SRI BHAVANI TEXTILE PROCESSING:

The plant performs the following operations of wet processing 1. Singeing(Fabric) -Gas Singeing 2. Desizing 3. Mercerisation(Fabric) 4. Scouring and Bleaching 5. Dyeing -Kier boiler -Jigger -Jet dyeing -Beam dyeing 6. Dyeing(yarn) -Cheese dyeing 7. Finishing -Stenter -Zero-Zero -Calendering 8. Printing -Flat bed printing 9. Dot coating

DESIZING: Mts=1095 Volume=650 Indent type=non organic Temp=80 Weight=378 Time: 1: 15 min Wash time:15 min ITEM NAME Beisol AFG Kleenox BAS Caustic SLYE KLENOX BAS Zycol TSA Hydrogen peroxide Contavan BRT KLEENOX BAS Acetic acid 99% Caustic soda LYE KLEENOX BAS ZYCOL TAS G/L 0 0 0 0 0 0 0 0 1.5 0 0 0 PERCENTAGE 0.5 0.1 4 0.5 0.3 1.5 0.25 0 0 2 0.25 0.15 QUANTITY 1.89 0.378 15.12 1.89 1.1340 5.6700 0.94500 0.945 0.975 7.56 0.945 0.567

BLEACHING: Mts=442 Weight=206.4 Volume=450l

Type=non organic Temperature=80 ITEM Bleaching liquor Soda ash Hydrogen peroxide Sodium silicate Sarometa Sapoleneconc Acetic acid 99% G/L 2 0 0 0 0 0.5 2 PERCENTAGE 0 0.05 1.5 0.5 0.1 0 0 QUANTITY 0.9 0.10 3.09 1.03270 0.206 0.295 0.90

MACHINE AND CAPACITY DETAILS

S.NO 1 2 3 4 5 6 7 8 9 10

M/C Kier make up tank Kier capacity Beam dying m/c Jet dyeing m/c Jumbo jigger 1-3 Jumbo jigger PACIFIC jigger Jigger 1 to 2 Jigger 3 to 4 Kier boiling

CAPACITY(kg)

VOLUME(litre) 735

WIDTH(inch)

1500 100 100 300 300 1000 150 125 1500

800 900 350 350 600 450 375 3000

63 74 74 84 72

KIER BOILER

It has capacity of 15000 to 17000 Fabric from grey mercerization undergoes cold wash. Fabric from desizing undergoes hot and cold wash Then the material from both undergoes caustic boil in kier boiler Inside kier hot wash and cold wash is done Then treated with Hcl for scouring twice. Then cold wash is done after that soda is added Then the fabric is treated with chlorine for two times.

Then cold wash along with tinting is done.Then treated in hydrogen peroxide boiling for 4 hours in open boil.

DHOTHY BLEACHING

Grey Mercerization (or) Desizing Cold Wash Chlorine 2 times 2 Times Cold Wash& wash in Kier Hydrogen Peroxide Bleaching with given Time & Temperature Cold Wash 2 Times Acetic Acid Cold Wash& Tinting & Opening

JUMBO JIGGER for dyeing

Desizing / Singeing

Caustic Soda Hot Wash & Cold Wash Chlorine Hydro chloric Acid 3 times Cold Wash Dyeing

Desizing Hot Wash Soda Boil Hot Wash & Cold Wash Hydrogen Peroxide Boil Cold Wash 2 Times Hot Wash - 3 Times Acetic Acid Cold wash Dyeing For white

Singing

 Caustic Soda Hot Wash Cold Wash Chlorine Cold Wash Peroxide Boil & (2B)- which gives half white 4 Times Washing

After 4 Times washing 2B is added with less steam Hot Wash Cold Wash Acetic Acid Cold Wash

Drying

BEAM DYEING In this process the solution only rotates. Beam width is 180 cm Holes to holes 150 cm

BEAM DYEING PROCESS making of beam batching as per the width of fabric and overlap should be 3.5 cm over the beam end piece should be placed to reduce the end variation in fabric fabric should winded with proper tension in beam dying m/c water capacity is 800 ml reverse I s 3 minutes glycerein should be placed in rubber washer above the end piece a fabric should be place to reduse the shade variation after placing fabric water is added. After accetic acid and saromata and then steam make it 60deg temperature then check pH when pH is 4 to 5 sarcomata carrier TCI is pump into it maintain to 60 deg and added leveling agent (cidogen DETC is pump into it) when pH is not B/W 4 to 5 acetic acid also added then dye is added then temp is added to 90 deg by 10 minute I.e for every 1 minute 3deg is increased afer attaining 90deg. Every 1 min 2deg is added attain 130 deg within 20 minutes At 130 is maintain to 10 to 15 minutes Simple is checked Temperature is redused to 90 deg m/c is ruin off when shade is not match again repeated after comes to 90 deg due to high temperature and pressure after complete rein off

