INTRODUCTION

Tirupur is a small town in Coimbatore district of Tamilnadu and is popularly known as knit city. Tirupur is situated at 60kms east Coimbatore with the land coverage of over 27.20 sq.kms. With a population of around 6 lakhs. It is learnt from the reliable sources that first hosiery factory with hand operated machines was set up in 1935. With a beginning of rs.19 crores in the year 1985, exports of knitwear from tirupur rose to 10,000 crores during the year 2008. A creation of high style and value added knitted garments are the key for success. At present tirupur tops in knitwear exports in india. Lots of foreign currencies come into india, it results in economic growth. At present the garment owners are looking ahead of free trade. They are eagerly waiting to widen their business. The main purpose of internship is to gain knowledge about the new technologies and machineries used in various companies. We had visits to spinning mill, knitting unit, dyeing factories, printing units, embroidery and sewing units. VELAN EXPORTS was established in the year 1989 in TIRUPUR, INDIA, with the purpose of 100% exports of KNITWEAR GARMENTS, primarily to EUROPE.

COMPANY PROFILE

COMPANY NAME TYPE OF BUSINESS

: VELAN EXPORTS :MANUFACTURERAND EXPORTER

LEGAL STATUS YEAR OF ESTABLISHMENT CONTACT PERSON OFFICE FACTORY

: PARTNERSHIP : 1989 : MR.S.BALASUBRAMANIAM : NO.1, PETHICHETTYPURAM, 3RD STREET, RAYAPURAM, TIRUPUR - 641604.

BANK PRODUCTION CAPACITY NO OF MACHINES TURN OVER

: INDIAN OVERSEAS BANK : 50000 PIECES PER DAY : 250 : 5 CRORES

PRODUCTS:
MENS LADIES T-SHIRTS NIGHT WEAR PANTIES CHILDREN HOOD SHIRTS SPORTS TOPS BOXERS SHORTS BRIEFS : GOVT.RECOGNIZED EXPORT HOUSE : TOM TAI T-SHIRT POLO SHIRTS SPORTS WEAR NIGHT WEAR BOXER SHORTS BRIEFS

RECOGINISATIONS BUYER

COMPANY LAYOUT :

COMPANY FLOW PROCESS

BUYER ORDER RECEIVING

DYED FABRIC RECEIVING

SPREADING

CUTTING

SEWING

CHECKING

PACKING

FINISHING

DOCUMENTATION

LOT SECTION
INTRODUCTION It is the department with supplies the fabric to the garment industry. The lot section are of two types. They are fabric lot and dyed lot. We are going to see about the dyed lot section, because in our garment industry there dyed lot section form which they are supplying for the whole unit the fabric. Here, in lot section there are many types of fabric in stores which they already used are their orders, but some of them are remaining are stored in racks. There are different types of fabric which they can use. ORGANISATION Here is lot manager and below him there are two sub managers, who will have contact with other two departments. The manager will dead with the out door knitting and dying that where it has to buy and how it should be delivered and all other details are given by him. Then there are five workers who will check the receiving order and they will check the fabric while it is taken to production.

MISTAKES TO BE NOTED It is a fabric roll came from the knitting and dyeing while it is enter into lot section at first they check gsm [grams per square meter] and then the shade variation the following are some of the details check by lot section after receiving a roll. 1. Knit dia 2. Roll no 3. Thick/thin yarn 4. Color yarn 5. Holes 6. Flower line 7. Needle line 8. Oil line 9. Dyeing holes 10.GSM holes KNIT DIA This knit dia is the diameter which is in the circular knitting machine. If we give 24 dia we will get 26 dia fabrics. According this adjustment the diameter of the fabric should be considered. It is an important factor in producing the fabric. If the dia changes then the fabric wastage will be more while cutting.

ROLL NO There is for every individual roll a number is to be given. The roll no is used for the further reference or identification there is no need of missing. We can maintain the rolls properly in some the roll no will be marked differently, and some mistakes should be prohibited. THICK\THIN\YARN The yarn which is in the knitted fabric will has some thick and thin places it should be verified at every there is no thick and thin places the yarn. Because in feature it will create some problem so it should cleared in fabric stage itself. COLOR YARN If in a lot a full of green color then only a single yarn comes on flow with pink color in the fabric which came to the fabric without the knowledge of knitting operator it should be noted. The fabric should be in some color there should not be any difference in it. HOLES There are some holes present in the fabric that comes by higher needle stretch ability and any other mental parts friction during knitting or dyeing. FLOWER LINE There is a defect in a knitted fabric which considered some time as a design. Mostly this defect is not taken as a higher defect. It will appear in the fabric less.

