196
NATIONAL INSTITUTE OF FASHION TECHNOLOGY C. A. Site No. - 21, Sector-1, 27 th main road, HSR Layout Bangalore. TEXTILE INTERNSHIP REPORT ON BHARAT VIJAY MILLS, KALOL NORTH GUJARAT. SUBMITTED BY: ISHITA PANDEY

TEXTILE INDUSTRY INTERNSHIP REPORT

Embed Size (px)

Citation preview

Page 1: TEXTILE INDUSTRY INTERNSHIP REPORT

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

C. A. Site No. - 21, Sector-1, 27th main road, HSR LayoutBangalore.

TEXTILE INTERNSHIP REPORTON

BHARAT VIJAY MILLS, KALOLNORTH GUJARAT.

SUBMITTED BY:

ISHITA PANDEY

NEENU SUKUMARAN

RANI TREASA JOSEPH

RASHMI AGARWAL

Page 2: TEXTILE INDUSTRY INTERNSHIP REPORT

ACKNOWLEDGEMENT

At the outset, we wish to express our gratitude to everybody who has assisted in

formulation of this report. There are a many to whom expression of gratitude is

inevitable, but there some special people who has to be given prominence, without

whom we would not have reached the conclusion of this project so quickly and so

efficiently.

We wish to thank Mr. A.K. Khare and Mr. Shivalingam for providing this wonderful

opportunity, channeling and motivation.

No amount of Gratitude is adequate for Mr. Rahul Patel and Mr. Amit Patel for their

consent in allowing us to conduct our internship in their venerated institution.

We express our deep indebtedness to Mr. M. K. Chaturvedy, the Human Resource

Manager who guided and supported us through every stage of our internship.

We also wish to thank Mr. H.J Shah, Mr. Daxesh Lala, Mr. Mukesh J. Shah, Mr H.

M. Raval, Mr. Atmaram Patel, Mr. Siraj, Mr .Subhash G. Patel, Mr. Ravin Mehta, Mr.

G. C. Bairi, Mr. Sunil Tailor, Mr. Ganesh Aher and Mr. Ravin Mehta for their

technical guidance and assistance.

We take this opportunity to express our affection towards our parents for their

consistent faith and support.

Ishita Pandey

Neenu Sukumaran

Rani Treasa Joseph

Rashmi Agarwal

Page 3: TEXTILE INDUSTRY INTERNSHIP REPORT

INDEX

PREFACE

1. INTRODUCTION TO BHARAT VIJAY MILL

2. DEPARTMENTS

i) OPERATIONS

a) SPINNING

b) YARN DYEING

c) WEAVING

d) GREY FOLDING

e) CORDUROY

f) PROCESSING

g) FINISH FOLDING

h) SQC

i) PRODUCTION PLANNING AND CONTROL

j) LABORATORY

k) ENGINEERING

l) ETP

ii) ADMINISTRATION

a) RETAIL SHOP

b) GENERAL ADMINISTRATION

c) HUMAN RESOURCE DEPARTMENT

d) PERSONNEL

iii) MARKETING

a) MARKETING

b) DESPATCH

c) DESIGN DEPARTMENT

iv) PROCUREMENT

a) PURCHASE

b) STORES

Page 4: TEXTILE INDUSTRY INTERNSHIP REPORT

c) WASTE

d) COTTON DEPARTMENT

v) FINANCE

a) ACCOUNTS

3. CONCLUSION

ANNEXURES

Page 5: TEXTILE INDUSTRY INTERNSHIP REPORT

PREFACE

The blend of the practice and principle- an industrial internship project transforms the

classroom student into a multidimensional internee. The real life experiences gathered

through the period helps the pupil to learn practical aspects and application of

theoretical knowledge. It provides a huge positive impact on the student in the spheres

of interpersonal skills, exposure, group work and experimentation.

The textile intership at Bharat Vijay mills is evidently the experience which provided

the spectrum of psychophysical knowledge and experience. Located at a centre of rich

culture and nationalistic history, Gujarat, the composite unit expresses a strict

environment which breeds exclusive expansion and development. As a internee at

Bharat Vijay Mills we assume our engrossment of an amount of this superior order

and management.

Our Major Objectives of study were:

1. To study the working environment of the industry

2. To study the departmental processes and their interrelation within the

organization

3. To study the Organisational Structure

We have tried our best to sum up the total work process of the industry through

observations and interactions.

Page 6: TEXTILE INDUSTRY INTERNSHIP REPORT

1

INTRODUCTION

Page 7: TEXTILE INDUSTRY INTERNSHIP REPORT

1. INTRODUCTION

Established in the year 1931, Bharat Vijay Mills (BVM), a composite textile mill,

initially operated on a very modest scale at Kallol, a town 30 Km in North of

Ahmedabad (India). In 1956, the present management took over. With an infusion of

motivation and enduring commitment to excellence the mill expanded.

It has grown into 50 million US$ group turnover with a dedicated

work force of 1600 people in the textile division. Today, BVM is a vertically

integrated plant having its own spinning to finishing facilities. BVM has been the

undisputed leader in varied product mix for the last 70 years with a continuous

expansion of its product range. Since last 20 years it has established a name in global

market with its Yarn Dyed / Piece Dyed Shirting, Corduroy & Bottom Weight.

BVM’s 80% of textile production consists of shirting and 20%

consists of suiting and corduroy. Their renowned buyers are Madhura garments. Allen

Solly, Peter England, Zodiac, San Francisco etc., is their major end buyers. The textile

division consists of 350 staff members and 1800 workers

BVM’S VISION:

To achieve global presence in Textile business, through continuous product and

technological innovation, customer orientation and a focus on cost effectiveness,

quality and services.

BVM’S MISSION:

Belief in strong customer orientation.

THE GEOSPHERE:

Ahmedabad, one of the fastest-growing cities in western India, is the commercial

capital of Gujarat. Located on the banks of the Sabarmati River, it has had a colourful

history dating back to antiquity unlike the new metropolitan city. It has numerous

fashionable hotels, glittering shopping malls, high-rise business buildings and

innumerable vehicles ranging from the latest sleek limousines to three-wheelers.

Page 8: TEXTILE INDUSTRY INTERNSHIP REPORT

Looking back in 1411, the city now known as 'Ahmedabad' was founded by Sultan

Ahmed Shah, who named it after himself. During the Sultanate, the rulers encouraged

the merchants, members and crafts in come to Ahmedabad and make it a flourishing

commercial and industrial city. An imperial atelier was located here, which produced

exquisite textile and other artifacts for the Imperial Court at Delhi. Even in those days,

experts contributed to Ahmedabad's prosperity A hilarious Ahmedabadi is renowned

for his spirit of enterprise. Over a hundred years ago, Indian entrepreneurs established

textile mills in Ahmedabad. Soon enough, the chimneystacks of these modern

composite mills covered almost the entire skyline, giving it the sobriquet 'Manchester

of India' over a hundred years. It is no surprise therefore that Ahmedabad continued to

grow. With the phenomenal increase in population, the demand for more urban

facilities, including accommodation, and the entire infrastructure considered essential

to modern life, began putting a tremendous strain on the existing civic amenities. The

main characteristic of Ahmedabad is that it continues to remain, as it was in the

beginning, a commercial city, and a major center of trade. Today's city, with its

teeming millions, its crowded streets, and burgeoning industries reflects some of these

changes.

Bharat Vijay Mills is expanded spinning mill from 18 million mtrs/yr to 24 million

mtrs/yr at Kalol in Gujarat. As of October 2005, construction work has been initiated

and equipment suppliers were appointed. The spinning mill is scheduled for

commissioning by end 2006. Plans are also on the anvil to set up a readymade

garment facility with an investment of Rs.400 million.

HISTORY OF BVM:

1931-1970’s- manufacturers of sarees.

1970’s – 1980’s – (while the textile industry faced business/ market crisis)

joined with Sintex (plastic manufacturing company) and sustained the crisis by

manufacturing Sintex plastic tanks

Since 1980s, 90s - started functioning as a textile division of Sintex industries.

Divided into both textile and plastic with textile consisting of the 1/3 rd of the

income.

Page 9: TEXTILE INDUSTRY INTERNSHIP REPORT

GENERAL INFORMATION

Name of the industry:

Bharat Vijay Mills, Kalol, North Gujarat

Address:

Bharat Vijay Mills

(Textile Division of Sintex Industries Ltd)

Kalol (N.G.) 382721, India

Phone: (91-2764)23731(6 lines), 20246, 20793

Fax: (91-2764) 20436

E-mail: [email protected]

www.sintex-india.com

Type of industry:

Composite mill consisting of spinning, weaving and processing

HEADS OF INSTITUTION:

Chairman:

Dineshbhai Patel

Vice Chairman:

Arunbhai Patel

Managing Directors:

Mr. Rahul Patel

Mr. Amit Patel

President Operation (production):

Mr. Ashok Mehta

Human Resource Manager:

Mr. M. K. Chathurvedy

Administration Manager:

currently vacant.

Marketing Manager:

Page 10: TEXTILE INDUSTRY INTERNSHIP REPORT

B.C. Sashidharan

Procurement Manager

Mr. R. K. Sharma

CFO

L.M. Rathore

Organization Chart

ORGANISATIONAL HIERARCHY

Managing Directors

PresidentOperations

President Marketing

PresidentProcurement

President Admin.

CFO

PersonnelT. K.I. R.Public RelationSecurityRetails ShopPower PlantGeneral AdministrationExcise

SpinningWeavingYarn DyeingEngineeringGrey FoldingProcessingFinish FoldingLabSQCPPCDesign CorduroyWare House

MarketingDespatch

PurchaseStores

FinanceAccountsSecretarial

HRD, IS, MIS

Page 11: TEXTILE INDUSTRY INTERNSHIP REPORT

Managing Director

President

General Manager

Deputy General Manager

Senior Manager

Manager

Deputy Manager

Senior Executive

Trainee (Qualif: B. Sc/Diploma/B.Tech- Stipend Rs.4500 – 15,000)

Worker (ITI)

PRODUCTION STATUS

56000 meters/day of shirting fabric

1.5 lakh meters of corduroy

PRODUCT

On the product front, company has added various bottom weight qualities in singles as

well as in doubles in addition to existing products like corduroy, yarn dyed and solid

Page 12: TEXTILE INDUSTRY INTERNSHIP REPORT

dyed shirti ng's which helps the company to supply widest product range coupled with

small and large quantities of products to meet the demand of garment

manufacturers/exporters. The product range also covers Men's and Ladies apparels

and furnishing etc. l Corduroy for bottom-wear as well as shirting from 4 Wales to 21

Wales per inch l Yarn Dyed stripes, Checks; Fil-a-fil, Chambray's in plains as well as

dobbies l Bottom-weights with different weaves

End use of Products

Men's Wear Top And Bottom

Formal As Well As Casual

Skirts

Jackets

Shorts

Furnishing

Count range In English(Ne)-12s,16s,20s,24s,30s,40s,50s,2/80s and 2/100s in 100%

Cotton and in Poly/Cotton and Poly/Viscose Blends-40s,45s and 60s.

Page 13: TEXTILE INDUSTRY INTERNSHIP REPORT

2

OPERATIONS

DEPARTMENT

2. I. OPERATIONS DEPARTMENT

2. I. a. SPINNING

The cotton fiber grows in the seedpod or boll, of the cotton plant.

Each fiber is a single elongated cell that is flat, twisted, and ribbon like with a wide

Page 14: TEXTILE INDUSTRY INTERNSHIP REPORT

inner hollow (lumen).It is composed of about 90 percent cellulose and about 6 percent

moisture; the remainder consists of natural impurities. The outer surface of the fiber is

covered with a protective wax like coating which gives the fiber a somewhat adhesive

quality.

After this hydraulic pressing is done and cotton is been tested for

the quality control. And then it has been sent for even moisture distribution. After all

these processes this bale cotton gone to traders and textile mills receives these bale

cotton from traders. As soon as the cotton arrives at the mill after ginning process in

large bales weighing about 500 pounds (225 kg) each it is been kept for 24 hours. And

then spinning process starts:-

1. BLENDING

STEPS:

Cotton is passed from bales and then to apron. Apron moves cotton

to blending apron. Blending apron has sharp spikes the raise cotton until part of it is

knocked off by the roll. Some of the cotton stays on apron. The cotton knocked back

(Bale cotton kept for 24 hrs rest before blending)

(Even moisture distribution is been done through the bale cotton)

(Stack of bales kept after hydraulic pressing)

Fan which distributes moisture

Page 15: TEXTILE INDUSTRY INTERNSHIP REPORT

by roll and continues to chum and blend until picked up again by apron. Another roll

strips off cotton that was not knocked back by previous roll. Cotton falls on conveyor

belt and is carried to next process.

WHY IT’S BEEN DONE?-

It is necessary so as to obtain uniformity of fiber quality.

2. OPENING

STEPS:

Lint cotton falls on apron and passes between feeder rolls to

beater cylinder. The rapidly whirling beater blades take off small tufts of cotton,

knock out trash, and loosen up the mass. The two screen rolls are made of screen

material and air is sucked out of them by fan. This draws the

cotton from beater and condenses it on the surface of the

screen rolls from which it is taken and passed on by the small

rolls. Air suction through cotton takes out dirt and trash.

Conveyor belt passes cotton to another type of beater. From

beater the cotton passes to a conveyor and is carried to

picker.

WHY IT’S BEEN DONE?-

It is necessary in order to loosen hard lumps of fiber and

disentangle them; cleaning is required to remove trash such as dirt, leaves, burrs, and

any remaining seeds.

Mechanical bale pickers pluck thin, even layers of the matted

fibers from each of a predetermined number of bales in turn and deposit them into a

hopper. The fiber is mixed and passed to an opener. As the mass of fiber passes

through the opener, cylinders with protruding fingers open up the limp and free the

trash. The kind and number of cylinders or beaters, employed depend upon the type of

cotton that is being processed. The commonly used porcupine beater revolves about

1000 revolutions per minute. As the cotton is opened, trash falls through a series of

(Cotton going through the opening machine where the fibers are loosened)

Page 16: TEXTILE INDUSTRY INTERNSHIP REPORT

grid bars. When the cotton emerges from the opener, it still contains small tufts with

about two-thirds of the trash. It may be conveyed as lap.

GBR- Here the cottons are fed for homogenous mixtures and for

removing dirts.MPM-8 – it has got 8 chambers. Generally used for homogenous

mixture of fibers like while harvesting some cotton are from matured plants and some

are not. So that it will affect the fabric. So, after homogenous mixing all will be the

same.

(Mixing of diff cotton bales) (Formation of lap)

(Laps formed)

Here fibers are rolled into roller at the same time they are pressed also.

Time taken to roll one lap:-

40s Count 600 sec

50s Count 666 sec

20s Count 500 sec

Page 17: TEXTILE INDUSTRY INTERNSHIP REPORT

3. CARDING PROCESS:

Before the raw stock can be made into yarn, the remaining

impurities must be removed, the fibers must be disentangles, and they must be

straightened. The straightening process puts the fibers into somewhat parallel

CARDING. The work is done by carding machine.

The lap is passed through a beater section and drawn o rapidly

revolving cylinder covered with very fine hooks or wire brushes slowly moves

concentrically above this cylinder. As the cylinder rotates, the cotton is pulled by the

cylinder through the small gap under the brushes; the teasing action removes the

remaining trashes, disentangles the fibers , and arranges them in a relatively parallel

manner in form of a thin web. This web is drawn through a funnel shaped device that

molds it into a round rope like mass called card sliver. Card sliver produces carded

yarns or carded cottons serviceable for inexpensive cotton fabrics.

(Card sliver formed)

(Lap is been fed into carding machine)

(Carding process taking place)

Page 18: TEXTILE INDUSTRY INTERNSHIP REPORT

STEPS:

The lap from pucker unrolls and feed roll passes cotton licker in roll

(covered with saw toothed wire).The licker in roll passes fiber against cleaner bars

and gives it up to large cylinder which passes between the thousands of fine wires on

surface of cylinder and on flats. The cotton follows large cylinder to doffer cylinder,

which remove lint from large cylinder. The doffer comb vibrates against doffer

cylinder and takes lint off in a filmy web that passes through condenser rolls, coiler

head, and then into can. The sliver may be passed from one can to combing for further

removal of foreign matter and parallelization of fiber or directly to drawing.

4. DOUBLING PROCESS:

After carding, several slivers are combined. This results in a

relatively narrow lap of compactly placed staple fibers. The compactness of these

fibers permits this cotton stock to be attenuated, or drawn out, to a sliver of smaller

diameter without falling apart.

5. COMBING PROCESS:

When the fiber is intended for fine yarns, the sliver is put through

an additional straightening called COMBING. In this operation, fine-toothed combs

continue straightening the fibers until they are arranged with such a high degree of

parallelism that the short fibers, called noils, are combed out and completely separated

out from the longer fibers.

Page 19: TEXTILE INDUSTRY INTERNSHIP REPORT

The combing process forms a comb sliver made of the longest fibers, which, in turn,

produces a smoother and more even yarn. This operation as much as 25% of the

original card sliver; thus almost one fourth of the raw cotton becomes waste. The

combing process, therefore, is identified with consumer goods of better quality. Since

long-staple yarns produce stronger, smoother, and more serviceable fabrics, quality

cotton goods carry labels indicating that they are made from combed yarns or combed

yarns.

6. DRAWING PROCESS:

The combining of several fibers for the drawing, or drafting,

process eliminates irregularities that would cause too much variation if the slivers

were pulling through singly. The draw frame has several pairs of rollers, each

advanced set of which revolves at a progressively faster speed. This action pulls the

staple lengthwise over each other, thereby producing longer and thinner slivers. After

(Combing process)

Page 20: TEXTILE INDUSTRY INTERNSHIP REPORT

several stages of drawing out, the condensed sliver is taken to the slubber, where

rollers similar to those in the drawing frame draw out the cotton further. Here the

slubbing is passed to the spindles, where it is given its first twist and is then wound on

bobbins.

STEPS:

Her six cans that were filled at cards feed each drawing from delivery. The spoons are

connected so that if any one of the six slivers from can should break, the machine

automatically stops. This prevents making uneven yarn later. Each of four set of rolls

runs successively faster than preceding set. The last set runs approximately six times

as the first set; consequently, sliver coming out is the same size as each one of six

going in. but is attenuated to six times the length per minute. The sliver is neatly

coiled again in roving can by coiler head. The sliver is now much more uniform and

fibers much more nearly parallel. The sliver is now ready for roving frames.

7. ROVING PROCESS:

(Drawing process-6 cans of comb sliver been fed)

(After drawing process)

(Inner arrangement-helical) (Cover) (Spring + helical structure)

Page 21: TEXTILE INDUSTRY INTERNSHIP REPORT

These bobbins are placed on the roving frame, where further

drawing out and twisting take place until the cotton stock is about the diameter of a

pencil lead. There are two stages of roving; intermediate and fine. The operations are

identical, but each machine yields a finer product than the stock is received. Roving is

the final product of several drawing out operations. It is a preparatory stage for the

final insertion of twist. To this point, only enough twist has been given the stock to

hold the fibers together. Roving has not tensile strength; it will break apart easily with

any easy pull.

