TEXTILE DIVISION CHHINDWARA

AN INTERNSHIP REPORT

ABHITOSH KUMAR NEERAJ KUMAR

NIFT-Hyderabad 2010-2014

Contents
Preface ................................................................................................................................ 3 Acknowledgement ............................................................................................................. 4 Introduction To Organisation.......................................................................................... 5 Raymond Ltd Textile Division ......................................................................................... 8 Organizational Chart...................................................................................................... 12 Process Flow of Department .......................................................................................... 13 Lead Period for Production Departments .................................................................... 14 Plant Layout .................................................................................................................... 15 Raw Material Godown ................................................................................................... 16 Wool Scouring .................................................................................................................. 50 Grey Combing Department .............................................................................................. 50 Dyeing Department .......................................................................................................... 50 Recombing Department ................................................................................................... 50 P/V Spinning Department ................................................................................................ 51 Worsted Spinning Department ........................................................................................ 59 Weaving Department ....................................................................................................... 59 Finishing Department....................................................................................................... 59

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PREFACE
As a part of our course curriculum, we were supposed to undertake an extensive study of the textile production in a textile industry to know the technical as well as aesthetic know how of the textile procedures. We undertook the same at the Raymond Limited, textile division at Chhindwara. The division specializes in the manufacturing of the worsted polywool and poly-viscose fabric and is a renowned name in its field.

The document has been framed in such a way so as to cover each and every aspect related to the company. The document gives the overview about the Raymond Group, general information about the division. It also spans comprehensively the various procedures that take for the production of the worsted fabric that the division specializes in. The processes have been explained in detail according to their incidence in the manufacturing process.

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ACKNOWLEDGEMENT
It is a highly reverent privilege for having got the illuminating opportunity to work under RAYMOND LIMITED (TEXTILE DIVISION) Limited for the fulfillment of our textile internship. This acknowledgement is a petite endeavor to thank all those who were directly / indirectly involved in this project and bestowed their kind co-operation in pursuit of the same. Our training at RAYMOND gave us the precious knowledge and insight in the study of textile background. We are highly indebted to the Raymonds family, CHHINDWARA who gave us a wonderful experience in industry that not only enriched our knowledge bank but also gave us larger than life lessons and work ethics. We are grateful to MR. NARESH KADU (Placement Officer) who gave us the wonderful opportunity to learn about a textile industry as esteemed as Raymonds, without his support this project would have never been what it is today. Then we would like to thank our Mentor MR. A.PHANI who was always there to guide us through this tedious task. Last but not least we thank all the people who have somehow been a reason for completion of this onerous task

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1. INTRODUCTION TO THE ORGANIZATION

Incorporated in 1925, Raymond Limited presently has five divisions comprising of textiles, Engineering file & tools, aviation, designer wear, and prophylactics and toiletries. With a capacity of million meters of wool & wool-blended fabrics making it the third largest integrated manufacturer in the world, Raymond Limited (Textile Division) has more than 60% market share of the Indian market for worsted suiting fabrics. Promoted as an essential accessory for the Complete Man, its products have set a benchmark in that genre. The company exports its suiting fabrics to more than 50 countries including USA, Canada, Europe, Japan and the Middle East. Raymond Ltd has laid great emphasis on developing strong in house skill for research & development since its inception. This unwavering attention to innovation has enabled it to introduce path- breaking new products in the market. Hailed as a pioneer and innovator, Raymond Ltd has raised the performance and product standards of the entire Indian textile industry. Raymond Limited rightfully recognized as the most respected Textile Company of Indian in January 2003 by Business World, also produces and markets plush- velvet furnishing fabric in a wide array of designs and colors including carpeting for the niche markets of India and Middle East. Manufacturing facilities include Four world- class fully integrated plants in India, employing state- of- the art technology from wool scouring to finishing stage and modern techniques of quality management. All the plants are self-sufficient in terms of providing educational, housing, recreation and spiritual support system for the employees and connected townships. The woolen mill by the creek in 1925 is presently transformed into a Rs. 1400 Crores conglomerate, but its mantra for continuous growth has remained the same: pursuit of excellence, to achieve enhanced customer satisfaction through ongoing innovation. And happily, the growth graph continues to rise higher and higher

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Cottons, blends and denim wear catering to the smart, fashionable and comfortable clothing segment. . DIVISIONS Textiles Produces world-class pure wool,wool blended, polyester viscose fabrics, blankets, and ranks among the top 3 integrated producers in the world. Also produces a wide range of furnishing fabrics. Denim The Denim division produces high quality ring denims and ranks among the top 3 producers in India. Files & Tools Files & Tools division manufactures complete range of Engineer's steel files & drills and is the worlds largest producer of steel files. Be An exclusive prt-a-porter line of ready-to-wear designer clothing for women and men in western, ethnic and fusion styles. Aviation Million Air was launched in 1996 to provide air charter services and enjoys a reputation for high quality reliable services. Raymond Apparel Ltd. It has three highly regarded mens wear brands in its folio: Park Avenue, Parx and Manzoni. J.K. Helene Curtis Ltd.

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It is the marketers of the Park Avenue and Premium brands of mens toiletries. Color Plus Fashions Pvt. Ltd. Established in 1993 Color Plus is one of the leading domestic brands for premium casual wear in the country. BRANDS Raymond The largest and most respected textile brand in India for 'The Complete Man' addressing the innate need of men to look good and at the same time possess strength of character. Park Avenue Formal readymade garments & accessories for men it has recently bagged the "Most Admired Brand" and "Most Admired Trouser Brand" awards. Parx The semi formal and casual range of cottons, blends and denim wear catering to the smart, fashionable and comfortable clothing segment. Manzoni The luxury range of mens shirts and ties acknowledged for its high quality and international styling. Be An exclusive prt-a-porter line of ready-to-wear designer clothing for women and men in western, ethnic and fusion styles. Premium The range of cosmetics & toiletries including after shaves, shampoos, cologne, shaving cream, soaps, deodorants, room fresheners, etc.

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2. RAYMOND LTD. TEXTILE DIVISION (CHHINDWARA)

Raymond Chhindwara, which is a part of the JK group (western zone), situated at distance of 57 km from Orange city Nagpur. It is spread over a total area of 100 acres. This plot stands as a pioneer in the socio-economics development of this region, operation at the plant commenced in July 1990. The plants were in full swing by 1st April, 1991. In short span of four years they have achieved stupendous success. They have rapidly improved upon the efficiency figure. The spinning and weaving department have charged ahead of 90% efficiency levels in all over the world. Quite frankly they have exceeded all expectation, strive for excellence. But then what are the parameter of performance, is it production, is it quality, is it customer or is it the people they have perhaps it is an amalgamation of all this that spurs them on. The present capacity of the plant after expansion, which has been concluded recently, is 45,000 mtrs per day. Thus approximately 153 lacs meters is produced per annum at Chhindwara. The finishing department is the largest of its kinds in Asia, with a capacity of 40000 mtrs per day. These facts open to the possibility of carrying out finishing for other plants. As of now they process the complete production of Jalgaon. The vision for setting up the unit at CHHINDWARA has been: To manufacture world class polyester -wool and polyester-viscose blended suiting and furnishing fabrics at competitive prices, To establish a large-scale unit in a backward area, which needed accelerated development, To ensure all- round socio-economic progress of the region and its hinterland, To catalyze the nascent industrial potential potential of smaller towns of the country, and To provide additional sources of employment to people in & around Chhindwara district.

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The installed capacity of chhindwara unit is 128 looms and 33528 spindles as against the license capacity of 1500 looms and 50000 spindles. The unit has a work force of more than 2900. The plant is located on a 100 acre plot with a built-up area of 1,40000 sq meters and a green belt area of 65%. The plant is well equipped with the most modern machinery, ensuring high efficiency and productivity. The work force is adequately skilled, well trained and competent. This unit became operational in the year 1991. ACCOMPLISHMENTS 1. Safety Award from National Safety Council M P Chapter for excellent work in Industrial Heath and Safety in the year 1994-96. 2. National Energy Conservation Award from Ministry of Power Govt. of India 1999- First position 2002- Second position 2003- Certificate of merit 2004- Certificate of merit

3. ICMFS Birla Economic & Textile Research Foundation for Energy Conservation in Textile Industry First prize for the year 2003-04. 4. Golden peacock Environmental Management Award. World Environment Foundationfor the year 2000. 5. MP State Level Award from MPPCB for excellence in Environment Performance for the Year 2004-2005. 6. National Safety Award for year 2007. 7. The company has pledged itself to the protection of environment, prevention of pollution and conservation of nature resources. The mechanical engineering department ensures the fullest compliance with all applicable regulatory requirements. The in-house environmental laboratory helps the operational staff to improve the environmental performance by providing monitoring and measurement services.

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VITAL STATISTICS
MANPOWER : Per day the no. of person working all around the three shifts

(Including official staff) are 3626. The staff strength is 415. POWER CONSUMPTION WATER REQUIREMENT COAL REQUIRED OUT PUT UNITS TURN OVER : 1, 67,000 Unit per day : 43 Lacs liter per day : 58 Metric tones per day : 50,000 mtrs fabric per day : Rs. 430 crores approx p.a

THE LIST OF FACTORS LEADING TO SELECTION OF PLANT LOCATION IS AS FOLLOWS: 1. Cheap land 2. Availability of power, fuel and water 3. Availability of man power on cheaper rate 4. Site is near to Nagpur which is well connected with all places of the country by Rail, Road and Air. 5. MP Government gives 15% subsidy on total cost of project (Rs.15 lacs) 6. Five percentage subsidy in electric charges (Rs.10 lacs)

GENERAL INFORMATION
MILL ADDRESS : RAYMOND LTD (TEXTILE DIVISION), CHHINDWARA : B-1 BOREGOAN INDUSTRIAL GROWTH CENTER A.K.V.N, KAILASH NAGAR TEHSIL SAUNSAR

HEAD OFFICE NIFT HYDERABAD

J. BLLARD ESTATE, BOMBAY-400038 Page 10

K.BLDG, N. MORARJEEMARG REGISTERED OFFICE : RAYMOND LTD, 56/ H.NO.F2 VILLAGE- ZADGAON,MAHARASHTRA WORKS DIRECTOR GOODS MANUFACTURE : Mr. VINOD PARMESHWARAN : SUITINGS ONLY, P/V AND P/W ALL WOOL AND FURNISHING FABRIC CAPACITY : 50,000 Mtrs. OF FABRICS DAILY

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3. ORGANIZATIONAL CHART

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4. PROCESS FLOW OF DEPARTMENT

PV-FD Dyeing Spinning Yarn Room Warping Weaving Mending Finishing Finish Mending Folding Warehouse PV-PD Spinning / O/s Yarn Yarn Room Warping Weaving Mending Finishing ( Pretreatment) Dyeing Finishing (Post treatment) Folding Warehouse PW-TD Grey Combing Dyeing Recombing Spinning Yarn Room Warping Weaving Mending Finishing * Finish Mending Folding Warehouse PW-PD Grey Combing Recombing Spinning Yarn Room Warping Weaving Mending Finishing ( Pretreatment) Dyeing Finishing (Post treatment) Folding Warehouse

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5. LEAD PERIOD FOR PRODUCTION DEPARTMENTS

Polywool Fabric

Department
Dyeing Recombing Spinning Yarn Room Weaving Mending Grey Room Finishing & Folding Contigency Total PolyViscose Fabric

Lead Period(Days)
05 06 14 07 11 03 04 16 04 70

Department
Dyeing Spinning Yarn Room Weaving Mending Grey Room Finishing & Folding Contigency Total

Lead Period(Days)
05 20 07 11 03 04 16 04 70

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6. PLANT LAYOUT

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7. RAW MATERIAL GODOWN

The Purpose of the raw material godown is to receive Raw material from outside party and also from inside departments and deliver as per the requirement with care. It stores the raw material with proper order, receives waste from various departments, and dispatches the waste material. The raw material go down is connected to the wool scouring department. And the wool scouring department provides scoured wool to the top go down through pipelines which are further processed for carding and combing. The waste materials are sorted color wise, matching soft waste and also white separately according to the shade chart. While the non moving wastes are sorted out in six month and are inform to commercial department, & GM. DEPARTMENTAL HIERARCHY PLANT IN CHARGE

G.M. WORKS

DEPUTY MANAGER (RMG)

ASSISTANT (RMG-1)

ASSISTANT (RMG-2)

ASSISTANT Waste Department

FORK LIFT OPERATOR Raw material Unloading, Delivery, Dispatch and

WORK MAN PSF/VSF/ GREASY Wool Receipt & Issue and Despatch NIFT HYDERABAD

WORK MAN TOPS Receipt and Issue Work

WORK MAN Waste packing, Sorting, Segregation

Machine Erection & Shifting work

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7.1. Godown has three sections:1. Raw material godown (RMG) 2. Top godown 3. Waste godown

7.2. Raw material norms 1. PSF- Polyester staple fibers 2. VSF- viscose staple fibers 3. TOW- Polyester continuous filament 4. GWL- Greasy wool 5. SWL- Scoured wool 7.3. Process material Top is a bundles of sliver conversion of wool/polyester.tow is converted top. Two types of top are prepared in the industry itself others are obtained in top form already. The two kinds of top that are prepared are: 1. Polyester top (8.5 kg) 2. Wool top (10 kg) The other top that are retained in the top go down are:1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Flax top(linen top) Viscose top Silk top Cashmere top Acrylic top Blended top Camel hair top Angora top Mohair top Lenzing top

Merino wool is imported from Australia, New Zealand and South Africa. Merino wool is considered to be the finest and best quality wool in the world.

