UNITEDWORLD INSTITUTE OF DESIGN

SUMMMER INTERNSHIP REPORT

2019

SHIVANGI BHARGAVA
KAJAL SHARMA
GARGI GARG
BINDI MAGIYA
 ACKNOWLEDGEMENT
The internship opportunity we had with BHARAT VIJAY MILLS was a great chance
for learning .We would thus like to express our thankfulness to our mentor
Mr.Nikhil Padhya and Mr. Ambrish Patel who in spite of being busy with their
duties took time out to hear , guide and keep us in correct path and complete our
project in their esteemed organization.

We are using this opportunity to express our deepest gratitude and special thanks
to HRD ofBHARAT VIJAY MILLSMr. Nishith Ozafor taking part in useful decision &
giving necessary advices and guidance and arranged all facilities. We would also
like to thank the general managers and other staffs and workers of all the
departments for their helping hand in explaining us the basic processes of
machinery and providing us some information about the departments.

Last but not the least we would like to thank other faculty members for their
constant support in guidance towards completion of this project.

Shivangi Bhargava
Kajal Sharma
Gargi Garg
Bindi Magiya
 CONTENTS

 OBJECTIVES
 COMPANY OVERVIEW
 COMPANY PROFILE
 THE PLANT
 FIBER TO FABRIC
 YARN DYEING
 WEAVEING
 DESIGN DEPARTMENT
 DYEING
 PRINTING
 BLEACHING /PROCESSING /FINISHING
 GREY INSPECTION
 FINISH FOLDING
 SQC LAB /TESTING
 CONCLUSION
 BIBLIOGRAPHY
 COMPANY OVERVIEW
Date of Establishment 1931

Revenue-₹51,079 million(US$740 million)

Market Cap.-

Corporate Address –Textile Division of Sintex Industries Limited, Near Seven

Garnala, Dist. , Kalol, Gujarat, 382721, India

Source- http://www.sintex.in/

Management Details

Chairperson-Mr.Dinesh Patel,

HR-Mr. Nishith Oza

MD-Mr. Amit Patel

Directors-Sh.Rahul A. Patel

Business Operation- Textile

Company Secretary-

Buyers-Supplying to Global and Domestic markets; Yarn Exports at 65 % of sales.

• Exporting to over 20 countries globally.
• Domestic brands like Arrow, Van Heusen, Marks& Spencer.
• Global fashion labels like Armani, Hugo Boss, Diesel, Burberry, and Tommy
Hilfiger Markets.
 OBJECTIVE

The objective of our textile internship at BHARAT VIIJAY MILL was to understand
the concept ofgrey fabric production, dyeing, printing and finishing of fabric,
textile testing and their quality aspects both technical as well as for commercial
purposes .Our first step was to learn about the profile of the company and their
basic dealings. We further dealt with the way the company handles the raw
material and sends it through to subsequent stages of manufacturing. We were to
learn about the various stages in the entire process of textile manufacturing, the
importance ofeach of these stages, the machinery features, machine and material
process parameters available in detail in the areas as mentioned below.

We summarize some of the major concepts that we were to observe and

understand
during our internship:

 Weaving Section
 Printing section
 Dyeing Section
 Production section
 COMPANY PROFILE

Bharat Vijay Mills – the textile division of SINTEX Industries Ltd. It was established
in 1931. Their chairman Mr.Dinesh Patel, reflects on changes with long term
implications that will enhance shareholder returns. It is modernized and
expanded its textile unit and set up a structured yarn dyed fabric business.One of
the most respected business groups today, Sintex has established itself as a force
to reckon with. There are far more than seven decades in textiles as a leading
manufacturer of fashion fabrics consisting of varied products mix in cotton
blends. Their plant is at Kalol about 30km from Ahmedabad city about 500km in
north of Mumbai, India.

Their product range includes yarn dyed shirting, jacquard & Dobby Structures,
corduroys, bottom weights, solid dyed, Poplins & Dobby Shirting with varieties of
weaves, varieties of jacquard, dobby & leno structured furnishing fabrics, organic
cotton certified by union control, linen, cotton with linen, silk, lycra, nylon, tinsel
and viscose and surface coating with pigment colors. To be strict on the quality
part, they practice ongoing quality checks at every level starting from input of raw
materials to the final product. After the final product is ready, a 100 % inspection
is conducted including shade sorting and grading etc. And only after successful
inspection, the final product is shipped to the client.

