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COSTS, OPERATIONAL PERFORMANCE

AND YARN QUALITY :

INTER - MILL STUDY OF KEY FACTORS

th 34

STUDY REPORT

CPQ

(OCTOBER - DECEMBER 2018)

THE SOUTH INDIA TEXTILE RESEARCH ASSOCIATION

COIMBATORE - 641 014

TRI AS

C o n t e n t s

Chapter Page no.

1 Introduction 1

2 Method of study 2

3 Method of comparison 2

4 Summary of individual mills performance 8

- Techno-commercial performance (Figure A) 10

- Contribution, sale value and SWC (Table A) 10

- Productivity particulars (Table B) 11

- Product diversification (Table C) 11

5 Comparison with last study (October - December 2017) 8

- Relative changes in the costs and operational performance of individual mills in 12 comparision with the last study (October - December 2017) (Table D)

- Comparison of costs and operational parameters between the 13 two studies (83 common mills) (Table E)

- Count-wise yarn selling price, raw material cost and NOV 14 in the two studies (Table F )

- Count-wise raw material cost relative to yarn selling price 15 in the two studies (Table G)

Acknowledgement 15

Table Mill-wise and count-wise tablesno.

1 Indices of yarn selling price, raw material cost, commercial - Mill-wise 16performance, technical performance and techno-commercial performance

2 Contribution, sale value and cost factors - Mill-wise 20

3 Average count vs. yarn sale value and contribution - Mill-wise 24

4 Power consumption particulars - Mill-wise 27

5 Captive power generation particulars - Mill-wise 31

6 Average count vs. power cost and power consumption - Mill-wise 34

7 Labour productivity - Mill-wise 37

C o n t e n t s (contd...)

Table Mill-wise and count-wise tables Page no.no.

8 Machine productivity - Mill-wise 41

9 Product diversification - Mill-wise 45

10 Yarn selling price, raw material cost, NOV and yarn quality - Count-wise 49

11 Yarn realisation & wastes and raw material quality - Count-wise 80

12 Production parameters of spinning - Count-wise 113

13 Production parameters of automatic cone winding - Count-wise 144

14 Production parameters of two-for-one twisting - Count-wise 170

15 Comparison of 83 common mills data - Mill-wise 178

16 Contribution, sale value and cost factors - Yarn type-wise 183

17 Major counts spun by the mills - Mill-wise 186

18 Installed capacity - spinning and post spinning - Mill-wise 192

Soft copy of the 34th CPQ study report

A soft copy of the study report was also uploaded in SITRA's web portal

'www.sitra.org.in' . User ID and password to download/view the 34th CPQ

study report have been sent to all the participants through E-mail.

It is interesting to note that four groups had contributed for about 35% of the total mills, while 2 mills

groups had contributed for about 25% of the mills (Figure 1). The groups with multiple units have been utilising the

CPQ study results for comparing the performance of their units not only among themselves but also with othercompeting mills and initiate necessary measures to improve their performance. A consolidated report (for groupshaving 3 mills and above) have been sent to various groups along with a hard copy of the report.

Figure 1 Pattern of participation in the 34th CPQ study

(As a % of the total mills)

2. Method of study

Data relating to various costs and operational parameters which affect the profitability like salaries

and wages, power and raw material costs, yarn selling price, power consumption, productivity and product-mix

were obtained from the mills for the fourth quarter of 2018 (October - December). Requisite data were collected from

the mills through a well designed questionnaire in MS Excel format.

In this report, more than 250 different counts and varieties of yarns have been covered. The overall

ratings with respect to raw material cost, yarn selling price and techno-commercial index (TCI) are based on up to

6 major counts spun in each mill. Count-wise figures for each mill are also tabulated to enable them to make detailed

comparisons. All other data relating to contribution, labour and machine productivity, power consumption, power

cost, salaries and wages cost and product diversification cover the entire production of the mills.

Necessary care has been taken to ensure that the figures obtained from the mills are reliable and

accurate. Salaries and wages cost figures were verified against those expected for HOK, wage rate and production

pattern of the mills. In the case of other items, in addition to giving clear guidelines to avoid ambiguity, wherever

the individual figures deviated widely, clarifications were obtained from the mills.

3. Method of comparison

3.1. Ranking of mills

The mills have been ranked based on contribution, i.e. yarn sale value less the sum of clean raw

material cost, salaries and wages cost and power cost which ultimately decides the profitability (contribution minus

overheads and stores costs = operating profit). Tables 2, 3 and 16 give the mill-wise contribution, sale value and

cost particulars.

***** 34th CPQ study

2 _____SITRA

40%

24%

18%

9%

5%4%

A

B

F E

D

C

A: Single mills

B: 2 mills group

C: 19 mills group

D: 9 mills group

E: 5 mills group

F: 4 mills group

3.2. Raw material cost, yarn selling price, net out-put value and production rate

Rating of a mill's performance is based on the average values that prevailed in the participant mills. In

each mill, data for up to six major counts have been considered. As these counts account, on an average, for about

three-fourths of the total yarn production, the rating can be expected to reflect more or less a mill’s entire production.

The overall cost for each mill, summing up all the six counts, is computed as follows:

Yarn selling price index (YSPI) has been arrived at by expressing the overall price realised by a mill in

the six counts (sum of yarn selling price/kg multiplied by the corresponding yarn production of the 6 counts) as a

percentage of the survey average yarn selling price (sum of average yarn selling price/kg multiplied by the

corresponding yarn production of the 6 counts). A similar procedure has been followed to compute the raw material

cost index (RMCI), commercial performance index (CI), technical performance index (TI), speed index (SI), TPI index

(TPII) and machine efficiency index (EI).