STEPS:

The can of sliver from drawing frames is fed between three sets

of drafting rolls. Each following set of rolls runs faster than preceding sets. This pulls

sliver and thins it down, making fibers nearly parallel. The spindle turns flyer and is

driven at a constant speed. The front rolls (nearest flyer) are set at a sped that gives

strand coming out of the rolls a predetermined number of turns of twist per inch as it

moves along between rolls and flyer. The bobbin is driven by a source separate from

gear that drives spindle and flyer. The bobbin is regulated to turn automatically at a

speed sufficiently faster than flyer, which causes roving to wind on bobbin at same

rate as it is delivered by front roll.

8. SPINNING PROCESS:

The roving, on bobbins, is placed in the spinning frame, where it

passes through several sets of rollers running at successively higher rates of speed and

is finally drawn out to yarn of the size desired. Spinning machines are of two types;

ring frame and mule frame. The ring frame is faster process, but produces a relatively

(Speed frame-back side) (Speed frame-front view-120 bobbins)

(Bobbin)

Page 22: TEXTILE INDUSTRY INTERNSHIP REPORT

coarse yarn. for very fine yarns, such as worsted, the mule frame is required because

of its slow, intermittent operation. The ring frame, which is general in use, is more

suitable for the manufacture of cotton yarns in mass production. Its hundreds of

spindles, whirling thousands of revolutions per minute, and its constant spinning

action provide a fast operation. The ring spinning frame completes the manufacture of

yarn (1) by drawing out the roving (2) by inserting twist, and (3) by winding the yarn

on bobbins-all in one operation. The bobbins of yarn are removed for such processing

as may be desired; for example, the yarn may be reeled into skeins for bleaching or

may be wound on cheeses, or spools, for ultimate weaving.

STEPS:

The principle of spinning is same as that used in roving except

that the operation is more refined and a ring and traveler are used instead of the flyer.

From bobbin roving is fed between set of drafting rolls to draw strand down to its

final desired size. The spindle turns bobbin at a constant speed. The front set of rolls

is adjusted to deliver yarn at a speed sufficient to insert desired mount of twist as

strand moves along. The traveler glides freely around ring. The tension caused by

drag of traveler causes yarn to wind on bobbin at same rate of speed as it delivered by

rolls.

SPINNING PROCESS FLOW CHART

(Ring Frame)

CARDED COMBED POLY/COT

Page 23: TEXTILE INDUSTRY INTERNSHIP REPORT

BALE OPENING

STACK MIXING

BLOW ROOM

CARD

BREAKER DRAW FRAME

FINISHED DRAW FRAME

SPEED FRAME

RING FRAME

WINDING

PARALLEL WINDNG

T.F.O

WINDING

WARPING

BALE OPENING

STACK MIXING

PRE OPENING

BLOW ROOM

CARD

PRE COMB

LAP FORMING

COMBER

BALE OPENING OF 100%POLYESTER

STACK MIXING WITH TINT COLOR

BLOW ROOM

CARD

DRAW FRAME PASSAGE OF POLYESTER

POST COMB

SPEED FRAME

WINDING

PARALLEL WINDING

T.F.O

WINDING

RING FRAME

DRAW FRAME BLEND

PASSAGE P+C

P/C BLEND 2nd PASSAGE

P/C BLEND FINAL

PASSAGE (3rd)

SPEED FRAME

WINDING

PARALLEL WINDING

T.F.O

WINDING

RING FRAME

Page 24: TEXTILE INDUSTRY INTERNSHIP REPORT

PROCESS CONTROL PARAMETER

MIXING 12S 20S 40S 50S SYNTHETIC

MAKE

(m/c form)

TRUMAC

New

TRUMAC

New

TRUMAC

Old

TRUMAC

New

LR

Old

SHELLROLL

(R.P.M)

11 11 11 11 9

LAP WEIGHT 20 20 20 20 13.2

LAP LENGTH 44.4 56 61 66.6 90

GRAMMO

METER

450 400 330 300 300

TOLERANCE

LIMIT

+ or – 300gm + or –

300gm

+ or –

300gm

+ or –

300gm

+ or – 300gm

YARN QUALITY PARAMETERS

1. CV% of count

2. CV% of strength

3 .C.S.P

4 .U% & imperfection ( thin, thick, neps) & yarn hairiness.

5. Classimat faults

o Raw material faults

o 16 class faults(A to D)

o Long thick faults(E+F+G)

o Long thin faults(H+I)

Page 25: TEXTILE INDUSTRY INTERNSHIP REPORT

o Objectionable fault(A4+B4+C3+C4+D3+D4)

6. T P I

7. Single yarn strength (gm)

8. R.K.M

9. CV% of single yarn strength

10. CV% of elongation

END USES

o Yarn dyed fabric

o Corduroys pile fabric

o Bottom weights fabrics

o Dobby fabrics & poplins

NAME OF THE MACHINE MAKE

INSTALLED

YEAR

NO.OF

MACHINE

1.BLOW ROOM

Trutzschler blow room line

with two finisher scutchers

TRUMAC 1992 1

New trutzschler blow room

line with one finisher scutcher

TRUMAC 2000 1

Old synthetic blow room line Laxmi-Reiter 1978 1

Page 26: TEXTILE INDUSTRY INTERNSHIP REPORT

with one scutcher

Pre filter & fine filter unit TRUMAC 1998 1

CVT – 3 TRUMAC 1999 1

Roving waste opener TATHAMS 1960 1

Bonda waste opener TATHAMS 1960 1

Bale braker PLATTS 1946 1

Mixing bale opener(MBO) Laxmi-Reiter 1989 1

2.CARDING

Trutzschler DK-740 card TRUMAC 1997-98 8

Trutzschler DK-780 cards TRUMAC 1998 4

Trutzschler DK-780 cards TRUMAC 2000 4

Waste collection system TRUMAC 1998 1

R.S.G grinder complete PERFECT 2000 1

3.COMBING

High speed comber E7/4(old) Laxmi-Reiter 1991-92 4

High speed comber E7/4 Laxmi-Reiter 1995-96 4

High speed comber LK-250 Laxmi-Reiter 1998-99 6

Lap former E 2/4A Laxmi-Reiter 1994 1

Lao former E2/4A Laxmi-Reiter 1997 1

High speed comber LK-250 Laxmi-Reiter 2002 2

4.DRAWING

HS draw frame DO/6 model Laxmi-Reiter 1989 2

HS draw frame padmatex –

720

Padmatex 1992 4

HS RSB – 1 draw frame RIETER 1998 2

HS RSB – D – 30 draw frame RIETER 1999 2

5.SPEED FRAME

Speed frame TS-15 model TEXTOOL 1992 4

Speed frame TS-15 model TEXTOOL 1994 1

Page 27: TEXTILE INDUSTRY INTERNSHIP REPORT

Speed frame LF-1400 Laxmi-Reiter 1989 4

Speed frame LF-1400A Laxmi-Reiter 1997-98 2

Speed frame LF-1400A Laxmi-Reiter 2000 1

6.RING FRAME

Ring frame MEI MEI 1989 4

Rig frame DJ-50N MODEL TEXTOOL 1992-93 50

7.WINDING/DOUBLING/T.F.O

Parallel winding m/c KAMITSU 1964 1

Parallel winding m/c KAMITSU 1971 1

Super doublers NMM 1978 1

T.F.O VEEJAY

LAKSHMI

1999-2000 3

7.ROLL SHOP SECTION

Cot mounting m/c C&C 1972 1

Cot mounting m/c DRONSFIELDS 1960 1

Cot mounting m/c VIRAJKA 1998 1

Cot buffing m/c SABAR 1980 1

Cot buffing m/c S draft DENIMAC 1992 1

Cot bercolising m/c H.SAGAR 1989 1

LAYOUT OF SPINNING DEPARTMENT

BLOW ROOM LINE

SME – 3SME – 2SME - 1

KA

MIT

SU

W

IND

ING

TFO

DOUBLING MACHINES

SPINNING OFFICE

WEAVING SECTION

T.T. DJ50NRING

FRAME(16)

WMM SUPER SPINNER RING FRAME(6)

T.T.PJ 50NRING FRAME

(34)MEI RING

FRAME (12)

T 151 SPEED FRAME

LR GS SPEED FRAME

MIXING ROOM

L F 1400 S F L F 1400 SPEED FRAME

E 7/4 LK250

COMBER

P.T.DRG

E 7/4COMBER

RSBDRGTRUMAC DK 780 CARDTRUMAC DK 740

SLIVER LAP

L.K

.250

CO

MB

ER

SL

IVE

R L

AP

E 7

/4 &

L.K

.250

CO

MB

ER

BLOW ROOM LINE

WIN

DIN

G D

EPA

RT

ME

NT

Page 28: TEXTILE INDUSTRY INTERNSHIP REPORT

2. I. B YARN DYEING

When dyeing is done after the fiber has been spun into yarn, it is

described yarn dyeing. There are several methods of yarn dyeing. The purpose is to

have the dyestuff penetrate to the fibers in the core of the yarn; this is similar to the

penetration of the fibers in stock dyeing. Cloth made of dyed yarns is called yarn

dyed.

Page 29: TEXTILE INDUSTRY INTERNSHIP REPORT

Yarn dyed fabrics are usually deeper and richer in color. Yarn dyed fabrics intended

for laundering must be quite colorfast, or bleeding could occur. The primary reason

for dyeing in the yarn form is to create interesting checks, stripes, and plaids with

different –colored yarns in the weaving process. Chambrays, for example, are usually

woven with a colored warp and white filling. Other combinations of different colored

yarns are checked gingham, shepherd’s check, plaid, seersucker, and heather

mixtures.

Yarns can be dyed in the form of skeins or packages. Package-dyed yarns are more

suitable for woven fabrics, whereas skein-dyed yarns as more suitable for knits and

carpets where a fuller bulk is more desirable. However, package dyeing can be

performed on a much larger scale and with more uniform results. Consequently, it is

the more commonly-used method.

PACKAGE DYEING MACHINES

In these enclosed machines where dyeing under pressure can take

place, the dye-liquor is circulated through wound packages of yarn until the dye is

evenly exhausted. The yarn is wound onto perforated tubes or springs, or other types

of holders and the packages formed are then mounted onto a perforated rod (spindle)

or tube. In a commercial dyeing machine seven hundred packages are tightly packed

on a number of spindles which are arranged vertically on a hollow base (the

carrier).After loading, the carrier is dropped into a seating in the dyeing tank, through

which the dye-liquor is circulated. The dye-liquor is pumped through the packages in

either direction, according to need.

Page 30: TEXTILE INDUSTRY INTERNSHIP REPORT

These type of machines are also used, with the proper modification, to

dye loose fibers, tops and sliver, and warp yarns. In dyeing

warp yarns, a single perforated cylinder of the yarns fits into

the seating of the dye tank.

Packages that are too loosely wound may

collapse during the dyeing process. However, packages that are

too tightly wound may interface with the circulation of the dye-

liquor. In any case, the packages must be wound as uniformly

as possible. Sudden pressures changes should be avoided to

prevent possible distortion of the packages. Therefore, newer

package dyeing machines have the capability of controlling

both flow and differential pressure. Many times the packages are covered by a

protective bag which acts as a filter to prevent deposits of insoluble dye and other

impurities on the yarn.

Modern package dyeing machines are made to operate at low liquor

ratios. This is achieved by eliminating the external expansion tank.

Carrier

Spindle

Yarn package

Main tank

(Carrier inserting into the main tank)

Carriage

Page 31: TEXTILE INDUSTRY INTERNSHIP REPORT

MAIN STEPS INVOLVED IN YARN DYEING

Yarn dyeing is done in mainly two stages:-

1) DEVELOPMENT

o Customer gives sample with its all specifications like count, color etc. The sample

given is generally known as eskloon (handkerchief shape).

o It is then checked in lab. There they will check it in a particular design like how

many threads they need.

o Then in hang form dyeing take place

o Approval from buyer. records of number of chemicals and recipe kept

o If its not correct they will re-produce or re-process. But if the quantity of shade

required is very less like 2 warp yarns in long intervals then shade variation in the

cone can be tolerated.

o If approved go for bulk order

2) BULK ORDER

o Production Planning Department takes charge of bulk order. Depending on load,

capacity, constraint, date is fixed.

o CYCLE OF YARN DYEING PROCESS

2.1 Receives soft package from winding department

o Yarn packages from winding department been received.

Page 32: TEXTILE INDUSTRY INTERNSHIP REPORT

o There is a spring attached to the yarn package which helps in shrinking the

yarn package.

o Uniform dyeing not possible if we use paper corn winded Yarn.

o So we generally use spring winding so that more yarn can be wounded as

well as gives uniform winding.

o It basically helps in loading process.

o Recipe is been made according to development stage.

o As per availability of recipe and P.P.C department dyeing is been done.

2.2 Loading yarn packages to carrier

o These packages are put in a carriage in compressed form.

o The main principle behind this is mechanism of compression. There is a

pressing device which compresses the packages.

o There is long cylindrical rod –spindle in which spring wounded yarns are

been kept. These rods have small pores in it which allows movement of

dyeing chemicals in and out during dyeing process.

SPRING

Page 33: TEXTILE INDUSTRY INTERNSHIP REPORT

o In each spindle there can be maximum 11 yarn packages can be kept. But it

again depends on compression mechanism.

o Compression is done according to

:-design

:-density package

:- vessel height in which these yarns are been dyed.

o These spindles are attached to a carrier. In one 400 kg carrier there can be

almost 61 spindles.

2.3 Dyeing

o The dyeing machine consist of:-

:-Microprocessor

It depends on light, medium, dark, reactive dyes. All details are feeded

onto the processor and locked. as per the requirement one program is used.

:-Closing tank

In this chemicals are been put. And tube passes from this tank to main

tank through which chemicals pass through.

:-Main tank

It’s the main tank in which carrier is been put.

o First they put the carriage in the main tank in which 900 liters of water is

been filled.

o Then chemical is put into chamber which later goes to closing tank.

o Programming done-according to chemicals, water, temperature

o Water coming out from bottom of spindle and spreads out.

Page 34: TEXTILE INDUSTRY INTERNSHIP REPORT

o There are mainly two stages;-in –out and out-in

o 9-10 hrs is taken for dyeing 1 carrier.

o Capacity is 5-6 tones/day

After dyeing process almost double amount of water is present inside the package.

Then water comes down due to gravity.

There is another system known as automatic dosing system. In this

chemicals are put in different tank according to color we want program is been feeded

and the chemicals are taken automatically from these tanks and recipe is made.

In same vessel we can have different capacity. There are carriers known as

dummy carriers. These carriers consist of

dummy spindles. Dummy spindles are plain rod

which doesn’t have holes in them so that when

dyeing process takes place water is not wasted

in and out through these spindles. So these rods

block the movement of water in and out through

the spindle.

Example;-

In-out

Out-in

Porous spindle

Dummy spindle

(The rod is made of steel and no holes present n it so that it controls the movement of water in and through.)

Page 35: TEXTILE INDUSTRY INTERNSHIP REPORT

Suppose in a 100kg m/c we want only 80 kg yarns to be dyed. We have to put all the

spindles but we cant waste 20 kg of dyed yarn. And if we use the simple porous

spindles then most of the colored water will try to come out of that spindle because

the pressure applied is very less in those spindles. So, variation in color may arise. In

that situation we use dummy spindles which is covered with the steel for the equal

distribution of pressure of water in all the spindles. And it also helps out in shade

variation problem.

2.4 Hydro extractor

After dyeing yarn contain almost double amount of water. This is been

removed through a hydro extractor. It

consists of a l oading device in which

yarns are kept. Then this is put into a

chamber. Inside this chamber the load

rotate in a speed of 1700rpm. Time

taken is 10 minutes. Due to the

centrifugal force water comes out.

8 yarn package in 1 floor

Total 2 floors present

2.5 R.F.Dryer (Radio Frequency Dryer)

After hydro extracting there is still some amount of water present inside the yarn.

Through radio frequency further drying is been done.I n this dryer machine electrodes

are present, which create an electromagnetic field.H+ and O- polar molecules are been

produced.This start vibrating and create

energy. Therefore H+ and O- get split. In

this temperature has to be controlled and

also height between these electrodes and

yarns have to be maintained.

Electrode 283.0mm

Conv.speed 5.7 m/h

Anode Ja 11.7 A

Page 36: TEXTILE INDUSTRY INTERNSHIP REPORT

Grid Ig 2.4 A

After the drying process, the yarn packages are winded in a cone, like 2 yarn packages

are winded in one cone to check for the shade variation among different yarn

packages.

TYPES OF DEFECTS

1. Shade matching

If the shade is not matching this can be rectified by reprocessing it.

2. Levelness of package

From 2 cheese to 1 cone

Dyes generally used are vat, reactive dyes.

Colors used:-

IND BROWN BR

IND GREY 4B

INDOLIVE T

IND OLIVE GREEN B

NOV BROWN 2G

NOV PURPLE LR

NOV BROWN P

NOV OLIVE R

NOV YELLOW 5G

NOV JADE GREEN XBN

YELLOW 3RT

IND NAV BLUE VH

IND BLUE BC

IND BLACK AC

BLACK BLWUWU

RED DYES

Page 37: TEXTILE INDUSTRY INTERNSHIP REPORT

CRIMSON HEXL

YELLOW HEXL

NAVY HEXL

BLUE HERD

BLUE HEXL

BLUE HEGL

RED HEXL

REACTIVE DYES

Page 38: TEXTILE INDUSTRY INTERNSHIP REPORT

2. I. C. WEAVING

Cotton yarn can be made into cloth by knitting or weaving but weaving is by far the

most important and the only one used here. Weaving is carried out on a loom where

warp yarns run lengthways from back to front. Using a shuttle, weft yarn is threaded

widthwise. In early times, using a hand-loom, it was found to be much difficult to raise

alternate warp threads and lower the others. The weft could then be carried between

them in a straight line. The position of the warp threads was then reversed and the weft

sent back in the opposite direction.

PREPARATORY PROCESS FOR WEAVING:

The yarns as manufactured and packaged after spinning are not in the optimum

condition to enter the looms directly so as to produce fabrics. Package size, build and

other factors make it necessary for the yarn to be further processed to prepare it to be

handled efficiently during fabric manufacturing. The yarn package as it comes from

spinning must be repackaged to meet the particular needs and demands of fabric

manufacturing.

Various steps for preparatory process of yarn for weaving are as follows:

WINDING (WARP WINDING AND WEFT WINDING)

WARPING

SIZING

DENTING AND DRAWING-IN

WEAVING

Page 39: TEXTILE INDUSTRY INTERNSHIP REPORT

1.) WINDING

OBJECTIVE: To transfer yarn from spinner bobbin to another suitable package for

warping machine.

REQUIREMENTS:

The fault level in the yarn must be reduced to an acceptable level.

The yarn must not be damaged in the winding process.

The package size, shape and build must be suitable for particular end use.

The package size should be controlled to meet the particular economic requirement.

MACHINERY:

i) AUTOCONERS: These are machines used to remove impurities, irregularities, and

imperfections like thick or thin places, slubs, nebs or loose fibers from the yarn

obtained from spinning. There is a special feature called ‘auto-doffing’ in all of these.

In this mechanism, after the yarn package finishes, another package automatically drops

and the winding process continues.

Doffing capacity = 60 doffs per hour.

Weight of the yarn = yarn length/ (1694* yarn count)

There are three types of autoconers used in the winding department:

a.) MURATEC MACHINE CONER 138 : Separation of electrics, pneumatics and

mechanics

No. of machines = 2

No. of spindles in each machine=60

b.) SCHLAFHORST AUTOCONER 238 : Single( individual) spindle machine

Page 40: TEXTILE INDUSTRY INTERNSHIP REPORT

Automatic splicing.

