At Ganges, the jute manufacturing process has been streamlined and customised to efficient and optimal standards.

Raw jute required for the production are available in bales of various grade and categories.

Various unit process and operations involved in manufacturing diversified jute gods are given below.


SELECTION / BATCHING

As jute grown in different areas varies in strength, color and fineness, the first step in preparing the fiber is "batching", consisting of blending the various fibers to obtain uniformity in strength and color to give the precise quality of yarn for spinning. This involves the opening of various qualities of bales. These are then examined, sorted and mixed to form various batches.


SOFTENING

In the first mechanical operation in the mill, the jute is fed into a softener in which the jute, treated with an emulsion oil and water, passes between sets of heavy spiral fluted rollers. This process renders the fiber thoroughly pliant and removes any barky portions adhering to the fiber. The piled jute is cut in order to remove the roots.

 


CARDING

The fibers are then carded in machines, known as breaker cards and finisher cards, which reduces the average length of the fibers by teasing and combing,, and deliver them in the form of a long continuous ribbon, 5" or 6" in width, called sliver.

 

 

 


DRAWING

The carded jute is next fed into drawing machines in three stages through the first, second and third drawing frames which draw out and attenuate the sliver, parallelize the fibres, and by means of a doubling process, produce a smoother, more even sliver. However, in case of sacking weft, the passage through, drawing frame is only done twice i.e, through first and second drawing frames.

 

 


SPINNING

The last operation in the preparing department is spinning, a process which imparts a slight twist to the sliver and delivers the material on to bobbins in the form of rove, a loose yarn ready for spinning. The spinning machinery known as sliver spinning, an extra drawing operation delivers a crimped sliver, which can be fed direct to the sliver spinning form. Spinning frames convert the rove to finished yarn.

 



BEAMING

After spinning, the yarns are wound into the form required - spools for warp yarn and cops for weft yarn - for subsequent processing. Jute yarn is processed much like other textile fibers, the yarn itself being dressed (i.e, sized or starched), before being passed on to the warp beam ready for weaving.

 

 


WEAVING

Jute fabrics are of simple construction and are woven on a variety of looms. Woven fabrics are inspected, damped and calendared to produce the desired smoothness of finish.

 

 

 

SEWING

The woven cloth is then folded in the desired length, packed in bales by hydraulic press, covered with gunny cloth for protection and stored in godowns (warehouses) to await shipment. Where jute goods are sold in the form of bags, the woven cloth is cut to the required size and then hemmed, sewn and hand stitched. These bags are folded and packed in bales. All such goods are then stored in the finished goods godown and are dispatched as per the delivery schedule.


Selection of mill site and development of a properly designed mill-layout has considerable impact on the operational and marketing efficiencies, capital cost and in turn overall economies of mill operation. The mill would be using raw jute as raw material that will be brought in from the adjoining areas including the nearby states and Bangladesh. Most of the finished goods will be exported.

Ganges Jute's unit is located at Bansberia, Hooghly District, West Bengal, 50 kms from Kolkata. The location has the advantage of easy accessibility to various inputs like raw jute in Hooghly district itself.

As depicted below, the unit is well connected by rails and roads.

The unit is very well connected with NH-4 through Rudra Main Road which also connects to Kalyani Highway.
The nearest port is Hooghly Port which is also around 50 Kms from the unit.
The nearest railway station is Bandel Station which is around 10-12 kms from the unit.

The unit enjoys excellent infrastructure and other facilities like availability of skilled and unskilled workforce, engineering stores, excellent transportation facilities etc. It uses the company's strong distribution network to its full advantage.

The site also enjoys close proximity to Kolkata, a major commercial hub that facilitates easy marketing of finished goods.