Illustration:- Calculation of YSPI :Mill ref. no.: 46

Yarn selling price Yarn(Rs/kg) production

Count Mill Survey during thefigure average quarter (kg)

40s K 218.0 207.5 3,36,947

40s C 240.7 232.6 1,04,210

60s C 289.5 288.6 2,15,303

40s C-Comp. 244.1 249.4 1,40,572

60s C-Comp. 298.4 314.3 27,775

Total 8,24,807

Total yarn sale value (Rs) :

Mill =(218.0x3,36,947)+(240.7x1,04,210)+(289.5x2,15,303)+(244.1x1,40,572)+(298.4x27,775)

=20,34,57,455

Survey=(207.5x3,36,947)+(232.6x1,04,210)+(288.6x2,15,303)+(249.4x1,40,572)+(314.3x27,775)

=20,00,92,904

Overall yarn selling price (Rs/kg) :

20,34,57,455Mill average = = 246.7

8,24,807

20,00,92,904Survey average = = 242.6

8,24,807

246.7Yarn selling price index = x 100 = 102

242.6

Overall yarn selling price of the mill, based on the 5 major counts, is 2% higher than the survey average.


3 _____SITRA

Yarn selling price is one of the most important parameters that decides a mill’s overall performanceinterms of profitability. However, as yarn selling price and yarn quality are to a large extent influenced by the costand quality of cotton, while judging yarn selling price, a mill’s rating of the raw material cost should also be takeninto consideration.

3.3. Techno-commercial Index (TCI)

TCI is a combined measure of YSP, RMC and production rate in relation to survey average. It is anuseful tool for mills to quickly assess the techno-commercial performance of various counts, either individually oralong with the comparison with the survey average. This information would also be helpful for mills to prioritisecorrective actions either in the commercial parameters or in the operational parameters.

NOVM

x PRM

CI x TITCI = x 100 (or)

NOVS x PR

S 100

Where,NOV = Net out-put value (Rs/kg of yarn).

PR = Production per spindle (rotor) per 8 hours in grams.

NOVM

CI = Commercial performance index, i.e. x 100NOV

S

PRM

SI x EITI = Technical performance index, i.e. x 100 or

PRS

TPIIM and S = Mill average and Survey average.

Calculation of techno-commercial index (TCI)

IllustrationMill ref. no.: 46

NOVM

NOVS

PR M

PR S

Yarn prodn.Count (Rs/kg of (Rs/kg of (g) (g) during the

yarn) yarn) quarter (kg)

40s K 64.9 55.1 119 102 3,36,947

40s C 64.7 55.8 129 124 1,04,210

60s C 113.5 111.4 64 62 2,15,303

40s C-Comp. 68.1 76.7 136 129 1,40,572

60s C-Comp. 122.4 126.5 66 67 27,775

Weighted avg. 80.0 76.0 107 98 -

Index CI = 105 TI = 109 TCI = 114

NOVM

x PRM

CI x TITCI = x 100 (or)

NOVS x PR

S 100

80.0 x 107 105 x 109= x 100 (or) => 114

76.0 x 98 100


4 _____SITRA

3.4. How to analyse techno-commercial performance of a mill ?

IllustrationMill ref. no.: 46

Techno-commercial index (TCI = 114)

Commercial performance Index Technical performance Index(CI = 105 ) (TI = 109)

Yarn selling Raw material Speed TPI Efficiencyprice index cost index index index index

(YSPI = 102) (RMCI = 100) (SI = 106) (TPII = 99) (EI = 102)

The TCI of the mill, based on the 5 major counts, is 14% more than its competitors manufacturing thesame counts. The good performance of the mill is mainly due to better technical performance (TI = 109) and alsodue to higher commercial performance (CI=105) when compared with its competitors.

From the above analysis, it can be deduced that the mill has been exercising a good control overboth technical and commercial performances when compared with its competitors' performance.

Mill-wise data with respect to YSPI , RMCI, CI, SI, TPII, EI, TI and TCI are presented in Table 1.Count-wise figures for each mill which form the basis for computing the overall rating are given in Tables 10 and 12.The major counts that were considered in each mill for estimating mill-wise indices are furnished in Table 17.

3.5. Salaries and wages cost (SWC)

Salaries and wages cost (SWC), expressed as a percentage of sale value, is generally independent ofthe counts spun by the mills. However, the type of yarn has an important bearing on the SWC. In mills manufacturinghosiery yarns, combed yarns, compact yarns, doubled yarns, processed yarns, fancy yarns, etc., the SWC tendsto be low. The wage levels prevailing in the mills also influence the SWC in direct proportion.

The SWC is thus primarily determined by three parameters, labour productivity, operative wage leveland type of yarn. It will be lower in mills achieving higher levels of labour productivity, paying lower wages andproducing high value yarns. The reduction in the SWC will be compounded, if more than one of these operatingconditions are present in the same mill. For example, in a mill with 20% higher labour productivity, 30% lower wagesand fetching 25% higher yarn sales realisation, the SWC will be lower by 53% [100 - (70 x 1002 / 120 x 125)]. On theother hand, a high SWC largely stems from low labour productivity.

A SWC value of 8% or more should be viewed with concern and calls for both short-term and long-term planning to increase labour and machine productivity. Percentile rankings of the SWC based on 103 mills aregiven in Figure 2.


