Fabric weaving and mill business in Bangladesh

 

What is fabric weaving?

Fabric weaving creates textile materials by interlacing thread yarns at right angles. It's one of the oldest techniques used to produce fabrics and has been a fundamental part of human history for thousands of years. Weaving involves crossing horizontal threads (weft or woof) through vertical lines (warp) in a specific pattern to create a cohesive and structured fabric.

The process of fabric weaving typically involves the following steps:

1. Warp Preparation: The warp threads, which run vertically on the loom, are measured, wound onto a beam, and then threaded through the loom's heddles and reed. The heddles allow for individual control of the warp threads during weaving, while the reed helps maintain the spacing of the lines.
2. Setting Up the Loom: The warp threads are attached to the loom, a frame designed to hold the cables under tension. Use the heddles to raise and lower specific warp threads, creating an opening called the shed through which we will pass the weft threads.
3. Weft Insertion: The weaver weaves the weft threads through the shed by raising some warp threads using the heddles. The weft is passed through the shed using a shuttle, a bobbin, or other weaving tools. After passing the weft through, the shed is closed by lowering the raised warp threads.
4. Beating the Weft: The newly inserted weft thread is beaten down tightly against the previous row of weft using a comb-like tool called a beater. This action helps compact the lines and creates a dense, even fabric.
5. Repeating the Process: Steps 3 and 4 are repeated, with the shed alternately created by raising different warp threads. The weaver continues to interlace warp and weft threads until they weave the desired length of fabric.
6. Finishing: The fabric is removed from the loom once the weaving is complete. It may undergo various finishing processes, such as washing, ironing, and cutting, to achieve the desired texture, appearance, and dimensions.

Weavers can create patterns, textures, and designs by varying how the warp and weft threads interact. Different types of looms, weaving techniques, and materials also contribute to the versatility of woven fabrics. Examples of woven fabrics include denim, twill, satin, canvas, and more.

 

Example of weaving fabric

here's a simple example of weaving fabric using a basic plain weave pattern:

Materials Needed:

1. Loom (or improvised weaving setup)
2. Warp threads (vertical threads)
3. Weft threads (horizontal threads)
4. Shuttle or weaving tool
5. Comb or beater
6. Scissors

Steps:

1. Warp Preparation:
   • Set up the loom by attaching the warp threads to the loom's beam.
   • Maintain even tension while threading the warp threads through the heddles and reed.
2. Setting Up the Loom:
   • Raise some of the warp threads using the heddles to create an opening called the shed.
   • Insert the shuttle (with the weft thread) through the shed from one side to the other.
   • Pull the shuttle through, leaving a bit of extra weft thread on the edges.
3. Beating the Weft:
   • After passing the shuttle through, use the beater to push the weft thread tightly against the last row of the weft.
   • It will secure the weft in place and create a dense fabric.
4. Repeating the Process:
   • Lower the raised warp threads and increase the opposite set of warp threads using the heddles to create a new shed.
   • Pass the shuttle with the weft thread through the new shed.
   • Beat the weft down with the beater.
   • Repeat these steps, raising and lowering the warp threads and passing the weft through the sheds.
5. Finishing:
   • Continue weaving until you achieve the desired fabric length.
   • When you finish, carefully remove the fabric from the loom.

The plain weave pattern creates a simple checkerboard-like appearance, with each weft thread passing over one warp thread and under the next. This pattern is just one of many possible weaving patterns that can create different textures and designs in the fabric. You can create intricate and visually appealing woven fabrics by experimenting with different ways and color combinations.

 

Fabric weaving process

Indeed, I'll provide a more detailed step-by-step explanation of the fabric weaving process, encompassing everything from warp preparation to finishing:

1. Warp Preparation:

• Select the type of yarn or thread you want for the warp. It is the set of lines that run vertically on the loom.
• Wind the warp threads onto a warp beam, ensuring even tension and alignment.
• Thread the warp threads through the heddles (small loops) attached to shafts in the loom. The heddles allow you to control individual warp threads.
• Thread the warp threads through the reed, a comb-like device that keeps the warp threads spaced evenly.