Uniform tension

Electrode sensors are present

No. of machines = 2

No. of spindles in each machine=60

c.) SCHLAFHORST AUTOCONER 338 : Sensor-controlled winding process.

This is the latest machine with the following features:

Uniform yarn tension.

Ecopack: Exact length measurement. Accuracy is

measured in terms of micro and millimeters.

Variopack: For stretchable yarns, to achieve uniform

tension without destroying the shape.

Cradle pressure: Proper compact package to maintain

uniform density.

Speed: Fastest machine fully computerized.

No. of machines = 2

No. of spindles in each machine=60

ii) SAMPLE WINDING MACHINE: VERSA WINDER

Here, the length of yarn to be winded can be feeded and after the length is achieved, the

machine automatically stops.

Number of machines = 1

Number of winders in each machine = 6

GAS YARN SINGEING MACHINE:

Every yarn has a different level of hairiness. To avoid this, yarn singeing is done. A

mixture of certain volume of gas and air at a certain speed and temperature is used in

the burner. As the yarn passes through the burner, only the protruding fibers get singed.

Page 41: TEXTILE INDUSTRY INTERNSHIP REPORT

Yarn singeing is generally done for stripe qualities, where the ground is of the same

color.

TYPES OF YARN PACKAGES:

Cone : this comprises of one or more threads, which are laid very nearly parallel to

layers already existing in the package. It may be tapered in both sides and package

weight varies from 1-2 kgs.

Cheese : This consists of a single thread, which is laid in the package at an appreciable

helix angle so that the layers cross one another to yield stability. It is generally in

cylindrical form and weight varies from 1-2 kgs.

2. WARPING

OBJECTIVE: To arrange a convenient number of warp yarns that can be collected in a

sheet form and wound on to a warper’s beam.

There are two types of warping methods followed:

i) DIRECT WARPING (BEAM WARPING): It is used for long runs of grey yarns, single

color yarns and simple patterns of colored

yarns. It can be used to make warp sheets. The

total amount of colored yarns involved is less

than 15% of the total.

Direct warping machines are not computerized.

No. of direct warping machines = 3(JUPITER)

Suction devices are provided in between warping

machines which suck all the unwanted cotton

fibers flying.

ii) SECTIONAL WARPING (PATTERN

WARPING): It is used for short runs especially for

fancy pattern fabrics where the amount of colored

yarn is more than 15% of the total.

Page 42: TEXTILE INDUSTRY INTERNSHIP REPORT

Sectional warping is a quick way to warp a loom with a sectional warp beam and is best

suited for very long warps (15 yards or more), any size or style of yarn and 2 inch

repeats (most sections on a sectional warp beam are 2" wide). It is not very well suited

for mixed warps with many or random yarn changes. It also requires more space and

equipment than other warping methods - spool rack with bobbins, bobbin winder, sley

hook and a tension box or warping paddle/guide.

STEPS FOR SECTIONAL WARPING:

i. Warp is winded onto spools (bobbins) - One spool per each warp end per 2"

of warp. Only one section of sectional

warp beam is winded at a time. Therefore

the spool rack should hold the number of

bobbins of warp needed to fill one section

of beam at the desired number of ends per

inch. If the weaving is set at 12 e.p.i, and

the sectional warp beam sections are 2", 24

bobbins of warp are needed in the spool

rack (2" x 12 e.p.i. = 24 warp ends, hence

24 bobbins per 2" section).

ii. The spool rack is positioned behind the loom.

iii. The warp is centered and number of warp sections is counted. For a 28" wide fabric, the

center 14 sections are used (28" divided by 2" sections = 14 sections).

iv. A cord is tied to the warp beam in each of the sections used.

Page 43: TEXTILE INDUSTRY INTERNSHIP REPORT

v. A warp end is threaded from each bobbin through the tension box or warping paddle.

The tension box or guide should be attached to the back beam to help in winding the

warp ends onto each section with even tension. The width of the spread in the tension

box reed or guide/paddle should be slightly less than 2" to allow for the width of the

pegs on the sectional warp beam. There may be a need to put more than one end per

dent or paddle hole to achieve this.

vi. The bundle of warp ends is knotted as close to the end as possible.

vii. Beginning at either of the outside sections of the specified sections, the cord is tied from

the warp beam to the knotted warp ends using a clove hitch knot. The tension box or

paddle is positioned on the back beam directly above the section to be filled. Note: the

bobbins on the spool rack are heavier at the beginning of the warping process. This

weight makes the first sections tighter than the later ones. It is best to have the tighter

sections on the outside edges. Starting at one side and filling sections in order straight

across the beam will produce fabric with warps tight on one end and loose on the other.

Similarly, starting at the center and working towards the edges will produce fabric with

rippled edges.

viii. The beam is turned, watching carefully to see that the section fills evenly. If the warp

piles up unevenly, position of the tension box is

adjusted. Each revolution of the beam is counted as

first section is filled. All the other sections should be

filled with the same number of turns to avoid tension

problems in the warp.

ix. When the section is full, a piece of masking tape is placed across the warp ends to keep

them in order. The tape takes the place of a cross. The warp is then cut one inch beyond

the tape. The tape is pinned into the filled section to secure it.

x. The tension box or paddle is moved to the other outside section and filled.

Page 44: TEXTILE INDUSTRY INTERNSHIP REPORT

xi. When all the sections are full, pins are removed from each section and warp is pulled

over the back beam toward the shafts. A long stick is laid across the width of the loom

and tied to the sides of the loom to secure. The warp sections are taped to this stick.

xii. Thread the loom is threaded as for warping back to front (heddles are

threaded; the reed is slayed and tied onto the front apron rod).

MACHINERY:

The sectional warping machine consists of a drum which can slightly shift horizontally

as the sections of yarn are being rotated on it. Length of the drum is marked on it. The

warp yarns comes from a predefined arrangement of cones as per the color and design

of the fabric. Length and width of each section of yarn is calculated and each section is

warped in a slanting manner on the drum to avoid intermingling of sections. A lace is

introduced and tied at the end hooks of the drum after each section of yarns is separated

by a rod. After all the sections are winded on the drum, this beam is than winded on to a

beam by the help of a roller. This beam is called the warp beam.

The sectional warping machines are fully computerized.

Creel capacity = 672

Hence, no. of sections = 672/ (no. of ends per section)

No. of sectional warping machines = 9 (PRASHANT GAMATEX, SUCKER MULLER

AND JUPITER)

FEATURES:

Separate warping & beaming structure

Separate warping & beaming structure ensures smooth vibration free operation at high

speed as well as at higher winding tensions. This division into units provides greater

processing flexibility such as.

i. Allowing the machine to be operated with single or multiple creel for higher

productivity in respect to capital investment.

Page 45: TEXTILE INDUSTRY INTERNSHIP REPORT

ii. Easy to reach the warping reel from every position during the different working

phases.

iii. Facility to add the additional unit like waxing etc.

iv. Extremely convenient in operation and maintenance.

Hydraulic Disc Brakes

To ensure gentle but extremely effective stopping of the machine, disc brakes are

provided on both sides of the drum, New Caliper braking device having sideways

installation facilitate easy servicing and settings of brake liners.

Constant Beaming Tension

Most important and high technological feature only offered by 'Prashant Gamatex' to

produce perfect weavers beam to get optimum efficiency for automatic looms.

Proportional control of the brakes in our high tech Hydraulic power pack with the help

of advance electronics, monitors constant tension of the yarn sheet during beaming.

Digital / Graphic On Line Display for desired process data

Intelligent Operational Panel (I.O.P.) having large size Digital display or graphic

display is provided for indicating total length, partial length, No. of section, section

width, rotation as well as all the messages and fault finding indications in case of

machine stoppage.

Solid steel drum - Dynamically balanced.

Frequency variable A/C drives

Hydraulic doffing & donning device

Auto section advancing

Constant warping and beaming speed

Lost end memory & auto stop during beaming

Broken and lost end during warping can be memorized. Machine stops automatically

before lost end position during beaming to trace and tie the lost end to complete warp.

This increases the overall efficiency of high speed looms. All lost end data can be

monitored on screen at a time and also can take printout of the same.

Page 46: TEXTILE INDUSTRY INTERNSHIP REPORT

On Site Programming Facility

The design is inbuilt to memorize atleast 100 sets of different programs, which can be

easily called back and start the machine without any further delay

Individually Controlled Tensioner Type model

Perfect warp beam can only be produced when

tension of each individual end is absolutely constant,

irrespective of warping speed, package diameter, or

the types of yarn, we offer high tech solution to meet

all these demand for quality conscious customers.

3. SIZING

OBJECTIVES:

To improve strength and abrasion resistance of the warp yarns by causing the

fibers to adhere together.

To make smooth and to lubricate the warp yarns so that there is minimum friction

where they rub together various parts in the weaving process.

In the weaving process, the warp yarns are subjected to rubbing and chafing against

various metallic parts of the looms as they are threaded through backrest, drop wires,

harness and reed. They constantly are rubbed together during shedding.

The warp yarns are subjected to tension constantly as well as intermittently during let-

off, take-up, shedding and beat up.

These two reasons lead to increase the end breakage level during weaving, which

should be minimized.

SIZING INGREDIENTS:

Adhesives: Modified starch (texoplast), fabric glue, thin volume starch, Potato starch,

starch from corn, wheat, rice, etc., Carboxyl methyl cellulose (CMC), Poly-vinyl

alcohol (PVA), Polyester resin (acts as binder).

Page 47: TEXTILE INDUSTRY INTERNSHIP REPORT

Lubricants:

Mineral waxes, oils, vegetable waxes and oils, animal fats

Additives:

Salicylic acid, zinc chloride, phenol, emulsifier, softeners, Polyethylene glycol

CHEMICAL 16Te 40COL 40

GREY

50 60 70 20 16OE Sample

sizing

Texoplast 40 50 50 70 60 50 20 70 ___

PVA 6 6 10 10 10 15 ___ 10 8

Falixlose 25 25 25 ___ ___ ___ 60 20 ___

Seycofilm 4 6 6 12 15 15 4 6 3

M. Tallow 5 5 5 5 5 5 5 4 3

Pep 1000 100 100 100 100 100 100 100 100 ___

LV 40 1 ___ ___ ___ ___ ___ ___ ___ ___

Water 15’’ 14.5’’ 14.5’’ 14’’ 14’’ 14’’ 14’’ 17’’ 100

1’’= 37.75 litres

MACHINERY:

1) SUCKER MULLER –HACOBA with PLC device( programmable logic control)

No. of machines = 1

Page 48: TEXTILE INDUSTRY INTERNSHIP REPORT

2) JUPITER ( No. of machines = 1)

OPERATOR INTERFACE

PLC BASED SERVO DRIVE CONTROLLED MULTI-CYLINDER SIZING MACHINE ( JUPITOR).

3) AMBICA ( No. of machines = 1)

No PLC device is present in this machine.

Sizing machine SE – C has one pair of squeezing rollers.

Sizing machine SD – C has two pairs of squeezing rollers.

TECHNICAL DETAILS:

1.) FEEDING DEVICE: Obtain a good point of grip for the warp.

This comprises of the following parts:

Pressure roller: This has two main functions:

Stretch measurement and pulse generation.

Carrier roller:carries the warp yarns forward

Floating roller: determines the drawing force between carrier roller

and first pair of squeezing rollers. Measured value is indicated on the scale.

Control bridge : protects the entire arrangement. The pneumatically

operated bridge automatically follows the roller movements.

Rotary switch : lifts the pressure roller off the carrier roller

pneumatically to allow knots or the feed aid to be pulled through when the warp is

being fed in.

It also moves the rollers back together.

Page 49: TEXTILE INDUSTRY INTERNSHIP REPORT

Guide roller: serves the pupose of length measurement in cases where sizing continues

filament yarn.

Contactless switch: Attached to a roller bearing. Pulses are transmitted to a second

measuring instrument (meter counter or stretch measuring device) located elsewhere.

2) SQUEEZING ROLLERS

MATERIAL- Rubber.

These rollers should be brushed down with hot water containing a desizing agent before

long periods out of use to wash out all traces of size from the pores.

The agent reaction time must be kept short to rule out solubilization of the roller

surface. Immediately afterwards, the cleaning agent is neutralized and removed with

water.

When regrinding one of the bottom squeeze rollers on a sizing machine with two

squeezers(SD-C), the roller with the largest external diameter must be installed in the

last squeezer.

Difference between two sqeezers in the first and second roller should not exceed

0.2 mm.

Three type of grindings: rough, normal and fine.

The rollers should be stored at 20 degree centigrade in a dark room and should be

lifted only by journals.

Stuffing box packing: ‘Kevlar Aramide’ packing code is used. If tightened too

securely,

i) Packing cord coated with Teflon on the backing will burn and sealing effect can be

lost.

ii) Can lead to damage of bearings.

Automatic squeezing roller control ( PLC) : The pneumatic load on the squeezing

roller is increased and decreased according to the operating statuses of the machine.

Squeezing pressure is usually set lower for standstill and creep speed than for normal

speed.

Page 50: TEXTILE INDUSTRY INTERNSHIP REPORT

The squeezing pressure control facility allows the squeezing roller pressure to be

adjusted depending on warp speed.

The programmable logic control device helps in checking the amount of size imparted

to a single yarn. It measures the degree of viscosity of each individual yarn and sends a

signal to the squeeze roller. If the amount of size imparted is more, the pressure of

squeeze roller has to be increased and vice-a-versa.

3) SIZING MACHINE HEATING AND STEAM LINES

Maximum permissible steam pressure = 3.5 bar

If the customer wishes to work with lower steam pressures, a separate pressure reducing

valve and a safety valve must be installed.

There is an electro- pneumatic temperature control system.

Heating and temperature control:

Heating is done by two systems:

i) Direct: By injecting steam directly into the size in the preliminary and main troughs

by way of distributor tubes. A condensate drain is used to prevent the size being

watered down.

ii) Indirect: By injecting steam into the double wall of the size trough and thus heating a

water bath, which in turn heats the size.

Speed (m /min)

SqueezingPressure( KN)

FQ1

FQ1

FQ2

FQ2

V2

V2

Page 51: TEXTILE INDUSTRY INTERNSHIP REPORT

Temperature of size is measured by a PT 100 temperature sensor in the main trough.

Temperature is regulated by means of a pneumatically controlled valve.

Temperature restriction of indirect heating:

Sensor of the control valve is installed in the expanded cross section of pressure

compensation line.

Water temperature = 80 degree centigrade

Size temperature = 70 degree centigrade

If internal heating temperature is too high, size can become baked on trough walls.

4) PRELIMINARY TROUGH CONDENSATE LINE

The condensate must be able to drain off at zero pressure. It consists of:

i) Double walled water bath.

ii) Sensor of temperature control valve.

iii)Condensate and pressure compensation line

5) LEVEL MONITOR IN MAIN TROUGH

The liquid level in the main trough is monitored with a bead tube. If the level falls too

low, the system shuts down.

MEASURING AND CONTROL DEVICES FOR DEGREE OF SIZING

If degree of sizing is too high or low, risk of thread breaks is increased.

Degree of sizing(%) = [Sa(%) * K(%)] / (100%) ; where

Sa = Sizing liquor take up. It is the ratio of the liquor taken up to the weight of untreated

yarn.

K = Concentration. It is measured by a refractometer.

Page 52: TEXTILE INDUSTRY INTERNSHIP REPORT

REFRACTOMETER MEASURING CUP

FACTORS AFECTING DEGREE OF SIZING:

i) Concentration

ii) Viscosity of sizing liquor

iii)Temperature of sizing liquor

iv) Speed

v) Squeezing pressure

ENERGY CONNECTIONS

Steam pressure:

Operating pressure = 0.5 to 3.5 bar

Steam quantity:

SE-C = 50 kg/h

SD-C = 80 kg/h

Condensate : must drain without back press.

Air pressure :

Maximum Operating pressure = 10 bar

With squeezing pressure upto:-

60 KN => 6,5 bar

100KN => 8,5 bar

Air quantity:

SE-C = 1.15 cubic mt/h (intake)

SE-D = 1.65 cubic mt/h

Air must be free of water, dust and oil.

Page 53: TEXTILE INDUSTRY INTERNSHIP REPORT

WAXING DEVICE (PVD)

This is used to apply various oils or waxes to the warp after sizing. It is fitted at the

beginning of the dry splitting zone immediately after the dancing roller, where the warp is

still undivided.

This device consists of:

i) A melting funnel for solid media (waxes).

ii) A tray to contain the lubricant:

a) Tray is made of stainless steel and protected from fiber fly and other

impurities with cover plates.

b) The tray has a heating coil for internal heating.

c) Wax temperature in tray is controlled by a temperature controller and a

pneumatic valve.

d) Lubricant can only be removed via drain cock

iii) An applicator roll:

a) Made of stainless steel with a specially treated surface.

b) Driven in properly to the sizing machine’s warp speed by a frequency –

regulated 3- phase a.c. motor with a worm gear.

iv) if liquid media (oils) are used, it is fed via a transparent bottle with a capacity of 10

liters.

Sizing machine layout plan:

Page 54: TEXTILE INDUSTRY INTERNSHIP REPORT

4. DENTING AND DRAWING – IN

All the warp threads have to be threaded through the heald eyelet and its gap in the reed

prior to weaving. The heald is the part of the loom that is used to move the warp threads

up and down. The threads pass through eyelets on the heald. For a simple weave pattern

alternate eyelets are moved up to raise the corresponding warp threads, and the threads

between are moved down. When the shuttle travels back their positions are reversed. The

reed is like a comb and its purpose is to control the separation of the warp threads.

Some basic terms:

PREPATORY PROCESS FOR DRAWING-IN: The open space between each wire of the

hook is called dent. A warp end is passed

Page 55: TEXTILE INDUSTRY INTERNSHIP REPORT

through a dent with the help of the reed hook, after it passes through the heald. This

process is called denting.

Automatic drawing-in machines multiply the productivity of each drawing-in operation 5-

to 10- times in relation to manual drawing-in thus enabling the required level of

processing flexibility.

MACHINERY:

1) STAUBLI DELTA 200 : The DELTA 200 is a high-performance drawing-in

installation. It is used wherever high production performance, a wide field of applications,

and maximum flexibility are required. The DELTA 200 draws-in warp yarns directly

from the warp beam with 1 or 2 sheets, and optionally up to 4 sheets.

2) STAUBLI DELTA 110 : These drawing-in installations are designed for weaving mills

with medium drawing-in requirements. The DELTA 110 also handles drop wires and is a

universal installation. Furthermore, a module is available that is specially designed for

drawing-in course yarns. Drawing-in takes place directly from the warp beam with 1

warp sheet, or optionally with 2 warp sheets.

Main characteristics:

DELTA 110 200

Drawing-in speed (ends/min) 100/140* 200

Number of warps in 8h (ca. ) 2-5 4-8

Warp widths (m) 2.3/ 4.0/ 6.0 2.2/ 2.8/ 4.0

Number of warp sheets 1 (2*) 2 (4*)

Reed density( teeth/ dm) 500 500

Max. number of frames (J/C-healds) 20 28

Max. number of frames (O-healds) 16 20

Max. rows of dropwires ____ 8

Page 56: TEXTILE INDUSTRY INTERNSHIP REPORT

Number of dropwire paths ____ 2

Drawing-in element Hook Rapier

Yarn count range (tex) 3-250 3-330

MACHINE CONCEPT: Modular system

The different modules of these machines are as follows:

1) Main Module Basic Equipment:

Part modules:

Control cabinet and electrics.