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4.7

6.3

7.1

8.1

9.9

11.2

12.5

15.0

0 5 10 15 20

10

20

30

40

50

60

70

80

90

SWC

%

%

SWC

%

%

%

%

%

%

23.0%

Avg. of 103 mills: 11.6%(excluding 100% OE mills)

Figure 2 Salaries & wages cost (SWC) as a % of sales revenue

If a mill achieves 20 percentile ranking (6.3%), it means that 20% of the mills are having SWC lowerthan this mill and 80% are with higher SWC.

3.6. Power consumption and cost

Power cost per spindle per year (PCY) is a function of the type of yarn and to a lesser degree thecounts spun. PCY is also determined by the power tariff, that is, primarily the location of the mill. Thus, acomparatively high PCY does not necessarily mean that there is a loss of power and a scope for conservation. Thismeasure nevertheless indicates how a mill ranks in relation to others and this is important in the context of overalland comparative profitability of the mills as power cost has become the largest component of conversion costsincurred by them.

Vital information pertaining to the power consumption are given in Tables 4, 5, and 6. The consumptionparticulars include units per kg of yarn (UKG), units per 1000 spindle shifts (USS), cost per unit, extent of use ofcaptive power, captive power generator details such as number of generators, age and capacity, type and cost of fuelused, units of power generated per litre of fuel, etc.

3.7. How the cost figures given in Table 2 have been calculated?Illustration:Mill ref.no.46

Data furnished by the mill for October - December 2018:

A. Total yarn production (kg) : 8,69,679

B. Total estimated yarn sale value (Rs) : 21,33,80,179

C. Net raw material cost (Rs) : 14,15,61,145

D. Total salaries and wages cost (Rs) : 1,71,77,368

E. Total power cost (Rs) : 2,19,48,382

F. No.of working days : 90

G. Installed capacity (spindles) : 34,128

H. Total spindle shifts worked : 87,08,681


6 _____SITRA

Per

cen

tile

ran

kin

g

Table 1Indices of yarn selling price, raw material cost, commercial performance, technical performance

and techno-commercial performance


16 _____SITRA

Yarn Raw Commercial Technical Techno-Sl. Mill selling material performance Speed TPI Efficiency performance commercialno. ref. price cost index index index index index index

no. index index (CI) (SI) (TPII) (EI) (TI) (TCI)(YSPI) (RMCI)

1 30 116 114 119 107 98 103 112 133

2 15 99 91 115 109 100 98 107 123

3 22 99 96 108 110 98 102 114 123

4 13 99 94 113 106 102 101 105 119

5 18 104 102 108 104 97 103 110 119

6 91 104 100 111 104 100 102 106 118

7 46 102 100 105 106 99 102 109 114

8 61 99 96 112 105 101 98 102 114

9 8 101 95 109 104 101 101 104 113

10 26 106 101 113 96 99 100 97 110

11 32 100 96 106 102 101 103 104 110

12 41 99 94 107 103 98 98 103 110

13 51 104 105 102 105 100 102 107 109

14 72 102 101 107 99 98 101 102 109

15 73 101 98 106 101 101 103 103 109

16 12 99 99 98 108 101 103 110 108

17 5 101 97 110 99 102 100 97 107

18 10 103 102 104 99 97 101 103 107

19 9 101 99 104 101 101 102 102 106

20 49 101 99 104 106 100 96 102 106

21 76 103 100 107 99 99 99 99 106

22 4 101 99 104 100 100 101 101 105

23 14 100 99 102 - 99 - 103 105

24 44 101 97 105 99 101 102 100 105

25 50 109 112 102 103 100 99 102 104

26 100 103 102 104 98 98 100 100 104

27 37 102 98 106 96 100 101 97 103

28 57 99 99 99 103 100 101 104 103

29 1 96 98 93 107 97 100 110 102

30 6 97 98 96 106 100 100 106 102

31 7 101 100 102 100 100 100 100 102

32 31 101 100 102 100 100 100 100 102

Table 2Contribution, sale value and cost factors - mill-wise

Mill Selling Sale RMC/ As % of sales Power cost Contribution#

rank price value kg of Avg.and /kg of /spl. yarn as /spl. /spl. /kg as countref. yarn /year (Rs) RMC SWC % of /year /year of yarn % of (Ne)no. (Rs) (Rs)@ sales (Rs)@ (Rs)@ (Rs) sales