2. Loom Setup:

• Attach the warp threads to the front beam of the loom.
• Raise or lower specific heddles to create an opening known as the "shed" between the upper and lower sets of warp threads.
• Insert a weaving tool (shuttle, bobbin) carrying the weft thread through the shed. The weft thread runs horizontally across the warp.

3. Inserting the Weft:

• Pass the shuttle through the shed from one side of the loom to the other, leaving a tail of weft thread hanging out.
• Use the beater (reed or other tools) to push the weft thread tightly against the fell (the last row of woven weft).

4. Beating and Tension:

• After each shuttle passes, beat the weft down with the beater to ensure it's tightly packed against the previous row.
• Maintain consistent tension on the warp and weft threads to prevent the fabric from becoming too loose or tight.

5. Shed Changing:

• Change the shed by raising or lowering the appropriate heddles to create a new opening.
• Pass the shuttle through the new shed in the opposite direction, going from the side where the shuttle initially started.

6. Repeating the Weaving Process:

• Continue alternating between changing the shed and passing the weft through it.
• It helps you beat down each weft pass tightly to create a compact and even fabric.

7. Selvages:

• Pay attention to the edges of the fabric, known as selvages. Keep them neat and consistent by adjusting the tension and beating as needed.

8. Weaving Patterns:

• Experiment with different patterns using varying sequences of raising and lowering the warp threads.
• Use different colored weft threads to create patterns and designs within the fabric.

9. Full Weaving:

• Keep weaving until you reach the desired fabric length. The warp threads will gradually advance toward the front of the loom as you twist.

10. Finishing:

• Once the weaving is complete, carefully remove the fabric from the loom's front beam.
• Cut the warp threads from the back of the loom.
• Many players are in the market, making the textile industry in Bangladesh highly competitive. Various looms, weaving methods, and patterns weave fabrics with varying textures, appearances, and properties.

Fabric weaving classes

There are several ways to do so, including enrolling in classes. Here are a few options for finding fabric weaving classes:

1. Local Arts and Crafts Centers: Many local arts and crafts centers, community colleges, and adult education programs offer weaving classes. Check these institutions' websites or course catalogs to see if they have any upcoming classes on fabric weaving.
2. Weaving Guilds: Weaving guilds are organizations that promote the art of weaving. They often offer workshops and classes for both beginners and experienced weavers. Search for weaving guilds in your area to find out about their offerings.
3. Craft and Textile Workshops: Craft stores, textile shops, and studios focusing on fiber arts sometimes offer weaving workshops. These workshops cover various weaving techniques, materials, and projects.
4. Online Platforms: Many online platforms offer virtual weaving classes. Websites like Craftsy (now called Blueprint), Udemy, Skillshare, and CreativeLive often have courses taught by experienced weavers that you can access from the comfort of your home.
5. Local Weaving Studios: Some areas have dedicated weaving studios offering beginner and intermediate weavers classes. These studios can provide hands-on experience and access to various looms and tools.
6. Art Schools and Universities: If you're looking for more in-depth and structured learning, consider checking the course offerings at art schools, universities, or colleges with textile or fiber arts programs.
7. Fibre Festivals and Events: Attend local or regional fiber festivals, conferences, and events related to textiles and weaving. These events often include workshops and classes taught by skilled weavers.
8. Books and Online Tutorials: While not a traditional class, there are many books, online tutorials, and instructional videos available that can guide you through the basics of weaving. Websites like YouTube can provide step-by-step instructions and demonstrations.

 

 

Fabric production calculation

There are several factors to consider when estimating the amount of fabric produced in a specific time.

Typically, fabric production calculations are in the following simplified overview.

