suitable database for dyeing jute fabrics

with different classes of dyes for reference and use by the industry. From the said preliminary

work, some difficulties and problems have been identified against its uses in the jute industry.

For print design system some preliminary work done by IJT called for the need of some R&D

trials to make it suitable for Jute products. Hence, it is thought appropriate to undertake this

project for implementing both the systems in process houses meant for jute products. However,

as these two systems are quite old at IJT and now, newrer versions of these equipment with

window based dedicated newer softwares are widely available, IJT need to upgrade these two

systems prior to the proposed R&D work.

Computer aided colour matching and print design system with separate hardwares and

softwares have become part and parcel of today’s textile dye house. Both the systems have

come into practical use in the nineties in textile industry. However, for jute products these

systems are still not in practice for common dyeing and printing of jute based products. There

are many studies available in literature indicating the high technical out put helping techno-

economically viable decisions for dyeing formulation even at cheaper cost and precession

match results.There are some handy books and literatures for consultation to know about these

two aspects. International markets talks about different colour parameters in technical terms to

specify certain bleached or dyed products. To satisfy all these , there is no other way than to

adopt these systems in the mill. For successful adopting these system for dyeing and printing of

jute products in small scale jute dyeing and printing unit or in large scale jute Bleaching-dyeing

and printing units ,a detailed research work is needed about different technical problems to

customize these systems for jute. Some reviews have been published from IJT on salient

features of instrumental colour measurement and computer aided colour matching A few studies

were earlier initiated at IJT and the outcome has been reported in different journals, which

indicate the need of further studies to make these systems user friendly for jute sector,

irrespective of its applications in small scale or large scale jute sector.

However, to implement the proposed R & D Work effectively in jute sector, it also felt necessary

to train relevant manpower for awareness and skill development to operate these two systems

through an Industry Association to be actively involved in implementing the same to small scale

jute dyeing and printing unit.

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B. Objectives and Rationale

Objectives :

1 To develop computer aided colour matching database for different dye classes to obtain

computer assisted dyeing-recipe/ formulation for precision colour matching recipe

2 To study compatibility of mixture of dyes and effects of different dyebath assistants / dye-fixing

agents /UV-absorbers and other adiitives /chemicals on consequent colour strength and other

colour interaction parameters using computer aided colour matching system for production of

wash-fast and light-fast dyed jute products .

3 To make industry people aware about this computerized facility for colour matching and testing

/quality control of dyed products and dyes through seminars and workshop and training

programmes so that industry can utilize the same for generation of cost effective and time

saving colour matching recipe in their laboratory/shopfloor.

4 To develop suitable print designs for jute and jute/cotton union fabrics using Computer

Aided Print Design System after study of suitability of design dimension for the particular

construction of fabrics and to improve the surface texture of the fabric for improving

the appearance of print design.

5 To acquire and utilize newer software on Computer aided print Design to develop a print design

library for generating newer/novel print designs with varying colour combinations suitable for

jute products and to utilize them for production of attractive jute diversified products.

6 To develop a network between IJT and Industry for industry-institute interaction chain for

utilizing the computer aided colour database and print-design library in effective manner for the

common users (for both decentralized jute sector and large scale jute sector).

Rationale

(a) International Market demands precession level of colour matching and novel print designs on any

textile products including that of jute decorative and home textiles.

(b) For widening the vistas of colour matching in jute based home textile products to create a niche

image in this growing sector.

(c) Both the Computer aided Colour matching and Computer aided Print Design Systems have

become an essential quality control tools for modern Dye-houses, butthere are no such systems

in most jute processing dye houses due to lack of knowledge on these systems to utilize and lack

of ready data base required to utilize the same.

(d) To satisfy todays’ buyers and international market demand of precission colour matching and

novel print designs , it is necessary to develop a computer-aided colour matching data-base and to

develop a print design library for utilization of the same for jute products

(e) Target beneficiaries are both the organized jute sector (who have bleaching, dyeing printing

arrangement) and decentralized jute sectors to pass on the benefits ultimately to consumers.

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C. Project Components:

Component-1 : Initial Literature Review , Survey and Need Assesment and Preliminary R & D Trials :

Initially literature review , survey of colour specifications required by the buyers for colouring

with common eco-friendly synthetic dyes used by the jute industry as well as assesment of the

practical need of the work will be taken up. Then along with selection necessary research

fellow and other project manpower required for the R&D work , setting up of laboratories

including repairing, fabrication and updating the special computer aided equipments required for

the R & D purpose will be taken up. After that ,all the chemicals/ dyes and raw materials

/consumables will be procured to start the experimental work. Initially the study of calibration

dyeing will be taken up as base work. After all these preparatory work, the laboratory

experimentation on callibration dyeing and database preparation will be started. All the base

and primary products dyed for database preparation will be tested at IJT utilising existing

equipments of IJT. However, some instruments are more than 5-15 years old and need to be

updated / upgraded to the required standard for testing and evaluation in the present context

After Collection of information about customer choice and preferences collection of different

print designs and art work will be taken up as base work for creating a computer aided print

design library. For this job newrer version of Print design software is to be procured and to be

installed in the existing Computer aided Print design system of IJT with necessary upgradation

of Computer system with Colour laser priter for printing in the tranparent sheet for screen

preparation.