1 207 56720 140 67.9 3.6 8.2 4630 11540 42 20.3 30

2 391 26590 173 44.4 9.9 4.4 1180 10980 161 41.3 52

3 226 45460 147 64.8 6.3 4.9 2210 10890 54 24.0 27

4 242 39830 153 63.0 6.6 4.3 1700 10400 63 26.1 34

5 235 48010 151 64.1 3.6 10.9 5230 10240 50 21.4 31

6 287 35500 155 54.2 5.4 11.7 4150 10190 82 28.7 45

7 283 32830 142 49.9 9.1 10.5 3440 10020 86 30.5 35 *

8 390 32090 216 55.2 5.5 9.4 3000 9610 117 29.9 55

9 229 49470 157 68.3 5.6 7.9 3900 9020 42 18.2 30

10 235 37610 162 69.0 4.2 3.4 1300 8800 55 23.4 32

11 249 30640 155 62.5 6.4 2.8 860 8680 70 28.3 44

12 219 47480 147 66.9 4.8 10.2 4830 8600 40 18.1 30

13 252 42500 159 62.8 7.2 9.9 4210 8530 51 20.1 33

14 206 52290 141 68.3 6.1 9.4 4930 8480 33 16.2 25

15 217 42720 138 63.6 3.6 13.1 5610 8400 43 19.7 31

16 209 57470 155 74.3 3.0 8.3 4800 8290 30 14.4 29

17 233 36390 159 68.1 4.8 6.1 2230 7630 49 21.0 37

18 285 32440 180 63.2 6.7 7.4 2390 7360 65 22.7 47

19 250 27810 149 59.6 6.6 7.5 2080 7310 66 26.3 41 *

20 199 50310 138 69.7 8.5 8.6 4310 6680 26 13.2 29

21 518 15910 227 43.7 10.9 3.8 600 6610 215 41.6 91

22 165 65460 125 75.6 4.3 10.1 6590 6590 17 10.0 18 *

23 410 18050 200 48.7 7.6 7.2 1290 6590 150 36.5 74 *

24 230 37310 160 69.5 7.1 5.9 2190 6560 40 17.5 31 *

25 337 22470 159 47.2 9.6 14.1 3170 6530 98 29.1 66

26 326 28420 183 56.2 7.2 13.9 3960 6440 74 22.7 49

27 282 51280 197 69.9 8.2 9.5 4860 6350 35 12.4 30

28 297 36130 190 63.8 7.1 12.1 4360 6160 51 17.0 41

29 239 33810 144 60.3 10.3 11.8 3980 5940 42 17.6 39

30 536 17820 244 45.5 7.8 13.8 2450 5870 176 32.9 107

31 182 57930 121 66.5 9.8 13.6 7890 5830 18 10.1 22

32 289 24540 169 58.6 8.0 10.0 2460 5730 67 23.4 48

33 236 26950 133 56.5 8.5 14.7 3960 5480 48 20.3 36 *

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Table 4Power consumption particulars - mill-wise

27 _____SITRA


UKG OverallMill Power consumption (%) Power cost per unit (Rs) power Stateref. cost per codeno. EB HSD HFO Pvt. Oth. EB HSD HFO Pvt. Oth. unit (Rs)

Ove

rall

Wit

hout

doub

ling

USS

Avg

.cnt

.(N

e)