Base Frame

Function:

i) Static auxiliary function

ii) Supporting unit for the machine infrastructure

iii) Holds electrics and pneumatics.

2) Yarn Drawn –in Module:

Function:

Serves to guide the separated warp ends through the heald, drop wire and reed.

3) Yarn Supply Module:

Part modules:

Lifting Device

Thread Frame

Page 57: TEXTILE INDUSTRY INTERNSHIP REPORT

Yarn Separation

Yarn Supply

Function:

i) Handling the warp beam and thread sheet

ii) Separating and preparing the warp end for drawn- in.

4) Heald Module:

Part modules:

Heald Magazine

Heald Separation

Heald Distribution

Shaft holder\ Stave holder (harness truck)

Function:

i) Handling the healds from the magazine stack

ii) Distribution between the shafts

5) Reed Module:

Part module: Reed Transport

Function: Reed Handling

6) Drop Wire Module:

Part modules:

Drop Wire Magazine

Drop Wire Separating

Drop Wire Distribution

Drop Wire Transport( Harness Truck)

Function:

i) Magazing the drop wires.

ii) Distributing the drawn-in drop wires between the shafts.

7) Control Module

Page 58: TEXTILE INDUSTRY INTERNSHIP REPORT

Part modules:

Function Keyboard

Control Keyboard

Function: Controls and co-ordinates the module computers assigned to the main

module.

8) Master System Module

Part modules:

Keyboard

Monitor

Master computer

Printer

Function:

i) Accepts the drawn-in data from the operator

ii) Transmits it to the control computer.

iii) Manages the operating data.

iv) Visualizes the process sequence.

SEQUENCE OF FUNCTIONS:

Band gripper starts the drawing-in sequence before all modules are ready for

drawing-in.

If reed module is not ready, it reports after reed test.

Gripper enters the dent (can be stopped if reed module is not ready, otherwise

continues its forward motion.

Heald module reports at heald test. If it is not ready, band gripper is stopped

before passing through heald eye. If it is in ready state, gripper moves on.

Drop wire module reports at drop wire test. If it is not ready, band gripper is

stopped before penetrating eye of the drop wire. If ready, gripper moves on.

Yarn supply module reports at yarn test. If it is not ready, band gripper is

stopped before entering yarn take over. If ready, the gripper continues its motion.

After yarn take over, band gripper which grips the yarn withdraws.

Page 59: TEXTILE INDUSTRY INTERNSHIP REPORT

Band gripper withdraws past the drop wire and heald positions.

Drop wire and heald distribution systems move on.

Reed transport ensures the reed position.

Yarn ejectors are actuated in position ‘e’ and ‘f’ (in the diagram).

One drawn-in cycle is over.

5. WEAVING

On the conventional loom, the warp beam is mounted at the back and the warp yarns are

conveyed to a cylinder called the cloth roll, which is at the front of the loom and on which

the fabric is rolled as it is constructed. Supported on the frame between these two

cylinders( warp beam and cloth beam), the warp yarns are ready to be interlaced by the

filling yarns that run in the width of the cloth, thus producing the woven fabric.

Four fundamental operations of weaving in any loom are as follows:

Shedding: raising specific yarns by means of the harness or heddle frame.

Picking : inserting filling yarns through the shed

Beating up( battening) : pushing filling yarns firmly in place by means of the reed.

Taking up and letting of : winding the finished fabric on the cloth beam and

releasing more of the warp from the warp beam.

Classification of power looms used is as follows:

Looms

DOBBY JACQUARD

No. of looms = 2

Page 60: TEXTILE INDUSTRY INTERNSHIP REPORT

RAPIER AIR-JET

RAPIER LOOMS: these have a double rapier device that is, one on each side of the

loom. one rapier feeds the filling yarn halfway through the shed of warp yarns to the

arm on the other side, which reaches in and takes it across the rest of the way.

These rapier looms operate at speeds ranging from about 200 to 260 ppm at about the

noise level of missile looms. They can produce a wide variety of fabrics ranging from

muslin to drapery and upholstery materials.

AIRJET LOOMS: these looms use a jet of air to propel the filling yarn through the

shed at rates of up to 600 ppm. Air jet looms require uniform filling yarns. They are

more suitable for use with heavier than lighter yarns because the lighter weight yarns

are more difficult to control through the shed. Yet, if the yarn is too heavy, the airjet

may not be able to carry the filling across the loom. Within these restraints, the air-jet

loom is effective and can produce a wide variety of fabrics. These looms operate at a

lower noise level than the shuttle, missile, or rapier looms.

JACQUARD LOOMS: If the number of harnesses are more than 24, jacquard looms

are used. Any intricate design or motive can be developed using these looms. 10,000

ends can be individually controlled in this loom

MACHINERY: Technical details

I ) RAPIER LOOM: PICANOL GTX PLUS

Page 61: TEXTILE INDUSTRY INTERNSHIP REPORT

Installing the machine:

i) Lifting the machine by means of an

overhead conveyor or fork-lift truck.

Always, the right side is lifted first.

ii) Leveling of the machine: leveling is

very important for the productivity

and life of the machine. This has to

be done with an accuracy of 0.3

mm/m over both the length and depth of machine. The level position of the

machine has to be checked in 3 places: on the two frames and on the sley shaft.

Bidirectional communication : loom monitoring is done by the use of connector

XCOMP at the bottom of the control box .

CONECTOR

XCOMP

SIGNAL

6 SELVEDGE BREAKAGE

7 IMPULSE

8 WARP BREAKAGE

9 START/STOP

10 FILLING BREAKAGE

11 VCOMP

12 RESERVE

Control clutch:

Control of the clutch and brake is obtained by a fixed programmed electric control.

This means that the current in the obtained clutch and brake coil can be changed by

the micro-processor, but can’t be adjusted through keyboard.

Page 62: TEXTILE INDUSTRY INTERNSHIP REPORT

Voltage on the clutch and brake coil = 340 V dc

Resistance = 10 to 14 ohms.

Clearance between clutch disc and rotor = 0.3 to 0.9 mm.

Clearance between clutch disc and brake coil = 0 to 0.05 mm

Starting cycle (weaving):

It consists of three phases as follows:

A current which is about 5 times more important than the nominal current is first

sent, in order to obtain a short regular movement of the clutch disc.

An intervening over excitation level, which is about equal to 3 times the nominal

current, until the clutch disc stops slipping.

A maintenance level, about equal to nominal current during the weaving cycle.

Weave settings for a symmetrical set-up of the warp beam with regard to the

machine:

All settings can be carried out without warp beam and with the grippers in the

machine.

Marks on the reed holder

Position of the slides

The race board

The lateral position of the left hand temple support

The lateral position of the left hand temple profile

Page 63: TEXTILE INDUSTRY INTERNSHIP REPORT

Position of the filling guide

Position of the right hand temple support

Position of the right hand temple profile

The temples: height and the lateral position.

The reed :

i) Reed length (machine without tucking in device) = b + (35 to 40 mm)

(machine with tucking in device) = b + 70 mm;

Where, b = drawing-in width in the reed.

ii) Position of the first warp yarn in the reed:

Machine without tucking in device = 15 to 20 mm

Machine with tucking in device = 30 mm

iii) Position of the reed: 1mm from the filling guide.

Position of the grippers (both left and right hand)

Course of the gripper: should be done without a reed in the

sley to avoid any damage on the reed or grippers.

Position of the gripper openers : sley position = 0 degree

Setting of the gripper

Weave settings for an asymmetric set-up of the warp beam with regard to the

machine:

Full set up is same as symmetrical except for that the left hand slide, temple profile,

temple, filling cutter and tucking-in device are not moved.

Filling and waste cutters:

There are two blades- fixed and movable both of which should be lubricated daily.

Fix blade is 1mm below the filling yarn.

Cutters are driven by cam and operate on every pick.

Tension of the filling clamp

Setting of the filling cutter: both the blades are moved till the fix blade is 1mm

from the filling guide.

i) lateral position of cutter blades

ii) depth(backrest) position

iii) vertical position of fix blade

Page 64: TEXTILE INDUSTRY INTERNSHIP REPORT

iv) vertical position of movable blade

v) cutting movement of the cutter

Waste cutter:

i) Lateral position of waste cutter : 3mm from fabric selvedge

ii) Cutting pressure of the blades

iii) Vertical position: tip of the fix blade is 2mm below the fabric.

iv) Cutting stroke of the cutter

Filling presentation:

There are two types of filling presentations available:

Independent filling presenter type W:

i) Position of the filling presentor : first hook at 185 mm from the left reed dent.

ii) Synchronization of the machine.

iii) Setting of the needle depth

Independent filling presentor type Quickstep

i) Quickstep is an electronic filling presentor for 2-4-6 or 8 channels. Each channel is

separately driven by an electric motor. No mechanical drive of the filling

presentation and the synchronization with the machine is carried by

microprocessor.

ii) Working: A channel can carry out two types of presentations:

a) A single presentation of a channel

b) Presenting the same channel several times.

Quickstep filling presentation is maintenance free and may consequently not be

lubricated.

iii) Weave Settings : a) Mechanical

b) Synchronization

iv) Trouble shooting

N TROUBLE REASON SHOOTING

1 Filling presentor

doesn’t work

Power supply is wrong/ wire is

not well connected/ no

Replace or reconnect the wire/

adjust the clearance between the

Page 65: TEXTILE INDUSTRY INTERNSHIP REPORT

synchronization signal proximity switch and cam.

2 Irregular needle

movement

Moving arm and motor shaft are

slipping/ motor doesn’t work

Tighten the screw on the moving

arm/ replace the module unit.

3 Position of needle

inversed

Motor polarity is connected the

wrong way

Change the wire connections in

straight way

v) Mounting settings:

a) Replacing the motor of a module

b) Replacing the needle

c) Adjustment of needle on motor shaft

The shed:

Position of the bottom shed:

improving the gripper flight, bottom shed rests on the race board as long as possible.

Shed height is determined by

position of two levers at a distance ‘c’.

C depends on harness frame number, required shed height, bottom shed pulled

lower than the guide plate.

Synchronization of the dobby :

Sley position should be between 300 and 350 degrees.

The warp beam:

Set up of warp beam – i) Symmetrical ii) Asymmetrical

Adjusting the position of the warp beam flanges with regard to the warp beam barrel.

The backrest:

i) Set up of the back rest: Equipped with 2 rolls- tension roll and rotating roll.

ii) Height and depth of the back rest to be adjusted:

For height, the essential conditions are grain of the fabric, warp breakages. There is

higher position for plain weave/heavy cloth and lower position for silk/ filament yarn.

Page 66: TEXTILE INDUSTRY INTERNSHIP REPORT

Depth depends on elasticity of warp yarns. For light fabrics, whip roller should be as

far as possible from heald frame and for heavy weights, it should be near to heald

frame.

Let off (with tension sensor, or feeling roller mounted)

i) Bevel gears adjusted for let off

ii) Spring diameter chosen for different colors

Warp detector :

Height and inclination of warp detector should be so that :

i) Warp yarns of bottom shed slightly touch the cross beams of warp stop during

open shed.

ii) Drop wires in the upper shed are lifted as little as possible by the warp yarns.

Take up motion

ETU electronic take up: Independent servo motor controlled by microprocessor.

Main parts of the take up motor:

i) Take-up housing

ii) Take up rolls and pressure rolls

iii) Cloth roll and friction clutch

Main oil bath of TU motion parts in TU housing reduces wear and tear.

Reverse take up facility

Pick density can be changed through auto- setting

Rotation speed controlled by mp

Functions of the parts:

i) TU Housing: transfer drive power, change speed, increase twisting force,

continuity, stability.

ii) TU Roll :

a) Leads the woven fabric smoothly away from the cloth roll. Pressing force of two

pressure rollers on both sides is the same.

Page 67: TEXTILE INDUSTRY INTERNSHIP REPORT

b) Depending on the type of fabric, the pressure imparted by pressure roller keeps

changing.

iii) Cloth Roll and Friction Clutch:

a) Woven fabric smoothly and evenly wound onto the cloth roll.

b) Friction clutch can be adjusted to suit the fabric construction, ensuring even

wounding.

Lubrication and maintenance of the take- up motion:

Following actions to be performed at regular intervals:

i) Oil level in the take-up housing is sufficient to lubricate the gears inside.

ii) Gears and chain wheels of the take-up roll should be lubricated. Same

tension on both sides should be maintained.

iii) Cloth roll clutch should not get stuck.

Leno Selvedge Device

I) KLOCKER LENO DEVICE:

Fixation of the device :

i) Device with needles is fixed on the first Aluminium profile( closest to the

weaver’s side).

ii) Back lath of the device is fixed on the second profile.

Drawing- in of the yarns:

i) The needle yarns are drawn in through the hole through the side walls of the

device. Upper yarn is drawn through the eye of upper needle and bottom yarn is

drawn through the eye of bottom needle.

ii) The leno yarns are directly drawn in through the two slots of the plastic sliding

piece. In double leno motion, leno yarns are drawn in at both sides in the same way.

Harness frames are put on harness crossing for easier drawing

in. a distance of 15mm in the reed is kept between the two groups of leno yarns in

case of double leno mechanism.

Working Principle:

Page 68: TEXTILE INDUSTRY INTERNSHIP REPORT

Leno yarns are both drawn in through the diagonal slots of the plastic sliding pieces.

Both plastic pieces can move separately. The front piece has a magnet.

For upward motion of pieces, front piece remains at bottom with regard to back

piece. For downward motion of pieces, front piece remains at top with regard to

back piece.

This can be divided into four phases:

i) Phase-I: Both leno yarns are positioned in the upper shed. Both needle yarns are

positioned in the bottom shed. One pick is inserted.

ii) Phase-II : Needles move upwards and leno yarns move downwards. At the

movement of harness crossing, leno yarns cross between needle yarns.

iii) Phase-III: Needle yarns are positioned completely upwards (in the upper shed )

Leno yarns are positioned completely downwards( in the bottom shed)

One pick is inserted.

iv) Phase-IV: Needles move downwards and leno yarns move upwards. During

harness crossing, leno yarns are again crossing between needle yarns. During

weaving, one leno yarn is straightened so that only one leno yarn is visible in the

fabric.

II) LENO HEDDLE OF KLOCKER

Fixation of the device.

Drawing in of the yarns :

Drop heald yarn is drawn-in through the eye of the drop heald between the two

listings.

Leno yarn is drawn-in between the two listings in same direction of drop heald yarn.

For easier drawing-in, machine is put in position with open shed. In case of double

leno mechanism, a distance of 15mm in the reed between the two groups of leno

yarns is maintained.

Working principle : movement of leno heddle is divided in 4 phases:

i) Phase I: At the moment of crossing, drop heddle yarn is positioned above leno

yarn.

Page 69: TEXTILE INDUSTRY INTERNSHIP REPORT

ii) Phase II : One listing is pulled downwards, drop heddle and other listing is pulled

upwards. Yarns obtain tension and are positioned under yarn guide which is lower

than bottom shed. So the leno yarn between listing and drop heddle will slide

downwards. Drop heald yarn is pushed upwards by drop heddle.

iii) Phase III: now, direction of both the listings is interchanged. Leno yarn is

positioned under drop heald yarn.( same as phase I)

iv) Phase IV : leno yarn slides downward between drop heddle and second listing.

Needle yarn is positioned in front of the drop heald yarn.( same as phase-II)

III) WEAVE SETTINGS

Lateral position of the device:

Sley position: On machines equipped with dobby, all harness frames are placed

downwards. The devices are moved until they warp yarns.

The shed height: For some fabrics, height of leno harnesses is set according to

warp yarns.

Position of the cam

Tucking-in Device

After the inserted pick has been beaten up by the reed and

when the selvedge ends hold the weft, weft is taken along the length of the

selvedge by gripper. Weft is then cut between the selvedge gripper and the

selvedge ends at 11mm from the first warp end by cutter.

Construction:

Number of weft ends is doubled on the selvedge edge stroke. No problems occur

with fabrics having less picks/inch than ends/inch.

With square clothes or clothes having higher weft density, higher tensions are

caused in the selvedge because of large shrink.

Hence, risk of warp breakages in the selvedges is greater during weaving and

difficulty may occur in the finishing of the cloth coz of construction of selvedge.

Solution:

i) Number of warp ends in selvedge zone should be reduced.

ii) The weave in selvedge zone should be changed

Page 70: TEXTILE INDUSTRY INTERNSHIP REPORT

iii) Thinner warp yarns should be used in selvedge

When the machine is equipped with a tucking in device, it is advisable to put extra

heald wires between the selvedges and ground fabric, so that the drawing-in can be

changed between the selvedges and the ground of the cloth.

Number of heald wires depends on length of the tucked ends. It selvedge is perfect,

extra heald wires should be cut out.

Drawing-in of the first warp yarn and the leno yarns:

In case of machines with tucking in device, reed is 70 mm longer than the drawing-

in of the fabric. The reed is also set at a distance of 1mm from the filling guide.

The first warp yarn is drawn-in at 30mm from the first left hand reed dent.

At the right hand side, the right hand waste yarn is positioned at 35-40 mm from the

last warp yarn.

II) AIRJET LOOM- OMNI 800 PLUS

ADense Warp

B

Square fabric

CWeft Density predominant

Reduce warp density by 30%

Reduce warp density by 15%

Use fine warp ends

Change selvedge weave

Page 71: TEXTILE INDUSTRY INTERNSHIP REPORT

Installing the machine

Unloading the machine

Moving the machine : The machine can be moved by means of a crane or

fork- lift track or by wheels. Appropriate lifting beam must be used. Whole length

varies from 3760mm to 6470mm.

Leveling the machine: Auxiliary tools for leveling the machine are :

i. A leveling instrument with an accuracy of 0.3mm/m

ii. Two hydraulic lifting jacks

iii. A lifting hook which supports front side of the frame.

iv. The back side is jacked up by means of the warp beam support.

Glueing the machine: To prevent the machine from moving due to

vibrations, it is glued to the floor with a two component epoxy glue.

Leveling the control panel support:

Fixing the double warp beam

Warp beam bearing poitions

Installing the control box

PARTS OF THE MACHINE:

The 1131 and 2231 CAN plus Prewinder

Page 72: TEXTILE INDUSTRY INTERNSHIP REPORT

Aligning the pre-winder

Positioning the balloon breaker

Changing the sense of rotation of prewinder

4-pick insertion

The fixed main nozzle: Parts of the fixed nozzle are:-

Replacing injectors

Changing assignment

Weaving setting

The fixed main nozzle should be positioned such that the line leading from the

prewinder drums’ centre to the movable main nozzle is as straight as possible.

The movable main nozzle

Parts of the movable main nozzle are:-

i. One or more main nozzle modules

ii. Injector

iii. Air inlet

iv. Nozzle extension

The filling yarn count dictates which injector and main nozzle body will be used.

The fixed and movable main nozzle cannot be exchanged with each other.

Injectors are available in different types like conical and cylindrical. The internal

operations uniquely identify the different injectors.

Replacing parts:

The following actions can be undertaken without dismantling the movable main

nozzle from the machine:- i) Replacing the injectors

ii) Replacing the main nozzle module

Channel assignment: It is advisable to use the channel nearest to the reed.