Component-2 : Major R & D Work :

Major R & D work will be continued on calibration dyeing with use variety classes of eco-friendly

synthetic dyes applicable for jute for preparation of computerised database for colour matching

solution, with identified wash and light fast data using non-azo eco-friendly synthetic dyes

mainly special wash fast direct dyes, reactive dyes and vat dyes. The effects of variation in

shade % on colour strength and other colourimetric parameters will be studied for the suitable

single and mixture of synthetic dyes to produce a suitable match. The efficacy of match results

will be investigated. The effects of variation in dye bath compositions and dyeing conditions on

shade change will also be studied for dyeing of jute and jute-cotton union fabrics with different

types of synthetic dyes. Relevant R&D work will be carried out to optimise and standardise

different dyeing parameters with all classes of possible synthetic dyes commercially available

from different sources/ different companies, those are mostly used by different jute dyers.

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Work related to creation of more and more design and their extension work for development of a

exhaustive computer aided novel print design library suitable for jute products will be cotinued

by utilizing new generation of textile print design auto-cad software and by customization of the

software for suitable Textile Print Designs for jute products as per requirement/choice of the

buyers. Required R & D work for reducing fibre shedding and required pre-treatments for surface

smoothening of bleached jute fabrics may also be taken up to improve the printing effects. To

improve rub-fastness of pigment printing on jute fabric may also be taken up , if required by the

user industry besides testing (inside and outside) of dyed and printed jute products.

Component-3 : Remaining R & D Work and Field-Trial for Transfer of Technology:

After the above said studies are completed testing of effectiveness of computerised database

will be re-tested for bleached jute fabrics to provide correct degree of colour matching at IJT-

colour chemistry lab as well as at outside laboratories for as per national and international

standards of colour codifications and colour difference standards for differently dyed jute fabrics

by using combinations of different synthetic dyes and sective dyeing auxiliaries and additives.

As print design is a continuous art work and depend on many factors of choice by different

consumers , it will be classified productwise , marketwise and country of export wise as well as

colour forecast and season wise with newer codification. Accordingly, the extension activities for

the classification of created computerised novel print design will be taken up. The suitability of

different design elements and design dimensions will be tested on bleached and dyed jute

fabrics. Lab scale study of imitation of created novel print designs and their registering on jute

and jute-cotton union fabrics will be taken up along with required testing.

At the middle of 3rd year of the project , after completing the above work, in this third component

of the work schedule, efforts will be taken up to create a sustainable common facility service

chain system with user industry for utilisation of computerised colour matching and

computerised print designs in consultation with the help of Industry Association like AJHEEI

(Association of Jute Handicrafts Entrepreneurs of Eastern India, Kolkata).

After identifying interested industrial organisations /process houses through AJHEEI, there will

be arrangement of Field-trial for transfer of technology for commercial exploitation and utilisation

of the developed suitable indigenous technology for computerised colour matching and print

design systems developed to be useful for dyeing and printing jute and jute–cotton union fabrics

with selective combinations of suitable identified synthetic dyes of different reputed companies

with or without suitable pre and post treatments to achieve acceptable grade of colour fastness

to wash, light and rubbing. For effective transfer of technology, AJHEEI have to arrange or to

5

procure the same systems of computer aided colour matching and computer aided print design

system compatible with IJT’s updated systems for the same by creating a common facility centre

for its members to use and to avail centralised services from there with technical assistance of

IJT. Required funds for this may either come from the project , if available or AJHEEI or its group

of interested members may arrange the same on co-opertive basis for creating such common

facility centre.

Such field-trial should preferably be organised at the common facility centre or at any selected

process house (to be selected by AJHEEI) having the same computer aided equipment facility.

The said field trial will encompass the necessary pre-treatments and preparatory processing of

selected jute based fabrics and then dyeing with selected clases of synthetic dyes in stock

procured from commercially available organisations for such mill based field-trial taking recipes

from computerised database for colour matching and taking print designs from print design

library.

Component-4 : Training, Feed back and Technical Services to be offered by IJT to AJHEEI or to the Industry member

Arrangement will also be made for seminar/workshop/ group meeting and required manpower

training at IJT for interested industry people to make them aware about the utility of these two

computer based systems and to utilise these for today’s need, in consultation with AJHEEI.

After completion of the research on database and Print design library creation part , the findings

will be documented both in hardware and software for future use of the same by the industry

and necessary transfer of technology. There will be some sort of coomon platform or service

chain system through AJHEEI to hold required training /seminar /workshop and group meeting

to discuss the implementation problems faced by the industry.

