Académique Documents
Professionnel Documents
Culture Documents
SUBMITTED BY:
PRIYANKA VISHNOI SHIVANGI B.F.TECH SEM V 2011-2015
INTRODUCTION
The textile internship has been completed in Welspun India Limited, Vapi, Gujarat.
The duration of the internship was of three weeks where we had covered nine different departments of textile processing. Familiarized us with the various aspects of a Textile Processing Unit starting from its Organizational hierarchy to the functionality of the various departments. Introduced us to the various brands of machineries available for carrying out the different textile processes to meet global standards.
OBJECTIVES
The textile internship was carried out to develop a clear understanding about the following: Flow process sequence and Technical details on machine particulars of weaving, dyeing, printing, finishing, laboratory etc. Particulars of raw material, intermediate products and final product, process details, product quality parameters. Particulars of the manufacturing environment. Human resource management. Productivity analysis for various processes. The internship helps us to:
To understand the structural and functional constituents of the industry. To adapt to real industrial situations which equips us for decision making in a realistic environment. To strengthen the relationship between the industry and students.
Global leadership
Largest terry towel producer in Asia. Worlds 3rd best and 4th largest terry towel producer. Largest specialty polyester filament yarn producer in India. Acquired 85% of Christy UKs leading towel manufacturer & sole supplier to Wimbledon. 80-90 % of products are exported.
COMPANY PROFILE
WELSPUN INDIA LIMITED, VAPI 1st June,1993- Establishment of textile unit at Vapi. Chairman and Managing Director(Welspun Group): Shri.B.K.Goenka. Managing Director(Welspun Global Brands Ltd) : Mrs. Dipali Goenka WELSPUNs VISION We aim to emerge as a global leader preferred by every home serve...with passion grow....@ speed innovate.....with quality excel...with ethics Delighting all stakeholders..... We are...WELSPUN WELSPUNs MISSION We endeavor to reach a leadership position in each Segment / Sector of our Product / Service. We are committed to satisfy our customers by providing best quality and service, which gives the highest value for money. We believe that employees are our most important asset through which we can reach the top in each category of our Product / Service. Therefore, we will emphasize on their continuous improvement through upgrading relevant knowledge and training. We commit ourselves to continuous growth, so as to fulfill the aspirations of our Customers, Employees and Shareholders.
CUSTOMERS
Categories Clubs Mass Merchants Global Clients Costco Sams Club Walmart Target Kohls JCpenny Tjmaxx Ross K-mart Sears LNT BBB Belk Dillards FEdeated Macys FortunOffs IKEA Tommy Hilfiger Nautica Umbra Sheridan Springs Welhome Welspun India Welspun USA
Discount Stores
Speciality Stores
Departmental Stores
Brands
TERRY TOWEL
Terry towels are woven pieces of fabric either cotton or cotton-polyester that are used to absorb moisture on the body after bathing. Terry towels are generally woven with a loop or pile that is soft and absorbent and is thus used to wick the water away from the body. Most towels have a two selvage edges or finished woven edges along the sides and are hemmed (cut and sewn down) at the top and bottom. The basic structure of towel is divided into these main parts: Plain Hem Terry Bar Body Border Selvedge
CATEGORIES OF TOWEL
SIZE OF TOWEL 33 X 33 30 X 30 15 X 21 41 X 21 40 X 76 50 X 100 60 X 110 60 X 100 70 X 140 76 X 132 CATEGORY OF TOWEL WASH TOWEL WASH TOWEL GLOVES HAND TOWEL HAND TOWEL HAND TOWEL BATH TOWEL BATH TOWEL BATH TOWEL BATH TOWEL
76 X 142
80 X 170 100 X 150 90 X 178 80 X 176 74 X 152 50 X 90 50 X 80
BATH TOWEL
BATH SHEET BATH SHEET BATH SHEET BEACH TOWEL BEACH TOWEL BATH MAT BATH MAT
At first the buyer sends his requirement for towel according to feel, look and absorbency. He also specifies the towel design and dimensions.
2. PRODUCT DEVELOPMENT
Nearly 30 pieces are developed as per the buyer's requirement by the product development department. Out of these 6 pieces are sent to the buyer for approval.
The buyer may approve the pieces sent to him or may send comments ask for some changes. If some changes are asked for then the towels are re-developed and again send to the buyer.
If the buyer is satisfied with the above parameters then it sends the shade of the towel as per his requirement
4. SHADE SENT BY BUYER
The product development department develops swatches of the shade send by the buyer and also 2 or 3 more shades which is very near to required shade and send to the buyer.
5. LAB DIP
6. SHADE
APPROVAL
The Product development department develops nearly 100 200 pieces of towels as per the buyers specifications in the approved shade. Out of these 12 20 pieces are sent to the buyer.
8. BUYER'S APPROVAL
The buyer approves the towel which meets his standards and this towel serve as the standard towel for reference between the buyer and the manufacturer.
9. PURCHASE ORDER
The buyer sends the bulk order in the form of purchase order to the Head Office in Mumbai.
The Head Office in Mumbai prepares and give the sales order to the PPC department of the plant through the plant merchandiser.
As per the sales order the PPC makes the production plan along with the material requirement plan. 11. PRODUCTION PLANNING
12. MATERIAL A purchase order is generated for the required yarns and trims and sent to the suppliers. PROCUREME NT
15. PROCESSING
Dispatch is done
18. SHIPMENT
TIME
15 days 15 days 15 days 10 days 5 days
Note: It must be noted the above stated time period is taken ideal but it is subject to change depending upon design features, raw materials availability and other buyers specifications. The timings are also given keeping in mind the average lots of orders fulfilled and delivered and may change as per the quantity of lot as well.