1. Weaving Efficiency and Speed:
   • Loom Efficiency: Calculate the efficiency of the weaving loom, which considers factors like loom stoppages, maintenance, and setup time.
   • Loom Speed: Determine the loom's weaving speed, usually expressed in picks per minute (PPM).
2. Warp and Weft Calculations:
   • Warp Ends: Calculate the fabric's total number of warp ends (threads). The desired fabric width and warp density influence this.
   • Weft Picks: Determine the number of weft picks per inch or centimeter, depending on the desired fabric quality.
   • Fabric Width: Decide on the desired fabric width in inches or centimeters.
3. Total Fabric Production Calculation:
   • Yards/Meters per Minute: Calculate the potential fabric production in yards or meters per minute by multiplying the loom speed (PPM) by the fabric width.
   • Yards/Meters per Hour: Multiply the yards/meters per minute by 60 to calculate the potential fabric production per hour.
4. Downtime and Efficiency Considerations:
   • Downtime: Account for rest due to loom stoppages, thread breaks, maintenance, and other factors. Subtract this downtime from the calculated production time.
   • Loom Efficiency: Apply the loom efficiency percentage to the calculated production time for a more realistic estimate of actual fabric production.
5. Batch Size and Orders:
   • Batch Size: Consider the typical batch size depending on the fabric produced. The batch size could affect how often the loom needs to be stopped and set up for a new batch.
   • Order Quantities: Consider the total fabric required for a specific order.
6. Calculating Total Production:
   • Multiply the adjusted production rate (after considering downtime and efficiency) by the number of hours the loom will operate for a particular order.

It's important to note that fabric production calculations can become complex due to different weaving patterns, yarn types, loom types, and maintenance schedules. Additionally, technological advancements in the textile industry can influence production rates and efficiency. Real-world production may also vary from calculations due to unforeseen circumstances and variables.

These calculations are often carried out by production managers, textile engineers, and skilled workers in the textile industry to estimate the potential output of a weaving operation and to plan for efficient production scheduling.

 

Advantages of a fabric weaving mill in Bangladesh

Setting up a fabric weaving mill in Bangladesh offers several advantages, contributing to the country's textile and garment manufacturing hub growth. Here are some of the key benefits:

1. Abundant Labor Force: Bangladesh has a large and relatively low-cost labor force, making it an attractive location for labor-intensive industries like textiles. This labor force is skilled in various textile-related tasks, including weaving.
2. Competitive Labor Costs: Bangladesh's Labor costs are generally lower than many other countries, allowing for cost-effective textile production.
3. Favorable Trade Agreements: Various nations grant Bangladesh trade benefits through agreements such as the Generalised System of Preferences (GSP), which provide duty-free or reduced-duty access to important markets such as the European Union and the United States. It helps export textile items.
4. Strong Textile Industry: Bangladesh has a well-established and vertically integrated textile and apparel industry, with a wide range of suppliers and service providers supporting various stages of production.
5. Proximity to Raw Materials: The country's strategic location near significant textile raw material suppliers, such as India and China, facilitates efficient sourcing of inputs.
6. Government Support: The Bangladeshi government has historically supported the textile and garment sector through various policies and incentives, including tax breaks, reduced energy costs, and infrastructure development.
7. Infrastructure Development: Over the years, infrastructure has improved, including transportation networks, ports, and energy supply, making it easier to manage operations and logistics.
8. Skilled Workforce: Bangladesh has developed a skilled workforce in the textile sector, including weavers, technicians, and engineers, which can contribute to efficient production and quality output.
9. Access to Markets: Bangladesh is a significant global textile and garment player. It has established connections with international brands and retailers, making marketing and selling products easier.
10. Economies of Scale: The concentration of textile-related industries in Bangladesh provides opportunities for economies of scale in procurement, production, and logistics.
11. Environmental Initiatives: With increasing emphasis on sustainability, many textile businesses in Bangladesh are adopting environmentally friendly practices, which can be advantageous for international markets with stringent environmental regulations.
12. Diversified Product Range: Bangladesh's weaving mills can produce various fabrics, from basic textiles to more specialized materials, for numerous applications, catering to different market segments.

While these advantages are significant, it's important to note that there are challenges, including labor conditions, compliance with safety standards, and environmental sustainability. Companies considering setting up fabric weaving mills in Bangladesh should carefully assess these factors and ensure ethical and responsible practices throughout their operations.

