textile Traning Report

UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE

Kanpur

A REPORT ONSUMMER VACATION PRACTICAL MILL

TRAININGAT

PRATIBHA SYNTEX LIMITED

(20.07.20011 TO 02.08.20011)

Submitted To: Submitted By:

Mr. MAHENDRA UTTAM DEVA NAND (0804461011)

(UPTTI KANPUR) SAURABH PATHAK (2904461002)

RAVINDRA KUMAR (0804461026)

SARVENDRA SINGH (0804461032)

ABHISHEK SINGH (0804461001)

AMIT Kr. SHARMA (0804461004)

SHAILENDRA KUMAR (0804461034)

ASHOK Kr. YADAV (0804461010)

BRANCH – TEXTILE TECHNOLOGY

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Acknowledgement

Success in any endeavor calls for co-operation and guidance from all, especially dear-ones, seniors and environment. This was amply brought to me while undergoing industrial training and project work.

This project Report gives me an opportunity to thank all those who have helped me to make this training a learning experience.

I am extremely grateful to Mr. P. K. Singh, Mr. SHAKEEL and Mr. SANJAY JAIN for providing me an opportunity to do summer training in this organization. I owe my indebt ness to

Mr. PRATEEK PANDEY (Spinning)

Mr. YAMUNA PRASAD YADAV (Knitting)

Mr. SAURABH (Garment &Plant-2)

Mr. KUL DEEP (Dyeing)

Mr. HEMANT KUMAR (Cutting)

Who helped me for completion training and project successfully. I am grateful to them for all their support, which helped me to know the practical aspects of the various services.

I express my heartiest thanks to:

Mr. PRAMOOD KUMAR (Director of UPTTI Kanpur)

Mr. V.K. MELHOTRA (Training Officer)

Mr. MAHENDRA UTTAM

Mr. A. K. S. GANGWAR

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Preface

Training in business organization infuses among students a sense of critical analysis of the real managerial situation to which they are exposed. My institutions has given me opportunity through training to be aware of and cope with fast rate changing technology, management policies, quality and productivity etc. This is a bold attempt to bridge the gap between the ‘world of work’ and ‘studies imparted in the institutions’

This training enables me to apply theoretical knowledge to practical situations, appreciate the sense of responsibility, importance of discipline, punctuality and the psychology of worker and their habits which make me more professional and near to the world of technology and team work. Industrial training brings out better citizens, better technocrats and better diplomats out of me.

I was lucky to get an opportunity to work in one of the top limited sector industries, i.e. PRATIBHA SYNTEX LTD. The purpose of this training was to gain knowledge about the industry, how it works and also to see the environment of the industry. I joined the training not only for these purpose, but also to learn something about operation of the machines and construction of spinning machines.

I have worked in the concern for 6 weeks and prepared my Industrial training report. Under the guidance of training office, I analyzed various aspects of production. This has helped me in boosting up my confidence and determination, which will help me to face any situation in the years to come.

This report is written account of what I learnt and experienced during this period. I wish, those going through it will not only find it readable but will also find useful information for future reference.

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CONTENTS

Sr. No CHAPTER Page No.

1. Company profile 5

2. Sequence of spinning department in production 10

3. Departmental information 11

4. Process/production particulars 18

5. Humidification systems 29

6. Sequence of dyeing department in production 32 (A) continuous dyeing (B) soft flow dyeing

7. Sequence of Cutting department in production 51

8. Sequence of Garment department in production 53

9. Sequence of Knitting department in production 67

10. Time office & staff 76

.

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CHAPTER 1

COMPANY PROFILE OF

PRATIBHA SYNTEX LIMITED

PRATIBHA SYNEX Ltd - AN OVERVIEWINTRODUCTIONMill Address : Pratibha Syntex Ltd. Plot No.-4, IGC KHEDA -454774, Pithampur, Distt. DHAR (M.P) INDIA

Established : 1997

C.E.O : S. K. CHAUDHARY

Plant Capacity : Ring Frame Spindle Unit 1 - 27216 Unit 2 - 18144 Unit 3- 2080 (Air-Jet) Unit 4- 3256(Open - End) Unit 5-12336 (Milange)

Products : Pratibha Syntex Pvt. Ltd. is India's first vertically integrated Textile Manufacturing company, going from raw material to finished products. It houses within itself, fibre-production, spinning, knitting, as well as apparel manufacturing facilities. See our wide range of offerings in men, women and kids wear.

Yarn

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Pratibha has a modern, well-equipped yarn manufacturing unit at Pithampur with an installed production capacity of 48,048 spindles operating. round the clock. This results in producing 12,875 tons per annum, fulfilling the requirements of customers across the globe.

Fabric

Pratibha has a state-of-the-art fabric manufacturing facility characterized by hi-tech machineries to produce variety of fabrics commensurate with global standards. It has a knitting capacity of 4725 tons per annum and a dyeing capacity of 4025 tons per annum.

Garments

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Pratibha manufactures high quality underwear, sportswear, leisurewear, high street fashionwear and loungewear for women, men, kids and infants. The capacity in the casualwear and the undergarments is 2.5 million pcs per annum and 8 million pcs per annum respectively.

Raw material suppliers : Punjab, Haryana, M.P.

Exporting countries : We are the dominant exporters of various types of yarns to USA, UK, Egypt, Austria, France, Switzerland, Bangladesh, Mauritius, Turkey, Italy, Poland, Malaysia, Israel, China, Canada, South Africa, Columbia, Brazil, Hungary, etc.

Electric supply : By the electric power station and own fire generators. To full fill its electric requirement.

Source of water : It has own arrangement by pumping set

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Quality Policy

Upgradation of Identification of Quality customer’s needs

QUALITY POLICY

Continuous Confirm the desired Improvement standards

Customer Satisfaction

This is achieved by:

Identifying customer’s requirements and converting them into products.

Pursuing the process of continuous improvement by the employees of the

organization.

Ensuring that quality standards are maintained and upgraded to reflect the changing

customer’s requirements

1.2. FUNCTIONS OF DIFFERENT DEPARTMENTS The whole unit has been divided into various departments such as production, human resources, R&D and QA etc. The brief functions of each dept. are as follows:

MARKETING:

1. Brand building2. To formulate strategies , plan & policies.3. Promotion of the business in overseas market.4. Ensures achievement of sales/financial objectives.

MIS, COSTNG & BUDGETING

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1. To prepare daily reports.(including profitability reports)2. To prepare product costing & related information.3. To conduct physical verification of stock as & when required.4. To monitor the unit performance against set targets.5. To ensure correct & timely information flow across the organization including areas

of concern.6. To facilitate monthly planning processes/BSC/weekly planning.7. To analyze performance parameters and making trends to analyze it etc.

MAINTENANCE:

1. To ensure uninterrupted availability of machines.2. To ensure & execute best maintenance work practice, system and SOP of textile and

their compliance of the unit.3. To improve the technical skills the subordinate to enhance decision making.4. To maintain best health of machines to produce quality yarn.5. To execute orders for the various spare parts.

ELECTRICAL:

1. To implement the preventive maintenance schedules of plant machinery2. To provide electrical maintenance support for all production equipments3. To implement energy saving initiatives and process improvement activities.

R & D and Q.A.:

1. To plan and manage R&D activities in the unit.2. To plan and manage raw material for the whole year.3. To conceptualize, Visualize, Plan and develop new products.4. To plan and execute process improvement activities.5. To operate and maintain all testing activities.6. To coordinate with production and marketing functions7. To produce customer centric products.

PRODUCTION:

1. Production Planning.2. Ensure timely availability of resources in coordination with commercial department.3. Continuously monitor and evaluate performance of production machinery to achieve

desired quality standard.

HUMAN RESOURCE:

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1. Manpower planning and recruitment.2. Ensure adherence to approved policies ,procedures(internal & external)3. Develop and enhance the potential of all members.4. Maintaining harmonious industrial relations.5. Controlling personnel costs.6. To implement HR policies in true spirits.

