TEXTILE DIVISION CHHINDWARAAN INTERNSHIP REPORT ABHITOSH KUMAR NEERAJ KUMAR NIFT-Hyderabad 2010-2014 Contents Preface ................................................................................................................................ 3 Acknowledgement ............................................................................................................. 4 Introduction To Organisation.......................................................................................... 5 Raymond Ltd Textile Division ......................................................................................... 8 Organizational Chart...................................................................................................... 12 Process Flow of Department .......................................................................................... 13 Lead Period for Production Departments .................................................................... 14 Plant Layout .................................................................................................................... 15 Raw Material Godown ................................................................................................... 16 Wool Scouring .................................................................................................................. 50 Grey Combing Department .............................................................................................. 50 Dyeing Department .......................................................................................................... 50 Recombing Department ................................................................................................... 50 P/V Spinning Department ................................................................................................ 51 Worsted Spinning Department ........................................................................................ 59 Weaving Department ....................................................................................................... 59 Finishing Department....................................................................................................... 59 NIFT HYDERABAD Page 2 PREFACE As a part of our course curriculum, we were supposed to undertake an extensive study of the textile production in a textile industry to know the technical as well as aesthetic know how of the textile procedures. We undertook the same at the Raymond Limited, textile division at Chhindwara. The division specializes in the manufacturing of the worsted polywool and poly-viscose fabric and is a renowned name in its field. The document has been framed in such a way so as to cover each and every aspect related to the company. The document gives the overview about the Raymond Group, general information about the division. It also spans comprehensively the various procedures that take for the production of the worsted fabric that the division specializes in. The processes have been explained in detail according to their incidence in the manufacturing process. NIFT HYDERABAD Page 3 We are grateful to MR.ACKNOWLEDGEMENT It is a highly reverent privilege for having got the illuminating opportunity to work under RAYMOND LIMITED (TEXTILE DIVISION) Limited for the fulfillment of our textile internship.PHANI who was always there to guide us through this tedious task. NARESH KADU (Placement Officer) who gave us the wonderful opportunity to learn about a textile industry as esteemed as Raymond’s. Last but not least we thank all the people who have somehow been a reason for completion of this onerous task NIFT HYDERABAD Page 4 . A. This acknowledgement is a petite endeavor to thank all those who were directly / indirectly involved in this project and bestowed their kind co-operation in pursuit of the same. Our training at RAYMOND gave us the precious knowledge and insight in the study of textile background. We are highly indebted to the Raymond’s family. Then we would like to thank our Mentor MR. CHHINDWARA who gave us a wonderful experience in industry that not only enriched our knowledge bank but also gave us larger than life lessons and work ethics. without his support this project would have never been what it is today. Raymond Ltd has laid great emphasis on developing strong in house skill for research & development since its inception. its products have set a benchmark in that genre. Europe. Manufacturing facilities include Four world.the art technology from wool scouring to finishing stage and modern techniques of quality management. This unwavering attention to innovation has enabled it to introduce path. also produces and markets plush. Canada. The company exports its suiting fabrics to more than 50 countries including USA.class fully integrated plants in India.breaking new products in the market. Promoted as an essential accessory for “the Complete Man”. Raymond Ltd has raised the performance and product standards of the entire Indian textile industry. housing. Hailed as a pioneer and innovator. With a capacity of million meters of wool & wool-blended fabrics making it the third largest integrated manufacturer in the world. recreation and spiritual support system for the employees and connected townships. Japan and the Middle East. The woolen mill by the creek in 1925 is presently transformed into a Rs. and prophylactics and toiletries. INTRODUCTION TO THE ORGANIZATION Incorporated in 1925. Raymond Limited (Textile Division) has more than 60% market share of the Indian market for worsted suiting fabrics. Raymond Limited rightfully recognized as the most respected Textile Company of Indian in January 2003 by “Business World”. to achieve enhanced customer satisfaction through ongoing innovation. And happily. Engineering file & tools.of. but its mantra for continuous growth has remained the same: pursuit of excellence. employing state. 1400 Crores conglomerate.velvet furnishing fabric in a wide array of designs and colors including carpeting for the niche markets of India and Middle East. All the plants are self-sufficient in terms of providing educational. the growth graph continues to rise higher and higher NIFT HYDERABAD Page 5 .1. designer wear. Raymond Limited presently has five divisions comprising of textiles. aviation. Files & Tools Files & Tools division manufactures complete range of Engineer's steel files & drills and is the world’s largest producer of steel files. NIFT HYDERABAD Page 6 . fashionable and comfortable clothing segment. blankets. Also produces a wide range of furnishing fabrics. Raymond Apparel Ltd. Aviation Million Air was launched in 1996 to provide air charter services and enjoys a reputation for high quality reliable services.wool blended. Helene Curtis Ltd. . Denim The Denim division produces high quality ring denims and ranks among the top 3 producers in India. Parx and Manzoni.K. DIVISIONS Textiles Produces world-class pure wool. Be An exclusive prêt-a-porter line of ready-to-wear designer clothing for women and men in western. J.Cottons. ethnic and fusion styles. blends and denim wear catering to the smart. It has three highly regarded men’s wear brands in its folio: Park Avenue. polyester viscose fabrics. and ranks among the top 3 integrated producers in the world. Be An exclusive prêt-a-porter line of ready-to-wear designer clothing for women and men in western.It is the marketers of the Park Avenue and Premium brands of men’s toiletries. room fresheners. Premium The range of cosmetics & toiletries including after shaves. shampoos. fashionable and comfortable clothing segment. Established in 1993 Color Plus is one of the leading domestic brands for premium casual wear in the country. BRANDS Raymond The largest and most respected textile brand in India for 'The Complete Man' addressing the innate need of men to look good and at the same time possess strength of character. NIFT HYDERABAD Page 7 . Park Avenue Formal readymade garments & accessories for men it has recently bagged the "Most Admired Brand" and "Most Admired Trouser Brand" awards. soaps. Ltd. cologne. deodorants. Parx The semi formal and casual range of cottons. shaving cream. Manzoni The luxury range of men’s shirts and ties acknowledged for its high quality and international styling. ethnic and fusion styles. Color Plus Fashions Pvt. blends and denim wear catering to the smart. etc. and To provide additional sources of employment to people in & around Chhindwara district. which is a part of the JK group (western zone). which has been concluded recently. They have rapidly improved upon the efficiency figure. The finishing department is the largest of its kinds in Asia. These facts open to the possibility of carrying out finishing for other plants. RAYMOND LTD. The vision for setting up the unit at CHHINDWARA has been: To manufacture world –class polyester -wool and polyester-viscose blended suiting and furnishing fabrics at competitive prices. with a capacity of 40000 mtrs per day.2. NIFT HYDERABAD Page 8 . situated at distance of 57 km from Orange city Nagpur. Thus approximately 153 lacs meters is produced per annum at Chhindwara. Quite frankly they have exceeded all expectation. This plot stands as a pioneer in the socio-economics development of this region. The spinning and weaving department have charged ahead of 90% efficiency levels in all over the world. To establish a large-scale unit in a backward area. It is spread over a total area of 100 acres. But then what are the parameter of performance. which needed accelerated development. To catalyze the nascent industrial potential potential of smaller towns of the country. TEXTILE DIVISION (CHHINDWARA) Raymond Chhindwara. is it customer or is it the people they have perhaps it is an amalgamation of all this that spurs them on. is it quality.round socio-economic progress of the region and its hinterland. The plants were in full swing by 1st April. operation at the plant commenced in July 1990. is it production. To ensure all. strive for excellence. 1991. is 45. As of now they process the complete production of Jalgaon. In short span of four years they have achieved stupendous success.000 mtrs per day. The present capacity of the plant after expansion. ensuring high efficiency and productivity. The company has pledged itself to the protection of environment.Certificate of merit 3. NIFT HYDERABAD Page 9 . The plant is located on a 100 acre plot with a built-up area of 1. Golden peacock Environmental Management Award. ACCOMPLISHMENTS 1.The installed capacity of chhindwara unit is 128 looms and 33528 spindles as against the license capacity of 1500 looms and 50000 spindles.First position 2002. 2. National Energy Conservation Award from Ministry of Power Govt. This unit became operational in the year 1991. The in-house environmental laboratory helps the operational staff to improve the environmental performance by providing monitoring and measurement services. prevention of pollution and conservation of nature resources. of India 1999. 4. well trained and competent. The mechanical engineering department ensures the fullest compliance with all applicable regulatory requirements.Certificate of merit 2004. The work force is adequately skilled. 7. National Safety Award for year 2007. MP State Level Award from MPPCB for excellence in Environment Performance for the Year 2004-2005.Second position 2003. World Environment Foundationfor the year 2000. ICMF’S Birla Economic & Textile Research Foundation for Energy Conservation in Textile Industry – First prize for the year 2003-04. The plant is well equipped with the most modern machinery. The unit has a work force of more than 2900.40000 sq meters and a green belt area of 65%. 6. 5. Safety Award from National Safety Council M P Chapter for excellent work in Industrial Heath and Safety in the year 1994-96. BLLARD ESTATE. POWER CONSUMPTION WATER REQUIREMENT COAL REQUIRED OUT PUT UNITS TURN OVER : 1. MP Government gives 15% subsidy on total cost of project (Rs. 67.K. 430 crores approx p. of person working all around the three shifts (Including official staff) are 3626. Availability of power. CHHINDWARA : B-1 BOREGOAN INDUSTRIAL GROWTH CENTER A. Site is near to Nagpur which is well connected with all places of the country by Rail.10 lacs) GENERAL INFORMATION MILL ADDRESS : RAYMOND LTD (TEXTILE DIVISION).000 mtrs fabric per day : Rs.N.000 Unit per day : 43 Lacs liter per day : 58 Metric tones per day : 50.VITAL STATISTICS MANPOWER : Per day the no. fuel and water 3. 5. Cheap land 2. Five percentage subsidy in electric charges (Rs. BOMBAY-400038 Page 10 .15 lacs) 6.a THE LIST OF FACTORS LEADING TO SELECTION OF PLANT LOCATION IS AS FOLLOWS: 1. The staff strength is 415.V. KAILASH NAGAR TEHSIL – SAUNSAR HEAD OFFICE NIFT HYDERABAD : J. Availability of man power on cheaper rate 4. Road and Air. BLDG.000 Mtrs. N.F2 VILLAGE. VINOD PARMESHWARAN : SUITINGS ONLY. P/V AND P/W ALL WOOL AND FURNISHING FABRIC CAPACITY : 50. MORARJEEMARG REGISTERED OFFICE : RAYMOND LTD.ZADGAON. OF FABRICS DAILY NIFT HYDERABAD Page 11 .MAHARASHTRA WORKS DIRECTOR GOODS MANUFACTURE : Mr.NO. 56/ H.K. 3. ORGANIZATIONAL CHART NIFT HYDERABAD Page 12 . 