UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE Kanpur

A REPORT ON SUMMER VACATION PRACTICAL MILL TRAINING AT PRATIBHA SYNTEX LIMITED

(20.07.20011 TO 02.08.20011) Submitted To: Mr. MAHENDRA UTTAM (UPTTI KANPUR) Submitted By: DEVA NAND (0804461011) SAURABH PATHAK (2904461002) RAVINDRA KUMAR (0804461026) SARVENDRA SINGH (0804461032) ABHISHEK SINGH (0804461001) AMIT Kr. SHARMA (0804461004) SHAILENDRA KUMAR (0804461034) ASHOK Kr. YADAV (0804461010) BRANCH TEXTILE TECHNOLOGY
1

Acknowledgement
Success in any endeavor calls for co-operation and guidance from all, especially dearones, seniors and environment. This was amply brought to me while undergoing industrial training and project work. This project Report gives me an opportunity to thank all those who have helped me to make this training a learning experience. I am extremely grateful to Mr. P. K. Singh, Mr. SHAKEEL and Mr. SANJAY JAIN for providing me an opportunity to do summer training in this organization. I owe my indebt ness to Mr. PRATEEK PANDEY (Spinning) Mr. YAMUNA PRASAD YADAV (Knitting) Mr. SAURABH (Garment &Plant-2) Mr. KUL DEEP (Dyeing) Mr. HEMANT KUMAR (Cutting) Who helped me for completion training and project successfully. I am grateful to them for all their support, which helped me to know the practical aspects of the various services. I express my heartiest thanks to: Mr. PRAMOOD KUMAR (Director of UPTTI Kanpur) Mr. V.K. MELHOTRA (Training Officer) Mr. MAHENDRA UTTAM Mr. A. K. S. GANGWAR

Preface
Training in business organization infuses among students a sense of critical analysis of the real managerial situation to which they are exposed. My institutions has given me opportunity through training to be aware of and cope with fast rate changing technology, management policies, quality and productivity etc. This is a bold attempt to bridge the gap between the world of work and studies imparted in the institutions This training enables me to apply theoretical knowledge to practical situations, appreciate the sense of responsibility, importance of discipline, punctuality and the psychology of worker and their habits which make me more professional and near to the world of technology and team work. Industrial training brings out better citizens, better technocrats and better diplomats out of me. I was lucky to get an opportunity to work in one of the top limited sector industries, i.e. PRATIBHA SYNTEX LTD. The purpose of this training was to gain knowledge about the industry, how it works and also to see the environment of the industry. I joined the training not only for these purpose, but also to learn something about operation of the machines and construction of spinning machines. I have worked in the concern for 6 weeks and prepared my Industrial training report. Under the guidance of training office, I analyzed various aspects of production. This has helped me in boosting up my confidence and determination, which will help me to face any situation in the years to come. This report is written account of what I learnt and experienced during this period. I wish, those going through it will not only find it readable but will also find useful information for future reference.

CONTENTS

Sr. No 1. 2. 3. 4. 5. 6.

CHAPTER Company profile Sequence of spinning department in production Departmental information Process/production particulars Humidification systems Sequence of dyeing department in production (A) continuous dyeing (B) soft flow dyeing Sequence of Cutting department in production Sequence of Garment department in production Sequence of Knitting department in production Time office & staff

Page No. 5 10 11 18 29 32

7. 8. 9. 10.

51 53 67 76

CHAPTER 1
COMPANY PROFILE OF PRATIBHA SYNTEX LIMITED

PRATIBHA SYNEX Ltd - AN OVERVIEW

INTRODUCTION Mill Address : Pratibha Syntex Ltd. Plot No.-4, IGC KHEDA -454774, Pithampur, Distt. DHAR (M.P) INDIA 1997 S. K. CHAUDHARY Ring Frame Spindle Unit 1 - 27216 Unit 2 - 18144 Unit 3- 2080 (Air-Jet) Unit 4- 3256(Open - End) Unit 5-12336 (Milange)
Pratibha Syntex Pvt. Ltd. is India's first vertically integrated Textile Manufacturing company, going from raw material to finished products. It houses within itself, fibre-production, spinning, knitting, as well as apparel manufacturing facilities. See our wide range of offerings in men, women and kids wear.