CHAPTER -2

SEQUENCE OF SPINNING DEPARTMENTS IN PRODUCTION

FLOW CHART FORSUPER CARDED YARN

MIXING ↓ BLOWROOM ↓ CARDING ↓ BREAKER DRAWFRAME ↓ FINISHER DRAWFRAME ↓ SIMPLEX ↓ RING FRAME ↓ AUTOCONER ↓ YARN CONDITIONING ↓ PACKING

FLOW CHART

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SUPER COMBED YARN

MIXING ↓ BLOWROOM ↓ CARDING ____________________________________ ↓ | BREAKER DRAWFRAME SLIVER LAP ↓ ↓ SUPER LAP RIBBON LAP ↓ | COMBER_____________________________________| ↓ FINISHER DRAWFRAME ↓ SIMPLEX ↓ RING FRAME ↓ AUTOCONER ↓ YARN CONDITIONING ↓ PACKING

CHAPTER -3DEPARTMENTAL INFORMATION

MACHINES IN UNIT-1

S.NO MACHINES NAME MAKE MODEL NO. OF MACHINES

BLOWROOM LINE 1 & 2AUTOMATIC BALE OPENER

CROSROL 1

SIX CHAMBER BLENDER CROSROL 2THREE ROLLER CLEANER CROSROL 2HEAVY PARTICLES SEPERATER CROSROL 2FINE CLEANER CROSROL 2CONTAMINATION SORTINGMACHINE

LOPTEX SORTER 1

VETAL SCAN POLYSENSOR 1DEDUSTER CROSROL 2

BLOWROOM LINE-3GBR TRUTZSCHLER 1CL-P CLEANER TRUTZSCHLER 1CVT-3 TRUTZSCHLER 1SINGLE CARDING M/C CROSROL MK5D/MK5C 4

TRUTZSCHLER 1TANDEM CARDING M/C CROSROL 16

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BREAKER D/F ZINSHER 720 3TRUTZSCHLER 1

SLIVER LAP M/C LAXMI LE 2/4A 2RIBBON LAP M/C LAXMI LE 4/1A 2SUPER LAP M/C TOYOTA TS100 2COMBER TOYOTA VC5 18FINISHER D/F TOYOTA DYH 6000 4

LAXMI LRSB 851 2SPEED FRAME TEXMACO

HOWA8

RING FRAME TOYOTA RXZ 220 25OERLICON SCHLAFHORST

ZINSHER 351 1

KTTM RXI 240 1AUTOCONER MURATEC MACH

CONER 7V6

SPG SAVIO ITEMA

POLAR 3

MURATEC 2YC 1YARN CONDITIONING PLANT SIEZER 1

FLOW CHART(UNIT-2)

BLOW ROOM ↓ CARDING ↓_________________SLIVER LAP M/C BREAKER DRAW FRAME ↓ ↓ RIBBON LAP M/C FINISHER DRAW FRAME ↓ ↓__________________COMBER M/C SPEED FRAME ↓ RING FRAME ↓ AUTOCONER ↓ YARN CONDITIONING PLANT ↓ PACKING

MACHINES IN UNIT-2

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(BLOW ROOM)

NAME OF MACHINE MAKE MODEL NO OF M/CAUTOMATIC BALE OPENER CROSROL 1SIX CHAMBER BLENDER CROSROL 1THREE ROLLER CLEANER CROSROL 1CONTAMINATION SHORTER LOPTEX 1DIDUSTER CROSROL 1FINE OPENER & CLEANER CROSROL 1PIND OPENER & CLEANER CROSROL 1HEAVY PARTICLE SEPERATOR CROSROL 1SINGLE CARDINGM/C CROSROL 12

TRUTZSCHLER 3BREAKER D/F ZINSHER 720 1SLIVER LAP MACHINE LAXMI LE 2/4A 3RIBBON LAPMACHINE LAXMI LE 4/19 3COMBER LAXMI LK 250 20FINISHERDRAW FRAME TOYOTA DX 7A 3SPEED FRAME LAKXMI LF 1400A 4

ELECTRO JET JET 5A 1RING FRAME KTTM RX 240 18AUTOCONER SCHLAFHORST R-338 1

MURATEC No.7V 6YARN CONDITIONING PLANT SIEZER 1

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FLOW CHART (UNIT-3)(AIR JET SPINNING) (MVS)

BLOW ROOM↓

CARDING↓

BREAKER DRAW FRAME-1↓

FINISHER DRAW FRAME-2 ______________↓________________ ↓ ↓

↓_______________________________________↓ ↓

YARN CONDITIONING PLANT↓

PACKING

UNIT-3(AIRJET SPINNING)MACHINE NAME MAKE MODEL NO. OF MACHINEAUTOMATIC BALE OPENER(POLYSTER)

JENN FENG ZF5/3 1

AUTOMATIC BALE OPENER(COTTON)

LAXMI LMW 1

OPENER(MIXING) TRUTZSCHLER 1GBC BLENDER TRUTZSCHLER 1GBR TRUTZSCHLER 1M.V.O LAXMI 1UNIMAX LAXMI 1UNIMAX LAXMI LA7/4R 1FAXI CLEAN LAXMI LB 5/6 1VERY CLEAN LAXMI LB 9/2 1

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MVS (POLYSTER & POLYSTER BLENDS)

MJS COTTON

OPENER TRUTZSCHLER 1VETAL SCAN POLYSENSOR 1CARDING(COTTON) LAXMI LC300A-V3 5CARDING(MIXING) LAXMI LC300A-V3 4CARDING(POLYSTER) LAXMI LC300A-V3 10BREAKERDRAW FRAME

LAXMI LDO/6 12

TOYOTA 1FINISHERDRAW FRAME

TOYOTA 7

RSB LAXMI 1MJS MURATEC No.802HR 14MVS MURATEC No.861 2

MURATEC No.851 14YARNCONDITIONING

SIEGER 1

UNIT-4FLOW CHART

(OPEN END)

BLOW ROOM↓

CARDING↓

BREAKER DRAW FRAME↓

FINISHER DRAW FRAME↓

OPEN END SPINNING↓


PACKING

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MACHINE IN OPEN END UNIT (UNIT-4)MACHINE NAME MAKE MODAL NO. OF

MACHINEAUTOMATIC BALE OPENER TRUTZSCHLER 1SIX CHAMBER BLENDER TRUTZSCHLER CL-P 2THREE ROLLER CLEANER TRUTZSCHLER MX-1 2HEAVY PARTICLE SEPERATOR TRUTZSCHLER SP-MF 1PIND OPENER AND CLEANER TRUTZSCHLER CL-C3 2FINE OPENER AND CLEANER TRUTZSCHLER SP-F 2SINGLE CARD TRUTZSCHLER TC-03 14BREAKER DRAW FRAME TOYOTA DX-8 3

TRUTZSCHLER TD-03 2FINISHER DRAW FRAME TRUTZSCHLER TD-03 5DOUBLER SCHLAFHORST PPW-A 2AUTOCORO SCHLAFHORST 10TFO VEEJAY LAKSHMI 11YARN CONDITIONING PLANT SIEMENS 1

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UNIT-5FLOW CHART

(MELANGE)

BLOW ROOM↓

CARDING↓

BREAKER DRAW FRAME↓

FINISHER DRAW FRAME↓

SPEED FRAME↓

RING FRAME↓

AUTOCONER↓


PACKING

MACHINE IN MELANGE SPG UNIT MACHINE NAME MAKE MODEL NO.OF MACHINEGBC BLENDER TRUTZSCHLER 1G.B.R TRUTZSCHLER 1M.B.O LAXMI LB-3/6R 3UNIMIXER LAXMI LB 7/4 2FLACSI CLEAN LAXMI LB 5/6 1SINGLE CARDING M/C LAXMI LA 7/5 9

TRUTZSCHLER D800 4CUTTER 1BREAKER D/F LAXMI LD 0/6 4FINISHER D/F LAXMI LRSB 851 4

LAXMI LFS 1600V 1COMBER LAXMI LK 250 3SLIVER LAP LAXMI LE 2/4A 1RIBBON LAP LAXMI LE 4/1A 1SPEED FRAME LAXMI LFS 1600V 3

LAXMI 2F 1400-A 1RING FRAME LAXMI LR 63/A 10

KTTM 2TOYOTA 3

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AUTOCONER SAVIO VEEJAY 1MURATEC 7V 4

CHAPTER- 4

PROCESS / PRODUCTION PARTICULARS

5.1.RAW MATERIAL PROCUREMENT AND BALE MANAGEMENT

INTRODUCTION: RAW MATERIALS ARE DIRECT INPUT WITH PRE- REQUIREMENT TO PRODUCE OUTPUT OF DESIRED QUALITY AND CHARACTERISTICS. RAW MATERIAL DEPARTMENT HAS TO ENDURE EXTREME PRESSURE GENERATED IN VIEW OF THE PRESENT INTERNATIONAL SCENARIO WHERE “CONSISTENT QUALITY’’ IS THE SUCCESS SLOGAN.