Totally, 2000 employees including the most professional candidates and

managers, together make Bharat Vijay Mills a preferred partner to their clients for
longer business relationships. A combination of their state of the art plant,
modern technology, reliable QA systems, qualified managers, and smart
workforce make it together to offer world class quality of products and services to
their clients and customers. They are totally a customer driven organization. Their
export markets are worldwide as they are regular suppliers to Europe, USA,
Middle East, India and neighboring Countries.
 THE PLANT

The idea of setting up a Yarn Division was inspired by the demand, market-growth
and fast-changing dynamics in the domestic and global textile industries. Sintex
Yarns has set up a Greenfield Textile Project which is strategically located along
the richest cotton belts of India and is in close proximity to the prominent
seaports of Gujarat. The project envisaged a capacity of one million spindles. The
production of value-added yarns is been incorporated as part of the project.

Sintex Yarns is working towards producing ‘no-touch’ yarns by adopting state-of-

the-art technology that will ensure high efficiency in the production process, in
material handling, in automatic packing and in transportation. This huge
investment in technology will result in an output that will transcend the existing
standards of yarn production. At full capacity, the plant will produce close to a
massive 500 tons of yarn per day.

MARKET

• Supplying to Global and Domestic markets; Yarn Exports at 65 % of sales.

• Exporting to over 20 countries globally.
• Domestic brands like Arrow, Van Heusen, Marks& Spencer.
• Global fashion labels like Armani, Hugo Boss, Diesel, Burberry, and Tommy
Hilfiger Markets.
HIERARCHY IN ORGANIZATION

MANAGING DIRECTOR

PRESIDENT

SENIOR GENERAL MANAGER

GENERAL MANAGER

DEPUTY GENERAL MANAGER

SENIOR MANAGER

MANAGER

DEPUTY MANAGERS

SENIOR EXECUTIVE

EXECUTIVE
PROCESS FLOW CHART
FIBER TO FABRIC

SPINNING

YARN DYEING

WEAVING

PRE TREATMENT

DYEING

PRINTING

TESTING

FINISHING

FINISH FOLDING
YARN DYEING
DEPARTMENT

Mr. MahendraPrajapati

Mr. Rajesh Yadav

YARN DYEING:
• Yarn dyeing is the dyeing of the yarns before they have been woven or
knitted into fabrics. Yarn dyeing is used to create interesting checks, stripes
and plaids with different-colored yarns in the weaving process. In yarn
dyeing, dyestuff penetrates the fibers in the core of the yarn.

Yarn dyeing machine

• In bharatvijay mill, there are total: 37 dyeing machine.

~Minimum 3kg maximum 1 ton

~Single slot= 1019

• It is done in single bath in continuous process.

• It is 12 hours process

• flow=> 1 min=>30 lit/1 kg water throughout.

Reactive dye:
1. Pretreatment

2. Peroxide bleaching

3. Acid treatment

Vat dye:
1) Pretreatment

2) Dyeing

3) Oxidizing

4) After treatment

5) Softening
The common dyeing process of cotton yarn with reactive dyes at package form is
given below:

Firstly the raw yarn is winded on spring tube to achieve package suitable for dye
penetration. Then, these softened packages are loaded on a dyeing carriers
spindle one on other. Then, the packages are pressed up to a desired height to
achieve suitable density of pkg. then, the carrier is loaded on dyeing machine and
yarn is dyed. After dyeing, the packages are unloaded from the carrier in to a
trolley.

Then, all the packages are hydro extracted using a HYDRO EXTRACTOR to remove
maximum amount of water. Then, all the packages are dried using
PRESSUREDRYER OR RF DRYER(RADIOFREQUENCY DRYER) to achieve the final
dyed package. At last the dyed yarn packages are packed and delivered. HYDRO

EXTRACTOR: After dyeing, the packages are sent to hydro extractor which extracts
maximum amount of water from the package. Then the packages are sent to
pressure or RF dryer for further drying.
RF DRYER(RADIO FREQUENCY DRYER)
More than 800 "RF" (Radio Frequency) model dryers, installed throughout the
world since 1981,are presently in oper-ation for the drying, to a conditioned
weight, o f yarns in packages and cakes, worsted fibres (tops) in bobbin and bump
form. Most combinations of natural, artificial and synthetic fibres, filament fibres
or worsted and spun, pure or blended, in every count and form can be dried
perfectly, down to the desired residual moisture level, with outstanding efficiency
and quality results. In the "RFA" (Radio Frequency Assisted) series dryers, the RF
treatment, precisely controlled in the different phases of the drying process
thanks to a special design of the RF application electrodes, is combined with a
conventional warm air circulation system.

