Académique Documents
Professionnel Documents
Culture Documents
Submitted By :
NAME
AHMER ADNAN BALOCH
DANISH HUSNAIN
ZAIN UL WAHAB
Preface
Company Profile
• Bed linen,
• Curtains,
• Kitchen Curtains,
• Table Covers,
• Men's Uniform,
• Blended Fabric,
• Cotton Fabric,
• Dyed Fabric,
• Grey Fabric,
• Printed Fabric,
• Bleach Fabric,
• Mercerized fabric,
• Finished fabric.
FLOW CHART FOR WET PROCESSING
Planning:
Planning is the most important step of every stage of the process
each and every person involve in the process must know flow of the
material process and parameters .
Job Cards:
Basically there are three types of Job cards.
1. Master card.
2. Travel card.
3. Colored card.
Master card:
Master card is directly given to the department on which Job cards
are stapled.
Travel card:
Travel card travel with the fabric on each and every stage of the
process from starting till finish it guide the operator that what si the
process flow of the material.
Colored cards:
There are 4 different colored cards used for the following
processes,
• White Bleaching.
• Green Dyeing.
• Yellow Sample.
• Pink Printing.
GREIG DEPARTMENT
• Making lots.
Mechanical Faults: -
Yarn Faults: -
Cockled Yarn, Weft Slub, Slubby Weft, CEP, Count Variation,
Hair, Jute, P Proplyene, Black Ends.
Others: -
Oily Weft, Sizing Stain, Hard Size.
Minor Faults: -
Major Faults: -
Those faults that can not be removed in further processing are
major faults such as starting mark, rapping mark, whole etc.
Tacoma(Spain) Batch Making:
Tacoma is brushing and batch making machine in greig
department. Batcher machine is used to made batch of the fabric.
Components of the machine:
1. Conveyor belt.
2. Scray.
3. Expanding rollers and guide rollers.
4. Winder.
5. Brush.
Whitness.
CMC.
Formaldehyde test.
Water testing.
Raw material check.
Barium activity test.
Core pH.
Troubleshooting.
New product accesment.
Degree of desize.
Absorbency test.
Spectrophoto meter:
Physical Testing:
All the fhysical tests on a textile sample or material is conducted in
physical portion of the lab.the test conducted by the physical portion are,
Tensile strength.
Tear strength.
Seam.
Abration
Air permeability.
Pilling.
Appearance.
Rubbing fastness.
Washing fastness.
Colour fastness.
Water fastness.
Perspiration fastness.
Dry cleaning fastness.
Light fastness.skew and boa.
Used for testing abrasion resistance of wool or blend of wool's woven, knitted and non
woven fabric in specified pressure, also used for testing balling in light pressure for most fabrics,
especially for wool woven fabric. Controlled by microcomputer, displayed by LCD, printing
reports, simultaneity show accumulative used times of every standard abrasive and working state
of each test head.
Orbiter Pilling:
Orbiter Pilling and Snagging Tester can be used to test both woven
and knitted materials. Determination of fabric propensity to surface
fuzzing and to pilling-
Standards:
EN ISO 129-1
Whirlpool:
Whirlpool Washing Machine is recommended by AATCC for AATCC
test methods requiring repeated home laundering.
Standard:
AATCC 135
Gyrowash:
Srandards:
ISO 5034,1393
ASTM 5035
Elmatear Digital Tear Tester:
Digital Tear Tester Elmatear: simplifies and accelerates routine
tear testing. Simply select the unit of measurement and the number of
plies and you are ready to test. The test results are displayed digitally.
No calculations are required.
Standard:
ISO 5077/6330
GSM Cutter:
This instrument is a circular fabric sample cutter with which a
uniform circular fabric is cut without measuring. The specimen which is
cut with the help of the Fabric GSM Cutter is 100 cm2 areas. This
instrument is complete with a piece of cutting board and 12 spare blades.
Light box:
• day-light
• incandescent
• back-light
• U-V light
Singe Desize Machine (Binninger Osthoff):
• Singeing position
• Flame intensity
• Fabric speed
• Distance between fabric and burner
Machine Components:
• Guide rollers
• Pre dryng
• Pre rushing
• Singeing chamber(4 burners).
• Cooling drums
• Post brushing
• Desizing unit
• Winder.
2
3
1. Tension rod:
The purpose of tension rods is to give tension to the fabric and to
stay away from crease formation.
