Silk Reeling and Re reeling - Seri.ap.gov.in

REELING & RE-REELING TECHNIQUESSilk Reeling is simply the unwinding of filaments from a group of cocoons inhot water bath on to a reel.There are two methods of reeling a) Direct Reeling method onstandard reels and b) Indirect method which includes preliminary reeling onsmall sized reels and transferring the reeled silk directly from the reels tostandard sized reels on re-reeling machines.Before reeling, cocoons have to pass various stages and production of qualitysilk depends upon various factors:Purchase of Cocoons :Selection of cocoons must be done carefully as any carelessness is thisrespect would spell serious losses to the reeling enterprise. Selectivepurchase of cocoons in an open market is extremely difficult, and becomesimperfect particularly in the absence of determined standards of quality forcocoons, and standard methods of testing for classifying cocoons into qualitygrades.Cocoons should not be too flossy. Floss merely adds to the weight of cocoonswhen yielding silk for reeling. Cocoons should have well-rounded and firmends and must not have too pronounced points. Well pointed ends are easy todetect because of their shape; thin ends can be detected by the lighter shadeof colour at the end which when pressed yields readily, when floss is peeledoff the cocoons, the surface must be fine grained and not deeply wrinkled.Transporting Techniques :The selected cocoons must be transported safely in perforated bamboobaskets or in loosely packed plastic crates, and must be transported duringthe cool hours. Packing the cocoons tightly and transporting them in the hotsun must always be avoided.COCOON STIFLING & PRESERVATIONCOCOON STIFLING:Cocoons in their fresh condition with the pupae alive in them cannot bestored for a long time as the living pupae are soon transformed into moths.They are useless for reeling raw silk because the continuity of the bave inthem is broken. Reeling cocoons, therefore, have to be subjected to a processof stifling with the object of killing the pupae inside without in anywayinterfering with the structure of the silk shell around it. Cocoons can be stifled

y several methods but the popular methods in reeling industry are sundrying, steam stifling and hot air conditioning.PRESERVATION:Storage of cocoons is an important problem especially when the stiledcocoons have to be stored for a very long period. Complete desiccation ofcocoons is a fairly satisfactory solution to the problem but even fullydesiccated cocoons are liable to mould damage if the storage room is keptdry.The other source of damage to cocoons in storage comes from the beetlepest, Dermestes lardarius. The following measures have to be followed forpreservation of cocoons.• Complete desiccation of cocoons before storing should be ensured.• All care should be taken to see that the relative humidity in the storeroom does not rise above 70%.• The store room must have good ventilation.• Cocoons should be given regular and frequent turnings during the periodof storage and on no account should they be allowed to become damp.• When fumigants are used care should be taken to keep the doors andwindows open until all the traces of fumigants are removedREELING & RE-REELING TECHNIQUESSilk Reeling is simply the unwinding of filaments from a group of cocoons inhot water bath on to a reel.There are two methods of reeling a) Direct Reeling method on standard reelsand b) Indirect method which includes preliminary reeling on small sized reelsand transferring the reeled silk directly from the reels to standard sized reelson re-reeling machines.Systems of ReelingThere are two systems of reeling cocoons :( i ) Floating System( ii ) Sunken System

Floating System of ReelingIn floating system, the cocoons are cooked only to the extent the shellbecomes wet, but is still impervious to water, so that they float in water whenthe cooked cocoons are put into the reeling basin. Floating system isassociated with1. Reeling of cooked cocoons which float in reeling basin.2. High speed reeling.3. High basin temperature.4. Less number of reeling ends.Sunken System of ReelingIn this system, the cooked cocoons sink in water at the time of reeling.In this system, not only the shell is cooked but in the process, the cocoon alsogets filled with water inside to the extent of 97 to 98%, with the result, thecocoon becomes heavy and sinks in the reeling water. This system of reelingis associated with :1. Reeling of cooked cocoons which sink under water in reeling basin.2. Slow speed reeling.3. Low basin temperature reeling.4. Large number of reeling ends.This system is suitable for superior quality cocoons like bivoltine.RE – REELINGRe – reeling is done to transfer the raw silk into standard sized hanks. Thegrant reeling helps in finding of broken ends of the thread and also itsknotting. In grant reeling the hank is divided into several parts which can bekept separately by means of lacing. The ratio of the bevels determine thewidth of the diamond. For finer denier silk, more number of teeth have to beused. Re – reeling speed is almost double the reeling speed. So one end rereelingwill be enough to take the input of two end reeling. 13/24 bevelcombination will produce 13 diamonds.SKEININGThe standard size hanks from the swift are carefully examined for defects ifany,it is laced and folded upon itself to form a skein with the help of skeiningmachine. The weight of the skeins varies from 50 g. to more that 100 g.The skeins of raw silk are then made into books and bales are marketed later.

DIFFERENT SILK REELING DEVICES WITH ECONOMICSReeling Devices:There are three distinct reeling devices in mulberry sector namely(a) Charka : It is a crude system of reeling. It is a simple hand drivendevice consists of a large cooking cum reeling pan where boilingwater is kept.(b) Cottage Basin System : It is improved over charka. It consists ofseparate cooking and reeling basin, where temperature is at boilingpoint only in the cooking basin, but reeling basin temperature ishardly 40 C.(c) Multiend Basin System : It is a further improved version over theCottage Basin and it is power driven. Boilers are installed andsteam is used for cooking and reeling purpose and also for cocoonstifling in the special steam chambers.Twin CharkaEconomicsSl.NoIItemCAPITAL INVESTMENTRs. InLakhsIIa) Landb) House cum workshedc) Cost of CharkaTotal capital costWORKING CAPITALOwn0.300.100.40i. a) Employment : Self employment --b) Workers wages :Reelers : 2 (Rs.50/- per day ( 25 days per monthfor one year 300 days)0.30Assistants : (Rs.50/- per day ( 25 days per monthFor one year 300 days)0.15