Established C.E.O Plant Capacity

: : :

Products

Yarn

Pratibha has a modern, well-equipped yarn manufacturing unit at Pithampur with an installed production capacity of 48,048 spindles operating. round the clock. This results in producing 12,875 tons per annum, fulfilling the requirements of customers across the globe.

Fabric

Pratibha has a state-of-the-art fabric manufacturing facility characterized by hi-tech machineries to produce variety of fabrics commensurate with global standards. It has a knitting capacity of 4725 tons per annum and a dyeing capacity of 4025 tons per annum.
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Garments

Pratibha manufactures high quality underwear, sportswear, leisurewear, high street fashionwear and loungewear for women, men, kids and infants. The capacity in the casualwear and the undergarments is 2.5 million pcs per annum and 8 million pcs per annum respectively.

Raw material suppliers Exporting countries

: Punjab, Haryana, M.P.

: We are the dominant exporters of various types of yarns to USA, UK, Egypt, Austria, France, Switzerland, Bangladesh, Mauritius, Turkey, Italy, Poland, Malaysia, Israel, China, Canada, South Africa, Columbia, Brazil, Hungary, etc.

Electric supply

: By the electric power station and own fire generators. To full fill its electric requirement. : It has own arrangement by pumping set

Source of water

Quality Policy

Upgradation of Quality

Identification of customers needs

QUALITY POLICY

Continuous Improvement

Confirm the desired standards

Customer Satisfaction

This is achieved by: Identifying customers requirements and converting them into products. Pursuing the process of continuous improvement by the employees of the organization. Ensuring that quality standards are maintained and upgraded to reflect the changing customers requirements

1.2. FUNCTIONS OF DIFFERENT DEPARTMENTS

The whole unit has been divided into various departments such as production, human resources, R&D and QA etc. The brief functions of each dept. are as follows:

MARKETING: 1. 2. 3. 4. Brand building To formulate strategies , plan & policies. Promotion of the business in overseas market. Ensures achievement of sales/financial objectives.

MIS, COSTNG & BUDGETING 1. 2. 3. 4. 5. To prepare daily reports.(including profitability reports) To prepare product costing & related information. To conduct physical verification of stock as & when required. To monitor the unit performance against set targets. To ensure correct & timely information flow across the organization including areas of concern. 6. To facilitate monthly planning processes/BSC/weekly planning. 7. To analyze performance parameters and making trends to analyze it etc. MAINTENANCE: 1. To ensure uninterrupted availability of machines. 2. To ensure & execute best maintenance work practice, system and SOP of textile and their compliance of the unit. 3. To improve the technical skills the subordinate to enhance decision making. 4. To maintain best health of machines to produce quality yarn. 5. To execute orders for the various spare parts.

ELECTRICAL: 1. To implement the preventive maintenance schedules of plant machinery 2. To provide electrical maintenance support for all production equipments 3. To implement energy saving initiatives and process improvement activities. R & D and Q.A.: 1. 2. 3. 4. 5. 6. 7. To plan and manage R&D activities in the unit. To plan and manage raw material for the whole year. To conceptualize, Visualize, Plan and develop new products. To plan and execute process improvement activities. To operate and maintain all testing activities. To coordinate with production and marketing functions To produce customer centric products.

PRODUCTION: 1. Production Planning. 2. Ensure timely availability of resources in coordination with commercial department. 3. Continuously monitor and evaluate performance of production machinery to achieve desired quality standard.

HUMAN RESOURCE: 1. 2. 3. 4. 5. 6. Manpower planning and recruitment. Ensure adherence to approved policies ,procedures(internal & external) Develop and enhance the potential of all members. Maintaining harmonious industrial relations. Controlling personnel costs. To implement HR policies in true spirits.