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7.4. POLYESTER STAPLE FIBERS ARE USED IN THREE FORMS: 1. Sparkle- it has good luster properties .its cross sectional view is tri-lobal 2. Normal- it is little dull in nature. Its cross sectional view is round. 3. Low pill- it is highly brittle and breaks easily. Low pill fibers are weaker because their strength is reduced by 70% during the manufacturing stage itself so that the pills do not cling to the fabric surface and fall off easily. Since they are, weak they break off easily during twisting hence the speed of machine should not be too high therefore the productivity is less and the cost of manufacturing low pill fibers is high. The polyester material has the type or merge no. which is maintained in such a way that two different type or merge no should be mixed together while in process because of the dyeing affinity 7.5. SUPPLIER NAME S no 1. Industry RIL Reliance industries FFL Futura fibers limited GIL Grasim industries limited Industry address Patalganga (ms) Surat gujarat Chennai Material Tow of PSF

2.

PSF top

3.

Nagda of M.P

VSF top

4. 5.

6.

7.

DAL Australia Dewavrin CDDL Compagnte impirtion de lafned BEAPL Australia Bwk elders Australia private limited RSA Uruguay Rantex SA NV NV jos vannestesa Belgium

Greasy wool Greasy wool

Greasy wool

Greasy wool

8.

Flax top greasy wool

and

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7.6. MACHINES MACHINE BALE PRESS FORK LIFT(diesel) BRAND Godrej Godrej (capacity=2 ton) NO. OF OBJECTIVE MACHINES 2 To pack the textile waste 2 Used to unload, shift and dispatch materials and machines Used to unload, shift and dispatch materials and machines

FORK LIFT(battery Macknell operated) (capacity=1.5 ton)

7.7. BALE SPECIFICATIONS:FIBRE TYPE 1. White sparkle and normal 2. Black sparkle and normal 3. Viscose 4. greige wool 5. tetra wool 6. scoured wool` 7. top WEIGHT( IN KG) 700 350 250 200 200 *3=600 150 120, 96

7.9. Raw material stock as on date (27.12.2010) CATEGORY 1.psf 2.vsf 3.tow 4.gwl 5.swl Total CAPACITY (IN TON) 80 70 180 120 80 530 TOTAL STOCK 54.5 65.4 185.9 236.0 78.9 560.7

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VSF- viscose staple fibre is a regenerated cellulosic fiber which is made from pulp generally it is doped by suppliers and is in fibrous form vsf are supplied from Grasim industries only. All the polyester and viscous received are in 2.0 d, 2.5 d, 1.5 d, 1.4 d, 0.8 d and lengthwise like 92 mm, 44 mm, 54 mm etc. Denier( it is making 9000 m yarn weight in gms) The polyester materials have a type or merge no which are maintained in such a way that two different types or merge should not be mixed together while in process because of the dyeing affinity. Tow- tow is a continuous filament purchased for making blend with wool. In tow it is possible to get variable length needed from converter machine it is converted to polyester top. Gwl- the greasy wool which is received from Australia, South America, South Africa in various micron value. It is merino wool which is suitable for making cloth greasy wool is supposed to be washed or scoured for the combing process which makes the wool top. Use psf/vsf- for grey dyed fabric vsf is directly purchased from Grasim industries(dope dyed) and psf is delivered to dyeing department for fiber dyeing mainly for vsf and psf pv / spinning . There they mix it in a certain ratio % for the pv fabric. Daily average consumption of vsf -1.8 tons Daily average consumption of psf - 2.9 tons Department is having 21 workers, 2 staff and one officer. 7.10. PROCESS PARAMETERS

1) UNLOADING:A. Done by Battery Forklift or Diesel Forklift. B. By forklift with good condition rope. C. By manual. 2) DELIVERY:A. By Battery or Diesel forklift. . B. By tractor, By Hydraulic pallet & hand trolley. C. Using polythene sheet & Nylon bag. 3) LOADING:A. By battery or diesel forklift. B. Systematic arrangements manually wherever necessary.

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C.

As per the dispatch list loading the bale by forklift and arranging in line manually .

4) WASTE PACKING:A. Bale press using polypropylene sheet. 5) SORTING OF WASTE:Color wise matching soft waste and also white separately according to the shade chart 6) SEGREGATION A. Category wise B. Party wise C. Undesired material should not be mixed up with textile waste. 7) NON MOVING WASTE:A. Sorted out nonmoving waste of six month. B. Inform to Commercial department, & GM 7.11. WASTE DAILY RECEIPT

Total waste - 1631.77kg Department Converter Designing Dyeing Plush PW spinning Finishing QC. Dept. Folding Weaving Grey combing Weight of waste 18.88kg 9.04kg 53.47kg 65.26kg 95.63kg 43.9kg 17.96Kg 105.52kg 267.62kg 352.84kg Waste percentage 1.16 0.55 3.28 3.99 5.86 2.69 1.01 6.47 16.40 21.62

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PV spinning Recombing 7.12.

181.44kg 152.11kg PROCESSBFLOWCHART

11.12 9.32

7.13.

WASTE GODOWN

Few Waste items are kept at the back of raw material godown and the rest are stored outside the company premises . The following waste items are received from all the departments regularly DEPARTMENT P/V spinning WASTE P/ V Soft P/V Hard P/V Sweeping T/W Soft P/W Hard P/W Sweeping T/W Soft Page 22

P/W Spinning W/spinning Recombing NIFT HYDERABAD

Converter

Plush Dyeing Grey Combing

Weaving (old and new)

R/C Noil R/C Sweeping All Wool Soft Tow sparkle soft Tow NP soft Tow BLK soft Tow Sweeping Reging flock Dyeing Soft All Wool Soft G/C first Noil G/C second Noil G/C first burr G/C second burr Shoddy Defective W/G selvedge W/G mix hard W/G Sweeping Plush Chhindies Raising flock

Plush

After receiving various wastes from the entire department it is segregated according to its category. Sorting and packing is done in bale press machine of all other category and sold to outside party. 7.14. PROBLEMATIC AREA OBSERVED

After much surveillance and deep analysis we felt that the housekeeping of raw material godown was not satisfactory. Waste material was not conglomerated properly and were seen lying randomly. Even the segregation of buffer stock was not properly done according to specified rules and regulations. Raw material being one of the less tedious and less effort involving department was neglected in many regards 7.15. SUGGESTIONS FOR IMPROVEMENT

Housekeeping department should be conduct periodic visits to check the hygiene and working conditions of raw material department.Techniques of motion economy can be applied to improve the productivity and efficiency for ex, tools used for opening the compressed bales should be kept at a particular fixed place which would avoid any confusion or ineffective time. NIFT HYDERABAD Page 23

8. WOOL SCOURING
Raw wool contains a number of impurities which must be removed to facilitate yarn production or further processing. Generally there are three types of impurities present in raw wool (a) Natural - Natural impurities are produced by sheep itself. These are wool grease, lint and the ex-creation stains caused by the dung and urine. Kemps may be regarded as impurities in fine wool (b) Acquired-Acquired impurities are picking up by sheep such as sand, soil, dust, burrs, seed and grass. (c) Applied- Applied impurities are the impurities which are added to the coat of the sheep for identification of their own sheep. These impurities are color, oil etc 8.1. OBJECTIVE OF SCOURING To remove all these impurities without damaging the fiber. The fat of the wool forms emulsion with alkali and is removing during emulsion scouring. The suint is soluble in water and can be removed by a preliminary wash with hot water. The dirt and sand in the wool are removed during scouring by mechanical agitation. The grass and insoluble impurities are removed by carding, Gilling or combing process. In scouring there is loss in weight amounting to about 40%. 8.2. FIBER OPENING AND SCOURING
PROCESS FLOWCHART

OBJECTICE To open the wool for better cleaning To avoid lumps formation. After the fiber opening machine has total 6 bowls & their functions are as below 1. Bowl No.1 : To remove mud & impurities other than grease temp. of the bowl is 280 0 C.

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2. Bowl No.2 : This is the main functional Bowl & temp. is 650 O C , more than 90% grease will be removed. Melting pt. of the grease is 400 0 C & 650 0 C helps to melt grease & other oily particles from the wool. 3. Bowl No 3 : Remaining mud, suint & grease is removed in this bowl & temp is 6000 C.

Detergent Alphox -200 is used in bowl no. 1 ,2 & 3 for the cleaning. Major part of the detergent is used in bowl no.2. Remaining 3 bowls are the rinsing bowls & only wash the wool & temp. are 4. Blow No 4 : 5500c

5. Blow No 5 & 6 :5000c After every bowl there is a squeeze roller which squeezes the water & does not allow to go in next bowl. After that 3 drying zones each have 2 drum types dryer & temp are 900 0 C. 8.3. MACHINE PARTICULARS AND PROCESS DETAILS Tank No. Capacity (Upper) Squeeze pressure (Kg/cm2) % Grease 1 2800 liters 4-5 2 2800 liters 3 2800 liters 4 2800 liters 5 2800 liters

4-5

4-5

4-5

4-5

22 30

5 6 3-4 582 Detergent 7 8

1 -1.5 0.4-0.7 562 Detergent 7 -8

1.0-0.9 0.3-0.4 542 Plain Water 7 -8

0.2-0.6 0.2-0.3 502 Plain Water 7 -8

% Grease 17-24 Removal Temperature 602 (C) Chemicals Soda Ash PH 8 10 Amount of Scouring Agents Initial (Kg) Soda 10

Nil

Nil

Nil

Nil

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Initial Nil Detergent (Kg) Water (liters) 10

Nil

Nil

Plain water

Plain water

ADDITION AFTER EVERY 30 MINUTES Tank No. Soda ash (Kg) 1 1 2 Nil 0.53 3 Nil 0.33 4 Nil Nil 5 Nil Nil

Detergent (Kg) Nil

8.4. OTHER PARTICULARS Efficiency of The Machine 40-80%. Production 400-450(Kg/Hr) Power Consumption 130 hp Dryer Temperatures Maintained Between 70 0 C to 11

8.5. VIGROUS PRINTING or VIGRO PRINTING Vigrous printing of top sliver is a recognized method for producing Mlange effect on wool. It is carried out on a machine of very simple construction consisting of a gill box and the printing compartment. 10-16 bands of about 20 gm/m are combined in a gill to produce a uniform fleece with a draft of 1.41.6. The material is fed to the printing rollers, which carry a relief pattern of diagonal strips. The dyestuff is transferred through a felt covered bowl by means of a rubber coated dipping roller.. The dye paste will impregnate the sliver coiled in the perforated cans, which are then placed in a steam autoclave for fixation of the dyes. The chemicals used for vigrous printing are Benzyl alcohol, Urea, Glycerin, Betafoam KS, and Formic Acid etc.

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9.

GREY COMBING DEPARTMENT

Grey combing is the process of removing short fibers, naps, pinpoints etc from the material for obtaining good quality of yarns. This process is done for the grey materials (which are not dyed e.g. 100% wool). in the grey combing, polyester top making as well as wool top making takes place. For this, wool is inspected for moisture regain and grease content % and then it is rendered for further processes. Polyester does not require any such checking. The grey combing department procures the raw material from the RMG department and the wool scouring department. grey combing is done for the grey fibers prior to dyeing .wool is checked for its grease content and moisture regain before going through the combing department polyester fibers are directly converted into tops in the convertor whereas wool goes through carding ,combing and gilling. Recombing is done for blends and dyed fibers. 9.1. OBJECTIVE OF COMBING a. b. c. d. To remove short fibers , neps, pin points etc from the material For uniform blending of fiber To remove dirts, dusts, foreign matter To get good quality yarns.

Grey combing department is further departmentalized as: 1. Top godown is integrated with the grey combing department which facilitates easy commutation of tops and fibers. 2. Polyester top processing section- here polyester tows are directly converted into tops by the convertor machines 3. Wool top processing section- requires an additional passage of carding and combing to remove short fibers and any other impurities.

