Module Descriptions – Production & Consumption Process (Leather)

Production:

            The preparatory stages are when the hide/skin is prepared for tanning. During the preparatory stages many of the unwanted raw skin components are removed. Many options for pretreatment of the skin exist. Not all of the options may be performed. Preparatory stages may include:

Preservation- the hide/skin is treated with a method which renders it temporarily unputrescible.

Soaking – water for purposes of washing or rehydration is reintroduced.

Liming – unwanted proteins and “opening up” is achieved.

Unhairing – the majority of hair is removed.

Fleshing – subcutaneous material is removed.

Splitting – the hide/skin is cut into two or more horizontal layers.

Reliming – the hide/skin is further treated to achieve more “opening up” or more protein removal.

Deliming – liming and unhairing chemicals are removed from the pelt.

Bating – proteolytic proteins are introduced to the skin to remove further proteins and to assist with softening of the pelt.

Degreasing – natural fats/oils are stripped or as much as is possible from the hide/skin.

Frizzing – physical removal of the fat layer inside the skin. Also similar to Slicking.

Bleaching – chemical modification of dark pigments to yield a lighter colored pelt.

Pickling – lowering of the pH value to the acidic region. Must be done in the presence of salts. Pickling is normally done to help with the penetration of certain tanning agents, e.g., chromium (and other metals), aldehydic and some polymeric tanning agents

Depickling – raising of the pH out of the acidic region to assist with penetration of certain tanning agents

  • Raw material indent:

Raw material required for manufacturing the products are estimated by the production manager. Then the required materials are arranged by the purchase manager. This data is uploaded in this module. In order to track the consumption details for the product manufactured raw material indent is must.

The leather manufacturing process is divided into three sub-processes: preparatory stages, tanning and crusting. All true leathers will undergo these sub-processes. A further sub-process, surface coating may be added into the sequence. The list of operations that leathers undergo vary with the type of leather.

Understanding the requirements of patrons, we are engaged in best quality Raw / Wet Blue Leather Imports. We import the leather from the most trusted vendors of the industry. Further, we make these leather undergo a treatment process under the supervision of expert professionals. Prior to dispatch, we check these leather so as to ensure their flawlessness.

 Our imports include: Miss-happen skins, under sized, Sheep skins, Goat skins, and Cow hides

 These imports are available in Raw, Pickle, Wet blue, Vegetable tanned and Crust leathers

  • Chemical Requirement

Leather chemical includes chemicals sodium nitrite, sodium nitrate, leather dyes, disinfectant, tannery cleaning chemicals, solvents, wax, silicone emulsion. The amount of chemicals required for manufacturing are estimated and submitted using this module.

  • Dyeing chemical process

A dye is a colored substance that has an affinity to the substrate to which it is being applied. The dye is generally applied in an aqueous solution, and requires a mordant to improve the fastness of the dye on the fiber. Both dyes and pigments appear to be colored because they absorb some wavelengths of light more than others. In contrast with a dye, a pigment generally is insoluble, and has no affinity for the substrate. Some dyes can be precipitated with an inert salt to produce a lake pigment, and based on the salt used they could be aluminum lake, calcium lake or barium lake pigments.

Archaeological evidence shows that, particularly in India and Phoenicia, dyeing has been widely carried out for over 5,000 years. The dyes were obtained from animal, vegetable or mineral origin, with none to very little processing. By far the greatest source of dyes has been from the plant kingdom, notably roots, berries, bark, leaves and wood, but only a few have ever been used on a commercial scale. Here dyeing process is carried out for finished leather manufacturing.

  • Dyeing machinery operations:

Leather Dyeing Machines which have been tested for its performance in all adverse conditions. These Leather Dyeing Machines are designed to fulfill all the requirements of the clients. This product exhibits high strength and is also known for its durable finish. Our highly skilled professionals have strived hard to ensure that the product is dimensionally accurate which in-turn enables our clients to fetch high levels of satisfaction in terms of its high end functionality. Features of dyeing machines are: Made from superior quality material, Best results and Low cost.

  • Finishing chemical process:

Our company is the world’s leading company in the treatment of leather and related products with nearly a century of experience in leather applications. Leather finishes add value to customers’ leather by their technical and aesthetic superiority and by tailor making leather finishing processes. The world’s best leather technicians work side-by-side with leading fashion experts to develop leather articles of superior quality and design, much appreciated by leading fashion and interior design brands worldwide.

Product range, with a wide product portfolio of finishing products, we ensure that all types of crust will be transformed into high-performance desirable fashion leather. Our product range cover:

Impregnation systems (aqueous and solvent borne) for fill and to strengthen the crust

Fillers (water and solvent based) to improve uniformity, adjust gloss, give oil and wax pull up effect, as well to adjust the feel.

Auxiliaries to optimize the performance of the finishing systems such as foaming, water repellence, spotting resistance, finish penetration and special effects.

Finishes ready for use or only require addition of water.

Modifiers (water and solvent based) offer improved surface handling, special tactile fashion effect and improve the physical performance of the leather.

Deller’s added to a basecoat and/or topcoat adjust the gloss, feel and appearance of the leather and give special fashion effects.