PRESSURE DRYER

Dyed yarns are fed into this machine for drying under high pressure and
temperature. The todays pressure dryer is equipped with an intelligent control
unit, high performance heat exchanger, separator and a special blower.
 WEAVING
DEPARTMENT

Mr. Ambrish Patel

 • WINDING
The process of transferring yarn from ring bobbins, hanks, cones etc onto a
suitable package is called Winding.

Purpose of Winding

1. To transfer yarn from one package to another package, this can be

conveniently used for the weaving purposes.

2. To remove yarn faults like hairiness, neps, slubs, and foreign matters.

3. To produce long length of yarn by serially joining one yarn package with
another.

4. To make bigger package.

5. To make soft package for package dyeing.

6. To permit easy unwinding during warping.

To avoid of excess looseness and tightnes

MACHINE USED CAPACITY SPEED

Auto cone 60 spindles 1000M/M

 • WARPING
After winding, Warping is the first step of fabric manufacturing process.
The primary objective of the warping process is to provide a continuous length
of yarn from individual wound yarn packages, in sheet form to a beam for the
succeeding process. There are several types of warping techniques, including:
ball, direct, draw indirect also called sectional and sample warping.

In the process of weaving, for warp yarns, we need to produce pre bean
which is also called warpers beam. To produce warpers beam we need warping
machine with a creel capacity about 400-700 cone capacity. To produce a
weavers beam we need 6 to 16warpers beam. Number of cones to be use in the
creel depends on production planning.

Warping at Bharat Vijay Mills:

Two types of Warping machines were used in the mill

 Direct Warping

 Sectional Warping

MACHINE USED CAPACITY SPEED

Prasantgamatex 672 ends 800- 1000 m/m

Hacoba 672+ 672 ends 150- 200 m/m

DIRECT WARPING MACHINE
Brand PrashantGamatex

Capacity 800 mtr/min

Power Consumption 30 kw

Machine Type Automatic

DIRECT WARPING
• In direct warping the yarn is wound parallel on the warping beam. All the
yarns are wound at once and simple flanged beam is used. It is a very high
speed process and is used for making fabric of single color.

Flow Chart of High Speed Warping

Creel
↓
Beam for sizing
↓
Weaver’s Beam

Features of Direct Warping

• It is used to make common fabrics in large quantities

• It is used to produce weavers beam from single yarn

• The production is high

• Large amount of yarn is required to produce a weavers beam

• Sizing is doneSimple flanged beam is used and drums are not required
SECTIONAL WARPING MACHINE
Brand Hacoba

Capacity 672 mtr/min

Power Consumption

Machine Type Sectional

SECTIONAL WARPING MACHINE

SECTIONAL WARPING
In sectional warping equal length of yarn is first wound in small sections or
sheets on a drum. Then from the drum it is transferred to the beam. By this
process we directly get the weavers beam. This is a two stage method and is used
for making fancy fabrics.

Sectional warping is used for short runs especially for fancy pattern fabrics.In
this case sections of the warp which may contain up to 1000 ends are first wound
onto a drum tapered with a given cone angle.

Flow Chart of Sectional Warping:

Creel
↓
Drum
↓
Beam (Weaver’s Beam)

Features of Sectional Warping

• This is suitable for making checked, stripped or other fancy fabric.

• We directly obtain weaver’s beam from this process

• As sizing is not done, so multi-ply yarns or yarns which do not require sizing
are used

• Small amount of yarn is required to produce the weaver’s beam

• Sectional warping is used to produce a warp beam with a greater member if

ends

• The production is less in sectional warping

• The yarn tension is less uniform

SIZING
Sizing is the most important part of Weaving technology. after winding and
warping ,sizing of yarn is done during beam preparation . Sizing is done by
applying various types of size materials on the yarn .during application of size
materials steam is needed

Sizing of warp yarn

A good sizing depends on various factors

• Sizing machine speed.

• Size add-on levels.

• Concentration of the size mixture.

• Volume of the size box.

• Threading arrangements.

• Condition of squeeze rolls.

• Squeezing pressure.

• Hardness of squeeze rolls.

In Bharat Vijay Mills , there were total four warp sizing of two different brand:
  Sucker Muller sizing machine – 1
 Jupiter sizing machine – 3

All the warp sheets from different beams are converted into 1 single sheet. Size is
made in a drum and is transported through pipes and applied on the beam. It is
then dried by hot rollers which are filled with steam

DRAWING –INThe term drawing-in and warp tying refers to the operations
involved in preparing the weavers beam for the purpose of weaving fabrics on the
loom. The drawing-in process primarily consists of drawing ends from the
weavers beam through heald eyes of different harnesses and then through the
dents of a reed in the order that is determined by the design of the fabric.