PRODUCT DEVELOPMENT
Then after the corrections are made if required and approval of the fit sample, shade is sent by the buyer.
Then a lab dip is done and the sample pieces of 5*5 inches of the nearest shades to the one sent by the buyer are sent for shade approval. This number is generally 4-5.
Then the preproduction samples of the desired look, shade, feel and trims are sent to the buyer for approval.
After the corrections are made if required and approval is done, the size set samples i.e. all the required sizes of the same towel are sent to the buyer if desired by the buyer.
Then the bulk order is sent by the buyer after which the product development department issues the order to the production planning and control department for the bulk production.
I. Sales Order
I. Sales Order
Sales order refers to the order placed by the buyer. The sales department issues a standard sales order. The planning in sales order leads to complete information from production of shades and packing information including raw material specifications. A particular sales order gives following basic information: Product quantity Product quality specification.
Production Plan
Spinning Plan Weaving Plan Processing Plan Cut & Sew Plan
SPINNING
Spinning Department
The spinning division serves as the first and one of the most crucial divisions in any textile industry. In this unit of 37235 spindles capacity, the raw fibre is converted (spun) into yarns through a series of processes. The main fibre spun in this unit is cotton and its blends along with some other special fibres that include polyester, modal, bamboo, static, etc. The cotton is mainly blended with polyester in the ratio depending on the end use and requirement. Capacity of the spinning division is approximately 55-60 tons per day.
There are mainly two types of spinning processes that are performed: Ring Spinning Open end Spinning
Fibre Procurement
Types of Fibre Shankar 6 Shankar 4 Oganic Cotton Pima Egyptian Giza Wool Noils PVA Bamboo Price Range (Rs. Per Kg) 70-75 57-63 65-70 114-118 102-106 70-75 144-148 148-152 Procured From Gujarat Gujarat Maharashtra,Orissa USA Egypt Imported Imported China Used in Towels, Rugs Towels Towels Towels Towels Towels, Rugs Towels, Rugs Towels
Other types of fibres include Acrylic, LRA, Viscose, Nylon, and Banana etc. Out of the all varieties of cotton only Pima and Egyptian variety is imported. The fibre is usually procured as per the buyers specification in terms of candies where one candy equals 355.62 kg. The fibre usually arrives in bales of 160 kg each and stored in a godown having capacity of 75000 bales. The bales of cotton that are to be spun are then taken from the godown to the spinning unit with the help of the fork lift.
Purchase
Blow Room
Carding
Breaker Drawing
YES
NO (Carded)
Combing UniLap
SPINNING CARDING PLAN LAP FORMATION DRAWING FINISHER COMBING After the blowroom activity comes In time production of yarn with After the doubling process has to an quality. end, the cotton fiber gets right BLOW ROOM The combed slivers are then After the laps arecans produced the been done, output from the ready for the first sliver formation combined and drawn to form the BREAKER DRAWING cotton isdraw then frames combed. breaker are combined through the carding process. Ensure that fibre procurement The fiber procured has to undergo final condensed sliver that is to is be a Combing is required to produce together to form laps for the Carding is the most important done on sequence of operations prior to the taken to time. the speed frame where The cans filled with sliver are fine yarns through an additional combing process. process which helps spinning foryarn opening of the fibers first roving isthe made. then passed on breaker draw straightening into this operation, fine 4 calendar rollers and large lap to open the flocks to Fibre requisition is done well in and cleaning of the same for trash The combination of several frames from the carding machines. toothed combs continues rollers allow for faultless batt individual fibers, advance in case of blends. removal so that the fibers can cans be slivers is known as drawing. Here, sliver from 6 of these straightening the fibers until they structure, and ensure a secure and process cleaning upblow the room has spun into yarns. The This are doubled into 1 can. are arranged ineliminates high degree of optimal lap construction. impurities, Fibre requisition should be made lines of operation, which are irregularities that would cause too Hence, the output sliver is more parallelism. The regulated automatic lap removing the neps, taking care of the available stock, independent to each other. They much variation if the slivers would compact, fine and ready to go into In this process the short fibers loading safeguards the ideal align the fibers etc, to processed waste and anticipated are: put through singly. the combing process. namely noils are removed. pressure of the lap on basic the lap rollers achieve the yarn rejection. 8 of the combed slivers are The output that comes out of cycle. the during thequality complete build-up and better 1. Blow Room Process for Pure combined together to form 1 combing machine is known as efficiencies in further Procedure cotton spinning condensed sliver by combed sliver or there combed cotton spinning processes. 2. Blow Room Process for Cotton producing longer and thinner which is very fine, smooth, strong Higher the production, the more Fibre requisition. Blends slivers. and used to produce more sensitive becomes the carding Fibre to yarn production. serviceable cotton fabrics. operation greater the danger Delivery and of yarn to weaving or of a negative influence on as quality. processing at Vapi unit the case may be.
