Woven Labels - Plant Setup

1
Woven Labels
A brief case study on woven labels and manufacturing for apparel industry

3
 Labels are not a functional component of a garment but essential for many reasons. 7 common labels those are found in garments
are Brand label, Size label, Care label, Flag label, Manufacturer code, Line mark label and special label.
 Each label has a specific purpose and carries some kind of information.
 Labels are among the main trims used in garments. Various information about garments are printed on the printed label - like fiber
content, wash and care instructions, size of the garment, and brand name.
 There are two types of labels used for garment labeling.
• Woven labels
• Printed labels
‐ The printed label is the label that is printed by ink on a narrow fabric or ribbon.
‐ The printed label production method, machines and equipment requirement are discussed in this article.
Labels in Apparel Manufacturing

4
Brand or
Main Label:
• Main labels
indicate a
Brand name or
Brand Logo of
the company
that sources
and sells
clothes.
• Woven
Size Label:
• Size label
defines a
specific set of
measurements
of the human
body. Sizes
labels may be
printed only a
later to denote
a specific size.
• Woven
Care Label:
• This label
includes wash
care and
ironing
instruction.
• Fiber contents
are also
included in care
labels. i.e. 40%
Poly and 60%
Cotton
• Printed
Flag Label:
• A small label
attached at
outside side
seam. Flag
labels are
normally made
of brand logos
and it is
primarily used
as design
features.
• Woven
Manufacturer
Label:
• This label
includes
manufacturer’s
code given by
buyers.
• Printed
Batch Mark
Label:
• A label that
indicates which
sewing line or
batch had
made the
particular
garment. This
label normally
is not asked by
buyers or
brands.
• Printed
Special Label:
• 100% Cotton,
Organic Cotton
are an example
of such special
labels. Special
labels normally
attached to
draw customer
attention at the
time of
purchasing.
• Woven
Types of Label used in a Garment

5
 Different types of printed labels
• Printed wash & care label,
• Printed content label
• Printed date/size label,
• Brand label,
• Special label
 Material Used for making printed care label
• Satin Tape/Ribbon Tape
• Liquid Ink
• Reducer Mix
• Color Smoothing agent
• Drying agent
Printed Labels

6
 Machine used for Care Label and Size label Made
• Label Printing Machine – 2 types of printing machines are
used
‐ Flexo-graphic printing machines - 6 color printing
machine and 3 color printing machine
‐ Rotary printing machine-6 color printing machine and
3 color printing machine
• Curing Machine
• Label Ultrasonic Cutting Machine
Printed Labels
Label printing machine
Label printing machine
Ultrasonic label cutting machine

7
 Woven labels are the icing on the cake when it comes to your finished product. Consumers know that a finely woven label takes more
time and money to create than a printed one. This dedication to quality gets recognized and appreciated, and becomes associated
with your brand.
 Brand identity is an essential part of a successful business, and in order to build a successful brand, one in which customers return to,
you need to let them know your quality is always there, even in something as small as a label.
 A woven label is not only a brand identification its also a way to emphasise quality and elevate a garments differentiation from
another.
Importance of Woven Labels

8
 What Is A Printed Label?
• These are commonly made of satin, cotton, tyvek, or a
poly blend fabric.
• These tags are made by making the tag itself first and then
digitally printed on the logo, instructions, or whatever you
need to go on the label.
• Labels like this are soft but they may not hold up over time
and many machine washes.
 What Is A Woven Label?
• Woven labels are made on a loom instead of being digitally
printed.
• This means that the design in your logo, text, and artwork
are actually woven into the tag rather than printed onto it.
• These labels are soft and usually a bit more durable than a
printed label.
• These tags can be made out of a variety of materials and
each comes with its own advantages and disadvantages.
Difference Woven and Printed Labels