NEEDLE LINE This line comes by drop needle that there will be any needle to form drop so only coarse yarn will be no Wales. OIL LINE If any fabricant is supplied it is controlled by the box, but some times it will be sparked on fabric without the knowledge. DYEING HOLES There some holes which happen during dyeing by the metal which will be corrosive present in the machine will damage the fabric these are considered as dyeing holes. GSM HOLES There will be some gsm holes which is there to check the gsm of the fabric, there will be a round cut about the fabric which is said as gsm holes. MOVEMENT OF FABRIC The fabric which are manufactured are based upon the orders given by the orders according to the order the knitting order is given. The movement of fabric is based on season. The order will change season to season for winter high gsm garment will be manufactured and in summer very low gsm garment will be manufactured on they were used according to season only.

TWO MAIN FACTORS In lot section the two main factors which has to be considered are, Gsm Color shade GSM It is grams per square meter of the fabric, this says about the quality of the fabric. For everything quality is important, this says the fabric quality. Very low gsm is 120 and the very gsm can be 280 these fabrics are tested using gsm cutter which is blades on four sides it is in round shape. This cuts the fabric in circle shape. Then it is weighted in grams machine. According to the fabric, gsm is calculated. We can increase the fabric gsm by using finer counts yarn in the knitting and courses counts yarn will be less gsm, after dyeing the gsm will be vary for all fabrics. COLOUR SHADE This color shad is noted after the dyeing. The fabric dyed with the colour should be even in all the places of the fabric, it should not have diferent colour in the same roll of the fabric. The shade variation gives the problem of the color diference. This is also noted this occurs under the improver dyeing. It can be varied along with the various properties should be maintained properly. There are some color matching systems in industry which is used for export orders. These are considereds as main problem of the dyeing industry.

KNITTING
Knitting is defined as the forming a chain of loop from a single yarn or more then one yarn and also the inter link the chain of loop with another looping element. Loop is the basic unit of knitted structure.it is formed by bending of yarn. CLASSIFICATION OF KNITTING WEFT

WARP

1) WARP i. ii. iii. iv. SINGLE JERSY DOUBLE JERSY JACQUARD NON-JACQUARD

2) WEFT I. II. III. IV. SINGLE JERSY DOUBLE JERSY JACQUARD NON-JACQUARD

SINGLE JERSY
This kind of fabrics are produced with one set of needles and one set of sinkers.

DOUBLE JERSY
This kind of fabrics are produced with two set of needles (dial & cylinder needles).

RAISING
The raising machine is composed of two raising drums placed one above the other,for a better optimisation of the space. All the motors are with power supply by digital inverters and the machine in controlled by PLC. The powers of the motors have been intentionally over-dimensioned,to allow a powerful operation and an high production. Nevertheless, thanks to the use of digital inverters,it is possible to have an infinite range of raising powers: from a smooth and delicate raising action,to a very powerful one.

The electronic control system allows to have very useful functions such as:

AUTOMATIC LOADING OF THE FABRIC ON THE TWO RAISING DRUMS. CHANGE OF RAISING FILLET DIRECTLY ON THE MACHINE. AUTOMATIC ADJUSTMENT OF RAISING POWERS. AUTOMATIC CUT-OFF OF RAISING POWERS (zero raising). MEMORISATION OF PROCESSING DATA. SERIAL PORT LINK TO FACTORY HOST COMPUTER FOR MONITORING AND RECORDING OF PROCESSING DATA.

According to the kind of fabric to process, the machine can be equipped with different accessories.

DE CURLING ROLLERS FOR KNITTED FABRIC IN OPEN WIDTH. EXPANDING RINGS FOR KNITTED FABRIC IN TUBULAR FORM. FABRIC TURNING DEVICE FOR TUBULAR. HEATED CYLINDER. ELECTROSTATIC ELIMINATOR. BATCHING UNIT. SPECIAL FABRIC FOLDER WITH VARIABLE LENGTH.

