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 Observations to be made on o Yarn manufacturing and Winding section o Weaving section o
  • Observations to be made on

o Yarn manufacturing and Winding section o Weaving section o Dyeing section o Testing and Quality control sections

8 Pillars of TPM 1. Focused Improvement 2. Autonomous maintenance 3. Planned maintenance 4. Education and

8 Pillars of TPM

1. Focused Improvement

  • 2. Autonomous maintenance

  • 3. Planned maintenance

  • 4. Education and Training

  • 5. Initial flow control

  • 6. Quality maintenance

  • 7. Office maintenance

  • 8. Safety health and environment

RSB 851

REITER F35 Roving

Frame

RSB 851 REITER F35 Roving Frame REITER Machines TRUTZSHLER DK 803 REITER Machin REITER Ring Frame

REITER Machines

TRUTZSHLER DK 803

REITER Machin

REITER Ring Frame F16

Schlafhorst/saurer

 The Blowroom is the 1 step of yarn production in the spinning mill.  :
  • The Blowroom is the 1 st step of yarn production in the spinning mill.

  • : Fabric in the form of Bales

INPUT

  • : Sliver

OUTPUT

 The Blowroom is the 1 step of yarn production in the spinning mill.  :
a) Opening b) Cleaning c) Dust Removal d) Blending e) Even Feeding of material to the
  • a) Opening

  • b) Cleaning

  • c) Dust Removal

  • d) Blending

  • e) Even Feeding of material to the card

Type Appearance Description Rollers Small Diameter, Widely used. e.g.: in STEP CLEANERS Drums Larger Diameter, little
Type
Appearance
Description
Rollers
Small Diameter, Widely
used.
e.g.: in STEP CLEANERS
Drums
Larger Diameter, little
used
e.g.: in MONO-
CYLINDER CLEANERS
Quilted Shaft
Shaft with many beater
rods, hardly used
 Cotton contains upto 18% trash, o in most cases ranging from 1% to 7% 
  • Cotton contains upto 18% trash,

o

in most cases ranging from 1% to 7%

  • Since this Cost is a considerable cost factor, it has to be kept as low as possible, which requires an assignment

Cleaning Degree

=

extracted trash*100

 

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

trash content in fed cotton

Cleaning Efficiency

=

extracted trash*100

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

Total Extracted Waste

 Unimix o o Model LB 7/3 By Lakshmi LMW
  • Unimix

o o Model LB 7/3 By Lakshmi LMW
o
o
Model LB 7/3
By Lakshmi LMW
  • The m/c is made up of 3 parts

o

Storage section,

o

Intermediate section, and

o

Delivery section

MACHINE: REITER UniClean 1. Special Design VIBRATING PLATE 4. Rollers for additional Dusting 5. Servomotor-controlled feeding

MACHINE: REITER UniClean

1. Special Design VIBRATING PLATE

  • 4. Rollers for additional Dusting

  • 5. Servomotor-controlled feeding plates

  • 6. Groove

  • 7. Operating Panel

 Ensuring that debris is removed while aligning the fibers to make them easier to spin.
  • Ensuring that debris is removed while aligning the fibers to make them easier to spin.

  • Without carding, cotton thread would be coarse and extremely fragile.

 Parallelize the fibres in card sliver along the sliver axis.  To improve the regularity
  • Parallelize the fibres in card sliver along the sliver axis.

  • To improve the regularity in linear density of card sliver by doubling.

  • Improve sliver quality.

  • To achieve the correct amount of blending.

 17-18% of short fibres are removed  Removal of neps  Parallelization of fibres 
  • 17-18% of short fibres are removed

  • Removal of neps

  • Parallelization of fibres

  • Kitty Level is Reduced

 The function of the speed frame is to attenuate the sliver and to form a
  • The function of the speed frame is to attenuate the sliver and to form a suitable supply package for the ring frame.

  • Twist + Strength + Winding

 The function of the speed frame is to attenuate the sliver and to form a
 To draft the roving until the required fineness is achieved  To impart strength to
  • To draft the roving until the required fineness is achieved

  • To impart strength to the fibre, by inserting twist

  • To wind up the twisted strand (yarn) in a form suitable for storage

  • Transportation and further processing.