Setting the pressure: The pressure can be set on the front left side of the

machine. The pressure of the main nozzle determines the speed of the filling

yarn.

Page 73: TEXTILE INDUSTRY INTERNSHIP REPORT

The filling clamp: there is a filling clamp per channel at the main nozzle inlet. It

is open during filling insertion and clamps the filling if insertion doesn’t take

place.

The directional nozzle: To lead the filling in a right direction during the

insertion start.

Weaving settings: This can be adjusted in two ways:

i) Lateral position

ii) Depth adjustment

The swinging main nozzle: Switching mechanism

Relay nozzles

Arranged over the entire length of the reed, these assist the movable main nozzle

in blowing the pick through the reed guiding channel. Relay nozzles are fitted to

the right of the last warp ends to direct the pick towards the suction mouth

Relay nozzles are divided up into groups, in that each group of nozzles is served

independently by a dedicated relay nozzle value. The second and rest of the

relay nozzles are placed at uniform distances, i.e., 74mm from one another.

The more the relay nozzle is turned towards the reed, the higher the yarn flight

in the insertion channel.

The higher the pressure, the lower the yarn flight in the insertion channels.

The pneumatic control

Compressed air

Pressure regulators

The pressure for the relay nozzles must be set as low as possible with no weaving

faults occurring and with a minimum number of machine stops.

i) MAIN VALVE REGULATOR: Regulates pressure on buffer tank(s) for main

nozzle. Pressure of main nozzle determines the speed of filling yarns.

ii) AUXILIARY PRESSURE REGULATOR: Regulates the pressure for the

auxiliary functions: a) pistons of pick finder

Page 74: TEXTILE INDUSTRY INTERNSHIP REPORT

b) Pre-winder, threading and PFT threading

c) Chimney stretching nozzle

d) Extraction nozzle

e) tucking-in device

f) Clamp on main nozzle

g) 8 color switching valve

This is set for fixed value 6 bar.

Auxiliary Pressure = Supply pressure – 1 bar

iii) LEFT RELAY NOZZLE REGULATOR: Regulates the pressure on the left hand

relay nozzle buffer tank.

iv) RIGHT RELAY NOZZLE REGULATOR: Regulates pressure on the RH relay

nozzle buffer tank.

iv) QUICK COUPLING: Pressure from different regulators can be measured by

means of a manometer through quick coupling.

Air distribution :

i) Main distribution block

ii) Air to buffer tank fixed main nozzles

iii) Air to buffer tank movable main nozzles

iv) Air distribution block

v) Air to LH and RH buffer tank

vi) Pneumatic unit above movable main nozzle (pneumatic unit)

vii)ELCA on buffer tank

viii) Parking brake

ix) Value block, pick finding, counter flow

Main Nozzle Modules

i) For movable main nozzle: Positioned on cross beam

ii) For fixed main nozzle: Positioned on power box support behind the left side cover

Temple Nozzle

i) Used for a filling detector in front of the reed or next to the reed.

ii) To prevent yarn ends RH side from returning in the fabric, temple nozzle

mounted on temple support.

Page 75: TEXTILE INDUSTRY INTERNSHIP REPORT

Chimney stretching nozzle

It ensures that the filling yarn remains stretched during the closing of the shed.

Extraction nozzle blows the filling waste out of the chimney stretching nozzle after the

sley beat-up.

Stretching relay nozzles

Waste guide is used to keep long filling waste away from the fabric. Extraction nozzle

blows the filling waste behind the waste guide. Filling detector is mounted nest to last

warp end.

Stretching nozzle is mounted next to filling detector. On machines equipped with a

waste guide, the stretching relay nozzle is positioned behind the waste guide.

Filling detectors (in front of reed and next to reed)

Functions:

To control the arrival of filling yarn at RH machine side.

Transmission of arrival time data to microprocessor.

To make machine stop when it detects a filling yarn.

The filling detector’s function is based on the reflection of a light beam. They should be

regularly cleaned by alkaline solution.

Filling cutter

It cuts the filling at the LH machine side at the end of insertion.

It is found on left side of the machine next to air preparation of the movable

main nozzle.

Timing of cutting: Time is set around 10 degrees and is adjustable for each

channel separately.

The filling clamp: Used for a better control of the filling yarn at the LH

machine side.

Reed

The Dobby

Page 76: TEXTILE INDUSTRY INTERNSHIP REPORT

The outside cam motion

Harness frames

The optimum height setting depends on a number of factors like article type, weave,

and machine speed(rpm).

TOPMATIC WARP TYING MACHINE

EFFICIENCY: Warp preparation on the TPF tying

frame is fast and comfortably.

Even at 600 knots per minute, the warp threads are

drawn through the weaving harness in a perfect

manner. Practically all staple fiber and filament yarns

can be tied without extensive adjustments.

QUALITY: The unique, patented electronic double thread detection of the

TOPMATIC PC operates in warps with or without lease. The considerable reduction

in double threads and redirected warp threads lead to an increased efficiency of the

weaving machine.

SPEED: 600 knots/minute, automatic repetition in case of a separation faults.

YARN COUNT RANGE: 0.8-500 tex / Nm 2-1250 / Ne 1.2-740

LEASE TYPE: All combinations in one machine, switch-over control for

irregular lease (optional)

DOUBLE END DETECTION: - Mechanical, for warps with lease

- Electronic, for warps with or without lease

Page 77: TEXTILE INDUSTRY INTERNSHIP REPORT

KNOT TYPES: - Single or double knots in one machine, selectable

- Length of knot ends selectable (optional)

III) JACQUARD LOOM: TYPE GT511 – II (ELECTRONIC JACQUARD)

FUNCTION DESCRIPTION

GT511 electronic jacquard adapts 16-bit high performance

handler for providing big function and ease of operation.

The dot pattern liquid crystal display has Chinese

operation I/F.

The controller is equipped with 1.44 MB, DOS

compatible, 3.5’’ floppy disc drive.

Maximum speed = 1000picks/ minute

Memory capacity = 8 MB. Therefore, data will not miss when in de-energized

state, for storing designs transmitted from floppy disc, to edit and weave the

complicated JOB, which is formed by various kinds of patterns.

Information in the controller and loom can be preserved.

Controller has configuration function, if used on special looms. Parameters like

warp program, weft program can be set.

It has eight LED’s on the panel to display the state of supply, controller and loom.

System will automatically start to self test when energized or operated and provide

loom’s test program for test weave when djusting the loom. .

Many anti-interference ways to control power interference, radiation interference

and conduction interference.

Each operation has detailed instruction, it is not necessary for the customer to

remember too much of the procedure.

Page 78: TEXTILE INDUSTRY INTERNSHIP REPORT

CONTROLLER FASIA: This includes:

LCD modular

8 LED’s

20 buttons

TECHNICAL DATA:

Temperature = -5 to 40 degree Centigrade

Relative humidity = 0% to 95% non condensation

Power = 110 V +- 15% , 45 – 60 Hz

Power consumption = 60 watts

COMMANDS:

Running state: LCD model displays :-

i) Job number

ii) Pattern name

iii) Weaved cycles

iv) Remaining cycles

v) Weave pattern cycles

vi) Current pick

vii)Current speed

Pattern program

Application program

viii)Pattern application

program :

a) Pattern directory

b) Memory usage

c) Pattern conversion

d) Return

TOP PORTION OF JACQUARD

(ATTACHMENT OF HARNESSES)

Page 79: TEXTILE INDUSTRY INTERNSHIP REPORT

ix) Job list application program :

a) Edit

b) Weave from first job

c) Weave from current pattern

d) Weave from designated pick number

e) Return

Controller configuration

Test program

Exit

2. I. d GREY FOLDING

Grey Fabric Inspection occurs in fabric inspection for the weaving/ spinning defects.

The removable defects are removed and noted down, and irremovable defects’

location is noted down and the frequency is noted. There is a roller attatched counter

which counts the number of metres inspected and helps in location the position of the

defect.

In 300 mtrs, if 30 points/100mtrs of defects are detected, then the fabric is a

defective one. Inspection machine, s manufacturers are D. S. Topiwala.

Folding and Plaiting machine

1000/2500/5000 meters of plaited fabric blocks are formed as per requirement fabric

passed through 4 sets of rollers cleaning inside the machine.

2 fabric beams are stitched together with a single needle chain stitch machine for

acquiring the required amount of the length of the fabric roll.

2 plaiting machines of the make D.S. Topiwala Enterprise is present.

No. of Workers is 50/shift and the no. of machines is 12. The no of plaits of fabric

folds to be formed can be set in the automatic plaiting m/c.

Page 80: TEXTILE INDUSTRY INTERNSHIP REPORT

Fabric inspection m/c Counter

2. I.e.CORDUROY

Corduroy is a fabric comprised of twisted fibers that when woven lay parallel

(similar to twill) to one another to form the cloth's distinct pattern, a "cord." Modern

corduroy is most commonly composed of tufted cords, sometimes exhibiting a

channel (bare to the base fabric) between the tufts.

As a fabric, corduroy is considered a durable cloth. Socially, the clothes made from

corduroy are considered casual, and are usually favored in colder climates during

seasonal periods. Corduroy is most commonly found in the construction of trousers.

The material is also used in the construction of (sport) jackets and shirts. The width of

the cord is commonly referred to as "wale"; the size of the wale. The width of the

wale makes some uses more common than others. Wide wale is more commonly

found on trousers; medium, narrow and fine wale fabrics are usually found in

garments used above the waist.

The Basic weave of the corduroy fabric consists of a chain structure in the back of the

cloth and an uncut pile formation in the front.The pile are cut using a circular

blade(cutter/knife) and a needle which guides the blde throough the uncut pile loop.

Yarn dyed corduroy is manufactured as both bottom (thick) and shirtings (thin).

The density of the cutting rings is 21-28 rings/blades per inch. The cut fabric is

collected in plaited batches.

Two suction tubes are present which continuously sucks in the particles released

while cutting.

Fabric inspection Plaiting Machine

Page 81: TEXTILE INDUSTRY INTERNSHIP REPORT

Pressing and brushing Machine

Water sprayed onto the fabric surface once entering the machine. 8 belts move

clockwise and anti clockwise.

The process flow is:

Uncut Grey|

|

Grey uncut brushed (dry conditioned)

Grey Cutting (on Cutting Machine)

Inspection (Any uncut portion is again cut by razor, manually)

Brush at grey cut(Wet conditioning)

Bleaching

Dyeing

Finishing

Corduroy (finish folding)

Production rate of the corduroy dept. is 600 to 700 metres/day

8 cutting machines are present

The make of the machines are Franz Muller(Germany)(for cutting , pressing)-

2 nos

- Bresgres(Bigger brushing machine)

- Amritsar

Brushing Machine

To and fro eccentric motion removes roughness further.18 circular rollers cum

brushers roll on the cut grey corduroy for brushing along the grain line.

Page 82: TEXTILE INDUSTRY INTERNSHIP REPORT

12 steam cylinders are used for drying after steaming in the first chamber, for

improved softness. At a temperature of 50 to 60 digree Celsius.

Corduroy inspection machines are Laxmi, tech shivam Industries, Vadodara)

In the brushing machine, moisture is imparted using a fine spray.

Then the fabric is passed through a set of 8 belts moving left and right alternatively.

5such sets of belts exist in the brushing system. After the brushing the cloth is

stretched through a set of 8 cylinders. !6 eccentric rollers are used for further

brushing. 2 sections with 3 rollers and 2 rollers are present before the plaiting.

2. I. f. PIECE DYEING AND FINISHING PROCESSES

PREPARATORY PROCESSES:

Preparatory processes are used:

To improve the wettability for dyeing(for uniform ness and depth of color)

To remove the impurities.

Fabric should have perfect white color before dyeing.

Grey goods must be cleaned before they can be finished. They may contain warp

sizing, oils, other additives, dirt and soil. Complete removal is necessary in order to

finish, dye, and print goods effectively. The method of cleaning depends upon the

fiber in the fabric, the kind of impurities present, and the construction of the fabric.

SINGEING (OR GASSING) AND DESIZING

If a fabric is to have a smooth finish, singeing

and desizing are one of the first essential

preparatory processes. Singing burns off lint and

threads as well as all fuzz and fibers ends,

leaving an even surface before the fabric passes

through other finishing processes. Especially for

achieving the uniform color in dyeing singeing is necessary because protruding fibers

causes dullness.

Page 83: TEXTILE INDUSTRY INTERNSHIP REPORT

Machine used:

OSTHOFF SENGE (GERMANY)

Goller singing with impregnation unit type ‘WA’.

Speed of the machine: 79m/min

Squeeze pressure: 0.8 bar

Compensator pressure: 2.0 bar

Number of machine: 1

Meter counter production: 46m

Process happening:

First of all when the fabric from pleating department comes for finishing it is singed

and desized in this machine. Singing is accomplished by passing grey goods rapidly

over gas flames, usually two burners to a side, at a speed of 100 to 250 yards per

minute. Fabric can be singed both face and back side of the fabric, after that the fabric

is washed with water to reduce the temperature, then it is passed through a chemical

solution to remove the starch and other chemicals while sizing, called Desizing. The

fabric collected at the end of the machine in a beam is hot and wet. A single thread

chain stitch machine is used to stitch two different fabrics. So the process is

continuous, only its setting has to be changed for different fabrics.

Burner:

The intensity of the flame depends on the type of fabric. It varies from 8mbr-12mbr.

According to roller setting and fabric type, the fabric can be singed in two ways:

One side for two times. For fabrics like corduroy the face side is singed two times.

Two sides for 1 time

Burner pressure: 10.0 mbar r more.

Flame intensity: 10mbar or more.

There is a sensor in the machine which detects the temperature of the fabric. If the

fabric is burned then it sense it and the temperature is then controlled in the burner.

Suction unit:

Page 84: TEXTILE INDUSTRY INTERNSHIP REPORT

In this unit the flames of the burned particles which are left on the fabric are

extinguished.

Brushing unit:

After the fabric is singed it is passed through brushing unit where the burned particles

are brushed out.

Desizing:

The purpose of a desizing process is to remove sizes that have been attached to warp

yarns during a weaving process. Prior to the desizing process, therefore, the size

analysis should be performed in order to set desizing conditions suitable for the sizes.

After the cotton cloth leaves the burners, it is pulled through a solution of an enzyme,

squeezed out in a heavy mangle, and usually allowed to lie for several hours to allow

the enzyme to digest the starch with which the warp yarns were sized. There is a

temperature indicator on the top which indicates the temperature.

Desizing temperature: 70 degrees Celsius.

Cotton fabrics contain primary and secondary impurities as shown in tables below,

and the purpose of Desizing and scouring is to remove these impurities.

Primary impurities Percentage

Pectic substance 2-3%

Cotton wax, cotton seed oil 0.3%

Protein 0.3-0.4%

Ash pigment 0.01-0.03%

Secondary impurities percentage

Starch 4-6%

PVA 3-5%

Page 85: TEXTILE INDUSTRY INTERNSHIP REPORT

Acrylic size 0.5-1%

Wax 0.2-0.5%

After-wax 0.5.%

Chemicals used in Desizing:

Enzymes: the pH range of the enzymes has to be maintained while desizing. There

may be difference in the enzymes used. It degrades the cellulose in fabric surface

which in turn affect the color of the fabric, the fabric becomes more faded. But the

softness of the fabric is increased by using enzymes in the chemical.

Sequestering agent: it removes the metal particles from the surface of the fabric.

Wetting agent

Stabilizer

Hydrogen peroxide

Acetic acid

Both direct and indirect heating is given to the fabric.

After desizing the fabric is collected in the beam where the beam is kept rotating for

6-8 hours. The rotation time is given for the enzymes to react with the fabric surface

and sizing particles and remove it.

Practically all cotton fabrics, except those that are to be napped, are singed.

Singing is basically of three types:

Roller singeing

Plate singeing

Gas singeing

Singeing may also be done at the yarn stage, especially when the yarns are to be used

for fine quality cotton goods. Usually such yarns are fully mercerized, and singeing in

this case is referred to as gassing. Mercerized gassed yarns are sold in the trade as

lisle.

Page 86: TEXTILE INDUSTRY INTERNSHIP REPORT

WASHING RANGE MACHINE:

After rotation for 8 hours, the fabric is washed

with hot water usually at 95`C.

Turbo rollers are used in this machine for

efficiency in washing which creates turbulence

while washing through rotating rollers. Some of

the rollers used for washing have motors.

One vacuum suction is present in the machine which removes the singing particles

from the fabric surface after reaction from enzymes for 8 hrs.

No. of machine: 1

Washing range for reactive dyed fabrics

After washing generally wet processing is done, dry processing is done only in few

cases.

BLEACHING:

Bleaching, a process of whitening fabric by removal of natural color, such as the tan

of linen, is usually carried out by means of chemicals selected according to the

chemical composition of the fiber.

Objective:

Page 87: TEXTILE INDUSTRY INTERNSHIP REPORT

To remove the natural coloring matters and make the fabric in perfect white

with minimum damage to fibers and within the shortest possible time.

This process is necessary if discoloration or stains have occurred during the previous

manufacturing processes. All bleaching processes reduce the strength of the fiber.

Bleaching is carried out near or above boiling temperature under pressure for one

hour or more. After bleaching, the fabric is thoroughly rinsed with slight amount of

basic solution to avoid formulation of insoluble silicates.

Chemical bleaching is usually accomplished by oxidation, destroying color by the

application of oxygen, or by reduction, removing color by hydrogenation. Cotton and

other cellulosic fibers are usually treated with heated alkaline hydrogen peroxide;

wool and other animal fibers are subjected to such acidic reducing agents as gaseous

sulfur dioxide or to such mildly alkaline oxidizing agents as hydrogen peroxide.

Synthetic fibers, when they require bleaching, may be treated with either oxidizing or

reducing agents, depending upon their chemical composition. Cottons are frequently

scoured and bleached by a continuous system.

Bleaching and Scouring

CBR (CONTINUOUS BLEACHING RANGE):

The wet fabric is feed. Normally wet fabric is preferred over dried.

Chemical unit (called as dip set):

The fabric is passed from the chemicals for bleaching and then it goes to the steamer

where the fabric is given reaction time at a temperature usually at 98`C. The pressure

Page 88: TEXTILE INDUSTRY INTERNSHIP REPORT

and the temperature are decided according to the fabric. There is a camera fixed in the

steamer to check for the fabric.

Washing:

After that the fabric comes down to washing unit where it is washed with simple hot

water. There are four washing chambers.

Drying:

Depending on the further processes the fabric is dried. It is optional. The fabric is

dried through indirect heating from the heated cylinders. There are total 10 cylinders

and the fabric is passed through them covering there surfaces. The temperature of the

cylinders varies from 120`C to 125`C. the temperature also depends upon the type of

the fabric and it is maintained automatically and if it is not required then steam is

turned off.

If the fabric is heavy then the temperature is high and for light weighted fabrics it is

low.

The drying process depends on further processes. The fabric is not dried if it is going

for mercerization; it is dried only if it is going for finishing.

MERCERIZATION:

The treatment of cotton fabrics or garments with a cold concentrated solution of

sodium hydroxide for a minute or less is called mercerization. It is a value added

process.

After this process the cotton fibers will swell, untwist and their beam shaped cross

section will change into round form giving smoothness to the fabric.

