50 Kg Capacity B. Twill Bagsfor Packing of Foodgrains

PRODUCTIVITY NORMS

FOR

50 KG CAPACITY B. TWILL BAGSFOR PACKING OF FOODGRAINS

(IS: 12650, 2003; 2nd REVISION)

Type-A Bag

Name of the Mill:

Date of Submission:

Period of Study:

Contact person:

Mobile No. and Email ID:

Production Capacity of Mill(Per Day):
Hessianb. Sackingc. Others

Average Production/day (Average of last quarter)
Yarn (quality wise)b. Fabric (quality wise)

CHAPTER 1

MACHINE AND PROCESS PARAMETERS

TYPE “A” BAG

Table – 1: Softener (for Warp, Weft and Sewing Twine)

Quality of Jute / Machine make / Date of Installation / No. of M/cs / No. of pairs of rollers / Delivery Speed (fpm) / Emulsion Application % / Efficiency% / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11

Oil% in Emulsion:Non-Usable Waste % (Dry)(@20% MR):Non-Usable Waste % (Wet)(@20% MR):

Table – 2: Spreader (for Warp, Weft and Sewing Twine)

Quality of Jute / Machine make / Date of Installation / No. of M/cs / Type of Feed (with/without Leader Roll) / Type of Machine (Pneumatic or oil pump) / Delivery Speed (fpm) / Draft / Emulsion Application % / Actual MR% / Convt. Sliver Wt. (lb/100 yd)@20 MR% / Eff.% / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15

Oil% in Emulsion:Non-Usable Waste % (Dry)(@20% MR):

Table – 3: Carding(S4AWarp) –Breaker Card

Quality of Jute / No. of M/cs / Make and Date of Installation / Pair of rollers / Doubling
/Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @20% MR / Efficiency% / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 20 % MR:Oil % of Droppings:

Table – 4: Carding (S4A Warp) –Inter Card (If any)

Proportion of Different Qualities of Jute / Make and Date of Installation / No. of M/cs / Pair of rollers / Doubling/
Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @20% MR / Efficiency% / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 20 % MR:Oil % of Droppings:

Table – 5: Carding (S4A Warp) –Finisher Card

Non Usable Wastage @ 20 % MR:Oil % of Droppings:

Table – 6: Carding (S4AWeft) –Breaker Card

Quality of Jute / Make and Date of Installation / No. of M/cs / Pair of rollers / Doubling/
Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @20% MR / Efficiency% / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 20 % MR:Oil % of Droppings:

Table – 7: Carding (S4A Weft) –Inter Card (If any)

Proportion of Different Qualities of Jute / Make and Date of Installation / No. of M/cs / Pair of rollers / Doubling
/Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @20% MR / Eff. % / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 20 % MR:Oil % of Droppings:

Table – 8: Carding (S4A Weft) –Finisher Card

Proportion of Different Qualities of Jute / Make and Date of Installation / No. of M/cs / Pair of roller / Doubling/
Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @20% MR / Eff. % / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 20 % MR:Oil % of Droppings:

Table – 9:1stDrawing (S4AWarp)

Type of Machine / Make and Date of Installation / No. of Frames / No. of delivery/m/c / Faller Drops/min / Doubling / DC/DP / Draft / Delivery Speed (fpm) / MR% / Sliver Wt. (lb/100 yd)@ 20%MR / Eff. % / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
SG / 1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14
RG
PB

Droppings @ 20 % MR:

Table – 10: 2ndDrawing (S4A Warp)

Type of Machine / Make and Date of Installation / No. of Frames / No. of delivery/m/c: / Faller Drops/min / Doubling / DC/DP / Draft / Delivery Speed (fpm) / MR% / Sl. Wt. (lb/100 yd)@ 20%MR / Eff. % / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15
SG
RG

Droppings @ 20 % MR:

Table – 11: InterDrawing (S4A Warp)(If any)

Droppings @ 20 % MR:

Table – 12: Finisher Drawing (S4A Warp)