2. Guide Roll :
Fabric is passed above the guide rollers for feeding the fabric in to
the brush rollers.
4. Singeing box :
After brush roller the fabric is moved over projectile of gas burner
to burn protruding fibres.4 burners are installed on this machine. The
flame is composed of 70% of air and 30% of gas. To avoid fabric
yellowish shade that’s why we use blue flame.
5. Chemical Bath :
Desizer Ecozyme
Wetting agent Recogen WBL
Sequestering agnt Secron 530
6. Winder :
The winder roll the fabric over the batcher and than it is left for 4
to 6 hours.
7. Cooling Drums :
In singeing section the fabric passed over the cooling drums to
down the temperature of the fabric after burners. The water circulates
inside the drums.
8. Donier rolls :
The donier rolls move in to and fro motion evenly distribute the
fabric.The time,temperature and pH must be maintained because the
enzyme will be active when the conditions are provided.
SCOURING & BLEACHING
SCOURING;
BLEACHING;
Scouring removes almost all the impurities except natural coloring
matters which are ultimately broken down with bleaching agents.
Bleaching is necessary for producing white goods either as finished
products or for dyeing pastel shades.
In Lucky textile 4continuous Binninger machine is used for scour
and bleach.the average production of the machine is 1.5 lacks and
another positive feature of the machine is that the finner fabric can run in
double.
Binninger Continuous Scour Bleach:
IMPECTA ( Impregnating):
In the IMPACTA the fabric is impregnated with chemicals for
subsequent trouble free steaming process. The clever design ensures that
a high liquor exchange is achieved. The chemicals are distributed
immediately at the right place in the fabric.
The cloth web is guided through two narrow casings and causes
the impregnation liquor to circulate in the fabric running direction. The
liquor enters the unit in the middle of the cloth web and is drawn off at
the side. This creates a horizontal circulation. In the narrow casings the
fabric run causes an additional current in the fabric running direction.
Hence an additional vertical circulation through both casings results.
CHEMICALS:
Hydrogen peroxide, WBL, Caustic, Stablizer OKR.
REACTA (Steamer):
In the REACTA steamer the chemicals react with the fibres
themselves and the accompanying substances. The combination steamer
with tight strand cloth run and plaiting on a roller bed permits reaction
times of 1 to 60 minutes. An automatic steam conditioning and
regulating. station guarantees constant conditions and an air free
atmosphere.
FORTRACTA( Pre-washing):
OBJECTIVES
To increase luster.
To increase the affinity for dyes.
To increase the tensile strength.
To give dimensional stability
Use of dye after mercerizing is less
Width control
Gauide rollers
J-box scray
Be control valve
Reaction zone.
Stablizing zone.
Brine Pump
Brine control valve
Recovery pumps
Filter 2
Chain Wheel
Selvedge Guider
Shower Pumps 30
Suction Pumps 20
Washers
Dryers
Heat Exchange
Guide rollers:-
BE CONTROL VALVE: -
BRINE PUMP: -
HEAT exchanger:-
Working Of Machine:-
Impregnation/reaction zone:
Stabilization zone
HEAT EXCHANGER: -
DRYERS: -
Important factors:-
Batcher
↓
Screy
↓
Cooling Drum
↓
Padding
↓
I.R (predrying)
↓
Chamber (drying and curing chambers)
↓
Cooling Drum
↓
Screy
↓
Batcher
CONFIGURATION OF MACHINE
• Teflon on rollers use for unsticking of dyes and pad rollers help in
sticking the chemicals.
• In I.R chambers there are some bricks in which air and natural gas
burnt.
• For reactive and vat dyes temperature is low inside the chamber
and for disperse dyes we use high temperature inside the chambers
for drying and curing.
• Thermosol use for pad dry cure, wet on wet and pad dry process.
Working of Machines:
The fabric is unwound and then pass through brushing section here
the fluff is brushed and fabric is collected and stored in scra.fabric
passes over cooling drums to cool down the temperature of fabric
because when we are dyeing PC fabric then after RC fabric is hot
enough.the fabric is then passed through Kuster padders,two types of
pressure used in Kuster padders hydraulic and neumatic.the central
pressure is hydraulic and sides pressure is neumatic.we can adjust the
pressure of the padders .