Customer Marketing Team Vardhman CPDC Located at Mahavir Textiles Technical Department Pilot Plant Central Design Cell
Customer
Customer
Marketing Team
Marketing
Team
Customer Marketing Team Vardhman CPDC Located at Mahavir Textiles Technical Department Pilot Plant Central Design Cell
Vardhman
Vardhman
Customer Marketing Team Vardhman CPDC Located at Mahavir Textiles Technical Department Pilot Plant Central Design Cell
 

CPDC Located at Mahavir Textiles

Technical

Department

Customer Marketing Team Vardhman CPDC Located at Mahavir Textiles Technical Department Pilot Plant Central Design Cell
Pilot Plant
Pilot Plant

Central Design Cell (CDC)

R&D(Small Length Sampling )

Bit Loom
Bit Loom
 Several sections are wound in sequence and parallel to each other on a dresser or
  • Several sections are wound in sequence and parallel to each other on a dresser or on a drum

  • the warping sections are as many as necessary to obtain, with the available creel capacity, the total number of threads composing the warp

  • The warping speed is about 800 m/min, while the beaming speed is about

300 m/min

 Several sections are wound in sequence and parallel to each other on a dresser or
 Before carrying out warping, following calculations are necessary: o If the calculation does not give
  • Before carrying out warping, following calculations are necessary:

 Before carrying out warping, following calculations are necessary: o If the calculation does not give

o If the calculation does not give an exact number, the last section will be produced with a number of threads lower than the other sections,

o Or the number of threads composing each section will be reduced.

  • so as to get all sections with one and the same number of thread,

 Before carrying out warping, following calculations are necessary: o If the calculation does not give
 A complementary operation which is carried out on warps formed by spun yarns with insufficient
  • A complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity

 A complementary operation which is carried out on warps formed by spun yarns with insufficient
Requirement of Style Change Drawing - in Transport and Loading of Beams and harness onto the

Requirement of Style Change

Drawing - in

Transport and Loading of Beams and harness onto the Weaving m/c

  • Drawing-in:

o consists of threading the

warp yarns

through the drop wires,

the healds

and the reed

1. Back rest roller (warp threads are wound) 2. Support special drop wires 3. Healds 5.
1. Back rest roller
(warp threads are
wound)
2.
Support special
drop wires
3.
Healds
5.
Dents of the reed
8.
Slay
6.
Motor driving the
take down roller
11. Cloth Beam
 the most flexible machines on the market  Their application range covers a wide variety
  • the most flexible machines on the market

  • Their application range covers a wide variety of fabric styles

  • Their present weaving speed of about 600- 700strokes/min

 the most flexible machines on the market  Their application range covers a wide variety
 the most flexible machines on the market  Their application range covers a wide variety
 weaving machines with the highest weft insertion performance and are considered as the most productive
  • weaving machines with the highest weft

insertion performance and are considered as the

most productive

  • 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

 Started in December 2000  Production - 30 lack Meters/ Month  One of the
  • Started in December 2000

  • Production - 30 lack Meters/ Month

  • One of the largest fabric processing unit in Asia.

  • Has area of 12 acres

  • Self- sufficient power supply

Processes:

  • Preparatory

  • Dyeing

Processes:  Preparatory  Dyeing  Finishing (both piece dyed and yarn dyed fabrics)  Inspection
  • Finishing (both piece dyed and yarn dyed fabrics)

  • Inspection and Packing

GREIGE SECTION PREPARATORY SECTION  PERBLE RANGE  NEW PAD STEAMER  MERCIRIZER DYEING SECTION 

GREIGE SECTION PREPARATORY SECTION

  • PERBLE RANGE

  • NEW PAD STEAMER

  • MERCIRIZER

DYEING SECTION

  • TANK COLOUR PREPARATION AREA

  • PAD DRY

  • HT STEAMER

  • THERMOFIX

  • PAD STEAMER

FINISHING SECTION

  • STENTER

  • SUEDING MACHINE

  • SANFORIZER

  • AIRO MACHINE

  • CURING MACHINE

TECHNICAL SECTION

  • PHYSICAL LAB

  • CHEMICAL LAB

  • PILOT PLANT

INSPECTION AND FOLDING SECTION

PRODUCTION PLANNING & CONTROL EFFLUENT TREATMENT PLANT

SINGEING

SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR

WASHING

SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR
SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR

DESIZING &

SCOURING

NaClO 2 BLEACH

SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR
SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR

WASHING

H 2 O 2 BLEACH

SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR

WASHING

SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR

DRYING ON

CYLINDERS

SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR

PLAITOR

SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR
SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR
SINGEING WASHING DESIZING & SCOURING NaClO BLEACH WASHING H O BLEACH WASHING DRYING ON CYLINDERS PLAITOR
 Section A: Singeing, Combined desizing and scouring  Section B: Chlorite Bleaching  Section C:
  • Section A: Singeing, Combined desizing and scouring

  • Section B: Chlorite Bleaching

  • Section C: Peroxide bleaching

  • Section D: Vertical Drying Range. In new Perble Machine, Only Peroxide Bleaching (3 sections)

PARTS OF MERCERIZER RANGE The mercerization machine has five sections:  Padding Section  Tenter chain
PARTS OF MERCERIZER RANGE The mercerization machine has five sections:  Padding Section  Tenter chain

PARTS OF MERCERIZER RANGE

The mercerization machine has five sections:

  • Padding Section

  • Tenter chain

  • Tenter pit

  • Washing range

  • Drawing unit

 To increase the dye uptake.  To increase the tensile strength of the fabric. 
 To increase the dye uptake.  To increase the tensile strength of the fabric. 
  • To increase the dye uptake.