Type of Machine / No. of Frames / Make and DOI* / No. of delivery/m/c: / Faller Drops/min / Doubling / DC/DP / Draft / Delivery Speed (fpm) / MR% / Sliver Wt. (lb/100 yd)@ 20%MR / Eff% / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15
SG
RG

Droppings @ 20 % MR:*DOI: Date of Installation

Table – 13:1stDrawing (S4A Weft)

Droppings @ 20 % MR:

Table – 14: 2ndDrawing (S4A Weft)

Droppings @ 20 % MR:

Table – 15: Inter Drawing (S4A Weft) (If any)

Droppings @ 20 % MR:

Table – 16: Finisher Drawing (S4A Weft)

Droppings @ 20 % MR:*DOI: Date of Installation

Table – 17: SpinningS4A Warp

Make and Date of Installation / Type of M/C (AD/SD) & Pitch / No. of M/c / Nominal Count@20%MR / Flyerrpm / No. of Spindles/frame / DC/ DP / TC/TP / Actual Count (lb/spy)@20% MR / Actual TPI / MR% / Eff.% / Prdn/M/c/8 hrs (Kg) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15

Droppings @ 20 % MR:

Table – 18: Spinning S4A Weft

Droppings @ 20 % MR:

Table – 19: Winding (S4A Warp)

Type of Machine / No. of M/C / Make and Date of Installation / No. of Sides (Single/
double ) / No. of Delivery/side / Machine Speed (yd/m) / Nominal Count (lb/spy) @ 20 % MR / No. of Spindles/Winder / Eff.% / Production/winder/8 hrs (Kg) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Thread Waste%Droppings % @ 20 % MR

Table – 20: Winding (S4A Weft)

Thread Waste%Droppings % @ 20 % MR

Table – 21: Carding (Sewing Twine) –Breaker Card

Non Usable Wastage @ 20 % MR:Oil % of Droppings:

Table – 22: Carding (Sewing Twine) – Inter Card (If any)

Non Usable Wastage @ 20 % MR:Oil % of Droppings:

Table – 23: Carding (Sewing Twine) – Finisher Card

Non Usable Wastage @ 20 % MR:Oil % of Droppings:

Table – 24:1stDrawing (Sewing Twine)

Droppings @ 20 % MR:

Table – 25: 2ndDrawing (Sewing Twine)

Droppings @ 20 % MR:

Table – 26: Finisher Drawing (Sewing Twine)

Droppings @ 20 % MR:*DOI: Date of Installation

Table – 27: Spinning (Sewing Twine)

Droppings @ 20 % MR:

Table – 28: Winding (Sewing Twine)

Thread Waste%Droppings % @ 20 % MR

Table – 29: Twisting (Sewing Twine)

Make and Date of Installation / Type of M/C & Pitch / No. of M/c / Nominal Count@20%MR / Flyerrpm / No. of Spindles/frame / TC/TP / Actual Count (lb/spy)@20% MR / Actual TPI / MR% / Eff.% / Prdn/M/c/8 hrs (Kg) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14

Droppings @ 20 % MR:

Table – 30: Beaming

Make and DOI* / No. of M/cs / Type (Group Drive/Individual) / Machine Speed (ypm) / Total No. of threads in beam / Additional threads for selvedge / Laid Length (yd) / No. of Cuts/beam / Wet Pick-up & Size Add on % (if any) / Avg. Beam MR% / Efficiency% / Production/M/c/8 hrs (yd) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14

Thread Waste%

Table – 31: Weaving

Make / No. of M/cs. / Type of Loom / Reed Space (inch) / Reed Porter / Loom speed (ppm) / Loom Constant and Short/change Pinion / Finished Length
yd / Shots/inch / Eff% / Production/loom/8 hrs (Kg) / Motor HP / Motor RPM
(yd) / (Kg)
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14

Installed looms:Working looms:Utilization %:Thread Waste%:Loom Caddies %:

Table – 32: Damping

Make and Date of Installation / No. of Machines / No. of Cloth Feed / Machine Speed (yd/min) / Production/m/c/8 hrs (yd) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7