1 30 2.58 - 690 100 - - - - 6.5 - - - - 6.5 GJ

2 52 7.88 5.68 555 98.74 1.26 - - - 2.0 # 15.5 - - - 2.2 TN

3 27 1.75 - 350 99.67 0.33 - - - 6.2 17.6 - - - 6.3 PB

4 34 3.72 3.51 605 76.94 0.06 0.20 22.80 - 2.0 # $ 17.0 9.2 5.3 - 2.8 TN

5 31 3.96 - 780 100 - - - - 6.5 - - - - 6.5 MP

6 45 5.76 - 685 98.95 1.05 - - - 5.8 11.5 - - - 5.8 HP

7 35 * 6.27 4.23 715 46.57 0.15 0.78 52.50 - 3.6 # 20.9 11.2 5.6 - 4.7 TN

8 55 7.08 - 570 49.48 1.21 - 49.31 - 4.3 # 21.6 - 5.6 - 5.2 TN

9 30 3.29 - 700 30.61 0.16 - 69.23 - 5.4 # 23.6 - 5.5 - 5.5 TN

10 32 3.69 - 625 99.19 0.81 - - - 2.0 # 21.7 - - - 2.2 TN

11 44 4.39 4.14 520 98.67 1.33 - - - 1.4 # 16.8 - - - 1.6 TN

12 30 3.82 - 805 99.27 0.73 - - - 5.7 17.4 - - - 5.8 HP

13 33 4.33 - 715 99.32 0.68 - - - 5.7 16.1 - - - 5.8 HP

14 25 2.74 2.50 670 99.97 0.03 - - - 7.1 $ 37.5 - - - 7.1 HR

15 31 3.97 3.81 755 21.62 0.03 - - 78.35 8.2 16.4 - - 6.9 7.2 MP

16 29 2.64 - 710 100 - - - - 6.6 - - - - 6.6 GJ

17 37 3.66 - 560 89.08 0.85 - 10.07 - 3.6 # 13.3 - 5.5 - 3.9 TN

18 47 5.53 - 605 56.66 0.56 - 42.78 - 1.5 # 22.2 - 6.6 - 3.8 TN

19 41 * 4.65 - 500 52.36 0.62 - 47.02 - 1.5 # 22.2 - 6.6 - 4.0 TN

20 29 2.81 2.67 700 99.97 0.03 - - - 6.1 19.6 - - - 6.1 PB

21 91 12.18 8.96 360 99.87 0.13 - - - 1.6 # 35.2 - - - 1.6 TN

22 18 * 2.19 2.07 840 100 - - - - 7.6 $ - - - - 7.6 RJ

23 74 * 8.01 7.89 345 59.73 1.23 - 39.04 - 2.1 # 20.3 - 5.6 - 3.7 TN

24 31 * 3.20 3.16 525 43.90 - 0.74 55.36 - 2.2 # $ - 13.5 5.8 - 4.2 TN

25 66 7.76 7.41 530 2.23 0.86 - 96.91 - @ 20.2 - 5.4 - 6.1 TN

26 49 6.41 6.03 555 98.41 1.59 - - - 6.8 25.2 - - - 7.1 TN

27 30 4.42 4.17 830 99.61 0.14 0.24 - - 6.0 21.8 10.5 - - 6.0 PB

28 41 5.84 5.21 695 0.26 - - 99.73 - 7.5 22.7 - 6.1 - 6.1 TN

29 39 3.71 - 505 99.52 0.48 - - - 7.6 13.9 - - - 7.6 MH

30 107 11.06 - 365 2.91 1.56 - 95.53 - 7.8 21.3 - 6.4 - 6.7 TN

31 22 3.19 2.46 1000 - - - - 100 - - - - 7.8 7.8 RJ

32 48 5.41 5.35 450 48.88 0.54 - 50.58 - 4.5 # $ 20.5 - 6.1 - 5.4 TN

33 36 * 4.33 - 485 100 - - - - 8.0 - - - - 8.0 MH

34 23 2.58 2.49 685 100 - - - - 5.0 - - - - 5.0 MP

Table 7Labour productivity - mill-wise

37 _____SITRA


Mill Up to ring frames@ Cone winding HOK@ Ring frame Avg.ref. Conv. Auto Tenter Doffer count (Ne)no. HOK OHSAM winding winding assign. assign. (ring

index* index* spinning)

1 - - - - 90 AD 30

2 13.4 1.7 8.3 2.8 129 108 52

3 - - - 1.0 241 AD 27

4 11.6 1.6 - - 126 AD 34

5 - - - - 238 AD 31

6 - - - - 200 AD 45

7 14.6 2.0 - 6.0 100 83 82

8 11.9 1.6 - - 106 AD 55

9 9.7 1.4 - - 119 AD 30

10 20.0 2.7 - - 69 AD 32

11 10.8 1.5 - - 93 100 44

12 - - - - 175 AD 30

13 - - - - 196 AD 33

14 11.0 1.7 - 2.0 88 AD 25

15 - - - - 165 AD 31

16 9.8 1.5 - 1.9 93 AD 29

17 13.0 1.8 - 1.9 - - 37

18 8.8 1.3 - - 175 AD 47

19 9.1 1.3 - - 136 AD 61

20 13.3 1.9 - 2.5 83 87 29

21 15.3 1.9 - 3.7 138 117 91

22 9.2 1.4 - - 204 AD 24

23 18.9 2.5 6.0 4.0 103 92 85

24 11.5 1.6 - 2.1 115 133 40

25 15.3 2.2 - 2.7 88 97 66

26 - - - - 120 122 49

27 - - - - 152 125 30

28 13.8 1.9 - 2.2 116 105 41

29 12.5 1.7 - 2.2 141 101 39

30 18.9 2.5 - - 71 92 107

31 - - - - 74 64 22

32 14.2 1.9 - 2.3 100 108 48

33 17.1 2.1 - 3.4 112 100 52

Table 8Machine productivity - mill-wise

41 _____SITRA


Prodn./ Spindle/ % loss in utilisationMill spl./ rotorref. 8 hrs. utilisation Repairs Labour Power MPIno. (g)@ (%) & maint- shortage shortage Others# Total

enance

1 145 98.20 1.40 - 0.20 0.20 1.80 132

2 95 91.73 1.04 7.00 0.13 0.10 8.27 80

3 - 95.88 1.20 1.00 0.39 1.53 4.12 -

4 114 96.00 2.01 0.21 1.47 0.31 4.00 102

5 - 98.19 1.27 - 0.08 0.46 1.81 -

6 - 99.09 0.78 - 0.05 0.08 0.91 -

7 110 97.40 1.55 - 0.15 0.90 2.60 99

7 * - 92.94 0.54 - 0.06 6.46 7.06 -

8 111 97.19 1.83 - 0.09 0.89 2.81 100

9 123 96.88 0.75 0.06 1.52 0.79 3.12 111

10 109 90.13 3.31 0.25 2.00 4.31 9.87 91

11 112 99.15 0.60 - 0.08 0.17 0.85 103

12 - 97.98 1.72 - 0.04 0.26 2.02 -

13 - 97.08 0.62 0.02 0.12 2.16 2.92 -

14 136 98.50 0.72 0.12 0.26 0.40 1.50 124

15 - 98.92 0.79 - 0.01 0.28 1.08 -

16 137 97.55 1.44 - 0.60 0.41 2.45 124

17 113 96.96 1.00 0.15 0.87 1.02 3.04 102

18 118 98.82 0.69 - 0.42 0.07 1.18 108

19 120 98.86 0.52 - 0.39 0.23 1.14 110

19 * - 97.10 0.72 - 1.98 0.20 2.90 -

20 114 96.94 1.09 0.04 0.12 1.81 3.06 103

21 96 99.35 0.49 0.13 - 0.03 0.65 89

22 131 98.01 0.63 1.04 0.32 - 1.99 119

22 * - 98.10 0.79 - 0.68 0.43 1.90 -

23 103 97.15 0.80 0.80 0.68 0.57 2.85 93

23 * - 97.56 1.74 - 0.61 0.09 2.44 -

24 110 93.83 1.70 0.36 1.64 2.47 6.17 96

24 * - 94.57 1.23 - 2.03 2.17 5.43 -

25 118 93.22 2.83 0.86 2.04 1.05 6.78 102

26 106 96.21 1.79 0.03 0.28 1.69 3.79 94

27 129 92.33 4.17 0.20 1.20 2.10 7.67 111

28 108 97.07 1.29 0.05 0.36 1.23 2.93 97

Table 9Product diversification - mill-wise

(as a % of total yarn production)