CHAPTER -2
SEQUENCE OF SPINNING DEPARTMENTS IN PRODUCTION

FLOW CHART FOR SUPER CARDED YARN

MIXING BLOWROOM CARDING BREAKER DRAWFRAME FINISHER DRAWFRAME SIMPLEX RING FRAME AUTOCONER YARN CONDITIONING PACKING

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FLOW CHART SUPER COMBED YARN

MIXING BLOWROOM CARDING ____________________________________ | BREAKER DRAWFRAME SLIVER LAP SUPER LAP RIBBON LAP | COMBER_____________________________________| FINISHER DRAWFRAME SIMPLEX RING FRAME AUTOCONER YARN CONDITIONING PACKING

CHAPTER -3 DEPARTMENTAL INFORMATION MACHINES IN UNIT-1

S.NO MACHINES NAME BLOWROOM LINE 1 & 2 AUTOMATIC BALE OPENER SIX CHAMBER BLENDER THREE ROLLER CLEANER HEAVY PARTICLES SEPERATER FINE CLEANER CONTAMINATION SORTING MACHINE DEDUSTER BLOWROOM LINE-3 GBR CL-P CLEANER CVT-3 SINGLE CARDING M/C MAKE CROSROL CROSROL CROSROL CROSROL CROSROL LOPTEX VETAL SCAN CROSROL MODEL NO. OF MACHINES 1 2 2 2 2 1 1 2

SORTER POLYSENSOR

TRUTZSCHLER TRUTZSCHLER TRUTZSCHLER CROSROL MK5D/MK5C TRUTZSCHLER

1 1 1 4 1
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TANDEM CARDING M/C BREAKER D/F SLIVER LAP M/C RIBBON LAP M/C SUPER LAP M/C COMBER FINISHER D/F SPEED FRAME RING FRAME

AUTOCONER

CROSROL ZINSHER TRUTZSCHLER LAXMI LAXMI TOYOTA TOYOTA TOYOTA LAXMI TEXMACO HOWA TOYOTA OERLICON SCHLAFHORST KTTM MURATEC SPG SAVIO ITEMA MURATEC SIEZER

720 LE 2/4A LE 4/1A TS100 VC5 DYH 6000 LRSB 851

16 3 1 2 2 2 18 4 2 8 25 1 1 6 3 1 1

RXZ 220 ZINSHER 351 RXI 240 MACH CONER 7V POLAR 2YC

YARN CONDITIONING PLANT

FLOW CHART (UNIT-2) BLOW ROOM CARDING _________________SLIVER LAP M/C BREAKER DRAW FRAME RIBBON LAP M/C FINISHER DRAW FRAME __________________COMBER M/C SPEED FRAME RING FRAME AUTOCONER YARN CONDITIONING PLANT PACKING

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MACHINES IN UNIT-2 (BLOW ROOM)

NAME OF MACHINE AUTOMATIC BALE OPENER SIX CHAMBER BLENDER THREE ROLLER CLEANER CONTAMINATION SHORTER DIDUSTER FINE OPENER & CLEANER PIND OPENER & CLEANER HEAVY PARTICLE SEPERATOR SINGLE CARDINGM/C BREAKER D/F SLIVER LAP MACHINE RIBBON LAPMACHINE COMBER FINISHERDRAW FRAME SPEED FRAME RING FRAME AUTOCONER YARN CONDITIONING PLANT MAKE CROSROL CROSROL CROSROL LOPTEX CROSROL CROSROL CROSROL CROSROL CROSROL TRUTZSCHLER ZINSHER LAXMI LAXMI LAXMI TOYOTA LAKXMI ELECTRO JET KTTM SCHLAFHORST MURATEC SIEZER MODEL NO OF M/C 1 1 1 1 1 1 1 1 12 3 1 3 3 20 3 4 1 18 1 6 1

720 LE 2/4A LE 4/19 LK 250 DX 7A LF 1400A JET 5A RX 240 R-338 No.7V

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FLOW CHART (UNIT-3) (AIR JET SPINNING) (MVS)

BLOW ROOM CARDING BREAKER DRAW FRAME-1 FINISHER DRAW FRAME-2 ______________________________ MJS MVS COTTON (POLYSTER & POLYSTER BLENDS) _______________________________________ YARN CONDITIONING PLANT PACKING

UNIT-3(AIRJET SPINNING)
MACHINE NAME AUTOMATIC BALE OPENER (POLYSTER) AUTOMATIC BALE OPENER (COTTON) OPENER(MIXING) GBC BLENDER GBR M.V.O UNIMAX UNIMAX FAXI CLEAN VERY CLEAN MAKE JENN FENG MODEL ZF5/3 NO. OF MACHINE 1

