textile internship at vardhman

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    Observations to be made on

    o Yarn manufacturing and Winding section

    o Weaving section

    o Dyeing section

    o Testing and Quality control sections

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    8 Pillars of TPM

    1. Focused Improvement2. Autonomous maintenance

    3. Planned maintenance

    4. Education and Training

    5. Initial flow control

    6. Quality maintenance

    7. Office maintenance

    8. Safety health and environment

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    REITER Machines

    TRUTZSHLER DK 803

    REITER Machin

    RSB 851

    REITER F35 RovingFrame

    Schlafhorst/saurer

    REITER Ring Frame F16

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    The Blowroom is the 1st step of yarn production in the spinning mill.

    INPUT : Fabric in the form of Bales

    OUTPUT : Sliver

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    a) Opening

    b) Cleaning

    c) Dust Removal

    d) Blending

    e) Even Feeding of material to the card

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    Type Appearance Description

    Rollers Small Diameter, Widely

    used.

    e.g.: in STEP CLEANERS

    Drums Larger Diameter, little

    used

    e.g.: in MONO-

    CYLINDER CLEANERS

    Quilted Shaft Shaft with many beater

    rods, hardly used

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    Cotton contains upto 18% trash,o in most cases ranging from 1% to 7%

    Since this Cost is a considerable cost factor, it has to be kept as low as

    possible, which requires an assignment

    Cleaning Degree = extracted trash*100

    --------------------------------------

    trash content in fed cotton

    Cleaning Efficiency = extracted trash*100

    --------------------------------------

    Total Extracted Waste

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    Unimixo Model LB 7/3

    o By Lakshmi LMW

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    The m/c is made up of 3 parts

    o Storage section,

    o Intermediate section, and

    o Delivery section

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    MACHINE: REITER UniClean

    1. Special Design VIBRATING PLATE

    4. Rollers for additional Dusting

    5. Servomotor-controlled feeding plates

    6. Groove

    7. Operating Panel

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    Ensuring that debris is removed while aligning the fibers to make

    them easier to spin.

    Without carding, cotton thread would be coarse and extremely

    fragile.

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    Parallelize the fibres in card sliver along the sliver axis.

    To improve the regularity in linear density of card sliver by doubling.

    Improve sliver quality.

    To achieve the correct amount of blending.

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    17-18% of short fibres are removed

    Removal of neps

    Parallelization of fibres

    Kitty Level is Reduced

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    The function of the speed frame is to attenuate the sliver and to form

    a suitable supply package for the ring frame.

    Twist + Strength + Winding

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    To draft the roving until the required fineness is achieved

    To impart strength to the fibre, by inserting twist

    To wind up the twisted strand (yarn) in a form suitable for storage

    Transportation and further processing.

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    Marketing

    Team

    VardhmanCustomer

    CPDC

    Located at Mahavir Textiles

    Central Design

    Cell (CDC)

    Bit Loom

    R&D(Small

    Length Sampling

    Pilot PlantTechnical

    Department

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    Several sections are wound in sequence and parallel to each other on a

    dresser or on a drum

    the warping sections are as many as necessary to obtain, with the

    available creel capacity, the total number of threads composing the warp

    The warping speed is about 800 m/min, while the beaming speed is about300 m/min

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    Before carrying out warping, following calculations are necessary:

    o If the calculation does not give an exact number, the last section

    will be produced with a number of threads lower than the other

    sections,

    o Or the number of threads composing each section will be

    reduced.

    so as to get all sections with one and the same number of thread,

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    A complementary operation which is carried out

    on warps formed by spun yarns with insufficient

    tenacity

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    Drawing-in:

    o consists of

    threading the

    warp yarns

    through the

    drop wires,

    the healdsand the reed

    Requirement of Style Change

    Drawing - in

    Transport and Loading of Beams

    and harness onto the Weaving

    m/c

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    1. Back rest roller

    (warp threads are

    wound)

    2. Support special

    drop wires

    3. Healds

    5. Dents of the reed

    8. Slay

    6. Motor driving the

    take down roller11. Cloth Beam

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    the most flexible machines on the market

    Their application range covers a wide varietyof fabric styles

    Their present weaving speed of about 600-700strokes/min

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    weaving machines with the highest weftinsertion performance and are considered as themost productive

    manufacturing of light to medium weight fabrics,

    preferably made of cotton and certain man-madefibres

    sheets, shirting fabrics, linings, taffetas and satinsin staple yarns of man-made fibres

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    Started in December 2000

    Production - 30 lack Meters/ Month

    One of the largest fabric processing unit inAsia.

    Has area of 12 acres

    Self- sufficient power supply

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    Processes:

    Preparatory

    Dyeing Finishing (both piece dyed and yarn dyed fabrics)

    Inspection and Packing

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    GREIGE SECTION

    PREPARATORY SECTION

    PERBLE RANGE

    NEW PAD STEAMER MERCIRIZER

    DYEING SECTION

    TANK COLOUR PREPARATION AREA

    PAD DRY

    HT STEAMER

    THERMOFIX

    PAD STEAMER

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    FINISHING SECTION STENTER

    SUEDING MACHINE

    SANFORIZER

    AIRO MACHINE

    CURING MACHINE

    TECHNICAL SECTION

    PHYSICAL LAB

    CHEMICAL LAB

    PILOT PLANTINSPECTION AND FOLDING SECTION

    PRODUCTION PLANNING & CONTROL

    EFFLUENT TREATMENT PLANT

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    SINGEING

    WASHING

    DESIZING &

    SCOURING

    WASHING

    NaClO2

    BLEACH

    H2O

    2BLEACH

    WASHING

    DRYING ON

    CYLINDERS

    PLAITOR

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    Section A: Singeing, Combined desizing and scouring

    Section B: Chlorite Bleaching

    Section C: Peroxide bleaching

    Section D: Vertical Drying Range.

    In new Perble Machine, Only Peroxide Bleaching (3

    sections)

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    PARTS OF MERCERIZER RANGE

    The mercerization machine has five sections:

    Padding Section

    Tenter chain Tenter pit

    Washing range

    Drawing unit

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    To increase the dye uptake.

    To increase the tensile strength of the fabric.

    To increase lustre of the fabric.

    Better coverage of immature cotton fibers. To remove crease marks.

    To remove naps from the fabric.

    To increase the reactivity and absorbency of the fabric.

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    The Caustic Soda used in the processes is heated and

    concentrated for reuse

    The CRP has an efficiency of 90-95%

    The principle of CRP unit is to evaporate the water from

    the weak lye.

    It helps save money and is less harmful to environment.

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    Most important feature of dyeing used is the continuous

    dyeing range (CDR)

    Consists of Padder Box with a capacity of 50-60 lts

    pad-dyeing method ensures a full penetration of dye

    inside the fabric at a relatively low consumption of dyes,

    chemical, steam and water

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    The cotton and P/C blend fabrics are dyed wit