Table – 33: Calendering

Make and Date of Installation / No. of Machines / No. of Cloth Feed / Machine Speed (yd/min) / Production/m/c/8 hrs (yd) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7

Cloth Cutting

Table – 34A: Machine Cutting

Make and Date of Installation / No. of Machines / No. of Cloth Feed / Machine Speed (strokes/min) / Cut Length (inch) / Production/m/c/8 hrs
(No. of Bags) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8

Table – 34B: Manual Cutting

Production/ 8 hrs (No. of Bags):Gunny Cutting %:

Table 35: Sack Sewing and Bundling

Stage / No. of Machines / Make / Date of Installation / Machine Speed (stitches/min) / Production/m/c/8 hrs
(No. of Bags) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 6 / 7 / 8 / 9
Hemming
Herakle
Safety (if any)
Bundling / -

Thread Waste%:

Table 36: Bale Press

Type of Press (Oil/Hydraulic) / Make / Date of Installation / No. of Machines. / No. of Bags/bale / No. of Bales/8 hrs / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8

Bale Details:

Bale Dimension:
Bags/Bale:
Average Bale Weight in kg (Net):
Type of Hoop Used (Steel/Plastic):
Weight of Hoop, pin and Buckle:

CHAPETR 2

PROFORMAFOR BATCH MIX AND BATCH COST

TYPE “A” BAG

Table 37: Proforma for Batch Mix

Yarn Quality / Fibre Grade / Batch Mix %
S4A Warp
Count (lb/spy): / Less Rejections:

Thread waste%
Caddies %
Any other%

Yield
S4A Weft
Count (lb/spy): / Less Rejections:

Thread waste%
Caddies %
Any other%

Yield
Sewing Thread
Count (lb/spy): / Less Rejections:

Thread waste%
Caddies %
Any other%

Yield

Table 38: Loading of Raw Jute

Fibre Grade / %
Fibre Quality:
Less (-)
Ropes & Habijabi
Downgrade
Cutting
Yield
Fibre Quality:
Less (-)
Ropes & Habijabi
Downgrade
Cutting
Yield
Fibre Quality:
Less (-)
Ropes & Habijabi
Downgrade
Cutting
Yield

CHAPTER 3

PROFORMAFOR SLIVER WEIGHT CALCULATION AT EACH STAGE OF CARDING AND DRAWING

TYPE “A” BAG

Table 39: Sliver Weight, Process Parameters at each stage of Carding, Drawing

Sl. No. / Particulars / Warp/Weft / Season 1 / Season
2 / Season 3 / Season 4 / Average
1 / Average Weight of Morah kg / Warp
Weft
Sewing Twine
2 / Morah Feeding rate / Warp
Weft
Sewing Twine
3 / Spreader Sliver Weight (lb/100yd) & MR% / Warp
Weft
Sewing Twine
4 / Draft at Breaker Card & No. of Spreader Roll (Warp) / Warp
Weft
Sewing Twine
5 / Breaker Card Sliver Weight & MR% / Warp
Weft
Sewing Twine
6 / Dropping at Breaker Card / Warp
Weft
Sewing Twine
7 / Draft at Inter Card and No. of B/C feed roll / Warp
Weft
Sewing Twine
8 / Inter Card Sliver Weight & MR% / Warp
Weft
Sewing Twine
9 / Dropping at Inter Card / Warp
Weft
Sewing Twine
10 / Draft at Finisher Card and No. of I/C feed roll / Warp
Weft
Sewing Twine
11 / Finisher Card Sliver Weight & MR% / Warp
Weft
Sewing Twine
12 / Dropping at Finisher Card / Warp
Weft
Sewing Twine
13 / 1st Drawing Weight (lb/100yd) & MR% / Warp
Weft
Sewing Twine
14 / Draft at 1st drawing and Doubling / Warp
Weft
Sewing Twine
15 / Dropping at 1st Drawing / Warp
Weft
Sewing Twine
16 / 2nd Drawing Weight (lb/100yd) & MR% / Warp
Weft
Sewing Twine
Sl. No. / Particulars / Warp/Weft / Season 1 / Season
2 / Season 3 / Season 4 / Average
17 / Draft at 2nd drawing and Doubling / Warp
Weft
Sewing Twine
18 / Dropping at 2nd Drawing / Warp
Weft
Sewing Twine
19 / 3rd Drawing Weight (lb/spy) & MR% / Warp
Weft
Sewing Twine
20 / Draft at 3rd drawing and Doubling / Warp
Weft
Sewing Twine
21 / Dropping at 3rd Drawing / Warp
Weft
Sewing Twine