Topcoats (aqueous and solvent based) to meet the required fashion effects and specific physical performance requirements by the most demanding markets. Our topcoats can impart a specific colour, shade, cover and minimize defects and give metal effects.

Pigments (aqueous and solvent based) either containing protein for shoe upper leathers or protein free for soft nappas and garment leathers as well as for upholstery.

Dyes (metal-complex) to shade undyed crust, increase anility and create fashion effects.

  • Jobwork machinery charges master

Jobwork machinery charges master consists of all different types of charges. The works include Pattern development, Pattern Grading, Paper patterns and Plastic patterns for Shoes, Boots, Sandals Chappals and Insoles. Sample development works are also undertaken.

Charges for Shoe CAD Services

S.No          Job       Charges (Rs)

1)   Digitizing, Grading & Cutting (Boot & Moccasin Styles)     1,500

2)   Digitizing, Grading & Cutting (Other Styles)            1,000

3)   Digitizing, Grading & Cutting of Sandal / Chappal   750

4)   Marking Patterns (Plastic)       750

5)   Conversion (Per Size) 750

6)   Conversion (Single Size)         500

7)   Insole Grading            300

8)   Vacuum Shell (odd)    100

9)   Vacuum Shell (Pair)    175

Die-less Cutting

Die-less cutting system is specially used for cutting components without dies. The upper and lining components can be directly cut from the shoe designing software file without the requirement of die.

Advantages and Charges This machine cuts the upper and lining components directly from the shoe designing software file without the requirement of die, thus saves the cost of making dies.The machine can give twice the output of a normal clicking machine, thus increases productivity and reduces manpower (the work done by clicking machines can be done by this one machine).Since the machine is computerized and highly sophisticated it gives maximum accuracy.This machine gives the markings and punches as exactly as required.It cuts materials such as leather, textle, foam, insole board, toe puff, stiffeners etc.

The nominal charges for availing this service is Rs.300/- per hour.

All Footwear Machineries

  • Leather order entry

Consists of Leather purchase order entry. This module provides the complete details about the purchase order given by the customers. This will be used as a master form in order to avoid the repetition of entries this master form will be used. 

  • Finishing machinery operation

Once a hide finishes the tanning process, the leather can be manipulated for a variety of looks and textures. At the tannery the leather undergoes a series of wet operations for coloring and oiling. After the hide dries and it is in the “naked state”, it can be mechanically conditioned for different look or feel. Some of these same techniques can be used at your work bench. Beyond dying and oiling the leather, we’ll take a look at physical conditioning methods to give plain old leather a new and different look.

The different finishing machinery operations are staking, buffing, boarding, plating (embossing), glazing, brushing,

  • IN / OUT for Jobwork process

Usually the entire factory setup will not able to in the same campus itself. Leather is a durable and flexible material created by the tanning of animal rawhide and skin, often cattle hide. It can be produced through manufacturing processes ranging from cottage industry to heavy industry. Because due to pollution problem raw state to wet blue state of leather will be done in the nonresidential area. For this case the leather is shifted to one factory to another one for various operations. This operations are updated in this module for tallying the stock. Usually leather will be referred by lot number with number of hides & sides.

Consumption:

  • Dyeing Chemical Consumption

 With the constant support of our expert team, we are engaged in offering a huge assortment of Dye Fixing Agents. This superior make Dye Fixing Agents is highly appreciated for its renowned attributes and cost effectiveness. Being very efficient and durable, this Dye Fixing Agents is easy to use and maintain. We offer this high grade Dye Fixing Agents with advanced features that is widely appreciated in the markets. Actual consumption details are updated in this module time to time. We bring forth an impregnable range of Wax Emulsions. With the constant support of our highly experienced and efficient engineers, we are able to design and develop this Wax Emulsions in line with the international quality standards. This Wax Emulsions is widely demanded for their easy operation and requires less space to be installed.

  • Finishing Chemical Consumption

The Leather chemicals are used for finishing of crust leather to produce final leather suitable for end use to make various articles like shoes, jackets, furniture, sports goods etc. Leather chemicals used for finishing chemicals provide the crust leather with protective coating and also add aesthetic look to the leather. These chemicals cover natural defects in the leather and make leather surface smooth and even and also make leather weather resistant, wear & tear resistant and durable. The complete consumption of chemicals are updated in this module.

  • Machinery Operation Cost for Dyeing

The different machinery operations involved in the dyeing process are calculated based upon the number of cycles. Here job work costing also included and if the operations are done in our own factory this cost also calculated to include in the cost sheet. Then only we get the accurate cost for manufacturing the product.

  • Machinery Operation Cost for Finishing

The different machinery operations involved in the finishing process are calculated based upon the number of cycles. Here job work costing also included and if the operations are done in our own factory this cost also calculated to include in the cost sheet. Then only we get the accurate cost for manufacturing the product.

  • Cost Sheet Summary

Final work out summary consists of dyeing consumption cost, finishing consumption cost, dyeing machinery operation, finishing machinery operation, other expenses done. This workout shows the order is profit or loss. Every time while preparing the quotation this cost sheet summary helps to quote best and competitive price. Also this avoids to get any loss in trade.

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