4. PROCESS FLOW OF DEPARTMENT PV-FD Dyeing Spinning Yarn Room Warping – Weaving Mending Finishing Finish Mending Folding Warehouse PV-PD Spinning / O/s Yarn Yarn Room Warping – Weaving Mending Finishing ( Pretreatment) Dyeing Finishing (Post treatment) Folding Warehouse PW-TD Grey Combing Dyeing Recombing Spinning Yarn Room Warping – Weaving Mending Finishing * Finish Mending Folding Warehouse PW-PD Grey Combing Recombing Spinning Yarn Room Warping – Weaving Mending Finishing ( Pretreatment) Dyeing Finishing (Post treatment) Folding Warehouse NIFT HYDERABAD Page 13 . LEAD PERIOD FOR PRODUCTION DEPARTMENTS Polywool Fabric Department Dyeing Recombing Spinning Yarn Room Weaving Mending Grey Room Finishing & Folding Contigency Total PolyViscose Fabric Lead Period(Days) 05 06 14 07 11 03 04 16 04 70 Department Dyeing Spinning Yarn Room Weaving Mending Grey Room Finishing & Folding Contigency Total Lead Period(Days) 05 20 07 11 03 04 16 04 70 NIFT HYDERABAD Page 14 .5. PLANT LAYOUT NIFT HYDERABAD Page 15 .6. DEPARTMENTAL HIERARCHY PLANT IN CHARGE G.M. Delivery. It stores the raw material with proper order.7. RAW MATERIAL GODOWN The Purpose of the raw material godown is to receive Raw material from outside party and also from inside departments and deliver as per the requirement with care. receives waste from various departments. Sorting. While the non moving wastes are sorted out in six month and are inform to commercial department. Segregation Machine Erection & Shifting work Page 16 . & GM. Dispatch and WORK MAN PSF/VSF/ GREASY Wool Receipt & Issue and Despatch NIFT HYDERABAD WORK MAN TOPS Receipt and Issue Work WORK MAN Waste packing. And the wool scouring department provides scoured wool to the top go down through pipelines which are further processed for carding and combing. The raw material go down is connected to the wool scouring department. and dispatches the waste material. matching soft waste and also white separately according to the shade chart. WORKS DEPUTY MANAGER (RMG) ASSISTANT (RMG-1) ASSISTANT (RMG-2) ASSISTANT Waste Department FORK LIFT OPERATOR Raw material Unloading. The waste materials are sorted color wise. 4. Process material Top is a bundles of sliver conversion of wool/polyester.tow is converted top. PSF. New Zealand and South Africa. Polyester top (8.7.Greasy wool 5. 10. NIFT HYDERABAD Page 17 . Two types of top are prepared in the industry itself others are obtained in top form already. TOW. 9. Waste godown 7. 2. SWL.5 kg) 2. Flax top(linen top) Viscose top Silk top Cashmere top Acrylic top Blended top Camel hair top Angora top Mohair top Lenzing top Merino wool is imported from Australia. 8.3.Scoured wool 7. Top godown 3. 7. 6.Polyester continuous filament 4. Merino wool is considered to be the finest and best quality wool in the world.2. Wool top (10 kg) The other top that are retained in the top go down are:1. The two kinds of top that are prepared are: 1.Polyester staple fibers 2. 5. VSF. 3.viscose staple fibers 3. Godown has three sections:1. Raw material norms 1. Raw material godown (RMG) 2. GWL.1. Since they are.7.P VSF top 4. 5. 7. Its cross sectional view is round. Flax top greasy wool and NIFT HYDERABAD Page 18 .it has good luster properties . Nagda of M.its cross sectional view is tri-lobal 2.it is highly brittle and breaks easily. 6. Low pill fibers are weaker because their strength is reduced by 70% during the manufacturing stage itself so that the pills do not cling to the fabric surface and fall off easily. Industry RIL Reliance industries FFL Futura fibers limited GIL Grasim industries limited Industry address Patalganga (ms) Surat gujarat Chennai Material Tow of PSF 2. Low pill. The polyester material has the type or merge no.it is little dull in nature. weak they break off easily during twisting hence the speed of machine should not be too high therefore the productivity is less and the cost of manufacturing low pill fibers is high. Normal. Sparkle. SUPPLIER NAME S no 1. POLYESTER STAPLE FIBERS ARE USED IN THREE FORMS: 1. DAL Australia Dewavrin CDDL Compagnte impirtion de lafned BEAPL Australia Bwk elders Australia private limited RSA Uruguay Rantex SA NV NV jos vannestesa Belgium Greasy wool Greasy wool Greasy wool Greasy wool 8. which is maintained in such a way that two different type or merge no should be mixed together while in process because of the dyeing affinity 7.4.5. PSF top 3. 3. 5 ton) 3 7.gwl 5. scoured wool` 7.4 185. BALE SPECIFICATIONS:FIBRE TYPE 1. tetra wool 6.2010) CATEGORY 1.0 78. White sparkle and normal 2. shift and dispatch materials and machines Used to unload. 96 7.tow 4. top WEIGHT( IN KG) 700 350 250 200 200 *3=600 150 120.7.6.7.vsf 3. shift and dispatch materials and machines FORK LIFT(battery Macknell operated) (capacity=1. MACHINES MACHINE BALE PRESS FORK LIFT(diesel) BRAND Godrej Godrej (capacity=2 ton) NO. Black sparkle and normal 3.swl Total CAPACITY (IN TON) 80 70 180 120 80 530 TOTAL STOCK 54. OF OBJECTIVE MACHINES 2 To pack the textile waste 2 Used to unload.9 236.psf 2.9.5 65. Viscose 4.7 NIFT HYDERABAD Page 19 .9 560.12. Raw material stock as on date (27. greige wool 5. VSF.0 d. 1. Tow. By tractor. B. South America. NIFT HYDERABAD Page 20 .9 tons Department is having 21 workers. By Hydraulic pallet & hand trolley. 0. By manual. Use psf/vsf. It is merino wool which is suitable for making cloth greasy wool is supposed to be washed or scoured for the combing process which makes the wool top. By Battery or Diesel forklift. . By battery or diesel forklift.the greasy wool which is received from Australia.for grey dyed fabric vsf is directly purchased from Grasim industries(dope dyed) and psf is delivered to dyeing department for fiber dyeing mainly for vsf and psf pv / spinning . 2 staff and one officer.4 d.5 d. South Africa in various micron value.8 d and lengthwise like 92 mm. 44 mm. There they mix it in a certain ratio % for the pv fabric. By forklift with good condition rope.2. B.viscose staple fibre is a regenerated cellulosic fiber which is made from pulp generally it is doped by suppliers and is in fibrous form vsf are supplied from Grasim industries only. Using polythene sheet & Nylon bag. Gwl.8 tons Daily average consumption of psf . Denier( it is making 9000 m yarn weight in gms) The polyester materials have a type or merge no which are maintained in such a way that two different types or merge should not be mixed together while in process because of the dyeing affinity.5 d. 3) LOADING:A. In tow it is possible to get variable length needed from converter machine it is converted to polyester top. C. B. Done by Battery Forklift or Diesel Forklift. 1.tow is a continuous filament purchased for making blend with wool. Systematic arrangements manually wherever necessary. All the polyester and viscous received are in 2. 2) DELIVERY:A. Daily average consumption of vsf -1. C. 2. 7. 54 mm etc.10. PROCESS PARAMETERS 1) UNLOADING:A. 40 21. Bale press using polypropylene sheet.86 2.96Kg 105. 7) NON MOVING WASTE:A. Party wise C.47 16. B. WASTE DAILY RECEIPT Total waste . As per the dispatch list loading the bale by forklift and arranging in line manually .04kg 53.1631.52kg 267.9kg 17.16 0.63kg 43. 4) WASTE PACKING:A.C.69 1.88kg 9.99 5.84kg Waste percentage 1. Sorted out nonmoving waste of six month. 5) SORTING OF WASTE:Color wise matching soft waste and also white separately according to the shade chart 6) SEGREGATION A.01 6. & GM 7. Inform to Commercial department.62 NIFT HYDERABAD Page 21 . Undesired material should not be mixed up with textile waste.11.28 3. Folding Weaving Grey combing Weight of waste 18.47kg 65. Category wise B. Dept.77kg Department Converter Designing Dyeing Plush PW spinning Finishing QC.55 3.26kg 95.62kg 352. 11kg PROCESSBFLOWCHART 11.PV spinning Recombing 7.12.12 9.44kg 152. WASTE GODOWN Few Waste items are kept at the back of raw material godown and the rest are stored outside the company premises .13. 181. The following waste items are received from all the departments regularly DEPARTMENT P/V spinning WASTE P/ V Soft P/V Hard P/V Sweeping T/W Soft P/W Hard P/W Sweeping T/W Soft Page 22 P/W Spinning W/spinning Recombing NIFT HYDERABAD .32 7. Techniques of motion economy can be applied to improve the productivity and efficiency for ex. Sorting and packing is done in bale press machine of all other category and sold to outside party. NIFT HYDERABAD Page 23 . Even the segregation of buffer stock was not properly done according to specified rules and regulations. tools used for opening the compressed bales should be kept at a particular fixed place which would avoid any confusion or ineffective time. PROBLEMATIC AREA OBSERVED After much surveillance and deep analysis we felt that the housekeeping of raw material godown was not satisfactory. Raw material being one of the less tedious and less effort involving department was neglected in many regards 7.15. SUGGESTIONS FOR IMPROVEMENT Housekeeping department should be conduct periodic visits to check the hygiene and working conditions of raw material department. 7.Converter Plush Dyeing Grey Combing Weaving (old and new) R/C Noil R/C Sweeping All Wool Soft Tow sparkle soft Tow NP soft Tow BLK soft Tow Sweeping Reging flock Dyeing Soft All Wool Soft G/C first Noil G/C second Noil G/C first burr G/C second burr Shoddy Defective W/G selvedge W/G mix hard W/G Sweeping Plush Chhindies Raising flock Plush After receiving various wastes from the entire department it is segregated according to its category. Waste material was not conglomerated properly and were seen lying randomly.14. 2.1. The dirt and sand in the wool are removed during scouring by mechanical agitation. Kemps may be regarded as impurities in fine wool (b) Acquired-Acquired impurities are picking up by sheep such as sand.1 : To remove mud & impurities other than grease temp. Generally there are three types of impurities present in raw wool (a) Natural .Natural impurities are produced by sheep itself. WOOL SCOURING Raw wool contains a number of impurities which must be removed to facilitate yarn production or further processing. These are wool grease. NIFT HYDERABAD Page 24 . dust. The fat of the wool forms emulsion with alkali and is removing during emulsion scouring.8. oil etc 8. soil. lint and the ex-creation stains caused by the dung and urine. of the bowl is 280 0 C. The suint is soluble in water and can be removed by a preliminary wash with hot water. 8.Applied impurities are the impurities which are added to the coat of the sheep for identification of their own sheep. FIBER OPENING AND SCOURING PROCESS FLOWCHART OBJECTICE To open the wool for better cleaning To avoid lumps formation. (c) Applied. These impurities are color. Bowl No. Gilling or combing process. seed and grass. burrs. The grass and insoluble impurities are removed by carding. After the fiber opening machine has total 6 bowls & their functions are as below 1. In scouring there is loss in weight amounting to about 40%. OBJECTIVE OF SCOURING To remove all these impurities without damaging the fiber. Blow No 5 & 6 :5000c After every bowl there is a squeeze roller which squeezes the water & does not allow to go in next bowl. Detergent “Alphox -200” is used in bowl no. are 4.3-0. of the grease is 400 0 C & 650 0 C helps to melt grease & other oily particles from the wool.2 : This is the main functional Bowl & temp. MACHINE PARTICULARS AND PROCESS DETAILS Tank No. more than 90% grease will be removed. Bowl No. is 650 O C . Melting pt. Bowl No 3 : Remaining mud.3.2-0. Remaining 3 bowls are the rinsing bowls & only wash the wool & temp. After that 3 drying zones each have 2 drum types dryer & temp are 900 0 C.5 0. 3.2 & 3 for the cleaning.2.2-0. Blow No 4 : 5500c 5.3 50±2 Plain Water 7 -8 % Grease 17-24 Removal Temperature 60±2 (°C) Chemicals Soda Ash PH 8 –10 Amount of Scouring Agents Initial (Kg) Soda 10 Nil Nil Nil Nil NIFT HYDERABAD Page 25 .4 54±2 Plain Water 7 -8 0.0-0.2.4-0. suint & grease is removed in this bowl & temp is 6000 C. Capacity (Upper) Squeeze pressure (Kg/cm2) % Grease 1 2800 liters 4-5 2 2800 liters 3 2800 liters 4 2800 liters 5 2800 liters 4-5 4-5 4-5 4-5 22 –30 5 –6 3-4 58±2 Detergent 7 –8 1 -1.6 0. Major part of the detergent is used in bowl no.9 0. 8.7 56±2 Detergent 7 -8 1. 1 . Glycerin. The dyestuff is transferred through a felt covered bowl by means of a rubber coated dipping roller. It is carried out on a machine of very simple construction consisting of a gill box and the printing compartment.4. which are then placed in a steam autoclave for fixation of the dyes.Initial Nil Detergent (Kg) Water (liters) 10 5 3 Nil Nil 8 5 Plain water Plain water ADDITION AFTER EVERY 30 MINUTES Tank No. Soda ash (Kg) 1 1 2 Nil 0.4–1. OTHER PARTICULARS Efficiency of The Machine – 40-80%. NIFT HYDERABAD Page 26 . Betafoam KS.53 3 Nil 0. The material is fed to the printing rollers. and Formic Acid etc.5. Production – 400-450(Kg/Hr) Power Consumption – 130 hp Dryer Temperatures Maintained Between 70 0 C to 11 8.33 4 Nil Nil 5 Nil Nil Detergent (Kg) Nil 8. The chemicals used for vigrous printing are Benzyl alcohol. 10-16 bands of about 20 gm/m are combined in a gill to produce a uniform fleece with a draft of 1. Urea. VIGROUS PRINTING or VIGRO PRINTING Vigrous printing of top sliver is a recognized method for producing “Mélange effect” on wool.. which carry a relief pattern of diagonal strips. The dye paste will impregnate the sliver coiled in the perforated cans.6. d. in the grey combing. To remove short fibers . The grey combing department procures the raw material from the RMG department and the wool scouring department. polyester top making as well as wool top making takes place. 9. Polyester top processing section.requires an additional passage of carding and combing to remove short fibers and any other impurities. For this. Wool top processing section. Top godown is integrated with the grey combing department which facilitates easy commutation of tops and fibers. 