Finisher Drawing
YES
NO
Auto Coners
YES NO
TFO
Assembly Winding
TFO
Storage
FINISHER DRAWING SPEED FRAME RING AUTO FRAME CONERS SPINNING OPEN END The combed slivers are then YARN CONDITIONING The condensed slivers which combined andof drawn to form YARN PACKAGING As Conversion the roving yarn small is fed spindles it have been obtained from the A process of spinning which is the final condensed sliver that passes to required from sizea set of cones rollers i.e. the A maximum of 570 cones are finisher draw frames are fed extremely fast and is best is to be taken to the speed The packages of yarns arerollers drafting where the taken tosystem a cylindrical chamber directly from the cans each of suitable for coarser yarns for frame where the first roving made as per the buyers move Waxing at progressively of the yarn higher i.e. Contexxor capacity 20 kg Compact to the drafting the use in denims, towels, yarn is made. specification or are generally speeds. xorella machine in which it is system of the speed frame carpets etc is Open End The combination of several made in the packages (cones or The Re-tensioning top the rubber rollers of the yarn and the to provided with 65 degree through creel to the feed spinning or Rotor spinning. slivers is known as drawing. cheeses) of 1.5kg ,1.89 kg,2.8 the bottom avoid tension steel rollers variations constitute celsius temperature with guide. This process eliminates kg for ring spun yarns and drafting system. almost 90% vacuum Each speed frame rovescause yarn that would packages of 2.5kg,3kg and 3.7 irregularities Then Splicing the yarn as and goes when to the yarn application so that the yarn is to 120 bobbins at a time from too much variation if the kg packages for open end guide required through to join the the nip two roller ends at of the conditioned and attains 120 respective cans. slivers would put through yarns. front. spindles moisture gaining capacity. The main objective of the singly. The conditioned yarn is yarn is wound on thethe spindle roving process is to give 8 of the combed slivers are then packed in two ways: which Cleaning rotates of at the a high yarn speed This process also increases first basic twist to the sliver combined together to form 1to Carton packing which is driven by the spindle the durability of the yarn. hold the short slivers together condensed sliver there by Pallet packing drive. and the resulting product. producing longer and thinner slivers.
Blow Room
The fiber procured has to undergo a sequence of operations prior to spinning for opening of the fibers and cleaning of the same for trash removal so that the fibers can be spun into yarns. The blow room has lines of operation, which are independent to each other. They are: Blow Room Process for Pure cotton spinning Blow Room Process for Cotton Blends For Pure Cotton Spinning: 1. Automatic Bale Opening And Mixing Machine used: Trutzschler Blendomat Bdt 019
The bales of cotton are taken from godown to the blow room and fed to the automatic Blendomat machine. It takes lay downs of up to 27 bales of raw material at a time in two bale groups on each side of the machine. The swivelling take-off tower on its travelling chassis has an optional device that scans the bale contours, thus ensuring uniform take-off. The machine then transports the material to the other machines for further processes through the channel of material transportation and suction tubes.
7. Blending Machine
The blending machine is used to blend the fibers in homogeneous mixture and least impurities with at least 2 and almost 8 kinds of materials can be blended and can be distributed to different carding trained each with different blend ratio.
Now the fiber coming out of this machine is directly fed to the carding machines for continuous process.
Carding
After the blowroom activity comes to an end, the cotton fiber gets ready for the first sliver formation through the carding process. It is the most important process which helps to open the flocks to individual fibers, cleaning up the impurities, removing the neps, align the fibers etc to achieve the basic yarn quality and better efficiencies in further spinning processes. Higher the production, the more sensitive becomes the carding operation and greater the danger of a negative influence on quality.
Technical Details of the Carding Machine
Speed (current)
182 m/mins 330 m/mins 9000 m 50 kg 0.100 Ne
Speed (maximum) Length of sliver per can Weight of sliver in 1 can Sliver hank
62 mins
79.6% 6% 51.4 Kg
Lap Formation
After the doubling process has been done, 22 28 of the output cans from the breaker draw frames are combined together to form laps for the combing process. Each lap of diameter 550 mm, weighing nearly 18.75 kg contains 250 meters of lapped cotton sliver. Only optimal drafting distribution can ensure the best drafting conditions and the resulting fiber parallelization. 4 calendar rollers and large lap rollers allow for faultless batt structure, and ensure a secure and optimal lap construction.
Speed (current)
Speed (maximum) Length of lap Input Sliver hank
75 gms/m
2.3 mins 3 hrs 80-85 %
Combing
Combing is required to produce fine yarns through an additional straightening in this operation, fine toothed combs continues straightening the fibers until they are arranged in high degree of parallelism. In this process the short fibers namely noils are removed. The noil that is removed constitute to about 15 20% of the lapped cotton fibers in case higher counts such as 80s and 100s. These noils are then used to produce yarns of coarser count through open end spinning. The output that comes out of the combing machine is known as combed sliver or combed cotton which is very fine, smooth, strong and used to produce more serviceable cotton fabrics.
Particular
Speed (current) Speed (maximum) Length of sliver Input weight of lap Output Sliver hank Time to fill 1 can (output) Time to finish 8 laps(input) Efficiency Impurities removed (Noil)
Rieter E 62
202.1 m/mins 400 m/mins 6700 m 75 gms/m 0.16 Ne 30-35 mins 2 hrs 80-85 % 20-21%
Rieter E 60
148 m/mins 400 m/mins 3800 m 75 gms/m 0.16 Ne 25 mins 2 hrs 80-85 % 20-21%
504 m/mins 900 m/mins 3500 m 0.16 Ne 0.16 Ne 7 mins 15-20 mins 70-75 %
Speed Frame
The condensed slivers which have been obtained from the finisher draw frames are fed directly from the cans each of capacity 20 kg to the drafting system of the speed frame through the creel to the feed guide. Each speed frame roves yarn to 120 bobbins at a time from 120 respective cans. Here the slivers are drawn through the sliver guide by a 4 roller double apron drafting system with 4 top rubber rollers and 4 bottom steel rollers. The main objective of the roving process is to give the first basic twist to the sliver to hold the short slivers together and the resulting product
Technical Details of the Speed Frame Machine Twisting range
10-100 twists per meter (202.54 tpi) Upto 63mm
247.7 minutes(approx)
20 kg 4600 m 1500 rpm 260 mm Easy spin systems 2.07 133704 m/hrs
Yarn Conditioning
A maximum of 570 cones are taken to a cylindrical chamber i.e. CONTEXXOR COMPACT xorella machine in which it is provided with 65 degree celsius temperature with almost 90% vacuum application so that the yarn is conditioned and attains moisture gaining capacity. This process also increases the durability of the yarn.