5.1.1. ROLE OF RAW MATERIAL DEPT. SUMMARISED AS:

IT ENSURES REGULAR FLOW OF MATERIALS TO THE PRODUCTION UNIT. IT HAS TO MAINTAIN THE STOCK POSITION OF VARIOUS RAW MATERIALS AND SEND IT TO CORPORATE RAW MATERIAL DEPARTMENT FOR DAY TO DAY PLANNING AND DECISION MAKING RAW MATERIALS

IT ALSO ENSURE PROPER STORAGE OF RAW MATERIAL

RAW MATERIAL INFORMATIONCotton (shanker-6, mech-1.organic) and bamboo fibres are mainly used in unit-1and 2. In open end spinning cotton (mech-1) and 2 is used. In MVS unit, apart from cotton, Polyester and viscose are also used. MAIN DATA Weight of one bale -158 to 168 kgTypes of cotton used -shanker-6, mech-1, H-4, organic (bio)Staple length (ring frame) -28.5 to 30.5 mmStaple length (open end) -25 to 27.5 mm

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Size of bale -3.5’*2.2’*4.5’Consumption (unit-1) -350bale/dayConsumption (all units) -500 bale/dayMIC -3.5 to 4.1Strength -22g/texAvg cost of fibres -23000/candyStaple length -38 mmMixing of various fibres is done in the most appropriate manner so as have the best yarn properties. The mixing is done according to a matrix.

5.2. MIXING

OBECTS:

1. TO HAVE A UNIFORM DISTRIBUTION OF DIFFERENT TYPES OF COTTON

2. TO REDUCE THE COST OF RAW MATERIAL USED3. TO APPLY SPIN FINISH & TINT ( IF REQUIRED ) ON MATERIAL TO

IMPROVE PROCESS PERFORMANCE & TO SEGREGATE THE MATERIAL FROM OTHER KINDS.

4. Removing waste and contamination by sorting.

IN ORDER TO HAVE BEST RESULT, FOLLOWING POINTS SHOULD BE UNDER CONSIDERATION

1. FIBRES MUST HAVE SAME ORIGIN 2. PRICE, COLOUR & GRADE OF COTTON IS ALSO KEPT IN MIND WHILE LAYING MIXING 3. QUALITY OF MIXING TO BE LAID 4. SOFT WASTE SHOULD BE ADDED AS PER REQUIREMENT

Types of mixing-1.Hand mixing2.Bin mixing3.Stack mixing The lots for the mixing should have somewhat identical properties. Very coarse and very fine or very short and long cotton are never mixed.

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Size of bales are approximately as follows:-

LENGTH-2.0 FEETBREADTH-1.5 FEETHEIGHT-4.5 FEET

CONTAMINATIONS REMOVED DURING SORTING PROCESS:

1. Plastic dori2. Paper3. Cloth4. Polythene5. Wires6. Coconut material7. Feather8. Coloured thread9. Wood10. Leather11. Hair12. Sutli13. Yellow cotton

PRECAUTION WHILE LAYING MIXING:

1. Material should not spread out of yellow line marked on floor. 2. The top layer of mixing should be in same level. 3. Waste should be added uniformly. 4. Bales should not fall after opening them. 5. House keeping should be proper.

BLOW ROOMOBJECT:-The object of blow room is opening and cleaning of cotton.It consist of the following sequence of the machines for the attainment of this object.

1.SIX CHAMBER BLENDER-There are six chamber filled with cotton.Here blending of cotton is to be done by six beater.2.THREE ROLLER CLEANER-There are three rollers having different spikes.The function of three roller cleaner is to clean the cotton.3.HEAVY PARTICLE SEPERATOR-The function of heavy particle separator is to remove the heavy particle by the principle of centrifugal force by circulating the cotton.

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4.PINNED OPENER AND CLEANER-The spikes of roller is pin-like which open the cotton and so impurities are removed,so clean tha cotton.5.FINE OPENER AND CLEANER-Here fine impurities are removed from cotton. Spikes of rollers are very fine.

6. CONTAMINATION SORTING MACHINE-There are two separators -

1. Vetal-It works on the camera vision. It has 24 sensors, which sense the contamination,And is recorded by the camera and is ejected by the air pressure.2. Loptex-Total 56 sensor sense the contamination and are ejected by the air pressure.

7. DEDUSTER-It removes the dust from the waste from the blow room line.

TECHNICAL SPECIFICATION (F.C.1)1. FINE CLEANER (F.C.1)Tower reserve beaterMotor pulley -110 mmBeater pulley -167 mmCalculated speed-930 rpmMotor speed – 1415 rpmFine cleaner beaterMotor pulley – 208 mmBeater pulley – 335 mmCalculated speed 500 rpmMotor speed 1430 rpmSix chamber beaterMotor pulley 110 mmBeater pulley -335 mmBeater speed -471 rpmBeater speed 1435 rpmThree roller beaterMotor pulley -115 mmBeater pulley -336 mmBeater speed -490 rpmBeater speed -1430 rpmBEATING POINT:-2

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CARDINGCarding is the heart of spinning.The objects of carding are:-

1. Individualization of fibre2. Disentanglement of neps3. Sliver formation 4. Cleaning action

The chute feed system feeds the machine. Types of card:-1. Tandem card (16 in no.)REAKER

The main carding action takes place between cylinder and flat. To control the feed autoleveller are installed in the machine.

DUO OR TANDEM CARDING

As the name implies, tandem cards consists of two individual cards joined together to make up a unit, in which the doffer of the first card feeds fibre material to the taker-in of the second card. Double carding of the raw cotton has a positive effect on quality and on blending. However, these advantageare purchased at the cost of expense in hardware and maintenance, and additional space is required.Modern cards of the latest generation give the same or nearly the same quality. Tandem cards come into consideration.

TECHNICAL SPECIFICATION1. Speeds

BREAKER CARD Licker in – 96 rpm Cylinder -640 rpm Doffer -57 rpmFINISHER CARDLicker in -963 rpmCylinder -570 rpmDoffer -57 rpm MAIN-DATA

No. of m/c =16 (Tandem Card) 5 (single card)

No. of motors = 11(Tandem card) 9(Single Card)

Feed system-chute feed system Wrapping count=0.120

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Completing Time for 1 can=48 mins. Sliver length in 1 can =9000 m Production rate = 180 m/min Weight of 1 can=44.38 kg Feed rate for calendar roller=4.9 g/min Output rate =4.73 g/min Production = 52.2 kg/hr Breaker card-

flat speed = 302 mm/minCylinder speed =640 rpmLicker speed =960 rpm

Finisher card-Doffer speed =57 rpmCylinder speed=570 rpmFlat speed =390 mm/minCoiler speed =120m/minCalendar speed =145 m/min

CAN SIZEHEIGHT-45’DIAMETER-30’

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SLIVER LAP MACHINEOBJECT:-The object of sliver lap machine is to prepare the lap from slivers for the ribbon lap. This is one of the preparatory machines for the combing operation.

TECHNICAL SPECIFICATIONS

No. of m/c=2 No. of heads=18 Doubling=18 Drafting system=4 over 6 Lap weight=10 kg Production per m/c=220-2250 kg/hr Time for completion 1 can=2 min 20 sec Wrapping count=73 g/min Doffing time=25 sec Length of lap=160 m Feed g/m=88.2 Bottom roller gauge:

Front zone : 35 Middle zone: 50 Back zone : 39

Delivery speed =65m/min

RIBBON LAP MACHINEOBJECT:-The object of ribbon lap machine is prepare the lap from the lap ofSliver lap machine for the combing operation which has regularity and uniformity across the length and the width.