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9.2. DEPARTMENTAL HIERARCHY

GM Plant Incharge

GM Works

MANAGER

DY. MANAGER PLANNING, PRODN & QUALITY

DY. MANAGER MAINTENANCE

SHIFT INCHARGE

Assistant Computer

Assistant Despatch

Blenders (3)

OFFICER

TECH. ASSISTANT 1/SHIFT

Fitter (3)

Oiler (1)

Helper (2) FITTER 1/SHIFT OPERATOR 14/SHIFT

HELPER
3/SHIFT

PACKER 2/SHIFT

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9.3. PROCESS FLOWCHART From RMG

To RMG

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9.4. MACHINES USED MACHINES Carding BRAND N.S.C NO. OF OBJECTIVES MACHINES 2 Individualize of fibers from tuft of fibers. Kicks-out vegetable matters. Attenuation of fibers into a strand of fibers which is called sliver. 2 Straightening and parallelization of fibers. To increase evenness of sliver by means of doubling and drafting. To apply antistatic agent and moistures in material if required. Straightening and parallelization of fibers. To increase evenness of sliver by means of doubling and drafting Prepare suitable material to feed the combers. To remove short fibers, neps, vegetable matters Parallelization of fibers.

Pre-gilling-1 and 2

N.S.C

Pre-gilling-3

N.S.C

Combing

N.S.C

11

Post gilling-1 N.S.C (GC4)

Straightening and parallelization of fibers. To increase the evenness of combed sliver by means of doubling & drafting. To apply antistatic agent and moistures in material if required. Straightening and Page 30

Post gilling -5 N.S.C NIFT HYDERABAD

(GC5) with coupled press

Parallelization of fibers. To increase evenness of sliver by means of doubling and drafting To make bump tops N.S.C 1 Conversion of filament fibers into required cut length fibers. Making strand of fibers (sliver).

Convertor

Gilling -3 N.S.C with coupled press

Straightening and Parallelization of fibers. To increase evenness of sliver by means of doubling and drafting To make bump tops

9.5. Wool carding-This is the next process after wool scouring. This process involves subjecting the fibres to the action of large number of pins in an attempt to separate each fibre from its neighboring fibre. This is necessary to facilitate further fibre manipulation and to remove impurities.

Objective
To separate each fiber from other with a minimum of fiber breakage. To remove impurities and fiber entanglement To mix the fiber together to provide a uniform distribution. To form a bulky sliver in which fiber are aligned.

9.6. SEQUENCES OF CARDING M/C:Hopper In hopper the scoured wool are deposited up to the maximum level. Then the material goes to the feed roller by the help of lattice. At the top there is a comb. It combs the wool flock and allows the small size tuff forward. There is a striping roller which strips the wool fiber from the incline lattice. Feed roller There are two rollers mounted. One is above and other is underneath. It helps the fiber to in to licker-in. Licker-in NIFT HYDERABAD Page 31

The three pairs of worker and striper rollers are covered to the licker-in. At the side of the worker roller there is also a burr beater. The function of the burr beater is to remove burrs from the wool fiber. Morel Burr Beater There are three roller device designed to eliminate vegetable impurities contain in the wool with minimum wool rejection. The moral transfer roller is fitted with a brush. Waste Container There is also a conveyer belt in between feed roller and licker-in. It helps to take the burrs and waste and collect in the container. Burr Beater All burrs beater in the card are equipped with covers and adjustable screen. The setting of screen determines the type and quality of impurities to be removed. Stripper roller The main function of the striper roller is to remove the short fibres from the worker roller and returns to them to carrier roller. Worker roller The object of worker roller is to perform a considerable fibre mixing and taking the fibre in the forward direction. Main swift roller In cotton process it is called as main cylinder. It is equipped with wire for providing better opening of the fibre and improving their transfer to doffer. There are also four pairs of worker & striper roller around the swift roller. Opening and cleaning of the wool fibers is done between worker, stripper and cylinder. Doffer The function of doffer is to paralyses the fibers. This doffer is gives the output in the web form. Fancy roller It is of three rollers assembly. The special type wire is present on its surface. The main function of it is to penetrate the fiber in to the main swift wire which is coming out due to the action. Transfer roller: This transfers the fibers from one carrier to another. 9.7. Process parameter of carding m/c Particulars Speed Feed roller 0.82 m/min. Licker-in 21 m/min

Diameter 110-120 mm 1200mm

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Worker 1st transfer roller 2nd transfer roller Calendar roller Delivery speed Out put delivery

21 m/min 38 m/min. 135 m/min. 80m/min 120m/min. 25+-2gm 314mm 310mm -

Ratios Doffer to delivery: 1:2 Doffer to swift : 1:10 Carding is followed by 3 stages gilling which aims at the removal of short fibers and better penalization. The entanglement of fiber and undesired elements like slubs, neps, and pin point are reduced. The next process is 2 stage combing whose basic objects include removal of short fibers non fibers impurities, neps, slubs, and straightening and parallelization of long fibers. The final stage includes 2 stages gilling, from where it is later transported to the bumpress which converts slivers into tops of 10 kg. 9.8. FACTS AND STATISTICS Draft (Ratio between cylinder and output) = max 2 Input weight = 22.5 micron Production/day= 2.5 ton Input = 1700 kg Output = 2000 kg Linear density = 24 gm/meter Anti-static =0.2% ISO 9000, 14000 (safety standards) 9.9. Polyester top making

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In the polyester top making, converter is very significant. It cuts down the polyester tow of continuous filament into certain length, which undergoes tension, falling , coiling etc thus deposited as slivers. In the g-c machine there is an automatic knotting machine is present. After keeping certain length of sliver, of sliver in to the can the can goes to packing zone automatically. Two compressors are there by which they press the material in to smaller size then by the automatic knotting machine, it ties this package. This package is known as top. 9.10. PROCESS PARAMETERS OF CONVERTER 2den 2 275 200- 250 2.5 den 2 275 200-250 21+- 1 3 den. 2 275 200-250 21+- 1

Denier type Tow doubling Speed in m / min. Front roller pressure in kg.

Delivery wrapping in 21+- 1 gm /m.

9.11. Objective 9.12.

GILLING MACHINE Parallelization of fibers. Reduction in wt per unit length of sliver. Improving uniformity of sliver. Removal of short fibers. DIFFERENT COMPONENTS OF THE MACHINE

DRAFTING HEAD Drafting head has two part-Top parts and a bottom part. Top part is called as top caterpillar and bottom part is called as bottom caterpillar. FALLER INSTALLATION The GC-14 head comprises 72 right and 72 left faller. The fallers are moves in alternately one are in right and one is to left SPRAY DEVICE This device permits to apply the spray solution through nozzle. This is placed between the drafting roller and coiler. The liquid is brought to the nozzle under pressure. AUTO LEVELLER NIFT HYDERABAD Page 34

At the machine input the feed web is measured by mechanically controlled roller system. The web section variations are registered in form of a memory wheel having certain number of memory rods. At the precise moment that these variations arrive at the draft zone, the memory transmits the pre-registered values to a variation by the way of "reader arm". By sift of belt the speed of the back roller increases or decreases according to the requirement. Due to this speed variation the draft increases or decreases and obtained the regular/uniform delivery sliver. FOR GILL BOX - 1 Make - NSC Model - GC-14 Denier type 2 den Doubling 8 Faller density 4R Delivery wrapping in 24+-1 gm / m Speed in m / min GILL BOX 2 Doubling Faller density Delivery wrapping in gm / m Ratch in mm Speed in m / min GILL BOX - 3 Doubling Faller density Delivery wrapping in gm / m Ratch in mm Top weight 300

Department - Polyester 2.5 den 3 den 8 8 4R 4R 24+-1 24+-1 300 300

6 5F 24+-1 40 300

6 5F 24+-1 40 300

6 5F 24+-1 40 300

6 5F 24+-1 45 8.5+- 0.3

6 5F 24+-1 45 8.5+- 0.3

6 5F 24+-1 45 8.5+- 0.3

Then the slivers collected from 6-7 containers are fed into 3 passage gilling machine. The tow led in the machine undergoes a tension, an opening, a cutting, a draft through fallers and is deposited in form of continuous slivers. The machine winds the certain sliver length and tied it with thread to form the top. Then the top is disposed outside. Polyester top weighs 8.5 kg. NIFT HYDERABAD Page 35

10. DYEING DEPARTMENT The dyeing department is to deliver dyed fiber to Recombing Department, and to PV Spinning Department dyed fabric to either Mending Department or Finishing Department, in required shade at required time. Dyeing is employed to give an all over shade to fiber and fabric. There are mainly two types of blends produced and dyed. Polyester/wool Polyester/viscose All wool

The materials are dyed in further different forms as under:10.1.

TOP DYEING

The prepared tops come from the Grey combing department which is pressed in the carrier by the help of top press m/c. There are many type of carriers having deferent capacities i.e. 10 kg ,20kg, 50 kg ,100kg, 200kg.. The loaded tops in carrier are load in to the vertical HTHP dyeing m/c by the Crain. The maximum Crain capacity is 10 tones. After loading the tops, the lid of the m/c is closed automatically. The dye solution and other required chemicals come in to the m/c automatically after giving the instruction from the control room because Automatic Dosing System works in the mill. The dyeing and other treatment periods depends upon the shade. For light shade 4.5 hrs, for medium shade 4.5 hrs and for dark shade 5 hrs. For wool dyeing, they are using metal complex and acid dye. For polyester they are using disperse dye. After dyeing they are doing RC for removal of surface dye which are mechanically attached on the surface of the material After completing of dyeing process the material comes out and goes to Hydro extractor for drying Hear 40% of water is removed from material. After this the material goes to RF dryer for 100% drying. These dried materials are kept as stock for further processing i.e. re-combing. On an average approx 1760 shade are being processed in the department that goes into production.

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10.2.

PROCESS FLOW CHART

TOP DYEING

FIBER DYEING

WHITE POLYESTER TOPS FROM GREY COMBING

WHITE GREY TOPS FROM GREY COMBING

WHITE POLYESTER FIBER

TOP PRESSING

TOP PRESSING

FIBER STAMPING

HTHP DYEING

HTHP DYEING

HTHP DYEING

COLOR FATSNESS TESTING (QC)

COLOR FATSNESS TESTING (QC)

COLOR FASTNESS TESTING (QC)

HYDRO EXTRACTO

HYDRO EXTRACTOR

HYDRO EXTRACTOR

RF DRYING

RF DRYING

RF DRYING

BLENDING AND SHADE MATCHING

SHADE APPROVAL BY QC

BLENDING WITH DOPE DYED VISCOSE & SHADE MATCHING

DELIVERY TO RECOMBING

DELIVERY TO P/V SPINNING

FINAL SHADE APPROVAL BY DESIGNING

DELIVERY TO P/W or P/V WORSTED SPINNING

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FABRIC DYEING
WHITE PW HEAT SET PIECES FROM FSG

CHEESE DYEING
WHITE PV GREY PIECES

WHITE CHEESE FROM WINDING

WHITE PERCH (LOT ARRANGEMENT)

SCOURING & DRYING

PRESSING
HTHP DYEING HEAT SETTING (FSG)

POLYESTER DYEING
ROPE OPENING
WHITE PERCH (LOT ARRANGEMENT)

DRYING ON STENTER

POLYESTER DYEING

VISCOSE DYEING

DYED PERCH

ROPE OPENING

COLOR FASTNESS TEST (QC)

VISCOSE DYEING

HYDRO EXTRACTOR
DRYING

PERCHING

RF DRYER

SWATCH PREPARATION AND SHADE CHECKING SHADE/ FASTNESS APPROVAL (QC) SHADE APROVL BY DSG/QC DELIVERY TO WARPING

DELIVERY TO FSG

FINAL SHADE APPROVAL IN FOLDING

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10.3.

FIBER DYEING

The fibres in the bale form brought from the RMG dept. After covering the basket with nylon fabric, it is filled with required amount fibres and compressed with the stamping machine by applying of the water. The prepared material is shifted to vertical dyeing machine for dyeing. Here only polyester fibres are dyed. After loading the basket the lid of the m/c is closed automatically. The dye solution and other required chemicals come in to the m/c automatically after giving the instruction from the control room. After dyeing they are doing RC for removal of surface dye which is mechanically attached on the surface of the material. After completing of dyeing process the material comes out and goes to Hydro extractor for drying. After this, material goes to RF dryer for 100% drying. These dried materials are going to PV department for further processing. 10.4.