During the transfer of technology, IJT will give necessary technical assistance and guidance for

dyeing and printing jute fabrics with selected dyes/pigments to the interested process house

/small entrepreneurs and converters. AJHEEI will find such interested entrepreneurs/process

house who has all the required facilities or AJHEEI will arrange the facilities by some means of

developing co-operation and mutual share basis . IJT will also guide in association with AJHEEI

to the coverters to fabricate suitable dyed and printed jute based products as per end-use

requirement of colour matching, colour fastness rating and novel print designs of customer

choice as per market feedback conforming the target standards. These materials will be tested

both at IJT and at outside national and International laboratories to conform the required

standards.IJT will assist to promote test marketing approaches by AJHEEI. The costs of such

bulk trial on natural dyeing will be initially be borne from the project ,but to continue the technical

services for further requirement of technical consultancy by the process houses /AJHEEI for

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commercialisation of the dyed jute fabrics or products , IJT will give the necessary technical

assistance and guidance only on chargable basis under the guidance of the project team

including the PI of the project.

Component-5 : Dissemination of Research Results and Prepared Database /Project Output and Preparation of Terminal Report.

IJT will also arrange demonstration for the utilisation of the relevant database prepared for

computerised colour matching and print designs for jute. Documentation will be made for the

research findings including details of the software and colour database developed and details of

the methodology of creating newer and novel print designs etc and those will be made

available for the use of Industry through AJHEEI. Thus, the dissemination of required

knowledge, skill, scientific information, and related research findings on colour database and

print design library etc. will be made available in two separate CD for transfer of technology , but

that CD will only work with the sanme system of computerised software only. Hence, AJHEEI or

Industry liking to use them, has to install such computerised systems at their own cost.

However, time to time feedback from concerned end-users will be taken up at the suitable stage

of the project (in 3rd or 4th Year) through AJHEEI for necessary assistance and guidance for its

effective use. At the end, required reporting and project winding up activities will be taken up i.e.

activities like research publications, ending seminar/workshop/Group meeting and publications

of technical monographs/manuals as well as arranging appropriate short term refresher man-

power training ( for industry personnel including technical personnel / chemical processors /

dyers etc.).and preparation of final terminal Report will be taken up.

At the end of the project , for sustainiability and future use of these two computerised systems

for easy and effective colour matching and also for creating novel print designs for jute based

fabrics, these databases prepared are to be maintained well and are to be stored properly and

also need to be updated accordingly. Initially for one year or so , this cost may be borned from

the project , but for further period of time AJHEEI has to find out a solution for this, by procuring

such two computerised systems with same specification as IJT have presently (to be updated).

Ultimately, Research Results/Project Output will be disseminated through group meeting,

research publications, seminar/workshop Report / technical notes and publications of technical

monographs/manuals besides preparation of CD for transfer of database to another same

system. Hence there should be a self-sustainable common facility centre is to be established at

the end of this project to maintain and to continue the services to the interested process houses.

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D. Summary Cost Table and Financing Plan:

Duration of the Project ( with date of commencement and Completion ): Four Yrs. ( September ,2007 to September-2010).

Table-1: Summary Cost Table by Component

Project Title : DEVELOPMENT OF APPROPRIATE COMPUTER AIDED COLOUR MATCHING DATA-BASE AND PRINT DESIGN LIBRARY FOR THE USE IN PRODUCTION OF

JUTE DIVERSIFIED PRODUCTS

Year Project Components Total cost(Rs. in lakh)

First

Component-1 : Initial Literature Review , Survey and Need Assesment and Preliminary R & D work and Related Costs :a) Review of literature, Need assessment and initial survey of eco-friendly synthetic dyes used by jute industry and tolerences of colour difference parameters required by the domestic and foreign buyers

0.50

b) Setting up of Laboratories and updating some equipments 5.00c) Project Manpower costs for 1st year 3.00d) Raw materials and consumables for preliminary R & D work (Procurement of synthetic dyes and chemicals/raw materials/print papers /transparent papers and other consumables for preliminary R & D work )

1.00

e) Initial R &D trial for study on calibration dyeing and database preparation for any one or two classes of dyes on jute based fabrics and costs related to such preliminary R&D work .

0.50

f) Use of updated software for initil base work to create computer aided novel print designs and creation and customization of the Print design library for jute products as per requirements/choices of the buyers.

0.50

g) Contingecy and Sundries 0.50Sub-Total(1st Year) 11.00

SecondComponent-2 : Major R & D Work and Related Costs :

a) Modification and updating of some equipments for R&D work at IJT 4.00b) ) Major R&D work and related costs for studies on further database preparation with different classes of synthetic dyes suitable for jute. Study on colour strength and other colour interaction parameters for variation of dyeing recipe and dyeing process variables using different class of synthetic dyes for colour matching problems.

1.50

(c) Collection of design ideas from different sources and preparation of computerised novel print design database to be used used by the jute industry, for ready use,catogorised as per products / source & colours.