LAXMI

LMW

TRUTZSCHLER TRUTZSCHLER TRUTZSCHLER LAXMI LAXMI LAXMI LAXMI LAXMI

LA7/4R LB 5/6 LB 9/2

1 1 1 1 1 1 1 1
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OPENER VETAL SCAN CARDING(COTTON) CARDING(MIXING) CARDING(POLYSTER) BREAKER DRAW FRAME FINISHER DRAW FRAME RSB MJS MVS YARN CONDITIONING

TRUTZSCHLER POLYSENSOR LAXMI LAXMI LAXMI LAXMI TOYOTA TOYOTA LAXMI MURATEC MURATEC MURATEC SIEGER

LC300A-V3 LC300A-V3 LC300A-V3 LDO/6

1 1 5 4 10 12 1 7 1 14 2 14 1

No.802HR No.861 No.851

UNIT-4 FLOW CHART (OPEN END)

BLOW ROOM CARDING BREAKER DRAW FRAME FINISHER DRAW FRAME OPEN END SPINNING YARN CONDITIONING PLANT PACKING

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MACHINE IN OPEN END UNIT (UNIT-4)

MACHINE NAME AUTOMATIC BALE OPENER SIX CHAMBER BLENDER THREE ROLLER CLEANER HEAVY PARTICLE SEPERATOR PIND OPENER AND CLEANER FINE OPENER AND CLEANER SINGLE CARD BREAKER DRAW FRAME FINISHER DRAW FRAME DOUBLER AUTOCORO TFO YARN CONDITIONING PLANT MAKE TRUTZSCHLER TRUTZSCHLER TRUTZSCHLER TRUTZSCHLER TRUTZSCHLER TRUTZSCHLER TRUTZSCHLER TOYOTA TRUTZSCHLER TRUTZSCHLER SCHLAFHORST SCHLAFHORST VEEJAY LAKSHMI SIEMENS MODAL NO. OF MACHINE 1 2 2 1 2 2 14 3 2 5 2 10 11 1

CL-P MX-1 SP-MF CL-C3 SP-F TC-03 DX-8 TD-03 TD-03 PPW-A

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UNIT-5 FLOW CHART (MELANGE)

BLOW ROOM CARDING BREAKER DRAW FRAME FINISHER DRAW FRAME SPEED FRAME RING FRAME AUTOCONER YARN CONDITIONING PLANT PACKING

MACHINE IN MELANGE SPG UNIT

MACHINE NAME GBC BLENDER G.B.R M.B.O UNIMIXER FLACSI CLEAN SINGLE CARDING M/C CUTTER BREAKER D/F FINISHER D/F COMBER SLIVER LAP RIBBON LAP SPEED FRAME RING FRAME MAKE TRUTZSCHLER TRUTZSCHLER LAXMI LAXMI LAXMI LAXMI TRUTZSCHLER LAXMI LAXMI LAXMI LAXMI LAXMI LAXMI LAXMI LAXMI LAXMI KTTM TOYOTA MODEL NO.OF MACHINE 1 1 3 2 1 9 4 1 4 4 1 3 1 1 3 1 10 2 3
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LB-3/6R LB 7/4 LB 5/6 LA 7/5 D800 LD 0/6 LRSB 851 LFS 1600V LK 250 LE 2/4A LE 4/1A LFS 1600V 2F 1400-A LR 63/A

AUTOCONER

SAVIO VEEJAY MURATEC

7V

1 4

CHAPTER- 4 PROCESS / PRODUCTION PARTICULARS

5.1.RAW MATERIAL PROCUREMENT AND BALE MANAGEMENT INTRODUCTION:
RAW MATERIALS ARE DIRECT INPUT WITH PRE- REQUIREMENT TO PRODUCE OUTPUT OF DESIRED QUALITY AND CHARACTERISTICS. RAW MATERIAL DEPARTMENT HAS TO ENDURE EXTREME PRESSURE GENERATED IN VIEW OF THE PRESENT INTERNATIONAL SCENARIO WHERE CONSISTENT QUALITY IS THE SUCCESS SLOGAN.