CHEESE DYEING/YARN DYEING

For cheese dyeing they are making special type of package in the winding section. For producing this cheese they are using wire spring. The density of the package is less than general package due to the better penetration of the dye solution. Density is 0.35 to 0.75 gm/cc. According to the carrier capacity the number of cheese s are filled in the spindle. It is then feed to the vertical dying machine by the help of Crain. After loading the material the lid of the m/c is closed automatically. The dye solution and other required chemicals come in to the m/c automatically after giving the instruction from the control room. . After dyeing they are doing RC for removal of surface dye which are mechanically attached on the surface of the material After completing of dyeing process the material comes out and goes to cheese Hydro extractor(1360 rpm) for drying. After this, material goes to RF dryer for 100% drying. These dried materials are going to warping section for further processing.

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10.5.

PIECE DYEING/FABRIC DYEING

As far as the fabric dyeing is concerned, the dyeing process is carried out either by one bath process or by two bath process. If the dyeing is carried out in the one bath process, then the dyes used are of combination type i.e., either disperse and reactive combination or disperse and acid combination. In the case of two-bath process, the polyester component is first dyed in the jet dyeing m/c and the wool/viscose component is dyed in the jigger dyeing m/c. The dyeing of polyester material is done on the basis of the high temperature and high pressure dyeing method whereas the wool/viscose dyeing is carried out on the basis of the conventional method. The general method of doing the production work starts from procuring the material from various departments as per the planning obtained from the PPD section and then planning for the dyeing schedules as per the weight of the material, the type of the shade, amount of the shade, form of the dyeing process and the delivery schedule of the order to other department. After planning all these things the sample is sent to the laboratory to predict the most appropriate recipe that can be used to obtain shade given. If the sample is already dyed in the section before, then from the previous records the recipe is taken out and then used. If it is nearby to an old shade, then a new recipe is created from the old recipe that is available. The laboratory is equipped with three beaker dyeing m/c and a colour matching cabinet. The dyes are prepared with 0.25 % concentration and they are kept in stock in the laboratory and as well as the chemicals in their respective concentrations too. When the recipe is finalized, the recipe is transformed to the shop floor for bulk production and the lab to bulk variation is maintained between a percentage range of 5 to 10. Before dyeing, the fabric is heat set in the stenter and after dyeing in the jet, they are opened from the rope form using the fabric opener and they are dried in the stenter again. For small lots & special shades, sample dyeing m/c is used. The material handling inside the dyeing section is very less.

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The dyeing of PET is done at 130C; wool at 90C and viscose at 60 to 70C. For single bath dyeing of P/W blends, the dyeing temperature of PET component is set at 120C, since wool cannot withstand more than 115C. So a wool protecting agent is added. Oil from pipe + blower from the motor fabric passing fabric drying

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VISCOSE DYEING IN JIGGER

Check DMF for heavy coloration

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10.6.

AUTO COLOUR SERVICE SYSTEM MODELS

The dyeing section is also equipped with a control room in which close monitoring of the dyeing process is done, i.e. all the dyeing machines (except jiggers) are connected to the control room through PLCs (Programmable Logic Controllers). By this, the temperature, pressure inside the dyeing machine and liquor level inside the machine is maintained. Also by this system the liquor circulation, pH check, process alarms can be possible.

This PLCs are linked with the color service section or color dosing system so that whenever any addition of dye or chemical is done, the call off is sent to the color service and either TRS, or DAP or DLV will come into function and the required material is fed into the machine. In the dyeing section, various dyeing programs are made and stored in the control room. The dyeing programmers are made depending upon the substrates to be dyed, shade to be dyed and the blend to be used and the quality of a fabric.

Depending on the conditions and the requirements, the necessary program is selected and then assigned for a particular lot and then sent to the color service system. In this way, production is carried out in the dyeing section. The dosing of dyes, chemical and water is done automatically using a dye and chemical dosing system called Color System. The color service consists of three dosing machines by names viz. TRS, DAP and DLV. The TRS is used for dosing dyes and DAP or Distribution of Anhydrous Product and DLV is used for dosing chemicals. All the dyeing machines are provided with two pipelines for the dosing of pipes and chemicals. A discipline of dosing liquids in one pipeline and powders through another pipeline is maintained. The dyes and chemicals are stored in separate storage tanks and they are taken out as required using suction and then fed into the dyeing machine using compressed air.The advantage of this system is that exact amount of dyes and chemicals are added into the dyeing machines with precision and control. NIFT HYDERABAD Page 43

10.7.

TRS (Transfer of residual is

into solution) is widely used in case of colors. This is a color rating method and the machine computer linked with all other machines. The coloring unit is equipped with sensors.

The working of TRS- TRS consists of 72 tanks (each containing different dyes). When the program is fed into the computer the required quantity of dye is weighed and poured into the container. Then through the roller conveyors it travels to the first unit and remains until the last container has transferred to the second unit. In the first unit the dyes are dissolved properly and then it is transferred to the distributor through suction pipes from where it is distributed to the respective dyeing unit. Then the empty container is transferred to another unit where the container is washed properly. After that it is again send for collecting next programmed dyes. This way cycle is repeated.

10.8.

DLV(Distribution of Liquor in Volume):

The working of DLV- DLV is used for distributing chemicals to the respective dyeing unit in liquid form. It distributes three types of chemicals: pretreatment chemicals, dyeing chemicals, and after dyeing chemicals. DLV consists of two parts, one is the doser which is used to collect the required amount of chemicals from the tanks through pipes and The second one is the distributor which sends these chemicals to the respective dyeing units.

It is also connected to computer in which different programs are fed according to light, medium, dark and extra dark shades. The required amount of chemicals is determined according to the weight of the dyes.

Automatic color selection Pc1-start the machine wash the cloth Dissolving Unit
NIFT HYDERABAD

Pc2-color selection

color to dye the cloth, chemical to

dyes distributor

to all the machine

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10.9.

SAMPLE DYEING UNIT

The sample dyeing unit consists of automatic color and chemical dispensing machine made in in Italy. This is a computerised automatic machine . The program is fed and the machine starts automatically. The micro- powder is weighed and mixed with hot water (60oC to 79oC) for 60secs to prepare 1g/lt of the solution. Then this dye solution is transferred to the sample pots (120 pots) and required quantity is pipette in the tube. Then in the super lab, frame (equipped with chip reader) containing four samples are loaded. Then the solution is passed through it until the solution is discolored. To remove the excess dye, the solution absorbed by the fabric on the surface, reduction cleaning is done. Reduction cleaning is achieved by using oxidizing agent. Sample dyeing is mainly done to match the color with respect to the customer order or party order. The four sample prepared in this process is send to supplier, sales department, industry itself and one is kept for testing purpose. The cost of the machine was 2.5 crores.

10.10.

MACHINES USED IN THE DIFFERENT TYPES OF DYEING:

FIBRE / TOP / CHEESE DYEING MACHINE TYPE Fibre Stamping Top Press HTHP Dyeing BRAND Dalal Dalal Dalal, Sanjay D. Parikh Strayfeild NO. MACHINES 1 4 Calico, 34 OF OBJECTIVE Stamping of polyester staple fibre in carrier for dyeing. Pressing of Polyester, Wool tops in carrier. Dyeing of Polyester staple fibres, Polyester Tops, Wool Tops, and Cheese. Removal of excess moisture from fibres, tops, cheeses. Final Drying of all the fibre, top & cheese dyed material

Hydro extractor R/F Dryer

6 3

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PIECE DYEING

MACHINE TYPE Perching machine

BRAND True shape

No. of machine 4

OBJECTIVE Inspection of white as well as dyed fabric for any abnormality. On the same machine, lot are arranged for dyeing Mainly used for dyeing of poly / wool blends. Some soft flow machines (e.g. Brazzoli33 & 34) are used for dyeing of poly/viscose blends. Dyeing of Poly / viscose blends. Opening of poly / wool blends Opening of poly / viscose blends Used for dyeing of viscose with reactive dyes 2. Used for washing of poly/wool & poly / viscose fabrics Drying of fabrics. Dyeing of samples for development, trial purpose. 1.

Overflow Soft Dalal flow Rapid Jet Rope opener Platter Jigger Calico Delta electrode Calico Harish

1 1 1 4

Stenter

S.M ltd.

1 4

Sample Dyeing R.B. Machines electronic

10.11.

NOTES

Types of dyes are used: Disperse dyes- it is used in HTHP (high temperature and high pressure) dyeing machine. Temperature maintained is about 135oC. Reactive dyes- temperature maintained is 100OC and pH value is 11.2. Forosol dyes- this dye is also known as Foro dyes. It is a mixture dye for P/W, synthetics .It is used for light shades, and pH maintained is 4 to 5. Following dyes are used for: All wool- acid dyes, chrome or reactive dyes ,metal complex and direct dyes. Polywool- disperse dyes + metal complex + color for the material. Polyester- disperse dyes.

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Polyviscose- disperse +direct (Forosol for light and medium colors) and double bath (for dark colors). Viscose- vat dyes. Type of heating done in the Stenter machine is thermo pack heating of the fabric and perching. In the machine, there is application of pressure for blowing heat. sometimes defects like moonmark is formed during heating, which is most common for lighter fabric. To avoid this , the fabric is fixed with handle brushes at the selvedges. Before going through stentor machine, fabric is passed through suction pipe. The fabric width should be at least 150 cm. the speed of stentor for drying P/V is in between 16 to 18 whereas, for P/W it ranges between 18, 20 and 25. The two rollers in the jigger dyeing machine runs at 20-40 m/sec For delicate materials, soft-flow machine is used to avoid distortion of fibres. Generally, the polyester fabric is processed under high temperature (1300 C). it is having impurities in white powder called OLIVOMERS which are removed at high temperatures. HTHP machines runs with the high speed of 400 rpm, these machines require 2 min to complete 1 cycle. Anti-cross staining agents are used to protect wool and polyester from each other. In rapid jet machine material and liquor both moves but in jigger machine only material moves and both edges of the material are stitched. Besides glauber salt, sodium hydrosulphite is also used in the dyeing. The storage tank for the salt has capacity 1000 kgs. In piece dyeing, plater is mostly used for opening the gathering of polyester viscose. This machine requires 3 labor. But rope opener is used for opening the polywool. Wool protecting agent used is lavasyn. A piece length which is dyed is 110 to 120m long. machine capacity: 8 pieces- Brazzoli 32 6 pieces- Brazzoli 32 4 pieces- Overflow(1,2), jet back, Sanjay 4 3 pieces- Rapid jet

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11. RECOMBING DEPARTMENT The Recombing department delivers recombed tops to PV and Worsted Spinning Departments in Chhindwara, Jalgaon & outside in full quantity at required time. The minimum cost meeting all quality parameters. The department is responsible for the conversion of the dyed and grey tops are to recombed tops. 11.1.

DEPARTMENTAL HIERARCHY

PLANT INCHARGE

GM WORKS

HOD (DY. MANAGER)

PLANNING

PRODUCTION

MAINTENANCE

ASST. MANAGER

EXECUTIVE

EXECUTIVE

ASSISTANTS

ASSISTANT

ASSISTANT

WORKMEN WORKMEN BLENDING WORKMEN PACKING & DESPATCH

WORKMEN

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11.2.

OBJECTIVES OF THE DEPARTMENT

Blending of the fibers viz. wool, viscose, polyester, Lenin, silk, etc. Removal of short fibers. and undesired elements like slubs, neps, and pin point Removal of entanglement at the time of dyeing. 11.3. PROCESS FLOW CHART

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MACHINES

BRAND

NO. OF MACHINES

OBJECTIVES

To defelt the wool, which became very much felted after dyeing.

LENGTHWISE DEFELTER

NSC

To apply wool lubricating oil for smooth working in further process. To make uniform length for proper blending

BLENDING DEFELTER NSC 5

To blend polyester & wool component homogeneously in required composition.

To apply antistatic oil in blend material. To open and parallelize the material.

PRE COMBING GILLING 1 NSC 4

To parallelize and homogeneous mixing of fibers

PRE COMBING GILLING 2 NSC 4

To parallelize and homogeneous mixing of fibers. To apply antistatic oil and moistures in material, if required.

PRE COMBING GILLING 3 NSC 2

To parallelize and homogeneous mixing of fibers. To prepare suitable material for feeding to combers

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 RECOMBING NSC 26

To remove short fibers, neps, pin points, foreign matters,

leading & trailing hooks from the material

POST COMBING GILLING - 1

NSC 4

To apply antistatic oil and moisture to material. To parallelize and homogeneous mixing of fibers.

