Varun t Report

Abhishek Home Textiles-II

Abhishek Industries Ltd.

Dhaula Complex, Barnala

SUBMITTED BY:

Varun Garg

The Technological Institute of Textile & Sciences

Bhiwani

ACKNOWLEDGEMENT

We would like to thank Mr. C. P. Punaini, who has been a great support

and guide during our training period. The projects given by him have

proved to be a source of immense learning for us.

We would also like to thank Mr.Lalit Kaushal, Mr. Naresh Kumar, Mr. M.K.

Ghosh and Mr. Puneet Bhatia for their constant guidance and support.

We are also very thankful to all the people working in Trident who co-

operated with us and were a great help during our training.

Varun Garg

Introduction to trident Group

Trident Group is the second largest terry towel manufacturing and

exporting unit in India. It is a Rs. 15 billion global enterprise in the

business of Yarn, Terry Towel, and Paper & Chemicals. The plant is spread

across 715 acres of land with a state-of-the-art Technology sourced from

Switzerland, Germany and Italy. Abhishek Industries Ltd (ABIL), Barnala

is now on an expansion spree with planned investments in a home textile

plant and sugar manufacturing plant

Trident Group is certified to use Supima Trademark as governed by

Supima Association of America Oeko-Texmark granted by Swiss Textile

Testing Institute for Terry Towels and Yarns thus certifying the eco-

friendliness of the technology. It is one of the largest exporters of terry

towels to international buyers such as Wal-Mart, JC Penny, Franco, Target

Stores, APE, K-Mart, CSC, Gozze, Burlington and Indian corporate like

ITC, Sahara, Jet Airways and Taj Hotels.

To enhance the value proposition to our customers and establish a

collaborative supply chain network the company has gone for

implementation of SAP, to standardize its operations. With this, Trident has

joined the elite group of global enterprises in embracing technologies and

processes for optimizing internal efficiencies and ensuring high quality

deliverables. It has successfully completed the first phase of its SAP R/3

Enterprise Resource Planning (ERP) Solution Implementation. Apart from

streamlining the current business processes and operations, it has also

maximized the production capacity and has helped to achieve faster outputs

in complex new product development. SAP is implemented on gigabit OFC

campus LAN's & across the offices of Trident in India through a Private

OFC networks. As part of Collaborative planning framework, the company

will shortly be extending this network to their business associates. With the

implementation of SAP R/3 and APO, the company has made its advent

into the world of e-business. Its CRM, SCM and B2B Applications and

Business Intelligence Warehousing are deployed on high-end systems

thereby linking all plants, operations, offices, projects, customers and

vendors.

Location: Village Dhaula, Mansa Road, Barnala

Total Area: 715 acres

Facility Comprises of:

· Abhishek Home Textiles Unit 1 (ABIL-AHT 1)

· Abhishek Home Textiles Unit 2 (ABIL-AHT 2)

· Industrial Organics Ltd( IOL)

· Paper & Chemicals Division 1 (ABIL-PCD 1)

· Paper & Chemicals Division 2 (ABIL-PCD 2)

Products

· Terry Towels & Toweling products

Piece Dyed Dobbies,Yarn Dyed Single & Double Jacquards, Undyed

Jacquards, Yarn Dyed Stripes weft inserts & Checks, Terry & Velour

Finish. Beach Towels, Bath Sheets, Bath Towels, Hand Towels, Guest

Towels, Face fringes, Bath Mats, Kitchen Towels & Gloves, Specialty

towels in Zero twist yarn, Egyptian cotton, and cotton with

Model/Tencel Blends.

TRIDENT BEST PRACTICES

Our Culture

TRIDENT promotes the family culture and hence emphasizes the

importance of transparency, openness, trust and empowerment in the

day-to-day work.

As TRIDENT is on its way to becoming a global organization we have

incorporated certain policies which we feel will give an impetus to the

workflow. These are

TPM

TPM stands for “Total Productive Maintenance” and builds a close

relationship between Maintenance and Productivity, showing how

good care and up-keep of equipment will result in higher productivity.

TPM is a philosophy of continuous improvement that creates a sense of

ownership in the operator(s) of each machine as well as in their

supervisor. We all reach a new attitude of higher responsibility and

commitment. TPM is to Maintenance very much as Total Quality is to

Production. TPM is another tool to help us reach our projects for the

competitive years to come.

