You must choose a target market and develop a business strategy with a manufacturing process if you want to launch a bedsheet manufacturing company. Typically, the procedure entails locating premium fabrics, cutting and stitching the sheets, and adding finishing touches like hemming and packaging before shipping.
The bedsheet manufacturing industry in India is well-known for home furnishings. Bedsheets made in India are shipped worldwide, owing to the vast cotton crop production. Establishing a business in “how to make bedsheets” is easy if you know the industry.
One must thoroughly research the market and choose the specialised business plan to operate. This blog will walk you through the steps to effectively launch a bedsheet manufacturing company in India.
Did you know?
The efficiency of the production process in fulfilling demand and keeping costs under control, as well as the design and aesthetic appeal of the product, all play a significant role in the success of the bedsheet manufacturing industry.
Bedsheet Manufacturing Business: The Procedure
The bedsheet manufacturing business typically involves the following procedure:
1. Research:
When launching any business, the first step is to look at the industry and assess success and failure percentages.
2. Understand the fundamentals of the industry:
When starting any business, have a fundamental awareness of all the different aspects of the business.
Learn about the income potential, the top brands in the market, and the fundamentals of beginning a bedsheet business and making sheets.
3. Competitive Evaluation:
Investigate the competition and become familiar with the marketing methods. Also, familiarise yourself with the many merchandises available in the market and the consumer base.
Bedsheet Manufacturing Business: Factors to Consider
When opposed to selling things, the manufacturing industry is more involved. Factors to consider when starting a bedsheet company include access to raw materials or fabric for making bedsheets.
In addition, there is production equipment, capital sources, a manufacturing site, and workers. You might sell your assets or obtain a bank loan to obtain the necessary funds for your business.
1. Raw Materials for Production:
A manufacturing company's first step is procuring raw materials. To begin a bedsheet manufacturing business, you must have access to bedsheet materials such as thread, fabric, cotton material, and other fibres such as satin, silk, etc.
2. Equipment:
The equipment required may differ depending on the company's model. Therefore, you should investigate this as well.
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Motorised double-needle stretch machine
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Foot-powered sewing machine
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Machine for embroidering
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Ironing board
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Accessories for machinery
3. Employees:
Any business or manufacturing requires people to perform tasks. As a result, you will need to hire some employees, like:
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Designers for designing and bedsheet descriptions
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A manager oversees everything at the plant
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Accountants handle the money and expenditures and shall keep a record of every penny expended
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Operators of the machines
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Additional factory employees for various other tasks will contribute to the production process.
4. Investment:
Setting up a bedsheet manufacturing firm costs around ten lakh rupees. But, it may differ according to your business's area, industrial unit, and size or scale of business.
You may also apply for a small business loan from a bank or financial institution using Udyam Registration and a Business Plan & Project Report. You must offer the relevant documentation and a well-organised and planned company proposal to obtain a business loan.
Also Read: Step-by-Step Process to Manufacturing Capsules
Bedsheet Manufacturing Business: The Legal Requisites
Before launching a bed fabric company, you must register to legally establish a bedsheet manufacturing business. You must create a corporation in India for the same. Business creation or certification requires paperwork and licenses.
1. A Permit for Land:
A land permit is required to establish a commercial unit for production, and this can be obtained by contacting the state's municipal administration.
2. Trade License and Fire Department:
A fire service license from the local authorities is required before launching a bedsheet manufacturing firm. Following a thorough examination of your company premises, the chief executive officer of the fire department will provide you with a no-objection document.
To legally operate your business, you must also obtain a Business Permit.
3. Register with the Ministry of Corporate Affairs:
The Ministry of Corporate Affairs oversees business registration. You can choose any of the following Business Registrations depending on your preferences and qualifying conditions.
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Private Limited Company Registration
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Partnership Firm Registration
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LLP Registration
4. GST Registration:
GST registration and GST return filing are also required. A Startup India certificate, a favourable initiative for entrepreneurs, can also be obtained to help your firm grow in its early stages.
Market Potential
India's sheet fabric industry has immense potential. As the world market is now online, the bedsheet manufacturing industry has developed over time and now approaches global borders. The most sellable goods in the sector include bedsheet materials, pillowcases, etc.
Demand is increasing across the board, including in middle and upper-class households. The rural textile industry expands due to increased demand in larger cities and international nations. Customers increasingly spend more on high-quality bedsheets, further driving the cotton sector forward.
As the industry grows, people become more conscious of buying superior bedsheet material. The product is also in high demand in the global hotel and tourist industries. India is the world's leading cotton exporter to developed countries. Government ministries also function in bedsheet manufacturing or textile manufacturing.
Bedsheet Manufacturing Process
What is a bedsheet? A bed sheet is a plain woven fabric used on a bed to separate an individual from the warm blanket. It is often manufactured from broadloom cloth and lacks a central seam. Bedsheet cloth rolls can be made of various kinds of fabric, including cotton, linen, synthetic fibres (typically combined with natural fibres like cotton), and, on rare occasions, silk. The bedsheet manufacturing technique described below discusses the production of bedsheet cloth material from unspun cotton bales.
Let us understand the manufacturing process in detail.
1. Procuring Cotton
Some manufacturers spin cotton bales (bundles), but others acquire cotton spun bales called "yarns". Many processes are involved in the production of bedsheet cloth rolls. Some manufacturers spin cotton bales, while others purchase spun bales called "yarn".
Silk, linen blossoms, and silkworms are used to make bedding. The linen manufacturer purchases the cotton bales.
2. Blending
Cotton bales are set out next to each other in the mixing area. The cotton bales are opened using a device known as "Unifloc." The Uniflock device aims to loosen the bales and separate them into bunches or flocs that are lighter and smaller.