The fibers are checked for quality parameters like anti-static content , blend composition and eveness %

11.4. PROCESS PARAMETERS FOR BLENDING DEFELTER (WHITE) Line A No of machine: 1 Model: -D-2GC 14 Make:-NSC Year: - 1994 HP: - 17.02 Specification:-Chain gill box Type of materials Feed wrapping gm / m Doubling Total feed gm / m Draft given in De felter Funnel diameter in mm Delivery speed m / min Spray gm / m White 24 P + 25 W 5 Poly + 4 Wool 210 - 220 1.2 - 1.4 20 200 - 225 75 +/- 5

11.5. PROCESS PARAMETERS OF PRE COMB GILL 1 & 2 Model: - GC 14 Make:-NSC Year: - 1994 HP: - 13.4, 14.4 Specification:-Chain gill box

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Type of material Count (Nm) Feed wrapping gm /m Doubling Total feed in gm Draft Faller pins / cm Ratch in mm Delivery speed in m /min Pressure in kg Delivery wrap in gm / m

White (GA1) 32/48/56/60/66/70/80 28 8 224 8 4R 42 45 200-225 200-250 28

White (GA2) 24/32/48/56/60/66/70 28 10 280 8.2 4F 40 - 45 200-225 200-250 34(17 x2)

11.6. PROCESS PARAMETERS OF COMBER Model:-PB 33LF Make:-NSC Year: - 1994 HP: - 6.23 Comber type : Rectilinear Can Diameter:- 700 mm.

DYED SECTION (RC3) 11.7. PROCESS PARAMETERS FOR LENGTH WISE DEFELTER
Make: - NSC Model: - D2GN 6 Year:-1994 Specification: - screw gill box It is same as gill box but before faller there is two drafting roller. These rollers have deferent speed. Due to this draft the materials which are felted at the time of dyeing are defelted. 11.8. PROCESS PARAMETERS FOR BLENDER Model: - DUO TR GC-15 Make:-NSC Year:-2001 Specification: - chain gill box Type of materials Dyed % of blend 55+45 Count in Nm 60/70 Delivery speed m / min 275 -300 Oil concentration 10 % NIFT HYDERABAD

Dyed 65+35 32/48/56/60 275-300. 10% Page 52

Spray gm / m

70

70

11.9. PROCESS PARAMETERS FOR COMBER Model:-PB 31LF Make:-NSC Year: - 1994 Type of materials Count in Nm Blend code % Blend Dyed 48 /56 360/365 65P , 35w Dyed 60 /70 262/276/370&mix shade 55p, 45w Dyed 56/32/34 535/981 75p, 25w

11.10. PROCESS PARAMETERS FOR POST GILL Model:-GC-14 Make:-NSC Year: - 1994 Specification: - Chain gill box Feed wrapping in gm /m Out put wrapping in gm / m Doubling Faller pin density Funnel diameter in mm Delivery speed m /min. 20 20 8 6F 20 200-225

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12. P/V SPINNING Spinning is the process in which we can produce yarn from fiber .The raw material of this department are polyester and viscose fibers which are coming RMG Department or dyeing department. For white yarn formation white color viscose and polyester come from RMG Department. For colored yarn the dope dyed viscose fibers come from RMG department and colored polyester come from the dyeing department. 12.1. DEPARTMENTAL HIERARCHY

GM PLANT INCHARGE

GM(Works)

HOD (Manager)

Manager

Planning. Dy. Manager ( 1 ) Asst. Manager (1)

Maintenance. Dy. Manager (1)

Production, Quality. (Dy. Manager ) (1) Planning Clerk (1) Asst. Manager ( 2) Officer ( 7 ) Clerk ( 6) Shift. General Shift. D.E.O(2) Officer (1)

Preparatory Spinning Section. Section NIFT HYDERABAD

Post Spinning Section.

Workmen (skilled )

Workmen (skilled) Semiskilled. Page 54

12.2.

PROCESS FLOWCHART FOR P/V SPINNING

12.3.

BLOW ROOM

The blow room has three lines a. Chute feed with 4 cards b. Lap feed with 6 cards c. Lap feed with 4 cards There are two feed systems in blow room Chute feed Lap feed 1. Firstly, the raw material is coming from RMG /dying department to p/v spinning department in bale form, then opening of polyester and viscose fibers are done. 2. They add some oil for decreasing static charge and add binding agent among polyester fibers. 3. Then conditioning i of polyester fibres is carried out for 24 hrs. This mixing is done manually. Then they prepare the layers of polyester and viscose. Polyester and viscose layer mix according to their required percentage. Page 55

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4. Then materials are fed to the 2nd MBO for mixing the P/V homogeneously and open the tuffs. Then the materials go to the 3rd MBO for better cleaning and opening. Then the materials go to the scutcher for lap formation. But in LINE- 2. The materials which are coming from the 3rd MBO direct go to carding m/c as chute feed.

12.4.

COMPARISON BETWEEN LAP FEED & CHUTE FEED

CHUTE FEED 1. In chute feed the production is more

LAP FEED 1. Here the production as compare to the chute is less. 2. Here if we required maintenance of any m/c 2. But here if any m/c will show problem in blow or any m/c show some problem, then the next room then the stock laps can be use in carding m/c will remain stop. m/c. 3. In chute feed system all carding m/c will work 3. In lap feed system different types of blends can for same blend of materials. be done in different carding m/c. 4. In chute feed material feed is uniform. So 4. Here the variation is more. variation in sliver is less.

12.5. Feed table 12.6.

PASSAGE OF MBO:Feed lattice PASSAGE OF CARDING:Incline lattice Evener roller Stripping roller

Feed roller

Tacker in

Main cylinder

Flats

Doffer

Can

Coiler roller

Callendar roller

Trumpet

12.7.

PASSAGE OF THE DRAW FRAME

Creel

Feed roller

Draft roller

Trumpet

Coiler roller

Can

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12.8.

PASSAGE OF THE SPEED FRAME:

Max head of the m/c 120 Back roller Middle roller Drafting apron

Creel

Trumpet

Bobbin

Pressure foot RING FRAME

Flayer

Front roller

12.9.

Spindle capacity: - (16 X 480) + (2 x 144) = 7968 in PV section PASSAGE OF RING FRAME

Creel

Guide bar

Back roller

Middle roller

Tradle box

Bobbin

Traveller

Baloon braker

Lapet eye

Front roller

12.10.

AUTO CONER

No of head: - 60 The main object of this auto coner is to prepare bigger package from smaller bobbin package and removes the yarn faults like thick and thin place and also week place. The cops are steamed and then rewound on Autoconer 138 having 60 spindles. The winding speed is around 600m/min giving cross-wound package. Air splicing is done here and usually the splice strength is 95% of the single yarn strength and the yarn dia. of 1.2 times the seed yarn. The machine is equipped with Loepfe NIFT HYDERABAD Page 57

yarn clearer, which works on the photo electric principle. The clearer curve setting is done so as to remove the objectionable faults. The machine has two splicer which traverses in between 10 spindles. The package produces weighs about 2 Kg each. The department has three Autoconer winding machine similar to that with the PW department and one Muratec Mach Coner of 60 spindle capacities. The yarn tension in Machconer is reduced by Balcon balloon breakers which adjust its position depending upon the position of the unwinding of the ring cop. Its an automatic winder with individual spindle driving type performing one cycle of yarn joining in 9 seconds. The winding speed, which can be achieved, is around 1200 m/min but here speed is kept around 800 m/min. They are mounted with yarn clearer. 12.11. Bobbin PASSAGE OF THE AUTO CONER Pre-cleaner Gate feeler Tensioner Waxing

Package

Winding drum

Splicer

Slub catcher

Yarn trap

The packages which are parallel wound in ply winding m/c are twisted on TFO. The machine runs between 8000-10500 rpm for twist ranging between 17-24 TPI. Finally this wound yarn is send to New double yarn room from where it is send to weaving as per requirement.

12.12.

TFO (TWO FOR ONE)

The packages which are parallel wound in ply winding m/c are twisted on TFO. The machine runs between 8000-10500 rpm for twist ranging between 17-24 TPI. Finally this wound yarn is send to New double yarn room from where it is send to weaving as per requirement. Package from ply winding Winding roller Spindle Balloon breaker Guide

Package

Winding roller

Travers guide

Stop motion device

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For setting the twist and preventing anti-snarling the yarn are steamed after every twist insertion stage. ELGI WELKER steaming machine are there in the departments. 12.13. MACHINES MACHINES: BRAND

NO. MACHINES 4

OF OBJECTIVES Opening of viscose & polyester. Conditioning of viscose & polyester, & spraying of polyester. Opening of bigger lumps of viscose & polyester into smaller uniform lumps.

MIXING

Lakshmi

BLOW ROOM

BATLIBOI.

To convert the material into a uniform sheet called lap. To feed properly opened & uniform material to the cards. To eliminate hard chips of fibers & foreign material. Individualization of the fibers Removal of short fibers, foreign matters, hard chips from the material. Make the uniform material sheet into a sliver form To get uniform weight per unit length of the sliver To parallelize and attenuate the card sliver To get the uniform sliver by doubling the slivers. Autolevelling

CARDING

Lakshmi

14

DRAWFRAME Lakshmi 9 (4 finisher 4 breaker 1auto leveler)

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RING FRAME

Lakshmi

24 22 x 480=10560 2 x 144=288 Total=10848 spindles

To convert roving into a uniform yarn. To insert twist of required amount for different counts. To get the required count & evenness To eliminate yarn defects from the ring yarn. To wind ring frame yarn onto cheeses (Bigger packages). to get better quality of splice. To make two ply yarn. To wind auto cleared yarn on ply tubes.

AUTOCONER

SCHLAFHORST

5 5 x 60= 300 drum

ASSEMBLY WINDING PEASS METLER 5 and 2 x 84= 168 FADIS 2 x 120=240 1 x 36= 36 Total=444 spindles ONE PRERNA 17 STAR 15 x 130=1950 VOLKMANN 2 x 156=312 5 x 144=720 11 x 160=1760 Total=4742 spindles ELGI WELKER STEAMING MACHINE 12.14. MORE ABOUT P/V SPINNING 1

TWO FOR TWIST

To get the quality double yarn after insertion of proper twist. To wind ply yarn on cheeses (Bigger packages)

To prevent anti- snarling To set the twist

Polyester viscose blend is a very cost effective blend. Property of viscose is almost similar to that of cotton the blend improves functional property. Spinning of 100% polyester is not possible (as no moisture is there) due to antistatic charge generated in polyester.. PRODUCTION : 4000 to 5500 kg per day WASTE PERCENTAGE: 7% to 8 NIFT HYDERABAD Page 60

13. WORSTED SPINNING DEPARTMENT The main aim of the worsted spinning department is to deliver single /double yarn to Yarn room in full quantity at required time with minimum cost, meeting all quality parameters. 13.1. DEPARTMENTAL HIERARCHY

GM PLANT INCHARGE

GM (Works) HOD (Sr. Mgr.)

Manager

Asst. Managers (2) Maintenance Section-in-charges Ring frame & Auto winding Shift Officer / Supervisor (Preparatory) 3 x 1 per Shift Shift Officer / Supervisor (Ring Frame T3 & Auto) 3 x 1 per Shift Fitter / S. Yarn Checker / Worker Shift Officer / Supervisor (Ring Frame T1 & T2) 3 x 1 per Shift NIFT HYDERABAD Fitter / Fitter Helper / Clg. Gang Staff- 2 Warping / Planning G/Shift Dy.Manager Prep. & Auto

Dy. Manager Doubling Section Asst. Manager (Doubling) Shift Officer Dy.Manager Ply & TFO R/F & Gen Dy. Manager Doubling 3 x 1 per Shift Fitter / D. Yarn Checker / Worker Prodn. Entry Clerk 3 x 3 per Shift Data Entry Operator - 2 General Shift Page 61

13.2. PROCESS FLOW FOR A & B LINE

PROCESS FLOW

Recombed tops from Recombing (To be taken for process only after the testing & approval of quality parameter against standard Norms)

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FOR LINE C

Additional passage for fine count material (56Nm and above), Single weft material and 100% wool materials.

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MACHINES Vertical Box (GV20):

MAKE Gill NSC

NUMBER 1

FUNCTION Additional passage for fine count material (56Nm and above), 24, 32Nm, Single weft material and 100% wool materials. To provide even draft distribution. To make uniform length in each can as per number of doubling for proper run out. To make Sliver even by means of doubling. To Produce wrapping (weight / unit length) as per requirement

Rubber Finisher (FM5P):

NSC

Additional passage for fine count material (56Nm and above), Single weft material and 100% wool materials. To provide even draft distribution. To make uniform length in each can as per number of doubling for proper run out. To make Sliver even by means of doubling. To Produce wrapping (weight / unit length) as per requirement

Roving Machine Rubbing Machine

NSC /

To produce wrapping (weight / unit length) as per requirement. To give required twist/rub to avoid stretch during unwinding in ring frame. To produce a package suitable for subsequent machine. To make uniform length in each package as per requirement of next machine for proper run-out.