Speed is 20 to 120 m/min and width of fabric from 60 to 160 cm Temperature varies, depends on fabric

DRYING / PADDING

Dyes : silicate = 4:1

To Remove excess colour

hydros caustic for 6 end

PRINTING: Flat screen Printing machine -1 No. Labours - 6 FLAT SCREEN PRINTING -Reactive -Discharge -Pigment Note: PVA is applied to the blanket to hold the fabric tightly whose intensity varies according to fabric thickness & repeat of the print. REACTIVE: Printing the fabric using reactive dyes. After printing is done, fabric is passed through silicate padding for curing for a minimum of 16 hrs to a max of 24 hrs. Drying

Calendaring Finishing

The fabric to be passed through silicate padding is passed with the print downside. Pressure of the padding mangle = 3.5 kg DISCHARGE: Fabric is passed through the ager for curing after printing. The color of the fabric/print looks grey i.e. in the dull dust color after printing. The required color of the print is attained only after ageing. PIGMENT: Pigment is used as the printing paste. The print is dried in steam after printing, which sets the print & gives the original color.

RECIPE FOR PREPERING PRINTING PASTE: 1. 2. 3. 4. Alsinate -45 kgs Cisalsin -8 kgs Kerosene Emulsion 7kgs Water - 40 kgs First mix cisalsin& kerosene Emulsion with water, then add Alsinate. Incase of Reactive paste, after mixing the paste with dye, purify the mixture. ALSINATE: 1. 2. 3. 4. Alsinate powder -3.5 kgs Printing gum -1 kg V.M Powder -0.5 kgs Hot water(40-45C) -95 Kgs Add in mixer & prepare the paste.

CISALSIN: 1. Cisalsin powder -10 Kgs

2. Emulsifier -1 Kg 3. M.T.O -20 Kgs 4. Hot Water(40-45C) -70 Kgs First add cisalsin powder & mix in hot water & then add M.T.O & Emulsifier. KEROSENE EMULSION: 1. M.T.O -90 Kgs 2. Emulsifier -1 kg 3. Water -10 Kgs First mix M.T.O & Emulsifier and then mix it with water slowly PIGMENT PASTE: 1. 2. 3. 4. 5. Binder -10 Kgs Lubrindal M.C.L -1.5 Kgs Lutex H.E.F -2 Kgs Urea -1.5 Kgs Water -70 Kgs First mix binder and urea with water and then add lubrindal M.C.L & then mix lutex H.E.F.

BOILERS: 1. STEAM BOILER Make Model Capacity Year Reg.No Fuel 2. THERMOPAC Make Model Capacity Year Fuel

:Thermax, Pune :CPF60A/W54/5 :6000Kgs/hr :2002 :T 6908 : Groundnut Shell :Thermax, Pune :VTA 15/121 :15 lakhs/Kcal/hr :2003 :Fire wood

YARN DYEING: Capacity: M/C Capacity Quantity Totalkgs Water

300 600 150 125 75 50 30 10 5 TOTAL

2 1 1 1 1 1 1 1 1

600 600 150 125 75 50 30 10 5 1545

Consumed/Mc 3000 Lts 6500 Lts 1500 Lts 1250 Lts 750 Lts 500 Lts 300 Lts 100 Lts 50 Lts 15950 Lts

DYEING PROCEDURE: S.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PROCESS Scouring/Boiling Hot Wash Acetic Acid/EAT Light & Medium shade dyeing Black Shade dyeing Dark Shade dyeing Addition Washing Washing(Acetic) Soap(ADW &Sapoline conic) Washing(Acetic acid/ZAB) Soap(Zycol AB) Cold Wash White Boil White Finishing Fixing(Hi fix) Fixing(For Pmf(erl)) Finishing Boil Soap & Soda(For TEMP (C) 95 80 50 60(1C/min) 60(1C/min) 60(1C/min) 60(1C/min) 50 50 95 60 98 27 100 50 50 40(1C/min) 50(1C/min) 95 TIME (mins) 45 10 15 60-75 90 90 30 15 15 15 30 20 10 90 15 15 30 15 20

20

P/model,viscose,P/Viscose) Polyester dyeing

135(1.5C/min)

30

HYDRO EXTRACTOR: Make: Lakshmi Max: 24 cheeses Time: 2 mins Production: 600 Kgs/Shift

RF DRYER: Make: Lakshmi Model: INSTA 40/11 Year: 2004 Supply Voltage: 415 V 5 % 3, 50 Hz Input Power Requirement: 86 KVA RF: 27.12 MHz 0.6 %

CONCLUSION
Thus this report provides the general features and composition of SRI BHAVANI TEXTILE PROCESSING equipped with latest machineries, skilled and qualified labours in the wet processing sector of both yarn and woven fabrics. This would prove to be an example of a well-managed industry in terms of technology as well as man power with sufficient resources and its effective utilization.