Garment factory setup modern jeans manufacturing facility capable of producing 10,000 pieces of 5-pocket denim jeans per day requires careful planning, efficient layout design, proper selection of machinery, utility planning, and end-to-end execution. At Lord Industrials Pvt. Ltd., we specialize in providing turnkey garment factory setup solutions, and this post outlines the major project requirements for such a high-capacity production unit, based on our recent work with one of the important client.
1. Production Capacity Assumptions
Daily Output Target: 10,000 pieces/day
Monthly Output: 250,000 pieces
Annual Output: 3 million pieces
Production Shift:
Cutting & Washing Sections: 2 shifts (8 hours each)
Sewing, Finishing & Packing Sections: 1 shift (12 hours)
Efficiency Assumed: 70-80%
Absenteeism Considered: 15%
This estimation ensures realistic projections and helps structure machinery needs, manpower, and infrastructure accordingly.
2. Production System: Progressive Bundle Unit (PBU)
To ensure continuous and balanced workflow, the production system is designed using the Progressive Bundle Unit (PBU) method. This system allows for:
Easy movement of parts in trays or trolleys
Better Work-in-Progress (WIP) management
Improved line balancing and reduced bottlenecks
3. Space and Building Layout for Garment factory setup for Jeans Pants (10,000 pieces/day)
A well-designed space is crucial for efficiency, safety, and scalability. The project proposes a two-floor setup with designated areas:
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Ground Floor:
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Raw Material Storage
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Cutting Section
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Washing & Finishing Units
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Packing & Dispatch
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Finished Goods Storage
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First Floor:
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Sewing Lines
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Parts Preparation
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Inspection and Quality Control
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Total Area Required: Approx. 50,000 sq. ft. of covered space.
4. Machinery & Equipment for Garment factory setup for Jeans Pants (10,000 pieces/day)
a) Cutting Room Equipment
Includes both automated and manual machines for bulk cutting:
CAD Software (Morgan / Lectra)
Plotter (72 inch)
Automatic Spreader Machines
Automatic Cutting Machine (Morgan / Lectra)
Air Floatation & Manual Cutting Tables
Band Knife, End Cutter & Straight Knife Cutting Machines
Continuous Fusing Press Machines
Investment: ₹1.83 Crores
b) Sewing Section Machinery
A mix of general and specialized sewing machines ensures versatility and precision:
1-Needle & 2-Needle Lockstitch Machines
Overlock (3-thread & 5-thread) Machines
Pocket Setters & Pocket Creasers
Chainstitch & Pattern Sewer Machines
Belt Loop Attachers & Button Holing Machines
Bartacking & Snap Attaching Machines
Total Machines: 305 Units
Investment: ₹4.62 Crores
c) Finishing & Pressing Equipment
Vacuum Ironing Tables
Form Finishers
Thread Sucking Machines
Trouser Frames (Vertical & Horizontal)
3D Pleating Machines
Brushing Machines
Spray Booths
Investment: ₹1.11 Crores
d) Washing Department Setup
Designed to support daily washing of 10,000 jeans:
6×400Kg Heavy Washing Machines
Tumble Dryers
Hydro Extractors
Sample Wash Equipment
Total Water Requirement: 3.0 Lakh Litres/day
Investment: ₹3.21 Crores
5. Utilities & Infrastructure for Garment factory setup for Jeans Pants (10,000 pieces/day)
a) Power Supply Requirements
Connected Load: ~464 KW (1-Phase), 244 KW (3-Phase)
Running Load: ~318 KW (1-Phase), 160 KW (3-Phase)
Recommended Transformer: 450 KVA
Backup DG Generator: 1 unit
Electrical Setup & Erection: ₹2.5 Crores
b) Compressed Air
Required Air Volume: 237 CFM
Recommended Air Compressor: 75 HP
Investment in Air System: ₹35 Lakhs
c) Steam Requirements
Daily Steam Need: 1,550 Kg/hour
Recommended Boiler: 2 Tonne capacity
Total Boiler & Assembly Setup: ₹1.3 Crores
d) Water Treatment & Safety Systems
ETP Plant: 3.00 Lakh Litres/day
RO Plant & Pipelines
Fire Hydrant and Alarm Systems
CCTV, PA System, and Biometric Access
Investment in Utilities & Electronics: ₹2.18 Crores
6. Production Furniture & Handling Equipment for Garment factory setup for Jeans Pants (10,000 pieces/day)
Industrial furniture improves operational flow, worker comfort, and workplace safety. Items include:
Operator Workstations with Light & Fan
Manual and WIP Tables
Racks (Light, Medium, Heavy Duty)
Trolleys (Fabric Roll, Flat, WIP, Net Trolley)
Pallets, Lockers, Shoe Racks
Canteen Tables & Benches
Total Quantity of Items Supplied: 2,000+
Investment: ₹1.18 Crores
7. Manpower Requirement for Garment factory setup for Jeans Pants (10,000 pieces/day)
Sewing Line Workers per Line: ~40
Finishing Section Workers per Line: ~14
Total Number of Workers (Sewing + Finishing): ~530+
Includes line supervisors, helpers, pressers, QC staff, and material handlers.
8. Operational Summary for Garment factory setup for Jeans Pants (10,000 pieces/day)
| Component | Details |
|---|---|
| Daily Output | 10,000 Pieces |
| Efficiency | 70–80% |
| Space Requirement | 50,000 Sq. Ft. |
| Machines Needed | 300+ |
| Power Load | ~350 KVA |
| Water Requirement | 3.00 Lakh Litres/day |
| Steam Requirement | 1,550 Kg/hr |
| Manpower | 500+ |
| Total Project Cost | ₹18.28 Crores (Approx.) |
9. Key Project Features for Garment factory setup for Jeans Pants (10,000 pieces/day)
Turnkey Execution by Lord Industrials Pvt. Ltd.
Precise Electrical & Mechanical Planning
Customized Layout Design to maximize efficiency
In-House Supply of Furniture and Handling Equipment
Optimized Utility Planning with provision for future scaling
Factory Built for Safety, Productivity & Sustainability
10. Why Choose Lord Industrials Pvt. Ltd.?
We are a trusted partner for industrial project execution. Our services include:
Complete project planning and feasibility studies
Plant layout and workflow design
Machinery selection and procurement support
On-site project management and execution
In-house manufacturing of furniture, racks, and trolleys
Compliance with safety and environmental regulations
Post-project support and scaling solutions
We follow the Skill – Speed – Scale (S-S-S) model to ensure on-time, in-budget, and future-ready factory setups.
Conclusion
Setting up a factory to manufacture 10,000 jeans pants per day is a complex project that demands engineering precision, industrial insight, and seamless coordination between teams. From utility systems and machinery selection to furniture and layout — Lord Industrials Pvt. Ltd. ensures every aspect is addressed professionally.
If you’re looking to start or expand your denim manufacturing unit, we are ready to help you plan, build, and launch a factory that delivers performance, quality, and scalability.
📞 Contact Us Today to discuss your factory project!
🌐 Visit: www.lordindustrials.com
📧 Email: info@lordindustrials.com
📱 Phone/WhatsApp: +91-7603035011 / 7603053011 / 7603059695