9
 Woven labels are the icing on the cake when it comes to your finished product. Consumers know that a finely woven label takes more
time and money to create than a printed one. This dedication to quality gets recognized and appreciated, and becomes associated
with your brand.
 Brand identity is an essential part of a successful business, and in order to build a successful brand, one in which customers return to,
you need to let them know your quality is always there, even in something as small as a label.
 A woven label is not only a brand identification its also a way to emphasise quality and elevate a garments differentiation from
another.
Importance of Woven Labels

10
TaffetaWovenLabels
•These labels are made from
woven polyester threads.
Taffeta is a thicker, slightly
stiffer fabric.
•The background of the design
is made of taffeta, while
damask threads make up the
text and design.
•It is also typically priced a
little lower than other
options, so it’s a good
economic choice. SatinWovenLabels
•Satin labels, made from
woven satin polyester
threads, are soft and shiny.
•They are recommended for
items that need to be soft to
the touch such as baby
clothes.
•The text and design of a satin
label is made with damask
threads, but the background
is the satin fabric which
comes in limited colors.
•The luxurious look of satin
labels is also great if you have
vintage style pieces.
DamaskWovenLabels
•These are the most common
clothing labels. Made from
100% polyester damask
threads, they have the
highest thread count which
means they show small
details of text and design
better than other options
making them great for
customizing with your own
logo.
•While these labels are priced
the highest, they’re the best
quality. They’re soft and
durable, and they offer the
best variety of color options.
Types of Woven Labels

11
TaffetaWovenLabels
• ADVANTAGES
• Lower cost
• Weave displays small text pretty
clearly
• Dries quickly, good for use in
items that might get wet such as
swim suits or towels
• More background colors
available than satin
• DISADVANTAGES
• Thick fabric feels
scratchy/uncomfortable against
skin
• Not as durable as other fabrics
such as satin and damask
• Weave does not display artwork
as clearly
SatinWovenLabels
• ADVANTAGES
• Soft feel
• Shiny, luxurious look
• Durable, stands up through
washes and wear and tear
• Great for vintage style pieces
• DISADVANTAGES
• Priced higher than tafetta
• Low thread count means weave
does not display design details as
clearly
• Limited background color choice
DamaskWovenLabels
• ADVANTAGES
• High quality
• Soft feel
• Durable, color safe, will last
through wear and tear and
washes
• Best display of details and text
• Widest variety of color options
• DISADVANTAGES
• More costly
Types of Woven Labels

12
 Step one - Concept and Design
• To start things off, the client will give a brief for the design. This brief will cover brand imaging, including colours, size, logos and
any text to be included on the label.
• Once label manufacturers get to work and come up with a proposed design for the label. They send their proposal back to the
client, and once everything's approved, they were ready for the next stage in the manufacturing process.
Manufacturing Process of Woven Labels

13
 Step two - The Prototype
• Using special weaving software, the artwork is transferred into a digital image, ready for the computer to take over. Unique
colours and sizes are added, as well as complex details such as weaving tension, warp type, number of picks per cm, and
finishing.
• Once all the details are created digitally, a test label is woven on the loom. Finished off by hand, the prototypes are then sent to
the client for approval.

14
 Step three - Large Scale Production
• Once the test labels are approved, the design is scheduled for production.
• The large industrial looms are used for mass production, and once the required number are produced, they are all joined
together in one long roll. These rolls are checked for quality and faults, and if there are no problems, the next step is the relevant
finishing machine.

15
 Step four - Finishing and Boxing
• Finishing involves cutting, folding and boxing the labels, ready for dispatch. The finished produced is carefully checked for quality
one more time, before being counted and weighed for packing and dispatch across the globe.