100% wool). This process is done for the grey materials (which are not dyed e. GREY COMBING DEPARTMENT Grey combing is the process of removing short fibers.here polyester tows are directly converted into tops by the convertor machines 3. pinpoints etc from the material for obtaining good quality of yarns. foreign matter To get good quality yarns.1.wool is checked for its grease content and moisture regain before going through the combing department polyester fibers are directly converted into tops in the convertor whereas wool goes through carding . grey combing is done for the grey fibers prior to dyeing . pin points etc from the material For uniform blending of fiber To remove dirts. neps.combing and gilling.9.g. OBJECTIVE OF COMBING a. Grey combing department is further departmentalized as: 1. c. Polyester does not require any such checking. b. NIFT HYDERABAD Page 27 . naps. 2. wool is inspected for moisture regain and grease content % and then it is rendered for further processes. Recombing is done for blends and dyed fibers. dusts. MANAGER MAINTENANCE SHIFT INCHARGE Assistant Computer Assistant Despatch Blenders (3) OFFICER TECH. MANAGER PLANNING. ASSISTANT 1/SHIFT Fitter (3) Oiler (1) Helper (2) FITTER 1/SHIFT OPERATOR 14/SHIFT HELPER 3/SHIFT PACKER 2/SHIFT NIFT HYDERABAD Page 28 . DEPARTMENTAL HIERARCHY GM Plant Incharge GM Works MANAGER DY.2.9. PRODN & QUALITY DY. 9.3. PROCESS FLOWCHART From RMG To RMG NIFT HYDERABAD Page 29 . 4. MACHINES USED MACHINES Carding BRAND N. Kicks-out vegetable matters.S.S. Attenuation of fibers into a strand of fibers which is called sliver. To apply antistatic agent and moistures in material if required. Straightening and Page 30 Post gilling -5 N. Straightening and parallelization of fibers. OF OBJECTIVES MACHINES 2 Individualize of fibers from tuft of fibers. Pre-gilling-1 and 2 N. To increase evenness of sliver by means of doubling and drafting. To increase evenness of sliver by means of doubling and drafting Prepare suitable material to feed the combers.C 1 Combing N.C Pre-gilling-3 N.S.C 11 Post gilling-1 N.S. To apply antistatic agent and moistures in material if required.S. To remove short fibers. vegetable matters Parallelization of fibers.9.S.C NIFT HYDERABAD 1 .C NO.C (GC4) 1 Straightening and parallelization of fibers. neps. To increase the evenness of combed sliver by means of doubling & drafting. 2 Straightening and parallelization of fibers. S.S. One is above and other is underneath.(GC5) with coupled press Parallelization of fibers. Wool carding-This is the next process after wool scouring. Then the material goes to the feed roller by the help of lattice. It helps the fiber to in to licker-in. There is a striping roller which strips the wool fiber from the incline lattice.5.C 1 Conversion of filament fibers into required cut length fibers. Making strand of fibers (sliver).6. Convertor Gilling -3 N. To form a bulky sliver in which fiber are aligned. To increase evenness of sliver by means of doubling and drafting To make bump tops 9. Objective To separate each fiber from other with a minimum of fiber breakage. Licker-in NIFT HYDERABAD Page 31 . This process involves subjecting the fibres to the action of large number of pins in an attempt to separate each fibre from its neighboring fibre. This is necessary to facilitate further fibre manipulation and to remove impurities. At the top there is a comb.C with coupled press 1 Straightening and Parallelization of fibers. It combs the wool flock and allows the small size tuff forward. Feed roller There are two rollers mounted. To increase evenness of sliver by means of doubling and drafting To make bump tops N. 9. To remove impurities and fiber entanglement To mix the fiber together to provide a uniform distribution. SEQUENCES OF CARDING M/C:Hopper In hopper the scoured wool are deposited up to the maximum level. Process parameter of carding m/c Particulars Speed Feed roller 0. The function of the burr beater is to remove burrs from the wool fiber. Transfer roller: This transfers the fibers from one carrier to another. Waste Container There is also a conveyer belt in between feed roller and licker-in. The main function of it is to penetrate the fiber in to the main swift wire which is coming out due to the action. stripper and cylinder. Licker-in 21 m/min Diameter 110-120 mm 1200mm NIFT HYDERABAD Page 32 .7. It is equipped with wire for providing better opening of the fibre and improving their transfer to doffer. Burr Beater All burrs beater in the card are equipped with covers and adjustable screen. Doffer The function of doffer is to paralyses the fibers. The setting of screen determines the type and quality of impurities to be removed. Worker roller The object of worker roller is to perform a considerable fibre mixing and taking the fibre in the forward direction. Stripper roller The main function of the striper roller is to remove the short fibres from the worker roller and returns to them to carrier roller. Fancy roller It is of three rollers assembly.82 m/min. There are also four pairs of worker & striper roller around the swift roller.The three pairs of worker and striper rollers are covered to the licker-in. This doffer is gives the output in the web form. Morel Burr Beater There are three roller device designed to eliminate vegetable impurities contain in the wool with minimum wool rejection. Main swift roller In cotton process it is called as main cylinder. Opening and cleaning of the wool fibers is done between worker. The moral transfer roller is fitted with a brush. At the side of the worker roller there is also a burr beater. The special type wire is present on its surface. It helps to take the burrs and waste and collect in the container. 9. 14000 (safety standards) 9. neps.9. slubs. 9. from where it is later transported to the bumpress which converts slivers into tops of 10 kg.Worker 1st transfer roller 2nd transfer roller Calendar roller Delivery speed Out put delivery 21 m/min 38 m/min. The final stage includes 2 stages gilling. The entanglement of fiber and undesired elements like slubs.5 micron Production/day= 2. 135 m/min.5 ton Input = 1700 kg Output = 2000 kg Linear density = 24 gm/meter Anti-static =0.8. neps. 25+-2gm 314mm 310mm - Ratios Doffer to delivery: 1:2 Doffer to swift : 1:10 Carding is followed by 3 stages gilling which aims at the removal of short fibers and better penalization. The next process is 2 stage combing whose basic objects include removal of short fibers non fibers impurities. and pin point are reduced. 80m/min 120m/min. FACTS AND STATISTICS Draft (Ratio between cylinder and output) = max 2 Input weight = 22. Polyester top making NIFT HYDERABAD Page 33 .2% ISO 9000. and straightening and parallelization of long fibers. In the polyester top making. Two compressors are there by which they press the material in to smaller size then by the automatic knotting machine. The fallers are moves in alternately one are in right and one is to left SPRAY DEVICE This device permits to apply the spray solution through nozzle. AUTO LEVELLER NIFT HYDERABAD Page 34 . This package is known as top.250 2. PROCESS PARAMETERS OF CONVERTER 2den 2 275 200. GILLING MACHINE Parallelization of fibers. coiling etc thus deposited as slivers. This is placed between the drafting roller and coiler.12. converter is very significant.1 gm /m. Objective 9. Top part is called as top caterpillar and bottom part is called as bottom caterpillar. Improving uniformity of sliver. Removal of short fibers.11. Front roller pressure in kg. After keeping certain length of sliver. which undergoes tension. The liquid is brought to the nozzle under pressure.10. FALLER INSTALLATION The GC-14 head comprises 72 right and 72 left faller. DIFFERENT COMPONENTS OF THE MACHINE DRAFTING HEAD Drafting head has two part-Top parts and a bottom part. Reduction in wt per unit length of sliver. of sliver in to the can the can goes to packing zone automatically. 9.1 3 den. 2 275 200-250 21+. 9.1 Denier type Tow doubling Speed in m / min. it ties this package.5 den 2 275 200-250 21+. Delivery wrapping in 21+. falling . It cuts down the polyester tow of continuous filament into certain length. In the g-c machine there is an automatic knotting machine is present. 5+. Due to this speed variation the draft increases or decreases and obtained the regular/uniform delivery sliver. a cutting.NSC Model .3 6 5F 24+-1 45 8.3 6 5F 24+-1 45 8.At the machine input the feed web is measured by mechanically controlled roller system. At the precise moment that these variations arrive at the draft zone.Polyester 2.3 Then the slivers collected from 6-7 containers are fed into 3 passage gilling machine.1 Make . The tow led in the machine undergoes a tension. The machine winds the certain sliver length and tied it with thread to form the top. the memory transmits the pre-registered values to a variation by the way of "reader arm".0.5 den 3 den 8 8 4R 4R 24+-1 24+-1 300 300 6 5F 24+-1 40 300 6 5F 24+-1 40 300 6 5F 24+-1 40 300 6 5F 24+-1 45 8. a draft through fallers and is deposited in form of continuous slivers.0.GC-14 Denier type 2 den Doubling 8 Faller density 4R Delivery wrapping in 24+-1 gm / m Speed in m / min GILL BOX – 2 Doubling Faller density Delivery wrapping in gm / m Ratch in mm Speed in m / min GILL BOX . NIFT HYDERABAD Page 35 . Polyester top weighs 8. FOR GILL BOX .3 Doubling Faller density Delivery wrapping in gm / m Ratch in mm Top weight 300 Department . an opening.0. By sift of belt the speed of the back roller increases or decreases according to the requirement. Then the top is disposed outside.5 kg.5+. The web section variations are registered in form of a memory wheel having certain number of memory rods.5+. Polyester/wool Polyester/viscose All wool The materials are dyed in further different forms as under:10. After loading the tops. The dyeing and other treatment periods depends upon the shade.5 hrs and for dark shade 5 hrs. For wool dyeing.1. There are many type of carriers having deferent capacities i. NIFT HYDERABAD Page 36 . These dried materials are kept as stock for further processing i.5 hrs. On an average approx 1760 shade are being processed in the department that goes into production. and to PV Spinning Department dyed fabric to either Mending Department or Finishing Department. TOP DYEING The prepared tops come from the Grey combing department which is pressed in the carrier by the help of top press m/c. DYEING DEPARTMENT The dyeing department is to deliver dyed fiber to Recombing Department. in required shade at required time. 10 kg .e. After this the material goes to RF dryer for 100% drying.20kg. After dyeing they are doing RC for removal of surface dye which are mechanically attached on the surface of the material After completing of dyeing process the material comes out and goes to Hydro extractor for drying Hear 40% of water is removed from material. For light shade 4. 50 kg . The dye solution and other required chemicals come in to the m/c automatically after giving the instruction from the control room because “Automatic Dosing System” works in the mill. they are using metal complex and acid dye.. The maximum Crain capacity is 10 tones. The loaded tops in carrier are load in to the vertical HTHP dyeing m/c by the Crain. re-combing. 200kg. There are mainly two types of blends produced and dyed.e. Dyeing is employed to give an all over shade to fiber and fabric.100kg.10. For polyester they are using disperse dye. the lid of the m/c is closed automatically. for medium shade 4. PROCESS FLOW CHART TOP DYEING FIBER DYEING WHITE POLYESTER TOPS FROM GREY COMBING WHITE GREY TOPS FROM GREY COMBING WHITE POLYESTER FIBER TOP PRESSING TOP PRESSING FIBER STAMPING HTHP DYEING HTHP DYEING HTHP DYEING COLOR FATSNESS TESTING (QC) COLOR FATSNESS TESTING (QC) COLOR FASTNESS TESTING (QC) HYDRO EXTRACTO HYDRO EXTRACTOR HYDRO EXTRACTOR RF DRYING RF DRYING RF DRYING BLENDING AND SHADE MATCHING SHADE APPROVAL BY QC BLENDING WITH DOPE DYED VISCOSE & SHADE MATCHING DELIVERY TO RECOMBING DELIVERY TO P/V SPINNING FINAL SHADE APPROVAL BY DESIGNING DELIVERY TO P/W or P/V WORSTED SPINNING NIFT HYDERABAD Page 37 .2.10. FABRIC DYEING WHITE PW HEAT SET PIECES FROM FSG CHEESE DYEING WHITE PV GREY PIECES WHITE CHEESE FROM WINDING WHITE PERCH (LOT ARRANGEMENT) SCOURING & DRYING PRESSING HTHP DYEING HEAT SETTING (FSG) POLYESTER DYEING ROPE OPENING WHITE PERCH (LOT ARRANGEMENT) DRYING ON STENTER POLYESTER DYEING VISCOSE DYEING DYED PERCH ROPE OPENING COLOR FASTNESS TEST (QC) VISCOSE DYEING HYDRO EXTRACTOR DRYING PERCHING RF DRYER SWATCH PREPARATION AND SHADE CHECKING SHADE/ FASTNESS APPROVAL (QC) SHADE APROVL BY DSG/QC DELIVERY TO WARPING DELIVERY TO FSG FINAL SHADE APPROVAL IN FOLDING NIFT HYDERABAD Page 38 . 10. After completing of dyeing process the material comes out and goes to Hydro extractor for drying. NIFT HYDERABAD Page 39 .75 gm/cc. it is filled with required amount fibres and compressed with the stamping machine by applying of the water. The density of the package is less than general package due to the better penetration of the dye solution.4. After covering the basket with nylon fabric. According to the carrier capacity the number of cheese s are filled in the spindle. After this. After dyeing they are doing RC for removal of surface dye which are mechanically attached on the surface of the material After completing of dyeing process the material comes out and goes to cheese Hydro extractor(1360 rpm) for drying. The dye solution and other required chemicals come in to the m/c automatically after giving the instruction from the control room. It is then feed to the vertical dying machine by the help of Crain. For producing this cheese they are using wire spring. After this.3. After loading the material the lid of the m/c is closed automatically.35 to 0. . material goes to RF dryer for 100% drying. material goes to RF dryer for 100% drying. After dyeing they are doing RC for removal of surface dye which is mechanically attached on the surface of the material. 