TECHNICAL SPECIFICATIONS No. of m/c =2 No. of heads =6 Doubling =6 Drafting =6 Drafting system =3 over 4 Lap weight =11.5 kg Production per m/c =220-250 kg/hr Time for completion 1 can =2 min 15sec Wrapping rate =72 g/min Doffing time =20 sec Length of lap =160 m Delivery speed =65 m/min

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Delivery gram/m =71 Bottom roller gauge :

Front zone : 31Middle zone : 50Back zone : 35

SUPER LAP MACHINEOBJECT:-The object of super lap machine is to make the lap from slivers comingfrom the breaker draw frame which have uniformity across the length and the widthfor the combing process.

TECHNICAL SPECIFICATIONS No. of m/c =2

No. of heads =30

Doubling =30

Draft =2

Drafting system =3 over 2

Lap weight =18 kg

Production per m/c =320-350 kg/hr

Time for completion 1 can =2 min 30 sec

Wrapping =72 g/m

Doffing time =30 sec

Length of lap =272 yards

Lap diameter =21”

Lap width=7”

Lap height =13”

Tension draft =0..994

Delivery speed = 90 m/min

Frequency = 54 Hz

Efficiency=70%

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COMBER No. of m/c =18 No. of heads =8 Doubling =8 Draft =11.04 Drafting system =5 over 4 Feed gram/m =72 Time for completion 1 can

(Lap from super lap m/c) =45 min (Lap from ribbon lap m/c)=35 min

Doffing time =1-1.5 min Length of lap =5000 m Nips/min=290 Wrapping count=0.130 Trumpet diameter =3.4 mm Distance between detaching step gauge to bottom roller=4.5-5.5 mm Distance between bottom nipper to cylinder=0.5-0.9 mm Noil % =16.5-22% Bottom roller gauges:

Front zone : 40 Middle zone : 40 Back zone : 44

SPEED FRAME

TECHNICAL SPECIFICATIONS:- No. of m/c =8 No. of heads =120 (Lakshmi)

=128(Electro-jet) Feed sliver hank =0.130 Draft =5.89 Drafting system -4 over 4 Bobbin weight = 1.74 kg Time for completion 1 bobbin =1 hr 45 min Wrapping count =0.75 (combed)

=0.78 (carded) Doffing time =7 min Length of roving in 1 bobbin =2126 m T.P.I =1.27 Bottom roller gauge:

Front zone =38 mm

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Middle zone=50 mm Back zone =50 mm

Flyer speed =1050 rpm

RING FRAMETECHNICAL SPECIFICATION:

No. of m/c=27 No. of Spindle =1008 Drafting system =3 over 3 & 4 over 4 Bobbin weight = 72 g Time for completion 1 bobbin =1 hr 45 min Spindle speed = 14000-16000 rpm Twist = Z Length of bobbin yarn = 3290 m T.P.I =16.48 T.M =3.67 Grams/spindle = 296 grams Doffing time =3 min 15 sec Efficiency =94.2-97.26 % Temperature conditions:

Dry : 37°c Wet : 28°c

Bottom roller gauge: Front zone: 45 mm Back zone : 56 mm

Count Time for completion8(SKW) 45 min12(SKW) 56 min13(SCW) 1 hr 15 min16(SKW) 1 hr 30 min28(SKW) 2 hr 30 min30(SCW) 3 hr

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AUTO CONERTECHNICAL SPECIFICATION:-

No. of m/c =10 Types of splicing : wet, air and mechanical. No. of heads = 60(muratec) & 64 (Savio) Cone weight =2.5kg Cone drum speed =1450 m/min for 30 count Cut groove on drum = 2 and half Bobbin length = 3454 m Bobbin weight = 68 g TEMPERATURE CONDITIONS:

DRY : 30°C WET : 25°C

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YARN CONDITIONING PLANTYarn formed in autoconer is not having so much strength. So, for this Yarn is conditioned under yarn conditioning plant.

In yarn conditioning plant the moisture content in yarn increases. Strength of the yarn improved by conditioning.

Moisture content =weight of cone before conditioning- weight of cone after conditioning

SPECIFICATIONS:

Name of machine : seiger(Y.C.P)Temperature conditions : 54-58°cPressure in mbar : -620 to -50Time for conditioning : 1 hourRH% :81%No. of packages conditioned in 1 hour : 600

PACKINGConditioned packages are finally packed into cartons and pallets to be sent to the buyer.

Weight of 1 carton = 50.8 kgWeight of 1 pallet = 941 kgCarton size = 685mm×450mm×510mmNo. of packages in one carton = 12(approx.)

CHAPTER -5

HUMIDIFICATION SYSTEM

OBJECT

THE BASIC OBJECT OF A HUMIDIFICATION SYSTEM IN A TEXTILE MILL IS TO CONDITION THE AIR SO THAT FIBRE CAN BE PROCESSED SMOOTHLY BY SUPPLYING THE CONDITIONED AIR TO THE DEPARTMENT.AN OPTIMUM RELATIVE HUMIDITY IS REQUIRED DURING SPINNING SO AS TO KEEP YARN BREAKAGE AT MINIMUM.IN SPINNING DIFFERENT DEPARTMENT HAS A DIFFERENT REQUIRMENT OF TEMPERATURE & RELATIVE HUMIDITY (RH), SO TO MAINTAIN THIS TO A CONSTANT LEVEL IS REALLY A TOUGH AS WELL AS IMPORTANT JOB.THIS IS ACHIEVED BY HUMIDIFICATION SYSTEM.

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CONDITION MAINTAINED BY HUMIDIFICATION SYSTEM

THE CONDITIONS THAT MUST BE MAINTAINED BY HUMIDIFICATION SYSTEM ARE-

1. DRY BULB TEMPERATURE-(DBT) 2. WET BULB TEMPERATURE-(WBT) 3. RELATIVE HUMIDITY-(RH)

HUMIDIFICATION SYSTEM

Atmospheric condition

Temperature 30 ± 2˚CHumidity 77 ± 2 %

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AIR WASHER

ROTARY AIR FILLTER

RETURN AIR FAN

PRODUCTION HALL

SUPPLY AIR FILLTER

PARAMETERS OF RELATIVE HUMIDITY (STANDARDS):

SECTION TEMPERATURE(°C) RH%

MIN MAX MIN MAXBLOWROOM 20 40 20 60CARDING 28 40 40 60COMBER 28 40 40 60D/FRAME 20 40 20 60S/FRAME 20 40 20 60R/FRAME 30 40 40 60WINDING 28 40 40 70TWISTING 28 40 20 60

RELATIVE HUMIDITY OF DIFFERENT SECTIONS OF DEPARTMENT:

SUCTIONS RH%BLOWROOM 50-55%CARDING 50-55%COMBER 50-55%DRAW FRAME 50-55%SPEED FRAME 50-55%RING FRAME 50-55%WINDING 65%T.F.O 62%

OPEN END 50-55%

31

CHAPTER -6

SEQUENCE OF DYEING DEPARTMENTS IN PRODUCTION

Pratibha Syntex Ltd has the wet processing unit at Pithampur (Dhar). Here wet processing of knit

fabrics of various blends take place. Apart from these here there are two types of dyeing process

available.

(A)Continuous dyeing

(B)Soft flow dyeing

So the Knitted fabric obtained from the Same Plant according to the order is processed in

processing unit.

Both these departments of dyeing (continuous and soft flow) are mainly used for wet processing

of knitted fabrics and have nearly the same working route except some few differences which are

as follows:

Continuous Dyeing Stop Flow Dyeing

Capacity of M/C-1100 kg. Capacity of M/C- 180-2500kg.

Washing, Bleaching, dyeing, soaping

occurs in different machines in a

continuous manner

Washing, bleaching, dyeing, soaping

occurs in one machine

In stop flow manner

The liquor required for dying is less. The liquor required for dyeing is more.

Machines Used-

- Stenter for Heat Setting

- Bleaching Machine

- Padding machine

- Batching machine

- Soaping machine

- Drying machine

- Sanforizing machine

Finishing machines used :

- Bleaching Dyeing soaping

occur in one machine

- Drying machine

- Stenter (4 units)

- Sanforizing Machine

32

(A) Continuous dyeing process-

H.O.D. - Mr. KULDEEP

PRODUCTION/ SHIFT- 4Ton

So the fabric initially in the roll form goes through the following path before it is made into a

finished usable material.