Conventionally drawing-in is carried out manually by two persons-one, the

reacher for selecting and presenting the ends from the beam, and the other, the
drawer for pulling ends through the drop-pins, heald eyes and reed dents.

Only two machines were used in Bharat Vijay Mills for drawing-in process. There
were two models of STAUBIL:

 DELTA- 100: The DELTA 100 is specially designed for filament weavers and
draws in the warp threads into healds and reed only.
 DELTA-110: The DELTA 110 drawing-in installations are designed for
weaving mills with medium drawing-in requirements. Drawing in at speeds
of up to 140 per minute takes place directly from the warp beam with 1
warp sheet, or optionally with 2 warp sheets into healds, drop wires and
reed. An optional module is available for drawing in coarse yarns

MACHINE USED DELTA- 100 DELTA-110

SPEED (ends/min) 100/140* 100/140*

WEAVING SECTION
PROCESS FLOW IN THE WEAVING UNIT

Weaving is the process of making cloth, rugs, blankets, and other products by
crossing two sets of threads over and under each other. Weavers use threads
spun from natural fibers like cotton, silk, and wool and synthetic fibers such as
nylon and Or lon. But thin, narrow strips of almost any flexible material can be
woven. People learned to weave thousands of years ago using natural grasses,
leafstalks, palm leaves, and thin strips of wood .

Today weaving ranks as a major industry in many countries. Weaving is often

completed on high speed looms. But weaving is not limited to cloth and textile
products . Weaving plays an important part in the manufacture of screens, metal
fences, and rubber tire cord. Craft workers also use varied fibers to weave baskets
and hats. Woven fabrics are classified as to weave or structure according to the
manner in which warp and weft cross each other.

The three fundamental weaves, of which others are variations:

• Plain

• Twill

• Satin
PLAIN WEAVE: Each weft yarn goes alternately over and under one warp yarn.
Each warp yarn goes alternately over and under each weft yarn. Some examples
of plain weave fabrics are crepe, taffeta, organdy and muslin .

TWILL WEAVE:Creates a diagonal, chevron, hounds tooth, corkscrew, or other

design. The design is enhanced with colored yarn is strong and may develop a
shine. Twill weave is characterized by diagonal ridges formed by the yarns, which
are exposed on the surface. Twill weaves are more closely woven, heavier and
stronger than weaves of comparable fiber and yarn size.

SATIN WEAVE:Floats one warp yarn over four or more weft yarns, then tied
down with one thread, resulting in a smooth face Common Fabrics: Satin, satin-
weave fabrics out of fabrics such as cotton &Charme use
 o LOOMS: A loom is a mechanism or tool used for weaving yarn and thread
into textiles. Looms vary in a wide assortment of sizes. They come in huge
free standing hand looms, tiny hand-held frames, to vast automatic
mechanical tools. A loom can as well pertain to an electric line construction
like that of a wiring loom. The main task of looms is to clutch the twist
threads under pressure to enable the progress of interweaving of the woof
strands. The looms system and exact form can differ to some extent;
however it still performs the basic application.

The weaving process consists of five basic operations

shedding,

o picking,
o beating-up,
o left off and take up

Shedding: Separating the warp yarns into two layers by lifting and lowering the
shafts, to form a tunnel known as the ‘shed’.,

Shredding
Picking or Filling: Passing the weft yarn (pick) across the warp threads through the
shed.

Picking

Beating-up: Pushing the newly inserted weft yarn back into the fell using the
reed.

Beating-up

Take up: The woven fabric is wound on the cloth beam during the above three
processes.
TYPES OF LOOMS: There are two types of looms depending upon the weft
insertion:

1. SHUTTLE

2. SHUTTLE-LESS

Bharat Vijay Mills Rapier and Air jet were used

MACHINE NO. OF MAXIMUM

M/C COLOR WEFT FEATURES

YARN

Gammax 50 8 colors Speed -400-500 mpm

20 shaft dobby running.

Toyota 18 6 colors Speed-800 mpm

(air jet ) 20 shaft dobby loom

Rapier 24 8 color Speed - 300-350 mpm .

20 shaft dobby running

Toyota Air jet Loom
AIR-JET LOOM
The air jet weaving machines are the weaving machines with the highest weft
insertion performance and are considered as the most productive in the
manufacturing of light to medium weight fabrics, preferably made of cotton and
certain man-made fibres (sheets , shirting fabrics, linings, taffetas and satins in
staple yarns of man-made fibres); it has anyway to be pointed out that technically
positive results are obtained at present also with heavy weight fabrics (denims)
and that some manufacturers produce also machine models for terry production.