10. Density is 0. The dye solution and other required chemicals come in to the m/c automatically after giving the instruction from the control room. FIBER DYEING The fibres in the bale form brought from the RMG dept. Here only polyester fibres are dyed. These dried materials are going to PV department for further processing. After loading the basket the lid of the m/c is closed automatically. The prepared material is shifted to vertical dyeing machine for dyeing. CHEESE DYEING/YARN DYEING For cheese dyeing they are making special type of package in the winding section. These dried materials are going to warping section for further processing. 25 % concentration and they are kept in stock in the laboratory and as well as the chemicals in their respective concentrations too.10. form of the dyeing process and the delivery schedule of the order to other department. the dyeing process is carried out either by one bath process or by two bath process. NIFT HYDERABAD Page 40 . In the case of two-bath process. The laboratory is equipped with three beaker dyeing m/c and a colour matching cabinet. the fabric is heat set in the stenter and after dyeing in the jet. then from the previous records the recipe is taken out and then used. The general method of doing the production work starts from procuring the material from various departments as per the planning obtained from the PPD section and then planning for the dyeing schedules as per the weight of the material. Before dyeing. PIECE DYEING/FABRIC DYEING As far as the fabric dyeing is concerned.. then a new recipe is created from the old recipe that is available. If it is nearby to an old shade.e. If the sample is already dyed in the section before. For small lots & special shades. amount of the shade. they are opened from the rope form using the fabric opener and they are dried in the stenter again. The dyeing of polyester material is done on the basis of the high temperature and high pressure dyeing method whereas the wool/viscose dyeing is carried out on the basis of the conventional method. After planning all these things the sample is sent to the laboratory to predict the most appropriate recipe that can be used to obtain shade given. When the recipe is finalized. the polyester component is first dyed in the jet dyeing m/c and the wool/viscose component is dyed in the jigger dyeing m/c. The dyes are prepared with 0. the recipe is transformed to the shop floor for bulk production and the lab to bulk variation is maintained between a percentage range of 5 to 10. sample dyeing m/c is used. then the dyes used are of combination type i. the type of the shade. If the dyeing is carried out in the one bath process. The material handling inside the dyeing section is very less. either disperse and reactive combination or disperse and acid combination.5. since wool cannot withstand more than 115°C. For single bath dyeing of P/W blends. So a wool protecting agent is added. wool at 90°C and viscose at 60 to 70°C. the dyeing temperature of PET component is set at 120°C.The dyeing of PET is done at 130°C. Oil from pipe + blower from the motor fabric passing fabric drying NIFT HYDERABAD Page 41 . VISCOSE DYEING IN JIGGER Check DMF for heavy coloration NIFT HYDERABAD Page 42 . e. NIFT HYDERABAD Page 43 . All the dyeing machines are provided with two pipelines for the dosing of pipes and chemicals. AUTO COLOUR SERVICE SYSTEM MODELS The dyeing section is also equipped with a control room in which close monitoring of the dyeing process is done. Depending on the conditions and the requirements. DAP and DLV. all the dyeing machines (except jiggers) are connected to the control room through PLCs (Programmable Logic Controllers). Also by this system the liquor circulation. chemical and water is done automatically using a dye and chemical dosing system called Color System.The advantage of this system is that exact amount of dyes and chemicals are added into the dyeing machines with precision and control. pressure inside the dyeing machine and liquor level inside the machine is maintained. By this. The dyes and chemicals are stored in separate storage tanks and they are taken out as required using suction and then fed into the dyeing machine using compressed air.6. pH check. The color service consists of three dosing machines by names viz. TRS. various dyeing programs are made and stored in the control room. production is carried out in the dyeing section. or DAP or DLV will come into function and the required material is fed into the machine.10. The TRS is used for dosing dyes and DAP or Distribution of Anhydrous Product and DLV is used for dosing chemicals. the temperature. process alarms can be possible. i. shade to be dyed and the blend to be used and the quality of a fabric. In the dyeing section. the necessary program is selected and then assigned for a particular lot and then sent to the color service system. This PLCs are linked with the color service section or color dosing system so that whenever any addition of dye or chemical is done. the call off is sent to the color service and either TRS. A discipline of dosing liquids in one pipeline and powders through another pipeline is maintained. The dyeing programmers are made depending upon the substrates to be dyed. The dosing of dyes. In this way. 7. and after dyeing chemicals. dyeing chemicals. The required amount of chemicals is determined according to the weight of the dyes. It distributes three types of chemicals: pretreatment chemicals. DLV(Distribution of Liquor in Volume): The working of DLV. one is the doser which is used to collect the required amount of chemicals from the tanks through pipes and The second one is the distributor which sends these chemicals to the respective dyeing units. The coloring unit is equipped with sensors. The working of TRS. It is also connected to computer in which different programs are fed according to light. After that it is again send for collecting next programmed dyes.8. This is a color rating method and the machine computer linked with all other machines. Automatic color selection Pc1-start the machine wash the cloth Dissolving Unit NIFT HYDERABAD Pc2-color selection color to dye the cloth. In the first unit the dyes are dissolved properly and then it is transferred to the distributor through suction pipes from where it is distributed to the respective dyeing unit. When the program is fed into the computer the required quantity of dye is weighed and poured into the container. 10. This way cycle is repeated. DLV consists of two parts.DLV is used for distributing chemicals to the respective dyeing unit in liquid form.TRS consists of 72 tanks (each containing different dyes). Then the empty container is transferred to another unit where the container is washed properly. chemical to dyes distributor to all the machine Page 44 . medium. Then through the roller conveyors it travels to the first unit and remains until the last container has transferred to the second unit. TRS (Transfer of residual is into solution) is widely used in case of colors.10. dark and extra dark shades. MACHINES USED IN THE DIFFERENT TYPES OF DYEING: FIBRE / TOP / CHEESE DYEING MACHINE TYPE Fibre Stamping Top Press HTHP Dyeing BRAND Dalal Dalal Dalal. Removal of excess moisture from fibres. frame (equipped with chip reader) containing four samples are loaded. Parikh Strayfeild NO. 10.powder is weighed and mixed with hot water (60oC to 79oC) for 60secs to prepare 1g/lt of the solution. Then this dye solution is transferred to the sample pots (120 pots) and required quantity is pipette in the tube. Then in the super lab. sales department. The four sample prepared in this process is send to supplier. Then the solution is passed through it until the solution is discolored. industry itself and one is kept for testing purpose. To remove the excess dye. and Cheese. The micro. reduction cleaning is done. 34 OF OBJECTIVE Stamping of polyester staple fibre in carrier for dyeing.5 crores. tops.10. the solution absorbed by the fabric on the surface. SAMPLE DYEING UNIT The sample dyeing unit consists of automatic color and chemical dispensing machine made in in Italy.9. Wool Tops. Dyeing of Polyester staple fibres. Final Drying of all the fibre. Pressing of Polyester. top & cheese dyed material Hydro extractor R/F Dryer 6 3 NIFT HYDERABAD Page 45 . The program is fed and the machine starts automatically. Polyester Tops. MACHINES 1 4 Calico. Sample dyeing is mainly done to match the color with respect to the customer order or party order. The cost of the machine was 2.10. Wool tops in carrier. Reduction cleaning is achieved by using oxidizing agent. Sanjay D. This is a computerised automatic machine . cheeses. Used for washing of poly/wool & poly / viscose fabrics Drying of fabrics. On the same machine.disperse dyes. chrome or reactive dyes .temperature maintained is 100OC and pH value is 11.acid dyes.PIECE DYEING MACHINE TYPE Perching machine BRAND True shape No.disperse dyes + metal complex + color for the material. Overflow Soft Dalal flow Rapid Jet Rope opener Platter Jigger Calico Delta electrode Calico Harish 2 1 1 1 4 Stenter S.this dye is also known as Foro dyes. NIFT HYDERABAD Page 46 . Dyeing of samples for development. Dyeing of Poly / viscose blends. Temperature maintained is about 135oC.It is used for light shades.it is used in HTHP (high temperature and high pressure) dyeing machine. Reactive dyes.11. Following dyes are used for: All wool. and pH maintained is 4 to 5. lot are arranged for dyeing Mainly used for dyeing of poly / wool blends. Brazzoli33 & 34) are used for dyeing of poly/viscose blends. Some soft flow machines (e. 1 4 Sample Dyeing R. synthetics . Opening of poly / wool blends Opening of poly / viscose blends Used for dyeing of viscose with reactive dyes 2. Polywool.2. Forosol dyes. Polyester.metal complex and direct dyes. 1.M ltd. of machine 4 OBJECTIVE Inspection of white as well as dyed fabric for any abnormality. Machines electronic 10. trial purpose. NOTES Types of dyes are used: Disperse dyes. It is a mixture dye for P/W.B.g. which is most common for lighter fabric. Sanjay 4 3 pieces. A piece length which is dyed is 110 to 120m long. the polyester fabric is processed under high temperature (1300 C). Besides glauber salt. sodium hydrosulphite is also used in the dyeing.vat dyes.Polyviscose. these machines require 2 min to complete 1 cycle. soft-flow machine is used to avoid distortion of fibres. 20 and 25. Anti-cross staining agents are used to protect wool and polyester from each other.Overflow(1. Type of heating done in the Stenter machine is thermo pack heating of the fabric and perching.Rapid jet NIFT HYDERABAD Page 47 .Brazzoli 32 6 pieces. Before going through stentor machine. But rope opener is used for opening the polywool. fabric is passed through suction pipe. jet back.2). there is application of pressure for blowing heat.disperse +direct (Forosol for light and medium colors) and double bath (for dark colors).Brazzoli 32 4 pieces. HTHP machines runs with the high speed of 400 rpm. sometimes defects like moonmark is formed during heating. Wool protecting agent used is lavasyn. machine capacity: 8 pieces. Generally. In piece dyeing. the fabric is fixed with handle brushes at the selvedges. The storage tank for the salt has capacity 1000 kgs. plater is mostly used for opening the gathering of polyester viscose. for P/W it ranges between 18. In the machine. Viscose. it is having impurities in white powder called OLIVOMERS which are removed at high temperatures. The fabric width should be at least 150 cm. To avoid this . In rapid jet machine material and liquor both moves but in jigger machine only material moves and both edges of the material are stitched. the speed of stentor for drying P/V is in between 16 to 18 whereas. This machine requires 3 labor. The two rollers in the jigger dyeing machine runs at 20-40 m/sec For delicate materials. RECOMBING DEPARTMENT The Recombing department delivers recombed tops to PV and Worsted Spinning Departments in Chhindwara.11. MANAGER EXECUTIVE EXECUTIVE ASSISTANTS ASSISTANT ASSISTANT WORKMEN WORKMEN BLENDING WORKMEN PACKING & DESPATCH WORKMEN NIFT HYDERABAD Page 48 .1. DEPARTMENTAL HIERARCHY PLANT INCHARGE GM WORKS HOD (DY. The department is responsible for the conversion of the dyed and grey tops are to recombed tops. 11. The minimum cost meeting all quality parameters. MANAGER) PLANNING PRODUCTION MAINTENANCE ASST. Jalgaon & outside in full quantity at required time. 11.3. viscose. OBJECTIVES OF THE DEPARTMENT Blending of the fibers viz. Lenin. wool. polyester. and undesired elements like slubs. etc.2. neps. and pin point Removal of entanglement at the time of dyeing. PROCESS FLOW CHART NIFT HYDERABAD Page 49 . silk. 11. Removal of short fibers. PRE COMBING GILLING –3 NSC 2 To parallelize and homogeneous mixing of fibers. To apply antistatic oil and moistures in material. To make uniform length for proper blending BLENDING DEFELTER NSC 5 To blend polyester & wool component homogeneously in required composition. To prepare suitable material for feeding to combers NIFT HYDERABAD Page 50 . To apply antistatic oil in blend material. if required. LENGTHWISE DEFELTER NSC 4 To apply wool lubricating oil for smooth working in further process. which became very much felted after dyeing. To open and parallelize the material. PRE COMBING GILLING –1 NSC 4 To parallelize and homogeneous mixing of fibers PRE COMBING GILLING –2 NSC 4 To parallelize and homogeneous mixing of fibers.MACHINES BRAND NO. OF MACHINES OBJECTIVES To defelt the wool. neps.5. To parallelize and homogeneous mixing of fibers.GC 14 Make:-NSC Year: .1994 HP: .17.225 75 +/.4 Specification:-Chain gill box NIFT HYDERABAD Page 51 .4. foreign matters.1 NSC 4 To apply antistatic oil and moisture to material.5 11.4 20 200 . 