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Ring frame

TEXTOOL, COGNETEX

62

To produce single yarn of required twist and count as per the instruction from PPD. To produce good quality of yarn. To make ring cops by means of building mechanism. To impart dimensional stability to single yarn which will help in smooth and snarl free running of yarn on next machine i.e. Machconer To remove objectionable faults available in the yarn and splice the yarn properly after fault removal and bobbin change. To produce a fault free package suitable for subsequent machine.

Machconer/ Padmatex Automatic Winders:

MURATA, PADMATEX

Ply winding

PEASS METTLER

To wind two single yarn of required shade and count ,as per the instruction from PPD department , parallel on a package suitable for subsequent machine

Two For One PRERNA Twister

48

To twist the two parallel wounded yarn from the ply package as per the TPI (twist per inch) instructed by PPD.

R.B. Double Yarn ELECTRONI-CS Steaming

To impart dimensional stability to double yarn which will help in smooth and snarl free running of yarn on next machine i.e. warping and weaving.

Precision Propeller winder

PEASS METTLER

To make soft package of double yarn suitable for cheese dyeing.

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13.3. GILLING To get the required parallelization and fineness we are generally 4 passage of gilling. There are 3 lines each having 4 gilling machines. OBJECTS OF GILLING To parallelize and mixing of fibers. To apply wool lubricating oil if needed for smooth working in further process. To make uniform length in each can as per number of doubling for proper run out. To make Sliver even by means of doubling. To Produce wrapping (weight / unit length) as per requirement

NSC GV 20 It is vertical gilling machine. This is 4-delivery machine. Its maximum speed is 400 m/min. its doubling is 4*2=8. Wrapping is around 6 gm/min. VERTICAL GILL BOX (GV20) Additional passage for fine count material (56Nm and above), 24, 32Nm, Single weft material and 100% wool materials. To provide even draft distribution. To make uniform length in each can as per number of doubling for proper run out. To make Sliver even by means of doubling. To Produce wrapping (weight / unit length) as per requirement

FALLER DENSITY GN series for normal fibers 6, 6, 7, 7/cm 13.4. RUBBING FRAME

Rubber Finisher (FM5P)

Additional passage for fine count material (56Nm and above), Single weft material and 100% wool materials. To provide even draft distribution. To make uniform length in each can as per number of doubling for proper run out. To make Sliver even by means of doubling. To produce wrapping (weight / unit length) as per requirement.

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There are 3 types of rubbing frames in the spinning section i.e. FM-7N, FM-8N and FM-5P. As shown in the flowchart, the coarser material goes to rubbing frame (FM-7N) and directly goes to the ring frame. The finer material goes to the intermediate rubbing frame (FM-8N), then goes to roving frame and then to the ring frame. For white material FM-5P is used in module C. 13.5. FM-8N In case of rubbing frame, 2 slivers are fed to each drafting head, the strand remaining separate as they are consolidated and given cohesions by means of oscillating rubbing action of aprons. The pair of consolidated rovings is cross wound on to a double meche package which is then used to feed to spindles on the spinning frame. The functions of the simplex are twofold. By drafting the material, it reduces the linear density of the gilled sliver and by twisting; it helps in the formation of suitable package for the subsequent process.
FM 5P

Another rubbing frame of the make FM 5P is also used. This machine has the main objective to reduce the wrapping of the material before being fed to the roving frame. This help in the production of finer counts. Bi coiling mechanism saves on creel space on roving frame. These machines convert sliver to roving thus eliminating the need of a roving frame passage. They have higher drafting and higher production capacities than roving frames. Two roving are wound on a single package thus saving on creeling time and number of bobbins in use. As the twist inserted in the roving material is done by the false twisting method, it facilitates the spinning of material, as a lesser break draft is required during spinning. There are two rubbing frames used for production of coarse count material. It is done to reduce the bulkiness of roving. A pair of fluted rubber aprons rubs the material. Here the feed material is sliver and the delivered material is rubbing. Rubbing speed can be adjusted by changing the driving pulley in gearing end. FM 7N Two ends are fed to the rubbing frame and these two individual ends are wound on the single package that reduces material handling. The sliver is passed through the feed rollers and through the drafting system. Drafting part is of the double apron type. The bottom apron is plain rubber rolling along a cast iron table. Top apron is also of the same type and the fiber control is sit weighted. As the slubbing emerges from the nip of the rubbing rollers, each of which runs on endless leather bands, from the rubbers the roving passes through a funnel is then wound on the bobbin. 13.6. TECHNICAL CHARACTERISTICS (FM 7N) Specifications 20

Characteristics Number of Drafting elements

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Ends/drafting element Maximum input/ end Maximum delivery weight Draft Range Tube diameter Bobbin Diameter Delivery speed Rubbing speed

2 15.9 gm/m 0.25-1 gm/ m 5 36 70 mm 300 125 m/ min 1100 rubs/ min

13.7. ROVING FRAME Roving Machine / Rubbing Machine To produce wrapping (weight / unit length) as per requirement. To give required twist/rub to avoid stretch during unwinding in ring frame. To produce a package suitable for subsequent machine. To make uniform length in each package as per requirement of next machine for proper run-out.

13.8.

Machine particulars BM15 64 8-12 Upto 50m/min 600-800rpm 24 tpm 5 ktex 0.4 ktex

Particulars No. Of spindles Draft range Delivery speed Flyer speed Twist range Sliver weight at feeding Deliver hank

13.9.

Roving frame (BM 14)

The draft system of the BM 14 machine comprises of a pendulum arm carrying three balloon rollers controlling the fibers on a wide apron. The flyer frame has overhanging flyers, both the flyers and spindles being driven by groups of toothed belts. Suction device present beneath the drafting roller and device for periodical lifting up of the scrapers on the pressure rollers. Starting a BM 14 roving frame with material requires 3 essential settings: 1. The twist, expressed generally in turns per unit length. Before fitting the twist change wheel the variator for the general speed of the machine is turned down. NIFT HYDERABAD Page 68

2. Building up of the bobbin comprising of pitch of the coil, increase of diameter of the bobbin after each layer and the angle of terminal coming from the bobbin. 3. the drafting system comprising of tension between creel and feed rollers, predraft or tension between feed rollers and draft aprons and draft ratio or speed ratio between draft aprons and front rollers. TECHNICAL CHARACTERISTICS (BM 14) Draft range Sliver weight at feeding Sliver weight at delivery Twist range Maximum delivery speed 3.6 - 36 15 to 18 g/m 1.5 to 0.25 g/m 9.2 to 100 tpm 100m/min

13.10. RING FRAME The rubbing and roving frame bobbins are brought to ring frame dept. the roving is converted into yarn by drafting and twisting. The objectives of the ring frame are as follows: To produce single yarn of required twist and count as per the instruction from PPD. To produce good quality of yarn. To make ring cops by means of building mechanism. Textool 3/3 Top arm 35 9000 5 45 245 50 60 47 51 75 15 35 30 40mm

Machine parts Drafting arrangement Drafting angle (o) Spindle rpm (maximum) Twist range (TPI) Bobbin lift (mm) Chase length (mm) Bobbin diameter (mm) Ring diameter (mm) Working efficiency Draft range No of machine Roller diameter

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13.11.

OTHER IMPORTANT POINTS

Spindle oil used in ring frames is SPIN 12 Ring oil: SPIN 12 + SOLUMOL ALL (Emulsifier)

SINGLE YARN STEAMING

To impart dimensional stability to single yarn which will help in smooth and snarl free running of yarn on next machine i.e. Machconer. MACHCONER/PADMATEX AUTOMATIC WINDERS To remove objectionable faults available in the yarn and splice the yarn properly after fault removal and bobbin change. To produce a fault free package suitable for subsequent machine. PLY WINDING To wind two single yarn of required shade and count ,as per the instruction from PPD department , parallel on a package suitable for subsequent machine i.e for TFO. TWO FOR ONE TWISTER To twist the two parallel wounded yarn from the ply package as per the TPI (twist per inch) instructed by PPD.
DOUBLE YARN STEAMING

To impart dimensional stability to double yarn which will help in smooth and snarl free running of yarn on next machine i.e. Warping and weaving. PRECISION PROPELLER WINDER To make soft package of double yarn suitable for cheese dyeing.

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Vertical Gill NSC Box (GV20):

Additional passage for fine count material (56Nm and above), 24, 32Nm, Single weft material and 100% wool materials. To provide even draft distribution. To make uniform length in each can as per number of doubling for proper run out. To make Sliver even by means of doubling. To Produce wrapping (weight / unit length) as per requirement

Rubber Finisher (FM5P):

NSC

Additional passage for fine count material (56Nm and above), Single weft material and 100% wool materials. To provide even draft distribution. To make uniform length in each can as per number of doubling for proper run out. To make Sliver even by means of doubling. To Produce wrapping (weight / unit length) as per requirement

Roving Machine Rubbing Machine

NSC /

To produce wrapping (weight / unit length) as per requirement. To give required twist/rub to avoid stretch during unwinding in ring frame. To produce a package suitable for subsequent machine. To make uniform length in each package as per requirement of next machine for proper run-out.

Ring frame

TEXTOOL, COGNETEX

62

To produce single yarn of required twist and count as per the instruction from PPD. To produce good quality of yarn. To make ring cops by means of building mechanism. To impart dimensional stability to single yarn which will help in smooth and snarl Page 71

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free running of yarn on next machine i.e. Machconer Machconer/ Padmatex Automatic Winders: MURATA, PADMATEX 9 To remove objectionable faults available in the yarn and splice the yarn properly after fault removal and bobbin change. To produce a fault free package suitable for subsequent machine.

Ply winding

PEASS METTLER

To wind two single yarn of required shade and count ,as per the instruction from PPD department , parallel on a package suitable for subsequent machine

Two For One PRERNA Twister

48

To twist the two parallel wounded yarn from the ply package as per the TPI (twist per inch) instructed by PPD.

R.B. Double Yarn ELECTRONI-CS Steaming

To impart dimensional stability to double yarn which will help in smooth and snarl free running of yarn on next machine i.e. warping and weaving.

Precision Propeller winder

PEASS METTLER

To make soft package of double yarn suitable for cheese dyeing.

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14. WEAVING Weaving is the term used in relation to produce fabric by interlacing two different series of yarns known as warp & weft. Warp ends are placed longitudinally whereas wefts are horizontally placed. Weaving process is commenced by dividing warp into two different sheets in opposite direction & then inserting weft into the shed. By interlacing it into the shed fabric is produced.

14.1.

DEPARTMENTAL HIERARCHY GM (PLANT IN CHARGE)

GM (WORKS) DGM - WEAVING

MANAGER WEAVING SULZER & GP

MANAGER WEAVING NP

PRODUCTION PLANNING

MAINTENANCE

PREPARATORY

LOOM SHED

PREPARATORY

LOOM SHED

DY. MANAGER

ASST. MANAGER

DY. MANAGER

DY. MANAGER

ASST. MANAGER

OFFICER

FITTER

OFFICER

OFFICER

ASSISTANT

FITTER

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Weaving department is divided into two sections1. warping 2. weaving WARPING The yarns which are coming from double yarn room are going for winding for preparing required amount of package. They are then creeled according to the warp pattern. The main object of warping is to produce a warp sheet according to the warp pattern and the formation of warp beam. 14.2. YARN ROOM

The weaving activities start from yarn room. After spinning and doubling the yarn, the PPD department and yarn room in charge checks the yarn particulars. Only the correct yarn is given entry in the yarn room according to the correct shade number, lot number etc. The yarn is weighed and its particulars are entered into the computer with specified quantity. After delivering the yarn, remaining yarn is brought back to the yarn room. After twisting & steaming, the yarn from the spinning department comes to the yarn room. In our plant we are having two Yarn Rooms called as Old Double Yarn Room and New Double Yarn Room. Old DYR is for PV blend yarn and New DYR is for PW blend yarns The yarn cheeses are transported by means of trolleys, which are numbered. The yarn cheeses are kept on trolleys and the material from trolleys is kept in a particular bin. The humidity in the yarn room is the same as in TFO twister. Precaution required to be taken Correct shade of yarn should be issued to the warping as well as weaving dept. Along with the shade the twist of the yarn should be checked. Checking of stains, oil marks, shade variation, contaminants etc.with the help of UV rays.

14.3.