Implementation of TPM at our plant should be

accomplished in accordance with the international

guidelines"

Our focus will be:

· Ease the operation

· Improve the Productivity

· Ease the maintainability

· Make the operation and area Safer!

Once implemented, TPM has just begun... it is an ongoing process of

continued improvement supported by all the team. The members of the team

should communicate with each other on a regular basis to find out how the

process is going and to decide if new improvements should be considered

and, if feasible, scheduled.

FIVE S

What are Five 'S'

Five 'S' are derived from the first letters of the words

SEIRI means Organisation or sorting

SEITON means straighten or prepare correctly

SEISO means Cleanup or Cleanliness

SEIKETSU means Standardisation

SHITSUKE means Discipline

They are five integrated parts of House keeping or work place

Management.

What benefit we get by practising Five 'S'?

A clear work place is high in Productivity

A clear work place is high Quality

A clear work place helps in Cost Reduction

A clear workplace ensures Delivery on Time

A clear workplace is Safe for people to work.

A clear workplace will bring high Morale.

Abhishek home textiles - 2

Layout of the plant is as follows:

The unit consists of following main sections:

1. Cheese winding

2. T.F.O

3. Soft winding

4. Package to cone winding

5. Package and fabric dyeing

6. Yarn packing

7. Weaving

8. Cutting/Hemming/Packing

9. Shearing

A brief introduction to these sections is as follows:

1.Cheese Winding :

This process is carried out to double the yarn by combining two strands of

single yarns. Yarn supply is on paper cones or cheeses & the two-ply yarn

is wound on to plastic tubes having approx one kilogram of yarn.

The waste incurred is on following basis: -

v Starting of a position, knotting etc.

v Yarn faults, breakage, stains, entanglement, package damage & cuts etc.

It is estimated that for each package of 1 kg, about 20 meters could be

wasted in piece ups including breakages. The wastage is proportional to the

coarseness of the yarn. For heavier yarns the weight of waste will be more.

Wastage because of start-ups, breakages, entanglements & package faults is

estimated to be 0.25% as standard.

2 T.F.O

This process is carried out to twist the cheese wound double yarn to make

twisted two-ply yarn. The final package is maximum 2.0 kgs.

The waste incurred is on following basis: -

● Starting of a position, knotting etc.

● Yarn faults, breakages, entanglements, stains etc.

The wastage is higher if coarser yarn is processed. With improved yarn

quality & reduced breakages the wastage can be reduced to a lower level.

The std. Wastage is 0.25%

3 . Soft Winding :

To prepare the yarn package, which can be dyed the material, is wound on

to s.s. wise tube which is compressible & allow the dye liqueur to flow

through the yarn layers from inside to outside & from outside to inside.

The package weight is approx. 1 kg. The amount of waste generation is of

the order of 0.25% under normal circumstances.

4 .Package to Cone Winding :

The dye yarn package on SS. spring tube after dyeing is taken to this

machine to wind the yarn on to paper cones, which is the final product.

The wastage is due to following:

· Start up string up.

· Breakages, entanglement.

· Shade variation portion removal.

To get desired quality package on an average 0.24% waste is incurred. The

reduction is possible with improvement in yarn quality & package dyeing

uniformity.

5. Package & fabric dyeing:

The process has three parts which are pretreatment, dyeing and after

treatment.

Dyeing is carried out in pressure vessels using reactive dyes of vinyl

sulphone and cyanuric chloride he type dyes. The dyeing liquor is forced to

circulate through the package. Before actual dyeing the material has to be

prepared to get good dyeing results. For this it is necessary to do the

following:

· Yarn should be clean, wet, free from impurities, waxes, oils, foreign

matter etc.

· Remove any traces of calcium/magnesium salts.

· There should not be any air present in the yarn or in the dyeing bath.

Treating the material with wetting agent, strong alkali, & bleaching agents

like H2O2.

For lighter shades this pretreatment has to be very thoroughly carried out to

remove all traces of waxes & oils present in cotton. During this process

there is a loss of material in addition to losses due to removal of cotton

waxes etc.

For achieving level dyeing results following factors are to be considered:

v Uniformly of package density.

(A) Material liquor ratio & rate of flow of liquor through the

package.

§ Temperature.

· Exhausting salts.

· Quality of dyes & chemicals.

v Use of clean soft water.

There is no method by which the actual loss in weight of cotton could be

controlled while in process. The estimates are possible by actual

weighments before & after dyeing of each lot. Necessary weighing

arrangements are being planned by installing suitable balance in dye house.

