Introduction
This article will be discuss how to calculate printing cost in garments industry. Printing differs from dyeing because, in printing process the colors are applied in a patterned manner in a localized manner based on the requirements. The dye materials are mixed with thickener and other chemicals to make it semi-solid. This solution is known as printing paste. Blocks, screens, rollers, etc., are used to apply this paste based on the design. A variety of processes are involved, depending on the method used; design development, screen preparation, printing paste preparation, fabric preparation, printing, drying, curing, and washing, if necessary.
Factors of Printing Cost Calculation
In order to determine the cost of printing, the following factors need to be considered:
- Types of printing process- pigment, discharge, reactive, resist, block, foil, etc.
- Size of the design.
- Methods used- screen, block, roller, or others.
- Dyes and chemicals used.
- Post-treatment- curing or drying
- Number of colors.
This article will be show you how to calculate printing cost in garments factory in case of screen printing process. To calculate screen printing cost, the following information need to be included in the costing process.
- Dye selection: Depending on the customer’s requirements, fabric type, and print design, dyes are selected. Generally, plastisols, pigments, discharge dyes, and non-PVC dyes are used commercially.
- Screen exposing and making charges: A separate film is required for each colour after the designs are made. In this example, six colours are used in the design. To complete a full design, six films need to be prepared and the fabric must be passed through all six screens. Depending on the size of the film, the exposure charges range from Rs. 0.50 to Rs. 1.50.
- Frame charges: A frame is required to fix the developed films with a material during the screen printing process. If the print design differs from commercial sizes, then the manufacturer must make the frames for that specific order. The cost of making frames is also included in the total cost if the print design differs from commercial sizes.
- Designing charges: Manufacturers are required to reproduce the design in the printing screen process. To do so, they conduct a designing process that may cost from Rs. 1.5 to Rs. 3.50 per square inch, depending on the complexity of the design.
Exercise: Calculate Printing Cost
The screen printing industry received a order for 30,000 T-shirts with a photo printed on the chest of the T-shirt in six different colours. The colour details are red, blue, grey, white, yellow, and green. The company spends Rs. 4.00 per square inch for designing, Rs. 400 for making a single frame, Rs. 2.00 per square inch for exposing of screen and Rs. 0.55 per garment for curing. Below is a table 1 with the quantity of dye consumed by color as well as the price for each dye. Now, calculate printing cost of the print per garment with 15% profit, if the company uses 10 workers with a wage of Rs. 300 per shift and averages production 3000 garments per shift. Additionally, the company charges Rs. 20,000 per month for electricity, Rs. 2000 for transportation, Rs. 40,000 for steam, and Rs. 85,000 for other expenses. The design size is 15×11 square inches, and the frame size is 22× 35 square inches. (Assume company works 26 day per month)
| S/N | Particulars | Consumed quantity in Kg | Price per kg |
| 1. | Red colour | 10 | 150 |
| 2. | Blue colour | 12 | 140 |
| 3. | Grey colour | 15 | 100 |
| 4. | White colour | 200 | 130 |
| 5. | Yellow colour | 15 | 120 |
| 6. | Green colour | 20 | 140 |
| 7. | Binder | 30 | 130 |
| 8. | Fixing agent | 7 | 130 |
N.B.: All data for calculate printing cost in garments industry are provided approximate values for understanding purpose. But when you calculate printing cost in your garments industry, please make sure the price and used according the market price.
Solution
Step 1: Total shift calculation
- The total order quantity= 30,000 garments
- Daily production of the company= 3,000 garments
- The total shifts required= Order quantity ÷ daily production= 30,000 ÷ 3,000= 10 shifts
Step 2: Labour cost
Total labour used are 10 with a wage of Rs. 300 per shift
- Labour cost of machine operator = number of labour× total working shifts × wage of per shift= 10× 10× 300= Rs. 30,000
Step: 3: calculation of raw material cost
- Designing charges
- Total design are= 15× 11
- Total number of colour= 6
- Charge per square inch= Rs. 4
- Total cost for design = ( 15× 11) ×6×4= Rs. 3,960
- Frame charges: given as Rs. 400
- So, total cost for making frame= 400 × 6= Rs. 2,400 (Since 6 colour required, for this design we need 6 frames.).
- Frame making charges: per square inch Rs. 2 (exposing)
- Total area= 22 × 35= 770 square inchTotal area for 6 color= 770 × 6= 4,620 square inch
- Total making cost= 4,620 × 2= Rs. 9,240
- Curing charges= Rs. 0.55 per garment
- Total cost= 30,000 × 0.55= Rs. 16,500
- Dyes and chemical costs.
- Red color= 10× 150= 1500
- Blue color= 12 × 140= 1680
- Grey colour= 15 × 100= 1500
- White colour= 200× 130= 26000
- Yellow color= 15 × 120= 1800
- Green color= 20 × 140= 2800
- Binder= 30 × 130= 3900
- Fixing agent= 7× 130= 910
- Total cost of dyes and chemical= (1500+1680+1500+26000+1800+2800+3900+910)= Rs. 40,090
- Total raw material cost= (3960+2400+9240+16500+40090)= Rs. 72,190
Step 4: Overhead cost
- Electricity charges= Rs. 20000 per month
- Transport charges= Rs. 2000 per month.
- Steam= Rs. 40000 per month
- Other expenses= Rs. 85000 per month.
- Total overhead cost= (20000+2000+40000+85000)= Rs. 147000
- Total overhead cost per day= 147000÷ 26= Rs. 5653.85 per day
- For this order company works 10 days hence, total overhead cost for this order= 5653.85 × 10= Rs. 56538.5
Step 5: Calculate printing cost per garment
- Total cost= labour cost + raw material cost + overhead= 30000+72190+56538.5= Rs. 1,58,728.5
- Cost per garment= 1,58,728.5 ÷ 30000= Rs. 5.29
- Cost per garment with 15% profit= 5.29 + (15% of 5.29) = Rs. 6.08
Conclusion
I think from above example we gained knowledge on how to calculate printing cost in garments industry. The data provided here are approximate and they are used only for your understanding purpose. In garments factory, merchandiser must quote the approximate price based on his previous experience. However, these are the example how to calculate printing cost in garments factory in merchandiser department. This example can following printing factory to calculate printing cost of their printing order.
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