5.1.1. ROLE OF RAW MATERIAL DEPT. SUMMARISED AS:

IT ENSURES REGULAR FLOW OF MATERIALS TO THE PRODUCTION UNIT. IT HAS TO MAINTAIN THE STOCK POSITION OF VARIOUS RAW MATERIALS AND SEND IT TO CORPORATE RAW MATERIAL DEPARTMENT FOR DAY TO DAY PLANNING AND DECISION MAKING RAW MATERIALS

IT ALSO ENSURE PROPER STORAGE OF RAW MATERIAL

RAW MATERIAL INFORMATION

Cotton (shanker-6, mech-1.organic) and bamboo fibres are mainly used in unit-1and 2. In open end spinning cotton (mech-1) and 2 is used. In MVS unit, apart from cotton, Polyester and viscose are also used.

MAIN DATA Weight of one bale -158 to 168 kg Types of cotton used -shanker-6, mech-1, H-4, organic (bio) Staple length (ring frame) -28.5 to 30.5 mm Staple length (open end) -25 to 27.5 mm
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Size of bale -3.5*2.2*4.5 Consumption (unit-1) -350bale/day Consumption (all units) -500 bale/day MIC -3.5 to 4.1 Strength -22g/tex Avg cost of fibres -23000/candy Staple length -38 mm Mixing of various fibres is done in the most appropriate manner so as have the best yarn properties. The mixing is done according to a matrix.

5.2. MIXING
OBECTS:
1. TO HAVE A UNIFORM DISTRIBUTION OF DIFFERENT TYPES OF COTTON 2. TO REDUCE THE COST OF RAW MATERIAL USED 3. TO APPLY SPIN FINISH & TINT ( IF REQUIRED ) ON MATERIAL TO IMPROVE PROCESS PERFORMANCE & TO SEGREGATE THE MATERIAL FROM OTHER KINDS. 4. Removing waste and contamination by sorting. IN ORDER TO HAVE BEST RESULT, FOLLOWING POINTS SHOULD BE UNDER CONSIDERATION 1. FIBRES MUST HAVE SAME ORIGIN 2. PRICE, COLOUR & GRADE OF COTTON IS ALSO KEPT IN MIND WHILE LAYING MIXING 3. QUALITY OF MIXING TO BE LAID 4. SOFT WASTE SHOULD BE ADDED AS PER REQUIREMENT Types of mixing1.Hand mixing 2.Bin mixing 3.Stack mixing The lots for the mixing should have somewhat identical properties. Very coarse and very fine or very short and long cotton are never mixed.

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Size of bales are approximately as follows:LENGTH-2.0 FEET BREADTH-1.5 FEET HEIGHT-4.5 FEET CONTAMINATIONS REMOVED DURING SORTING PROCESS: 1. Plastic dori 2. Paper 3. Cloth 4. Polythene 5. Wires 6. Coconut material 7. Feather 8. Coloured thread 9. Wood 10. Leather 11. Hair 12. Sutli 13. Yellow cotton PRECAUTION WHILE LAYING MIXING: 1. 2. 3. 4. 5. Material should not spread out of yellow line marked on floor. The top layer of mixing should be in same level. Waste should be added uniformly. Bales should not fall after opening them. House keeping should be proper.

BLOW ROOM
OBJECT:-The object of blow room is opening and cleaning of cotton.It consist of the
following sequence of the machines for the attainment of this object.

1.SIX CHAMBER BLENDERThere are six chamber filled with cotton.Here blending of cotton is to be done by six beater.

2.THREE ROLLER CLEANERThere are three rollers having different spikes.The function of three roller cleaner is to clean the cotton.

3.HEAVY PARTICLE SEPERATORThe function of heavy particle separator is to remove the heavy particle by the principle of centrifugal force by circulating the cotton.

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4.PINNED OPENER AND CLEANERThe spikes of roller is pin-like which open the cotton and so impurities are removed,so clean tha cotton.

5.FINE OPENER AND CLEANERHere fine impurities are removed from cotton. Spikes of rollers are very fine.

6. CONTAMINATION SORTING MACHINEThere are two separators 1. VetalIt works on the camera vision. It has 24 sensors, which sense the contamination, And is recorded by the camera and is ejected by the air pressure. 2. LoptexTotal 56 sensor sense the contamination and are ejected by the air pressure. 7. DEDUSTERIt removes the dust from the waste from the blow room line.