There is no other material wastage in dyeing. In fabric & hank dyeing

process is similar but it does not require the use of pressure because

material is in loose form & offers no resistance to liquor flow.

In dyeing normal material wt. Loss (invisible) ranges between 5.0-6.0%

6. Yarn packing:

The losses could be on two accounts:

v Faulty weighments.

v Lower moisture% in material.

The weighments are done very accurately within + 20 gms. Accuracy &

moisture %age in yarn is maintained at 7.5 to 8.5 % level.

7. Weaving:

In weaving three type of supply package are used normally ground warp,

pile warp & weft.

Weft is used in yarn package form & it could be either in grey or in dyed

form.

Ground warp/pile warp is prepared in beam form in the preparatory section

having following machines:

● Direct warping

● Sizing

● Sectional warping

All beams, which are prepared on direct warping using single yarns, are

taken to sizing machine where weavers beam is prepared by combining 6 to

8 warper beams after applying the size.

Two-ply yarns do not require size application & weavers beams are directly

prepared on sectional warping machine.

The total waste% in preparatory section (direct warping, sizing & sectional

warping) is 1.25%.

Warping operations left out yarn packages on warping creels. With

appropriate planning the left out yarn butts should be within 4% of the

production. This is generally not possible due to various reasons of

production/colour requirements. The left out yarn (remnant) is combined by

rewinding into full packages. Smaller butts will cause more knotting in the

wound package. Larger butts will result into high amount of rewound

(remnant) material. Under normal conditions if the production of same

material/ shade continues these rewound/remnant material is reusable &

generally it is not a waste.

In weaving following are the sources of waste:

● Selvedges cutting.

● Knotting of beams & drawing in/ start up of a new set.

● Yarn breaks.

Selvedge cutting is unavoidable part of shuttle less weaving. For a wide

looms like ours 1.5cm fabric on either side as selvedge for a 300cm wide

fabric weaving accounts to about 0.5% wastage.

Waste generated due to style change/ knotting, denting etc accounts to

additional 1.0% waste.

Total weaving waste (as yarn & selvedge) = 1.5%

Defective fabric which is woven due to negligence & or by machine faults

is additional wastage which has to be controlled. Normally 98% production

is expected to be fault free. Higher % of defective fabric indicated higher

wastage/losses. Another important aspect in weaving/designing is that

fabric gsm should be controlled as accurately as possible within +/- 3%

range. The customer does not pay for the higher GSM & lower GSM is

rejected.

8. Cutting / Hemming / Packing:

Fabric from looms is either sent to fabric dyeing (in case of piece dyeing)

or directly to cutting / hemming section (in case of yarn dyed goods).

Fabric is cut into towels lengthwise & then width wise. Stitching is done on

all sides. The fringes are cut as waste. Fabric at joints is also removed as

waste. Some towels are spoiled by malfunctioning of the machine or

machine operator due to uneven/short selvedge, which leaves no place for

stitching of the border. The total wastage due to all factors is to be

controlled within 1.5%. During stitching the labels etc are also inserted

along as per the customer requirements.

9. Shearing:

The pile fabric (terry towel) is subjected to shearing on one side, which cuts

all the pile (loops) to a certain extent giving a plush (velvet) feel. The

weight loss is generally 11% to get a proper effect on the surface and the

desired towel quality parameters. The working of shearing m/c requires

some length of the fabric at each fresh start up to go waste to carry out

adjustments. Every stoppage may also result into marks to develop on the

surface of the fabric. Depending upon the continuity & uniformity of the

m/c working. Wastages / defective cloth can be reduced but certain

wastages are unavoidable (minimum 11%).

PROCESS HOUSE

The terry towel division -2 has a highly advanced fully automatic

processing house. Following

· Highly modern Theis dyeing machines.

· Orgatex system to control all the dyeing machines.

· Auto dispensing unit for dispensing the chemicals and dyes into the

machines through MPS-S, MPS-L and MPS-D

· Latest technology fully automatic MCS multiflow machine section.

