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Observations to be made on
o Yarn manufacturing and Winding section
o Weaving section
o Dyeing section
o Testing and Quality control sections
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8 Pillars of TPM
1. Focused Improvement2. Autonomous maintenance
3. Planned maintenance
4. Education and Training
5. Initial flow control
6. Quality maintenance
7. Office maintenance
8. Safety health and environment
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REITER Machines
TRUTZSHLER DK 803
REITER Machin
RSB 851
REITER F35 RovingFrame
Schlafhorst/saurer
REITER Ring Frame F16
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The Blowroom is the 1st step of yarn production in the spinning mill.
INPUT : Fabric in the form of Bales
OUTPUT : Sliver
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a) Opening
b) Cleaning
c) Dust Removal
d) Blending
e) Even Feeding of material to the card
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Type Appearance Description
Rollers Small Diameter, Widely
used.
e.g.: in STEP CLEANERS
Drums Larger Diameter, little
used
e.g.: in MONO-
CYLINDER CLEANERS
Quilted Shaft Shaft with many beater
rods, hardly used
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Cotton contains upto 18% trash,o in most cases ranging from 1% to 7%
Since this Cost is a considerable cost factor, it has to be kept as low as
possible, which requires an assignment
Cleaning Degree = extracted trash*100
--------------------------------------
trash content in fed cotton
Cleaning Efficiency = extracted trash*100
--------------------------------------
Total Extracted Waste
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Unimixo Model LB 7/3
o By Lakshmi LMW
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The m/c is made up of 3 parts
o Storage section,
o Intermediate section, and
o Delivery section
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MACHINE: REITER UniClean
1. Special Design VIBRATING PLATE
4. Rollers for additional Dusting
5. Servomotor-controlled feeding plates
6. Groove
7. Operating Panel
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Ensuring that debris is removed while aligning the fibers to make
them easier to spin.
Without carding, cotton thread would be coarse and extremely
fragile.
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Parallelize the fibres in card sliver along the sliver axis.
To improve the regularity in linear density of card sliver by doubling.
Improve sliver quality.
To achieve the correct amount of blending.
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17-18% of short fibres are removed
Removal of neps
Parallelization of fibres
Kitty Level is Reduced
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The function of the speed frame is to attenuate the sliver and to form
a suitable supply package for the ring frame.
Twist + Strength + Winding
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To draft the roving until the required fineness is achieved
To impart strength to the fibre, by inserting twist
To wind up the twisted strand (yarn) in a form suitable for storage
Transportation and further processing.
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Marketing
Team
VardhmanCustomer
CPDC
Located at Mahavir Textiles
Central Design
Cell (CDC)
Bit Loom
R&D(Small
Length Sampling
Pilot PlantTechnical
Department
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Several sections are wound in sequence and parallel to each other on a
dresser or on a drum
the warping sections are as many as necessary to obtain, with the
available creel capacity, the total number of threads composing the warp
The warping speed is about 800 m/min, while the beaming speed is about300 m/min
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Before carrying out warping, following calculations are necessary:
o If the calculation does not give an exact number, the last section
will be produced with a number of threads lower than the other
sections,
o Or the number of threads composing each section will be
reduced.
so as to get all sections with one and the same number of thread,
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A complementary operation which is carried out
on warps formed by spun yarns with insufficient
tenacity
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Drawing-in:
o consists of
threading the
warp yarns
through the
drop wires,
the healdsand the reed
Requirement of Style Change
Drawing - in
Transport and Loading of Beams
and harness onto the Weaving
m/c
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1. Back rest roller
(warp threads are
wound)
2. Support special
drop wires
3. Healds
5. Dents of the reed
8. Slay
6. Motor driving the
take down roller11. Cloth Beam
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the most flexible machines on the market
Their application range covers a wide varietyof fabric styles
Their present weaving speed of about 600-700strokes/min
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weaving machines with the highest weftinsertion performance and are considered as themost productive
manufacturing of light to medium weight fabrics,
preferably made of cotton and certain man-madefibres
sheets, shirting fabrics, linings, taffetas and satinsin staple yarns of man-made fibres
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Started in December 2000
Production - 30 lack Meters/ Month
One of the largest fabric processing unit inAsia.
Has area of 12 acres
Self- sufficient power supply
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Processes:
Preparatory
Dyeing Finishing (both piece dyed and yarn dyed fabrics)
Inspection and Packing
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GREIGE SECTION
PREPARATORY SECTION
PERBLE RANGE
NEW PAD STEAMER MERCIRIZER
DYEING SECTION
TANK COLOUR PREPARATION AREA
PAD DRY
HT STEAMER
THERMOFIX
PAD STEAMER
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FINISHING SECTION STENTER
SUEDING MACHINE
SANFORIZER
AIRO MACHINE
CURING MACHINE
TECHNICAL SECTION
PHYSICAL LAB
CHEMICAL LAB
PILOT PLANTINSPECTION AND FOLDING SECTION
PRODUCTION PLANNING & CONTROL
EFFLUENT TREATMENT PLANT
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SINGEING
WASHING
DESIZING &
SCOURING
WASHING
NaClO2
BLEACH
H2O
2BLEACH
WASHING
DRYING ON
CYLINDERS
PLAITOR
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Section A: Singeing, Combined desizing and scouring
Section B: Chlorite Bleaching
Section C: Peroxide bleaching
Section D: Vertical Drying Range.
In new Perble Machine, Only Peroxide Bleaching (3
sections)
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PARTS OF MERCERIZER RANGE
The mercerization machine has five sections:
Padding Section
Tenter chain Tenter pit
Washing range
Drawing unit
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To increase the dye uptake.
To increase the tensile strength of the fabric.
To increase lustre of the fabric.
Better coverage of immature cotton fibers. To remove crease marks.
To remove naps from the fabric.
To increase the reactivity and absorbency of the fabric.
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The Caustic Soda used in the processes is heated and
concentrated for reuse
The CRP has an efficiency of 90-95%
The principle of CRP unit is to evaporate the water from
the weak lye.
It helps save money and is less harmful to environment.
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Most important feature of dyeing used is the continuous
dyeing range (CDR)
Consists of Padder Box with a capacity of 50-60 lts
pad-dyeing method ensures a full penetration of dye
inside the fabric at a relatively low consumption of dyes,
chemical, steam and water
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The cotton and P/C blend fabrics are dyed 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.