16
Case Study – Woven Label Manufacturer, Punjab

17
 INTRODUCTION
• Labels are used in every garment industry of Textile and Leather as well as by the tailors to give the identity of the manufacturers
and the specifications of the material used. With the increasing awareness of the consumer towards the better quality product
and feeling the brand consciousness, this has become a necessity for the garment manufactures and the tailors.
 MARKET POTENTIAL
• There are very few units in the State which are engaged in manufacturing lables. These labels are required by each and every
type of garment manufacturing unit as well as leather products.
• Due to the increase in the production of garments, the demand of labels is also being increased day-by day. The export of
readymade garments to different countries has also been increased. Still there is a gap of supply of labels to the manufacturing
units.
• There is good scope if some units come forward for manufacturing of labels.
Case Study – Woven Label Manufacturer

18
 BASIS AND PRESUMPTIONS
1. The scheme has been prepared on the basis of 75% efficiency on single shift considering 25 working days in a month.
2. The rate of 10% interest in the scheme has been worked out on the basis of 10% on an average however, this figure is likely to
vary depending on the financial out-lay of the project as well as location of the unit.
3. The break-even point in the scheme has been calculated on the full capacity utilization basis.
4. The cost of machinery and equipment as indicated are approximate which are fuling locally at the time of preparation of the
scheme when a tailor cut project profile is prepared, necessary changes are to be made.
5. The rate quoted in respect of salaries and wages for workers and others are the minimum rates in the State, neighbouring
states.
6. Margin money required is minimum 30% of the Projected investment.
7. After the initial gestation period of one and half year, it will require approximately 4 years to pay back the loans.
8. Working capital for 3 months has been taken into consideration for smooth running of the project.

19
 IMPLEMENTATION SCHEDULE
S. No. Activity Period
1. Preparation of the Project Report:
a) Calling quotations
b) Preparation of Project report
1 month
2 weeks
2. Provisional registration as SSI unit 1 week
3. Financial arrangements 3 months
4. There is no need for Pollution Control equipment. Even then NOC from Pollution
Control Board is required
1 week
5. Purchase and procurement of machinery and equipments 3 months
6. Installation of machines and equipments 2 months
7. Electrification 1 month
8. Recruitment of staff 2 months
Total 1 Year

20
 TECHNICAL ASPECTS
• Process of Manufacture –
‐ The main raw material required to manufacture Labels is Polyster Yarn/Silkyarn/Cotton yarn/Viscose yarn/ Blended yarn of
different counts and colours. The yarn normally comes in the market on cones, from these cones warp is made on warping
machine. The design which is required to be produced is punched through punching machine on card.
‐ Some people use few ends of Jari yarn to enhance beauty of the label.
‐ The width of the label depends from one inch to two inches. Accordingly, the warp is made and the yarn is inserted to
shuttle for weaving the labels in a continous length.
‐ These labels are checked and packed for marketing to the garment manufacturers.
• Quality Control and Standards –
‐ The Bureau of Indian Standards has not brought out any specifications for labels. Labels are manufactured as per the
customer design and selection of material.
‐ So far, no unit is adopting any quality standard for this purpose. However, quality of the woven labels depends upon the
materials use and the fast colour of the yarn used for manufacturing woven labels.

21
 TECHNICAL ASPECTS
• Production Capacity –
• Pollution Control –
‐ No effluents are required, since the process involves weaving of yarn into woven labels. So, there is no requirement of
installation of effluent plant.
• Energy Conservation –
‐ Energy Conservation has become essential in these days. It becomes the individuals duties to realise its necessity.
Quantity Value (Rs.)
42,50,000 labels 19,12,500

22
 FINANCIAL ASPECTS
• A. Fixed Capital
‐ (i) Land and Building
‐
‐ (iI) Machinery and Equipments
Land and Building Value (Rs.)
Rented 7,500 sq. ft. @ Rs. 20 sq. ft. 1,50,000
S. No. Description Unit Rate (Rs.) Total (Rs.)
1. Reel Winder 8 spindle. 1 50,000 50,000
2. Pirn winder 8" (Automatic) 1 1,75,000 1,75,000
3. Beam winding M/c (Warping) 1 75,000 75,000
4. Woven Labels making machine with
Jacquard
8 25,00,000 2,00,00,000
5. Creel Stands 1 30,000 30,000
6.
Card punching and stitching machine 1 70,000 70,000
Total 13 29,00,000 2,04,00,000