PRODUCTION:-

Yarn: 7.0 tons/ day

Fabric: 68 tons/ day

PROCESS FLOW CHART FOR YARN

GREY YARN

SOFT WINDING

HYDROEXTRACTION

RF DRYING

PTC WINDING

PACKAGE DYEING

WARPING PACKING

SIZING

WEAVING

DISPATCH

CHEESE WINDING

TFO

PROCESS FLOW CHART FOR TOWELS

WEAVING

GREIGH INSPECTION

LOT MAKING

FABRIC DYEING

HYDROEXTRACTION

STENTER

LOT

INSPECTION

SHADE

PASS

SHADE FAIL

GR

EIG

H

FO

LD

IN

G

PR

OC

ES

SIN

GR

& D

ROPE OPENER

LOOP DRYER

LENGTH CUTTING

LENGTH HEMMING

CROSS CUTTING

FIN

ISH

ING

BAR CODE + LABEL

CARTON PACKING

DISPATCH

CROSS HEMMING

PACKAGE

DYEING

INTRODUCTION

In this section, the yarn is dyed in package form. For this purpose HTHP

package dyeing machine is used. The packages are loaded into the carrier

situated in the machine where in to- out & out to- in liquor flow is used to

dye the package. The dyeing is carried out at temperature of 60 to 80 deg

C.. The package dyeing has a capacity of dyeing 6.5 tons of yarn per day

MACHINES USED IN PACKAGE DYEING:

M/c no Make Capacity( kg) Power (k.w.)

1 Theis Ecobloc (Germany) 903 75





6 Theis Ecobloc (Germany) 55 7.5

7 Theis Quattro (Germany) 24(6×4) 3.06

8 Theis Quattro (Germany) 16(4×4) 3.06

9 Theis SPDM (Germany) 1 1.1

THEIS ECOBLOC PACKAGE DYEING MACHINE

The ecobloc is a high temperature dyeing machine designed according to

the latest technical and technological know how regarding liquor flow,

liquor circulation, dye liquor penetration and economic efficiency due to

the possibility to reverse the liquor flow direction and to adjust the

differential pressure.

Depending upon the kind of material to be processed, the machine operates

with a proven dyeing process at a short liquor ratio of 1:3to 1:6.

Furthermore the liquor level can be raised until the textile material is fully

covered (fully flooded).

A flow reversal allows many functions for instance filling, draining,

reversal of the liquor circulation when dyeing with long liquor, steaming,

hydroextraction using compressed air and rapid drainage via pump.

The speed of the differential pressure build up is infinitely adjustable and

can therefore be adapted to different kinds of material. Electronic

controllers control and regulate all machine functions in conventional

dyeing processes.

The dyeing kier is laid out for a dyeing temperature upto 140 deg C for a

pressure of 5 bars.

All the machines run automatically of the orgatex system in which dye and

chemicals are dispensed automatically by MPS-S, MPS-L and MPS-D.

CONSTRUCTION:

This machine consists of following main parts:

· MAIN DYE VESSEL:

Yarn dyeing machine contains the main dye vessel in which the spindles

are loaded. The cheeses are loaded on to the spindles and dyeing is

carried out using into- out &out to- in flow of the dye liquor. The dye

tank contains heating coils lying at the bottom of the machine. Steam is

used to heat the liquor in the tank.

· ADDITION TANK:

An addition tank is situated near the main dye tank. All the dyes and

chemicals can be fed to the main dye tank through this tank with the

help of feeding system.

· DISSOLVING TANK:

A dissolving tank is also situated near the main dyeing vessel to dissolve

the dye. Addition of the dye liquor through this tank to the dye vessel

with salt in case of dark shades. Similar to the addition tank it also

contains the mixer.

· MAIN CIRCULATION PUMP:

The main circulation pump performs the function of circulating the dye

liquor with into- out &out to- in flow from the package.

· DOZING PUMP:

Dozing pump doses the dye or chemical at a fixed rate to main dyeing

tank with the salt.

· SAFETY VALVE:

Maximum pressure in the machine is kept to be 4 bars. If the pressure

inside the vessel exceeds this value then excess pressure is released by

the safety valve.

· WATER INLET VALVE:

One water inlet valve is attached at the bottom of the machine. It

performs the function of water inlet to the tank.

· WATER OUTLET VALVE:

This is called as drain valve. With the help of drain valve all the liquor is

drained after use.

· STEAM INLET & OUTLET VALVE:

Steam comes for the purpose of heating the liquor. It comes through the

steam inlet valve & goes out from outlet valve. A cold water pipe is

connected to this steam valve for the purpose of cooling.

· AIR PRESSURE VALVE:

Air pressure valve increases the pressure after lid is closed & decreases

the pressure before opening of the lid.