 

Disadvantages of a fabric weaving mill in Bangladesh

While there are several advantages to setting up a fabric weaving mill in Bangladesh, there are also some potential disadvantages that businesses should consider:

1. Labor Conditions: Labor conditions in Bangladesh have been a subject of concern, with reports of low wages, long working hours, and sometimes inadequate worker rights and safety standards.
2. Compliance Challenges: Ensuring compliance with international labor and safety standards can sometimes be challenging, requiring ongoing monitoring and investment in training and facilities.
3. Environmental Concerns: Bangladesh has faced ecological challenges related to water pollution and waste management in the textile industry. Addressing these concerns requires substantial investment in sustainable practices.
4. Power Supply and Infrastructure: Although infrastructure has improved, challenges in power supply and infrastructure, such as frequent power outages, can disrupt production and increase operational costs.
5. Supply Chain Vulnerability: Relying heavily on imports of raw materials can make the supply chain vulnerable to disruptions in neighboring countries or changes in trade policies.
6. Dependence on a Few Key Markets: While Bangladesh benefits from trade agreements, a significant portion of its textile exports are concentrated in a few key markets, making it susceptible to changes in demand or market conditions.
7. Market Competition: Many players are in the market, making the textile industry in Bangladesh highly competitive. This competition can lead to pressure on prices and margins.
8. Currency Fluctuations: Exchange rate fluctuations can impact costs and profitability, especially when dealing with international transactions.
9. Skill Development: While Bangladesh has a skilled workforce, continuous investment in skill development and training is essential to maintain quality and efficiency.
10. Political and Economic Stability: As with any country, political instability or economic fluctuations can affect the business environment and operational stability.
11. Social Compliance: Meeting social compliance requirements, such as ethical sourcing and fair labor practices, can be demanding and time-consuming.
12. Logistics and Transportation: Logistics and transportation infrastructure challenges can impact the timely delivery of products despite improvements made.
13. Changing Consumer Preferences: Global fashion trends and consumer preferences can shift rapidly, requiring flexibility and adaptability in production and design.
14. Regulatory Complexity: Navigating complex regulatory frameworks, permits, and approvals can be time-consuming and require local expertise.

Businesses considering setting up a fabric weaving mill in Bangladesh should conduct thorough market research, consider these potential disadvantages, and develop strategies to mitigate them. Responsible and ethical business practices and a social and environmental sustainability commitment can help address many of these challenges.

 

fabric weaving mill cost in Bangladesh

The cost of setting up a fabric weaving mill in Bangladesh can vary widely depending on several factors, including the scale of the operation, the type of machinery and technology used, the location of the mill, and various other operational considerations. Below are some key cost components to consider when estimating the cost of establishing a fabric weaving mill in Bangladesh:

 

Land and Infrastructure:

• Cost of purchasing or leasing land for the mill.
• Construction and infrastructure development costs, including building structures, utilities, roads, and facilities.

Machinery and Equipment:

• The cost of weaving looms can vary based on the type (air-jet, rapier, projectile, shuttleless) and the number of looms.
• Warping machines, sizing machines, and inspection machines are auxiliary equipment.

Raw Materials:

• Cost of yarn and other raw materials needed for weaving.
• Color and finish dyes and chemicals.

Labor:

• Skilled and unskilled labor incur initial recruitment and training costs.
• We incur ongoing labor expenses, which include wages, benefits, and training.

Utilities:

 

• The machinery consumes energy, including electricity and fuel costs.
• Water supply and treatment costs.

Operational Expenses:

• Machinery and equipment maintenance and repair costs.Administrative and management expenses.
• Marketing and sales expenses.

Compliance and Certifications:

 

• Ensuring compliance with labor, safety, and environmental standards incurs costs.
• Responsible and sustainable certifications.

Technology and Software:

 

We should invest in weaving technology, automation, and software systems for production monitoring and management.

 

Contingency budget for unforeseen expenses.

