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Textile Costing · Lecture 22
Concept of Routes
Different process routes for the same dyed fabric cost very different amounts; building the per-metre cost of one process from machine depreciation and utilities.
Process routesCost per metreBleaching cost build-up
Five ways to dye a fabric
A dyed fabric can reach the same shade through different sequences of machines. Each process has a cost per metre; the route cost is the sum. Choose a route in the sheet to see its cost, and edit the process costs to reflect your own plant.
| A | B | ||
|---|---|---|---|
| 1 | Cost per metre by process | ||
| 2 | Bleaching | ||
| 3 | Cold pad batch dyeing | ||
| 4 | Mercerizing | ||
| 5 | Pad steam dyeing | ||
| 6 | Stenter | ||
| 7 | Stenter dyeing | ||
| 8 | Thermosol | ||
| 9 | Washing | ||
| 10 | Routes | ||
| 11 | 1. Bleaching → Mercerizing → Pad steam dyeing → Stenter | 34.05 | |
| 12 | 2. Bleaching → Mercerizing → Thermosol → Washing → Stenter | 38.05 | |
| 13 | 3. Bleaching → Pad steam dyeing → Stenter | 20.05 | |
| 14 | 4. Bleaching → Cold pad batch dyeing → Washing | 13.05 | |
| 15 | 5. Bleaching → Mercerizing → Stenter dyeing | 25.05 | |
| 16 | Selected route | ||
| 17 | Cost per metre of selected route | 34.05 | |
blue = input (edit me)grey = formula (click to see it)
Route 4 (cold pad batch) costs a third of route 2, but it is slower, ties up fabric for batching time and suits reactive dyes only. Routing is a cost decision and a quality and delivery decision — the costing sheet gives the price of each choice.
Where the Rs 3.05 for bleaching comes from
A continuous bleaching range costing €2.5 million is depreciated over ten years with 10% a year of financial cost on top. Spread the yearly amount over the hours of the year, convert to rupees, divide by the metres the machine actually processes in an hour, and add chemicals and the utilities it consumes per hour.
| A | B | C | |
|---|---|---|---|
| 1 | Machine cost | € | |
| 2 | Depreciation period (years) | ||
| 3 | Financial cost (10% of machine cost per year) | 250,000 | € |
| 4 | Depreciation per year | 250,000 | € |
| 5 | Total capital cost per year | 500,000 | € |
| 6 | Per hour | 57.08 | € |
| 7 | Exchange rate (Rs/€) | ||
| 8 | Capital cost per hour (Rs) | 4,066 | |
| 9 | Speed (m/min) | ||
| 10 | Cloth processed per hour (m) | 7,800 | |
| 11 | Efficiency | ||
| 12 | Fraction of fabric undergoing this process | ||
| 13 | Effective cloth per hour (m) | 6,240 | |
| 14 | Capital cost per metre | 0.6516 | |
| 15 | Chemical cost per metre | ||
| 16 | Water: litres/hour × Rs/litre | ||
| 17 | Water cost per metre | 0.5288 | |
| 18 | Air: m³/hour × Rs/m³ | ||
| 19 | Air cost per metre | 0.1346 | |
| 20 | Steam: kg/hour × Rs/kg (2030+560+2820 kg) | ||
| 21 | Steam cost per metre | 0.3468 | |
| 22 | Power: kW × Rs/kWh | ||
| 23 | Power cost per metre | 0.3846 | |
| 24 | Total bleaching cost per metre | 3.0465 |
blue = input (edit me)grey = formula (click to see it)