PROCESS PARAMETERS

1. Flow of liquor: In to out (time 4 min)

Out to in (time 6 min)

2. Pressure inside vessel: 2.5-3.0 bar

3. Steam pressure: 6-6.5 bar

4. Water pressure: 3-4

5. Pressure: In to out: 1 bar

Out to in: 1.2 bars

6. Heating system: Indirect

7. Pump efficiency: In to out: 70%

Out to in: 80%

8. Filling height of machine: 165 cm.

9. Material to liquor ratio: 6-7

FABRIC

DYEING

DYEING:

Fabric dyeing is done by Softflow machines. It is based on the

principle in which both fabric and liquor moves.

In dyeing section, there are 2 types of machines, these are;

1. Thies Dyeing machines :

Make :- Germany

Construction: - It consist of following main parts:-

· Main dyeing tank: In this tank, also known as KIER, whole process is

done. All processing steps, including pretreatment (scouring, bleaching

etc), dyeing, softening and washing are done in a single tank.

FABRIC DYEING

Thies dyeing machines MCS dyeing machines

· Stock tank: This tank is used to mix dyes, chemicals and other

auxiliaries inside the main tank.

· Addition tank: In this tank, dyes and chemicals are mixed

homogeneously to make them ready for dyeing etc .

· Operator penal: This is used to operate the machine. It shows the

current as well as previous status of machine.

· Window: it is fitted with sight glass. Direction of flow of fabric can be

viewed from this sight glass. There is a lock fitted at the window, which

automatically locks the window after temperature is raised above 80

degree Celsius to prevent any accident.

· Winch: this is fitted to assist the entrance of fabric to the main dyeing

tank. It can move with speed upto 125m/min.

· Dosing pump: This is used to transfer dyes, chemicals and salt to the

main tank.

· Heat exchanger: It is used to maintain temperature of liquor inside the

main chamber.

· Main pump: It is used for circulation of liquor uniformly inside the

tank.

· Safety valve: It helps in avoiding the blast inside the main chamber due

to increased pressure. When pressure inside the tank exceeds certain

limit, it automatically opens.

· Pleater : This is used to plait the fabric inside the bath. Pleater

oscillates during the whole running process to pleat the fabric

continuously.

MACHINE OPERATION

The machine is filled to the requested level using a valve. The amount

of water varies depending on the quantity of the fabric to be dyed. The

pump sucks the liquor in from the lower part of the dye chamber. The

pump transports the liquor through the heat exchanger into the nozzles.

The fabric is carried by the transport winch to the nozzle and through the

transport pipe into the rear of the chamber, where it is plaited down. The

liquor flow and the weight of the fabric package take the fabric to the front

and then the transport winch transfers it to the nozzle again.

MACHINES: -

M/C

NO

MAKE CAPACIT

Y KG

NO OF

ROPES

ROPE

WEIGH

T

1 Theis Ecoflow (Germany) 80 1 80

2 Theis Ecosoft (Germany) 350 1 350











14 Theis Ecomaster(Germany) 1050 3 350







MACHINE PARAMETERS:

S. no Parameter Value

1. Diameter of nozzle 100 mm

2. Cycle time

For whites: 3 hrs

For washing: 2 hrs

For piece dyeing: 6-8

hrs

3. Pump set percentage: 90%

4. Production3 to 4 batches per day

per machine

5. Liquor ratio 1:4.5(mostly)

6. Carry over 250%

7. Winch speed

90 – 125 mt / minute

(According to fabric

gsm)

8. R.P.M. of circulation pump: 900

9. Heating gradient 3°C/min

10. Cooling gradient 1°C/min

11. Pressure of nozzle 0.4 -0.5 bar

2. MCS dyeing machines : Make -- Italy

Total number of machines – 8

Bulk dyeing machines -- 7

Capacity – 1000kg (1 machine), 1500 kg (6 machines)

Sampling dyeing machines -- 1

Capacity – 50 kg

Parameters (for 1500 kg):

Total number of chambers 6

Pasage time from one chamber to another 1.5 min

Main tank capacity 1000 lit

Stock tank capacity 9800 lit

Number of addition tanks 2

Addition tank capacity 800lit, 1500lit

To start the pump minimum liquor required 3500 lit

Number of filters 10

Breather pump works at 6kg/cm sq

Heating gradient 3deg C/min

Cooling gradient 2 deg C/min

Filling speed 1000 lit/min

loading time 30 min

Unloading time 20 min

Normal drain 3 min

Circulation pump rpm 1110 rpm

Internal reel 110 m/min

Maximum achieveable temperature 140 deg

CHEMICALS AND AUXILIARIES USED IN FABRIC DYEING

Serial

no.