Yarn Packaging
The packages of yarns are made as per the buyers specification or are generally made in the packages (cones or cheeses) of 1.5kg ,1.89 kg,2.8 kg for Ring spun yarns and packages of 2.5kg,3kg and 3.7 kg packages for open end yarns. The conditioned yarn is then packed in two ways: In carton packing, the cartons were manually packed with transparent tape. Each carton may have 3050 cones or even more depending on the buyers specification. In Pallet packing 250 cones are arranged in a 5*5 manner with 10 layers of the same, one above the other with a supporting layer in between. Then the cones are wounded over by polythene sheet . This kind of packing is mainly done for in house transportation. Then the particular packed carton or other form is labeled with the lot number, gross weight, net weight, number of cones, count of yarn, fiber name and content and buyersuppliers name etc.
WEAVING
WEAVING PREPARATORY
The weaving department forms the core of fabric production in a textile industry. In this department our study concerns about the weaving of terry towels i.e. uncut pile weaving. The weaving department has following sub departments in it: Textile design department Weaving preparatory department Weaving department Grey folding department
The objective of this department is to prepare a pattern for the weaving process to achieve the desired effect and look on the fabric as per the buyers specification.It does the following things.
Weaving Preparatory
As per the design and structure specified the design of the towel is made. According to the design the yarn requirement is calculated with the help of the software tools. The required amount of yarn is sourced and then a warping plan is made and is followed.
FORMATION OF DESIGN WARPING PATTERN PLAN
SIZING
WARPING
Process Flow
Winding Yarn from the spinning department
Winding
Beam Warping
Sectional Warping
Sizing
Knotting
Loom Shed
Inspection
Packing
Dispatch
Direct Warping
There are 4 direct warping machines from: Benninger Ben-direct 2 machine Jupiter - 2 machines The cones are placed on the creels and the ends are passed through two pre stationary rods out of which one is stationary and one is movable. These rods are responsible to give proper tension to the yarns. The yarns are passed through a Zig-Zag yarn guide to the gear-controlled cylindrical beam that continuously rotates and prepares the warping beam.
Sectional Warping
There are 5 sectional warping machines from: Benninger (SuperTronic) 1 machine Sucker Muller (hacoba) - 1 machines Vamatex (Servomatic M 08) 1 machine Prashant Gamatex 1 machine Karlmayer 1 machine The sectional warping has a warpers beam in the form of a composite solid made from a drum and a cone of length 3.4 m. Drum density is 400g/dm3. After the cones are placed on the creels and passed through the pre stationary rods and thread control unit and the end guides, the sectional beam rotates at high speed and the beam automatically moves laterally to get a uniformly wound.
Sizing
Sizing is a process in which the warp yarns are stretched and given a size bath, dried and in the process thousands of warp yarns from a warpers beam are transferred into a weavers beam. Sizing is mainly done to increase the strength of the warp yarns that have to sustain the high tension and regular abrasion during the weaving process. The warp yarns are subjected to a stretch of 1%. Sizes like Terrysize UFC, Sizebond WD, Softsize PB, Sizecare CWS and Sizol TDY are used which contain starch based or synthetic like polyvinyl alcohol or a water-soluble acrylic polymer, depending on the fiber content of warp yarns. They are given a bath of a water base sizing solution with a concentration of 1.7% for 1/13 count to 10% for 1/10 count. The input yarn is subjected to maximum tension of 650 N and the output yarn is subjected to maximum tension of 1250 N.
WEAVING
After the sizing process of the pile and the ground beams, they are manually transported to the weaving looms. The looms present in the weaving department are Airjet looms and Rapier looms. There are a total of 151 looms that were in production out of which 58 are Rapier looms and 93 are Airjet looms.These looms have either Dobby attachment or Jacquard attachment. Out of these 151 looms, 62 have Jacquard and 89 have Dobby. According to the orders coming to the unit, looms are allotted for specific towel weaving.
Weaving Process
Based on the production plan and the textile design plan, the beams of the pile & ground are gaited on to the loom as specified in the loom plan. Each of the ground and the pile beams carry yarns of length nearly 3000 and 9000 meters respectively. The weft yarns are arranged on the weft feeder/dispenser based on the color pattern. The weft yarns are usually supplied from cones. The design through floppy/ programmer is set on the looms. The loom process control parameters for the functioning of the beams are set, like the reed, the pick, the terry motion, let off, take up etc & weaving starts. It must be noted that for the formation of the pile loops, the speed of the pile beam (let off) is more than the speed of the ground beam. As such the ratio of yarn consumption of ground beam to pile beam is 1:5. Once the cloth roller for winding of the towel is full which can take upto 1200 kg of grey fabric roll, the roll is doffed & sent to the Grey folding area. Before sending to the Grey folding area, relevant production entries are made in the system.
Weaving Mechanism
DRAWING IN Here 16 heald dobby attachments are used for terry towel designing. The pile threads are drawn on four healds, & the ground threads (if the loop formation is to be continuous) on eight healds for a 2 ground-2 pile order of arrangement. 2 healds are used for leno and 2 are used for selvedge. DROP PIN MECHANISM There are drop pins for every single yarn. Yarn is passed through the whole provided in the drop pin. SHEDDING Shedding is the process of division of warp sheet in two layers to create space for insertion of weft yarn.