ii. Cost of Raw materialcost of raw material for 300 days ( @ 16 kgs per day@ cost of Rs.90/- per kg for 4800 kgs)4.32iii. Other expenses (Fuel and Transport etc) 0.35iv. Total working capital required for one year (i + ii + iii)5.12v. ( Actual working capital required for two (2) months(6 operating cycles Rs.0.85 lakhs)vi. Interests :a) Interest on Capital investment (16%) 0.064b) Interest on working capital (16%)for Rs.0.85 lakhs0.136c) Depreciation on capital cost (10%) 0.04IIITotal Production cost ( iv + vi ) 5.36RealisationEstimated production of Raw Silk from Twin Charka( 50 kgs per month @ 2 kgs per day for 25 days)Total Raw Silk Production : 600 kgs per yeari) Sale value of silk yarn per kg @ Rs.900/-ii)Total value of raw silk producedSale value of Silk bye products5.40a) Silk waste @ 25% of the yarn@ Rs.150/- per kg for 150 kgs 0.225b) Double Cocoons ( 5% Green cocoons)240 kgs @ Rs.60/- per kg 0.144IV PROFIT :Gross income 5.769Gross income (Annum)Total Expenditure ( Annum)Net income5.7695.3600.409

(6) COTTAGE BASIN SILK REELING UNITS.No. Item Rs. InLakhs1 Capital Investmenta) Land Ownb) Building Ownc) Cost of reeling machinery 1.002 Operating cost for production of 1165 kgs of silk yarn/AnnumCost of raw material @ 35 kgs per day for 300 days –10500 10.50kgs @ Rs.100/- per kga) WagesSupervisory Charges (self)1)Total amount towards wages @ Rs.40/- per day 1.44for 12 workers for 300 days2)Other expenses (Fuel, Transport etc) @ Rs.300/- 0.90per dayTotal working capital per annum 12.843 Working Capital requirementActual working capital required for two months considering ( 2.146 ) operating cycles in a year (Rs.12.84/6 )4 InterestDepreciation on capital investment (10%) 0.14Interest on capital cost (16%) 0.16Interest on working capital of Rs.2.14 lakhs (16%) 0.342Rent of the building @ Rs.800/- month for year 0.096Total production cost/Annum (2 + 4) 13.5385 Estimated production of raw silk from 6 basin 6 end 13.048Cottage basin.. 1165 kgs/ per annuma) Total sale value of silk yarn @ Rs 1120/- per kgb) Sale value of silk bye products1) Silk waste ( 290 kgs @ Rs. 200/- per kg) 0.582) Double Cocoons (525 kgs @ Rs.65/- per kg) 0.373) Pupae ( 200 kgs @ Rs. 3/- per kg ) 0.06Gross income 14.058ProfitGross income ( per annum ) 14.058Total Expenditure ( per annum ) 13.538Net income 0.5206 BASIN MULTIEND REELING UNITS.No Item Rs. InLakhs1 Capital investmenta) Land Ownb) Building Own/rentedc) Cost of reeling machinery 4.702 Operating cost production of 1260 kgs of silk yarn /Annuma) Cost of Raw material @ 40 kgs per day for 300 13.20Days --- 12000 kgs @ Rs.110/- per kgb) Wages1) Total amount towards wages @ Rs.42/- per day 1.44For 12 workers for 300 days

2) Other expenses (Fuel, Transport etc) @ Rs.350/- 1.05Per dayTotal working capital per annum 15.693 Working Capital requirementActual working capital required for two monthsConsidering 6 operating cycles in a year ( Rs.15.69 /6 )Rs.2.614 InterestDepreciation on capital cost ( 10% ) 0.320Interest on working capital of Rs. 2.61 ( 16% ) 0.417Total production cost per annum ( 2 + 4 ) 16.4075 RealisationEstimated production of raw silk from 6 basinMultiend Reeling unit…..1260/- kgs / annuma) Total sale value of silk yarn @ Rs.1250/- per kg 15.75b) Sale value of Silk bye products1) Silk waste ( 315 kgs @ Rs.275/- per kg ) 0.8662) Double Cocoons (600 kgs @ Rs.70/- kg ) 0.4203) Pupae ( 200 kgs @ Rs.3/- per kg ) 0.060Gross income 17.096ProfitGross income ( per annum ) 17.096Total expenditure ( per annum ) 16.487Net income 0.609BYE – PRODUCTS USESDuring the process of mulberry silk reeling, the different qualities of mulberrysilk waste obtained as bye-products:a) Waste from cocoons:Floss or Blaze, Spelaia (Italian) or Keba (Japan)Discarded cocoons, pierced, double, stained etc.,Floss or Blaze: Floss silk or blaze also known as borra is the first part ofthe bave extruded by the worm for the frame work of the cocoon. Most ofit is removed from the cocoons during their collection and rest whilesorting. This can be used for noil spinning.Discarded cocoons : This includes all cocoons found to be unreelableduring sorting like :Double Cocoons: which are jointly formed by the combination of twoworms in the same shell and which due to the the interlocking of thecontinuous filaments cannot be reeled alongwith good cocoons. Thesecocoons are also employed for reeling ‘dupion silk’Inferior Cocoons:The improperly built cocoons and those deformed in shapeand also melted cocoons and other cocoons which become unfit for reelingdue to some reason or the other.b) Reeling waste :It may be filature, Cottage basin or charka silk wastec) Winding waste: Re-reeling, winding or throwster’s waste,Weaving waste (Hard waste)***