Mill Doubled 100% 100% Cotton/ref. Gassed cotton non- MMFno. Ring TFO Eli-twist cotton blendedE

xpor

t

Com

bed

Hos

iery

Com

pact

Che

mic

alpr

oces

sed

45 _____SITRA

1 100 100 100 - - - 100 - - 100 - -

2 100 100 - 54 40 - - - 31 100 - -

3 52 80 98 - 11 - - - - 27 7 66

4 98 30 98 - - - 93 - - 32 - 68

5 80 100 78 - - 5 - - - 100 - -

6 12 100 40 - - - 67 - - 100 - -

7 41 100 - - 47 - 100 - 10 100 - -

7* 6 - 6 - - - - - - 100 - -

8 - 100 - - - - 100 - - 100 - -

9 4 - 100 - - - 42 - - 27 - 73

10 - 80 100 - - - - - - 100 - -

11 81 100 81 - 10 - 72 - - 100 - -

12 18 19 65 - 8 - 15 - - 43 - 57

13 74 83 76 - - - 18 - - 74 9 17

14 72 45 73 1 19 - 1 - - 100 - -

15 6 66 6 - - - 55 - - 71 - 29

16 50 100 100 - - 8 100 - - 100 - -

17 60 75 100 - - - 100 - - 100 - -

18 - 100 11 - - 1 100 - - 100 - -

19 - 100 44 - 34 - 100 - - 100 - -

19 * - - - - - - - - - 100 - -

20 16 63 - - 28 - - - - - 37 63

21 52 95 6 6 40 - 21 - 15 100 - -

22 62 13 64 - 25 - - - - 100 - -

22 * 55 - - - - - - - - 68 - 32

23 - 92 - - 2 5 83 - 2 83 4 13

23 * - - - - - - - - - 100 - -

24 90 91 54 - - - 99 - - 40 - 60

24 * - - - - - - - - - 100 - -

25 - 100 - - 5 - 100 - - 100 - -

26 - 100 10 - 15 - 100 - - 100 - -

27 34 1 43 - 18 - 3 - - 30 16 54

28 62 100 39 - 19 - 16 - - 100 - -

Table 10Yarn selling price, raw material cost,

net out-put value and yarn quality - count-wise

49 _____SITRA


Yarn Raw Net out-put value Ring yarn qualityMill selling material Hairi-ref. price cost (Rs/ (Rs/ Count Imperfections/1000 m nessno. (Rs/ (Rs/kg kg of spl./ CV% CSP@ U% index

kg) of yarn) yarn) shift)* Thin Thick Neps TotalStr

engt

hC

V%

Ring spun yarn

Cotton carded yarn

Domestic market

12s K86 160.0 147.4 12.6 5.0 1.4 2580 3.3 10.2 0 80 94 174 -

16s K32 173.0 138.0 35.0 11.8 1.3 2340 4.7 13.1 19 290 289 598 9.2

20s K15 195.0 132.9 62.1 19.9 1.0 2600 3.1 11.0 1 90 127 218 7.222 188.6 138.7 49.9 15.6 1.0 2750 3.2 11.0 1 95 57 153 6.9

101 196.0 157.0 39.0 8.6 - - - - - - - - -Avg. 193.2 142.9 50.3 14.3 1.0 2670 3.1 11.0 1 93 92 186 7.1

24s K69 204.8 150.7 54.1 12.2 1.2 - 3.5 10.8 2 91 220 313 -22 185.6 138.7 46.9 12.1 0.9 2700 3.3 11.5 2 149 108 259 6.5

29s K77 189.4 155.0 34.4 6.0 2.1 2190 4.5 13.1 50 711 991 1752 -

32s K72 201.0 151.0 50.0 7.3 1.6 2630 4.1 12.6 7 363 702 1072 -67 182.1 145.5 36.6 5.3 1.2 2610 5.0 11.9 5 246 657 908 -

34s K67 197.0 145.5 51.5 6.6 1.4 2600 4.5 12.2 9 288 760 1057 -85 198.2 149.5 48.7 6.2 1.0 2420 3.7 14.3 53 693 2272 3018 -

102 197.1 151.2 45.9 4.7 2.1 2210 5.3 14.0 41 632 645 1318 -Avg. 197.4 148.7 48.7 5.8 1.5 2410 4.5 13.5 34 538 1226 1798 -


80 _____SITRA

Table 11Yarn realisation & wastes and raw material quality - count-wise

Stre

ngth

(g/te

x)

Blo

w r

oom

& c

ard

was

te(%

)Yarn realisation and wastes Average cotton quality

Mill Yarn Hard Sweep Invisible Proportion of 2.5% Unifor- Fine- Trashref. reali- waste waste loss cotton(s) in span mity ness inno. sation (%)* (%)* (%)* the mixing** length ratio (µg/ mixing

(%) (mm) (%) inch) (%)