The device then simultaneously hammers the cotton clusters to eliminate impurities. A blower pushes the cotton fibres into the tube funnels for a similar treatment.
3. Carding
After being blended, the fibres are sent via pipe funnels to a carding machine. This carding device aligns the fibres in the same direction. The device has cylinders with several enamels that aid in straightening the fibres and removing contaminants.
4. Drawing, Testing and Roving
After the carding process, the cotton fibres are positioned and placed parallel in bundles. The fibres are then pulled out in several strands using a roving mechanism that slightly bends the threads to produce the right length for the spinning machine.
These twisted threads of fibre are known as rovings.
5. Spinning
The drawn-out fibres or the rovings are spun together to form yarn in the spinning process. Spinning can be done in a variety of ways. A ring spinner is employed in the ring-spinning method, and it is the most unconventional but popular approach globally.
After spinning, the yarn is wrapped or coiled into a cylindrical structure called a bobbin. The bobbins are then loaded onto winders, which cause the thread to coil around or encircle the segment shafts. Segment shafts are structural details that hold the load.
6. Wrapping a Section of Beam
Approximately 2000 to 5000 warps are often required to make one span of a sheet. A warp represents a vertical stretch of yarn/thread. Nevertheless, the warping beam that bears all of the yarns is quite large and cannot be loaded simultaneously.
Therefore around 500-600 yarns are used to create one segment beam, and then several segment beams are put onto a single large loom beam.
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7. Slashing
In the process of slashing, the strands are covered or slashed with starch or sizing. This process protects the ends of the thread and prepares the threads for an easy weave. A slasher is used in this process. Throughout this stage, each segment beam passes through a slasher.
8. Wrapping the Beam
After the multiple-segment beams have been lined with starch or sizing, they are put onto a single large loom beam. Finally, a "knotter" device ties the knots at the top of the strands automatically and efficiently. These knots are threaded through the loom to begin the weaving process.
9. Weaving
Weaving is the process through which weft (horizontal) threads are interlaced or interwoven with the warp (vertical) threads to produce a fabric. This weaving is done on very high-speed automated air-jet looms.
The weft threads connect with the warp threads at a rate of approximately 500 insertions per minute. This implies that each weft thread takes roughly one-tenth of a second to fill the warp thread, and a sheet requires around ninety insertions.
As a result, 5 inches of a sheet are woven in one minute and ten yards of a sheet in one hour. Generally, around 8000 yards of the sheet are produced on a loom and then wrapped for similar processing.
10. Cleaning and Bleaching
Due to residual impurities, freshly woven bedsheet cloth rolls generally have a grey hue. These sheets are cleaned and bleached when they are out of the weaving process. The sheets are de-sized by soaking them in water and washing them with soap, removing all impurities.
The caustic chemical solutions are then used to remove dirt and residues of any particles deposited in cotton yarn. These caustic chemical compounds are also rinsed out, and targeted bleaches are employed to eliminate the grey tint. The sheets are now bright white, carefully wrapped in a loop, and placed in the dryer.
The dryer then absorbs all moisture from the sheets before they move to the dyeing process.
11. Dyeing
All sheets must be dyed, even white ones, to maintain brightness. Coloured sheets are made by adding pigments in vats. Vats are huge tanks or tubs filled with coloured solutions.
A giant roller press is then employed to put the dye onto the sheets. After the sheets have been dyed, they are put through the steaming process to ensure satiation. Then, the resin is applied to the sheets to make them resistant to shrinking.
The sheets are then rolled onto large rollers and prepared for reduction and stitching.
12. Cutting and Sewing
The computerised reduction mechanism consistently cuts bedsheet cloth rolls to the appropriate length. These sheets are then transported to sewing machines for stitching the bedsheet hemline.
13. Packaging
Sewn bedsheet materials are then folded by hand or machine. The sheets are covered in a thin, flexible plastic layer to protect them from dust and other damage. These efficiently packed bedsheets are then packed in appropriate brand-tagged boxes.
14. Quality Control
The bedsheet materials produced should pass all the required parameters regarding quality checks. Bedsheet producers must guarantee that their products correspond to criteria established by numerous organisations, independent testing laboratories, and authorities.
Essential bedsheet inspection and quality control criteria must be included in an effective testing and inspection program.
The laboratory gathers and evaluates statistical samples at key points in the manufacturing process of bedsheets.
The finished items are subjected to physical testing. And the various chemical solutions employed during bleaching and dyeing operations are monitored since these chemicals need to be precisely blended.
Additionally, staff at the facility need to closely supervise the process and visually examine the product at each step of production.
15. Byproducts/ Waste
The bedsheet manufacturing industry works hard to eliminate harmful effluvia and cotton lint. Fibre leftovers from spinning can be recycled and utilised to make other cotton products.
Earlier, the cotton lint produced in the factories was dangerous to employees, but with the advent of air-jet looms, these lint emissions are much less. There are automated sweeping and cleaning equipment at the point where greige items are handled to remove ambient dust from the rooms.
The chemicals employed in the items' cleaning, bleaching, and dyeing concern the authorities. The residual discharge from the facility must fulfil the clean water rules, and the manufacturing plant must have a pollutant discharge elimination system license.
The larger mills do construct their wastewater treatment systems. Emissions must be controlled, and manufacturing plants must adhere to approved standards.
Conclusion
The bedsheet manufacturing sector is one of the most profitable, and the business offers great opportunities for entrepreneurs to establish a company by themselves. We have outlined the key actions and the manufacturing process you must follow to start a bedsheet manufacturing business in India. Hope this article will help you.
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