14.13. PROCESS PARAMETERS FOR BLENDING DEFELTER (WHITE) Line A No of machine: 1 Model: -D-2GC 14 Make:-NSC Year: .02 Specification:-Chain gill box Type of materials Feed wrapping gm / m Doubling Total feed gm / m Draft given in De felter Funnel diameter in mm Delivery speed m / min Spray gm / m White 24 P + 25 W 5 Poly + 4 Wool 210 . leading & trailing hooks from the material POST COMBING GILLING .1994 HP: . pin points. blend composition and eveness % 11.1.220 1.2 .4. RECOMBING NSC 26 To remove short fibers. PROCESS PARAMETERS OF PRE COMB GILL 1 & 2 Model: . The fibers are checked for quality parameters like anti-static content . 45 200-225 200-250 34(17 x2) 11. These rollers have deferent speed. 10% Page 52 .700 mm.chain gill box Type of materials Dyed % of blend 55+45 Count in Nm 60/70 Delivery speed m / min 275 -300 Oil concentration 10 % NIFT HYDERABAD Dyed 65+35 32/48/56/60 275-300.Type of material Count (Nm) Feed wrapping gm /m Doubling Total feed in gm Draft Faller pins / cm Ratch in mm Delivery speed in m /min Pressure in kg Delivery wrap in gm / m White (GA1) 32/48/56/60/66/70/80 28 8 224 8 4R 42 – 45 200-225 200-250 28 White (GA2) 24/32/48/56/60/66/70 28 10 280 8.screw gill box It is same as gill box but before faller there is two drafting roller.7.6.NSC Model: .8.DUO TR GC-15 Make:-NSC Year:-2001 Specification: .1994 HP: . PROCESS PARAMETERS OF COMBER Model:-PB 33LF Make:-NSC Year: .2 4F 40 .D2GN 6 Year:-1994 Specification: . DYED SECTION (RC3) 11. PROCESS PARAMETERS FOR LENGTH WISE DEFELTER Make: . PROCESS PARAMETERS FOR BLENDER Model: . 11.23 Comber type : Rectilinear Can Diameter:. Due to this draft the materials which are felted at the time of dyeing are defelted.6. 1994 Specification: .10. PROCESS PARAMETERS FOR POST GILL Model:-GC-14 Make:-NSC Year: .Spray gm / m 70 70 11.1994 Type of materials Count in Nm Blend code % Blend Dyed 48 /56 360/365 65P . 20 20 8 6F 20 200-225 NIFT HYDERABAD Page 53 . 35w Dyed 60 /70 262/276/370&mix shade 55p.9.Chain gill box Feed wrapping in gm /m Out put wrapping in gm / m Doubling Faller pin density Funnel diameter in mm Delivery speed m /min. 25w 11. PROCESS PARAMETERS FOR COMBER Model:-PB 31LF Make:-NSC Year: . 45w Dyed 56/32/34 535/981 75p. Manager (1) Maintenance. DEPARTMENTAL HIERARCHY GM PLANT INCHARGE GM(Works) HOD (Manager) Manager Planning. P/V SPINNING Spinning is the process in which we can produce yarn from fiber . For white yarn formation white color viscose and polyester come from RMG Department. Page 54 .12. Dy. General Shift. Manager (1) Production. Manager ( 1 ) Asst. Workmen (skilled ) Workmen (skilled) Semiskilled. For colored yarn the dope dyed viscose fibers come from RMG department and colored polyester come from the dyeing department. Manager ) (1) Planning Clerk (1) Asst. (Dy.E. D.The raw material of this department are polyester and viscose fibers which are coming RMG Department or dyeing department. Dy. 12.1.O(2) Officer (1) Preparatory Spinning Section. Section NIFT HYDERABAD Post Spinning Section. Manager ( 2) Officer ( 7 ) Clerk ( 6) Shift. Quality. PROCESS FLOWCHART FOR P/V SPINNING 12. the raw material is coming from RMG /dying department to p/v spinning department in bale form.12. Lap feed with 6 cards c. Page 55 NIFT HYDERABAD . Chute feed with 4 cards b. This mixing is done manually. Lap feed with 4 cards There are two feed systems in blow room Chute feed Lap feed 1. Polyester and viscose layer mix according to their required percentage. then opening of polyester and viscose fibers are done. BLOW ROOM The blow room has three lines a. They add some oil for decreasing static charge and add binding agent among polyester fibers. Then conditioning i of polyester fibres is carried out for 24 hrs.2. Then they prepare the layers of polyester and viscose. Firstly. 2. 3.3. 12. In lap feed system different types of blends can for same blend of materials. But here if any m/c will show problem in blow or any m/c show some problem. In chute feed system all carding m/c will work 3. Here the production as compare to the chute is less. Then materials are fed to the 2nd MBO for mixing the P/V homogeneously and open the tuffs. then the next room then the stock laps can be use in carding m/c will remain stop. be done in different carding m/c. 4. So 4. variation in sliver is less. PASSAGE OF THE DRAW FRAME Creel Feed roller Draft roller Trumpet Coiler roller Can NIFT HYDERABAD Page 56 .7. COMPARISON BETWEEN LAP FEED & CHUTE FEED CHUTE FEED 1. In chute feed the production is more LAP FEED 1. m/c. Feed table 12.4.4. Here if we required maintenance of any m/c 2. PASSAGE OF MBO:Feed lattice PASSAGE OF CARDING:Incline lattice Evener roller Stripping roller Feed roller Tacker in Main cylinder Flats Doffer Can Coiler roller Callendar roller Trumpet 12. The materials which are coming from the 3rd MBO direct go to carding m/c as chute feed. But in LINE.6. Here the variation is more. 12. Then the materials go to the 3rd MBO for better cleaning and opening.2. Then the materials go to the scutcher for lap formation. 2. 3.5. In chute feed material feed is uniform. 9. The machine is equipped with Loepfe NIFT HYDERABAD Page 57 . The winding speed is around 600m/min giving cross-wound package.60 The main object of this auto coner is to prepare bigger package from smaller bobbin package and removes the yarn faults like thick and thin place and also week place.(16 X 480) + (2 x 144) = 7968 in PV section PASSAGE OF RING FRAME Creel Guide bar Back roller Middle roller Tradle box Bobbin Traveller Baloon braker Lapet eye Front roller 12. Spindle capacity: . AUTO CONER No of head: .8.10. The cops are steamed and then rewound on Autoconer 138 having 60 spindles.12. PASSAGE OF THE SPEED FRAME: Max head of the m/c – 120 Back roller Middle roller Drafting apron Creel Trumpet Bobbin Pressure foot RING FRAME Flayer Front roller 12.2 times the seed yarn. of 1. Air splicing is done here and usually the splice strength is 95% of the single yarn strength and the yarn dia. The machine runs between 8000-10500 rpm for twist ranging between 17-24 TPI. 12. The clearer curve setting is done so as to remove the objectionable faults.11. They are mounted with yarn clearer. Package from ply winding Winding roller Spindle Balloon breaker Guide Package Winding roller Travers guide Stop motion device NIFT HYDERABAD Page 58 . which can be achieved. The machine runs between 8000-10500 rpm for twist ranging between 17-24 TPI. The package produces weighs about 2 Kg each. Bobbin PASSAGE OF THE AUTO CONER Pre-cleaner Gate feeler Tensioner Waxing Package Winding drum Splicer Slub catcher Yarn trap The packages which are parallel wound in ply winding m/c are twisted on TFO. The winding speed. The department has three Autoconer winding machine similar to that with the PW department and one Muratec Mach Coner of 60 spindle capacities. 12. The machine has two splicer which traverses in between 10 spindles. which works on the photo electric principle. The yarn tension in Machconer is reduced by Balcon balloon breakers which adjust its position depending upon the position of the unwinding of the ring cop. is around 1200 m/min but here speed is kept around 800 m/min. Finally this wound yarn is send to New double yarn room from where it is send to weaving as per requirement.12. Finally this wound yarn is send to New double yarn room from where it is send to weaving as per requirement. It’s an automatic winder with individual spindle driving type performing one cycle of yarn joining in 9 seconds.yarn clearer. TFO (TWO FOR ONE) The packages which are parallel wound in ply winding m/c are twisted on TFO. 3 To convert the material into a uniform sheet called lap. ELGI WELKER steaming machine are there in the departments. Autolevelling CARDING Lakshmi 14 DRAWFRAME Lakshmi 9 (4 finisher 4 breaker 1auto leveler) NIFT HYDERABAD Page 59 . MACHINES 4 OF OBJECTIVES Opening of viscose & polyester. Opening of bigger lumps of viscose & polyester into smaller uniform lumps.13. & spraying of polyester. MIXING Lakshmi BLOW ROOM BATLIBOI.For setting the twist and preventing anti-snarling the yarn are steamed after every twist insertion stage. MACHINES MACHINES: BRAND NO. 12. hard chips from the material. Conditioning of viscose & polyester. To eliminate hard chips of fibers & foreign material. foreign matters. To feed properly opened & uniform material to the cards. Make the uniform material sheet into a sliver form To get uniform weight per unit length of the sliver To parallelize and attenuate the card sliver To get the uniform sliver by doubling the slivers. Individualization of the fibers Removal of short fibers. MORE ABOUT P/V SPINNING 1 TWO FOR TWIST To get the quality double yarn after insertion of proper twist. To wind ply yarn on cheeses (Bigger packages) To prevent anti. to get better quality of splice.. PRODUCTION : 4000 to 5500 kg per day WASTE PERCENTAGE: 7% to 8 NIFT HYDERABAD Page 60 .RING FRAME Lakshmi 24 22 x 480=10560 2 x 144=288 Total=10848 spindles To convert roving into a uniform yarn.14. To insert twist of required amount for different counts.snarling To set the twist Polyester viscose blend is a very cost effective blend. To make two ply yarn. To wind auto cleared yarn on ply tubes. Property of viscose is almost similar to that of cotton the blend improves functional property. To get the required count & evenness To eliminate yarn defects from the ring yarn. Spinning of 100% polyester is not possible (as no moisture is there) due to antistatic charge generated in polyester. To wind ring frame yarn onto cheeses (Bigger packages). AUTOCONER SCHLAFHORST 5 5 x 60= 300 drum ASSEMBLY WINDING PEASS METLER 5 and 2 x 84= 168 FADIS 2 x 120=240 1 x 36= 36 Total=444 spindles ONE PRERNA 17 STAR 15 x 130=1950 VOLKMANN 2 x 156=312 5 x 144=720 11 x 160=1760 Total=4742 spindles ELGI WELKER STEAMING MACHINE 12. 13. WORSTED SPINNING DEPARTMENT The main aim of the worsted spinning department is to deliver single /double yarn to Yarn room in full quantity at required time with minimum cost.2 General Shift Page 61 . Entry Clerk 3 x 3 per Shift Data Entry Operator . Manager Doubling Section Asst.Manager Prep. Manager (Doubling) Shift Officer Dy. Yarn Checker / Worker Shift Officer / Supervisor (Ring Frame T1 & T2) 3 x 1 per Shift NIFT HYDERABAD Fitter / Fitter Helper / Clg. Mgr.) Manager Asst.1. Gang Staff. DEPARTMENTAL HIERARCHY GM PLANT INCHARGE GM (Works) HOD (Sr. meeting all quality parameters.2 Warping / Planning G/Shift Dy. & Auto Dy. 13.Manager Ply & TFO R/F & Gen Dy. Yarn Checker / Worker Prodn. Manager Doubling 3 x 1 per Shift Fitter / D. Managers (2) Maintenance Section-in-charges Ring frame & Auto winding Shift Officer / Supervisor (Preparatory) 3 x 1 per Shift Shift Officer / Supervisor (Ring Frame T3 & Auto) 3 x 1 per Shift Fitter / S. 2.13. PROCESS FLOW FOR A & B LINE PROCESS FLOW Recombed tops from Recombing (To be taken for process only after the testing & approval of quality parameter against standard Norms) NIFT HYDERABAD Page 62 . FOR LINE C Additional passage for fine count material (56Nm and above), Single weft material and 100% wool materials. NIFT HYDERABAD Page 63 MACHINES Vertical Box (GV20): MAKE Gill NSC NUMBER 1 FUNCTION Additional passage for fine count material (56Nm and above), 24, 32Nm, Single weft material and 100% wool materials. To provide even draft distribution. To make uniform length in each can as per number of doubling for proper run out. To make Sliver even by means of doubling. To Produce wrapping (weight / unit length) as per requirement Rubber Finisher (FM5P): NSC 3 Additional passage for fine count material (56Nm and above), Single weft material and 100% wool materials. To provide even draft distribution. To make uniform length in each can as per number of doubling for proper run out. To make Sliver even by means of doubling. To Produce wrapping (weight / unit length) as per requirement Roving Machine Rubbing Machine NSC / 7 To produce wrapping (weight / unit length) as per requirement. To give required twist/rub to avoid stretch during unwinding in ring frame. To produce a package suitable for subsequent machine. To make uniform length in each package as per requirement of next machine for proper run-out. NIFT HYDERABAD Page 64 Ring frame TEXTOOL, COGNETEX 62 To produce single yarn of required twist and count as per the instruction from PPD. To produce good quality of yarn. To make ring cops by means of building mechanism. To impart dimensional stability to single yarn which will help in smooth and snarl free running of yarn on next machine i.e. Machconer To remove objectionable faults available in the yarn and splice the yarn properly after fault removal and bobbin change. To produce a fault free package suitable for subsequent machine. Machconer/ Padmatex Automatic Winders: MURATA, PADMATEX 9 Ply winding PEASS METTLER 5 To wind two single yarn of required shade and count ,as per the instruction from PPD department , parallel on a package suitable for subsequent machine Two For One PRERNA Twister 48 To twist the two parallel wounded yarn from the ply package as per the TPI (twist per inch) instructed by PPD. R.B. Double Yarn ELECTRONI-CS Steaming 3 To impart dimensional stability to double yarn which will help in smooth and snarl free running of yarn on next machine i.e. warping and weaving. Precision Propeller winder PEASS METTLER 1 To make soft package of double yarn suitable for cheese dyeing. NIFT HYDERABAD Page 65 Single weft material and 100% wool materials. VERTICAL GILL BOX (GV20) Additional passage for fine count material (56Nm and above). To make Sliver even by means of doubling. OBJECTS OF GILLING To parallelize and mixing of fibers.13. To apply wool lubricating oil if needed for smooth working in further process.4. Wrapping is around 6 gm/min. To make uniform length in each can as per number of doubling for proper run out. To make Sliver even by means of doubling. NIFT HYDERABAD Page 66 . To make uniform length in each can as per number of doubling for proper run out. GILLING To get the required parallelization and fineness we are generally 4 passage of gilling. Single weft material and 100% wool materials. To Produce wrapping (weight / unit length) as per requirement FALLER DENSITY GN series for normal fibers 6. 