0.50

d) Optimization of dyeing process parameters for colour matching problems and related testing (inside and outside) of dyed and printed jute fabrics

1.00

e) Project manpower costs for 2nd year 3.00

f) Contingecy and Sundries 0.50

SubTotal (2nd Year) 10.50

8

Table-1 ContinuedYear Project Components Total cost

(Rs. in lakh)Third Component-3 : Remaining R & D Work and Field-Trial for Transfer of

Technology:a) Remaining R & D studies of the effectiveness of colour database for accurate colour matching and batch correction. To study the changes in colour strength and colour fastness behaviour for variation in dyeing conditions & dye bath compositions

1.50

b) Remaining R & D work and extension activities to develop suitable print designs for jute and jute/cotton union fabrics using Computer Aided Print Design System after study of suitability of design dimension for the particular construction of fabrics and to improve the surface texture of the fabric for improving the appearance of print design and testing rub fastness for pigment printed jute fabrics.

1.50

c) Field-Trial in consultation with AJHEEI, to organize demonstration on working with both the computerised systems of colour matching and print design along with lab scale and bulk scale dyeing and printing in a process house (Processing costs of the process house is to be paid from the project) with different class of synthetic dyes to match different shades utilizing the colour matching database prepared and to imitate any given print designs (new or modified/resized/restyled) preparing suitable screens with the aid of computerised design system.

6.00

d)Transfer of Technology and Techno-economic viability analysis. 1.00e) Project manpower costs for 3rd year 3.00f) Contingecy and Sundries 0.50

Sub-total(3rd year) 13.50Fourth Component-4 : Training, Feed back and Technical Services to be

offered by IJT to AJHEEI or to the Industry membera) In consultation with AJHEEI, to arrange training of industry people/dyers/printers to develop their skill on utilisation of thse two systems

1.00

b) Feed back and Technical servicesand Transfer of Technology in consultation with AJHEEI and related costs. Techno-economic viability analysis in consultation with AJHEEI/ related Process House.

0.50

Component-5: Dissemination of Research Results and prepared Database / Project Output and Preparation of Terminal Report and Related Costsa) Costs for Publications, Books/Manuals, Group meetings, Seminar/Workshop for dissemination of Project findings

1.50

b) Maintenance of prepared colour matching database and print design database and preparation of CD and required transfer of technology transfer in hardware to industry and AJHEEI or any other users in jute sector by creating a sustainable common facility service chain system with AJHEEI or its industry members for utilisation of computerised colour matching and print designs system for manufacture of quality jute diversified products .

6.00

c) Preparation of Final Terminal Report etc. 0.50Project Manpower costs for 4th year for components- 4 & 5 3.00Contingecy and Sundries 0.50

Sub-Total (3rd Year) 13.00Total : 48.00

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Table-2 : Summary Project Cost by Component and year

Project Title : DEVELOPMENT OF APPROPRIATE COMPUTER AIDED COLOUR MATCHING DATA-BASE AND PRINT DESIGN LIBRARY FOR THE USE IN PRODUCTION OF JUTE DIVERSIFIED PRODUCTS

Components PY-1(Rs. in

lakh)

PY-2(Rs. in

lakh)

PY -3(Rs. in

lakh)

PY -4(Rs. in lakh)

Total Cost(Rs. in lakh)

Component-1 : Initial Literature Review , Survey and Need Assesment and Preliminary R & D work and Related Costs :a) Review of literature, Need assessment and initial survey of eco-friendly synthetic dyes used by jute industry and tolerences of colour difference parameters required by the domestic and foreign buyers

0.50

11.00

b) Setting up of Laboratories and updating some equipments 5.00

c) Project Manpower costs for 1st year 3.00d) Raw materials and consumables for preliminary R & D work (Procurement of synthetic dyes and chemicals/raw materials/print papers /transparent papers and other consumables for preliminary R & D work )

1.00

e) Initial R &D trial for study on calibration dyeing and database preparation for any one or two classes of dyes on jute based fabrics and costs related to preliminary R&D work .

0.50

f) Use of updated software for initil base work to create computer aided novel print designs and creation and customization of the Print design library for jute products as per requirements/choices of the buyers.

0.50

g) Contingecy and Sundries 0.50Sub-Total(1st Year) 11.00

Component-2 : Major R & D Work and Related Costs :

a) Modification and updating of some equipments for R&D work at IJT

4.00

10.50

b) ) Major R&D work and related costs for studies on further database preparation with different classes of synthetic dyes suitable for jute. Study on colour strength and other colour interaction parameters for variation of dyeing recipe and dyeing process variables using different class of synthetic dyes for colour matching problems.

1.50

(c) Collection of design ideas from different sources and preparation of computerised novel print design database to be used used by the jute industry, for ready use,catogorised as per products / source & colours.

0.50

d) Optimization of dyeing process parameters for colour matching problems and related testing (inside and outside) of dyed and printed jute fabrics

1.00

e) Project manpower costs for 2nd year 3.00

f) Contingecy and Sundries 0.50

SubTotal (2nd Year) 10.50

Table-2 Continued.

