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INDUSTRIAL EXTENSION BUREAU

Udyog Bhavan
Gandhinagar 382 011
Gujarat

MODERN GINNING AND PRESSING UNIT

I Product and its Applications

Cotton lint is produced from raw cotton (Kapas) by ginning process. Cotton seed is the
by-product of the ginning process. Lint cotton is one of the oldest and most known
commodity in our country. Trading of raw cotton and lint cotton is being carried out by a
large number of small and large traders and trading houses all over India. Gujarat is one
of the major centers for the same. Gujarat is also one of the major producers of both raw
cotton and lint cotton. With increasing awareness about use of cotton in the textile field,
demand for better quality of lint cotton has been increasing. The Cotton seed oil is well
accepted as a substitute of groundnut oil.

II An Overview of the Market

Cotton ginning and pressing units in Gujarat is estimated to be around 350 to 400. Since
Gujarat is one of the major producers of raw cotton, the number of such units has been
increasing.

It is estimated that in the year 1993-94, the total pressing done by the units in Gujarat was
to the tune of 21.37 lakh bales. In the following table, area-wise data of pressing work
carried out in the state is given for the last four years.
 1992-93 1993-94 1994-95 1995-96 1996-97 1997-98 1998-99
North Gujarat 7.68 8.43 10.47 12.92 14.78 18.94 21.50
Broach Line 3.45 3.56 3.67 4.04 4.14 4.45 4.30
A.P.Line 1.89 1.43 2.21 2.32 2.19 2.42 2.46
Saurashtra 10.20 7.49 11.60 13.82 14.98 16.45 19.53
Kutch Area 0.35 0.27 0.51 0.55 0.50 0.66 0.73
Surat Area 0.21 0.20 0.09 0.17 0.21 0.44 0.13
Total 23.78 21.38 28.56 33.82 36.80 43.06 48.65

(Source: GITCO Data Bank)

The total pressing of cotton bales during the period 1992-93 to 1998-99 was 238.05 lakh
bales. The average of these seven years comes to about 34.00 lakh bales while in the year
1998-99, the total pressing amounted to 48.65 lakh bales. However, as compared to 1992-
93 in the year 1993-94, there has been a decline of about 10% in the crop and resultantly
in the pressing activity.

As can be observed from the above table, North Gujarat and Saurashtra account for lions
share with North Gujarat accounting for about 44% of the pressing and Saurashtra
account for about 40% of the total pressing in Gujarat in the year 1998-99. It is also
observed that there has been significant rise in Saurashtra region after the year 1994-95.

III Suggested Project Size

The production capacity of the unit is determined on the basis of the output rates of the
ginning machines. The suggested machinery require for modern ginning and pressing unit
are 32 double roller gins, complete automatic pneumatic conveyer system, hydraulic
press and post cleaning machine.The calculation of installed capacity are as follows:

1) Proportion of lint cotton and cotton seeds is as under:

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 - Type of Cotton seeds : Sankar-4
- Raw Cotton : 100%
- % of Lint : 34%
- % of Cotton seed : 65%
- % of wastage : 1%

2) Installed Capacity:
50 (Kgs.) x 16 hrs. (i.e. 2 shift) x 234 days x 32 (Gins) = 5990 MTPA Lint
Cotton.

IV Raw Materials
Raw Cotton (Kapas) is the only raw material required which is easily available from
agriculture produce markets.

V The Suggested Location

The plant can be located at Ahmedabad, Sabarkantha, Surendranagar, Viramgam, Amreli
and Rajkot Districts.

VI TECHNOLOGY AND MANUFACTURING PROCESS

Technology Source
Modern technology for Cotton Ginning and pressing is available in our country from
leading textile research organizations like ATIRA, BITRA and CITRA. Cotton ginning
and pressing is well established industry in our country running for more than one
century. However, there is need to modernize this sector to make it more competitive and
produce cotton of international quality. In this context role of Textile research institutes
is very crucial and they are supplying technology of international level at most
competitive rate. Based on these technologies, Double roller Ginning, pneumatic cotton
handling system and post ginning cotton cleaning machinery as well as compact cotton
press have been commercialized in our country. Even they are also supplying cotton
testing machinery.
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 Manufacturing Process
Cotton lint is produced from raw cotton by ginning process. Cotton is passed between
toothed rolls, which are moving in opposite directions. Cotton lint is separated from
cottonseeds in this process. Cotton lint is coming out from one side and being light
weight from top. Cottonseeds, which are heavy, are collected at bottom of ginning
machine from bottom spout. This ginned cotton is pneumatically picked up from ginning
house and they are taken in hall for cotton storage. Prior to this cotton cleaning
machinery is used in which cotton lint is passed over moving belt containing steel wire
brushes and pneumatically dust, cotton stalks and other impurities are removed from
ginned cotton.

After this cotton is sent to intermediate storage hall where humidity is maintained using
humidifiers also called Bensaw machines. Cottonseeds are packed in gunny bags
manually and are sold to cottonseed crushing units or to people who use them as
cattlefeed directly.

Cotton from intermediate storage is kept under humid condition and cotton is picked up
pneumatically to pressing section. Here cotton is pressed in a hydraulic press to make
compressed bale of cotton. Usually each bale of cotton is having 170 Kg weight. Cotton
bales are tied using flat steel strips and Jute cloth is used to cover up entire bale. Now in
some places instead of Jute cloth HDPE / PP woven cloth is also used this also helps in
protecting cotton from moisture and dirt. During storage of cotton bales it must be kept
away from moisture and direct sun heat. Ideally if they are kept over wooden planks it
will protect them from moisture and dirt from ground.