It's important to note that costs can vary significantly based on the specific goals and requirements of the fabric weaving mill. Additionally, working with experienced professionals, consultants, and experts in the textile industry is recommended to estimate costs and plan for a successful mill setup accurately.

Given the complexity of cost estimation, conducting a thorough feasibility study, engaging with local experts, and developing a detailed business plan before making significant investments are advisable. It will help ensure that you understand the costs and can make informed decisions for your fabric weaving mill project in Bangladesh.

Cost of fabric weaving mill equipment in Bangladesh

 

Price of fabric weaving mill equipment in Bangladesh

The cost of fabric weaving mill equipment in Bangladesh can vary widely depending on factors such as the type of equipment, the brand, the technology, the capacity, and whether the equipment is new or used. Here are approximate cost ranges for some common types of weaving equipment:

1. Weaving Looms:
   • Shuttle Looms: The cost of shuttle looms can range from $2,000 to $10,000 per loom, depending on the quality and specifications.
   • Shuttleless Looms (Air-jet, Rapier, Projectile): The cost of shuttleless looms is generally higher, ranging from $30,000 to $150,000 per loom, based on the technology and features.
2. Warping Machines:

• The cost of warping machines, which prepare the warp yarns, can range from $5,000 to $30,000, depending on the capacity and features.

1. Sizing Machines:
   • Sizing machines, used to apply a protective coating to the warp yarns, can range in cost from $10,000 to $40,000, depending on capacity and technology.
2. Inspection and Quality Control Equipment:
   • Inspection and quality control machines can range from $5,000 to $30,000, depending on the complexity and features.
3. Auxiliary Equipment:
   • Other auxiliary equipment like spooling machines, pirn winders, and creels can range from a few hundred to several thousand dollars each.

It's important to note that these approximate cost ranges can vary significantly based on factors like brand, features, capacity, and technological advancements. Prices for textile machinery are affected by global market trends, currency fluctuations, and changes in technology.

Fabric Lagbe Limited recommends planning to purchase equipment for a fabric weaving mill. Collaborating with experienced consultants or industry experts can help you make informed decisions regarding equipment selection and costs.

 

The fabric weaving mill in Bangladesh has high transmission costs.

The transmission cost for a fabric weaving mill in Bangladesh can refer to various expenses related to moving goods, information, and services within and outside the mill. These costs can include transportation, communication, data exchange, and more. Here are some components that might contribute to transmission costs:

1. Raw Material Transportation:
   • Cost of transporting raw materials, including yarns, dyes, chemicals, and other inputs, to the weaving mill from suppliers.
2. Finished Product Distribution:

• The mill delivers finished fabric products to buyers or retailers, incurring transportation costs.

1. Logistics and Freight:

• Arranging transportation services incurs freight charges, shipping fees, and customs clearance.

1. Energy Transmission:

• The mill's machinery and operations require expenses for transmitting energy sources like electricity or fuel.

1. Data and Communication:

• The mill uses communication systems, internet connectivity, data exchange, and software applications to manage its operations, sales, and administration. These incur costs.

1. Inter-departmental Communication:

• The mill connects different departments using communication systems to ensure smooth workflow and coordination, incurring costs.

1. Maintenance and Repairs:
   • Expenses for maintaining and repairing machinery can involve costs related to the transportation of technicians, spare parts, and tools.
2. Supply Chain Coordination:

• Coordinating with suppliers and buyers incurs communication, data exchange, and monitoring costs.

1. Information Technology Infrastructure:

• Establishing and maintaining IT infrastructure for data storage, network connectivity, and software systems incurs expenses.

1. Inventory Management:

• Inventory management systems and data transmission incur costs for tracking raw materials, work-in-progress, and finished products.

1. Communication with Regulatory Authorities:

• We incur expenses for communicating and submitting data to regulatory authorities, including compliance-related information.

1. Document Transmission:

• Sending and receiving documents, contracts, invoices, and other paperwork incurs costs.