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Components PY-1(Rs. in

lakh)

PY-2(Rs. in

lakh)

PY -3(Rs. in

lakh)

PY -4(Rs. in lakh)

Total Cost(Rs. in lakh)

Component-3 : Remaining R & D Work and Field-Trial for Transfer of Technology:

a) Remaining R & D studies of the effectiveness of colour database for accurate colour matching and batch correction, and to study the changes in colour strength and colour fastness behaviour for variation in dyeing conditions & dye bath compositions

1.50

13.50

b) Remaining R & D work and extension activities to develop suitable print designs for jute and jute/cotton union fabrics using Computer Aided Print Design System.

1.50

c) Field-Trial in consultation with AJHEEI, to organize demonstration on working with both the computerised systems of colour matching and print design along with lab scale and bulk scale dyeing and printing in a process house (Processing costs of the process house is to be paid from the project) with different class of synthetic dyes.

6.00

d)Transfer of Technology and Techno-economic viability analysis.

1.00

e) Project manpower costs for 3rd year 3.00

f) Contingecy and Sundries 0.50Sub-total(3rd year) 13.50

Component-4 : Training, Feed back and Technical Services to be offered by IJT to AJHEEI or to the Industry member

a) In consultation with AJHEEI, to arrange training of industry people/dyers/printers to develop their skill on utilisation of thse two systems

1.00

13.00

b) Feed back and Technical servicesand Transfer of Technology in consultation with AJHEEI and related costs. Techno-economic viability analysis in consultation with AJHEEI/ related Process House.

0.50

Component-5: Dissemination of Research Results and prepared Database / Project Output and Preparation of Terminal Report and Related Costsa) Costs for Publications, Books/Manuals, Group meetings, Seminar/Workshop for dissemination of Project findings

1.50

b) Maintenance of prepared colour matching database and print design database and preparation of CD and required transfer of technology transfer in hardware to industry or AJHEEI or any other users in jute sector by creating a sustainable common facility service centre/ chain .

6.00

c) Preparation of Final Terminal Report etc. 0.50Project Manpower costs for 4th year for components- 4 & 5 3.00Contingecy and Sundries 0.50

Sub-Total (3rd Year) 13.00

Total : 11.00 10.50 13.50 13.00 48.00

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Table-3: Detailed Cost Table by Category and Item of Expenditure

Project Title : DEVELOPMENT OF APPROPRIATE COMPUTER AIDED COLOUR MATCHING DATA-BASE AND PRINT DESIGN LIBRARY FOR THE USE IN PRODUCTION OF JUTE DIVERSIFIED PRODUCTS

1 2 3 4 5 6 7Category of Expenditure

Sub-category of Expenditure PY-1(Rs. in lakh)

PY- 2(Rs. in lakh)

PY-3(Rs. in lakh)

PY-4(Rs. in lakh)

Total Cost

(Rs. in lakh)

Updating of newer version of software and Repairing/ Modification and Maintenance of some existing equipments for latest version of computer aided system.

Updating of Existing Equipment to Newer generation of Reflectance Spectro--photometer with computer and latest software and spares like UV-lamps, battery holder , Standard tiles and colour analysis kits & gloss meter etc..

4.00 4.00

Updating of software to New Generation Computer aided Print Design Software and latest Computer and Accessories like colour plotter and colour laser Printer .

1.50 1.50

Updating of Existing Equipment to a semi-automatic/automatic Temperature controlled Dyeing Test Machines with programmer for dyeing cycle

1.50 1.50

Textile Printing screens, Photo Table and screen developers and other accessories and consumables and squeeze with binder , lacker and sensitizer etc..

1.00 1.00

Fabrication and Repairing of Miscelleneous Small Equipments ( All Local and Indegenious ) like Magnetic Stirrers, Viscometer, Small Glass apparatus, Precission Water bath and heater and computer accessoriesand peripherals and papers as required

1.00 1.00

Project Manpower (a)Two Sr. Research Fellow / Research Associate @ Rs. 10000/per month (Consolidated) + Other costs . as per approved Govt. Rate) including one Fellow for field/Bulk trial/Transfer of Technology and Co-ordination with AJHEEI for last 1.5 years.

2.50 2.50 2.50 2.50 10.00

(b) Contractual/Hired/ Casual manpower/ Assistants

0.50 0.50 0.50 0.50 2.00

Recurring Cost related to Major R & D Work

Raw-materials,stationery, dyes, auxiliaries, Chemicals and Other Consumables like transparent paper etc.

1.50 1.50 1.00 1.00 5.00

General lab. equipment maintenance and other misc. jobs for the database preparation and related costs.

----- 0.50 0.50 0.50 1.50

Travel / Works Visits & Seminars/workshop (Travel for collection of natural dyes & interaction/co-ordination with industry /AJHEEI

0.50 0.50 1.00 1.00 3.00

Purchase of Books and Publication of Papers, Manuals & Technical Notes etc.