Then there is given I.R system the temperature of I.R is about 60-
50 c.there are two I.R installed the temperature of first I.R kept 850 c
and second 800c.the function of I.R is to remove 30-35% moisture.the
fabric is then passed through the thermos, 5 chambers are provided,
• 1-2 Drying.
• 3 Drying.
• 4-5 Fixation.
The fabric is then passed through cooling drums and finally fabric is
collected on a batcher.
PAD STEAM DYEING MACHINE (Benninger)
Pad steam is used for dyeing light shades and the fastness
propertiws of the pad steam is better than pad thermosol.on pad steam
fixation of dyes also done.the max temperature of the machine is 100
cand speed 80 m/min.we can done RC,VAT develop,wet on wet and
chemical pad. In pad steam there are three types of flows
1-Counter flow
2-Static flow
3-Over flow
In pad steam there are two I.R for high production. We can
plant one I.R for normal production.In pad steam we use urea and steam
for increasing the moisture but we use steam in the replacement of urea
because is less costly then urea also the urea damage the environment. In
pad steam there is an E control or economical control. E control provide
good results but initially produce some variations.
CONFIGURATION OF MACHINE:
• There is a steamer for curing, the temperature of base and the roof
of the steamer is change to prevent the dropping effect.
• After steamer the fabric enters into the washing range for removing
the unfix dyes.
Termo Chem
Termo Print:
• Head 2
• Mixer
• Filter
• Printer.
Head 1:
Head 1 contain chemical tanks.
Head 2:
Head 2 contains pigments or dyes.
Mixer:
Mixer is used to mix the paste, two stirrers are present each work
at a time. If one is operational other one is washed before running.
Filter:
To filter the past otherwise some contaminant will may combined
with the past and printed on to the fabric.
Printer:
The recipe is printed on a paper than pasted on the past box.
Process flow:
Head 1 → Head 2 → Mixer → Filter
High stirrer:
High stirrer is used when the paste is prepared in bulk and also for
urgent mixing of the paste.
Print Paste:
• Liquor Ammonia.
• Binder.
• Urea.
• Thickner.
• Fixing Agent.
• Softning Agent.
Types of Pastes:
After the aproval of the design by the customer design is sent to the
engraving department.
Engraving department:
Phenyl
Formic Acid
Formic Acid
Methylene
• The number of mashes or a screen varies as 60, 80, 100, 125, 155,
180 per linear inch.
• The diameter of screen is 640, 720, 820, 914, 1018mm
• Max screens length = 3500or 350 cm
Screen exposing:
The exposing machine is called CST ink Jet and it works on almost
the same way as an ink jet printer. The header is loaded with color
pasted and it prints the pattern in the required paste.In DLE engraving
The coated screen is directly exposed with UV light, without masking by
wax, ink or film. No consumables are needed.
Screen Developing:
The screen is developed which means only that parts where patterns are
printed on screen are removed from coating while other remains same.
Finally the screen is heated and dried and sent to the rotary
machine
On the sample table the print paste is prepared a/c to the sample
colors. The recipie of the print paste includes,
Water, Urea, L.Ammonia, thickner etc.
The machine works on magnetic systems.GTE and TE are the
adisives to stick the fabric maximum 27 meter fabric can be print on the
machine.the sample is taked about 2-7 meter.speed of the convayor belt
is about 5-18 m/min.the colour is dosed iinto the screen and different
dia rods are used for different shades for darker we use a heavy rod
instead od a lighter one. Washing area at the end of the blanket for the
washing of the convayor belt.
Process flow:
Entry → Printing → Dryer→ Exit
Components of machine:
• Entry
• Suction
• Flat rollers
• Trolley
• Printing zone
• Sensor
• Conveyor belt washing
• Dryer
The fabric is passes through guide screen rollers to the suction area
here the sucker sucks the fabric fluff and dust particles.flats are provided
when we use knit fabric.the fabric enter into the trolley where PVA is
aapplied to stick he fabric with the blanket belt.the machine is provided
with an I.R system and cambered plate to give temperature to the
thermoplastic glue.then the fabric enters into the printing zone.the fabric
is sandwiched b/w the rollers and the blanket,magnetic system of
printing is used.
Colour is dozed into the sqeegee through pumps automatically.the
first screen roller is to press the fabric and the secong gathers the
remaining fluff.the printing starts from the third screen.each screen
prints a single colour.the number of the screen depends on the type of
design.the sensor is used to control the speed of the blanket.the fabric
than entered into compact HC dryer 160-180 c.the dryer has 5
burners.the dryer has three passages air is blown into the chambers 2
time.finally the fabric is collected by a crank gear mechanism to a
trolley.