SPREADING Only an effective spreading will reduce wastage and improve the quality of the garment. Therefore every garment industry performs two types of spreading. They are: Manual Spreading Machine (or) Computerised spreading MANUAL SPREADING Done by manual action of workers It leads to more wastage It is a time taking process Checking can be done manually

MACHINE (OR) COMPUTERISED SPREADING it is a time saving process reduces wastage Operated through computerized controls Widely used process in the industry

CUTTING
Cutting is the process of preparing component parts of the garment. In this concern cutting done manually and by using machines.

MANUAL CUTTING
In this manual cutting hand sheers are used. Striped fabrics are usually cutted manually to avoid mismatches of stripes.

MACHINE (or) LASER CUTTING

In this concern Straight knife, band knife and computerized machines are used for cutting process. Computerized cutting machine is specialized in this concern. In this the cutting process is programmed first and set in the LECTRA system.

SEWING
The basic process of sewing involves fastening of fabrics, leather, furs or similar other flexible materials with the help of needle and threads. Sewing is mainly used to manufacture clothing and home furnishings. In fact, sewing is one of the important processes in apparel making. Most of such industrial sewing is done by industrial sewing machines. The cut pieces of a garment are generally tacked, or temporarily stitched at the initial stage. The complex parts of the machine then pierces thread through the layers of the cloth and interlocks the thread.

Industrial Sewing Although it seems to be a simple process, industrial sewing is quite a complex process involving many preparations and mathematical calculations for the perfect seam quality. Good quality sewing also depends on the sound technical knowledge that goes into pattern designing and making. Flat sheets of fabric having holes and slits into it can curve and fold in three-dimensional shapes in very complex ways that require a high level of skill and experience to manipulate into a smooth, wrinklefree design. Aligning the patterns printed or woven into the fabric also complicates the design process. Once a clothing designer, with the help of his technical knowledge, makes the initial specifications and markers, the fabric can then be cut using templates and sewn by manual laborers or sewing machine.

SEWING FABRICS The sewing process consists of mainly two functions- guiding fabric towards needle; sewing of the fabric edge; and rotation around the needle. The fabric is guided along the sewing line with a certain speed that is in harmony with the speed of sewing machine. Significant Aspects of Sewing There are certain aspects that have to be carefully considered while the sewing process as they are very crucial for high quality sewing.

1.THREAD TENSION AND CONSUMPTION: Correct balancing of the stitch and the tension given to the threads is very important for quality stitch formation. Thread consumption, which is closely associated with correct stitch geometry and thread tension, is usually measured by digital encoders. 2.NEEDLE PENETRATION FORCE MEASUREMENT: The interaction of needle with fabric is very crucial. Fault-free needle penetration depends chiefly on the properties of fabric and needle choice. Needle penetration force is one of the variables whose measurement is important for the

analysis of quality problems or "sewability testing" and also quality monitoring. Ittakes various factors into consideration, such as the needle

ACCESSORIES
INTRODUCTION: The accessories are in the garments for value added purpose. The garments are manufactured with the fabric, but the actual need of the garment is to cover the body of the human being. But some else think that have to give attraction to their garment, on the way the accessories are added in the garment which gives a perfect look to the garment. LAYOUT

Manger

Asst. Manager

K Exit

K Enter

ACCESSORIES The following are the accessories used in the garment export industry. Button Zipper Lace Label Tag Cardboard Hanger Sizer Polybag Carton Box Stickers Now we can briely expalin about the accessories needed for garments as per the quoted above.

BUTTONS The button helps to cover the parts which is open in garment. Maximum four buttons or minimum two buttons are used in garment. Buttons are classified into three types these are:

Covered buttons These are fabric-covered forms with a separate back piece that secures the fabric over the knob.

Mandarin buttons Frogs are knobs made of intricately knotted strings. Mandarin buttons are a key element in Mandarin dress where they are closed with loops. Pairs of mandarin buttons worn as cuff links are called silk knots.

Worked or cloth buttons are created by embroidering or crocheting tight stitches (usually with linen thread) over a knob or ring called a form.