Chemical Function

1 Caustic soda lye Scouring agent

2 Soda ash Fixing agent

3 Hydrogen peroxide Bleaching agent

4 Glauber salt Exhausting agent

5 Spectra 197 Soaping agent

6 Depsoluble ACL Lubricating Agent

7 Lenatol S Stabilizer

8 Lenatol DMCP Sequestering

Agent

9 Spectra LD Wetting agent

10 Lenotol HPLF Wetting agent

11 Metazil NZPN Peroxide killer

12 Tuboblanc Optical whitener

13 Sodium hydro sulphide Reducing agent

14 Green acid Mild acid

15 Ultrasil SX Softener

16 Tinozym 44L Bio wash

17 Drimagen ER Levelling agent

18 Edunine NZ-2PX Bio Wash

19 Ultrasil 2D Softener

20 Ultrasil BGX Softener

DRYING

1. HYDRO EXTRACTOR: -

During hydroextraction, excess water is removed from the fabric

rope .hydroextractor is based on centrifuging principle .the fabric rope is

loaded into the hydroextractor and centrifuged at a rpm of 350 – 450

(according to fabric quality). The residual moisture content after hydro is

between 50% – 60 %. The cycle time is 15 – 20 min.

M/C No. MADE CAPACITY

1 SWASTIK 350

2 SWASTIK 350

3 SWASTIK 350

4 SWASTIK 350

5 SWASTIK 350

6 SWASTIK 350

7 SWASTIK 350

8 SWASTIK 350

2. LOOP DRYING (SEMI DRYING): -

It is used for semi drying. After this operation the moisture content of the

fabric is reduced to 15-17 %. In the loop dryer fabric loops are formed with

the help of a chain and the loops move forward inside the chamber in which

hot air is circulated.

· MAKE NATIONAL ,SWASTIK

· NO OF MACHINES 2 +1

· LOOP LENGTH 55-65 INCHES

· PRODUCTION 10 TONN/SHIFT

· TEMPERATURE 140 – 160 deg C

· MASTER SPEED 35 % FOR TUBMAT

60% FOR BATH, HAND, WASH.

3. TUMBLE DRYER:-

Number of machines – 3

Make ---- Indian

Function --- To dry the fabric completely and to give softer feel

It is a batchwise machine whereas loop dryer is a continous machine.

Differences between tumbler and loop dryer are as follows:

Parameters Tumbler Loop dryer

1. Feel Softer Normal

2. Max. Set Temp 140 deg C 200 deg C

3. Achivable Temp 120 – 130 deg C 160 deg C

4. Nature Batch wise Continous

5. Loading time 12 – 15 min -

6. Unloading time 20 – 25 min -

7. Run time 30 min Depends on speed

8. Speed Depends on run time Max. 28 m/min

9. Max. production 3200 kgs 10 ton

10. Fluff generation More Normal

11. Pile nature Open Flat

12. Steaming option Yes No

13. Manpower needed 1worker 2workers

3. STENTER

The final drying of the rope is done in stenter. After this operation the

moisture content of the fabric is reduced to 3-5 %. There are 4 stenter in the

processing house. The fabric is passed trough the stenter in open width

form. The width of the fabric is adjusted by adjusting the distance between

the chains. The details of the machine are as follows:

· MAKE SWASTIK INDIA LTD and HARISH INDIA LTD.

· NO OF MACHINES 3 , 1

· TEMPERATURE 170- 190°C

· NO OF CHAMBERS 3

· TYPE clip type

· SPEED 15-30 mts / min depending on the fabric quality

· PRODUCTION 20-22 TON/SHIFT.

AUTO DISPENSING UNIT

The most important feature of the process house is the auto dispensing

unit .The dyes and chemicals are dispensed automatically to all the

machines with the help of MPS-S, MPS-L and MPS-D, thus reducing the

manpower required for running the machines. Apart from this it reduces the

chances of manual errors. The auto dispensing unit can be divided into 3

parts:

· MPS-S

· MPS-L

· MPS-D

The details of each of them are as follows:

1. MPS-S:

In this section the salt and soda solutions are prepared for dispensing into

the dyeing machines during the dyeing cycle. There are two tanks for salt

and two for soda ash.

The capacity of tanks is as follows:

Salt dosing Capacity

Tank 1 15000 kg

Tank 2 3500 kg

Soda dosing Capacity

Tank 1 3500 kg

Tank 2 3500 kg

Dispensing procedure:

Salt is added in bucket of MPS-S and then it is transferred to the stock tank

with the help of a motor.