Note: We mostly use Pigments because pigments are not too much
costly and the process is also easy.
PROCESS
Entry
↓
Curing
↓
Exit
The fabric entered into the curing chambers for about 80 min in
loop form for the fixation. Suction system is provided the rollers present
in the machine for loop formation moves with the help of chains.
Components of Machine:
• Paders
• Weft straightner (Mahlo)
• Burners 10
• Heat recovery
• Attraction rollers
• Circulating fans 10,8
• Exhaust fans 2
• Winder 2
• Clips
• Pins
• I.R
• Cooling drums 2
The fabric is collected from the batcher to the scray and then it is passed
through the padders where the finishes are applied and some times shade
variation is corrected.The fabric is entered into the mahlo (weft
straigtner) the function of the mahlo is to set the bow and also weave of
the fabric is griped by the clips and pins are also provided but the pins
has a disadvantage that they pins make holes at the selvedge but the
stretchning of the pins are greater than the clips.these clips and pins are
joined to endless chain.there are 8 to 10 chambers provided on the
machine each chamber contains a burner and filters are provided to
separate dust from air.the circulating fans blow air from the base to the
upper side and exhaust fans sucks all the hot air within the
chambers.Attraction rollers ar provided to stretch the warp yarn.
After stentering we can increase the width of the fabric up to 1.5-2
inch.The speed of the machine is about 7-150 m/min.3 meters fabric can
run in each chamber.temperature is adjusted that a/c to the fabric as for,
• PC 210 c
• Cotton 110-130 c
Stenter 10 F:
The basic difference of the knit stenter machine is that it is used for
knit fabric weft straightning,heat setting,dyeing, light shades and also
for print and knit fiishing chemicals applicaions.Pins are also
provided with the clips.flat rollers are present and a brush to hold the
pin,the L-guide is also used for knit fabric and a selvedge cutter with
suction privided.
• Winder
• Metal detector
• Seam detectol
• Rollers (cotton,reclon and steel)
• Anti static rod
• Oscillating roll
• Batcher sensor
• cooling drum
Seam detector:
Small winder:
When we have to calender short width fabric and we can also run
short width fabric with long width fabric.
Oscillating roll:
Cotton roll:
For soft finish the fabric is passed through cotton bowl. This roller
is made up of cotton.
Steel roll:
When fabric passess through Reclon roll and steel roll giving
smooth and luster effect is generated.when it runs with steel roll and
reclon roll and cotton roll dull effect is generated.when it runs b/w steel
and reclon gloss effect is generated.
Cooling drum:
Cool down the fabric water circulates inside the cooling drum.
SANFORISING MACHINE:
Monforts Sanforizer:
Taking samples from each and every roll and faults are detected
and the grading is done then shade is forwarded to the shading
department.the rolls are seperated in shade wise.the defected fabric is
seperated.the grading is done a/c to the customer requirement.
• Rolling machine.
• Flat folding machine.
The rolling machine is used for making the rolls of A and B grade
fabrics and other graded fabrics are separated and folded on flat folding
machine.
LOOS Boiler:
In Lucky textile 4 processing loos boiler is equiped which is
generating 16 ton/hour steam.Two boilers are working while other two
are in standby.
LOOS boilers a hot water boilers and steam LOOS includes three-
pass steam boilers in a performance range from 175 to 55,000 kg/h, hot
water boilers for capacities up to 38 and heating boilers up to 19.2 MW.
The various models of boiler are manufactured in all pressure stages and
for all fuels and can be fitted if required with heat recovery systems to
improve efficiency for all technical heating processes.Boiler house
components based on modular technology for easy planning, quick
assembly and fully automated, safe operation complete the range of the
LOOS boiler manufacturer. The boiler manufacturer is individual plant
parts and components for the steam plants are correctly dimensioned,
matched to each other and assembled into a ready-to-connect
module.Servicing support around the clock, every day of the year: As a
boiler manufacturer, LOOS offers a competent, fast, efficient customer
service. Trained customer service engineers on 24-hour standby
combined with a central spare parts service guarantee optimum
availability of your steam plant.
CAT G3516 ENGINE - POWER GENERATOR: