Start a Zipper Making Plant

 (142) Start a Zipper Making Plant
  

Zippers are the most important assures of garment industry. It’s investment weather will depend on the business development and scale of textile industry. The classification of zipper varies according to the manufacturing methods, the raw materials used and its intended uses. Zippers can be classified as metal zippers and polyester zippers or general type zippers and hide type zippers, or Garment use zippers and Medical use zippers, open-end zippers and close-end zippers.
     In this proposal we will recommend the polyester zipper which is most useful for our daily necessities.
The complete polyester zipper consists of Fabric Braiding, Slid Head and Stopper. The main materials used in making zipper are textile fabric, metal, aluminum alloy and polyester etc. the process zipper production is very developing in Taiwan. Because of simple making method low investment cost and high value of final products are the main reason why polyester zipper plants promise to be profitable enterprises not only now, but in the future as well.

2.     General Process Information

2.1.    Flow Chart

2.2.    Process Description

2.2.1.        Textile Fabric Weaving:
     The raw materials such as cotton, T/C, T/R yarn in warp and weft are interlaced at right angle to cross each other to form webs of high volume narrow fabrics with a high speed needle loom to produce woven edge braiding. Before the complete edge braiding of zipper must be through weaving, cutting and winding processes.

2.2.2.        Zipper Chain Forming:
     Forming: The polyester resin is then fed into the holding tank of the direct injection mould machine to form zigzag line.

2.2.3.        Zipper Slide Head and End Stopper:
     Casting: Put the metal material or aluminum alloy into die casting machine to produce zipper slider and end stopper in to the desired sizes and shapes automatically.

2.2.4.        Assembly:
     Sawing: The textile fabric braiding and zipper chain must be jointed to gather by sawing machine.
     Fitting: The zipper slider, top and bottom stopper of zipper must be fitted and adjusted precisely.

3.     Plant Description

3.1.    Production Capacity150 dzs zipper per day (Based on an 8 hour shift operation)

3.1.1.   Zipper Chain Forming Machine
        #3  180-190 yards/Hr
        #5  210-220 yards/Hr
        #8  190-200 yards/Hr

3.1.2.   Zipper Sawing Machine
        #3  140-165 yards/Hr
        #5  160-180 yards/Hr
        #8  180-200 yards/Hr

3.1.3.   Injection Mould Machine
        #3  450 pcs/Hr
        #5  450 pcs/Hr
        #8  450 pcs/Hr 

3.2.    Raw Materials

Polyester Resin
Nylon, Cotton, T/C, T/R Yarn
Aluminum alloy

3.3.    Manpower Required

Job Classifications	Person/Shift
Weaving workers	2
Setting worker	1
Sawing worker	3
Forming worker	1
Casting worker	1
Dyeing worker	1
Assembly worker	6
Technician	1
Total	16

3.4.    Machinery & Equipment

Item	Set
Warping machine	1
Weaving loom	3
Injection mould	1
Die casting	1
Setting machine	1
Cutting machine	1
Winding machine	1
Sewing machine	3

3.5.    Utilities Required

Electric power required   30 HP
Fuel Oil                80 L/day

3.6.    Land Area

40 M (L) x 20 M (W) x 5 M (H)
Office room, storage room and packing area are not inclused.

3.7.    Plant Layout

4.   Supplier Information

       Company Name: Ti Sing Enterprise Co., Ltd.
       Add: No.46, Alley 10, Lane 204, Sec.3, Ming Chih Rd., Taishan, Taipei Hsien, Taiwan
       Tel:             886-2-29064055      
       Fax: 886-2-29066320
       URL: http://www.zippers.com.tw
       E-Mail: tising@ms16.hinet.net

Polyester Zipper Making Plant (2)

1.     Introduction

     If all the fasteners used to join one fabric to another, not one is more practical or efficient than the zipper. The fact that zippers can be attached to many types of fabric to form a strong and secure bond make them ideal to other types of fasteners for use in all types of clothing as well as a wide variety of other items including tents, shoes, handbags and suitcases.
     Most zippers are made from either polyester, plastic, or some type of metal alloys. However, zippers made from polyester are rapidly replacing zippers made from other material because polyester is lighter, equally durable, more flexible and less expensive.
     The polyester zipper making plant outlined in this proposal is capable of producing virtually any size or color of open or closed end zipper. Open end zippers are those which can be completely separated, such as the ones used on jackets and coats. Closed end zippers are the type used for pants which as the name implies does not open at one end.
     The R.O.C. which is an international leader in the production of textiles has consequently become a leading maker of zippers. The methods and machinery used to make polyester zippers in Taiwan have undergone years of research, testing, and improvement. The result of all of this work is now available to any interested in establishing a plant to make polyester zippers.

2.     General Process Information

2.1.    Flow Chart:

2.2.    Process Description:

     The process of making polyester zippers is divided into several stages of production. They are material fabrication and preparation, ribbon production and preparation, closed end finishing, open end finishing, inspection and packing.

2.2.1.   Material Preparation
A. Slider
The slider is the device used to fasten and unfasten the zipper. It is made by four sets of automatic machinery.
   a.   Two sets of die casting equipment are used to produce the components necessary for making the sliders, one for the production of the carriage and one for making the tabs used to pull the carriage.
    b.   The carriage and the tab are then automatically assembled by a separate machine after trimming both parts.
    c.   Finally, the slider is painted with enamel paint and baked, thus forming an attractive and protective finish.

B. Zipper Chain
     The zipper chain, the portion of the zipper consisting of teeth which interlock or separate to fasten or unfasten the zipper, is made by a single machine which spins polyester fiber around monofilaments to ultimately form two separate chains of nylon teeth. They are automatically zipped together and expelled as a single chain.

C. Fabric Tape
     The fabric to which the zipper chain is connected is called fabric tape. It is made simply and easily by automatic machinery, which weaves various types of yarn into fabric tape.

2.2.2.   Ribbon Production and Preparation
A.     The fabric tape and the zipper chain are then joined together by sewing machines to form ribbons of zipper.
B.     These ribbons are wound into rolls which are placed in a high-pressure, high temperature dyeing machine.
C.   The dyed ribbons are then automatically dried and ironed.
D.   Segments of teeth in the ribbon are removed by the gapping and stripping machine, thus determining the length of each zipper being produced.

2.2.3.   Closed End Finishing
A.     An aluminum brace is clamped onto one end of the zipper chain to serve as a bottom stop.
B.     A slider is affixed to each zipper as the ribbon passes through the slider attaching machine.
C.     Aluminum braces, similar to, but smaller than the ones used as bottom stops, are clamped onto the top of each side of the zipper to serve as top stops.
D.     The zipper ribbon is then fed into the ribbon cutting machine where it is cut into individual closed end zippers.

2.2.4.   Open End Finishing
A.     One tooth from the left side of the zipper is removed.
B.     The portion of the fabric tape with no teeth at the bottom of the zipper is covered with a film of nylon.
C.     The ribbon is then T-cut just below each tab of nylon to form individual zippers.
D.     At the bottom of the zipper a pin is attached to one side and a box is attached to the other side.
E.      The slider is then placed on the side of the zipper with the box at the bottom.
F.      Top stops are clamped onto the top of the zippers thus forming open ended zippers.

2.2.5.   Inspection and packing
Both types of zippers are then inspected and packed into the appropriate packing.

3.     Plant Description

3.1.    Production Capacity:

     The production capacity of a polyester zipper making plant, which is expressed in terms of yards produced per year, will be determined by the size of machinery purchased. The machines described in this proposal are available in a number of sizes each with a different production capacity. One popular production line (#3) produces six million yards of zipper per year. Another line (#5) produces only four million yards annually using smaller-sized equipment.

3.2.   Raw Materials:

The raw materials and the amounts of each needed to produce 100 yards of zipper are listed below.

Commodity	No.3	No.5
Polyester Monofilament	0.3 Kg	0.6 Kg
Core Thread	0.07 Kg	0.14 Kg
Sewing Thread	0.05 Kg	0.12 Kg
Clothing Tape	0.56 Kg	0.83 Kg
Aluminum Tape	0.02 Kg	0.02 Kg
Slider	44 Dzs	15 Dzs
Pin & Box	**	8 Dzs
Film	**	3.3 M

3.3.   Manpower Required:

Job Classification	Persons
Technician	1
Machine Operators	62
Inspection and Packing Personnel	20
Other	2
Total	85

3.4.   Machinery and Equipment:

Function of Machine	Quantity
Zipper chain making machine	15
Warp yarn reeling machine	2
Fabric tape weaving machine	20
Sewing machine	18
Gapping and stripping machine	5
Die casting machine	2
Slider molds machine	6
Slider assembly machine	3
Tank carrier machine	1
Painting machine	1
Dyeing machine	2
Winding machine	1
Drying and ironing machine	2
Top stop setting machine	14
Bottom stop setting machine	8
Ribbon cutting machine	6
T-cutting machine	2
Box setting machine	2
Pin setting machine	2
Tape sealing machine	2

3.5.   Inspection and Testing Equipment:

Items	Set
Pulling tester	1
Zipper life tester	1
Dye testing machine	1

3.6.   Utilities:

Electric Power: Approximately 120 HP

3.7.   Area of Land and Building

3.7.1        Land Area:
Capacity (10,000,000 yds/year): 45 M x 40 M x 40 M includes area for office, storage, warehouse, maintenance, and factory.
3.7.2        Building Area:
Capacity (10,000,000 yds/years): 42 M x 38 M x 38 M

3.8.   Plant Layout:

A.     Forming M/C                                                   N.    Box setting M/C
B.     Sewing M/C                                                    O.    Slider attaching M/C
C.     Tape weaving M/C                                        P.    Warp yarn reeling M/C
D.     Gapping M/C                                                 Q.    Inspection and packing M/C
E.      Bottom-Stop attaching M/C                        R.    Tank carrier M/C
F.      Top-Stop attaching M/C                              S.    Slider assembly M/C
G.     Slider attaching M/C                                    T.    Painting M/C
H.     Cutting M/C                                                   U.    Die-Casting M/C
I.        Inspection and packing M/C                     V.    Dye testing M/C
J.       Tooth stripping M/C                                   W.    Winding M/C
K.      Tape sealing M/C                                        X.    Dyeing M/C (50 kgs capacity)
L.      T-Cutting M/C                                                Y.    Dyeing M/C (30 kgs capacity)
M.      Pin setting M/C                                            Z.    Drying and ironing M/C 

4.     Supplier Information

       Company Name: Ti Sing Enterprise Co., Ltd.
       Add: No.46, Alley 10, Lane 204, Sec.3, Ming Chih Rd., Taishan, Taipei Hsien , Taiwan
       Tel:             886-2-29064055      
       Fax: 886-2-29066320
       URL: http://www.zippers.com.tw
       E-Mail: tising@ms16.hinet.net