TECHNICAL SPECIFICATION (F.C.1) 1. FINE CLEANER (F.C.1) Tower reserve beater

Motor pulley -110 mm Beater pulley -167 mm Calculated speed-930 rpm Motor speed 1415 rpm

Fine cleaner beater

Motor pulley 208 mm Beater pulley 335 mm Calculated speed 500 rpm Motor speed 1430 rpm

Six chamber beater

Motor pulley 110 mm Beater pulley -335 mm Beater speed -471 rpm Beater speed 1435 rpm

Three roller beater

Motor pulley -115 mm Beater pulley -336 mm Beater speed -490 rpm Beater speed -1430 rpm BEATING POINT:-2

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CARDING
Carding is the heart of spinning. The objects of carding are:1. Individualization of fibre 2. Disentanglement of neps 3. Sliver formation 4. Cleaning action The chute feed system feeds the machine. Types of card:1. Tandem card (16 in no.) REAKER The main carding action takes place between cylinder and flat. To control the feed autoleveller are installed in the machine.

DUO OR TANDEM CARDING

As the name implies, tandem cards consists of two individual cards joined together to make up a unit, in which the doffer of the first card feeds fibre material to the taker-in of the second card. Double carding of the raw cotton has a positive effect on quality and on blending. However, these advantage are purchased at the cost of expense in hardware and maintenance, and additional space is required. Modern cards of the latest generation give the same or nearly the same quality. Tandem cards come into consideration.

TECHNICAL SPECIFICATION
1. Speeds BREAKER CARD Licker in 96 rpm Cylinder -640 rpm Doffer -57 rpm FINISHER CARD Licker in -963 rpm Cylinder -570 rpm Doffer -57 rpm MAIN-DATA No. of m/c =16 (Tandem Card) 5 (single card) No. of motors = 11(Tandem card) 9(Single Card) Feed system-chute feed system Wrapping count=0.120
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Completing Time for 1 can=48 mins. Sliver length in 1 can =9000 m Production rate = 180 m/min Weight of 1 can=44.38 kg Feed rate for calendar roller=4.9 g/min Output rate =4.73 g/min Production = 52.2 kg/hr Breaker cardflat speed = 302 mm/min Cylinder speed =640 rpm Licker speed =960 rpm Finisher cardDoffer speed =57 rpm Cylinder speed=570 rpm Flat speed =390 mm/min Coiler speed =120m/min Calendar speed =145 m/min

CAN SIZE HEIGHT-45 DIAMETER-30

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SLIVER LAP MACHINE

OBJECT:-The object of sliver lap machine is to prepare the lap from slivers for the ribbon lap.
This is one of the preparatory machines for the combing operation.

TECHNICAL SPECIFICATIONS
No. of m/c=2 No. of heads=18 Doubling=18 Drafting system=4 over 6 Lap weight=10 kg Production per m/c=220-2250 kg/hr Time for completion 1 can=2 min 20 sec Wrapping count=73 g/min Doffing time=25 sec Length of lap=160 m Feed g/m=88.2 Bottom roller gauge: Front zone : 35 Middle zone: 50 Back zone : 39 Delivery speed =65m/min

RIBBON LAP MACHINE

OBJECT:-The object of ribbon lap machine is prepare the lap from the lap of
Sliver lap machine for the combing operation which has regularity and uniformity across the length and the width.

TECHNICAL SPECIFICATIONS
No. of m/c =2 No. of heads =6 Doubling =6 Drafting =6 Drafting system =3 over 4 Lap weight =11.5 kg Production per m/c =220-250 kg/hr Time for completion 1 can =2 min 15sec Wrapping rate =72 g/min Doffing time =20 sec Length of lap =160 m Delivery speed =65 m/min
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 Delivery gram/m =71 Bottom roller gauge : Front zone : 31 Middle zone : 50 Back zone : 35

SUPER LAP MACHINE

OBJECT:-The object of super lap machine is to make the lap from slivers coming
from the breaker draw frame which have uniformity across the length and the width for the combing process.