PICKING Picking is said to be passing of weft yarn through the shed opening.
BEATING UP The weft thread that has been inserted across the warp thread in a shed is pushed upon the fell of the cloth. Fell of the cloth is the position of the last pick in the cloth woven on the loom.
LET OFF It allows the warp yarns to move in forward direction by unwinding weavers beam maintaining a predetermined warp tension. TAKE UP A motor is provided which winds the fabric produced in the loom. WEAVE CONSTRUCTION The Turkish toweling structures form a class of warp pile-termed terry pile in which certain warp threads form loops or curls on the face of the cloth. Only one kind of weft may be used, but 2 series of warp threads, placed on separate beams, are necessary for the production of the cloth- viz. ground threads & pile threads.
Terry Towel weaves construction: red lines represent the pile threads and blue lines represent the ground threads.
TRANSPORT VEHICLES
GREY FOLDING
GREY FOLDING
After the required fabric is woven by the weaving department, each doff is then sent to the next department known as the Grey Folding It is the store house of the grey fabric. It can store about 8000 tons of grey fabric at a time. Inspects the grey fabric for weaving defects and to generate quality reports of the fabric inspected. It also prepares the fabric for delivery to the processing department as per the present requirement or demand. It stores the grey goods in the roll form, until they are issued to the processing. It also mends all the repairable defects prior to rolling & storage. Before sending into the Grey Folding Department, a computer data entry of the details of the fabric doff is made for the Weaving & Grey Folding Department and the data card of the same is fixed on to the doff roll for easy identification. The details entered are: Order no. Sort no / design no. Length of the fabric roll Weight of the roll Total no. Of pieces produced per size.
Grey fabric store
Automatic stop arrangement to stop the machine at the end of the fabric piece.
Bow bar has been provided in the batching device to open out the creases in the fabric. Perfect tension during the flow of the fabric is provided using guide roll assembly, thus no hassles of nip rolls. Meter Counter is installed in front on platform top for easy reading.
PROCESSING
PROCESSING
Objectives of Processing: To remove the impurities. To increase the lustre and appearance of the fabric. To make the fabric attractive and sellable. To improve the softness and water absorbency of the fabric. To color the fabric of different shade.
Dyeing Machine
Hydroextractor
Inspection
Dryer
Rope Opener
Yarn Dyeing
Process: The yarn is loaded in the ECO-BLOCK machine and the program is set that consists of all the steps of scouring, bleaching, dyeing ,soaping and fixing. After the material has been loaded firstly scouring chemical is used i.e. EM clean cp and HTC chemical. The temperature is raised to 80C and is run for 10 minutes. EM clean cp, soda miratol WA and caustic is put and runned for 20 minute at 80 degree C then hydrogen peroxide is added. Temp is raised to 100 degree C and held for 30 minutes . Then the bath is drained , then hexa phosphate is added at 90 degree and run for 10 minutes. In dyeing process first salt and saracol-s is added at 60 degree. Then color solution is added by dosing to avoid more strike of color generally dosing time is 20-30 minute. Then add soda at 60 degree and run for 15 minute then add caustic and run for 15 minute the and run for drain the bath. And give a cold wash to the dyed fabric. Then raise the temp to 60 degree and add acid for neutralization. Run time for acid is 10 minute. Then drain the bath and add miratol that is a soaping agent and raise temp. To 95 degree and run for 10 minute. Then give a hot wash at 80 degree for 10 minute. Then take out material and cut sample and match with standard depth. Then go for softening at temp. 60 degree for ten minute. For heavy shade we do use a fixer before softening at 60 degree for 20 minute. Drain the bath and give a cold wash and unload the material.
Make
Fongs Thies Thies Thies Thies Thies Thies Thies Dalal engg. Pvt.Ltd Dalal engg. Pvt.Ltd Thies Thies
No.of chamber 8 1 1 1 1 1 1 1 1
Addition tank 1 1 1 1 1 1 1 1 1
Pump speed 100 rpm 1440 rpm 1440 rpm 1440 rpm 1440 rpm 1440 rpm 1440 rpm 1440 rpm 1440 rpm
Liquor capacity 60 lit. 750 lit. 1500 lit. 1500 lit. 1500 lit. 3000 lit. 6000 lit. 6000 lit. 280 lit.
ECOBLOCK-9
ECOBLOCK-14 ECOBLOCK-15
1
1 1
1
1 1
1440 rpm
1440 rpm 1440 rpm
105 kg
292 kg 292 kg
525 lit.
1500 lit. 1500 lit.
Yarn Dryers
M/c name Yarn Drier-1 Yarn Drier-2 Manufacturer Thies Thies Capacity 300 1236 Tempt. 120C 120C
Yarn Drier-3
Thies
1236
120C
Fabric Dyeing
Process: First take the material and load it in the eco soft machine. Main objective of scouring is to remove the PVA and chemical used is EM clean CP. After this treatment bleaching chemical is added, which includes miratol WA, Tinochloride GI for the bleaching temp. Required temperature is100 degree and treatment time is 10 minutes. Then hydrogen peroxide is added at 100 degree and run for 30 min. Then hot wash is given at 80 degree for 10 minute. After hot wash addition of CAT is done but temp. must be cool down to 55 degree first and then run for 15 minute .CAT is a peroxide killer & needed for good results. In dyeing process first add salt and saracol-s at 60 degree. Then add color solution by dosing to avoid more strike of color generally dosing time is 20-30 minute. Then add soda at 60 degree and run for 15 minute then add caustic and run for 15 minute the and run for drain the bath. And give a cold wash to the dyed fabric. Then raise the temp to 60 degree and add acid for neutralization. Run time for acid is 10 minute. Then drain the bath and add miratol that is a soaping agent and raise temp. To 95 degree and run for 10 minute. Then after ward give a hot wash at 80 degree for 10 minute. Then take out material and cut sample and match with standard depth. Then go for softening at temp. 60 degree for ten minute. For heavy shade we do use a fixer before softening at 60 degree for 20 minute. Drain the bath and give a cold wash and unload the material.