32Nm. To make Sliver even by means of doubling. 7. 24. 6. To provide even draft distribution. There are 3 lines each having 4 gilling machines. it’s doubling is 4*2=8. Its maximum speed is 400 m/min. To produce wrapping (weight / unit length) as per requirement. To make uniform length in each can as per number of doubling for proper run out.3. 7/cm 13. To Produce wrapping (weight / unit length) as per requirement NSC GV 20 It is vertical gilling machine. RUBBING FRAME Rubber Finisher (FM5P) Additional passage for fine count material (56Nm and above). This is 4-delivery machine. To provide even draft distribution. This machine has the main objective to reduce the wrapping of the material before being fed to the roving frame. For white material FM-5P is used in module C. FM-7N. The sliver is passed through the feed rollers and through the drafting system. Two roving are wound on a single package thus saving on creeling time and number of bobbins in use. FM-8N In case of rubbing frame.5. The finer material goes to the intermediate rubbing frame (FM-8N). These machines convert sliver to roving thus eliminating the need of a roving frame passage. Here the feed material is sliver and the delivered material is rubbing. Rubbing speed can be adjusted by changing the driving pulley in gearing end. The bottom apron is plain rubber rolling along a cast iron table. By drafting the material. TECHNICAL CHARACTERISTICS (FM 7N) Specifications 20 Characteristics Number of Drafting elements NIFT HYDERABAD Page 67 . it reduces the linear density of the gilled sliver and by twisting. As shown in the flowchart. They have higher drafting and higher production capacities than roving frames. it helps in the formation of suitable package for the subsequent process.6. from the rubbers the roving passes through a funnel is then wound on the bobbin. As the twist inserted in the roving material is done by the false twisting method. it facilitates the spinning of material.e. The pair of consolidated rovings is cross wound on to a double meche package which is then used to feed to spindles on the spinning frame. the strand remaining separate as they are consolidated and given cohesions by means of oscillating rubbing action of aprons. As the slubbing emerges from the nip of the rubbing rollers. 2 slivers are fed to each drafting head. This help in the production of finer counts. 13. Bi coiling mechanism saves on creel space on roving frame. A pair of fluted rubber aprons rubs the material. each of which runs on endless leather bands. 13. There are two rubbing frames used for production of coarse count material. FM-8N and FM-5P. as a lesser break draft is required during spinning. FM 5P Another rubbing frame of the make FM 5P is also used. the coarser material goes to rubbing frame (FM-7N) and directly goes to the ring frame. then goes to roving frame and then to the ring frame. It is done to reduce the bulkiness of roving. FM 7N Two ends are fed to the rubbing frame and these two individual ends are wound on the single package that reduces material handling.There are 3 types of rubbing frames in the spinning section i. Top apron is also of the same type and the fiber control is sit weighted. The functions of the simplex are twofold. Drafting part is of the double apron type. Roving frame (BM 14) The draft system of the BM 14 machine comprises of a pendulum arm carrying three balloon rollers controlling the fibers on a wide apron. Machine particulars BM15 64 8-12 Upto 50m/min 600-800rpm 24 tpm 5 ktex 0. expressed generally in turns per unit length. NIFT HYDERABAD Page 68 . Starting a BM 14 roving frame with material requires 3 essential settings: 1.8. To give required twist/rub to avoid stretch during unwinding in ring frame. 13.4 ktex Particulars No. Before fitting the twist change wheel the variator for the general speed of the machine is turned down.9. The flyer frame has overhanging flyers. Of spindles Draft range Delivery speed Flyer speed Twist range Sliver weight at feeding Deliver hank 13. To make uniform length in each package as per requirement of next machine for proper run-out. To produce a package suitable for subsequent machine. both the flyers and spindles being driven by groups of toothed belts. ROVING FRAME Roving Machine / Rubbing Machine To produce wrapping (weight / unit length) as per requirement.25-1 gm/ m 5 – 36 70 mm 300 125 m/ min 1100 rubs/ min 13.Ends/drafting element Maximum input/ end Maximum delivery weight Draft Range Tube diameter Bobbin Diameter Delivery speed Rubbing speed 2 15.7.9 gm/m 0. Suction device present beneath the drafting roller and device for periodical lifting up of the scrapers on the pressure rollers. The twist. 3. the drafting system comprising of tension between creel and feed rollers.5 to 0. The objectives of the ring frame are as follows: To produce single yarn of required twist and count as per the instruction from PPD. increase of diameter of the bobbin after each layer and the angle of terminal coming from the bobbin.36 15 to 18 g/m 1. TECHNICAL CHARACTERISTICS (BM 14) Draft range Sliver weight at feeding Sliver weight at delivery Twist range Maximum delivery speed 3.6 . RING FRAME The rubbing and roving frame bobbins are brought to ring frame dept. the roving is converted into yarn by drafting and twisting. Building up of the bobbin comprising of pitch of the coil.2.10.25 g/m 9. predraft or tension between feed rollers and draft aprons and draft ratio or speed ratio between draft aprons and front rollers. To make ring cops by means of building mechanism. Textool 3/3 Top arm 35 9000 5 – 45 245 50 – 60 47 51 75 15 – 35 30 40mm Machine parts Drafting arrangement Drafting angle (o) Spindle rpm (maximum) Twist range (TPI) Bobbin lift (mm) Chase length (mm) Bobbin diameter (mm) Ring diameter (mm) Working efficiency Draft range No of machine Roller diameter NIFT HYDERABAD Page 69 .2 to 100 tpm 100m/min 13. To produce good quality of yarn. DOUBLE YARN STEAMING To impart dimensional stability to double yarn which will help in smooth and snarl free running of yarn on next machine i.13. PLY WINDING To wind two single yarn of required shade and count .11. Machconer. OTHER IMPORTANT POINTS Spindle oil used in ring frames is SPIN 12 Ring oil: SPIN 12 + SOLUMOL ALL (Emulsifier) SINGLE YARN STEAMING To impart dimensional stability to single yarn which will help in smooth and snarl free running of yarn on next machine i. To produce a fault free package suitable for subsequent machine. NIFT HYDERABAD Page 70 . Warping and weaving.e.as per the instruction from PPD department . PRECISION PROPELLER WINDER To make soft package of double yarn suitable for cheese dyeing. parallel on a package suitable for subsequent machine i. MACHCONER/PADMATEX AUTOMATIC WINDERS To remove objectionable faults available in the yarn and splice the yarn properly after fault removal and bobbin change.e.e for TFO. TWO FOR ONE TWISTER To twist the two parallel wounded yarn from the ply package as per the TPI (twist per inch) instructed by PPD. To make uniform length in each can as per number of doubling for proper run out. Ring frame TEXTOOL. To provide even draft distribution. To produce good quality of yarn. Single weft material and 100% wool materials. To make Sliver even by means of doubling.Vertical Gill NSC Box (GV20): 1 Additional passage for fine count material (56Nm and above). To produce a package suitable for subsequent machine. 24. To give required twist/rub to avoid stretch during unwinding in ring frame. To make uniform length in each can as per number of doubling for proper run out. 32Nm. To provide even draft distribution. To impart dimensional stability to single yarn which will help in smooth and snarl Page 71 NIFT HYDERABAD . To Produce wrapping (weight / unit length) as per requirement Roving Machine Rubbing Machine NSC / 7 To produce wrapping (weight / unit length) as per requirement. To make Sliver even by means of doubling. COGNETEX 62 To produce single yarn of required twist and count as per the instruction from PPD. To Produce wrapping (weight / unit length) as per requirement Rubber Finisher (FM5P): NSC 3 Additional passage for fine count material (56Nm and above). To make uniform length in each package as per requirement of next machine for proper run-out. Single weft material and 100% wool materials. To make ring cops by means of building mechanism. Double Yarn ELECTRONI-CS Steaming 3 To impart dimensional stability to double yarn which will help in smooth and snarl free running of yarn on next machine i. To produce a fault free package suitable for subsequent machine. PADMATEX 9 To remove objectionable faults available in the yarn and splice the yarn properly after fault removal and bobbin change. parallel on a package suitable for subsequent machine Two For One PRERNA Twister 48 To twist the two parallel wounded yarn from the ply package as per the TPI (twist per inch) instructed by PPD.free running of yarn on next machine i.e. R.as per the instruction from PPD department . Ply winding PEASS METTLER 5 To wind two single yarn of required shade and count .e. Precision Propeller winder PEASS METTLER 1 To make soft package of double yarn suitable for cheese dyeing.B. NIFT HYDERABAD Page 72 . Machconer Machconer/ Padmatex Automatic Winders: MURATA. warping and weaving. 14.1. WEAVING Weaving is the term used in relation to produce fabric by interlacing two different series of yarns known as warp & weft. DEPARTMENTAL HIERARCHY GM (PLANT IN CHARGE) GM (WORKS) DGM .WEAVING MANAGER WEAVING SULZER & GP MANAGER – WEAVING NP PRODUCTION PLANNING MAINTENANCE PREPARATORY LOOM SHED PREPARATORY LOOM SHED DY. MANAGER OFFICER FITTER OFFICER OFFICER ASSISTANT FITTER NIFT HYDERABAD Page 73 . MANAGER DY. Warp ends are placed longitudinally whereas wefts are horizontally placed. 14. MANAGER ASST. MANAGER DY. MANAGER ASST. Weaving process is commenced by dividing warp into two different sheets in opposite direction & then inserting weft into the shed. By interlacing it into the shed fabric is produced. shade variation. The yarns must be parallel and under uniform tension. which are numbered. all of the yarns forming are presented in the sheet form. oil marks. Only the correct yarn is given entry in the yarn room according to the correct shade number. The humidity in the yarn room is the same as in TFO twister. They are then creeled according to the warp pattern.3.with the help of UV rays. lot number etc. In the fabric forming system. weaving WARPING The yarns which are coming from double yarn room are going for winding for preparing required amount of package. It is therefore necessary to remove or unwind the yarns from the winding package and arrange the desired number of ends in a sheet form & wind it on package under controlled tension on a package called a beam. YARN ROOM The weaving activities start from yarn room. the yarn from the spinning department comes to the yarn room. After twisting & steaming. In our plant we are having two Yarn Rooms called as Old Double Yarn Room and New Double Yarn Room. Checking of stains. the PPD department and yarn room in charge checks the yarn particulars. After delivering the yarn. 14. The yarn cheeses are kept on trolleys and the material from trolleys is kept in a particular bin. NIFT HYDERABAD Page 74 . contaminants etc.2. The yarn is weighed and its particulars are entered into the computer with specified quantity. warping 2. WARPING The yarns which are coming from DOUBLE YARN ROOM are going for winding for preparing required amount of package. Old DYR is for PV blend yarn and New DYR is for PW blend yarns The yarn cheeses are transported by means of trolleys. Along with the shade the twist of the yarn should be checked. Precaution required to be taken Correct shade of yarn should be issued to the warping as well as weaving dept.Weaving department is divided into two sections1. After spinning and doubling the yarn. remaining yarn is brought back to the yarn room. 14. The main object of warping is to produce a warp sheet according to the warp pattern and the formation of warp beam. The main object of the warping is to produce the warp sheet according to the warp pattern and formation of warp beam. Then they are then creeled according to the warp pattern. TENSIONING DEVICES Tensioners should be capable of fulfilling the following requirements. Even tension of the ends within the yarn sheet. BRAKE: The warpers must be provided with a break to stop the machine immediately wherever an end breaks or when pre determined length of yarn has been wound on to the beams. MEASURING MOTION: Warpers are equipped with a measuring motion to measure the length of yarn wound on to the beam and to stop it as soon as the pre determined length of yarn has been wound. The maximum capacity ranges from 300 packages to 1400 packages. & tensioning devices. of ends are collected together & wind it onto a beam called as a warpers beam. BEAM WARPING Beam warping is simply the winding of yarns directly from the supply packages onto a beam. Creels are equipped with package holders on which the supply package are placed . This is necessary otherwise it would be difficult to locate the broken end.the no.TYPES OF WARPING 1. guides to direct the yarn and to help keep the ends apart and stop motion to detect broken ends and or empty packages. 