0.50 0.50 0.50 0.50 2.00

Costs of Field Trial /Processing/Dyeing at selected Process House and Supervision by IJT and AJHEEI.+ costs of Shade card preparation/

--- ---- 2.00 2.00 4.00

Costs of Related Testing (Colour Fastness and Eco-parameters testing –at IJT and Outside)

0.50 0.50 1.00 0.50 2.50

Costs of /Manpower training and Transfer of Technology .

--- ----- 1.00 1.00 2.00

Costs of Demonstration and maintenance of Database prepared for both computerized colour matching and print design problems and costs of transfer of technology

---- --- 3.00 3.00 6.00

Costs for Group meeting/Interaction with AJHEEI and Preprn. Of annual Reportand Final termination Report

--- 0.50 0.50 1.00

Total : 11.00 10.50 13.50 13.00 48.00

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Table-4: Work Plan and Implementation Schedule

Project Title : DEVELOPMENT OF APPROPRIATE COMPUTER AIDED COLOUR MATCHING DATA-BASE AND PRINT DESIGN LIBRARY FOR THE USE IN PRODUCTION OF JUTE DIVERSIFIED PRODUCTS

Work Plan

PY Quarter Main Activities Responsibility Output1 1 Review of Literature , planning and

design of experiments for data base preparation for computer aided colour matching and print design library.

Faculty-Members and Project Team of IJT

Review of earlier work and finalising the plan of experimental work.

2 Need Assesment/Survey of type of dyes used by jute dyers and survey of customers (National and International) need of achievable colour standards

- do - Survey report on need and Requirement of customers and colour tolerances and coding.

3 Preliminary R &D study to identify suitable synthetic wash fast and light fast dyes for database preparation & colour match analysis.

- do - Identification of suitable chemicals / formulations

4 Creation of Print design library and relevant testing and data entry for colour matching database preprn. and 1st Annual Progress Report

- do - Initial database for colour matching and Design library witht est Results for both and 1st

Annual Progress Report.

2 1 Lab. experiments for R&D Study with different synthetic dyes suitable for colour matching of jute and creation of print design library through design collections and modifications using Auto-cad tools

- do - Test Results of Lab. study . Newer database to get colour matchingf formulation and to get novel print designs.

2 Testing of dyed yarns & Fabrics for optimisation of Dyeing process variables and fastness for data-base prepration for computeised colour matching.

- do - Optimisation of suitable recipe and conditions for different dye-fibre combination for preprn. off database for colour matching.

3 Customisation of computer software for print desgn library and preparation of screen , printing and testing of Print design on bleached/dyed jute fabric

- do - Creation of print design library with newer/ colour modified/ re-sized/re-styled print designs.

4 Testing of efficacy of colour matching database and testing of print design generation efficacy and their suitability to jute and 2nd Annual Progress Report

- do - Tested colour matching data-base and print design library and 2nd

progress Report.

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Table-4 Continued.PY Quarter Main Activities Responsibility Output

3 1 Continued Lab. Trial for R&D Study with different synthetic dyes for colour matching data base preparation to generate ready Recipe/Formulations

Faculty-Members and Project Team

of IJT

Optimisation of suitable recipe and conditions for ready database for colour matching with other synthetic dyes.

2 Continued R&D Study with different print design problems and actual print test taking design from computer generated designs and to investigate surface texture problems of printing jute fabrics.

- do - Newrer Print design library extended with newer collections and modifications for ready use in computer.

3 Seminar & workshop to dissiminate lab. Trial results and publications and arranging Man power Training to utilize these computer aided colour matching and print design systems and –trial with Initial Field in a process house or with AJHEEI

Faculty-Members and Project Teamof IJT in consultation

with AJHEEI

Seminar / conference Papers Published Research Papers / and publications of technical notes and manuals /Books etc.And Field Trial Results .

4 Testing and Optimisation of dyeing process variables and their effect on colour strength and colour matching efficacy for the colour database and Preparation of 3rd

Annual Progress Report etc.

- do - Ready colour matching Data- base and customized print design library and Test Results & 3rd Annual Progress Report.

4. 1. Continuing Field-Trial in consultation with AJHEEI for utilization of both the computerized colour matching database and print design library developed by actual bulk dyeing and printing in a process house selected by AJHEEI.

Faculty-Members and Project Team in

consultation with AJHEEI

Field-Trial and Transfer of Tehnology to relevant industry with ready database for colour matching and print designs.

2. Practical demonstration and Seminar/workshop to dissiminate results of R& D and field trail with ready database & Manpower training in consultation with AJHEEI

- do - Demonstration to utilize both the database for practical use in industry and Trained Supervisors and Operators .

3. Estabilishing a common facility centre of technical service chain system for implementing and utilizing and maintaining the computer aided colour matching and print design centre under AJHEEI with assistance of IJT .

- do - To create a common facility centre For future sustainability and use of these ready developed databases on both colour matching and print designs

4. Publication of Papers/notes /technical manuals for Industry and Technoeconomic analysis of the process

Group meeting/ Feedback and Preparation/ Presentation of Final Terminal Report

- do - Publications of papers/ books/ manuals and Seminar Reports and Techno-economic analysis Report for the same Final Report on Project findings & achievement with relevant scope and recommendations.

