Download pdf - textile internship at vardhman

7/30/2019 textile internship at vardhman

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Observations to be made on

o Yarn manufacturing and Winding section

o Weaving section

o Dyeing section

o Testing and Quality control sections


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8 Pillars of TPM

1. Focused Improvement2. Autonomous maintenance

3. Planned maintenance

4. Education and Training

5. Initial flow control

6. Quality maintenance

7. Office maintenance

8. Safety health and environment


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REITER Machines

TRUTZSHLER DK 803

REITER Machin

RSB 851

REITER F35 RovingFrame

Schlafhorst/saurer

REITER Ring Frame F16


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

INPUT : Fabric in the form of Bales

OUTPUT : Sliver


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a) Opening

b) Cleaning

c) Dust Removal

d) Blending

e) Even Feeding of material to the card


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Type Appearance Description

Rollers Small Diameter, Widely

used.

e.g.: in STEP CLEANERS

Drums Larger Diameter, little

used

e.g.: in MONO-

CYLINDER CLEANERS

Quilted Shaft Shaft with many beater

rods, hardly used


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

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

possible, which requires an assignment

Cleaning Degree = extracted trash*100

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trash content in fed cotton

Cleaning Efficiency = extracted trash*100

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Total Extracted Waste


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Unimixo Model LB 7/3

o By Lakshmi LMW


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The m/c is made up of 3 parts

o Storage section,

o Intermediate section, and

o Delivery section


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MACHINE: REITER UniClean

1. Special Design VIBRATING PLATE

4. Rollers for additional Dusting

5. Servomotor-controlled feeding plates

6. Groove

7. Operating Panel


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Ensuring that debris is removed while aligning the fibers to make

them easier to spin.

Without carding, cotton thread would be coarse and extremely

fragile.


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Parallelize the fibres in card sliver along the sliver axis.

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

Improve sliver quality.

To achieve the correct amount of blending.


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17-18% of short fibres are removed

Removal of neps

Parallelization of fibres

Kitty Level is Reduced


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

a suitable supply package for the ring frame.

Twist + Strength + Winding


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To draft the roving until the required fineness is achieved

To impart strength to the fibre, by inserting twist

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

Transportation and further processing.


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Marketing

Team

VardhmanCustomer

CPDC

Located at Mahavir Textiles

Central Design

Cell (CDC)

Bit Loom

R&D(Small

Length Sampling

Pilot PlantTechnical

Department


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

dresser or on a drum

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

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

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


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Before carrying out warping, following calculations are necessary:

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

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

sections,

o Or the number of threads composing each section will be

reduced.

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


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A complementary operation which is carried out

on warps formed by spun yarns with insufficient

tenacity


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Drawing-in:

o consists of

threading the

warp yarns

through the

drop wires,

the healdsand the reed

Requirement of Style Change

Drawing - in

Transport and Loading of Beams

and harness onto the Weaving

m/c


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1. Back rest roller

(warp threads are

wound)

2. Support special

drop wires

3. Healds

5. Dents of the reed

8. Slay

6. Motor driving the

take down roller11. Cloth Beam


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the most flexible machines on the market

Their application range covers a wide varietyof fabric styles

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


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

manufacturing of light to medium weight fabrics,

preferably made of cotton and certain man-madefibres

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


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Started in December 2000

Production - 30 lack Meters/ Month

One of the largest fabric processing unit inAsia.

Has area of 12 acres

Self- sufficient power supply


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Processes:

Preparatory

Dyeing Finishing (both piece dyed and yarn dyed fabrics)

Inspection and Packing


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GREIGE SECTION

PREPARATORY SECTION

PERBLE RANGE

NEW PAD STEAMER MERCIRIZER

DYEING SECTION

TANK COLOUR PREPARATION AREA

PAD DRY

HT STEAMER

THERMOFIX

PAD STEAMER


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FINISHING SECTION STENTER

SUEDING MACHINE

SANFORIZER

AIRO MACHINE

CURING MACHINE

TECHNICAL SECTION

PHYSICAL LAB

CHEMICAL LAB

PILOT PLANTINSPECTION AND FOLDING SECTION

PRODUCTION PLANNING & CONTROL

EFFLUENT TREATMENT PLANT


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SINGEING

WASHING

DESIZING &

SCOURING

WASHING

NaClO2

BLEACH

H2O

2BLEACH

WASHING

DRYING ON

CYLINDERS

PLAITOR


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Section A: Singeing, Combined desizing and scouring

Section B: Chlorite Bleaching

Section C: Peroxide bleaching

Section D: Vertical Drying Range.

In new Perble Machine, Only Peroxide Bleaching (3

sections)


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PARTS OF MERCERIZER RANGE

The mercerization machine has five sections:

Padding Section

Tenter chain Tenter pit

Washing range

Drawing unit


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To increase the dye uptake.

To increase the tensile strength of the fabric.

To increase lustre of the fabric.