Pratibha Syntex Lmt. has its own Knitting plant. So it has its own production of Knitted fabric as

per sales order which is issued from the buyers. The main advantage of this is that it receives

pre-inspected fabric that’s why inspection process is not being much concentrated but still there

is random inspection takes place during opening & stitching process.

Various activities have been done here as follows:

First of all, the sales order issued by Buyers is received. Production of fabric is as per

required sales order quantity, construction & design.

Then this fabric is dispatch to Cutting Department as per sales order & roll number

specifications.

Challan number/date entry at Cutting department.

Sort wise unloading of fabric rolls & allocation of rolls in greige store take place

G.R.N (good receipt note is made)

33

Greige opening

Bleaching

Dyeing

Finishing

Folding

Made Ups

PPC deptt. Make the production plan & issue it to grey fabric for opening as per priority.

Opening of grey fabric & random inspection also takes place, defects observe such as

hole, knots, oil stain, grease stain, knitting defects etc.

Stitching of small rolls of same quality is being done.

Roll wise checking report is made consisting type of defects, meterage, sort number,

party name, sales order no. (S.O.), production no. (P.O.).

Trolleys & batch number is issued to Bleaching department.

Description of fabric quality is as follows:

100% cotton fabric.

Cotton/Lycra (C/L) blend

Various Design such as: Single jersey, double jersey, Interlock etc.

Lot number -C110102219

Quality: - VISC Lycra Shade: - purple

Residual H2O2 - Nil Light source: - D-65Absorbency: - Ok Whiteness Index : - 70 Water Ph: - 7.2 P.F.D. Ph: - 6.9Enquiry No-180011442/B

First digit of sort number signifies:

If 1 - 100 % cotton

3 - P/C blended

Grey fabric received in the form of rolls of different length.

Roll length may vary from 1000-1100kg.

Sample length may vary from 10-15 g.

34

Machinery description:

Name : Stenter for heat setting

Number of machine : Two

Make : NAVIS Arrytex

Name of machine : Bleaching Machine

Number of machine : One

Make : ERBATECH (D64711) Germany.

Name of machine : Padding Machine


Make : ROTACENT (Germany).

Name of machine : Dryer


Make : Pin Dryer – 603 (syntax group)

Name of machine : Compactor


Make : Lafer compactor - 705

Man power:

Operator/Shift (11 hrs.) 2

Supervisor & helper 2 & 10

B. BLEACHING DEPARTMENT

The grey fabric consists of various kinds of impurities like vegetable matter, waxes etc. In this section all of these impurities are removed and whiteness in fabric is imparted.In this department two main steps are carried out:

35

Pre-treatment

Bleaching

i) Pre-treatment

a) Scouring: Scouring is the first process carried out with or without chemicals, at room temperature or at suitable higher temperatures with the addition of suitable wetting agents, alkali and so on. Scouring removes all the waxes, pectins and makes the textile material hydrophilic or water absorbent.

b) Bleaching: The next process of decolorization of greige material in to a suitable material for next processing is called bleaching. Bleaching of textiles can be classified in to oxidative bleaching and reductive bleaching.

Oxidative bleaching

Generally oxidative bleachings are carried out using sodium hypochlorite, sodium chlorite or hydrogen peroxide. Natural fibres like cotton, ramie, jute, wool, bamboo are all generally bleached with oxidative methods.

Reductive bleaching

Reductive method of bleaching is done with Sodium hydrosulphite, a powerful reducing agent. Fibres like Polyamide, Polyacrylics and Polyacetates can be bleached using reductive bleaching technology.

In this step scouring and bleaching are carried out in a single machine.

The Benninger continuous pretreatment concepts comprise continuous desizing and bleaching in one cycle with just one steaming process. In one step grey cloth is turned to dye ready fabric.

This process is fast, economical and of immaculate quality. Due to this optimized one-level process the operational costs are lowered by approximately thirty percent, and the impact on the environment is significantly lower.

Machine DescriptionMachine Make ERBATECHModel D 64711Made In GermanyYear Of Mfg 2008No. of machine One

36

http://en.wikipedia.org/wiki/Alkali

http://en.wikipedia.org/wiki/Wetting_agent

The ERBATECH machine is mainly divided into 5 main parts

1. Parcowash Zone -1

In this initial step the Dust,impurities etc are removed using hot water and steam. All the processes are carried out in a chamber known as parcowash-1. There are 3 chemicals used for pre-washing.

Name of chemical Working

Sirrix N Sequesting agent2UDI Water hardness controllerMRZ Wetting AgentTemp. 70oc

2. Impregnating:

In the main Bleaching zone the fabric is impregnated with chemicals for subsequent troublefree

37

steaming process. The design ensures that a high liquor exchange is achieved. The chemicals are distributed immediately at the right place in the fabric. The chemicals added are as follows:

Chemical used Working of chemical

H2O2 Bleaching agent

Sifa M Reaction Stablizer

MRZ Wetting agent

Caustic soda Swelling,cleaning agent

Sirrix N Sequesting agent

Temp. 97 oc

3. Steaming:

In the steamer the chemicals react with the fibres themselves and the accompanying substances. The combination steamer with tight strand cloth runsand plaiting on a roller bed permits reaction times of 1 to 60 minutes. An automatic steam conditioning and regulating station guarantees constant conditionsand an air free atmosphere. In this machine steaming time was 13-14 minutes. The steam is used in the following conditions:

Temperature of steam mix: 102oc4. Washing:

The chemicals which have been made soluble by steaming, are washed out. The high washing effect of this machine is achieved through exact liquor segregation andcounter-flow guidance. It has been designed for especially low power and water consumption. Final washing is done in 4 subsequent chambers.

Compartment No. Set Temperature (in deg C)

Actual Temperature (in deg C)

Length of fabric that can be treated (in m)

1 90 90 272 90 94 303 90 63 284 (chamber 1) 63 28 (chamber 2) 60 28

5. Neutralizing

In this chamber ph of fabric is maintained.

38

Working parameters

Speed 70mt/min

Dwell time 15min.

Inject steam flow 500kg/hr

Impecta nip pressure 0.5N

Steamer temp 100±2˚c

Steamer content 1200 m/min

Pick-up(%age) 75

Steam flow in steamer 1200kg/hr.

Steam pressure 3.5kg/cm²

Water pressure 5kg/cm²

Air pressure 7.0kg/cm²

Pre-washer flow 5.0lt/kg of fabric

Post-washer flow 5.0lt/kg of fabric

Acid dosing 4-5 PH

Operator 2

Helper 4

Production/machine/day 80,000 – 90,000 mts.

C. DYEING DEPARTMENT

Dyeing is the process of imparting colors to a textile material through a dye (color). Dyes are obtained from flowers, nuts, berries and other forms of vegetables and plants as well as from animal and mineral sources. These are known as natural dyes.

The other class of dyes is known as synthetic dyes. These are based on a particular type of chemical composition. Some of these dyes are- Acid (Anionic) dyes, Basic (Cationic) dyes, Neutral- Pre metalized dyes, sulfur dyes, vat dyes, reactive dyes, pigment dyes etc.

Colour is applied to fabric by different methods of dyeing for different types of fiber and at different stages of the textile production process. These methods include Direct dyeing; Stock dyeing; Top dyeing; Yarn dyeing; Piece dyeing; Solution pigmenting or dope dyeing; Garment dyeing etc. Of these Direct dyeing and Yarn Dyeing methods are the most

39

http://www.teonline.com/knowledge-centre/dyeing.html



http://www.teonline.com/textile-chemicals/pigments-dye.html

popular ones.

Dyeing is defined as the application of dye to fibers (according to their affinity) to have desired colour. Every natural or synthetic fiber varies in affinity or capacity to take the dyestuffs. Dyeing is done at fabric stage. Main types of fabrics those are dyed are:

1) 100% cotton fabric2) L/C blend

(A)DARK SHADE DYEING In dark shade dyeing of cotton cloth we use Reactive dyes are used. And the machine used is Cold pad batch and soaper.