BUTTON SIZES The size of the button depends on its use. Shirt buttons are generally small, and spaced close together, whereas coat buttons are larger and spaced further apart. Buttons are commonly measured in lignes (also called lines and abbreviated L), with 40 lignes equal to 1 inch. For example, some standard sizes of buttons are 16 lignes (10.16 mm, standard button of men's shirts) and 32 lignes (20.32 mm, typical button on suit jackets). ZIPPER He bulk of a zipper consists of two strips of fabric tape, each affixed to one of the two pieces to be joined, carrying from tens to hundreds of specially shaped metal or plastic teeth. These teeth can be either individual or shaped from a continuous coil, and are also referred to as elements.[1] The slider, operated by hand, moves along the rows of teeth. Inside the slider is a Y-shaped channel that meshes together or separates the opposing rows of teeth, depending on the direction of the slider's movement. Some zippers have two sliders, allowing variation in the opening's size and position. In most jackets and similar garments, the opening is closed entirely when one slider is at each end. In most baggage, the opening is closed entirely when the two sliders are next to each other at any point along the zipper. LACE Lace is an openwork fabric, patterned with open holes in the work, made by machine or by hand. The holes can be formed via removal of threads or cloth from a previously woven fabric, but more often open spaces are created as part of the lace fabric. Lace-making is an ancient craft. True lace was not made until the late

15th and early 16th centuries. A true lace is created when a thread is looped, twisted or braided to other threads independently from a backing fabric. Originally linen, silk, gold, or silver threads were used. Now lace is often made with cotton thread. Manufactured lace may be made of synthetic fiber. A few modern artists make lace with a fine copper or silver wire instead of thread.

There are many types of lace, classified by how they are made. These include:

Needle lace; Cutwork, or whitework Bobbin Lace Tape lace Knotted lace Crocheted lace Knitted lace Machine-made Guipure

LABEL A label is a piece of paper, polymer, cloth, metal, or other material affixed to a container or article, on which is printed a legend, information concerning the product, addresses, etc. A label may also be printed directly on the container or article. Labels have many uses: product identification, name tags, advertising, warnings, and other communication. Special types of labels called digital labels (printed

through a digital printing) can also have special constructions such as RFID tags, security printing, and sandwich process labels. In garments three types of labels used like Main label Size Label TAG Tags are the thing which will come under the accessories. The second costly thing in the accessory is tag. This comes under the various different types of tags according to the brand or buyer the tag will be changed. The tags are made up of sheet which is under smooth surface which it can be having the cost sticker on it. Mostly the tag will be denoted indollars and euros. These tags are implemented in the place of shirt buttons and in other place such as inner part of the garment. CARDBOARD This is used in the export unit to note the some o the requirements. This cardboard sheet is in the laboratory and in some other required departments. The color fastness card and the other reports are developed in this sheet only. This cardboard sheet comes under the garment accessories. Wash Care Label

HANGER The hangers are produced by plastic which are used in the garment to give the value for the garment. In the boutuques and shops the garment are hanged in the hangers. These hangers gives the value for the garment. There are different sizes which are used in the garment industry. They purchase the hanger mostly in the Chennai and Mumbai. Some export orders are ask that they need the garments with hangers so the hanger also plays a role in the garment industry. SIZER The sizer is an accessory that is used in hangers. The sizer is made up of plastic. It is round shaped a small circle. It is located at the neck portion of the hanger. This is used to size the hanger.This is the value added one for the hanger. POLY BAG Poly bags are the accosseries, at which after the complete finishing the garment is inserted in the poly bag should contain the warning, hazard and the brand names and caution terms. The most important term printed on it is keep reach out children. The poly bags are manufactured using polypropylene. The perforation is to be there in poly bag by small holes in it. The some types produced in poly bag they are, Individual Mass Hanger

CARTON BOX Carton box are the accessories which is used to protect the garment while transfering them to some other places . These are made by using cardboard sheet with high GSM; they are manufactured with the water repellent agent which is considered as higher cost . These boxes are produced based on the size of the garment . It should be comfortable with garment. The sample carton approvalshould be got from the buyer . It should not be damage anywhere. STICKERS Stickers are the onewhich is used to paste on the garments and used in some other places. The stickers are very useful to identiy something and to write the detailed on the stickers and paste it. Mostly the stickers are manufactured in white color. The stickers some will be printed that the detail about what is present there we have to mark in the pen. The marking stickers are also there which gives note there is a hole garment in that place that the sticker is pasted. CONCLUSION These are the accessories used in the department. These accessories are purchased by the manager who is in the department. According to the outdoor orders they are selling it for 10% pronit in their accessories. The orders given to the manufacturers mostly in Chennai and in local Coimbatore district.