12s K

86 84.5 12.3 0.7 1.0 0.5 B1 (100%) - - - 3.7 4.0

16s K

32 83.3 14.8 0.5 0.6 0.5 S6 (75%)+V (25%) 25.9 47.7 19.0 3.8 7.2

20s K

22 87.8 10.7 0.5 0.1 0.9 - - - - 4.5 3.2

15 86.9 10.5 0.6 0.2 1.4 - - - - 4.0 2.6

101 84.9 11.8 0.8 1.8 0.7 B2 (100%) 29.6 46.1 21.6 - 3.9

Avg. 86.5 11.0 0.6 0.7 1.0 - - - - 4.3 3.2

24s K

22 87.8 10.7 0.5 0.1 0.9 - - - - 4.5 3.2

69 84.2 11.8 0.6 0.9 (+) 0.1 M2 (100%) - - - 4.3 3.4

29s K

77 86.1 11.0 0.8 1.2 1.0 B2+H 29.7 46.5 24.6 - 3.4

32s K

67 86.9 11.4 0.4 0.7 0.5 M1 (100%) 29.9 47.3 24.6 4.6 2.5

72 86.1 11.2 0.5 0.7 1.6 B1 (100%) 30.0 48.0 - 4.1 3.0

34s K

67 86.9 11.4 0.4 0.7 0.5 M1 (100%) 29.9 47.3 24.6 4.6 2.5

85 85.3 10.4 0.6 1.0 0.1 M2 (100%) - - - 4.2 3.5

102 85.1 11.0 1.0 - 2.9 B2 (100%) 29.5 47.2 23.5 - -

Avg. 85.8 10.9 0.7 0.9 1.2 - 29.7 47.3 24.0 4.4 3.0

38s K72 86.1 11.2 0.5 0.7 1.6 B1 (100%) 30.5 48.0 - 3.9 3.0

102 85.1 11.0 1.0 - 2.9 B2 (100%) 29.5 47.2 23.5 - -

Ring spun yarn

Cotton carded yarn

Domestic market

Table 12Production parameters of spinning - count-wise

113 _____SITRA

Ring spun yarn

Cotton carded yarn

Domestic market

12s K86 12.2 398 10500 13.7 5.0 3.0 180x42 3024 6000

16s K32 16.0 337 14250 17.8 4.8 1.1 180x40 1440 AD

20s K15 20.2 320 18000 18.7 4.3 1.0 170x38 3600 AD22 20.2 312 17700 18.8 3.6 0.8 185x40 3360 AD

101 20.0 221 14200 20.6 8.8 4.0 178x40 1080 3200Avg. 20.1 284 16630 19.3 5.6 1.9 - 2680 -

24s K22 24.2 257 19150 20.7 3.4 0.8 185x40 3360 AD69 23.7 225 16000 19.9 4.7 2.3 170x38 1632 AD

29s K77 29.5 175 18000 24.2 4.6 2.2 - 1008 AD

32s K72 32.8 145 17230 24.0 7.0 2.7 152x36 3200 600067 32.5 144 17100 24.5 7.2 3.4 170x38 1800 4800

34s K67 34.5 128 - 26.3 7.8 3.5 170x38 1800 480085 34.5 128 16800 25.7 6.8 2.4 180x40 1656 4200

102 34.5 102 14200 26.7 10.0 3.5 170x38 1512 3200Avg. 34.5 119 15500 26.3 8.2 3.1 - 1656 4067

38s K72 38.5 113 16450 26.0 7.0 2.7 152x36 3200 6000

102 38.5 90 14800 29.0 12.5 3.5 170x38 1512 3200

Mill Actual Prodn./ Spindle End Pneumafil Lift (mm) Tenter* Doffer*ref. count@ spl./ speed Tpi breaks/ waste & ring assign. assign.no. (Ne) 8 hrs.(g) (rpm) 100 spindle (%) dia. (mm) (spls.) (spl.

hours doffs)


Table 13Production parameters of automatic cone winding - count-wise

144 _____SITRA


Ring spun yarn

Cotton carded yarn

Domestic market

Mill Production/ Average Drums Clearer Cop Deliveryref. tenter/ winding- assigned Efficiency cuts/one content cone wt.no. 8 hours on speed per (%)+ lakh (g) (kg)

(kg) (mpm) tenter metres

12s K86 500 1300 30 54 - 70 1.89

16s K32 521 1200 35 70 35 55 2.00

20s K15 - 1500 300 # - 90 50 2.5068 308 1100 30 66 32 45 1.50

101 287 900 30 75 60 60 1.50Avg. 298 1170 120 71 61 52 1.83

24s K14 1883 1577 146 # 69 30 61 2.8069 1894 1400 151 # 76 27 50 1.89

29s K77 275 1100 30 85 - 45 1.50

30s K68 - 1100 30 - 32 45 1.50

32s K67 378 1550 40 69 75 50 2.0072 215 1450 20 84 60 38 1.89

34s K67 352 1550 40 68 75 50 2.0085 368 1400 40 79 22 62 1.89

102 184 1000 30 74 41 40 1.50Avg. 301 1320 37 74 46 51 1.80

Table 14Production parameters of two-for-one twisting - count-wise


170 _____SITRA

Mill Production/ Average Breaks/ Feed Deliveryref. spindle/ spindle Tpi Efficiency 100 weight weight Spindles/no. 8 hours speed (%)

@spindle (g) (g) tenter

(g) (rpm) hours

Ring spun yarn

Cotton carded yarn

Domestic market

2/20s K15 838 9500 13.6 83 0.3 945 1890 158468 1250 10500 11.0 91 5.0 600 1500 240

2/24s K14 1214 9200 8.6 95 1.9 833 2500 245

2/30s K19 468 9000 17.1 93 0.5 945 1890 960

2/60s K90 158 10000 25.0 82 1.9 300 1500 432

2/40s K-Comp.79 243 7000 19.5 94 - 500 1500 480

2/60s K-Comp.79 131 8500 25.5 82 - 500 1500 480

Export market

2/20s K-Ex.22 1552 7000 5.5 85 0.5 1000 2000 2160

2/24s K-Ex.22 1202 8000 7.0 88 0.5 1000 2000 2160

2/30s K-Ex.57 518 10270 17.9 94 1.0 830 2520 456

Table 17Major counts spun by the mills


186 _____SITRA

Prodn. CountsMill of major spun during the quarter*ref. Major counts counts as Totalno. % of total Min. Max. Range per

prodn. 30000spls.