Bleaching
Neutralization
Sequestering Agent
Check pH
Dyeing starts
Cold Wash
Acid Wash
Soaping
Softening
Draining
Unload
Open beaker dyg. Machine Laundrometer Electronic pipette Surface water absorbing testing machine machine Digiflame digital fire retardency tester
FINISH FOLDING
Length Slitting
Checking
AQL
Length Hemming
Cross Hemming
Cross Cutting
Embroidery
Dispatch
Cross Cutting
Length Slitting
The main objectives of length slitting are lengthwise slitting of the fabric into individual pieces and correct slitting of fabric using sensors. Processed fabric is fed from the trolleys that are brought from the processing unit. Rollers are provided to feed the fabric on the cutter. Knives are activated according to the number of parts that have to be taken out from the fabric.
Number of machines Speed (current) Speed (maximum) Efficiency Production per hour (current) Production per hour (maximum) Production per day (current) Production per day (maximum) 3 25 m/min 35 m/min 70% 1470 meters 2100 meters 35280 meters 50400 meters
Length Hemming
The main objectives of length hemming are lengthwise hemming of the fabric into individual pieces and correct stitching of fabric using sensors. The fabric is fed lengthwise and the stitching is done on both of its edges in the lengthwise direction. These machines are off Schmale Durate with Pegasus chain stitch swing machine attachment. There a total off 8 length hemming machine performing single needle stitch and 3machines performing double needle chain stitch. The main reason for the usage of chain stitch is that there need not to be any bobbin change after fixed intervals and also,fewer chances of thread breakages. Number of machines 11
Speed (current) Speed (maximum)
Stitches Per Inch Type of stitch Efficiency Production per hour (current) Production per hour (maximum)
15 m/min 20 m/min 9-11 Chain Stitch 70% 840 meters 1200 meters
Sides Overlock
Sleeves Hemming
Sleeves attachment
Placket Attachment
Pocket hemming
Belt Formation
Shoulder Attachment
Pocket attachment
Loop Making
Specifications
Spreading done manually. Total ply height is 7 inches. No. of lays in a spread = 40 GSM of fabric = 420 If GSM 360 or lays no. of plies = > 70 Production per 12 hours = 550 pieces
At the time of observation: 4 way marker SM size 420 gsm Time taken in laying 0.5 hour Length of ply = 586 cm Width of ply = 232 cm White colour fabric No. of plies = 40
Stitching Defects
The following defects are encountered with during the cut and sew process.
Alter CORNER IN CORNER OUT CORNER OPEN CORNER IMPROPER LOOSE STITCH JUMP STITCH WAVY STITCH DOWN STITCH DOUBLE STITCH UNCUT THREAD LOOSE THREAD RAW EDGE PIPING ROPING PUCKERING SPI JOINT MIS MATCH WRONG THREAD USED FABRIC FACE/BACK Mending NEEDLE MARK P. FOOT MARK SMALL HOLE CONTAMINATION SMAL L SLUBS Stain OIL STAIN SOIL STAIN RUST STAIN INK MARK Reject BIG HOLE BIG SLUB SHADE VARIATION DYE STAIN BOWING MENDING MARK PATCHY DYEING WHITE SPOT DOUBLE PICK MISSING PICK DOUBLE END DRAWING MISTAKE DAMAGE FABRIC REVERSE FABRIC MISSING END BAD DAMAGE SELVEDGE SPOT STITCH MARK MAJOR CONTAMINATION
Packaging
Packaging of terry towels is done as per the buyers requirement. Each buyer has their own specific way of folding the towels and size of the carton in which the goods are to be shipped. The packaging is usually done manually. There are four ways of packing the towel. They are: Solid color solid size This type of packaging contains same colored and same sized towels packed in one carton. Solid color assorted size This type of packaging contains same colored but different sized towels i.e. one piece each of wash, hand, bath, and bath sheet in one carton. Assorted color solid size This type of packaging contains different colored but same sized towels to be packed on one carton. Assorted color assorted size This type of packaging contains different colored towels of different sizes to be packed in one carton. The towels according to the desired category are first packed in poly bags. Poly bags are provided with air holes to allow air-flow. The cartons used for packing are manufactured by local vendors and have handling instructions printed on them.
A carton can usually contain from 6 to 24 towels poly bags and 12 to 60 in case of hand and wash towels as per the buyers requirement. Here once again checking is done. This time the checking is done randomly where 20 to 25 pieces of towels is picked from a group of 100 pieces. If more than two to three pieces are found defective then the entire lot is rejected. This checking process is termed here as FSA or Final statistical audits. It usually takes place after packaging.
Once the lot is approved for shipment they are loaded in trucks for the delivery. An average big container has the capacity of 64 cubic meters that is for example if we take bath towels of the standard size, then 800 cartoons of bath towels and each cartoon containing 12 towels weighing approximate 4 tons can be stored comfortably in one container. Containers are usually of 20 & 40 feet. Everyday there is a shipment of almost 55 60 tons of terry towels. They have 120 employees working per shift.