1. Cybersecurity and Data Protection:

• Implementing cybersecurity measures to protect sensitive data during transmission incurs costs.

The specific breakdown of transmission costs will depend on the scale of the weaving mill, the types of equipment used, the distances involved in transportation, the complexity of communication systems, and other operational considerations. Businesses must assess their needs and consider these transmission costs as part of their overall budgeting and planning process.

 

Weaving yarn consumption calculation

Calculating weaving yarn consumption involves determining the amount of yarn required to produce a certain length of fabric on a weaving loom. Factors such as the type of weave, fabric density, yarn count, the width of the material, and any design considerations influence yarn consumption. Here's how you can calculate weaving yarn consumption:

The formula for Yarn Consumption:

Yarn Consumption (in pounds or kilograms) = (Length of Fabric in yards or meters) * (Yarn Count in Ne or Tex) * (Width of Fabric in inches or centimeters) * (Fabric Width Factor) * (Wastage Factor)

Where:

• Length of Fabric: The desired length of the woven fabric.
• Yarn Count: The thickness of the yarn, usually measured in Ne (cotton count) or Tex (metric count).
• Width of Fabric: The weaver is weaving the width of the fabric.

• The fabric width factor compares the weaving width to the loom's width (usually around 1.1 to 1.2).

• Wastage Factor: Buffer for unavoidable losses like those caused by loom breakdown knots.

Example Calculation:

Let's say you want to calculate the yarn consumption for weaving 100 meters of fabric with a warp yarn count of 20 Ne, a fabric width of 150 cm, a fabric width factor of 1.1, and a wastage factor of 1.1%:

Length of Fabric = 100 meters Yarn Count = 20 Ne Width of Fabric = 150 cm Fabric Width Factor = 1.1 Wastage Factor = 1.1% = 0.011

Yarn Consumption = (100 meters) * (20 Ne) * (150 cm) * (1.1) * (0.011) Yarn Consumption ≈ 363,000 Ne cm

This value gives yarn consumption in Ne cm (Ne per centimeter). To convert it to other units or to get the total weight of yarn required, you may need to know the density or linear density of the thread (grams per meter for Tex or pounds per yard for Ne) and use appropriate conversion factors.

How does "Fabric Lagbe Ltd." help the Bangladeshi fabric weaving industry expand?

Here are several ways in "Which Fabric Lagbe Ltd." can contribute to the expansion and growth of the Bangladeshi fabric weaving industry:

1. Technology and Innovation: Innovating technologies and modern weaving equipment can enhance fabric production efficiency, speed, and quality. It can lead to increased productivity and competitiveness in the global market.
2. Skill Development: Offering training and skill development programs for weavers and textile professionals can improve their expertise and efficiency, ensuring a skilled workforce for the industry's growth.
3. Market Expansion: By exporting quality fabrics to international markets, companies can contribute to the growth of the Bangladeshi fabric weaving industry and strengthen the country's position as a textile and garment manufacturing hub.
4. Sustainable Practices: Implementing eco-friendly and sustainable practices can enhance the industry's reputation and meet the growing demand for environmentally responsible products.
5. Collaboration and Partnerships: Collaborating with other companies, research institutions, and government bodies can lead to knowledge sharing, innovation, and joint efforts to drive industry growth.
6. Support for Small Weavers: Providing support and resources to smaller weaving operations can empower them to improve their productivity and product quality.
7. Infrastructure Investment: Investing in modern infrastructure, such as weaving facilities and supply chain management, can boost efficiency and competitiveness.
8. Quality Assurance: Ensuring consistent quality in fabric production can increase buyers' demand and trust.
9. Adoption of E-Commerce: Embracing e-commerce platforms can provide broader exposure and accessibility to global markets.
10. Local Sourcing: Supporting local suppliers of raw materials can strengthen the entire textile ecosystem.
11. Market Research and Trend Analysis: Staying informed about market trends and consumer preferences can guide product development and marketing strategies.
12. Compliance with Standards: Adhering to international labor, safety, and environmental standards can enhance the industry's credibility.