Note: Sliver Weight should be given @20% MR and mention Actual MR%

CHAPTER 4

PROFORMAFOR HANDS EMPLOYMENT

FOR TYPE ‘A’ BAG

Table 40A: Jute Department
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Jute Import Sardar
2 / Sangras/Tulandars/Sajandars
3 / Jute Issue Mazdoor
4 / Sweeper
Total:
Hands/Ton
Table 40B: Batching
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Emulsion Plant Attendant
2 / Softener/Spreader Feeder
3 / Softener/Spreader Receiver
4 / Spreader Roll carrier (from M/c.to Pile)
5 / Jute Carrying Coolie (Selection to spreader/Softener)
6 / Jute Carrying Coolie (Softener to pile)
7 / Selector
8 / Selector Sardar
9 / Reliever
10 / Sweeper
Total:
Hands/Ton
Table 40C: Carding & Drawing
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Breaker Card Operator –Roll Feed
2 / Breaker Card Feeder – Hand Feed
3 / Root Cutter (for Hand Feed)
4 / Breaker Card Receiver & Inter Card Feeder
5 / Inter Card Receiver & Finisher Card Feeder
6 / Picker (Carding)
7 / Dust Coolie
8 / Spreader Roll Carrier from Pile to Breaker Card
9 / Sardar(Carding)
10 / Finisher card receiver & 1st Drawing Feeder
11 / 1st Drawing receiver & 2nd Drawing Feeder
12 / 2nd Drawing receiver & 3rd Drawing Feeder
13 / 3rd Drawing Receiver
14 / Picker (Drawing)
15 / Dust Coolie(Drawing)
16 / Sliver waste Coolie/ Tarawala
17 / Sardar (Drawing)
18 / Finisher drawing can coolie
19 / Reliever(Carding & Drawing)
Total:
Hands/Ton
Table 40D: Spinning & Twisting
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Spinner
2 / Spinning Piecer
3 / Bobbin Coolie
4 / Sliver feeder
6 / Sardar
7 / Sweeper
8 / Felt Bobbin Cleaner
9 / Listing Man
10 / Reliever
11 / Twister
12 / Twisting Majdoor
13 / Twister Bobbin Coolie
14 / Blowers & Humiditification
Total:
Hands/Ton
Table 40E: Winding
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Warp + weft winder
2 / sewing twine (scroll)
3 / Bobbin & Spool Centre Cleaner
4 / Spool Carrying Coolie
5 / Sweeper
6 / Sardar
7 / Precision Winder (for herakle sewing twine)
8 / Spool Carrying Coolie for P.Winding
Total:
Hands/Ton
Table 40F: Beaming
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Beaming operator
2 / Sweeper
3 / Sardar
4 / Empty Beam Carrier
5 / Starch Man (optional)
Total:
Hands/Ton
Table 40G: Weaving
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Weaver
2 / Helper
3 / Sweeper
3 / Dust Coolie
4 / Beam Coolie
5 / Line Sardar
6 / Dept majdoor for cleaning, carrying spools
Total:
Hands/Ton
Table 40H: Finishing & Sack sewing
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Damping Feeder
2 / Damping Receiver
3 / Cloth Carrier(Damping to Calender)
4 / Calender Feeder
5 / Calender Receiver
6 / Cloth Repairer
7 / Cloth Carrier(Calender to cutting)
8 / Cutting MachineFeeder
9 / Cutting Machine Receiver
10 / Cutting Mazdoor for carrying
11 / Hemming Machine Operator
12 / Hemming Machine Helper
13 / Hkle M/ operator including joint bag maker
14 / Herakle M/c. helper
15 / Bag Carrier(Herakle to Branding)
16 / Hand Sewer / Bundler
17 / Bag Carrier(Bundle to Press)
18 / Bag Joiner
19 / Sewing Sardar
20 / Hoop Cutter
21 / Press Man
22 / Pump Man
23 / Marker
24 / Packing Mazdoor
25 / Pack sheet cutter
26 / SQC Mazdoor
27 / Sweeper cum dust collector
28 / Spool Carrier (Winding to Sewing)
Total:
Hands/Ton
Table 40I: Shipping
Sl. No / Basis / No. of Hands Required
1
Total:
Hands/Ton
Table 40J: Mill Mechanic
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Line Mistry-Jute Spreader
2 / Line Mistry-Cards
3 / Line Mistry-Drawings
4 / Line Mistry-Spinning & Twisting
5 / Vice Mistry - Card
6 / Vice Mistry - Drawing
7 / Vice Mistry-Spinning
8 / Roll Former Mistry
9 / General Mazdoor
10 / Preventive Maintenance Mistry
11 / Pin Boy - Card
12 / Pin Boy Drawings
13 / Oiler - Line shaft
14 / Oiler - Machines
15 / Carriage Mistry
16 / Tinsmith
17 / Blacksmith
18 / Welder-Gas
19 / Welder-Electric
20 / Cork-Rubber roller Grinder
21 / Overhauling Mistry Spreader & Card
22 / Overhauling Mistry Drawing
23 / Overhauling Mistry Spinning
24 / Overhauling Mazdoor
Total:
Hands/Ton
Table 40K: Factory Mechanic
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Line Mistry-Winding
2 / Line Mistry-Beaming
3 / Line Mistry-Weaving
4 / Line Mistry-Sack Sewing, Finishing & Press
5 / Oiler - Line shaft
6 / Oiler - Winding & Beaming
7 / Oiler - Weaving
8 / Oiler Sack Sewing, Finishing & Press
9 / Beam Flange Repairer
10 / Major Breakdown Mistry
11 / Vice Man
12 / Overhauling & Preventive Maintenance Mistry
13 / Mazdoor
Total:
Hands/Ton
Table 40L: Workshop
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1
Total:
Hands/Ton
Table 40M: Electrical, General Engineering, Civil(Including Generator)
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1
Hands/Ton
Table 40N: Monthly Paid & Other Hands(including Supervisor)
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1
Hands/Ton