WARPING

The yarns which are coming from DOUBLE YARN ROOM are going for winding for preparing required amount of package. Then they are then creeled according to the warp pattern. The main object of the warping is to produce the warp sheet according to the warp pattern and formation of warp beam. In the fabric forming system, all of the yarns forming are presented in the sheet form. It is therefore necessary to remove or unwind the yarns from the winding package and arrange the desired number of ends in a sheet form & wind it on package under controlled tension on a package called a beam. The yarns must be parallel and under uniform tension. NIFT HYDERABAD Page 74

TYPES OF WARPING 1. 2. BEAM WARPING SECTIONAL WARPING 14.4. BEAM WARPING

Beam warping is simply the winding of yarns directly from the supply packages onto a beam.In a beam warping, depending upon the creel capacity ,the no. of ends are collected together & wind it onto a beam called as a warpers beam. IMPORTANT PARTS CREEL: A frame to hold the package is known as creel. Its function is to hold the packages in a manner so as to facilitate warping. Creels are equipped with package holders on which the supply package are placed ,tension devices to help maintain uniform tension throughout the creel, guides to direct the yarn and to help keep the ends apart and stop motion to detect broken ends and or empty packages. The maximum capacity ranges from 300 packages to 1400 packages. Creels are either single or multiple package creels. In Benninger & Gamatex maximum creel capacity is 480.the creel is having smooth porcelain guides, thread stop motion, & tensioning devices. TENSIONING DEVICES Tensioners should be capable of fulfilling the following requirements. 1. Even tension of the ends within the yarn sheet. 2. Wide tension range. 3. Quick threading THREAD STOP MOTION: The thread stop motion is fitted on the creel though the machine is fitted with an efficient break. This is done to stop the warping before the broken ends are buried in the beam. This is necessary otherwise it would be difficult to locate the broken end. BRAKE: The warpers must be provided with a break to stop the machine immediately wherever an end breaks or when pre determined length of yarn has been wound on to the beams. MEASURING MOTION: Warpers are equipped with a measuring motion to measure the length of yarn wound on to the beam and to stop it as soon as the pre determined length of yarn has been wound.

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DOFFING MECHANISM: The warpers beam is too heavy, therefore a warping machine must be provided with a mechanism to place the full beam on the floor or on the trolley. 14.5. SECTIONAL WARPING

The main object of the warping is to produce the warp sheet according to the warp pattern and formation of warp beam. Sectional warping is done when one needs to produce some design i.e. beam contain some different colours of yarn then sectional warping is used. In sectional warping, the warp threads are wound on the warping drum sectionally. After winding on drum it is then taken on weavers beam. In Raymond, sizing operation is omitted, as all the yarns are doubled and have got a good abrasion resistance and are strong sufficiently. For good abrasion resistance, wax is applied during warping. Waxing is done to prevent the static charge generation, for smooth running of the loom and less fly and fluff generation. The yarns which are coming from DOUBLE YARN ROOM are going for winding for preparing required amount of package. Then they are then creeled according to the warp pattern. OBJECTIVE With the help of the creel, to accumulate required no. of ends on drum, section by section, according to the design. To facilitate to insert lease in the warp sheet with the help of the leasing reed so as to keep all the warp ends intact in their sequential position. To collect all the warped ends from drum and to facilitate to wind them in a beam. To apply requisite amount of wax coating on the warp ends during beaming to reduce hairiness of the yarn and thus producing a weavers beam. LEASE REED The reed is very deep & alternate dents soldered, the ends are drawn through one in dent,this separate all the odd & even ends SECTION REED The section reed consist of umber of dents which corresponds to the required number of ends per cm. in the fabric. The ends wound on section drum in required length ,the warp sheet is then wound on the warpers beam. BEAMING After sectional warping they prepare the Weavers beam from the warp sheet. Warping faults Yarn cone of wrong size. NIFT HYDERABAD Page 76

 Warping reed

Wrong built of cone Tension variation during warping. Count mix during creeling. Broken ends improperly repairs.

There are three different count reeds used for different yarn count. 1. Reed Count 5.0 for 2/24 to 2/48Nm 2. Reed Count 6.06 for 2/48 to 2/56Nm. 3. Reed Count 8.33 for 2/56 and above Nm. Waxing

14.6.

For good abrasion resistance, wax is applied during warping. Waxing is done to prevent the static charge generation, for smooth running of the loom and less fly and fluff generation.

Waxing recipe Cirosol TF :-19%

Poly Ethelene Glycol :-12% H2O :- 69%

For 2/24 to2/48 waxing is not done as yarn itself has enough abrasion resistance. At a time 500lit. solution is done at a time ia solution tank. 14.7. DRAWING IN In weaving, it is necessary to space the warp threads properly in order to get the required compactness of the cloth. This is affected by passing the warp yarn through the dents of the reed of appropriate count so that the cloth woven from the warp may contain the required number of threads. Passing the warp threads through the close drop wires (warp stop motion), heald wires and the dents of the reed are carried out by a process known as Drawing In. Manual Drawing In The process is carried out on an upright frame. The beam is brought on a trolley and placed at the bottom of the frame. The operative opens knots on the warp section and then the yarn is passed through 2 lease rods and then through drop wires, heald frames and reed. The heald shafts and reed are held on separate brackets. The operation of drawing in is carried out in the following manner. One operative is called the reacher and the other is called the drawer who sits in front of the frame. At the start, the reacher takes a bunch NIFT HYDERABAD Page 77

of warp threads in his hand, straightens them up and selects the yarn one by one from one extreme end of the loom beam in the proper sequence. By this time, the drawer inserts the hook through the corresponding heald eyes. At the extreme end of one heald as soon as the hook reaches the other side, i.e. on the side of the reacher the latter will insert the appropriate end in the eye of the hook which will be immediately drawn on the other side by the drawer. For manual drawing-in, the speed is around 5000 ends per shift. Special incentives are given to those who cross a particular limit when it comes to extra number of threads drawn in. Drawing in the ends in the yarn tensioner, yarn guide and yarn stop motion when drawing the ends in the yarn tensioner, yarn guide and yarn stop motion, we always have to start with the nearest end in the uppermost tiers. Automatic Drawing In Raymond has one of the latest of its kind of drawing in machine the SUPER VEGA. The capacity of this machine is to draw a staggering 25,000 ends per shift. But from year 2004 the Raymond Ltd. Chhindwara introduces a new Automatic Healding M/C made in Italy, for drawing in work. This m/c is drawing the yarn in to the heald automatically. Here they are using one yarn package. One gripper is there which inserted in to the one heald eye as well as one drop pin and collect yarn from package and again come back through drop pin and heald eye. By this the yarn is inserted in to the drop pin and heald eye. After drawing there is a cutter which cut the yarn at the package. Again the gripper goes through the heald eye and drop pin for next drawing. According to the design they are feeding program to the computer. According to the program one deflector guide is there which guide the heald to go the respective heald shaft according to the design. After complete the required amount of drawing they are joining each end with required beam. Automatic Drawing In Machine: Make Model Year Speed Max speed Frequency SUPER VEGA Automatic Drawing- in machine ELM SPA, ITALY Super Vega 2400 2005 70ends/min 80ends/min 4 beams/shift

Some of the special features of this machine are as follows: Automatic computer controlled drawing in of single beam warps. Up to 80 drawing in operations per min. Automatic heald wire separation from magazine and its distribution. NIFT HYDERABAD Page 78

 Automatic drop wire separation and distribution also. Automatic reed, heald wire, drops pin transport.

Operation Make a set of frames The beam should be knotted first Draft, peg plan feed in the computer and it will take care of drawing 4-5 times production is more than manual drawing.

M/C No.3 Make Model Year Max. Speed Max. Speed

Prashant Gamatex Prashant India GE405 1996 Gamatex

M/C No.1 Make Model Year Max. Warping Speed Max. Beaming Speed

Beninger Warping M/c Benninger Switzerland EROGOTRONIC 2000 800 200

Warping 600 Beaming 90

14.8 Knotting Machines M/C Max Speed Total No. of M/C Staubli Topmatic 350 Knots per Min 3

Automatic Knotting M/c:In case for knotting, two warp sheets of different colors but having same design/pattern. This is done at two places 1. Knotting on warping M/c 2. Knotting on Loom

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14.8.

WEAVING MACHINES

There are total 112 looms, which includes 34 Picanol Gamma, 56 Nuovo Pignone (NP) and 22 Picanol Gammax looms. The total output of this department is 23000 meters per day. The machines are running with speed of in between 450 530 rpm. The weaving department has only one loom type rapier. Rapier loom types are as follows: flexible rapier, flexible free flight, flexible guided hooks ( one guide roller between which ribbon passes to pick warp).

14.9.

RAPIER WEAVING

In Rapier looms, the weft insertion element resembles a rapier or a thin bladed straight sword; hence the name Rapier Weaving. There are many varieties of Rapier systems such as single, double, flexible, rigid, telescopic and two phased. A Rapier in its simplest form consists of a single rigid bar, solid or telescopic and a damp device called gripper head screwed at its feed end. Here the control over the weft is positive during the whole pick insertion cycle. The rapier may be also be of the rigid rod type or flexible, made of metal or plastic tapes. Flexible tapes invariably need guide meters inside the shed that emerge during the pick insertion and sink back into the sley before beat-up. The Rigid rapiers that include telescopic type remain suspended from the fulcrum and may get help from right upper warp sheet. FEATURES OF RAPIER WEAVING MACHINE Electronically controlled weft tensioner reduces the yarn tension especially during insertion. Automatic package switching device prevents the machine from being stopped in the even weft break between the package and weft feed. The weavers can repair the fault while the machine is running and reactivate the unit that has been stopped. Electronically controlled warp let-off and cloth take up units ensure a high degree of fabric regularity and prevents all kinds of start and stop marks. Grippers are redesigned to ensure better clamping of the yarn and prevent rubbing against the warp yarns.

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 Electronic monitoring control systems have simplified the communication with the machine and facilitated its easy handling by anyone concerned with the operation of the machine. 14.11 PICANOL AND NUOVO PIGNONE LOOMS Picanol and NP loom works on Flexible Rapier principle of Tip transfer. The weft insertion rate for Picanol is around 800mpm while of NP loom is around 600mpm with maximum working width of 190cm and 220 cm for Gamax. Both these looms have an electronic let-off motion for constant warp tension regulation and auto take-up setting mechanism, which eliminates change of pick wheel. Both these looms are adapted to Quick style change, which is necessary with shorter lots as practiced here. Grosse electronic Jacquard controls the name selvedge with 40-hook capacity. The usual heald shafts are controlled by Staubli electronic dobby having a maximum capacity of 18 shafts. The weaver beam capacity for these looms is 500 Kg. Both these loom have tuck-in selvedge. Weft insertion is through yarn accumulator for a controlled weft insertion. Both these looms have provision for multi-colour weft insertion. Here usually four are used.

14.12. FACTS AND STATISTICS

output -23000 mts/day The machines are running with speed of in between 450 530 rpm. Attachments for jacquard machine is main selvedge, while in dobby machine, it is shedding mechanism. Fabric design 1. Plain 2. Twill 2/1, 2/2, 3/1, 3/3 3. Satin = 5-end satin , 4-end satin (warp face) 4. Herringbone (broken twill) 5. Hopesack (double plain) 6. Basket weave (fancy weave) Types of fabric = linen, all wool, poly-wool, poly-viscose ,silk fabric , lycra ,bamboo fiber Efficiency = 84% Average rpm = 400 rpm Safety measures are : photo sensors on warping machine and ear plugs.

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14.13. PLUSH WEAVING

Plush is a special type of fabric weaving by which we can produce piled fabric. The warp piled fabric is called as velvet and weft piled fabric is known as velveteen. In Raymond ltd. they are producing warp piled fabric. For producing this 6 Jacquard and 5 dobby m/cs are used. For dobby m/cs two type of warp piled fabric. The main purpose of the plush department is to produce furnishing fabric for automobile industries as well as for interior decoration. Plush department has two sub departments: Weaving Finishing Most of the yarns used for the manufactured of the plush fabrics are outsourced, other than the polyester yarns which are supplied In- House. Designing studio creates and selects the designs for furnishing fabrics which includes home furnishing, automotive furnishing, carpets (middle weight), bed-ups, aviation etc The department has 11 looms for plush weaving and 8 looms as flat looms. Out of 11 plush looms, 5 - Dobby 6 - Jacquard looms. Out of 6 jacquard looms, only 3 are engaged in carpets while rests three are used in making other things. Out of eight flat looms 4 Auto furnishing over seat-covers 1 Suitings (Sherwinis) 2 Home furnishing 1 Sampling

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For plush fabric P/V base fabric P/acrylic pile fabric

In flat furnishing 100 % polyester is used while in aviation, viscose blends are used. In auto furnishing, OEM (own equipment manufacturer) is used fabric, foam and screen. Screen can be woven or knitted (warp knitted or circular knitted). Firstly, the screen is laminated with foam and then screen with fabric.

In aviation, wool/nylon 90/10 blend as well as poly wool 65/35. Sometimes, 100% polyester is used since aviation fabrics require warm feeling fabrics.90/10 is non-washable but 65/35 is washable.