3. Wide tension range. This is done to stop the warping before the broken ends are buried in the beam. 1. BEAM WARPING SECTIONAL WARPING 14. depending upon the creel capacity . thread stop motion.4.the creel is having smooth porcelain guides. Creels are either single or multiple package creels.tension devices to help maintain uniform tension throughout the creel. 2. 2. NIFT HYDERABAD Page 75 . In Benninger & Gamatex maximum creel capacity is 480. IMPORTANT PARTS CREEL: A frame to hold the package is known as creel.In a beam warping. Its function is to hold the packages in a manner so as to facilitate warping. Quick threading THREAD STOP MOTION: The thread stop motion is fitted on the creel though the machine is fitted with an efficient break. BEAMING After sectional warping they prepare the Weaver’s beam from the warp sheet.the warp sheet is then wound on the warpers beam. NIFT HYDERABAD Page 76 .this separate all the odd & even ends SECTION REED The section reed consist of umber of dents which corresponds to the required number of ends per cm. according to the design.5. 14. of ends on drum. to accumulate required no. Waxing is done to prevent the static charge generation. The yarns which are coming from DOUBLE YARN ROOM are going for winding for preparing required amount of package. To collect all the warped ends from drum and to facilitate to wind them in a beam. In sectional warping.e. OBJECTIVE With the help of the creel.DOFFING MECHANISM: The warpers beam is too heavy. therefore a warping machine must be provided with a mechanism to place the full beam on the floor or on the trolley. LEASE REED The reed is very deep & alternate dents soldered. the ends are drawn through one in dent. as all the yarns are doubled and have got a good abrasion resistance and are strong sufficiently. for smooth running of the loom and less fly and fluff generation. For good abrasion resistance. The ends wound on section drum in required length . To facilitate to insert lease in the warp sheet with the help of the leasing reed so as to keep all the warp ends intact in their sequential position. sizing operation is omitted. SECTIONAL WARPING The main object of the warping is to produce the warp sheet according to the warp pattern and formation of warp beam. Warping faults Yarn cone of wrong size. in the fabric. wax is applied during warping. the warp threads are wound on the warping drum sectionally. To apply requisite amount of wax coating on the warp ends during beaming to reduce hairiness of the yarn and thus producing a weaver’s beam. beam contain some different colours of yarn then sectional warping is used. section by section. Sectional warping is done when one needs to produce some design i. In Raymond. After winding on drum it is then taken on weavers beam. Then they are then creeled according to the warp pattern. Passing the warp threads through the close drop wires (warp stop motion). 3. Count mix during creeling. This is affected by passing the warp yarn through the dents of the reed of appropriate count so that the cloth woven from the warp may contain the required number of threads. The heald shafts and reed are held on separate brackets. Reed Count 8. The operative opens knots on the warp section and then the yarn is passed through 2 lease rods and then through drop wires. Reed Count 5. The beam is brought on a trolley and placed at the bottom of the frame. At a time 500lit. Warping reed Wrong built of cone Tension variation during warping. There are three different count reeds used for different yarn count. 1. One operative is called the ‘reacher’ and the other is called the ‘drawer’ who sits in front of the frame. At the start.69% For 2/24 to2/48 waxing is not done as yarn itself has enough abrasion resistance. For good abrasion resistance. 14. Broken ends improperly repairs.06 – for 2/48 to 2/56Nm. heald wires and the dents of the reed are carried out by a process known as “Drawing In”. The operation of drawing in is carried out in the following manner. solution is done at a time ia solution tank.7. Manual Drawing In The process is carried out on an upright frame. Waxing recipe Cirosol TF :-19% Poly Ethelene Glycol :-12% H2O :. DRAWING IN In weaving.0 – for 2/24 to 2/48Nm 2. for smooth running of the loom and less fly and fluff generation. the reacher takes a bunch NIFT HYDERABAD Page 77 . it is necessary to space the warp threads properly in order to get the required compactness of the cloth.6. Waxing is done to prevent the static charge generation. Reed Count 6. wax is applied during warping.33 – for 2/56 and above Nm. heald frames and reed. Waxing 14. ITALY Super Vega 2400 2005 70ends/min 80ends/min 4 beams/shift Some of the special features of this machine are as follows: Automatic computer controlled drawing in of single beam warps. Automatic heald wire separation from magazine and its distribution. By this the yarn is inserted in to the drop pin and heald eye.000 ends per shift. By this time. Drawing in the ends in the yarn tensioner. But from year 2004 the Raymond Ltd. the speed is around 5000 ends per shift. The capacity of this machine is to draw a staggering 25. Here they are using one yarn package. Chhindwara introduces a new “Automatic Healding M/C” made in Italy. For manual drawing-in. NIFT HYDERABAD Page 78 . yarn guide and yarn stop motion – when drawing the ends in the yarn tensioner. Automatic Drawing In Raymond has one of the latest of its kind of drawing in machine the SUPER VEGA. yarn guide and yarn stop motion.in machine ELM SPA. Automatic Drawing In Machine: Make Model Year Speed Max speed Frequency SUPER VEGA Automatic Drawing. the drawer inserts the hook through the corresponding heald eyes. straightens them up and selects the yarn one by one from one extreme end of the loom beam in the proper sequence. we always have to start with the nearest end in the uppermost tiers. for drawing in work. Special incentives are given to those who cross a particular limit when it comes to extra number of threads drawn in. After drawing there is a cutter which cut the yarn at the package.of warp threads in his hand. i.e. Again the gripper goes through the heald eye and drop pin for next drawing. Up to 80 drawing in operations per min. on the side of the reacher the latter will insert the appropriate end in the eye of the hook which will be immediately drawn on the other side by the drawer. At the extreme end of one heald as soon as the hook reaches the other side. After complete the required amount of drawing they are joining each end with required beam. One gripper is there which inserted in to the one heald eye as well as one drop pin and collect yarn from package and again come back through drop pin and heald eye. According to the program one deflector guide is there which guide the heald to go the respective heald shaft according to the design. According to the design they are feeding program to the computer. This m/c is drawing the yarn in to the heald automatically. Knotting on Loom NIFT HYDERABAD Page 79 .8 Knotting Machines M/C Max Speed Total No. two warp sheets of different colors but having same design/pattern. Beaming Speed Beninger Warping M/c Benninger Switzerland EROGOTRONIC 2000 800 200 Warping 600 Beaming 90 14. heald wire. Warping Speed Max. Automatic reed. Speed Prashant Gamatex Prashant India GE405 1996 Gamatex M/C No. Automatic drop wire separation and distribution also. drops pin transport. peg plan feed in the computer and it will take care of drawing 4-5 times production is more than manual drawing.3 Make Model Year Max. Operation Make a set of frames The beam should be knotted first Draft. Knotting on warping M/c 2. Speed Max. M/C No. of M/C Staubli Topmatic 350 Knots per Min 3 Automatic Knotting M/c:In case for knotting.1 Make Model Year Max. This is done at two places 1. Here the control over the weft is positive during the whole pick insertion cycle. made of metal or plastic tapes. which includes 34 Picanol Gamma. rigid. flexible free flight.9. The total output of this department is 23000 meters per day. telescopic and two phased. There are many varieties of Rapier systems such as single. WEAVING MACHINES There are total 112 looms. The weavers can repair the fault while the machine is running and reactivate the unit that has been stopped.14. The machines are running with speed of in between 450 – 530 rpm. 56 Nuovo Pignone (NP) and 22 Picanol Gammax looms. hence the name Rapier Weaving. The Rigid rapiers that include telescopic type remain suspended from the fulcrum and may get help from right upper warp sheet. Automatic package switching device prevents the machine from being stopped in the even weft break between the package and weft feed. FEATURES OF RAPIER WEAVING MACHINE Electronically controlled weft tensioner reduces the yarn tension especially during insertion. Grippers are redesigned to ensure better clamping of the yarn and prevent rubbing against the warp yarns. NIFT HYDERABAD Page 80 . The weaving department has only one loom type “ rapier”. flexible guided hooks ( one guide roller between which ribbon passes to pick warp). The rapier may be also be of the rigid rod type or flexible. A Rapier in its simplest form consists of a single rigid bar. flexible. solid or telescopic and a damp device called gripper head screwed at its feed end. Flexible tapes invariably need guide meters inside the shed that emerge during the pick insertion and sink back into the sley before beat-up.8. RAPIER WEAVING In Rapier looms. double. Electronically controlled warp let-off and cloth take up units ensure a high degree of fabric regularity and prevents all kinds of start and stop marks. Rapier loom types are as follows: flexible rapier. the weft insertion element resembles a rapier or a thin bladed straight sword. 14. Both these looms have provision for multi-colour weft insertion. Both these looms are adapted to Quick style change. all wool.11 PICANOL AND NUOVO PIGNONE LOOMS Picanol and NP loom works on Flexible Rapier principle of Tip transfer. poly-wool. NIFT HYDERABAD Page 81 . The weft insertion rate for Picanol is around 800mpm while of NP loom is around 600mpm with maximum working width of 190cm and 220 cm for Gamax. Electronic monitoring control systems have simplified the communication with the machine and facilitated its easy handling by anyone concerned with the operation of the machine. poly-viscose . Both these loom have tuck-in selvedge. Grosse electronic Jacquard controls the name selvedge with 40-hook capacity. 3/3 3. Here usually four are used. while in dobby machine. Twill – 2/1. Satin = 5-end satin . Both these looms have an electronic let-off motion for constant warp tension regulation and auto take-up setting mechanism. Weft insertion is through yarn accumulator for a controlled weft insertion.bamboo fiber Efficiency = 84% Average rpm = 400 rpm Safety measures are : photo sensors on warping machine and ear plugs. Attachments for jacquard machine is main selvedge. Hopesack (double plain) 6. 14. 14. lycra . 2/2. 4-end satin (warp face) 4. it is shedding mechanism. The weaver beam capacity for these looms is 500 Kg. Herringbone (broken twill) 5. FACTS AND STATISTICS output -23000 mts/day The machines are running with speed of in between 450 – 530 rpm. which is necessary with shorter lots as practiced here. Plain 2. 3/1. Basket weave (fancy weave) Types of fabric = linen.silk fabric . Fabric design 1. which eliminates change of pick wheel. The usual heald shafts are controlled by Staubli electronic dobby having a maximum capacity of 18 shafts.12. Out of eight flat looms 4 – Auto furnishing over seat-covers 1 – Suiting’s (Sherwini’s) 2 – Home furnishing 1 – Sampling NIFT HYDERABAD Page 82 . Out of 6 jacquard looms.Jacquard looms. Out of 11 plush looms. automotive furnishing. For producing this 6 Jacquard and 5 dobby m/cs are used. PLUSH WEAVING Plush is a special type of fabric weaving by which we can produce piled fabric. For dobby m/cs two type of warp piled fabric. The warp piled fabric is called as velvet and weft piled fabric is known as velveteen.13. aviation etc The department has 11 looms for plush weaving and 8 looms as flat looms. only 3 are engaged in carpets while rests three are used in making other things. The main purpose of the plush department is to produce furnishing fabric for automobile industries as well as for interior decoration.Dobby 6 . In Raymond ltd. they are producing warp piled fabric.House. carpets (middle weight). Designing studio creates and selects the designs for furnishing fabrics which includes home furnishing. bed-ups.14. 5 . other than the polyester yarns which are supplied In. Plush department has two sub departments: Weaving Finishing Most of the yarns used for the manufactured of the plush fabrics are outsourced. For fancy yarns counts are chosen as per appearance and textures. For plush fabric P/V – base fabric P/acrylic – pile fabric In flat furnishing 100 % polyester is used while in aviation. In auto furnishing.14 Yarns used For plush dobby: 2/40 Nm For pile : 2/35 Nm For plush J/Q : 2/50 Nm for round and 2/30 Nm for pile. 14. foam and screen. In warp yarns.90/10 is non-washable but 65/35 is washable. 