AIR-JET WEAVING
• Air jet weaving is a type of weaving in which the weft yarn is inserted
into the warp shed with compressed air.

• The air-jet weaving machine combines high performance with low

manufacturing requirements.

• It has an extremely high weft insertion rate.

• Due to its exceptional performance, air-jet machines are used primarily for
the economical production of standard fabrics, covering a wide range of
styles.

• Meanwhile, more and more special fabrics are also covered: heavy cotton
fabrics such as denim, terry fabrics, glass fabrics, tire cord,etc.
Rapier loom

RAPIER LOOM
The rapier weaving machines are the most flexible machines on the market. Their
application range covers a wide variety of fabric styles. Their present weaving
speed of about 600-700 strokes/min is the result of the use of a state-of-the-art
construction technique, characterized by the use of gear sets without plays and
by minimum vibrations of the reed, the slay and the heald frames .
 DESIGN
DEPARTMENT

Mr. Ambrish Patel

FABRIC ANALYSIS

Fabric Analysis Fabric analysis is the study of the construction, properties,

features, orientation and dip of particles within a fabric.

In this process, I have to learn about the thread density, yarn count, GSM & design (weave plan,
drafting plan, lifting plan & repeat size) of woven fabric. This is help to analysis of woven fabric.

Analysis:

1. Face Side & Back Side: The face side & back side are almost same. The face
side is slightly lighter & smoother than the back side. So it is very difficult to
indicate face side & back side.

2.Warp and weft:Warp and weft are the two basic components used in
weaving to turn thread or yarn into fabric. The lengthwise or
longitudinal warp yarns are held stationary in tension on a frame or loom while
the transverse weft (sometimes woof) is drawn through and inserted over-and-
under the warp.

3. Thread Density:
EPI: EPI means ends per inch. Number of yarn in warp direction is measured
by EPI and

PPI:PPI means picks per inch. Number of Weft yarn in fabric is measured by PPI
4. Reed Count:
It is calculated in stock port system.No. of dents in 2 inches is called Reed Count.
Reed Count = EPI/(1 + Weft crimp %age)
Analysis of Cloth Sample: On analyzing a sample of cloth made from cotton;
rayon, silk or flax with view of its reproduction produced thus: -

1. Record whether a fabric is in the grey or the finished state.

2. Determine which threads constitute warp and which weft.

3. If in grey, test for the presence of size material by staining with iodine, when
the starch in the size warp turns deep blue in colour, the weft being unaffected.

4. Examine for direction of spinning twist in the yarns, and also if either set of
threads is two-fold yarn. If crepe yarns have been used it may be necessary to test
for amount of twist present.
EXAMPLES:

Sample 1 plain weave

EPI=72

PPI=68
Sample 2 Twill Weave

EPI= 92

PPI= 88
Sample 3 Dobby Weave

EPI- 124 (GREY FABRIC )

PPI- 76

EPI- 120 (FINISH FABRIC )

PPI-76
Total warp thread= 44 in 1 repeat

Dobby thread (44 – 38 )= 8

Total shaft count = 4 Plain (TOTAL 8 SHAFT )

4 Dobby =

Total weft thread = 24 in 1 repeat

Dobby thread = (24-16) = 8

Finish EPI Calculation: on loom EPI * Reed space

Fabric width

Grey EPI Calculation: Finish EPI * Reed space

Fabric width
 DYEING,BLEACHING AND
PROCESSING DEPARTMENT

Mr. ManojSukhedia

Mr. HemalPanchal
PRE-TREATMENT

Natural fibers and synthetic fibers contain primary impurities that are contained
naturally, and secondary impurities that are added during spinning, knitting and
weaving processes.Textile pre-treatment is the series of cleaning operations. All
impurities which causes adverse effect during dyeing and printing is removed in
pre-treatment process.

Major steps involve in textile pre-treatment are:

Singeing Desizing Scouring

Mercerization Bleaching
Singeing:-
Also called gassing, singeing is a process applied to both yarns and fabrics to
produce an even surface by burning off projecting fibres, yarn ends, and fuzz. This
is accomplished by passing the fibre or yarn over a gas flame or heated copper
plates at a speed sufficient to burn away the protruding material without
scorching or burning the yarn or fabric.