14.14 Yarns used For plush dobby: 2/40 Nm For pile : 2/35 Nm For plush J/Q : 2/50 Nm for round and 2/30 Nm for pile. For flat auto furnishing: 360 D, 600 D, 750 D For home furnishing, chenille yarns of counts 3.5 Nm, 5 Nm are in use. In warp yarns, 150 D polyester is used. For fancy yarns counts are chosen as per appearance and textures. One should be careful in selecting fibers for pile fabrics. Pile should have soft feel, which is given by acrylic and its blends. From wool, it is not possible. Pile length = 4 8 mm Efficiency of the plush weaving = 51% Bundle requirement=4-5 shift Replacement of all the yarns = 2-3 shift 14.14. YARN SUPPLIERS FOR PLUSH DEPARTMENT Banswara Grasim RSM mill) (Rajasthan Acrylic/polyester cotton Polyester/viscose spinning 2/30& 2/24 Ne dyed, 2/24&2/30 grey.

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PSM Ventura Jayashree cotton mill Gokak mills

100% polyester, 2/20 Ne cotton cotton cotton

14.15. BRAND NAMES La crme La mode Electra Fusion Decora Sparkle Designo Home Jacquard. Shadow Jacquard Auto Jacquard Semi Jacquard Made ups/ runner Flat auto Jacquard Chenille

14.16. JACQUARD In jacquard m/c carpet fabric and designed pile fabric are produced. Here they are using maximum four colors for designed. There are eight shafts for ground weave, 4 shaft for selvedge and 4 for main body. There are 4736 harness for pile fabric and 4680 harness for carpet. Here each end is controlled by electronic jacquard. Jacquard designs are complicated . The fabric when on loon is of 180 cm width,and finally it becomes 165 cm. it has creels. The machine runs at 200 rpm. Production of jacquard (plush) = 150/day Materials used For ground P/V blend yarn For pile - Poly/ acrylic 60/40 for carpet & acrylic 100% for other fabric For weft Cotton yarn of 6 s Ne Generally the yarns are coming from Bansuwara Syntax, RSWM, Priyadarsini mill (Coimbatur), Malwa industry (Ludhiyana), Raymond Ltd. Jalgaon etc. before preparing their own fabric they are rewinding NIFT HYDERABAD Page 84

the yarn in the cheese form. These are used on creel for Jacquard m/c. They are also using sectional warping m/c to prepare the ground warp beam for all Jacquard, Dobby and also design beam for Dobby.

14.17. DOBBY The dobby machine has shafts through which yarn passes. The design area is limited, as simple geometric shapes can be weaved. The machine runs at 240 rpm. The fabric width is 1.5 meter. It has beam. Production of dobby ( plush)= 225m/day

14.18. DEPARTMENT PLUSH-WEAVING

Sr. No. 1. 2. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Description of machine Knotting m/c Perching m/c Perching m/c Mending Winding m/c Winding m/c Warping m/c Warping m/c

Model HL-210 STAFI STAFI N.A RECO SA DA PF2000E GE405 BENTRONIC MPS32 EJP2 VMM32 EJP2 VMM32 EJP2

Make TODO STAFI STAFI N.A PS.METLER PSA OTT PRASHANT GAMATEX BENNINGER, M.V.W GROSSE M.V.W GROSSE M.V.W GROSSE

Year 1996 1980 1979 N.A 1996 2006 1996

No. Of m/c 1 1 1 2 1 1 1

1989 1996 1996

1 1 1

J/q& loom J/q &loom J/q &loom

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10. 11. 12.

J/q &loom J/q &loom J/q &loom

VMM32 EJP2 VMM32 EJP2 MPS32

M.V.W GROSSE M.V.W GROSSE M.V.W GROSSE

1996 1996 1989

1 1 1

EJP2 13. Dobby loom VMM22 M.V.W 14. Dobby loom VMM22 M.V.W 15. Dobby loom MPS22 M.V.W 1989 1 1996 1 1996 1

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15.

FINISHING

Finishing is the final process of preparation of the fabric. Finishing processes are carried out to improve the natural properties of the fabric. Its primary objective is to enhance the quality of the cloth, imparting the woven fabric a specific appearance, handle in order to make it attractive, the aesthetic appeal and its serviceability. The finishing department receives the fabric either from mending department or from the fabric-dyeing department. The processes of the finishing treatment differs according to the blends, shades etc. Finishing department in Raymond is divided into 3 sections viz. grey room, wet section and dry section.

15.1.

GREY ROOM

This section is called grey room because all the grey material from the weaving department after perching and mending is being sent to grey room. Here all the pieces are sorted according to weaving machine number. 15.2. WET SECTION

This section is known as wet finish section because all the treatments that are carried out on the material are in wet form that includes Batching, Pre-scouring, Heat set, Shearing, Singeing, Wetting, Solvent scouring, Rope scouring, Squeezing, Drying. 15.3. DRY SECTION

This section is called the dry finish section as here the fabric is treated in dry form throughout. Only mechanical operations are rendered to the fabric in order to enhance its look, shine and feel. This

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treatment is generally under the influence of pressure and steam which includes Damping, Nikki press, Dolphin-Contipress, Stabila (antishrink), TMT (kier decatising) and Super finish (open decatising).

15.4.

Process flow chart of the Finishing Department (wet section) P/W piece dyed

P/W top dyed

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P/V fiber dyed

P/V piece dyed

15.5.

Definitions (wet section):

BATCHING: It is the process of matching or shade sorting each beam of fabric to make a bigger batch from the individual smaller ones. SCOURING : Scouring is a process essentially carried out for each and every fabric in the finishing department aimed at removing all sorts of oils, fatty acids, impurities and waxes from the fabric as well as the oil marks in the selvedge of the fabric, marks on the body of the fabric, greasy matters and other unwanted foreign materials on it. There are two types of scouring machine viz. NIFT HYDERABAD Page 89

open width scouring machine and rope scouring machine

ROPE OPENER: After rope scouring, the fabric is in the wet condition and in rope form. So it comes to rope opener for the opening and washing purpose. STENTER :The stenter can be used for heat setting, drying and resin treatment. Before passing the fabric through the heating chamber, it is passed through a tank containing water and softener. Pins on the conveyor grip the fabric properly before entering into the chamber. 10 coils heat the drying chamber. It comprises of five chambers and each chamber is provided with heated radiators and two blower fans. These radiators are heated with continuously circulating heated oils through it. Heated oil enters at one end of radiator and goes back for reheating from the other end. Thus, the same oil is continuously circulated in these radiators. A fan does the function of blowing the heat of radiators on the fabric passing through these chambers. Suction is provided for extracting the moisture. For heat setting, the temperature of the chamber is kept about 185C and for drying; it is around 140C. Before the heat setting is carried out by stentering an operation called as bowing is carried out. This operation helps in maintaining the width of the fabric. If the fabric requires resin treatment then resin is applied thorough padding mangle. SINGEING: In singeing, the fabric is perfectly opened out and passed on direct flame of fully combusted flue at a very high speed while the height of the flame can be adjusted as per the quality of the material to avoid the damage to the fabric by burning the protruding fibres. At the time of contact between the flame and the fabric, the fabric is passed over water cooled guide rollers for avoiding any damage to the fabric. SHEARING: The object of shearing is to remove protruding fibres from the cloth surface and to even out or level the fibre or neps that has been previously rose. After rescouring the yarns in the fabric swells resulting in the opening of twist in the yarn thus increasing the surface fibres. Shearing is the most important process in the dry finishing department. This process makes further process very easier and imparts goods sharpness on the surface.

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 WETTING: it is a process used to remove the dust and ash particles formed during the singeing process and to improve the absorbency of fabric by using wetting agent. The solution used for this is water and Sandozin MRN (wetting agent- 2g/l).

15.6.

Process flow chart of the Finishing Department (dry section) P/W piece dyed P/V (piece & fiber dyed)

P/W top dyed

15.7.

Definations (dry section):

DAMPING: Damping is the operation carried out before pressing and decatising. In all pressings, temperature goes above 100oC, which can cause complete evaporation of the water particles from the fabric. Before pressing it is very important for the fabric to have sufficient amount of water to give better finish. In this process, moisture is artificially given to the fabric by evenly spraying water under certain pressure thus giving the required amount of moisture to the fabric.

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 PRESSING: The aim of pressing is to make the fabric smoother by subjecting it to the strong compression against polished and heated rollers. Objective of pressing are aesthetic and partly commercial. Many times the finishing operation disturbs the surface of the yarn and the fabric. The unevenness and the impurities cannot be reduced till it is blown and pressed. Pressing can be considered as mild, mainly cohesive setting treatment. In Raymond, pressing is carried out on Nikki press machine. RELAXATION: The main objective of this process is to minimize the process shrinkage. Due to various finishing processes the fabric gets stretched in lengthwise and widthwise. Therefore it becomes necessary to remove the excess tension of the fabric. This is done by passing the fabric over the conveyor belt through saturated steam and hot air pressure. The conveyor is subjected to vibration through vibrator roller. Fabric is pressurized through the steam of 3.5kg pressure. The tunnel temperature is maintained at 1050C to 1100C. At the same time dry air is blown through perforated conveyor and fabric. This overall process gives relaxation to the fabric and minimizes the process shrinkage which reduces shrinkage after finishing. DECATISING: The object of decatising is merely to remove excessive lusture, and the thin papery handle from previous processes, as well as to prepare for pressing and cutting. There are two types of decatising: open and kier. In the case of kier decatising(K.D), pressure is applied to the material along with steam while in the case of open decatising, no pressure is applied and only steam is passed through the drums. The results obtained from K.D are more permanent. SUPER FINISH: This machine is used to give special type of shine and lusture to the fabric. Here temperature, pressure and steam are maintained according to the quality of the fabric. Therefore, decatising process also occurs in this machine. The fabric fed to the pressing unit is passed dry or moist at high temperature between the mirror bright chromated effect roller and the rubber coated surface of the guide belt under high belt tension wherein actual setting and pressing takes place. The WEKO humidifier situated immediately upstream of actual press unit, to prevent irregularities on the moist side of the moistened fabric to ensure uniform moisture application adjustments.

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15.8. NAME

Machine details: NO. OF M/C 4 MODEL Calico (Bombay) Type: - PPM/076 FEATURES Max 700 to 800 meters per lot

Batangas Batchmaking m/C Open width washing m/c Jigger m/c

Dhall Ahemadabad

For pre-scouring, speed-16mt/min, pH-7.5

JT10

For pre-scouring, chemicalsDidavin-EWN, Baysolux, Oxalic acid, etc, speed-50mt/min

Stenter

Harish (Gujarat) Model: Supra 5

For heat set, speed-22mt/min, 170185 C m/c speed- 25mt/min, cutter1100rpm, 4 brushes at 500 rpm, brush direction- reverse to fabric. Burner distance-10-12mm, flame intensity- 10-14 bar, speed- 80-100 mt/min 100 liter H2O 2 gpl Sandozin MRN (wetting agent)

Shearing m/c

Lafer Italy Model :-CMI2(1996), CMI-200(2003),

Singeing m/c

osthoff senge (germany) Model: - VP-97 (1998)

Wetting m/c

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

Rope scouring m/c

11

MAT SPA (Italy), Hemmer, Dolly, Serracant, Zonco(Italy), Dhall (Ahmadabad)

Detergent- Ascodet ECN, softnerSarasoft 485 , fabric remains inside for 60 min

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Squeezer Stenter Damping m/c Conti press m/c

2 3 2 1

Supervelox Harish , supra 5 Stabila Hemmer, Germany Model:-GPP400 (2001)

Mangle pressure: - 50 lbs/inch2 For II Dry and resin treatment, speed 12-14mt/min Speed- 12-15 mt/min Speed- 12 mt/min, 85C

Nikki press

Nikki (Japan) Model: -4G-4P 6038 (1985), 6G-6P 6185 (1990)

m/c 1 has 4 plates and m/c 2 has 6 plates, 85C, 125Kg pressure

TMT machine (Technologia Meccanica Tessle) Kier decatising

TMT (Italia) Model: - P-F 2000-1503 Magnums and P-F 20001593 New Multiprogram

For decatising,

KD (Italia) Model: - KD Suprema 95/1600 Permanent finish

For decatising,

Super finish

Germany Model:-GFP 800/900 (2004)

Used only for special finishes

Perching m/c

27

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

CCl4 in white petrol is used to remove stains,oils etc

After passing of fabric through all the sections, it is kept in an area from where it is send to folding department. Every fabric roll has a piece ticket with it which contains piece no., all the descriptions of fabric make like weave, gsm, selvedge, etc and also the various defects that remains even after the finishing process.

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