VII Manpower & Utility

The total power requirement of the unit is estimated to be 165 HP.

Manpower Requirement
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 The unit will require 146 persons in various categories to carry out its operations
including 100 seasonal workers. Necessary manpower will be easily available from the
surrounding areas.

VIII PROJECT COST AND MEANS OF FINANCE

The unit will require following infrastructure requirement.
Land
Approximately 30,000 Sq.mtrs. of land required for the project.

Building
The project will require about 1900 sq.mtrs. of built up area. This is derived as follows.
Ginning House - 807 Sq.Mtr.
Cotton Seed Godown - 730 "
Cyclone Hall - 200 "
Office - 163 "
At the prevailing construction cost of Rs.2600/sq.mtr. The cost of the building will be
Rs.50.00 lacs.

Project Cost
Sr Particulars Cost (Rs.lacs)
No
1 Land 10.00
2 Building 50.00
3 Plant & Machinery 45.00
4 Other Assets 40.00
5 Electrification 35.00
Total 180.00

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XI FINANCIAL PROJECTIONS
(Rs. in lacs)
Sr Particulars 1st Year 2nd Year 3rd Year
No
1 Installed Capacity
(MT)
Lint Cotton 5990
Cotton Seed 11275
2 Capacity 80% 90% 90%
Utilization
3 Sales
Lint Cotton 2492 2803 2803
Cotton Seed 541 607 607
Total 3033 3411 3411
4 Raw Material 2748 3091 3091
Cost
5 Other Cost 227 241 240
6 Operating Profit 40.53 55.63 56.72

X CRITICAL FACTORS/KEY ELEMENTS

The Critical Factors
The most critical factor for the proposed project is Cotton Fiber quality. It will also be
important to monitor overall cotton lint yield in ginning process. The most critical factor
for Cotton ginning and pressing unit is its optimum operation. It must work at least for
more than 150 days per annum. This will ensure the economic viability of such unit.
Equally it will be very much important to have marketing tie-up for finished product at
best possible rate and terms. Furthermore, the quality of finished product has to be as per
international standards, for this also appropriately equipped quality control laboratory
will be necessity and properly trained manpower for the manufacturing as well as
laboratory will be critical.

The Key Element

The key elements for success of this project will be efficient operation of ginning and
pressing plant. The availability of water and electric power will also be key aspects for
successful smooth operation of such unit. As such water is not used in process directly

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 but for maintaining humidity during cotton storage and handling will be vital as this will
prevent loss of weight during ginning and pressing operation as well as it will help in
preventing occurrence of fire during post ginning open storage of cotton. Since, cotton is
sold to textile units through out year its proper storage is very much important. Usually
open type shade is used for such storage but in monsoon season proper godowns should
be used to prevent cotton bales picking up moisture and dirt. This will ensure round the
year remunerative price for cotton producer as it also prevents yellowing of cotton lint.
Though it is looking simple, it is strongly recommended that manpower should be trained
properly to have these key elements looked after properly.

XI GOVERNMENT FORMALITY/PROCEDURE
i) Term Loan Application with the State Financial Corporation or Banks.
ii) Electric Power Supply Application with GEB local office
iii) NOC certificate from Gujarat Pollution Control Board.

The Other Requirement

This unit will require manufacturing licensee from Secretariat of Industrial Approvals,
(SIA), Ministry of Industries, Govt. Of India, as it will have medium scale industrial
investment as ginning and pressing composite unit. As medium scale unit it will require
permission also from Textile ministry for ginning and pressing. In case unit is put up as
ginning and pressing unit separately, in that case it can have license from District
Industries Centers (DIC) and each of this section plant and machinery investment will be
in small scale investment level.

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XII Machinery & Plant Supplier

Sr No Particular Manufacturer
1 Ginning Machinery K K Engineering Co.
8, Sukrut Industrial Area
Near Bansidhar Mill, Naroda Road
Ahmedabad - 380 025
U D Patel & Co.
204, Vikas, II, Bank Street, Fort
Mumbai- 400023
Bajaj Steel Industries Ltd.
Imamabad Road, Nagpur - 440 018
Jadhao Gears
Shed No. W-2-A, Street No.5
MIDC Estate, Amravati-444 606 (Maharashtra)
Jagadish Auto Industries
Sakhiya Nagar, Gokuldham Main Road, Rajkot -4
2 Bale Press Machinery M/s.M Govind & Sons
Rajaj Garden, Guntur - 522 011
KAY BEE Industries
51, Rama Road, Najaf Ghar Road
Industrial Area, New Delhi - 110 115
Ajit Sons
B-40, Industrial Area, Phase-III,S A S Nagar, Mohali
General Engineering Enterprise
4, Vinod Chambers, 5th Floor, Outside Dariyapur Gate
Ahmedabad-4
3 Pneumatic Truemake Ginning Machinery
system/Cleaning 11, Sahajanand Industrial Estate
Machine Opp.Shri Rang Chemicals, Near Ambica Nagar, Odhav
Ahmedabad - 382 415
Note: This AVI Ginning Machinery
project profile 330,GIDC
is based on Odhav, Ahmedabad - 382 415
preliminary
study to M/s.General Engineering Enterprise
facilitate 4, Vinod Chambers, 5th Floor, Outside Dariyapur Gate
prospective Ahmedabad -4.
entrepreneurs
to assess a
prima facie
scope. It is,
however,
advisable to
get a detailed
feasibility 8 iNDEXTb
study
prepared
before taking
a final
investment
decision.