TECHNICAL SPECIFICATIONS

No. of m/c =2 No. of heads =30 Doubling =30 Draft =2 Drafting system =3 over 2 Lap weight =18 kg Production per m/c =320-350 kg/hr Time for completion 1 can =2 min 30 sec Wrapping =72 g/m Doffing time =30 sec Length of lap =272 yards Lap diameter =21 Lap width=7 Lap height =13 Tension draft =0..994 Delivery speed = 90 m/min

Frequency = 54 Hz Efficiency=70%

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COMBER
No. of m/c =18 No. of heads =8 Doubling =8 Draft =11.04 Drafting system =5 over 4 Feed gram/m =72 Time for completion 1 can (Lap from super lap m/c) =45 min (Lap from ribbon lap m/c)=35 min Doffing time =1-1.5 min Length of lap =5000 m Nips/min=290 Wrapping count=0.130 Trumpet diameter =3.4 mm Distance between detaching step gauge to bottom roller=4.5-5.5 mm Distance between bottom nipper to cylinder=0.5-0.9 mm Noil % =16.5-22% Bottom roller gauges: Front zone : 40 Middle zone : 40 Back zone : 44

SPEED FRAME
TECHNICAL SPECIFICATIONS: No. of m/c =8 No. of heads =120 (Lakshmi) =128(Electro-jet) Feed sliver hank =0.130 Draft =5.89 Drafting system -4 over 4 Bobbin weight = 1.74 kg Time for completion 1 bobbin =1 hr 45 min Wrapping count =0.75 (combed) =0.78 (carded) Doffing time =7 min Length of roving in 1 bobbin =2126 m T.P.I =1.27 Bottom roller gauge: Front zone =38 mm
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Middle zone=50 mm Back zone =50 mm Flyer speed =1050 rpm

RING FRAME
TECHNICAL SPECIFICATION:
No. of m/c=27 No. of Spindle =1008 Drafting system =3 over 3 & 4 over 4 Bobbin weight = 72 g Time for completion 1 bobbin =1 hr 45 min Spindle speed = 14000-16000 rpm Twist = Z Length of bobbin yarn = 3290 m T.P.I =16.48 T.M =3.67 Grams/spindle = 296 grams Doffing time =3 min 15 sec Efficiency =94.2-97.26 % Temperature conditions: Dry : 37c Wet : 28c Bottom roller gauge: Front zone: 45 mm Back zone : 56 mm Count Time for completion 8(SKW) 45 min 12(SKW) 56 min 13(SCW) 1 hr 15 min 16(SKW) 1 hr 30 min 28(SKW) 2 hr 30 min 30(SCW) 3 hr

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AUTO CONER
TECHNICAL SPECIFICATION: No. of m/c =10 Types of splicing : wet, air and mechanical. No. of heads = 60(muratec) & 64 (Savio) Cone weight =2.5kg Cone drum speed =1450 m/min for 30 count Cut groove on drum = 2 and half Bobbin length = 3454 m Bobbin weight = 68 g TEMPERATURE CONDITIONS: DRY : 30C WET : 25C

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YARN CONDITIONING PLANT

Yarn formed in autoconer is not having so much strength. So, for this Yarn is conditioned under yarn conditioning plant. In yarn conditioning plant the moisture content in yarn increases. Strength of the yarn improved by conditioning. Moisture content =weight of cone before conditioning- weight of cone after conditioning

SPECIFICATIONS:
Name of machine : seiger(Y.C.P) Temperature conditions : 54-58c Pressure in mbar : -620 to -50 Time for conditioning : 1 hour RH% :81% No. of packages conditioned in 1 hour : 600

PACKING
Conditioned packages are finally packed into cartons and pallets to be sent to the buyer. Weight of 1 carton = 50.8 kg Weight of 1 pallet = 941 kg Carton size = 685mm450mm510mm No. of packages in one carton = 12(approx.)