  • To increase the tensile strength of the fabric.

  • To increase lustre of the fabric.

  • Better coverage of immature cotton fibers.

  • To remove crease marks.

  • To remove naps from the fabric.

  • To increase the reactivity and absorbency of the fabric.

 The Caustic Soda used in the processes is heated and concentrated for reuse  The
 The Caustic Soda used in the processes is heated and concentrated for reuse  The
  • The Caustic Soda used in the processes is heated and concentrated for reuse

  • The CRP has an efficiency of 90-95%

  • The principle of CRP unit is to evaporate the water from the weak lye.

  • It helps save money and is less harmful to environment.

 Most important feature of dyeing used is the continuous dyeing range (CDR)  Consists of
  • Most important feature of dyeing used is the continuous dyeing range (CDR)

  • Consists of Padder Box with a capacity of 50-60 lts

  • pad-dyeing method ensures a full penetration of dye inside the fabric at a relatively low consumption of dyes, chemical, steam and water

The cotton and following dyes P/C blend fabrics are dyed with the 1. Vat dyes for

The cotton and

following dyes

P/C blend fabrics are

dyed with

the

1. Vat dyes for 100% cotton

  • 2. Reactive dyes for 100% cotton

  • 3. Disperse/Vat dyes combinations for P/C blends

4.Reactive/Disperse dye combinations for P/C blends

Reactive (HT Method) PDHT  Dye X gpl  Sanspol AMC 20gpl  Resist salt 5gpl

Reactive (HT Method) PDHT

  • Dye

X gpl

  • Sanspol AMC

20gpl

  • Resist salt

5gpl

  • Sodium bicarbonate

20gpl

  • Urea

50gpl

 High temperature steamer is used for the fixation of reactive dyes on cotton and on
  • High temperature steamer is used for the fixation of reactive dyes on cotton and on cotton component of P/C blend.

  • The steam here is used for dual purpose: to provide heat energy and also to act as a source of water to transfer

rapidly and uniformly on dyed surface.

FABRIC

INLET

 High temperature steamer is used for the fixation of reactive dyes on cotton and on

STEAMERS

 High temperature steamer is used for the fixation of reactive dyes on cotton and on

PLAITOR

 This technique utilizes the high rate of dyeing achieved at high temperature (commonly in the
  • This technique utilizes the high rate of dyeing achieved at high temperature (commonly in the region of 210C).

  • A dyeing achieved in less than one hour at 130C can be attained in 20-60 seconds at about 200C.

FABRIC CHEMICAL STEAMER INLET TROUGH VERTICAL 13 WATER DRYING WASHERS SEAL RANGE
FABRIC
CHEMICAL
STEAMER
INLET
TROUGH
VERTICAL
13
WATER
DRYING
WASHERS
SEAL
RANGE
PLAITOR
PLAITOR
 Stenter  Peaching Machine  Sanforizing Machine  Airo machine  Curing Machine
  • Stenter

  • Peaching Machine

  • Sanforizing Machine

  • Airo machine

  • Curing Machine

CHEMICAL FINISHING  SOFTENING  RESIN FINISH  TEFLON FINISH  ETI(Easy to Iron) MECHANICAL FINISHING
CHEMICAL FINISHING  SOFTENING  RESIN FINISH  TEFLON FINISH  ETI(Easy to Iron) MECHANICAL FINISHING

CHEMICAL FINISHING

  • SOFTENING

  • RESIN FINISH

  • TEFLON FINISH

  • ETI(Easy to Iron)

MECHANICAL FINISHING

  • PEACH FINISH

  • SANFORISATION

1. PHYSICAL TESTING LAB 2. CHEMICAL LAB 3. PILOT PLANT

1. PHYSICAL TESTING LAB

2. CHEMICAL LAB 3. PILOT PLANT

 4 Point system used for Inspection Fabric divided into A, B, C Grade  Packing
 4 Point system used for Inspection Fabric divided into A, B, C Grade  Packing
  • 4 Point system used for

Inspection

Fabric divided into A, B, C Grade

  • Packing done in sizes as per the

order or buyer specification.