Tension is applied to the fabrics in the machine in the vertical direction with a tension

cylinder, and in the horizontal direction with a clip tenter. The processing time by the

cylinder and the tenter in total is 30 to 60 seconds. To prevent the fabrics from

shrinking after going through the tenter, the NaOH concentration in the fabrics needs

to be decreased sufficiently when the fabrics leave the tenter.

Page 89: TEXTILE INDUSTRY INTERNSHIP REPORT

Also, since the piling on thick fabrics in a wet state leaves creases on the fabrics, the

thick fabrics need to be dried promptly.

Change in a cross-section of a cotton fiber during a mercerization treatment.

1-5 Swelling process in an alkaline solution

6 Removal of alkali by water substitution

7 After drying

Objectives:

To increase the strength. It is increased by 15-25%

To further enhance the lusture.

To increase the affinity to water, dyes and other chemical finishes.

Stable dimention

Machine type:

Mercerizing range type “optima”

No. of machine: 1

Speed of the machine: 40 m/min-50 m/min

Production per hour: 2400 m

No. of workers: 3

The machine runs depending on the order

Mercerizing zone:

Page 90: TEXTILE INDUSTRY INTERNSHIP REPORT

Fabric is padded with about 20-25% caustic soda (NaOH solution) containing a

wetting agent. The temperature of the mercerizing zone is usually maintained at 65`C.

Two types of mercerization are done:

Wet on wet: Where wet fabric is used. It is not dried.

Hot mercerization: Where dried fabric is used for the process.

Stabilizing zone:

In this section the width of the fabric is stabilized, NaOH stabilizes the fabric

structure. NaOH is washed here because less GLP (gram per liter) NaOH is used for

washing.

Washing zone:

There are four chambers for washing or four washers. In the last chamber Acetic acid

is dozed to neutralize the fabric before sending it to other departments. The fabric

should be either neural or acidic but not alkaline.

pH is controlled at 4.5

Water flow in each chamber: 1.01 /kg

Rubber is used in the rollers. If the rubber is damaged then it will affect the fabric and

will leave stains. Metal bearings are used in the machine. There is no sensor in the

machine to detect the fabric damage.

DYEING:

Main objective in the dyeing of textile materials are:

Color the fibers uniformly.

Achieve acceptable durability of the color to further treatments in production

and normal use. Fastness of the color material to sunlight and multiple

cleaning is of prime importance.

Conventional process:

The majority of the textile fibers are dyed by conventional batch method of dyeing

referred to as ‘exhaust dyeing’. In a typical exhaust dyeing a concentrated solution or

dispersion of the dye(s) in water is made first. Then the dye-bath is prepared by

diluting the concentrated dye solution with proper amount of water. Certain

chemicals, used as dyeing assistance, are usually added to the dye-bath before and/or

Page 91: TEXTILE INDUSTRY INTERNSHIP REPORT

during the dyeing to assist in the proper absorption of the dyes by the fibers.

Throughout the dyeing process, the dye solution is circulated through the substrate

(fabric) and/or the substrate is moved within the dye-bath. The temperature is

gradually raised usually to temperatures close to boiling point of water, where it is

kept for 30-60 minutes or more, according to need. While dyeing, the dye is taken up

slowly (exhaustion of the dye-bath) by the fibers. Usually almost all of the dye is

consumed, and the dye-bath is said to be exhausted.

PAD STEAM MACHINE:

Padding dyes the fabric as it is held at full width. The fabric is passed through a

trough containing dye and then between two heavy rollers which force the dye into

the cloth and squeeze out the excess. It is generally done on a continuous dye range

which can accommodate a large amount of fabric. The material is run in one operation

through a pad, into a heat or steam chamber to set the dye, then successively into a

washer, a rinser, and a dryer.

Machine type: Goller (Germany)

Number of machine: 2

One machine is for reactive dyed machine and caustic size where there is no steamer.

And one machine has steamer which is for wet dyed fabric and caustic size.

After wet dyeing the fabric is feed to this machine. First of all the fabric from the

beam is passed through hydro caustic where the hydro caustic is put in a tank. Hydro

caustic is used to fix the color on the fabric and also for leveling.

Biancalani PRATO ITALI: used for polishing the fabric.

Quantity of hydro caustic: 35 gpl (grams per liter)

Streamer:

After that the fabric goes to the steamer which is located at a higher level where direct

heating is given to the fabric. Only steam is present in the streamer. The temperature

of the steamer is usually 100`C. The fabric stays in the steamer for a minute.

On the sides of steamers there are four tanks having hydro caustic after A-Ring.

Page 92: TEXTILE INDUSTRY INTERNSHIP REPORT

The steamer is used only if the fabric is dyed from wet dyes, for a reactive dyed fabric

the steamer is switched off because reactive dyed fabrics are kept in rotation for 8

hours and no rotation is required for wet dyed fabrics.

Water lock:

From the steamer which is located on the top of the machine the fabric comes down to

water lock where the fabric is cooled. The temperature of the fabric has to be reduced

so it is washed with water and other chemicals.

Number of washers: 7

Speed: 60 m/min

washer Set temperature(in C ) Real temperature( in C)

1 40 56

2 60 71

3 60 71

4 95 90

5 95 92

6 70 83

7 60 86

First and second washer has soft H2O.

Third washer has peroxide for wet dyed fabric and if the fabric is dyed through

reactive dye then Hexa Meta phosphate (HMP) is used.

Fourth and fifth washer contains soap for both wet and reactive dyed fabric.

Seventh washer contains acetic acid. Water from seventh washer can be

transferred to the first washer.

Water in the washers is changed if a new lighter shade of the fabric is used after

darker shade. Also if the shade of the color is changed or a new color fabric is fed

Page 93: TEXTILE INDUSTRY INTERNSHIP REPORT

then the currently used water is discharged and new water is fed. Generally water

is changed after every 1 or half an hour.

For drying the fabric for further processes eighteen hot cylinders are used and

through direct heating fabric is dried. Out of them two cylinders were in the front,

they are known as pulling cylinders.

Basically the cycle which the fabric undergoes in pad steam machine is:

Beam A Ring hydro caustic Steamer

Final Fabric Hot Cylinders 7 Washers

Then it is passed through nip rollers where it is squeezed between two rollers.

Basically nip rollers are used to remove the excess water in the fabric.

The speed of the machine can be changed according to the fabric type like

For Bottom weight fabrics: 45 m/min

For shirting fabrics: 30 m/min.

PDR (PAD DRY RANGE) MACHINE:

Parameters:

POPLIN VAT DYES REACTIVE DYES

1. Temperature 120 120 130 0 120 130 130 0

2. Fan speed 50 50 50 0 50 50 50 0

3. Damper 5 5 5 5 5 5 5 5

5 5 5 5 5 5 5 5

4. I.R 3+1 2+0

5. Moist 21% 45%

Page 94: TEXTILE INDUSTRY INTERNSHIP REPORT

BOTTOM VAT DYES REACTIVE DYES

1. Temperature 120 130 140 150 120 130 140 150

2. Fan speed 70 70 80 80 70 70 80 80

3. Damper 5 5 5 5 5 5 5 5

5 5 5 5 5 5 5 5

4. I.R 3+3 3+2

5. Moist 22% 30%

CORDROY(bottom) VAT DYES REACTIVE DYES

1. Temperature 120 135 150 150 170 200 200 200

2. Fan speed 70 70 80 80 80 80 80 80

3. Damper 5 5 5 5 5 5 5 5

5 5 5 5 5 5 5 5

4. I.R 3+3

5. Moist 30% 40%

CORDROY(shirting

)

VAT DYES REACTIVE DYES

1. Temperature 120 135 150 150 180 200 200 200

2. Fan speed 70 70 80 80 80 80 80 80

3. Damper 5 5 5 5 5 5 5 5

5 5 5 5 5 5 5 5

4. I.R 3+2 2+2

5. Moist 30% 40%

COLOR KITCHEN:

In this section colors are prepared for dyeing. Colors are mixed in a tank.

Number of tanks: 5

One dissolving tank and four tanks for different tanks.

Page 95: TEXTILE INDUSTRY INTERNSHIP REPORT

The tank who needs the color for the particular machine takes the color from the

dissolving tank. Colors are prepared by mixing the dye with water and chemicals.

Following parameters are considered while preparing the dye:

Dissolving volume: 120 l

Preparations: 1

Preparation tank: anyone from the four tanks.

Total volume: 586 l

Heating mode: heating

Temperature 1: 50 C (temperature before adding color)

Temperature 2: 30 C (after adding color if more color is to be added after stirring)

Mixing time: according to the dye and chemicals used

CPB (cold patch batch):

This technique is a variation of pad dyeing. The fabric is immersed in the dye liquor

at room temperature. After the excess liquor is squeezed out by the pad rollers, the

roll of fabric is wrapped to prevent drying. It is then rotated slowly for up to 48 hours

to obtain uniformity of dye application. The fabric is then washed in a mild alkaline

solution to remove the liquor additives and unfixed dyes. Finally the cloth is extracted

and dried.

The dye stuff and alkali are combined in one bath through which the fabric is passed.

Excess liquor is squeezed out on the mangle and the fabric is batched on rolls which

are then covered with plastic sheets to prevent evaporation. It is then subsequently

washed.

Advantages:

This method uses less energy and less water which results in less pollution

It is as fast as the continuous range system at less capital expenditure

Has the desired stability and rapid fixation while providing reliable and

consistent shade.

Page 96: TEXTILE INDUSTRY INTERNSHIP REPORT

This machine is used for reactive dyes. Dye or color and silicate caustic are put in

trough. Only colors are imparted to the fabric, no drying of the fabrics happens.

FINISHING PROCESS:

Newly constructed fabric is called greige goods or grey fabric. The goods must pass

various finishing processes to make it suitable for its intended end use. Finishing may

change the appearance of the fabric, its hand (feel), its serviceability, and its

durability.in this unit:

Number of machine: 10

Number of workers: 25- 30 per shift

Monforts shrinkage range:

In a huge tank plaited fabric is kept where it is continuously fed to the

machine. When one plait of fabric gets over, the second plait of fabric is

stitched to the end of first fabric by single needle lock stitch machine. First off

all the fabric enters a unit containing a cylinder, two big rollers, a trough

containing liquid, liquid is sprayed from one thin roller over a big roller for

cooling the fabric.

Then the fabric enters a huge unit containing one huge cylinder.

After coming out through the cylinder.

Dhall shrinking range (sunforising machine):

Standard shrinkage: 4-5 %

Shrinkage in bottom weights: 7%

Page 97: TEXTILE INDUSTRY INTERNSHIP REPORT

Plaited fabric 5-6 rollers 1 cylinder 5-6 rollers

Pre shrinkage

In this machine the fabric is passed through two different rollers and steam

and it is made to pass through a palmer which is like a thick blancket. After it

is passed through this the fabric gets its own shrinkage.

00 shrinkage or no shrinkage is there in the fabric after this process.

This processes required especially for cotton fabrics. Chemicals which gets

spread over it when it breaks it smoothes the surface.

+- 3% shrinkage is allowed.

STENTERING:

This process is applied at various stages of finishing. Usually the fabric is wet when it

is run into a tenter. After being relaxed during dyeing and finishing, all fabrics are

coaxed back to normal width on a tentering frame. The endless chain of mechanical

fingers, or tenter-frame clips, grips the fabric selvedges on entering the machine,

which has been set for the narrowest width of the fabric. Gently but firmly, the fingers

stretch the fabric to a predetermined width as is passes down the length of the tenter

over live steam and subsequently heat, which dries and sets the fabric.

Objectives:

drying of the fabric

Evening of the fabric width

This machine basically consists of two

endless chains carried in rugged rails with a

distance between them that can be adjusted. The chains are equipped with clips or

pins, which grip the selvedge of the fabric and carry it into the heated housing where a

blast of hot air removes any moisture. Pin frames are mostly used on woolens or

knitted goods; clip frames are favored for cottons.

Stentering is a continuous operation in that the goods enter one end of the frame,

which usually 90 feet (30 m) long, and emerge from the other. The frame is equipped

Page 98: TEXTILE INDUSTRY INTERNSHIP REPORT

with devices that straighten the filling and keep it at right angles to the warp, thus

avoiding biased goods.

No of machine: 3

i. BRUCKER STENTER: Mahlo machine

ii. Harish stenter

iii. Primatex FS-100 stenter

Strength of the fabric is also improved from Stentering. Moreover silicon finishing is

also given simultaneously for feel improvement.

BRUCKER STENTER

Mahlo: weft straightener

For checking of the fabric

For bow and skew

Number of cameras: 4(for identifying bow and skew)

There are rollers in the machine which imparts bow and skew to some fabrics. For

example, for bottom fabric skew is necessary, so the rollers are set according to the

amount of skew required.

Photo sensors are fixed in the machine for better rest. The fabric stretched here where

fan is given to cool the excess temperature while heating. There are 4 heating system

after Stentering.

There are 10 chambers each with different temperature and the distance between two

chambers is 3 meters. Every chamber has a fan.

CHAMBERS TEMPERATURE IN ` C

1st chamber 90

2nd chamber 98

3rd chamber 101

4th chamber 1135th chamber 115

Page 99: TEXTILE INDUSTRY INTERNSHIP REPORT

6th chamber 107

7th chamber 120

8th chamber 106

9th chamber 109

10th chamber 109

Every chamber has a fan inside it.

The standard temperature for all kinds of shirting fabrics is 110 `C but for

bottom weights it is kept 150 `C.

Oil heating system. Oils are used for heating.

Cooling cylinders

Moisture controller: 3 small rollers. It is necessary for keeping the fabric a

little wet also necessary for shrinking the fabrics.

HARISH MACHINE:

This machine is also used for Stentering. Its working is equivalent to mahlo

type the difference lies in hearting mode. Here gas heating is given to the

fabric instesd of oil heating in Mahlo.

Moreover bow and skew is adjusted manually.

It has only 5 chambers.

Pigment coating machine is attached to it especially for denims and only on

one side. Then effect is given after enzyme washing.

PREMATEN MACHINE:

It has only 4 chambers

Oil heating is given

MONFORT MACHINE:

Latest machine

Page 100: TEXTILE INDUSTRY INTERNSHIP REPORT

Rubber unit is present to give pressure. Shrinkage is set here. So the fabric is

squeezed inside.

Vaco: sprays moisture in the fabric.

After that the fabric goes for cooling.

Pamer unit: made up of woolen blanket. Two cylinders are present one big and

one small for drying.

After the fabric is being processed various types of finishes are given to the fabric

according to the intended end use of the fabric.

It is basically of three types:

Finishing

Normal finishing Mechanical Specific requirement according

finishing to the order

Other types of finishing include:

Silicon finish

Softener finish

Wrinkle free finish:

These finishes are also sometimes referred to as crease resistance finishes.

The purpose of this finish is to prevent deformation of the fabric by

undesirable and unintentionally introduced folds and rumples.

Chemical finish

Water repellant finish:

A water repellent fabric is one that will resist absorption and penetration of

water for a given period of time, depending upon the length of exposure and

the force of water.

Mechanical finish which includes peach finish, brush, calendaring, raise finish

Teflon finish

Soil release finish:

Page 101: TEXTILE INDUSTRY INTERNSHIP REPORT

This finish will facilitate the removal of dirt or stains from fabrics treated

with a permanent press finish.

Vitamin E finish

Aloe Vera finish

Anti-microbial finish:

Chemical antiseptic finishes impart a self-sterilizing quality to a fabric. The

appearance and feel of the fabric are unchanged, and no chemical odor

remains. Dry-cleaning does not impair the finish.

Uv cut

3X dry finish

Durawhite finish etc

In chemical finishing, heat treatment is given where the fabric is passed through a

vessel called trough where chemical is put. And then through nip rollers which

squeeze the fabric. The speed and temperature of the machine is maintained according

to the fabric type. The chemical gets bonded with the structure of the fabric while it

comes out this result in harsh surface of the fabric so in the final stage softening finish

is given to the fabric.

Peach finish (Mechanical finish):

Machine type:

Zetma (advanced gamatex)

Amerising machine:

For smoothening the surface of the machine.

Calendar machine:

Gives the fabric extra shine

Heating system. Heat is applied through steam.

Page 102: TEXTILE INDUSTRY INTERNSHIP REPORT

Calendaring is a final process in which heat and pressure are applied to a fabric by

passing it between heated rollers, imparting a flat, glossy, smooth surface. Luster

increases when the degree of heat and pressure is increased. Calendaring is applied to

fabrics in which a smooth, flat surface is desirable, such as most cottons, many linens

and silks, and various man-made fabrics. In such fabrics as velveteen, a flat surface is

not desirable, and the cloth is steamed while in tension, without pressing. When

applied to wool, the process is called pressing, and employs heavy, heated metal

plates to steam and press the fabric. Calendering is not usually a permanent process.

Raising machine:

This process is given to the fabric for improving the aesthetic value of it. There are

two rollers in the machine and pins are protruding out of the outer surfaces of these

rollers. When the fabric is rubbed with these surfaces the yarns of the fabric gets

pulled outwards which gives a different feel.

It gives flammel effect.

Page 103: TEXTILE INDUSTRY INTERNSHIP REPORT

2. I. f. FINISH FOLDING

4 point inspection happens in randomly selected samples of the fabric rolls.

A 4 point defect is considered a 2 defect and a 2 point defect is considered as a single

defect.

A sample from each roll is taken for shade sorting and grouping

The reasons for the major defects (ex.-Crease, tight selvedge, stain) are analysed and a

backup report is sent to the concerned department. Acc. to the variations

After grouping, sent to checking for packing thela packing –India and Cartons are

used for corduroy .Plastic covers are used for packing

If the roll length is less than the specified length by the buyers, there are possibilities

of rejection or discount.

The shipment time also delays with defects and quality issues.

In 100 mtrs 35 points are allowed. 4 point defects not more than 4 are allowed in

100metres.

The packing and transferring data is fed simultaneously into the computer as the

processes occur. Processing of the order is done in small parts.

Requirement sheet comes from party and name of the method includes full detailing.

Randomly reinspection is done for every 5-10% of the lot and reports are made every

day.

Pantaloon, Zodiac, Aditya, etc are major buyers of BVM..

According to size, fabric is classified into different categories:

1) Press( as Per buyers requirement)

2) Press Short length(If length is less than required)

3) Seconds(Continuous)

Page 104: TEXTILE INDUSTRY INTERNSHIP REPORT

4) Good cut(Multiples of 1.3, etcmtrs)

5) Fent(45cm to 90 cmlength)

6) Dex(23to 44cm length)

7) <20cm long Chiwndy cleaning cloth

44 varities of type 7 are present. It is also used for children’s wear.

4 chain functions are present in the finish folding department:

1) Inspection

2) Feed back to concerned departments

3) Packing

4) Sampling

- Sent to aspiring customers if they like the sample, the bulk is ordered.

50,000 metres of fabric are inspected per day.

50,000 mtrs are packed per day

No. of workers are 78, ITI trainees are 15 and Unskilled workers are 20.