750 D For home furnishing. 600 D. NIFT HYDERABAD Page 83 . In aviation. For flat auto furnishing: 360 D. 100% polyester is used since aviation fabrics require warm feeling fabrics. One should be careful in selecting fibers for pile fabrics.5 Nm. the screen is laminated with foam and then screen with fabric. Firstly. viscose blends are used. Pile length = 4 – 8 mm Efficiency of the plush weaving = 51% Bundle requirement=4-5 shift Replacement of all the yarns = 2-3 shift 14.14. it is not possible. YARN SUPPLIERS FOR PLUSH DEPARTMENT Banswara Grasim RSM mill) (Rajasthan Acrylic/polyester cotton Polyester/viscose spinning 2/30& 2/24 Ne dyed. Pile should have soft feel. 150 D polyester is used. 2/24&2/30 grey. 5 Nm are in use. which is given by acrylic and its blends. Screen can be woven or knitted (warp knitted or circular knitted). From wool. wool/nylon 90/10 blend as well as poly wool 65/35. chenille yarns of counts 3. OEM (own equipment manufacturer) is used – fabric. Sometimes. There are 4736 harness for pile fabric and 4680 harness for carpet. Priyadarsini mill (Coimbatur).16. Here they are using maximum four colors for designed. 4 shaft for selvedge and 4 for main body. There are eight shafts for ground weave. Jacquard designs are complicated . Jalgaon etc. Shadow Jacquard Auto Jacquard Semi Jacquard Made ups/ runner Flat auto Jacquard Chenille 14. 2/20 Ne cotton cotton cotton 14. Here each end is controlled by electronic jacquard. JACQUARD In jacquard m/c carpet fabric and designed pile fabric are produced. Production of jacquard (plush) = 150/day Materials used For ground – P/V blend yarn For pile . before preparing their own fabric they are rewinding NIFT HYDERABAD Page 84 . The machine runs at 200 rpm.and finally it becomes 165 cm. The fabric when on loon is of 180 cm width. Raymond Ltd. BRAND NAMES La crème La mode Electra Fusion Decora Sparkle Designo Home Jacquard.15.PSM Ventura Jayashree cotton mill Gokak mills 100% polyester. RSWM. it has creels.Poly/ acrylic 60/40 for carpet & acrylic 100% for other fabric For weft – Cotton yarn of 6 s Ne Generally the yarns are coming from Bansuwara Syntax. Malwa industry (Ludhiyana). Of m/c 1 1 1 2 1 1 1 1989 1996 1996 1 1 1 J/q& loom J/q &loom J/q &loom NIFT HYDERABAD Page 85 .A 1996 2006 1996 No. 9. The fabric width is 1. 8. 1. The design area is limited. It has beam.METLER PSA OTT PRASHANT GAMATEX BENNINGER. 2. 6.A RECO SA DA PF2000E GE405 BENTRONIC MPS32 EJP2 VMM32 EJP2 VMM32 EJP2 Make TODO STAFI STAFI N.V. Description of machine Knotting m/c Perching m/c Perching m/c Mending Winding m/c Winding m/c Warping m/c Warping m/c Model HL-210 STAFI STAFI N.18. 7. 3.V. M. They are also using sectional warping m/c to prepare the ground warp beam for all Jacquard.W GROSSE M. DOBBY The dobby machine has shafts through which yarn passes. These are used on creel for Jacquard m/c.W GROSSE M. 5. 1.V. Dobby and also design beam for Dobby. No. 2. Production of dobby ( plush)= 225m/day 14. 14.17. DEPARTMENT PLUSH-WEAVING Sr.the yarn in the cheese form.W GROSSE Year 1996 1980 1979 N. 4. The machine runs at 240 rpm.5 meter.A PS. as simple geometric shapes can be weaved. 10. 11. 12. J/q &loom J/q &loom J/q &loom VMM32 EJP2 VMM32 EJP2 MPS32 M.V.W GROSSE M.V.W GROSSE M.V.W GROSSE 1996 1996 1989 1 1 1 EJP2 13. Dobby loom VMM22 M.V.W 14. Dobby loom VMM22 M.V.W 15. Dobby loom MPS22 M.V.W 1989 1 1996 1 1996 1 NIFT HYDERABAD Page 86 15. FINISHING Finishing is the final process of preparation of the fabric. Finishing processes are carried out to improve the natural properties of the fabric. Its primary objective is to enhance the quality of the cloth, imparting the woven fabric a specific appearance, handle in order to make it attractive, the aesthetic appeal and its serviceability. The finishing department receives the fabric either from mending department or from the fabric-dyeing department. The processes of the finishing treatment differs according to the blends, shades etc. Finishing department in Raymond is divided into 3 sections viz. grey room, wet section and dry section. 15.1. GREY ROOM This section is called grey room because all the grey material from the weaving department after perching and mending is being sent to grey room. Here all the pieces are sorted according to weaving machine number. 15.2. WET SECTION This section is known as wet finish section because all the treatments that are carried out on the material are in wet form that includes Batching, Pre-scouring, Heat set, Shearing, Singeing, Wetting, Solvent scouring, Rope scouring, Squeezing, Drying. 15.3. DRY SECTION This section is called the dry finish section as here the fabric is treated in dry form throughout. Only mechanical operations are rendered to the fabric in order to enhance its look, shine and feel. This NIFT HYDERABAD Page 87 treatment is generally under the influence of pressure and steam which includes Damping, Nikki press, Dolphin-Contipress, Stabila (antishrink), TMT (kier decatising) and Super finish (open decatising). 15.4. Process flow chart of the Finishing Department (wet section) P/W piece dyed P/W top dyed NIFT HYDERABAD Page 88 SCOURING : Scouring is a process essentially carried out for each and every fabric in the finishing department aimed at removing all sorts of oils. impurities and waxes from the fabric as well as the oil marks in the selvedge of the fabric. fatty acids. Definitions (wet section): BATCHING: It is the process of matching or shade sorting each beam of fabric to make a bigger batch from the individual smaller ones.P/V fiber dyed P/V piece dyed 15.5. NIFT HYDERABAD Page 89 . There are two types of scouring machine viz. marks on the body of the fabric. greasy matters and other unwanted foreign materials on it. drying and resin treatment. Before passing the fabric through the heating chamber. SINGEING: In singeing. Suction is provided for extracting the moisture. For heat setting. STENTER :The stenter can be used for heat setting. So it comes to rope opener for the opening and washing purpose. If the fabric requires resin treatment then resin is applied thorough padding mangle. This operation helps in maintaining the width of the fabric. After rescouring the yarns in the fabric swells resulting in the opening of twist in the yarn thus increasing the surface fibres. A fan does the function of blowing the heat of radiators on the fabric passing through these chambers. Shearing is the most important process in the dry finishing department. It comprises of five chambers and each chamber is provided with heated radiators and two blower fans. Before the heat setting is carried out by stentering an operation called as bowing is carried out. the same oil is continuously circulated in these radiators. These radiators are heated with continuously circulating heated oils through it. NIFT HYDERABAD Page 90 . This process makes further process very easier and imparts goods sharpness on the surface. the fabric is perfectly opened out and passed on direct flame of fully combusted flue at a very high speed while the height of the flame can be adjusted as per the quality of the material to avoid the damage to the fabric by burning the protruding fibres. the fabric is in the wet condition and in rope form. open width scouring machine and rope scouring machine ROPE OPENER: After rope scouring. the fabric is passed over water cooled guide rollers for avoiding any damage to the fabric. At the time of contact between the flame and the fabric. Thus. it is around 140ºC. the temperature of the chamber is kept about 185ºC and for drying. it is passed through a tank containing water and softener. Pins on the conveyor grip the fabric properly before entering into the chamber. SHEARING: The object of shearing is to remove protruding fibres from the cloth surface and to even out or level the fibre or neps that has been previously rose. Heated oil enters at one end of radiator and goes back for reheating from the other end. 10 coils heat the drying chamber. The solution used for this is water and Sandozin MRN (wetting agent. NIFT HYDERABAD Page 91 . In this process. 15. which can cause complete evaporation of the water particles from the fabric. Before pressing it is very important for the fabric to have sufficient amount of water to give better finish. In all pressings. moisture is artificially given to the fabric by evenly spraying water under certain pressure thus giving the required amount of moisture to the fabric.7. Definations (dry section): DAMPING: Damping is the operation carried out before pressing and decatising. WETTING: it is a process used to remove the dust and ash particles formed during the singeing process and to improve the absorbency of fabric by using wetting agent. temperature goes above 100oC. Process flow chart of the Finishing Department (dry section) P/W piece dyed P/V (piece & fiber dyed) P/W top dyed 15.2g/l).6. Therefore it becomes necessary to remove the excess tension of the fabric. This is done by passing the fabric over the conveyor belt through saturated steam and hot air pressure. RELAXATION: The main objective of this process is to minimize the process shrinkage. Many times the finishing operation disturbs the surface of the yarn and the fabric. In the case of kier decatising(K. At the same time dry air is blown through perforated conveyor and fabric. The WEKO humidifier situated immediately upstream of actual press unit. This overall process gives relaxation to the fabric and minimizes the process shrinkage which reduces shrinkage after finishing. as well as to prepare for pressing and cutting. Here temperature. The conveyor is subjected to vibration through vibrator roller. DECATISING: The object of decatising is merely to remove excessive lusture. pressure and steam are maintained according to the quality of the fabric. to prevent irregularities on the moist side of the moistened fabric to ensure uniform moisture application adjustments. and the thin papery handle from previous processes. decatising process also occurs in this machine. The tunnel temperature is maintained at 1050C to 1100C.D). In Raymond.D are more permanent. Therefore. PRESSING: The aim of pressing is to make the fabric smoother by subjecting it to the strong compression against polished and heated rollers. Objective of pressing are aesthetic and partly commercial. SUPER FINISH: This machine is used to give special type of shine and lusture to the fabric. Fabric is pressurized through the steam of 3. NIFT HYDERABAD Page 92 . The fabric fed to the pressing unit is passed dry or moist at high temperature between the mirror bright chromated effect roller and the rubber coated surface of the guide belt under high belt tension wherein actual setting and pressing takes place. no pressure is applied and only steam is passed through the drums. The results obtained from K. mainly cohesive setting treatment. Due to various finishing processes the fabric gets stretched in lengthwise and widthwise. pressure is applied to the material along with steam while in the case of open decatising. The unevenness and the impurities cannot be reduced till it is blown and pressed. There are two types of decatising: open and kier. Pressing can be considered as mild.5kg pressure. pressing is carried out on Nikki press machine. 8.reverse to fabric. Hemmer. Zonco(Italy). Oxalic acid. Serracant. etc.80-100 mt/min 100 liter – H2O 2 gpl – Sandozin MRN (wetting agent) Shearing m/c 3 Lafer Italy Model :-CMI2(1996). brush direction. speed-16mt/min.Ascodet ECN. Dhall (Ahmadabad) Detergent. pH-7. Dolly.15. fabric remains inside for 60 min NIFT HYDERABAD Page 93 .25mt/min. NAME Machine details: NO. speed-22mt/min.VP-97 (1998) Wetting m/c 1 ------------------------ Rope scouring m/c 11 MAT SPA (Italy). Baysolux. Burner distance-10-12mm.PPM/076 FEATURES Max 700 to 800 meters per lot Batangas Batchmaking m/C Open width washing m/c Jigger m/c 1 Dhall Ahemadabad For pre-scouring. OF M/C 4 MODEL Calico (Bombay) Type: . flame intensity. softnerSarasoft 485 . speed. Singeing m/c 2 osthoff – senge (germany) Model: .5 3 JT10 For pre-scouring. 4 brushes at 500 rpm.10-14 bar. CMI-200(2003). speed-50mt/min Stenter 2 Harish (Gujarat) Model: Supra 5 For heat set. 170185 C m/c speed. cutter1100rpm. chemicalsDidavin-EWN. 85C. Germany Model:-GPP400 (2001) Mangle pressure: . it is kept in an area from where it is send to folding department. 1 KD (Italia) Model: . selvedge.P-F 2000-1503 Magnums and P-F 20001593 New Multiprogram For decatising. speed – 12-14mt/min Speed. Every fabric roll has a piece ticket with it which contains piece no.oils etc After passing of fabric through all the sections. supra 5 Stabila Hemmer. 125Kg pressure TMT machine (Technologia Meccanica Tessle) Kier decatising 2 TMT (Italia) Model: .KD Suprema 95/1600 Permanent finish For decatising. 6G-6P 6185 (1990) m/c 1 has 4 plates and m/c 2 has 6 plates.50 lbs/inch2 For II Dry and resin treatment.Squeezer Stenter Damping m/c Conti press m/c 2 3 2 1 Supervelox Harish . all the descriptions of fabric make like weave. NIFT HYDERABAD Page 94 .12 mt/min. etc and also the various defects that remains even after the finishing process. 85C Nikki press 2 Nikki (Japan) Model: -4G-4P 6038 (1985). Super finish 1 Germany Model:-GFP 800/900 (2004) Used only for special finishes Perching m/c 27 -------------------------- CCl4 in white petrol is used to remove stains.. gsm.12-15 mt/min Speed.