23
• A. Fixed Capital
‐ (iii) Other Fixed Assets
 TOTAL FIXED CAPITAL –
Other Fixed Assets Value (Rs.)
Electrification and Installation Electric Motors 1,50,000
Furniture and office equipments 2,00,000
Total 3,50,000
Descriptions Value (Rs.)
Land and Building 0
Machinery and Equipments 2,04,00,000
Other Fixed Assets 3,50,000
Total 2,07,50,000

24
• B. Working Capital (per month)
‐ (i) Staff and Labour (per month)
Designation No’s Salary per Person Total Salary
Administrative and Supervisory
1. Manager 1 50,000 50,000
2. Supervisor 1 25,000 25,000
3. Accountant 1 30,000 30,000
4. Peon/Watchman 1 10,000 10,000
Skilled/Unskilled Worker
1. Operators for label making machines 5 15,000 75,000
2. Operators (Real winder pirn winder/Beam
winder)
3 12,000 36,000
3. Helpers 3 8,000 24,000
Management Expenses 1,50,000 1,50,000
Total 15 3,00,000 4,00,000
Perquisites @ 20% 20% 60,000 80,000
Total 4,80,000

25
‐ (ii) Raw Material (per month)
‐ Note :
 Woven Labels are also made out of cotton, silk and nylon yarn.
 For calculations purpose, we have mentioned here polyester and viscose yarn.
‐ (iii) Utilities (per month)
Raw Material (per month) Value (Rs.)
Polyster yarn III denier 600 kg. @300 1,80,000
Viscose yarn 120 denier 200 kg. @250 50,000
Total 2,30,000
Utilities (per month) Value (Rs.)
Power and Electricity 70,000

26
‐ (iv) Other Contingent Expenditure
Other Contingent Expenditure Value (Rs.)
1. Rent 10,000 1,50,000
2. Postage and stationery 2,000
3. Repair and maintenance 10,000
4. Telephone 3,000
5. Transportation charges/cartage 5,000
6. Oil and Lubricants 5,000
7. Insurance 5,000
8. Office expenditure 4,000
9. Packing expenses 10,000
Total 1,94,000

27
‐ (v) Total Working Capital (per month)
‐ (v) Total Working Capital for 3 months = 9,74,000 * 3 = Rs. 29,22,000
‐ (vi) Total Capital Investment (Machinery and Equipment's + Total Working Capital for 3 months )
 = 2,07,50,000 + 29,22,000 = Rs. 2,36,72,000
Working Capital (per month) Value (Rs.)
Staff and Labour 4,80,000
Raw Material 2,30,000
Utilities 70,000
Other expenditure 1,94,000
Total 9,74,000

28
• 1. Cost of Production (per month)
Cost of Production (per month) Value (Rs.)
Raw Material 2,30,000
Staff and Labour 4,80,000
Utilities 70,000
Other contingent expenses 1,94,000
Depreciation on Machinery @ 6% 1,02,000
Interest on total investment @ 10% 1,97,267
Depreciation on Office furniture. 40,000
Total 13,13,267

29
 FINANCIAL ANALYSIS
• 2. Turn Over (per month)
• 3. Net Profit (per month)
Turn Over (per month) Value (Rs.)
By sale of : 42.5 Lacs Labels @ Rs. 450 per thousand 19,12,500
Net Profit (per year) Value (Rs.)
Profit = Sales - Production Cost
= 19,12,500 - 13,13,267 =
5,99,233

30
• 6. Break-even Point
‐ = Total Investment/Net Profit
‐ = 2,31,32,000 / 5,71,233
‐ = 40 months
• 4. Net Profit Ratio
‐ = Net Profit per year × 100
Turn over per year
‐ = 31%
• 5. Return on Investment (ROI) –
‐ = 3.3 : 1 ratio