When a call comes, required amount of salt or soda and equal quantity of

water is mixed in the mixer tank.

The temperature of the mixer tank is raised to dissolve the salt or soda in

water.

Then the pump pumps the solution into the respective machine.

2. MPS-L:

The MPS-L is used to dispense the chemicals into the dyeing machine. The

unit consists of 26 tanks filled with different chemicals. These tanks are

connected to all the machines through MPS-L pipelines. Whenever a call

for chemical comes, the required amount of chemical is pumped into the

respective machine.

TANK

NO

CHEMICAL FUNCTION CAPACITY

(liters)

1 H2O2 Weak Bleaching Agent 1396

2 Neutra FAB Hardness Killer 1396

3 Formic Acid Neutraliser(pH setter) 1396

4 Chromofix Fixer 1417

GBCA

5 Ultrasil 2D Softener(silicone) 1498

5A Ultrasil 2D Softener(silicone) 1872

6 Ultrasil SX Softener(silicone) 1872

6A Ultrasil SX Softener(silicone) 1700

7 Spectra 197 Soaping Agent 1546

8 Ultrasil BGX Softener(silicone) 1620

9 Spectra LD Wetting agent 1326

10 Metaxil NZPN Peroxide killer 1630

11 Hydrogen

peroxide(50%)

Bleaching agent1783

11A Hydrogen

peroxide (50%)

Bleaching agent 2228

12 Tubingal 7023 Softener(cationic) 1745

12A Tubingal 7023 Peroxide stabilizer 1745

13 Lenetol DMCP Sequestering agent 1827

14 Sabasoft SFC Softener(Non-Ionic) 1340

15 Edunine

Aquasoft

Softener(cationic)1745

16 Lenetol HPLF Wetting Agent 1745

17 Green acid (50%) Organic acid 1745

18A Caustic lye Alkali 2575

18 Caustic lye Alkali 2060

19 Lenapex S Stabiliser 2060

20 Depsoluble ACL Lubricating Agent 2060

3. MPS-D:

The MPS-D unit is used to prepare dye solutions and pump it into the

respective machines. The unit consists of 4 dye dissolving machines. The

operator weighs the required amount of dyes (according to the drug sheet)

and adds it into the machine. The machine automatically takes required

amount of water and the temperature is raised so as to dissolve the dyes

properly. After the completion of dye dissolution, the solution is pumped

into the respective machine.

PROCESS

LAB

Processing lab of AHT-2 has following lab equipments...

· Spectrophotometer (1) :

It is used for Recipe prediction, Cost Management and Quality

Control. In this equipment, sample is inserted and corresponding

information can be taken regarding it. This machine can also be used

for colour matching.

Type: - SF600X

Manufacturer: - datacolor

COMPUTERIZED COLOR MATCHING

The color of textile product is one of the important parameters which

determine its salability as there is a demand for precise shade control and

its repeatability within acceptable limit of tolerance.

Even today a large no of industries practice visual color matching and

determine color recipe for a given shade by trial and error method.

The foundation of instrumental color measurement was laid in 1931

when CIE (international commission for illumination) defined standard

observer and illuminants. This subsequently led to instrumental match

prediction

(Known as CCM)

SOP FOR EVALUATION OF TERRY TOWELS THROUGH

CCM .

CALIBRATE THE SYSTEM THROUGH DATACOLOR

CALIBRATION KIT

GO TO THE DESKTOP AND CLICK COLOR TOOLS IKON

ENTER THE NAME OF STANDARD

PLACE THE STANDARD ON SPECTROPHOTOMETER AND

CLICK

STANDARD INS AVG BUTTON

MEASURE 3 AVERAGE READINGS

ENTER THE BATCH NAME

PLACE THE BATCH ON SPECTROPHOTOMETER AND

CLICK

BATCH INS AVG BUTTON

MEASURE 3 AVERAGE READINGS

CLICK THE COLOR COORDINATE IKON AND CHECK

FOR a* AND h VALUES

CLICK THE COLOR DIFFERENCE IKON AND

CHECK THE VALUES OF ∆H AND SEE WHETHER IT LAYS WITHIN

THE PERMISSIBLE LIMIT OR NOT

FINALLY CLICK THE CIE DE PLOT AND LOCATE THE POSITION

OF BATCH W.R.T. STANDARD AS WELL AS

PREVIOUS BATCHES

FINALLY GIVE THE DECISION PASS/FAIL

● Solution maker(1) :

This machine is used to make stock solutions. 30 % of warm water

is automatically added by machine to raise to required level and dye

is added in the bottle manually. This solution made is then put on the

mixer for 2 minutes. After that, remaining 70 % water is added. Now

solution is ready to be fed in autodispensor.