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

To remove naps from the fabric.

To increase the reactivity and absorbency of the fabric.


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The Caustic Soda used in the processes is heated and

concentrated for reuse

The CRP has an efficiency of 90-95%

The principle of CRP unit is to evaporate the water from

the weak lye.

It helps save money and is less harmful to environment.


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Most important feature of dyeing used is the continuous

dyeing range (CDR)

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

pad-dyeing method ensures a full penetration of dye

inside the fabric at a relatively low consumption of dyes,

chemical, steam and water


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The cotton and P/C blend fabrics are dyed with the

following dyes

1. Vat dyes for 100% cotton

2. Reactive dyes for 100% cotton

3. Disperse/Vat dyes combinations for P/C blends

4.Reactive/Disperse dye combinations for P/C blends


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Reactive (HT Method) PDHT

Dye X gpl

Sanspol AMC 20gpl Resist salt 5gpl

Sodium bicarbonate 20gpl

Urea 50gpl


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High temperature steamer is used for the fixation of

reactive dyes on cotton and on cotton component of P/C

blend.

The steam here is used for dual purpose: to provide heat

energy and also to act as a source of water to transferrapidly and uniformly on dyed surface.

FABRICINLET

STEAMERS PLAITOR


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This technique utilizes the high rate of dyeing achieved

at high temperature (commonly in the region of 210C).

A dyeing achieved in less than one hour at 130C can be

attained in 20-60 seconds at about 200C.


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FABRICINLET

CHEMICALTROUGH

STEAMER

WATERSEAL

13WASHERS

VERTICALDRYINGRANGE

PLAITOR


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Stenter

Peaching Machine

Sanforizing Machine

Airo machine Curing Machine


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CHEMICAL FINISHING

SOFTENING

RESIN FINISH

TEFLON FINISH ETI(Easy to Iron)

MECHANICAL FINISHING

PEACH FINISH SANFORISATION


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1. PHYSICAL TESTING LAB

2. CHEMICAL LAB

3. PILOT PLANT


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4 Point system used forInspection

Fabric divided into A, B, C Grade

Packing done in sizes as per the

order or buyer specification.

Shipping to both buyer/garment

manufacturer


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Fiber Dyeing: Cotton, Polyester.

Yarn Dyeing: Cotton. P/C blend, A/C blend

The unit has technical collaboration with Japaneseconcern. Most of the machinery is Imported from Japan.


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It comprises of fivesections:

a) Pre Winding

b) Dyeingc) Post Winding

d) Conditioning

e) Dispatch


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In this section cones of yarn are converted to

soft cheeses for processing.

It is also called Soft package section. Various counts running 10s To 100s (single

and Double)


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Done In HTHP (High Temperature High Pressure)

Dyeing Machines

48 Machines

Hisaka (Japan), Fong (China), Pozzi (Italy)

Machine Package load varying from 50Kg to more than

500 Kg depending upon model.

Complete Dyeing cycle done in the HTHP machines.


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RAPID DRYER

Uses Centrifugal force to extract the excess liquid out

from the soft package.

RADIO FREQUENCY DRYER

Uses high frequency Radio waves to completely dry the

soft packages


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After processing, yarn is wound onto cones in post

winding section .

Three types of machines are used in this section.

1. PSM

2. 138 AUTOCONER

3. MACH CONER

Post winding is followed by conditioning of the yarn


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After conditioning the material is dispatched in cartons.Following parameters are mentioned on carton.

MILL:

SUBSTRATE: COUNT:

SHADE N0.

LOT N0:

N0.OF CONES:

DATE:

NET WT.:

GROSS WT.:


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Types of fibers dyed

COTTON

ACRYLIC TOW

POLYESTER

WOOL

MILANGE


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RAW MATERIAL(Cotton,

Polyester,Acrylic)

STAMPING

PRESSING

DYEINGHYDROEXTRAC

TION

CAKEUNLOADING

WASHING

DRYING BALE PACKING

DISPATCH


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The main objective of this department is to execute the

orders placed to the organization by effective scheduling.

They also keep a control over the orders by daily

monitoring at each stage of SPDM, dyeing and dispatch.

This department has to decide the date for the dyeing of

the particular lot in the bulk


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RESEARCH & DEVELOPMENT has the following sub

departments

a) Quality Control Input

b) Quality Control Output

c) SPDM Section

d) Yarn Dyed Shirting Cell

e) PDC


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Technorama M/c

OBBDM

SPDM

Knitting M/c (Quality)


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Vardhman is one of the biggest names in textiles worldwide.Our Internship in the company gave us immense exposure tothe processes that take place in the production of fabric inmany forms starting from the fiber stage up to final packingand despatch to the buyers.

The experience of being a part of such a big company foreven a short time was amazing and helpful in learning aboutthe different processes in textile manufacturing.

We are very thankful to all the people at Vardhman, Rightfrom executives to the labourers who selflessly helped usgather information and explained everything in detail.