Desizing:-
Desizing is the process of removing the size material from warp yarns after
a textile fabric is woven.
Scouring :-
Scouring’ applies to the removal of impurities such as oils, was, gums, soluble impurities and
sold dirt commonly found in textile material and produce a hydrophilic and clean cloth.

Scouring process depends on:

 The type of cotton
 The color of cotton
 The cleanliness of cotton
 The twist and count of the yarn
 The construction of the fabric.

Mercerization :-
Mercerization, in textiles, a chemical treatment applied to cotton fibres or fabrics
to permanently impart a greater affinity for dyes and various chemical finishes.
Mercerizing also gives cotton cloth increased tensile strength, greater absorptive
properties, and, usually, a high degree of lustre, depending on the method used.

Bleaching :-
Textile bleaching is one of the stages in the manufacture of textiles. All raw textile
materials, when they are in natural form, are known as 'greige' material. This
greige material will have its natural color, odor and impurities that are not
suitable for clothing materials. Not only the natural impurities will remain on the
greige material but also the add-ons that were made during its cultivation, growth
and manufacture in the form of pesticides, fungicides, worm
killers, sizes, lubricants, etc.
 DYEING
Dyeing is the application of dyes or pigments on textile materials such as fibres, yarns,
and fabrics with the objective of achieving color with desired fastness.

At Bharat Vijay mill two methods are used in dyeing:-

Types of dyeingThe following are the basic types of fabric dyeing machines:

 Batch dyeing machine

 Semi-continuous dyeing machine
 Continuous dyeing machine

1)Batch dyeing:Batch Dyeing Process is the most popular and common

method used for dyeing oftextile materials. Batch dyeing is also sometimes
referred to as Exhaust dyeing. This isbecause in this process, the dye gets slowly
transferred from a comparatively largevolume dyebath to the substrate or
material that is to be dyed. The time taken is alsolonger. The dye is meant to
exhaust from dyebath to the substrate. In batch processes,

The following are the types of batch dyeing processes:

1)Beck dyeing

2) Jet dyeing(soft flow dyeingmachine)

3) Jigger dyeing

MachineImage showing Popular machinesutilizing the batch dyeing

methodillustrated above

Beck Dyeing
Beck dyeing is a versatile, continuous process used to dye long yards of fabric.
About 1,980 pounds (900 kg) of fabric can be dyed on beck equipment at a time.The
fabric is passed in rope form through the dyebath. The rope moves over a rail onto a
reel which immerses it into the dye and then draws the fabric up andforwards to the
front of the machine. This process is repeated as long as necessary to dye the material
uniformly to the desired color intensity.
At Bharat Vijay Mills, the following machines were used for batch dyeing

Jig Dyeing
Fabric is dyed in its open or full width and hence there is no problem of creasing
during dyeing.

The machine consists of a small tub and two drawing rollers located above the
dye bath.

First the fabric is wound around one of the rollers. During dyeing thefabric is
passed though the dye bath and rewound onto the second roller.

When the complete fabric is passed though the bath, the direction of fabric
movement is reversed and this is repeated until the fabric is dyed completely.

During dyeing, tension is imparted along the length of the fabric.

Liquor ratio is low

Suitable for light weight and delicate fabrics.

At BHARAT VIJAY MILLS:

 No. of machines – 5(200 kg – 1 machine, 800kg – 4 machine)

Maximum speed – 100m/min

Jet Dyeing
In this machine the fabric being dyed iscirculated through the dyeing machine on
ajet flow of dye bath. The high speed dyeliquor jet carries the fabric rope along,
fromone end of dye vessel to the other end.Less water,energy,time and chemicals
arerequired in this machine as compared toother dyeing machine.It is used for
dyeing of delicate woven orknits, textured and light weight fabrics .The liquor
ratio is very low
At BHARAT VIJAY MILLS:

Model – fong’s

 No. of machines – 1

Pad Dyeing
Pad dyeing, like jig dyeing, dyes the fabric at full width. The fabric is passed
through a trough containing dye and then between two heavy rollers which force
the dye into the cloth and squeeze out the excess.

To increase washing efficiency based on the proven principles like reduction of

carry-over and counter-current washing.At Bharat Vijay Mills, the following
continuous dyeing machines were used …

(i) Pad dry dyeing machineNo. of machines at BVM – 1Machine model –

kusters calico machineryDYE BATH Dye =10 g/l Ant migrant =10 g/l
Reduction inhibitor =10 g/lCHEMICAL RECIPE Caustic soda (48 Be) = 4-8
g/l Soda ash = 10 g/l Salt = 250 g/l PROCEDURE

 Prepare dye bath and auxiliary bath separately.