Project Title : DEVELOPMENT OF APPROPRIATE COMPUTER AIDED COLOUR MATCHING DATA-BASE AND PRINT DESIGN LIBRARY FOR THE USE IN PRODUCTION OF JUTE DIVERSIFIED PRODUCTS

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Table-5 : Implementation SchedulePY Quarter Component Activity1 1

Component-1 : Initial Literature Review, Survey and Need Assesment and Preliminary R & D work

Review of Literature , planning and design of experiments for data base preparation for computer aided colour matching and print design library.

2 Need Assesment/Survey of type of dyes used by jute dyers and survey of customers (National and International) need of achievable colour standards

3 Preliminary R &D study to identify suitable synthetic wash fast and light fast dyes for database preparation & colour match analysis.

4 Creation of Print design library and relevant testing and data entry for colour matching database preprn. and 1st Annual Progress Report

2 1

Component-2 : Major R & D Work

Lab. experiments for R&D Study with different synthetic dyes suitable for colour matching of jute and creation of print design library through design collections and modifications using Auto-cad tools .

2 Testing of dyed yarns & Fabrics for optimisation of Dyeing process variables and fastness for data-base prepration for computeised colour matching.

3 Customisation of computer software for print desgn library and preparation of screen , printing and testing of Print design on bleached/dyed jute fabric

4 Testing of efficacy of colour matching database and testing of print design generation efficacy and their suitability to jute and 2nd Annual Progress Report

3 1Component-3 : Remaining R & D Work and Field-Trial for Transfer of Technology in consultation with AJHEEI for effective use of experimental outcome by the Industry

Continued Lab. Trial for R&D Study with different synthetic dyes for colour matching data base preparation to generate ready formulations

2 Continued R&D Study with different print design problems and actual print test taking design from computer generated designs and to investigate surface texture problems of printing jute fabrics.

3 Seminar & workshop to dissiminate lab. Trial results and publications and arranging Man power Training to utilize these computer aided colour matching and print design systems and –trial with Initial Field in a process house or with AJHEEI

4 Testing and Optimisation of dyeing process variables and their effect on colour strength and colour matching efficacy for the colour database and Preparation of 3rd Annual Progress Report etc.

4 1Component-4 : Training, Feed back and Technical Services to be offered by IJT to AJHEEI or to the Industry member

Component-5: Dissemination of Research Results and prepared Database / Project Output and Preparation of Terminal Report

Continuing Field-Trial in consultation with AJHEEI for utilization of both the computerized colour matching database and print design library developed by actual bulk dyeing and printing in a process house selected by AJHEEI.

2 Practical demonstration and Seminar/workshop to dissiminate results of R& D and field trail with ready database & Manpower training in consultation with AJHEEI

3 Estabilishing a common facility centre of technical service chain system for implementing and utilizing and maintaining the computer aided colour matching and print design centre under AJHEEI with assistance of IJT .

4 Publication of Papers/notes /technical manuals for Industry and Technoeconomic analysis of the processGroup meeting/ Feedback and Preparation/ Presentation of Final Terminal Report

8. Bar Diagram for each Activity of the Project ( 4 years duration, i.e. 48 months)

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ACTIVITY PERIODS 1-4 5-8 9-12 13-16 17-20 21-24 25-28 29-32 33-36 37-40 41-44 45-48

1. Review of Literature and planning and design of experimental. Survey & Need Assesment (National and International ) of achievable standards.

2. To update both the computer aided colour matching and print design systems and to customize the software for jute items

3. Preliminary R &D study to prepare database after identifying suitable dyes & dyeing process / chemicals / salts and other additives and Related Testing /analysis

*To develop & create a print design library and related art work./design collection

4. 1st Annual Progress Report

5.Lab. study of calibration dyeing variables for R&D trials with different classes of dyes used in jute and varying dyeing coditions /dye bath variables /additives

* To extend the creation of print design library and to work on design dimension

6. Testing of match results of dyed jute fabrics under different conditions of dyeing for optimisation of dyeing process variables & Compatibility of mixture of dyes to test.

*Lab study of imitation of print design registering on jute fabrics & allied testing .

7. 2nd Annual Progress Report

8.To consult AJHEEI to organise Seminar & workshop to disseminate lab. trial results and publications and Manpower Training

9 . To continue remaining R & D Work & to identify Interested Process house through AJHEEI and Bulk Trials for Lab to Mill transfer of technology for both the systems

10. 3rd Annual Progress Report

11. With AJHEEI, continuing bulk trial and manpower training & Dissemination of results of Bulk Trial & preparation of sample with novel print designs and shades

12.FurtherSeminar/workshop to dissiminate results of bulk trials and Organizing Demo. & Manpower training with AJHEEI

13. With AJHEEI, Dissemination of Results of Lab. & Bulk Trials and Publication of Papers/notes / manuals.

14.Group meeting & Feedback from AJHEEI, re-desigining/ re-sampling/ re-testing.Preparation and Presentation of Final Terminal Report

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Role of AJHEEI and IJT-AJHEEI Interaction for Commercialisation of R & D Results

(a) AJHEEI will be associated with IJT in this project for commercial Exploitation of research results/findings/methods/

technology developed by arranging Bulk trial of the processes developed, after identifying suitable process

house/converter equipped with necessary infrastructure facility required for such bulk trials.IJT will conduct such

bulk trials and demonstration of the processes and also arrange to test the products to conform any given national

or international standards / buyers’standards as applicable.