Cold pad batch (CPB)

M/c DescriptionMachine make ROTACENT/Germany/No. of m/c OneCloth capacity 1100mt

Working parameters (Kuster)Speed 44 m/min.dye capacity 1250 lt.Nip level 100%Nip pressure(Bar) L:M:R – 0.4:1.5:0.4Dye temp. 30˚cTemp. of pedding 25˚Colour: alkali ratio 4:1Trough PH 10.5-11.5

Dyeing recipe

Colour G.P.L.Ever. Yellow LX 2.5Ever Red ED3B 30.70Ever Blue ED 6.30

AuxiliaryMaterial G.P.L. Total amount

Lionil UH 1 0.125 lit

40

Caustic lye 7 0.875 litSoda ash 18 2.250 kg

Process of Cold Pad Batch is as follows:

Fabric is passed through the cold rollers to keep the temperature of the fabric even so that the classes of dyes used are better reactive .

Then fabric is passed through the Padding mangle where the colour padding takes place. The color recipe used here is 1 part Sodium Silicate as fixing agent and 4 parts of colour. speed here is 44Mts./min.

The fabric is then sent for rotation of 8 hours. The time allotted is the dwelling time and within this time the colour fixing happens and the fabric absorbs the dye equally.

And at the end fabric is sent on the washing range where the fabric is washed and dried on the drying range.

Flow of fabric in Cold Pad Batch Machine

ERBATECH SOAPER

The washing range primarily is used to wipe out the superficial colour absorbed by the fabric and then send to the finishing department.

The process of Washing Range is as follows: The dyed fabric is washed with the counter flow of water at 98 degree of temperature. Then the fabric is washed in soap solution in two chambers. Then again the fabric is passed through water. And finally the fabric is passed through acetic acid where it is neutralized and then the fabric

is dried as the acetic acid is volatile in nature thus it does not require any further washing. After the fabric is passed through the drying range it is drying in Pin Dryer and sent to

finishing department.Excellent results have been obtained with the pad batch (cold) system utilizing high reactivity dyes. Dyers have experienced many benefits,

41

Some of which are listed ahead:1. Reduction in waste loads in effluent 2. Low capital outlay. 3. Low energy requirements. 4. High production speed 5. Less labour requirement. 6. High colour yield 7. Outstanding productivity. 8. Excellent dye penetration and levelling characteristics. 9. Rapid fixation10. Substantial overall cost savings (dyes, chemicals, labour, water. The fabric undergoes less turbulence during the cold pad batch dyeing process, and therefore retains a smooth, uniformly coloured appearance with added luster and a soft touch and drape. It is also brighter in shade, has superior wet fastness properties, and has a better look and feel.

D. FINISHING DEPARTMENT

Finishing is the final series of operations that produces finished textile fabric from greige goods. Finishing operations are predominantly wet operations requiring large amounts of thermal energy for water heating and drying.

Finish is applied on the textile material by different chemical and mechanical means. The finish

to be applied on textile material depends upon the end use of the fabric.

OBJECTIVES

To improve the appearance of fabric

To increase the whiteness

To provide anti-shrink properties

To provide soft feel to the fabric

To increase the width of the fabric

To improve dimensional stability.

Average production shift = 4 ton.

No. of Stenters = 2

Machine name: Mahlo (Mechanical Finishing)

PROCESS FLOW IN FINISHING DEPARTMENT

GREY

42

BLEACHING

PADDING

BATCHING

SOAPING

DRYING

SANFORIZING

MACHINERY IN FINSHING DEPARTMENT

STENTER(NAVIS Arrytex) 2PIN DRYER -603 (syntax group) 1

SANFORISER(Lafer-705) 2

STENTERPROCESS AT STENTER MACHINEOBJECTIVES

Heat Setting Resin Finish Water Repellant Finish Soft Finish Stretching Skew, Bowing

Working parameters (temp. in ˚C)Chamber 1 2 3 4 5 6 7 8 9 10

Light shades 120 130 140 150 150 160 160 160 160 170

43

Med. & dark 120 130 140 160 160 170 170 170 170 180

Shirting wt. 100 100 110 110 120 120 120 120 120 120

White goods 100 120 130 140 150 150 150 150 150 150

Bottom wt. 100 120 130 140 150 150 150 150 150 150

RFD(stretching) 150 160 170 180 180 180 180 180 180 180

Heat setting 210 210 210 210 210 210 210 210 210 210

Specification of Machine (stenter)No. of chambers 10,10Length of one chamber 3 mt.Heating system Thermic oil (300˚C)Model NAVIS ArrytexWorking width 180 cms.Threading length 75 mtSpeed 5- 100 mt/min.Trough cap. 50 lt.Equipped Mahalo system

Different parts of stenter :Brushes after pinning: Since the pinning shoes only bring the fabric on to the tips of the pins, the function of the subsequent brushes to press the f/c fully on to the pins. The brushes are mounted on a pivoting lever, which after releasing a locking handle, can be moved to the non operational position or working.

Vertical feed roller: The feed roller is located right ahead of the pinning or clipping positions. It can be moved to various positions by means of pneumatic cylinders.Steam spray cleaning unit clips/pins: Some time finish chemicals such as softener etc. cling or stick to the pin over a period of time softener, residue of glue & condensates can build up on the needle bars & clip tables the steam spray cleaning unit for pin chains or combination chains can be used.Brushes for needles: Over a period of time softener residue of glue & condensates can build up on the needle bars &clip tables, impairing the function of the stenter chain. The residue must therefore be removed at regular interval by actuating the brush system.Main track guide selvedge feeder: The width of the in feed track is controlled by the selvedge feeder when there is no f/c in the m/c the chain track run with the activated feeders swung fully increases.

44

Rotary compensator: Is used even running speed it is infinitely pneumatic variable so that necessary longitudinal tension can be produced in the f/c Rotary tensioner it can be infinitely by hand so that requisite longitudinal tension can be created via f/c friction.Break roller: When unbreaked the break roller is driven by f/c. actuating the pneumatic break slow the roller movement & thus increase the f/c tension.My-cock bent stretching (curved roll): The bent stretching to prevent fold & stretches out the edges of the f/c.depending on the type & design of the f/c ,the adjustment angle of the stretching roller can be varied while the f/c is running.Lifting device: The liquor can be lowered pneumatically so that internal element in the trough is easily accessible. This facilitates threading in of the f/c& simplifies the cleaning of the trough & internal element.Matex three roll padding mangle system: The rolls are press together by two pneumatic cylinder thereby pressing excess liquor out of the f/c.Spreading roller: This roller has severe like profile running out to the left & right.Drawing screens: The screens prevent fluffs, threads etc. carried by the f/c from entering the air circulation system. The screens are located on the suction duct depend on the type & design /the m/c may be equipped with fixed base screens which can be removed after opening the service doors or with auxiliary screen which can be removed during the m/c operation.Integrated suction ducts: The m/c is equipped with an integrated suction duct. The exhaust air volume can be regulated via mechanically adjustable air valves.Rip cord switch: The safety system comprised a ripcord switch located at the outlet of the stenter. Pulling the ripcord trips the emergency stops function for the whole m/c.Master switch: When the master switch is in the Zero position, all power to m/c is switched off. In this operation the master switch can be locked with a pad lock to prevent restarting.Compressed air maintenance unit: A separate maintenance unit is provided in the control desk to prepare the compressed air for the mangle pad. The maintenance unit consists of filter with water trap a compressed air oilier & shut off tap.Pinning unit: The function of two pinning unit is to position the fabric selvedge as closely & uniformly as possible in line with the pressed overfeed on to the tips of the pins on the rubber brush roller & the continuous shrink belt underneath.Heating system: It is based on the oil circulating heating .the machine should be heated up only with the stenter chains running. in the same way, the heated machine Should never be left for prolonged periods with the stenter chain stationary. for this reason heating is automatically switched off when the machine is stopped on machine, without bypass flaps, when the machine is empty, the air circulation fan & suction fans must continue to run for approximately 15 min. after switching off the heating in order to condensation of the vapour treatment chamber monforts stenter are therefore adequate control reserve. the large heating capacity allows the circulating air in Monforts stenter to be heated up very quickly from room temperature to the desired temperature .for physical reasons the circulating air heats up more quicker than the steel construction, so steel parts can therefore still be cold even when the circulating the air has already reached the desired treatment temperature when starting the machine, cold before the beginning of production, heat up the range without fabric to 250˚c at least one hour. After one hour the desired temperature can be set.