 Pad the fabric in dye bath at 60 - 70 % pick up and then dry the fabric.

Then again pad the dyed piece of fabric in chemical bath at 80 % pick up

and put it in steam for 1.5 min.

(ii) Pad steam dyeing machine No. of machines at BVM – 1 Machine model –
kusters calico machineryRECIPE Dye = 10 g/l Glaubar salt =10 g /l Soda ash = 15 g/l
GREY INSPECTION AND
FINISH FOLDING
DEPARTMENT

Mr.Anand joshi
GREY FOLDING:
• It is the process of identifying weaving faults in the fabric.

• Fabric comes to grey folding after weaving.

• They are checked mended and sorted here.

• The fabric comes with a lot card and is maintained by a register containing
lot no., sort no., date bandha kg, meters, finish width, contract no, grey
width, buyer, pallet no, number of pieces, samples etc.

Method:
1. As the fabric reaches its “set cut length” in the loom the cloth is cut and the
cloth roll is doffed off from the loom.

2. The cloth roll might also be cut and doffed off before the preset length as and
when it is needed.

3. According to set rule the “cloth doffer” cuts and doffs off cloth roll and record
the doff length in the loom quality/doffing card and also sticks a doffing stickers
over the cloth roll for identification.

4. The roll is then unrolled over the inspection table where it is visually checked
yard to yard (100%) against light and repaired or mended for any smaller extent
of faults like protruding or projecting yarn, yarn naps, slubs, crack, floats, oil stains
which can’t be repaired, the fault area is identified by putting yarn tails or laces in
the selvedge area.

5. The mended fabric is then inspected over the grey fabric inspection machine
visually against light in a pre-set speed (m/min).
Faults in spinning:
• Slub

• Knot

• Stain

• Impurities

Faults in weaving:
• Broken ends

• Broken warp

• Broken picks

• Broken weft

• Loose warp

• Double ends

Faults in production:
• Csv

• Ksv

• Hole

• Stain

• Shale

Finish folding:
• The main function of folding department is fabric inspection and then
dispatching. This is the department where the quality of the finished
product is checked, i.e. whether it satisfies the customer requirement or
not.
Flow chart:
Inspection:
In inspection the operator check the processing fault like (weaving faults, dyeing
faults, printing faults and finishing faults)

Four point system:

In this inspecting system the checkers give points to the fault, according to the
fault length.

1.0-3 inches damage is considered as 1 point

2.3-6 inches damage is considered as 2 point

3.6-9 inches damage is considered as 3 point

4.9-12 inches damage is considered as 4 point

Method of inspection:

1. Lumb

2. Folding

Grouping:
• In grouping mainly the LSV (lengthwise shade variation) is checked for the
fabric.

Packing:
• Packing is done to protect the fabric from moisture and damage and it also
help in transportation.

Dispatch:
• In dispatch section the package is loaded and sent to the customers.
SQC LAB

Mr. Dipak Joshi

TESTING QUALITY CONTROL AND INSPECTION
Quality is ultimately a question of customer satisfaction. Good Quality increases
the value of a product or service, establishes brand name, and builds up good
reputation for the fabric manufacturer, which in turn results into consumer
satisfaction, high sales and foreign exchange for the country. The perceived
quality of a fabric is the result of a number of aspects, which together help
achieve the desired level of satisfaction for the customer. Therefore quality
control in terms of garment, pre-sales service, posts –sales service, delivery,
pricing, etc are essentials for any fabric manufacturer.

QUALITY CONTROL AT BHARAT VIJAY MILLS

At Bharat Vijay Mills, quality control commences from raw material procurement.
They use eco-friendly dyes and chemicals that are sourced from reputed
companies. Their fully computerized quality-control laboratory checks everything
from fibre to fabric to chemicals, dyes and auxiliaries.

AATCC (American Association of textile chemist and colorist) and ASTM(American

society for testing and materials)standards are followed at Bharat Vijay mills for
quality control and testing of fabrics.4 – Point inspection system was followed for
inspection of fabrics. This numeric grading system is endorsed by the American
Society for Testing and Materials (ASTM), The American Apparel Manufacturers
Association (AAMA) and the European Clothing Manufacturing Association
(ECMA).
 LENGTHS OF DEFECTS (in Inches) POINTS
< 3" 1
3" to 6" 2
6" to 9" 3
> 9" 4

DIAMETER OF HOLES (in Inches) POINTS

<1 2
>=1 4

Points calculation in 4 Point System

TOTAL POINTS × 10,000

DEFECTS POINT PER SQ. METER = (Fabric width in cms × Total length inspected
in m)