(b) AJHEEI will be actively involved in this project for the last 1.5 years only for the above said jobs related to bylk trial

and transfer of technology. IJT will consult AJHEEI for samples to be prepared in required quantity/sizes/style

depending upon the market and buyer’s requirement and numbers of shade cards to be produced. The project cost

include the costs involved for bulk trials, co-ordination/mill visit/ demonstration, feedback / group meting /

workshop / seminar and for preparation of shade cards / publications of technical mongraphs and other necessary

documents to be prepared.

(c) AJHEEI will inform all its members and non-members small scale jute organizations about the Processes/Methods

and Technology being developed and bring them under one umbrella for the demonstration / dissemination of

knowledge and/or bulk trial. At the end, AJHEEI will also prepare a list of interested trainees from small scale and

large scale jute sector and IJT will organize and deliver the manpower training at a suitable place or at the Institute.

(d) There should be an MOU in concurrence with Project authority mentioning all terms and conditions in clear terms

(to be finalized by mutual discussion) among IJT-AJHEEI and the concerned Process house / Converter agreeing

to extend all facilities on chargable basis to conduct the bulk trials/demonstration and coversion/ manufacture of

suitable products as per end uses.

(e) IJT will consult AJHEEI to identify type of shades/colour/design/specifications of buyers (textile related or end-use

related physical and chemical properties including colour fastness ratings) required for particular variety of products

as per end uses and help to produce samples to the process house concerned and AJHEEI will arrange feedback

from market/buyers through its members after test marketing and getting feedback from prospective buyers.

(f) IJT will consult AJHEEI to disseminate research findings , to take bulk trial and processing in a pre-identified / pre-

desgnated process house and arrange testing of such products at IJT or at outside laboratory to prepare and

distribute shade cards for natural dyed jute based fabrics along with preparation of well organized document /notes

for the methods to be followed for such dyeing.

(g) AJHEEI or its member will prepare required samples with the technical assistance and help of IJT and will send

samples to their buyers to take market feedback to reprocess/redevelopment of some items to achieve particular

standards and specifications within the last 1.5 years out of 4 years project duration.

(h) The costs of work to be done by AJHEEI or its members or the Process House/converter concerned will be paid

by IJT from Project Cost on production of actual bills on pre-approved work agreed by IJT to pay.

(i) No problem solving or trouble shooting consultancy will be given by IJT to AJHEEI or its members at free of cost or

from the project cost during the project period. For any such work or for regular colour fastness testing of dyed

samples of AJHEEI or its members should be treated as separate cases of their own and in those cases IJT will

charge the corresponding party its usual consultancy charges/testing fees as applicable.

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Bench Mark :

(a) Availability of ready colour database for different classes of dyes for dyeing recipe generation from computerized colour matching system for jute based fabrics.

(b) Availability of methods to create novel print design along with ready availability of novel print design library.

(c) The industry people will be aware and trained in utilization of these two computerized systems in their regular work for precission colour matching and developing novel print designs to develop value added products for niche market of home textiles.

(d) Facilitate promotion of Export market for dyed and printed jute decoratives , by which both the large scale jute sector and decentralised jute sector will be benefited, who will learn and get used to utilize the se two modern computerized aids in their regular processing.

Finally Two Training manuals and Two database and Design Library CD will be prepared for easy accessibility and utilisation of the same for industry who will adopt such systems for precession level of colour matching and/or to create novel print design after manpower training and dissemination research findings .

Project Team :

ResponsibilityLevels in Project

Name Existing Designations

Qualifications Experiences Internal/ External

Principal Investigator

Prof. (Dr) Ashis Kr. Samanta

Professor (Textile Chemistry)

B.Sc. (Hons), B.Tech, M.Tech., Ph.D.(Tech), Dip. In Jute Tech., FIE, FIC.

20 years Teaching and Research exp.

Interanl

Two Sr. Research Fellow/Research Associate & one Project Asst.

To be appointed

One SRF/RAand one Project Assistant

Atleast M Sc or M Tech for One SRF/RA and B Sc or B Tech for Project Asst.

Not specified, but 1-2 years exp. preferred

External

Representatives of AJHEEI,Kolkata after 2.5 years i. e. at the last 1.5 years

Technical person to be nominated/ selected

One of the SRF /RA will work with AJHEEI in last 1.5 years .

Depends upon the choice of AJHEEI. However deputed person should have technical experience and Knowledge

At least 5 years experience is preferred

External or Internal of AJHEEI

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