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 pollution.
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
2. Chemical Requirement
Leather chemical includes chemicals sodium nitrite, leather dyes, disinfectant, tannery cleaning chemicals, solvents, wax, silicone emulsion. The amount of chemicals required for manufacturing are estimated and submitted using this module.
3. Dyeing/Finishing chemical process
A dye/Finish 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. Here dyeing process is carried out for finished leather manufacturing
4. Dyeing/Finishing 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
5. 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
6. 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
7. 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.
8. Dyeing/Finishing 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.
9. Machinery Operation Cost for Dyeing/Finishing
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.
10. 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.