45

Cooling zone: The fan draws in the ambient air & blows it via the nozzle system as top & bottom air current on the fabric. The fabric is carried on the air current.

Sanforizing machine

Objective: The purpose of this machine is to provide the fabric with relaxation shrinkage so that it does not shrink during later washings. This finish also increases the lusture and softens the handle of the fabric.

The main function is to give shrinkage in the warp direction and fix it, until the next home wash, to avoid that the fabrics have any dimensional variation (shrinkage), and also improving the touch of fabric.

(B) SOFT FLOW DYING PROCESS-H.O.D. - Mr. VINAY

PRODUCTION/ SHIFT- 4Ton

So the fabric initially in the open form goes through the following path before it is made into a

finished usable material.

Machinery description:

MACHINE USED FOR SAMPLE

Name : DYING MACHINE

46

Bleaching

Dyeing

Finishing

Folding

Made Ups

Number of machine : SIX

Make : KRSNA, SCLAVOS, KROMSON

CAPACITY : 6kg. , 10kg. , 18kg. , 40kg. , 40kg. , 80kg.

MACHINE USED FOR BULK

Name : DYING MACHINE

Number of machine : NINE

Make : SCLAVOS

CAPACITY : 360kg. , 360kg. , 540kg. , 540kg. , 720kg. , 180kg. . 280kg, 1500kg. , 1500kg.FINISHING MACHINESName : DRYING MACHINE

Number of machine : TWO

Make : LAFOR

Name : STENTER

Number of machine : ONE

Make : BRUCKNER

Name : COMPACTOR MACHINE


Make : LAFOR, SANATA COMPACT

Name : ROLL CHECKING MACHINE


Make : RAMSONS, ALMAC

PROCESS OF DYEING:-

Filling7liquor (i.e. 7lit for 1kg)

Tank-2(wetting agent + caustic soda)Tank-1(H2O2)

Transfer to tank and hold for 15 min at 95oc

47

Wisdom rinsing

Drain

Filling soft water (2lit/kg)

Rinsing at 60oc

Aciding for 5 min

Killer agent for 10 min (B.F.S.P.)Then rinsing at 0oc

Check PhThen unloading and drain

Filling soft water 4lit/kg and heat at 50oc

Dyeing chemical

Levelling agentCheck hardness

Colour dosingHold time 10 min

Salt transfer

48

Increase temperature about 80oc at 1.5o gradientHolding time 30 min

Water in tank -2 for soda

Cooling about 60 oc at 1.5o gradientHold time 15 min

Dosing of sodaHold time 15 min

Check hardnessHold time 45 min

Drain

Filling 2lit/kgCheck Ph

Heat at 50ocRinsing at 50oc (8 lit/kg.)

Rinsing at 50oc (12 lit/kg.)

Water filling in tank – 1

Acid transfer 8 min hold time

49

Soft water filling 2 lit/kg.

Tank – 2 water for soaping

Check Ph

Transfer soaping agent from Tank-2Hold at 95oc for 10 min

Cooling about 80oc at 2o temperature gradient

Rinsing at 13 lit/kg

Rinsing at 70oc at 12 lit/kg

Rinsing at 0oc at 2 lit/kg

Check clarity

Drain

Unload

Finishing: From Dyeing machine

Stenter (Buckner) Dryer at 140oc Open width fabric Tubuler fabric

50

Compactor Compactor KST-500 Sanata compact Syntex Lafor

Roll Checking Roll Checking ALMAC RAMSONS

CHAPTER -7

SEQUENCE OF CUTTING DEPARTMENTS IN PRODUCTION

THE RAW MATERIAL OF CUTTING IS FINISHED DYED MATERIAL. FIRSTLY WE DONE SPREADING BY LECTRA M/C. SPREADING IS DONE TWO TYPES. FIRST IS MANUAL SPREADING&SECOND IS AUTOMATIC SPREADING. SPREADING LAYER WIDTH CAN NOT BE MORE THEN 4”. AFTER SPREADING WE PREPARE MARKER FOR MINIMISE THE WASTE. AND THEN WE DOING CUTTING BY LECTRA CUTTING M/C.

THE FOLLOWING REQUIREMENT FOR CUTTING ARE USED. NO. OF TABLE USED IN CUTTING 6. TYPES OF TABLE→ (1) LECTRA TABLE (2) MANUAL TABLE. TYPES OF FABRIC →SINGLE JERSEY, LYCRA, VISCOSE, RIB (1/1, 8/4, 2/2). CUSTOMER→SARA LEE, CAN, NIKE, HANS, CARREFOUR. PRODUCTION OF ONE SHIFT →60,000 PIECE.

NOTE THE CAPACITY OF SPREADING M/C IS ABOUT 100KG. THE BUTTER PAPER IS USED FOR TO FIND THE NO. OF ROLL ON SPREADING

LAYER. TWO TYPE OF KNIFE ARE USED IN THE CUTTING M/C.

51

LECTRA CUTTING M/C→BEND KNIFE. MANUAL CUTTING M/C→STRIPE KNIFE.

FLOW CHART

DYED FABRIC↓

COMPACTOR↓

PACKING↓

CUTTING DEPARTMENT↓

4” LAYING (SPREADING)↓

CUTTING (LECTRA M/C)↓

TROLLY↓

STORAGE (FEEDING DEPARTMENT)↓

PRINTING

CHAPTER -8

SEQUENCE OF GARMENT DEPARTMENTS IN PRODUCTION

52

GARMENT:-Garment is the final product obtained. It is the final outcome of all the processes; it is mainly constrained with the sewing.

PRODUCTS OF GARMENT DIVISION:- Men undergarment, ladies innerwear etc.

MAJOR BUYERS: Carrefour Marinopoulos.SA, HANES, LINGRIGE. These are the buyers which give the order for manufacture of the garment.

TYPE OF MACHINES USED AND THEIR MANUFACTURERS:1. over lock machine (YAMATA-JAPAN) 2. lock stitch machine (BROTHER and SUNSTAR-CHINA)3. cover seam machine (YAMATA-JAPAN)4. Bartech machine (BROTHER-CHINA)5. F.S machine (YAMATA-JAPAN)6. Attach elastic7. chain lock

MACHINE DISCRIPTION:

1. Over lock machine- there is a needle and two loops, with the combination of the above two they form 10 taka in an inch. It is used for elastic attach.

2. Lock stitch machine- there is a needle and a luper. It is similar to the sewing machine used at homes.

3. Covers seam machine- it is basically used to attach the fly folding. In this machine there are two needles and a luper.

4. Bartech machine- It provides taka at the specified point not on the entire fabric area. It is done in order to provide strength and extra extensibility. 24 takas are provided in one operation by this machine.

5. F.S. machine- The basic operation of this machine is to sew two or more heads of fabric. It is also used for fly attach. There are four needle and two lupers. 14-15 takas are provided in an inch by this machine.

6. Attach elastic machine: in this machine there are three needles and a luper. This machine is used to attach elastic, this elastic provide the required extensibility to the fabric.

7. Chain lock machine- The interlacement of the thread form a chain at the time of sewing. It has a luper and two needle.

SPECIFICATION PROVIDED BY BUYERS-

53

SIZE SPECIFICATIONS:-

S- SMALL- 28-30inches

M- MIDDLE- 32-34inches

L- LARGE- 36-38inches

XL-EXTRA LARGE- 40-42inches

STYLE SPECIFICATION:- 1. STYLE- 7460-P4 SM-MD- 9.5 inches

L4-XL- 10.5 inches

2. STYLE- 7694-P4 V4, C4, 4B/7690

3. STYLE- 5624-P4, V4, AS, AT - 7795-P4/AB -7470CM -7480-P4

TYPE OF NEEDLE IN CARREFOUR BUYERS-

NAME OF THE MACHINE TYPE

TYPE OF THE NEEDLE MODEL NO. OF THE NEEDLE

Folding,5T,Cover seemPullar, C/SOpen elastic, all Hat Lock

TV X3 60/8,65/9,70/10,75/11, 90/14

All over lock DC X1 60/8,65/9,70/10,75/11,90/14

Zigzag Bartek DP X5 60/8,65/9,70/10,75/11,90/14

FS, Full att, net folding UY X113 65/9,70/10,75/11Lock stitch DB X1 65/9

THREAD USED IN GARMENT DIVISION:

*TEX-18 (Colour-black, white, navy blue) *Texturized polyester Filament

54

*CFP Textursed Oeko-tex standard 100 Shirley.