Defects after finishing

Dyeing :-

1) color stain

2) discharge daghi

3) dropping

4) dyed dhabba

5) Dyed tapki daghi

6) Dyed daghi

7) Dyeing crease

8) Dyeingpatches

9) Dyeing patta

10) Dyeing stopmark

11) Dyeing other

12) Group

13) Selvedge patta

Page 105: TEXTILE INDUSTRY INTERNSHIP REPORT

14) Stitch impression

15) Watermark

Bleaching:

1) Abrasion

2) Bleaching other

3) Crease

4) Hairiness

5) Backup Report:-1) hairiness

2) Hole

3) Tappi Daghi

Finishing:

1) Abrasion

2) Blanket Impression

3) Bowing

4) Finishing others

5) Finish crease

6) Finish variation

7) Holes

8) Mild stain

9) Selvedge torn

10) Tapki daghi

11) Width variation

Page 106: TEXTILE INDUSTRY INTERNSHIP REPORT

2. I. g. SQC

QUALITY STANDARDS

Stage-I: Quality control of the Input Materials such as Fiber, Yarns, Grey Fabrics,

Chemicals and Dyes

Stage-II: Quality control of the Process through surveillance at each manufacturing

stage

Stage III: Quality control of Final Products

Fully computerized & well-equipped in-house laboratory ensures high quality

parameters from fiber to finished fabric including all other inputs.

Well-equipped physical and chemical testing laboratory to check all incoming

materials and finished products for their strength and colour fastness, washing

properties, shrinkage and shading, etc. as per international norms.

The quality of fabric is checked at grey and finished stages under 4-point grading

system. Finally folding and packing department has roll to roll inspection facilities

to ensure fault-free longer length quality fabric prior to its delivery to customers.

Moisture meter Aquadon: Portable digital moisture meter %of moisture is

measured

USTER TESTER 4 SX has 3sensors:

1) Sensor OH for Hairiness: Uneveness %, Thin% thick%, Neps, Hariness,

Standard deduction(variation) of hairiness, Relative count, Mass

Diagram(cardiogram)

2) Sensor CS: Weighs

3) Conveyer: - Movement of rolls.

Follows Total Quality Management, People, technology, product and services.

Page 107: TEXTILE INDUSTRY INTERNSHIP REPORT

Fully computerized and well equipped in house laboratory ensures high quality

parameters from fiber to finished fabric including all other inputs.

The Equipment include Uster Hvi 900 Classic, Uster UT4-SX and Uster

Classimat CMT-3, Data Colour Matching system SF 600, Ahiba Spectra Dye with

Auto dispersing system, Labourtex Padder, dryer and pad steam.

TESTING INSTRUMENT MANUFACTURER APPLICATION

FIBRE TESTING- Uster

HVI-900 and bias software

MODEL

Zell wager-uster

Switzerland

All cotton properties like

length, strength, micronnaire,

color, trash

Cotton trash analyzer Statex eng. Ltd,

coimbatore

Trash%

Moisture meter Star electronics and

engineering, Baroda

Moisture %of Bale cotton

yarn packages,etc

Yarn Testing;

Uster tester-4(UT-43x)

With hairiness module

Zell wager-uster

Switzerland

Unevenness of sliver

Roving and yarn(frequently

faulty)

Uster classimat-3 with P.S.

High speed winder machine of

6 spindles

Zell wager-uster

Switzerland

P.S. Mattler

Seldom occurring faults like

short length, long

length(Total 23 in number)

KMI computerized electronic

tensile tester

Kamal metal Industries

Ahmedabad

Single yarn strength, fabric

tensile strength

Af coset electronic count

balance model FX-300

Straten eng. (p) ltd.

Coimbatore

Count Checking

Yarn appearance examination

machine

Ten lab industries

Ahmedabad

For ASTM grade(yarn

Appearance Board)

Kmi electronic twist tester Kamal metal Industries

Ahmedabad

For twist Checking- z&s

direction

Double yarn twist tester Good Brand and Co. ltd

England

For twist Checking- z&s

direction

Libra electronic digital Libra industries For weight purposes

Page 108: TEXTILE INDUSTRY INTERNSHIP REPORT

weighting balance model

8801M

Bombay

Fabric testing count checking

instrument

Good Brand and Co. ltd

England

Fabric Count Checking

KMI computerized electronic tensile tester

Page 109: TEXTILE INDUSTRY INTERNSHIP REPORT

2. I. h PRODUCTION PLANNING AND CONTROL

Overall in charge of production activities of all the departments, quality of finished

products, total operation of production activities, waste reduction, judicious use of

raw materials, spare parts etc.

To arrange production activities as per the requirement of marketing department

To plan overtime work in various department, whenever necessary in consultation

with unit head

Production scheduling and working out raw material requirements.

Process control and associated activities in all production department/sections,

reviewing and disposition of nonconforming products during in process and final

stages.

Monitoring and measurement of processes and product in his area and

implementing appropriate corrective action to achieve planned results. Monitoring

progress against quality objectives and continual improvement and projects in

consultation.

The other functions of the PPC includes receiving inspection of all purchased

products, in process and final inspection and testing, compilation and maintaining the

result of defect analysis every month as applied to each manufacturing process, with

hold in process and finished items not meeting the requirement and reporting to

management.

Note:

1. More Delay in production occurs in rainy and summer seasons

2. Major role in competition with other mills

Page 110: TEXTILE INDUSTRY INTERNSHIP REPORT

3. Main strengths of the industry is considered, dobby looms and corduroy

4. spinning produces 56,000 mtrs per day

5. According to the Customer complaints, satisfaction, Monitoring of Process

(marketing, purchasing/ stores, production, delivery, maintenance, QC, sales)

happens with an Internal Audit.

6. 2 SQC persons are involved between the PPC department and SQC, because

complete coordination is required.

7. currently, 80% of finishing department is utitlised

8. 10 days in a production season is provided for sampling

WEAVING PRODUCTION REPORT 2005 (AUGUST)

DATE DIRECT WARPING SECTIONAL WARPING

(Beams/day)

SIZING (Total meters/

month)

1 JAN. 1,16,057 18.3 11,29,615

2 FEB. 1,39,965 17.7 10,65,695

3 MAR. 1,83,930 17.5 10,38,715

4 APR. 2,15,145 19.4 11,34,925

5 MAY 1,48,637 19.9 10,42,630

6 JUNE 2,00,030 16.8 9,99,580

7 JULY 2,36,681 18.4 11,71,366

8 AUG 1,82,045 20.9 10,60,245

9 SEP 1,74,445 17.56 10,78,500

10 OCT 2,02,798 17.25 11,26,240

11NOV 2,26,520 20.2 10,43,453

12 DEC 2,54,805 19.5 12,19,719

LOOM PRODUCTION REPORT:

MONTH PRODUCTION/ MONTH (in meters)

Page 111: TEXTILE INDUSTRY INTERNSHIP REPORT

1 9,58,086

2 9,17,783

3 10,00,738

4 10,02,280

5 9,14,719

6 8,80,885

7 10,42,005

8 9,25,160

9 9,84,231

10 10,00,596

11 _______

12 _______

2. I. h ENGINEERING

The engineering department takes control over the overall maintenance of

machineries, processing plans and utilities, Building maintenance, overall in charge of

electric maintenance, Liaison work with Pollution Control Board, directorate of boiler

and electrical inspectorate, Overall supervision of security department, Maintenance

of telephones, both internal and external.

2. I. i EFFLUENT TREATMENT PLANT:

1. Equalization: It’s a primary treatment. Water coming from dyeing section is

washed. It is then equalized or neutralized.

2. Reaction Tank: It’s a primary treatment. Piclic acid is used for slug formation,

caustic for neutralization of the water.

3. Magna Block: Slug and solids present are settled and precipitated.

4. Clarifier tank: Further separation of lighter solids.

Page 112: TEXTILE INDUSTRY INTERNSHIP REPORT

5. Supernant Tank: Complete separation of water

6. slug slump collection of solid slug

7. filter press compresses the slug

8. Aeration tank: In this oxidation and removal of odors takes place.

2. I. j. LABORATORY

A laboratory in the manufacturing industry plays an important role in the production

standards of the company. A sample production is carried out as per the proposed

Supernant tank Clarifier Tank

Page 113: TEXTILE INDUSTRY INTERNSHIP REPORT

standards and variations required are analysed as per the practicality. Chemical

processing done at a small scale sampling

3 main activities in lab:

1) Fabric dyeing: Detects absorbency

2) Yarn dyeing

3) Before absorbency and after shrinkage and fastness testing

Lab Dyeing has two steps:

1. Lab dyeing before order for preparation before order and is matched with lab dip

after drying over original fabric pieces, IPC department.

2. Lab to bulk correlation is done after RFD and finishing. If shade variation comes it

is sent back to dyeing. RF dyeing: Ready for dyeing H2O2 improves whiteness.

Dye lab and process control lab consists of the following equipments.

Equipments for testing state of the fabric at the start and the end of the fabric

1) Wagner hot press.

2) Digi washer paramount

3) Washing machines: whirlpool

4) Tumble dryer

5) Oven

6) Tear tester: paramount

7) GSM cutter

8) Crock meter

9) PH meter

10) Microwave oven

11) Hank Preparation machine

12) Labortex padding machine

13) Labortex drying machine

14) Labortex pad steam

Page 114: TEXTILE INDUSTRY INTERNSHIP REPORT

15) Data color dispenser: Combined lab dispenser and solution maker and

is used for yarn dyeing. Manually, values are fed into the computer for

the dye recipe and the recipe is combined automatically by the

dispenser. It is only used for yarn dyeing, the concentration not enough

for fabric dyeing.

16) Data color CCM-SF600 plus

17) Crease recovery tester

Spectra photometer XW-2000 infrared sampling machine: Spectral value of the

shade is determined. A Spectrometer scans the color and calculates the spectral

value.

Dyeing Lab Equipment

1) Color computer matching SF-600 plus(DCI)

2) Ahiba Spectra dye(DCI)

3) DCI combine lab dispenser and solution maker(AUTOLAB YO)

4) Labortex padding mangle

5) Labortex mini dryer

6) Labortex pad steam range

7) Gretage macbeth view box

8) Judge ii view box

Process Control Lab Equipment

1) Digiwash laundrometer

2) Tearing strength tester

3) Crock meter

4) GSM cutter

5) AATCC shrinkage ruler

6) Digital Ph meter

7) Wrinkle recovery tester

8) IFB, Miele Washing machines

9) IFB Tumble dryer

Page 115: TEXTILE INDUSTRY INTERNSHIP REPORT

10) COD Assembly

Dark Room

GTI mini matcher

Dye sampling is same for fabric and yarn. The prepared sample is wrapped in paper,

washed and developed

1. Cold pad batch for reactive dyes

2. Steam pad dry for VAT dyes and light shades

3. Guhaust method: requires high temperature.

YARN DYEING MACHINE X-W-2000

Infra red sample dyeing machine

Fabric is dyed in a separate lab room.

Dye + caustic +silicate: This recipe is added to the trough of padding mangle

machine, sample fabric inserted into it, then dried in the oven.

Different pieces of fabric are stitched together so that all can be processed at the same

time.

Paramount Tearing strength tester is also present

Spectra photometer XW-2000 Infrared sampling machine Data color dispenser

Page 116: TEXTILE INDUSTRY INTERNSHIP REPORT

ADMINISTRATION

2. II. a. RETAIL STORE

DJ&C is a major brand of direct buyers of BVM. UPPERLOOK is an apparel brand

of BVM. It has a retail outlet for its fabric in the company premises.

Page 117: TEXTILE INDUSTRY INTERNSHIP REPORT

2. II. b. GENERAL ADMINISTRATION

MANAGING DIRECTOR:

Exercises Overall control of all company activities, approves quality, ensures that

quality policy and quality objectives are established, periodic review of the quality

management system, ensuring availability of resources and communicating to the

organization the importance of meeting customer as well as statutory and regulatory

requirement.

HEAD OF THE DEPARTMENTS:

Responsible for setting quality objectives in their areas and obtaining MD’s approval;

also periodic review of progress against established objectives and continual

improvement projects.

HUMAN RESOURCE MANAGER

Responsible for Consolidating training requirements and preparing training calendar

based on approved training needs, Organizing requisite training programs inline with

training calendar, Induction training for new entrants, Safety and welfare activities,

Maintenance of training records.

SECOND LEVEL MANAGERS

Ensuring development, implementation and maintenance of quality management

system, issue and control of the quality manual, quality system procedures, (and their

revisions, resolving and taking appropriate actions on matters of conflicting nature on

quality system, arranging periodical internal audits, reporting on the performance and

any need for improvement, ensuring promotion of awareness of customer

requirements through out the organization., coordinating management reviews,

maintaining records of management reviews etc.

THIRD LEVEL MANAGERS

Page 118: TEXTILE INDUSTRY INTERNSHIP REPORT

Executing various decisions taken by the board and the management, day to day

functions of the unit, overall responsibility for smooth functioning of all

departments/sections and other related functions of the unit, participation in the

committee for review and disposition of nonconforming product during various

processing stages, approval of operational procedures applicable exclusively to the

unit, Monitoring progress against quality objectives and continual improvement

projects consolation with concerned HODs /Section Heads and MR.

2. II. c. HUMAN RESOURCE DEPARTMENT

Hire The Best Add Value to Retain

Empower to Build Mutual Trust and Opportunity to Grow

Induction to BVM value system training imparts Behavior, Culture,

Knowledge and Skill.

There exists a union, BVM workers union for the welfare and representation of

the workers. There is a peaceful coexistence amongst the employees, workers and

management.

STAFF AND WORKERS

Department Staff Workers

Spinning 19 414

Weaving 63 862

Processing

-Yarn dyeing

-Bleaching

-Dyeing

40 233

Engineering 44 104

Lab 26 10

SQC 20 0

Page 119: TEXTILE INDUSTRY INTERNSHIP REPORT

Sales, Marketing,

grey & finish

57 144

General

-finance

-accounts

78 41

2. II. d. PERSONNEL

Overall in charge of administration and personnel department, Looking after the

duties of office administration, liaison works with labor department, inspector of

factories, ESI, PF and other offices, Attend legal matters/court cases i.e. labor court,

industrial tribunal, civil courts and labor departments, Discussing with trade union of

factory with regard to production, discipline, grievances etc.,Settlement of terminal

benefits of retired/VRS employees and those died in service, Submissions of

periodical returns to various Govt. departments, To supervise the functions of Time

Office as well as establishment, Maintenance of various files in connection with

official, legal matters, court cases, disciplinary matters etc., Conducting domestic

enquiries, initiating disciplinary proceedings against workers/staff., Recruitment and

training.

Page 120: TEXTILE INDUSTRY INTERNSHIP REPORT

MARKETING

2. III. a. MARKETING DEPARTMENT

Page 121: TEXTILE INDUSTRY INTERNSHIP REPORT

Responsible for overall in charge of marketing activities, entering into requisite

agreements with dealers, agents, franchisees and monitoring their performance

Identifying new products to be produced and also requirements of corporate

customers

Consolidate monthly indents from showrooms, dealers, etc and present data in the

monthly production review meetings

Maintain proceedings of monthly production review meeting and intimate

production targets to all concerned

Finalization of sale prices in consultation with management and implements sales

promotion schemes approved by managing director

Maintain communication with dealers on progress against indents and

coordinating with dealers about the sales activities.

Mr. Kaushik Pandey is the HOD of marketing

2. III. b. DESPATCH DEPARTMENT

Page 122: TEXTILE INDUSTRY INTERNSHIP REPORT

The dispatch department is concerned with the dispatch of the ordered goods and its

accounting. The delivery details, the mode and the package details are recorded at this

department. The following are the norms, conditions and functions followed by the

dispatch department:

1) Carrying forward ex- mill deliveries.

2) Charging of Excise duty and all other government taxes to the customers.

3) Transport, bank commission, Insurance and any other charges are denoted to the

buyers to be paid by them

4) If Hundi will be returned, interest will be charged at 30% per annum from the date

of hundi and they can even propose to the managing system to cancel all pending

contracts of the buyers

5) Settlement of claim of fabric at fabric stage only

6) Verifying the count, pick-reed variation is as per T/C standard

7) Notification to the buyers about delay of delivery.

8) Charging of interest on the goods not taken within 1o days, at 30% per annum.

2. III. c. DESIGN DEPARTMENT

Deskloom

The yarn sample which is developed in the lab, is used for development of small

swatches using the desk loom which in turn is send to the buyer. If the sample is

accepted by the buyer, they produce the bulk order which the PPC manipulates.

There exists another sequence of order formation:

The buyer provides the design/ weave pattern which is processed by the design

section and provided to the deskloom for development, and the same process occurs

Either way, the deskloom section plays a very important role in the development of

fabric and order of it.

The design of the sample is forwarded from the design section.

Sizing machine(small, winding and size spreading ) is present for prearation of the

yarn for weaving.

Page 123: TEXTILE INDUSTRY INTERNSHIP REPORT

Small samples of the size 6*16 inch are produced woven. Currently, 5 desk hand

looms are present which produce 15 samples per day.

Total number workers who work in the design department are 9 to 10.

Design

3 designers and 4 trainees are present in this section who develop the design and the

weave structure of the fabric as per buyer specifications or innovative fashion design

release. They use CAD for development of the designs:

The designs once developed are send to the marketing department who interact with

the target customers and sent the report to the PPC who in turn notify the design

department about the changes and to develop the final weave structure.

The software use for design development is: TEXTRONICS

Dobby designs are developed using individual colors for the warp and weft and

providing the intersection points as the dobby design.

A color card is used for detection of the color match.

Denting can also be done in the software(Since creel capacity is 480, the designs

are done accordingly).

Scanned picture can be converted into a pixilated digital image which coverts into a

jacquard design, the repeat size specified

Page 124: TEXTILE INDUSTRY INTERNSHIP REPORT

PROCUREMENT

2. IV. a. PURCHASE

Page 125: TEXTILE INDUSTRY INTERNSHIP REPORT

Carries forward purchase activities since from the purchase requisition stage till

settlement of payment to the supplier and is responsible for stores activities since

from receipts stage to till accounting departments as per their requirement against

indents. Service contracts like transportation, calibration, maintenance, annual

maintenance contract for computers, scales etc. and looking after day to day

correspondence pertaining to stores and purchase department, pursuance of proposal

which we sent to SPC for approval.

Approved and completed orders are checked.

Vendors are selected from ASL (Approved Select List)

Due date for submission of tender is mentioned.

Tenders are opened in front of committee members.

Comparative statements are prepared.

Intenders and user departments are consulted for suitability of the items.

Proposal sheets are prepared with justifications/recommendations.

Proposal is placed before JPC (Junior Purchase Consultant) for approval.

PO (Purchase Order) is issued after the approval by JPC to the successful

tender/supplier.

Suppliers are pursued for timely supplies.

Store department is informed for arrangement of inspections soon after the receipt

of items/materials.

If items are accepted, then relevant document is sent to accounts department for

payment to the supplier as per payment terms.

Rejected items are arranged.

2. IV. b. STORES

Responsible for Receipt and inspection of finished products, Stock entry separately

for accepted/rejected items, Separate storage of accepted/rejected items as per the

conditions laid down in the procedure. Maintenance of stock ledger. Inspections of

rejected materials for fixing discounts and declaring as seconds.

Issue/receipt of materials:

Page 126: TEXTILE INDUSTRY INTERNSHIP REPORT

Incoming items are checked with reference to purchase order details.

Test certificate (TC)/ Test Report (TR) is checked.

Items are kept in designated place marked as ‘A waiting’ inspections.

Inspection of items by the Quality Control/user department is arranged.

The accepted materials are shifted to the reserved/designated locations.

Material inspection (MI) and Inspection Report (IR) are prepared, then signature is

obtained of inspecting authorities, department heads, SPO (Store Purchase Officer)

and UH (Unit Head). In case of rejection, purchase department is informed for

rectification and follow up).

Entries are made in GIR (Goods Inward Register).