1 30s CH-Comp.-Ex., 26s CH-Comp.-Ex., 29s CH-Comp.-Ex., 100 26 32 6 5

28s CH-Comp.-Ex., 32s CH-Comp.-Ex.

2 2/30s C-Ex., 2/38s C-G-DHCR-Ex., 2/60s C-Ex., 36 30 115 85 9

2/60s C-G-Ex., 2/100s C-G-Ex.

3 30s CH-Slub, 40s Mod./C-CH-Slub (40/60), 20s KH, 10 10 40 30 -

32s C/A-KH (49/51), 18s C/A-KH-Ex. (48/52), 30s C/A-CH-Ex. (48/52)

4 40s CH-Comp.-Ex., 30s P/C-KH-Comp.-Mel.-Ex. (10/90), 74 20 60 40 10

32s P/C-CH-Comp.-Ex. (45/55), 30s P/C-CH-Comp.-Ex. (45/55),

32s P/C-KH-Comp.-Mel.-Ex. (01/99), 40s C-Comp.-Ex.

5 20s CH-Comp.-Ex., 26s CH-Comp.-Org.-Ex., 30s CH-Comp.-Ex., 69 - - - -

2/40s C-ET, 40s CH-Comp.-Org.-Ex., 32s CH-Comp.-Ex.

6 30s CH-Ex., 40s CH-Ex., 40s CH, 50s C-Comp.-Ex., 50s C-Comp., 47 30 80 50 8

60s CH-Comp.-Ex.

7 2/66s C-Comp.-Ex., 2/80s C-Comp., 80s C-Comp., 70s C-Comp., 31 60 160 100 13

2/100s C-Comp.-Ex., 7s OE

8 50s C-Comp., 50s C-Comp.-Ex., 70s C-Comp.-Ex., 30 30 80 50 5

60s C-Comp., 60s C-Comp.-Ex.

9 30s P/C-CH-Comp. (20/80), 24s P/C-CH (40/60), 30s P/C-CH (40/60), 49 10 42 32 52

30s P/C-CH (48/52), 30s CH-Comp., 36s CH-Comp.

10 30s CH-Slub, 30s CH, 34s CH, 36s CH, 40s CH, 30s KH 76 25 40 15 35

11 40s CH-Comp.-Ex., 40s CH-Comp., 50s CH-Ex., 60s C-Comp., 100 40 60 20 5

2/40s C-Ex.

12 20s P/C-CH (48/52), 24s P/C-CH (48/52), 30s P/C-CH (48/52), 62 10 42 32 6

40s P/C-CH (48/52), 20s CH, 40s C-Comp.

13 30s CH-Ex., 24s CH-Ex., 30s CH-Comp., 32s CH-Ex., 30s CH, 57 16 120 104 29

40s CH-Comp.-Ex.

14 26s CH-Ex., 21s KH-Ex., 16s K-Ex., 2/24s K, 32s KH-Ex., 21s CH-Ex. 41 12 40 28 7

15 40s C-Comp., 30s C-Comp., 20s K, 20s P/C-C (65/35), 32 10 45 35 8

30s P/C-C (65/35), 40s P/C-C (65/35)

16 24s CH-Comp.-Ex., 26s CH-Comp.-Ex., 28s CH-Comp., 100 24 34 10 7

30s CH-Comp.-Ex., 34s CH-Comp., 2/40s CH-ET

17 30s CH-Comp., 34s CH-Comp.-Ex., 40s CH-Comp.-Ex., 87 30 44 14 7

40s KH-Comp., 42s CH-Comp.-Ex., 44s CH-Comp.-Ex.

Table 18Installed capacity - spinning and post spinning - mill-wise

Mill Year Ring Doubling TFO Auto No.of daysref. of esta- spindles@ Rotors spindles spindles winder workedno. blishment drums during the

quarter

192 _____SITRA


1 2017 27500 - - - 660 92

2 1956 57500 - 22544 8160 1096 91

3 * 1965 47500 - - 1728 1020 91

4 * 1981 62500 - - 2368 1568 91

5 * 2012 56500 - - - 1565 91

6 * 1998 55500 - - - 1392 91

7 * 1956 31000 576 - 10592 620 90

8 * 1992 56500 - - - 1244 90

9 * 1993 35000 - - - 840 89

10 2014 13000 - - - 324 91

11 * 1994 51000 - - 1920 1064 90

12 * 2002 87500 - 186 3996 2346 91

13 1996 44000 - - - - 91

14 * 1991 115000 - 1760 4428 2413 91

15 * 2007 115000 - - 7920 2842 91

16 2015 27500 - - - 660 92

17 1996 24500 - - - 560 91

18 * 2006 56000 - - - 960 91

19 * 1953 57000 3320 - 5760 972 91

20 * 1995 66000 - - 5036 1440 91

21 * 1947 119000 - 14592 19928 1804 91

22 * 2007 28500 2208 112 2160 617 91

23 * 1990 103500 720 - 3900 1140 91

24 * 1946 41000 1440 - 2124 896 91

25 2006 27500 - - 1824 440 92

26 * 1992 36000 - - 4056 690 91

27 * 1981 108000 - - 8442 3050 91

28 * 2007 62500 - - 6828 1140 91

29 * 1994 55500 - - - 1140 92

30 * 2006 14000 - - - 188 91

31 * 1989 63500 - 8224 17908 1768 91

32 1956 30000 - - - 500 90

33 1995 35000 640 - 2352 660 85

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