• Maximum no. of points in any one linear yard is 4 regardless of no. of defects.
• Grading irrespective of end use
• Not sensitive to width variations of the fabric
• Does not consider defects in inconspicuous areas (patterns/markers)
• No standard viewing conditions
 TYPES OF TESTING AT BHARAT VIJAY MILLS

FIBER TESTING

Raw material represents about 50 to 70% of the production cost of a short-staple

yarn. This fact is sufficient to indicate the significance of the raw material for the
yarn producer.
It is not possible to use a problem-free raw material always , because cotton is a
natural fibre and there are many properties which will affect the performance.
The basic charateristics of cotton fibre :

 Strength
 Rigidity
 Fineness
 Maturity
 Fibre
 Length

YARN TESTING

Yarn occupies the intermediate position in the manufacture of fabric from raw
material. Yarn results are therefore essential, both for estimating the quality of
raw material and for controlling the quality of fabric produced.

The important characteristics of yarn being tested are:

 Yarn hairiness
 Yarn strength
 Yarn evenness
 Linear density
 Yarn elongation
 Yarn twist
FABRIC TESTING

The textile industry is becoming an increasingly competitive environment.

Differentiating products is therefore important and this can be facilitated through
improving quality .Testing can be used to improve product quality and achieve
compliance to international, regional or retailer specific standards.

Various testing instruments in Bharat Vijay Mills

 Cotton testing machine – Uster

 Cotton trash analyzer HVI 900
 Trash separator
 Count strength product(CSP)
 Fabric Strength tester
 Single yarn strength tester
 GSM tester
 Uniformity tester-Uster tester-4- SX 10) Wrap reel
 Fault Tester – Usterclassimat – 3
 Yarn twist tester
 Tearing tester

SINGLE YARN STRENGTH TESTER

TECHNICAL SPECIFICATIONS

Tensile strength and elongation are the two prime characteristics of most of the
raw materials.
 Capacity Of The Tester : 5 Kg, Acc. 1 g, 30 Kg, Acc. 5 g
 Speed Of Traverse : 300 mm/min.
 Motor : ¼ H.P. 230 volts AC.
 Gripping Distance : Minimum – 8” and Maximum -20”
 Elongation : 80 – 100%
 Over Load Safety : Provided
 FABRIC STRENGTH TESTER

This instrument is a robust motor driven floor model machine which records
breaking strength and elongation at break point with graph facility.

GSM TESTER

 Sample cutters are designed to cut fabric samples to determine the GSM
 Sample cutter is applicable to Woven, Knitted & Non-Woven Fabrics.
 Sample cutter is used to determine accurately the GSM (Grams per square
meter) of any type of fabrics.
 Ergonomic latest design with modern aesthetics.
 Smooth precision engineered components for excellent performance.
 Stainless steel blade holders for lifelong excellent operations.
  Complete with all accessories along with four special rubberized foam
cutting pad for smooth cutting & long life of the blades & two sets of
cutting blades.
 Weight: 1.7 Kgs
 Dimension

DIAMETER HEIGHT
160 mm 110mm
6.25 inch 4.3 inch

TEARING TESTER

 Tearing strength tester to determine tearing strength of knitted and woven

fabrics.
 Capacity up to 6.400Kgs.
 With adjustable cutting knife
 Having three variable capacity 1.600kg, 3.200kg & 6.400kg for different
type of fabrics.
 Latest design with modern sophisticated look.
 Complete with accessories including three calibration weights.

DYEING LAB
 DATA COLOR DISPENSER
 YARN DYEING MACHINE
 COLOR COMPUTER MATCHING
 COLOR MATCHING MACHINE
 CONCLUSION
Our Summer Internship at Bharat Vijay Mills ,Kalol, Gujarat came to an end on 1st
July 2019, the knowledge we gained their will make us go far. It was really a
learning and knowledgeable experience interning at Bharat Vijay Mills.

We came to learn about the Printing and Weaving process, machines and all other
vital processes in the textile mill.

Thus, summer internship not only helped us increase our basic knowledge but
also acquire knowledge of other subjects and even broadened our outlook. It was
really wonderful and knowledge gaining experience at BHARAT VIJAY MILLS,
KALOL GUJARAT.
 BIBLIOGRAPHY
Internet Sources :
 www.apparelsearch.com
 www.apparelsearch.com
 www.textiletechnology.com
 www.Sintexgroup.com
 www.bvm.com
 www.cotton.org

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