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
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.
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.
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.
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.
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.
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.
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.
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.
port is Hooghly Port which is also around 50 Kms from the unit.
railway station is Bandel Station which is around 10-12 kms from
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.
site also enjoys close proximity to Kolkata, a major commercial hub that
facilitates easy marketing of finished goods.