 4 Point system used for Inspection Fabric divided into A, B, C Grade  Packing
  • Shipping to both buyer/garment manufacturer

 Fiber Dyeing: Cotton, Polyester.  Yarn Dyeing: Cotton. P/C blend, A/C blend  The unit
  • Fiber Dyeing: Cotton, Polyester.

  • Yarn Dyeing: Cotton. P/C blend, A/C blend

  • The unit has technical collaboration with Japanese concern. Most of the machinery is Imported from Japan.

It comprises of five sections: a) Pre Winding b) Dyeing c) Post Winding d) Conditioning e)

It comprises of five sections:

  • a) Pre Winding

  • b) Dyeing

  • c) Post Winding

  • d) Conditioning

  • e) Dispatch

 In this section cones of yarn are converted to soft cheeses for processing.  It
  • In this section cones of yarn are converted to

soft cheeses for processing.

  • It is also called Soft package section.

  • Various counts running 10s To 100s (single and Double)

 In this section cones of yarn are converted to soft cheeses for processing.  It
(High Temperature  Done In HTHP High Dyeing Machines  48 Machines Pressure)  Hisaka (Japan),
(High Temperature
(High
Temperature
  • Done

In

HTHP

High

Dyeing Machines

  • 48 Machines

Pressure)

  • Hisaka (Japan), Fong (China), Pozzi (Italy)

Machine Package load varying from 50Kg to more than 500 Kg depending upon model.

Complete Dyeing cycle done in the HTHP machines.

 RAPID DRYER Uses Centrifugal force to extract the excess liquid out from the soft package.
  • RAPID DRYER Uses Centrifugal force to extract the excess liquid out

from the soft package.

  • RADIO FREQUENCY DRYER

Uses high frequency Radio waves to completely dry the soft packages

 After processing, yarn is wound onto cones in post winding section .  Three types
  • After processing, yarn is wound onto cones in post winding section .

  • Three types of machines are used in this section.

1.

PSM

  • 2. 138 AUTOCONER

  • 3. MACH CONER

Post winding is followed by conditioning of the yarn

After conditioning the material is dispatched in cartons. Following parameters are mentioned on carton.  MILL:
After conditioning the material is dispatched in cartons. Following parameters are mentioned on carton.  MILL:

After conditioning the material is dispatched in cartons. Following parameters are mentioned on carton.

  • MILL:

  • SUBSTRATE:

  • COUNT:

  • SHADE N0.

  • LOT N0:

  • N0.OF CONES:

  • DATE:

  • NET WT.:

  • GROSS WT.:

Types of fibers dyed  COTTON  ACRYLIC TOW  POLYESTER  WOOL  MILANGE

Types of fibers dyed

  • COTTON

  • ACRYLIC TOW

  • POLYESTER

  • WOOL

  • MILANGE

RAW MATERIAL (Cotton, DRYING BALE PACKING Polyester, Acrylic) STAMPING DISPATCH WASHING CAKE PRESSING UNLOADING HYDROEXTRAC DYEING
RAW MATERIAL
(Cotton,
DRYING
BALE PACKING
Polyester,
Acrylic)
STAMPING
DISPATCH
WASHING
CAKE
PRESSING
UNLOADING
HYDROEXTRAC
DYEING
TION
 The main objective of this department is to execute the orders placed to the organization
 The main objective of this department is to execute the orders placed to the organization
  • The main objective of this department is to execute the orders placed to the organization by effective scheduling.

  • They also keep a control over the orders by daily monitoring at each stage of SPDM, dyeing and dispatch.

  • This department has to decide the date for the dyeing of the particular lot in the bulk

RESEARCH & DEVELOPMENT has the following sub departments a) Quality Control Input b) Quality Control Output

RESEARCH & DEVELOPMENT has the following sub

departments

  • a) Quality Control Input

  • b) Quality Control Output
    c) SPDM Section

  • d) Yarn Dyed Shirting Cell
    e) PDC

 Technorama M/c  OBBDM  SPDM  Knitting M/c (Quality)
  • Technorama M/c

  • OBBDM

  • SPDM

  • Knitting M/c (Quality)

 Vardhman is one of the biggest names in textiles worldwide. Our Internship in the company
 Vardhman is one of the biggest names in textiles worldwide. Our Internship in the company
  • Vardhman is one of the biggest names in textiles worldwide. Our Internship in the company gave us immense exposure to the processes that take place in the production of fabric in many forms starting from the fiber stage up to final packing and despatch to the buyers.

  • The experience of being a part of such a big company for even a short time was amazing and helpful in learning about the different processes in textile manufacturing.

  • We are very thankful to all the people at Vardhman, Right from executives to the labourers who selflessly helped us gather information and explained everything in detail.

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