Water goes to the Sreen chamber for the removal of big solid wastes by eiltration to decrease the BOD & COD. Water reaches the homogenizing tank for equalizing temperature, color , pH solid percentage, BOD & COD Water reaches a neutralizing tank where the PH is made normal to 7.5 by adding recycled H2SO4.
20% of treated water discharged in open agricultural lands & 80% discharged to the water bodies through drainage.
Water is bubbled with atmospheric air @ 800m3/hr for two days.Here bacteria takes oxygen and consumes upto 60 % of dyes in water and decreaes the BOD & COD
Water reaches the distribution tank which adds bacteria contained sludge to the water to decrease the BOD and distributes the water to the oxidation tank.
Quality of raw materials used Quality of infrastructure and machinery used for production Quality of the finished goods Quality of the working area Quality of human capital and management
The objectives of the TQM department are: To sustain the quality of the goods To satisfy the customer by sustaining the quality parameters crucial to customer and crucial to quality. To develop a system so that factors critical to quality and critical to customer are sustained under all circumstances To ensure that the quality providers also get the quality working environment and are paid accordingly. Working deeply on the factors Crucial to Customer and Crucial to Quality that are considered as the core of the departmental values.
RUGS
RUGS DIVISION
Rugs is a general term embracing many coarse woven or plaited fibrous materials used for covering floors or furniture, for hanging as screens, for wrapping up heavy merchandise and for other miscellaneous purposes. Rugs are made both through Power loom & Handloom. Rugs are being widely used in USA and European countries, due to its soft nature. Rugs in this plant is being manufactured by the process of tufting. Tufting is a type of textile weaving in which a thread is inserted on a primary base After the knitting is done, short U-shaped loops of extra yarn are introduced through the fabric from the outside so that their ends point inwards. Production of rugs consists of following processes: 1. Tufting 2. Latex Coating 3. Processing 4. Inspection By TQM 5. Finishing & Packaging
RUGS DIVISION
Rugs Production
Rugs Dyeing
Tufting Coating and Latex Heat setting and Cabling Cut and Sew Packaging
TUFTING
Tufting is the process of creating textiles, especially carpet, on specialized multineedle sewing machines. Several hundred needles stitch hundreds of rows of pile yarn tufts through a backing fabric called the primary backing. The needles push yarn through a primary backing fabric, where a loop holds the yarn in place to form a tuft as the needle is removed. The yarn is caught by loopers and held in place for loop-pile carpet or cut by blades for cut-pile carpet. Next, secondary backings of various types are applied to render a variety of performance properties. Here are some key steps in the tufting process: Yarn comes from cones on creel racks (or from big spools called beams) into the machine.The primary backing feeds into the machine. Yarn and primary backing come together in the machine (full shot of machine Yarn is fed through needles on a needlebar of a tufting machine. Needles repeatedly penetrate or tuft into the primary backing. The tufted carpet is mended and inspected. Carpet is rolled onto large rolls for the next step (whether its to be dyed or to be backed.)
Tufting in this plant takes place in two ways: 1. Machine tufting 2. Table tufting
Tufting
CUT AND SEW: After the latex coating is done the it is sent for cut and sew. There the roll is spread on the spreading table transferred to the cutting table through air floatation table and cutting is done by automatic Gerber cutting machine. A maximum of 10 plies of spreading is done for the machine tufted roll and 45 plies of canvass roll spreading is done. After the cutting is done as per required design the pieces sent foe edge finishing. It includes either piping the edges or overlocking it as per requirement of the buyer. DYEING: Dyeing is the process of coloring materials by impregnating fiber, yarn or fabric with with dyestuff. Coloration in rugs can be achieved at two possible times in the manufacturing process either by dyeing the fiber or yarn before the fabric is tufted or by tufted or by dyeing the tufted fabric before the application of the secondary backing and backing and the finishing process. Yarn dyed rugs are only washed and dried for finishing whereas grey rugs undergoes undergoes dyeing followed by washing and drying. FINISHING AND PACKAGING : After drying the rugs, finishing is done like trimming of the threads, mending etc. they they are further inspected by the TQM and after their clearance they are ready for dispatch. Inspection is also done at packaging stage.