CHAPTER 5

PROFORMAFOR POWER CONSUMPTION

PER METRIC TON

FOR TYPE ‘A’ BAG

Table 41: Power Consumption

Sl. / Machines / UtilisationFactor(UF)(%) / RatedMachineHP / ActualMachineHP / KWH Per M/c./8 hr.at UF / No. of Machinefor 100Looms / Total KWH
1 / 2 / 3 / 4 / 5 / 6 / 7
1 / Emulsion Plant
2 / Jute Spreader with Blower
3 / Compressor for spreader m/c[one m/c feeds -- spreader]
4 / Breaker Card
4 / Inter Card
5 / Finisher Card
6 / First Drawing
7 / Second Drawing
8 / Finisher Drawing
9 / Spinning Warp(100 Spindle)
10 / Spinning Weft(100 Spindle)
11 / Spinning Sewing Twine (100 Spindle)
12 / Twisting 128 Spindle (sacolowell)
13 / Warp+ Weft Winding(Scroll) 32 Spindle/M/c.
14 / sewing yarn Winding(Scroll) 32 Spindle/M/c.
15 / P.Winding (1 Spindle / M/c.)
16 / Beaming
17 / Loom S4A Loom
18 / Compressor for S4A (1 m/c to Feed 50 S4A Looms & 1 beaming m/c)
19 / Damping
20 / Calender
21 / Cutting
22 / Hemming
23 / Herakle
24 / Press & Pump

______

Signature & Seal of the Mill