PC (purchase Credit note) is prepared.

Material against complaint indents are issued after obtaining receivers signature.

Receipts, issues, consumptions of materials accounts are maintained in prescribed

documents/ledgers/registers.

2. Storage and Preservation:

Storage and preservation are arranged depending upon type, quality, and life of

materials.

Items are checked once in a month.

3. Handling: Proper handlings equipments are used ton avoid damage, spoiling,

wastage of materials.

4. Store accounting:

Monthly statements of issues, consumptions are prepared and sent to Accounts.

Receipt and pending order quantity are prepared.

Purchase statements are cashed

2. IV. c. COTTON DEPARTMENT

100% of the Raw material cotton/ cotton yarn fiber is composite. On an average the

cotton fibre consumption is 50 bales per day. Various counts of cotton, (such as 40s

etc.,) are consumed. The count of cotton will also depends on the type of fabric order

and market conditions.

Page 127: TEXTILE INDUSTRY INTERNSHIP REPORT

A major amount of cotton is sourced from Gujarat (based at ahmedabad and

manavadar), which is shanker quality.

The sourceing is done through agents and direct deals with trading companies

such as vishal trading company.

MCV 5, PCH qualities are 50s count and are imported from USA.(12,000 bales

were imported recently.

Cotton yarn produced is 125 metric tonne per month(28,000 spindles)(upto march

2006) but from march 2006 the spinning mill has been expanded. The

consumption of yarn in april was 200 metric tonne. T

he deficient yarn quantity is provided by a supplier range namely arun textile,

kkp spinning, in salem, Nahar, Vardhman, Raja palyam mills, etc.

The superior count of yarn bought is 2/80s and 2/100s counts. Gold / silver coated

yarn is also bought.

2. IV. d. WASTE DEPARTMENT

The waste generated is tender every month. Ahmedabad cotton waste merchant

association dalal within 15 days of tender

If the Quantity of waste more the waste is tendered at the rate of 1000 kg/ day(at an

average rate of 35 rs/kg)

1. Trumat cuttling rs. 28

2. Luma file 38 rs/ kg

3. Comber waste mixed count 35 rs/kg

4. Cool zool 12 rs(50kg per day)

5. Cleaning wasters 13/KG, 50KG/DAY

6. Dropping 9-10rs/kg 200kg/day

7. Fly17-18rs/kg, 15-25 kg/day

8. Colored airjet waste

9. White airjet

Page 128: TEXTILE INDUSTRY INTERNSHIP REPORT

10. Oiling waste

11. Soft waste

12. Hard waste perday

VAT 4% is added in the costing of the waste .

Ex: Sundar waste, Niranjan waste are the waste buying agents. The waste sales

produce around 5-6 crores Rs per year.

WASTE PRODUCTION REPORT:

MONTH TOTAL

WEAVING

WASTE

LOOMSHED

WASTE

WEAVING +

SIZING

WASTE

WINDNG

WASTE

1 5.47 3.41 2.44 1.15

2 6.60 4.06 2.86 1.12

3 5.40 3.38 2.64 1.09

4 5.01 3.26 2.04 1.32

5 5.52 3.63 2.28 1.21

6 5.09 3.41 2.34 1.10

7 5.39 3.62 2.09 1.35

8 5.59 3.82 1.94 1.30

9 5.99 3.99 2.3 1.39

10 5.96 4.1 2.04 1.21

11 5.68 3.9 1.94 1.12

Page 129: TEXTILE INDUSTRY INTERNSHIP REPORT

FINANCE

2. V. ACCOUNTS

FINANCIAL EXPANSION STATUS

Page 130: TEXTILE INDUSTRY INTERNSHIP REPORT

The Textile division increased its turnover by 30% to Rs.194.44 crore in 2004-05,

accounting for 27% of the Company's turnover of which domestic turn over has

increased by 62% and production has been grown by 21% over the previous year. Net

revenue for the year 04-05 is Rs.188.61 crores which is grown by 32% over the

previous year. The previous year was the first full year of working of the expanded

capacity of 18 mn metres per annum and the business arrangement with Canclini

Tessile S.p.A, the only such association within the industry with a reputed

international textile company. The Company serviced brand-enhancing customers like

Van Heusen, Louis Phillip, Allen Solly, Peter England, Park Avenue and Pantaloons

with larger volumes. Value addition: Introduction of value-added products (structured

fabrics with higher thread counts in the shirting segment, yarn-dyed corduroy shirting

and Pima cotton yarn-based corduroy fabric in the corduroy segment).

Prompt settlement of supplier bill, Participation in committee for evaluation and

selection of new suppliers, Collecting information from units regarding for cash flow,

MIS and other necessary information, Preparation of balance sheet, Maintenance of

accounts relating to corporation, Scrutiny of wages bill and other bills connected to

business transactions, Liaison with banks, AG audits/statutory auditors, PF and ESI

office etc

SINTEX INDUSTRIES LIMITEDREGD. OFFICE :- Near Seven Garnala, Kalol (North GUJARAT) - 382 721.

AUDITED FINANCIAL RESULTS FOR THE FINANCIAL YEAR ENDED 31st MARCH 2006(Rs. In lacs)

. Particulars Nine Months

Ended on

31/12/2005

Quarter Ended

on

31/3/06

Quarter

Ended on

31/03/05

YearEnded

on31/03/2006

(Audited)

YearEnded

on31/03/2005

(Audited)

[1] [2] [3] [4] [5]1 Net Sales / Income from Operations 53538.29 31804.15 24186.04 85342.44 65871.56

2 Other Income 1381.33 1597.62 12.02 2978.95 1053.02

3 Total Income 54919.62 33401.77 24198.06 88321.39 66924.58

4 Total Expenditure 43908.65 27004.85 19865.65 70913.50 54553.23

(a) (Increase)/ Decrease in Stock in Trade

(185.54) 1032.58 (2112.24) 847.04 (1873.25)

(b) Consumption of Raw Material 30975.93 20077.72 17310.58 51053.65 41486.77

(c) Consumption of Stores & Spare

parts

3908.81 1622.08 2096.06 5530.89 4859.02

Page 131: TEXTILE INDUSTRY INTERNSHIP REPORT

(d) Staff Cost 2427.51 1314.94 832.30 3742.45 3055.00

(e) Other Expenditure 6781.94 2957.53 1738.94 9739.47 7025.695 Interest 2082.51 826.75 602.06 2909.26 2485.26

6 Depreciation 2233.12 835.37 668.29 3068.49 2825.03

7 Profit (+) / Loss (-) Before Tax 6695.34 4734.81 3062.07 11430.15 7061.06

8 Provision for Taxation

- Current Tax (Incl.FBT) 1886.97 (152.51) 304.13 1734.46 758.50

- Deferred Tax (309.91) 801.29 633.55 491.38 1290.51

9 Profit After Tax & Before Prior Period Items

5118.28 4086.03 2124.39 9204.31 5012.05

Excess/(Short) Provision of Taxation

earlier

Year(Net) (2.66) 378.63 (2.66) 378.6310 Profit After Tax 5118.28 4083.37 2503.02 9201.65 5390.68

11 Paid - up Equity Share Capital (face

value of Rs. 2 each) See Note :3

1847.67 1973.17 1847.67 1973.17 1847.67

12 Reserve and Surplus (Excluding Revaluation Reserves )

(See Note - 7)

42973.39 32371.44

13 Earning per share of Rs.2/- each (Rs.)

-Basic EPS 5.54 4.40 3.32 9.95 7.14

-Diluted EPS 5.04 3.96 3.20 8.93 7.10

14 Aggregate of Non-Promoter

Shareholding

-   Number of Shares 61284125 66084125 61284125 66084125 61284125

-   Percentage of Shareholding 66.34% 66.98% 66.34% 66.98% 66.34%

Notes:1

The above Financial Results were reviewed by the Audit Committee and were thereafter taken on record by the Board of Directors at its

meeting held on April 25, 2006.2

The Board of Directors have recommended dividend @ 44 % i.e. Rs.0.88 per equity share for the year 2005-06,subject to approval of

shareholders.3

Equity Share of Rs.10/- has been sub-divided in to Five Eqity Shares of Rs.2/- each, hence all related references for the previous year periods

have been restated for the sake of comparability.4

62,75,000 equity shares were allotted during the period 23rd March, 2006 to 31st March, 2006 consequent to exercise of 12,55,000 warrants

out of 31,85,000 warrants issued in 2004-05 and outstanding on 31/03/05 at Rs.56.02 per share. Further, the holders of 19,30,000 remaining

warrants in respect of the said issue are entitled to apply for five equity shares per warrant at any time up to 31st July, 2006

5During the year the Company issued USD 50 million Zero Coupon   Foreign Currency Convertible Bonds due 2010. The bonds are

convertible into 1,19,56,575 shares at any time upto 14th September,  2010. Subsequent to 31st March,  2006, FCCBs aggregating to US$ 8.5

million (Rs.3731.50 lacs) have been converted into 20,32,616 equity shares upto 24th April, 2006.6

The Company has received Rs.15021.76 lacs from proceeds of preferential allotment of equity shares/ warrants up to 31.03.2006. The

proceeds have been utilised for capital expenditure of Rs.9655.32 lacs including ongoing capital expenditure of Rs.3070.47 lacs and for

repayments of loans of Rs.5366.44 lacs7

Reserve is reduced by Rs.16500 lacs on account of adjustment of Brand Value.8

There were no Investors' complaints pending as on 01-01-06. Complaints received and disposed off during the quarter were 16 each and no

Investors' complaints were lying unresolved at the end of the quarter.

9 Figures for the previous year/quarter have been re-grouped / rearranged wherever necessary.

Page 132: TEXTILE INDUSTRY INTERNSHIP REPORT

FOR SINTEX INDUSTRIES LIMITED

Date : 25/04/2006 (Dinesh B. Patel)

Place : Ahmedabad Chairman

Rs. in lacs

BALANCE SHEET AS AT 31ST MARCH

2005 2004

SOURCES OF FUNDS: Schedules Rupees Rupees Rupees

Shareholders' Funds:

Share Capital 1 1847.67 1456.17

Reserves & Surplus 2 48871.44 33742.01

50719.11 35198.18

Share Warrants-Fully Convertible 1392.12  -

(See Note 6- Schedule 20)

Loan Funds :

Page 133: TEXTILE INDUSTRY INTERNSHIP REPORT

Secured Loans 3 33822.26 29822.23

Unsecured Loans 4 18.66 35.49

33840.92 29857.72

Deferred Tax Liability (Net) 5703.56 4413.05

(See Note 13-Schedule 20 )

TOTAL 91655.71 69468.95

APPLICATION OF FUNDS

Fixed  Assets:

Gross Block 5 66942.44 62951.62

Less: Depreciation 17598.33 14926.48

Net Block 49344.11 48025.14

Capital Work in Progress 2962.47 1833.20

52306.58 49858.34

Investments: 6 16746.75 5686.22

Current Assets, Loans & Advances:

Inventories 7 10684.68 7545.67

Sundry Debtors 8 14811.39 11572.65

Cash & Bank Balances 9 7831.52 1922.80

Loans & Advances 10 4445.16 3598.76

37772.75 24639.88

Less: Current Liabilites & Provisions 11 15780.65 11035.38

Net  Current Assets 21992.10 13604.50

Miscellaneous Expenditure

(To the extent not written off or adjusted) 12 610.28 319.89

TOTAL 91655.71 69468.95

Significant Accounting Policies 19

Notes forming part of Accounts and 

Contingent LIabilites 20

Segment Wise Revenue, Results and Capital Employed For Financial Year ended 31st March 2006.

(Rs. In lacs)

Sr. Particulars Nine Months Quarter Quarter Year Ended onYear

Ended on

No. Ended on Ended on Ended on 31/03/2006 31/03/2005

31/12/2005 31/03/06 31/03/05 (Audited) (Audited)

1 Segment Revenue

Page 134: TEXTILE INDUSTRY INTERNSHIP REPORT

a) Textile 17625.78 7307.00 6507.87 24932.78 19096.29

b) Plastics 36306.94 24479.23 17566.51 60786.17 47497.64

c) Un allocated 221.63 115.43 54.02 337.06 141.51

Total 54154.35 31901.66 24128.40 86056.01 66735.44

Less: Inter Segment

Revenue0.00 0.00 0.00 0.00 0.00

Total Revenue 54154.35 31901.66 24128.40 86056.01 66735.44

2 Segment Result

Profit/Loss (before tax and

interest from each

segment)

a) Textile 2549.06 1359.35 1315.39 3908.41 3090.22

b) Plastics 5268.88 2598.33 2227.32 7867.21 6148.39

c) Un allocated 959.91 1603.88 121.42 2563.79 307.71

Total 8777.85 5561.56 3664.13 14339.41 9546.32

Less : Interest 2082.51 826.75 602.06 2909.26 2485.26

Total Profit before Tax: 6695.34 4734.81 3062.07 11430.15 7061.06

3 Capital Employed

(Segment Assets - Segment

Liabilities) :

a) Textile 17482.96 24086.40 14875.16 24086.40 14875.16

b) Plastics 20775.86 12175.12 5692.87 12175.12 5692.87

c) Others 23360.46 14969.03 37246.76 14969.03 37246.76

Total 61619.28 51230.55 57814.79 51230.55 57814.79

Notes:1

The Company is organized into two main business segments, namely:

Textile - Fabric and Yarn

Plastic - Water Tanks, Doors, Windows, Prefab, Sections, etc.

Segments have been identified and reported taking into account the nature of products and services, the differing risks and returns, the

organization structure, and the internal financial reporting systems.

2 Segment revenue in each of the above business segments primarily includes sales service charges, rent, profit on sale of Fixed Assets

(net), Miscellaneous sales and Export Incentive.

3 Figures for the previous year/quarter have been re-grouped / rearranged wherever necessary.

Disclaimer clause: The information furnished above is certified by Sintex Industries Limited to be

true, fair and accurate (except in respect of errors in or omissions from documents filed electronically

that result solely from electronic transmission errors beyond our control and in respect of which we

take corrective action as soon as it is reasonably practicable after becoming aware of the error or the

omission). SEBI, the Stock Exchanges or the NIC do not take any responsibility for the accuracy,

validity, consistency and integrity of the data entered and updated by it.

Name of the compliance officer :

Page 135: TEXTILE INDUSTRY INTERNSHIP REPORT

Mr. L.M. Rathod

C.F.O & Company Secretary

Sintex Industries Limited

Kalol (N.G.) - 382 721

Rs. in lacs

PROFIT & LOSS ACCOUNT FOR THE YEAR ENDED 31 ST MARCH

2005 2004

INCOME: Schedules Rupees Rupees Rupees

Gross Sales  71516.37 58077.54

Less: Excise duty & Sales Tax recovered on Sales 5644.81 5108.39

Net Sales 65871.56 52969.15

Other Income 13 1053.02 875.71

Increase in stock of  Finished and Process stock 14 1873.25 882.23

68797.83 54727.09

EXPENDITURE:

Raw Materials consumed 15 31814.72 25437.04

Employees' Emoluments 16 3055.00 2646.22

Manufacturing & other expenses 17 21556.76 16834.96

Interest and finance charges 18 2485.26 2623.68

Depreciation 2825.03 2263.45

  61736.77 49805.35

Profit before Taxes 7061.06 4921.74

 Provision for Taxation

           Current Tax 758.50 545.00

           Deferred Tax 1290.51 995.10

2049.01 1540.10

PROFIT AFTER TAX & BEFORE PRIOR PERIOD ITEMS 5012.05 3381.64

Excess/(Short) provision of taxation of earlier years (Net) 378.63 (15.51)

PROFIT AFTER TAX 5390.68 3366.13

Balance brought forward from previous year 7533.10 7302.53

Profit available for Appropriations 12923.78 10668.66

APPROPRIATIONS:

Interim Dividend - Preference  Shares 0.00 126.54

Proposed Dividend - Equity Shares 739.07 436.85

Tax on Dividend 96.60 72.17

General Reserve 1000.00 1000.00

Page 136: TEXTILE INDUSTRY INTERNSHIP REPORT

Capital Redemption Reserve 0.00 1500.00

Balance carried to Balance Sheet 11088.11 7533.10

TOTAL 12923.78 10668.66

Earnings per share ( Refer Note  15 of Schedule 20 )

Basic 35.71 22.14

Diluted                                                         35.49 22.14

Significant Accounting Policies 19

Notes forming part of Accounts and

Contingent Liabilities 20  

3. CONCLUSION

Plant Capacities

- Overall capacity22 million meters per annum

- Can deliver finished widths up to 63 inch

- Plant specifically designed for varied product mix ( 115

GSM to 450 GSM)

- Can handle 100% Cotton as blended fabric

- Equipped to provide specialized finishes

- Testing and QC Lab equipped to satisfy most discerning

customers

- On line quality checking system

Page 137: TEXTILE INDUSTRY INTERNSHIP REPORT

TECHNOLOGY

A tradition of continuous modernization and up-gradation of technology has enabled

BVM in becoming globally competitive. It is fully geared to offer international

quality textile products, manufactured to the latest trends and styles.

Machineries and Capabilities:

- Spinning Division : 30000 spindles

- Trumac Blow Room (2000)DK780 Cards (2000)

- RSB1 Draw Frame from Rieter (1999)

- LK 250 Comber (2002)

- LF 1400 Speed Frames Textool Ring Frame (2000)

- TFO Vijay laxmi (2000)

Winding Section

Murata & Schlafhorst, Automatic 238 and 338 models. All the machines are equipped

with Automatic Splicing, Electronic Yarn Clearers and other automatic devices.

LoomShed

38 Air-jet and 123 Rapier looms from PICANOL. (Year of Installation - 1999) The

existing Rapier looms are capable of producing checks of 4 to 8 colors in weft and are

equipped with dobbies which can produce designs up to 22 shafts. 72 more Omni Air

Jet looms with the capacity of producing fault-free cloth.

Processing MachineriesSelected latest state of the art, eco friendly, open-width continuous process system

ensuring consistent whiteness / shade across and along the fabric, higher productivity

and shorter lead times. It consists of pretreatment machineries like the Osthoff

Singeing with eco friendly dust free Vibra plus cleaning system. Goller Desizing,

washing, bleaching and mercerizing machines. High level of automation and on-line -

on-site process control gives high degree of consistency and reproductivity.

Page 138: TEXTILE INDUSTRY INTERNSHIP REPORT

Criteria of selecting technology in BVM are:

- Maximum possible accuracy first time, on time and every time.

- Eco- friendly technology

- Economizing on water, energy and salt utilization.

Pretreatment Machineries

- OSTHOFF singing - Goller desize

- EFFECTA Washer- Goller

- Continuous Bleaching - Goller

- OPTIMA Chainless Mercerize-Goller

Fabric Dyeing

Fully computerized German machineries from the Kusters, Bruckner and Goller are

present. All continuous machines with automatic colour kitchens and all level micro

processor controls are installed for better productivity and quality in shorter lead time.

Dyeing machineries (year of installation)

- Cold-pad batch- KUESTERS ( 2001 )

- Pad-dry - BRUECKNER ( 2001 )

- Pad-steam-Goller ( 2001 )

- FONG's / STAFFI Yarn Dyeing Machines ( 1998 )

- RF- dryer ( 1998 )

Finishing machineries

- Shrinking range - MONFORTS

- Stenter- BRUCKNER

An excellent management system provides the backbone to the development process

of the instition.