PROJECT
BEAM FAULTS
S.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 LOOM NO. 62 68 72 52 50 56 59 134 132 112 115 170 75 78 77 80 85 86 165 160 193 178 180 GROUND/PILE P G G P G G G P G P G P P G P G P G P P G,P G P NO. OF CONES 1 1 5 2 1 6 3 1 2 1 2 1 5 1 2 2 1 1 4 1 1,1 1 1 BEAM NO. WP20 WG27 BG21 BP8 BG12 BG35 WG61 KP76 KG29 AP7 HG32 SP3 TP13 TG16 TP3 TG16 TP23 TG29 KP97 KP66 NG51,KP13 NG56 KP28 COUNT 13 KC 2/20 KC 2/20 KC 2/20 KC 2/20 KC 2/20 KC 2/24 KC 11 HYGRO 10 OE 2/20 RC 10 0E 2/24 KH PIMA 2/20 RC 10 OF 2/2O RC 2/24 KC 13 KC 2/20 KC 2/20 RC/SHE 11 HYGRO 10 OE,16 KC 10 OE 11 HYGRO REASON CUT END CUT END CUT END,WEAK ENDS CUT END CUT END CUT END,WEAK ENDS CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END
DATE: 11.06.2013
SIZING MACHINE B/N-1 JUPITER JUPITER JUPITER JUPITER JUPITER JUPITER B/N-2 S/M B/N-2 S/M B/N-2 B/N-1 S/M B/N-2 JUPITER B/N-2 JUPITER B/N-2 B/N-2 S/M,B/N-1 S/M B/N-2
DATE: 12.06.2013
S.NO LOOM NO. GROUND/PILE NO. OF CONES BEAM NO. COUNT REASON SIZING MACHINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
G G G P P G P G G G P G G P P P P
1 1 4 1 2 2 1 1 1 1 2 1 1 1 1 2 4
WG48 SG8 BG21 BP30 BP3 WG37 WP67 KG7 KG9 KG31` SP17 WG22 KG26 TP13 TP30 NG66 KP55
10 OE 10 OE 2/20 KC 2/20 RC 2/25.3 RC(S-6+60PVA) 2/20 KC 2/25.3 RC(S-6+60PVA) 1O OE 2/20 KC 2/20 KC 2/24 KC 2/20 RC 2/24 KC 2/20 RC 2/24 RH PIMA 10 OE 16 KC
CUT ENDS CUT ENDS WEAK ENDS CUT ENDS WEAK ENDS CUT ENDS WEAK ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS YARN ENTANGLED INSIDE OTHERS YARN AT FLANGE CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS B/N-2
S/M S/M JUPITER B/N-2 B/N-2 JUPITER B/N-2 S/M JUPITER JUPITER S/M S/M JUPITER B/N-1 B/N-2 S/M B/N-1
18 19 20 21 22 23 24
P P G G P P P
1 4 1 2 1 1 EXTRAENDS -22
B/N-2
DATE: 13.06.2013
S.NO 1 2 3 4 5 6 7 8 9 LOOM NO. 52 56 60 59 57 32 150 144 138 GROUND/PILE P G,P G G G G G G G NO. OF CONES 1 3,2 2 3 1 1 1 1 1 BEAM NO. BP33 BG37,BP17 BG28 W646 WG4 WG11 KG5 KG7 KG14 COUNT 2/20 RC 2/20 KC,2/20 RC 2/20 KC 10 OE 10 OE 2/20 KC 10 OE 10 OE 2/20 KC REASON CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS SIZING MACHINE B/N-1 JUPITER,B/N-2 JUPITER S/M S/M JUPITER JUPITER S/M S/M
10
11 12 13 14 15 16 17 18
126
120 118 76 78 97 93 173 160
G,P
P G G G P G G G
1,1
3 1 1 1 1 1 4 1
SG3,SP21`
SP13 SG25 TG10 TG16 TG26 TG31 NG6 NG9
2/20 KC,2/20 RC
2/24 RH PIMA 2/24 RH PIMA 10 OE 10 OE 2/24 RC 2/24 KC 10 OE 10 OE
CUT ENDS
CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS,WEAK ENDS CUT ENDS
JUPITER
JUPITER,B/N-2 B/N-2 B/N-2 S/M S/M S/M JUPITER S/M
19 20
187 178
G P
1 1
NG26 KP15
2/20 KC 16 KC
JUPITER B/N-1
6% 3%
1%
3%
7% 1% 2% 2%
23%
13 KC 2/20 KC 2/24 KC 11 HYGRO 10 0E 2/24 KH PIMA 10 OF 2/20 RC/SHE 16 KC 10% 2/25.3 RC(S-6+60PVA) 2/24 RH PIMA
25%
2/24 RC 4%
13%
10%
29%
30%
Beam faults Cut ends Extra ends Crossings Over dried ends Over sized ends Sizing patch Count mix Sticky ends Migration or entanglement of one layer into other Conclusion Ground beam is more prone in beam faults. Generally ground beams having yarn count 2/20 kc or 10 oeare greatly included in beam faults. Beams made on sizing machines jupiter and sucker muller are more in numbers which have cutends(beam fault). Effect of beam faults Because of cutends we have to use cone /cheese in place of that missed end in the further cause below given problems. 1. Tension variation in the specific ends in the warp sheet. 2. Threading time is more which further lowers down the m/c efficiency. 3. Fabric faults like Variable loop height leads to uneven appearance
Remedies Look into the yarn quality given by spinning department to the weaving preparatory department Tenacity Yarn regularity Package faults Maintain the proper creel tension level in the warping and sizing for different yarn count. Reduce the peak tension level for the yarn count(10 oe,2/20 kc) in the warp sheet on the jupiter and sucker muller sizing machine. Optimise the speed for different yarn counts like low fpe single yarn and more for ply yarn. Proper working of stop motion on warping m/c. Proper temperature maintain in the time zone in sizing m/c. Worker should be more attentive towards warps breakages in sizing m/c. There should no short length of the warp sheet. Maintenance should be properly and regularly checked and maintained and there for the weaving preparatory machines. There should be proper preparation of sizing paste in term of their concentration of sizing material and its cooking time. Seepage of water on warp sheet from the roof should not be there. Operator should be aware about beam faults,its causes and there remedies so that he/she would take corrective action as per his knowledge and experience.
THANK YOU!
BIBLIOGRAPHY
http://www.osthoff-senge.com/en/produkte.html http://www.thiess.com.au/smart-solutions http://schlafhorst.saurer.com/en/products/winding/bobbin-processing/
http://www.noiseandhealth.org/article.asp?issn=14631741;year=2011;volume=13;issue=54;spage=348;epage=355;aulast=Dube
http://welspunindia.com/content.asp?Submenu=Y&MenuID=1&SubmenuID=1 http://www.rieter.com/en/spun-yarn-systems/about-spun-yarn-systems/ http://www.welspun.com/content.asp?Submenu=Y&MenuID=1&SubmenuID=14 http://www.fibre2fashion.com/industry-article/3/297/safety-and-health-issues-in-thetextile-industry2.asp