DEFECTS-

Broken, MS MT, Strain, shade, hole

CHECKING-

If there is oil stains then the fabric is rejected

SPOTTING-

Chemical, steam and air pressure is used to clean the spotting. The chemical is usually washing soda. If there is a spot found in fabric or garment then the garment can be rejected.

PACKING:

After all the above mentioned operation the garment are packed to exported to the buyers.

CHAPTER -9

SEQUENCE OF KNITTING DEPARTMENTS IN PRODUCTION

M/C

TYPE MODAL MAKE M/C TYPE MODAL MAKE CAPACITY

55

1 RIB FV2.0 MAYER&CIE

1 RIB FV2.0 MAYER&CIE

350d

2 RIB FLDR FUKUHARA

JAPAN 60 30 18 400d

3 RIB FLDR FUKUHARA

JAPAN 60 30 18 400d

4 RIB I 1108 TERROT GERMANY

54 30 18 300d

5 8 LOCK FIL 8AE FUKUHARA

JAPAN 84 30 18 450d


JAPAN 84 33 18.24 500d


JAPAN 84 33 18.24 500d


54 30 18 300d

9 8 LOCK OV 2.0 MAYER&CIE

GERMANY

96 30 24 360d

10 INTER RIB

INOVIT 2.0

MAYER&CIE

GERMANY

60 30 18 350d

11 INTER RIB

INOVIT 2.0

MAYER&CIE

GERMANY

60 30 18 350d


54 30 18 300d


GERMANY

108 34 18 550d


GERMANY

108 34 18 550d


54 30 18 300d


50 30 18 300d

17 FLEECE MBF 3.2 MAYER&CIE

GERMANY

96 30 20 400s


GERMANY

96 30 20,24,28

400s

19 SINGLE JERSEY

MV4 3.2 MAYER&CIE

GERMANY

96 30 28 400S


54 30 18 300d


GERMANY

96 30 20,24,28

400s


GERMANY

96 30 20,24,28

400s

23 SINGLE JERSEY

MV4 3.2 MAYER&CIE

GERMANY

84 26 24,28 350s

56

24 SINGLE JERSEY

MV4 3.2 MAYER&CIE

GERMANY

96 30 20,24,28

400S

25 SINGLE JERSEY

S 296 LAXMI TERROT

INDIAN BASED

96 30 24,28 250s

26 TERRY MPU 1.6 MAYER&CIE

GERMANY

48 30 24 300s

27 RIB FLDR FUKUHARA

JAPAN 60 30 18 400d


GERMANY

96 30 20,24,28

400s


JAPAN 84 33 18,24 500d


GERMANY

96 30 20,24,28

400s

31 RIB I3P154 TERROT GERMANY

64 36 18 450d


64 36 18 450d


64 36 18 450d


64 36 18 450d


64 36 18 450d


64 36 18 450d


100 36 18 600d


100 36 18 600d


100 36 18 600d

40 SINGLE JERSEY

S296-1 TERROT GERMANY

100 34 28 550s

41 SINGLE JERSEY


109 34 28 550s

42 SINGLE JERSEY


109 34 28 550s

43 SINGLE JERSEY


109 34 28 550s

44 SINGLE JERSEY

RELANIT II

MAYER&CIE

GERMANY

114 36 28 550s

45 SINGLE JERSEY

RELANIT II

MAYER&CIE

GERMANY

114 36 28 550s

46 SINGLE RELANI MAYER GERM 114 36 28 550s

57

JERSEY T II &CIE ANY47 SINGLE

JERSEYRELANIT II

MAYER&CIE

GERMANY

114 36 28 550s

48 SINGLE JERSEY

RELANIT II

MAYER&CIE

GERMANY

114 36 28 550s

49 SINGLE JERSEY

RELANIT II

MAYER&CIE

GERMANY

114 36 28 550s

50 SINGLE JERSEY

RELANIT II

MAYER&CIE

GERMANY

114 36 28 550s

51 SINGLE JERSEY

RELANIT II

MAYER&CIE

GERMANY

114 36 28 550s

52 SINGLE JERSEY

S296-1 BW

TERROT GERMANY

115 36 28 400s

53 SINGLE JERSEY

S296-1 BW

TERROT GERMANY

115 36 28 400s

54 SINGLE JERSEY


115 36 24,36 650s

55 SINGLE JERSEY


115 36 24,36 650s

56 SINGLE JERSEY


115 36 24,20 650s

57 SINGLE JERSEY


115 36 24,20 650s

58 SINGLE JERSEY


115 36 24 650s

59 SINGLE JERSEY


115 36 24 650s

FLAT KNITTING MACHINES/ TAPE MACHINE

31 FLAT MACHINE CMT 211 STOLL GERMANY 632 FLAT MACHINE CMT 211 STOLL GERMANY 633 FLAT MACHINE CMT 211 STOLL GERMANY 634 FLAT MACHINE CMT 211 STOLL GERMANY 635 TAPE MACHINE VARITEX INDIAN BASED 6 HEAD36 FLAT MACHINE SMA 121J FLYING TYGER TAIWAN 637 FLAT MACHINE SMA 121J FLYING TYGER TAIWAN 6

58

KNITTING INSPECTION MACHINES1 INSPECTION MACHINE CALATOR2 INSPECTION MACHINE GUVEN CELIK3 INSPECTION MACHINE GUVEN CELIK4 INSPECTION MACHINE CARDWELL

TYPES OF FABRIC SINGLE JERSEY SINGLE JERSEY ELASTANE 1X1 RIB LYCRA 2X1 RIB LYCRA SINGLE PIQUE LYCRA DOUBLE PIQUE & LYCRA HONEY COMB 3T FLEECE 2T FLEECE TERRY FABRIC TWILL FABRIC SINGLE JERSEY DRIFIT SINGLE PIQUE DRIFIT

TYPE OF LYCRA CREORA DUPORIT→(1) 1U025 (2) ELASPANE

TYPE OF NEEDLES

GROZ BACKERT – HIGHER COST(AVG.RS.27) SAMSUNG -CHEAPER COST(AVG.RS.15)

TYPE OF KNITTING OIL CASTROL-LOW COST VICKERS –HIGH COST

59

COST NEEDLE COST→RS.0.25/KG OIL COST →RS.0.35/KG POWER COST→RS.2.5/KG

REJECTION LYCRA STITCH/LYCRA OUT 30-40% NEEDLE LINE 30-40% SETTING 5-10% OTHERS 10-35%

NOTE SINGLE JERSEY→ONLY SINKER & NEEDLES (NO. OF SINKER=NO. OF

NEEDLE)

DOUBLE JERSEY→NEEDLES

[ NO OF NEEDLES = DIA X GAUGE X 3.14 ]

CHAPTER -10

TIME OFFICE

It is the initial and final stage for the worker. The function of time office is to record

keeping (record for rest, leave) and to keep the record of the attendance.

60

The function of the time office is to maintain the workers in shift as per requirement

of the shift.

The function of the time office is to keep the record of overtime and give extra benefit

to that worker.

Thank You

UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE

Kanpur

61

A REPORT ONSUMMER VACATION PRACTICAL MILL TRAINING

ATPRATIBHA SYNTEX LIMITED

(20.07.20011 TO 02.08.20011)

Submitted To: Submitted By:

Mr. GOPAL DIXIT SANJEEV SINGH

(UPTTI KANPUR) (0804463031)

VIRENDRA KUMAR KANAUJIYA

(0804463042)

SATYAJEET LENKA

(2904463002)

BRANCH – TEXTILE ENGINEERING

62

Documents

textile Traning Report