Type: - Autolab SPS solution maker.

Manufacturer: - Datacolor

· Autodispensor (1) :

It is used for dispensing the dyes and chemicals required for

dyeing the Textile Substrate in lab. This machine eliminates the

occurrence of manual error during dispensing. 120 colours and 7

chemicals can simultaneously be fed into this for recipe formation.

Procedure:-

1. Switch on the machine and turn on computer.

2. Through database, specify the bottle number.

3. Make the solution in solution maker.

4. Place the bottle at its specific place and close the door.

5. Feed the recipe and make their batches.

6. Place the beaker tray on conveyor.

7. Forward the batch.

Type: - Autolab TF.

Manufacturer: - Datacolor.

· Ahiba Dyeing Machines (3) :

This machine is used to dye the samples. In this machine, IR

radiations are used to heat the dye bath to attain temperature required

for dyeing.

There are 3 machines of this type in lab:-

1. Capacity : 19 pots

2. Capacity : 19 Pots

3. Capacity : 14 Pots

Average Cycle time per batch - 5 Hrs.

Number of Batches per Machine: 4.8

Number of Lab Dips produced per Machine per Day: 8

Manufacturer: - Datacolor.

· Multi –Precise Ahiba Dyeing Machine (1) :

This machine is used to dye 100 gms Yarn in the form of soft

package. Package is loaded inside the machine. Lid is closed properly

and dyeing is carried out according to the program fed into it.

· Hot Air Oven (1) :

This is used for Drying the samples and chemicals to check their

solid content.

Manufacturer: - Paramount.

· Electronic Balance (1) :

This is used to weigh the Samples, Dyes and Chemicals with

accuracy upto 4 decimal places.

· Hot Plate (1) :

This is used for heating of Chemicals, Water and Dye baths.

· Ph Meter (1):

This instrument is used to check the pH of Liquids.

· Wrap Reel (1):

It is used to make the lees for dyeing Yarn in Ahiba Dyeing

Machines.

Manufacturer: - Innolab.

· Light Box (1) :

It is used to check the shades under different light sources (like

TL84, D65, UV36 etc.) as per the recommendation of customers.

Manufacturer: - Gretag Macbeth.

· Winder (1) :

It is used to wind the soft packages used for dyeing. Programs (0 to

6) can be adjusted according to the requirement.

Manufacturer: - datacolour.

● Technorama Multifastest :

To check the washing fastness, chlorine fastness, hot water

bleeding and many other fastness except crocking fastness and

light fastness at different temperature and pressure.

PROCESS

DEVELOPMENT

CELL

THE MAIN OBJECTIVES OF PDC SECTION ARE:-

1) TO DEAL WITH PROBLEMS IN DYEING

If any problem in the bulk or lab occurs related to dyeing then it is dealed

by PDC cell and controlled by this section by controlling and studying all

the related parameters of dyeing. For example to get the shade right first

time (RFT) all the parameters related to the process are studied and

controlled.

2) TO DEAL WITH COMPLAINTS

If there are any complaints by the customer then that complaint is dealed by

the PDC cell. This section studies various parameters and reasons related to

that problem. Mostly the complaint arises related to quality of the substrate

and necessary steps are taken to solve that problem for the complete

satisfaction of the customer.

3) TO INTRODUCE NEW DYES AND CEMICALS

If new dye or chemical is to be introducing in the process then testing of

that sample is done in this section. The testing is done through AHIBA

dyeing machine or if necessary then through SPDM section. If the results

are satisfactory then that dye or chemical is introduced into the process.

4) TO INTRODUCE NEW DEVELOPMENTS

New development related to process, shade or the materials are done in this

department.

5) TO DEVELOP VARIOUS METHODS OF COST AND TIME

SAVING

This department introduces various methods of cost and time saving.

By studying thoroughly the related process, which helps in higher

productivity and lower dyeing cost.

6) TO INTRODUCE THE NEW WORK PRACTICES

The PDC section introduces the new method of doing the work so that it could be feasible and comparatively easier for the worker to do that work.

Documents

Varun t Report