Embroidery
Embroidery is the art of decorating fabric or other materials with designs stitched in strands of thread or yarn using needle. In Machine embroidery, Embroidery designs are stitched with an automated embroidery machine. These designs are "digitized" with Embroidery Software. They can have different types of "fills" which add texture and design to the embroidery. Almost all basic types of embroidery can be created with Machine Embroidery. These include: Applique, Free Standing Lace, Cutwork, Cross-stitch, Photo Stitch, and Basic Embroidery. Most often this type of embroidery is associated with business shirts, gifts, apparel and commercial use.

CHECKING Here the mistakes are identified and then rectified, trimming is done. Oil stains are removed using stain remover or CTC oil (carbon tetra chloride) or soap oil. Number of tables Number of labours Oil stain remover : 23 : 40 :2

In this stage garments are fully finished. The garment is send to the next stage of trimming and checking any defects the in the garment. If any stains are in the garment are also removed in this stage. The defects is identified the garment is send back to the particular area and correction is done by reworking. DEFECTS FOUND IN CHECKING Foreign fibres Yarn knots Dead fibres Latch holes Shade variation Rust Marking stain

IRONING The purpose of ironing is to remove the wrinkles and to increase esthetic value. Steam ironing is done. Ironing is given more importance in the area like band area, neck area, etc., Features : vacuum table, Steam ironing Machine details Number of Vacuum tables Number of steam ironing Number of Workers : 12 : 12 : 24

PACKING
Tags are attached in the label. Garments are covered in poly bags as per buyer wants. Covering the garment to protect it and to increase its esthetic value. To attract the customers. Carton box may be 2 plied or 4 plied as per buyer wants. Carton box should carry the following information: Style no Order no Net wt Gross wt No of pieces No of packing labours : 25

QUALITY ASSURANCE DEPARTMENT

Nowadays the lab is greaterly needed. Because the buyers are very serious in the case of knowing the lab approvals for even value addition made in the garment. Hence the industries making efforts in showing their quality so need of the lab is greatly increased. TESTS MADE IN LABS Yarn count test Yarn strength test Blend composition test Twist per inch determination Color fastness to rubbing Dimensional stability test Color fastness test CHEMICAL TESTS Acid test Saliva test Enzyme test Gas test Sublimation test Sea water test Flame test

LAYOUT
EMERGENCY EXIT

TUMBLE DRIER

LAUNDRO METER

TABLE

WASHING MACHINE

CROCK METER ENTRANCE FILES

DOCUMENTATION
The documentation process starts right from the preparation of the invoice o the prder till the receiving of the payment. The main function of the documentation department starts after the production process for the dispatch of the goods. This department looks after the receiving of various garments, they are: Invoice Certificate of origin from government Certificate of origin from Tirupur Exports Association Shipping bills Bill of lading

CONCLUSION
This gives an overall idea regarding the working, maintaining all the departments in the garment industry. This industrial programe has provided us basic knowledge in the field of garment unit. This helps us to get trained in an Industrial atmosphere in aspects such as punctuality, behaviour, communication, workmanship, etc... Lords along with its employee aims at developement of local manpower by innovative training methodology. Lords beleives in marching ahead in global apparel business through continuous focus on quality and dedication and teamwork. It is one of the leaders in the race for technolog and quality. The main motto is customer satisfaction by adherence to buyers requirements. The entire production process ollows R & D oriented approach. Hence this internship training was very useful and it would be very helpful for our future endevours. We heartfully thank Tirupur Kumaran College For Women For giving such an opportunity to undergo am internship training. We also thank Managing Director for granting us permission and supporting us throughout the internship program. Last but not the least our special thanks to our aculty guide Mrs.K.Subulakshmi