31
Machines and Suppliers Details

32
 Addresses of Machinery Manufacturers and Suppliers –
• 1. M/s. Nota Machinery Works, Industrial Area-A,
Ghorrawali Factory, Ludhiana.
• 2. M/s. Nota Machinery Corporation, Sherpur, Ludhiana.
• 3. M/s. Hamdard Textile Engineers, Putlighar, Amritsar.
• 4. M/s. Guru Nanak Textile, Machinery Manufacturers, G.T.
Road, Amritsar.
• 5. M/s. Nanak Chand and Sons, Ganesh Nagar, St. No. 3,
Link Road, Ludhiana.
Suppliers for Woven Label Manufacturing
 Raw Material Manufacturers and Suppliers –
• 1. M/s. J.C.T. Ltd., Phagwara (Punjab).
• 2. M/s. Modi Cone Ltd., Modinagar-201204.
• 3. M/s. Esslon Synthetics Ltd., Dakshineshwar Building, 10-
Hailey Road, New Delhi.
• 4. M/s. Shree Shyam Filaments, 15/17, Barwar House,
Ajmer Road, Jaipur-110065.
• 5. M/s. Rajasthan Patro Synthetics Ltd., 4, Community
Centre, East of Kailash, Delhi-110065.
• 6. M/s. J.K. Synthetics Ltd., Kota.
• 7. M/s. Vardhman Spinning and General Mills Ltd., Samrala
Road, Ludhiana.
• 8. M/s. Mahavir Spinning and General Mills Ltd., Hoshiarpur
(Punjab)
• 9. M/s. Govindwal Cooperative Spinning Mills, Goindwal
Sahib, Amritsar (Punjab)

33
 Woven Label Machines
 Features:
• Technically precise
• Superior in functioning
• Durable
• Rugged in construction
• Rust proof
 Price:
• Approx. Rs 25 Lakh / Onwards
Machines used for Woven Labels

34
 Woven Label Machine
 Features:
• Robust construction
• Low maintenance
• Long working life
 Price:
• Approx. Rs 20 Lakh / Onwards

35
 Vaupel Label Machine
 Features:
• Trouble free operations
• Corrosion resistance
• Energy efficient
• Longer service life
 Price:
• Approx. Rs 2.5 Lakh / Onwards

36
 Mei Dornier -
The Most Efficient Woven Label Loom in the World
 Features:
• Model- Dornier Vaupel MEI DA18-TER-S1-T
• Type- Slitting MEI
• Harness Type- Taffeta 2,900 Threads
• Colors- 8 Colors
• Repetitions- 8 repetitions of 200mm
 Price:
• N/A

37
 Vaupel Dornier - EWM90-180E
 Features:
• Model- Vaupel Dornier EWM90-180E
• Harness Type- Satin & Staubli Jacquard LX
• Colors- 8 Colors
• Type- Satin
• Repetitions- 8 repetitions of 200mm
 Price:
• N/A

38
 Advantages To Rapier Looms:
• More productive per Square Mt, less factory space!!
• Servo motor for warp beam.
• Servo motor for Pick control.
• Digital warp sensor controlling up to 30 denier warp
denier.
• Automatic start and weft fixer.
• 50% less operator vs mugrip.
• Lower energy cost vs small loom of 1 Mt. Guaranteed Low
weaving defects and jacquard mistakes.
• Staubli Jacquard is the Leader in the technology.
• Jacquard will not need to use floppy-can be sent directly
via IP to the loom.
• Labels ready from the loom due to professional
thermofixing.

Woven Labels - Plant Setup

Empfohlen

Empfohlen

Weitere ähnliche Inhalte

Was ist angesagt?

Was ist angesagt? (20)

Ähnlich wie Woven Labels - Plant Setup

Ähnlich wie Woven Labels - Plant Setup (20)

Mehr von Abhishek Raj

Mehr von Abhishek Raj (20)

Kürzlich hochgeladen

Kürzlich hochgeladen (20)

Woven Labels - Plant Setup