CHAPTER -5 HUMIDIFICATION SYSTEM

OBJECT
THE BASIC OBJECT OF A HUMIDIFICATION SYSTEM IN A TEXTILE MILL IS TO CONDITION THE AIR SO THAT FIBRE CAN BE PROCESSED SMOOTHLY BY SUPPLYING THE CONDITIONED AIR TO THE DEPARTMENT.AN OPTIMUM RELATIVE HUMIDITY IS REQUIRED DURING SPINNING SO AS TO KEEP YARN BREAKAGE AT MINIMUM.IN SPINNING DIFFERENT DEPARTMENT HAS A DIFFERENT REQUIRMENT OF TEMPERATURE & RELATIVE HUMIDITY (RH), SO TO MAINTAIN THIS TO A CONSTANT LEVEL IS REALLY A TOUGH AS WELL AS IMPORTANT JOB.THIS IS ACHIEVED BY HUMIDIFICATION SYSTEM.
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 CONDITION MAINTAINED BY HUMIDIFICATION SYSTEM

THE CONDITIONS THAT MUST BE MAINTAINED BY HUMIDIFICATION SYSTEM ARE1. DRY BULB TEMPERATURE-(DBT) 2. WET BULB TEMPERATURE-(WBT) 3. RELATIVE HUMIDITY-(RH)

HUMIDIFICATION SYSTEM

AIR WASHER

SUPPLY AIR FILLTER

ROTARY AIR FILLTER

PRODU CTION HALL

RETURN AIR FAN

Atmospheric condition
Temperature Humidity 30 2C 77 2 %

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PARAMETERS OF RELATIVE HUMIDITY (STANDARDS):

SECTION TEMPERATURE(C) RH%

BLOWROOM CARDING COMBER D/FRAME S/FRAME R/FRAME WINDING TWISTING

MIN 20 28 28 20 20 30 28 28

MAX 40 40 40 40 40 40 40 40

MIN 20 40 40 20 20 40 40 20

MAX 60 60 60 60 60 60 70 60

RELATIVE HUMIDITY OF DIFFERENT SECTIONS OF DEPARTMENT:

SUCTIONS BLOWROOM CARDING COMBER DRAW FRAME SPEED FRAME RING FRAME WINDING T.F.O OPEN END RH% 50-55% 50-55% 50-55% 50-55% 50-55% 50-55% 65% 62% 50-55%

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CHAPTER -6 SEQUENCE OF DYEING DEPARTMENTS IN PRODUCTION

Pratibha Syntex Ltd has the wet processing unit at Pithampur (Dhar). Here wet processing of knit fabrics of various blends take place. Apart from these here there are two types of dyeing process available. (A)Continuous dyeing (B)Soft flow dyeing

So the Knitted fabric obtained from the Same Plant according to the order is processed in processing unit. Both these departments of dyeing (continuous and soft flow) are mainly used for wet processing of knitted fabrics and have nearly the same working route except some few differences which are as follows: Continuous Dyeing Capacity of M/C-1100 kg. Washing, Bleaching, dyeing, soaping occurs in different machines in a continuous manner The liquor required for dying is less. Machines UsedStenter for Heat Setting Bleaching Machine Padding machine Batching machine Soaping machine Drying machine Sanforizing machine Stop Flow Dyeing Capacity of M/C- 180-2500kg. Washing, bleaching, dyeing, soaping occurs in one machine In stop flow manner The liquor required for dyeing is more. Finishing machines used : Bleaching Dyeing soaping occur in one machine Drying machine Stenter (4 units) Sanforizing Machine

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(A) Continuous dyeing processH.O.D. - Mr. KULDEEP PRODUCTION/ SHIFT- 4Ton

So the fabric initially in the roll form goes through the following path before it is made into a finished usable material.

Greige opening Bleaching Dyeing Finishing Folding Made Ups

Pratibha Syntex Lmt. has its own Knitting plant. So it has its own production of Knitted fabric as per sales order which is issued from the buyers. The main advantage of this is that it receives pre-inspected fabric thats why inspection process is not being much concentrated but still there is random inspection takes place during opening & stitching process.

Various activities have been done here as follows:

First of all, the sales order issued by Buyers is received. Production of fabric is as per required sales order quantity, construction & design. Then this fabric is dispatch to Cutting Department as per sales order & roll number specifications. Challan number/date entry at Cutting department. Sort wise unloading of fabric rolls & allocation of rolls in greige store take place
33

G.R.N (good receipt note is made) PPC deptt. Make the production plan & issue it to grey fabric for opening as per priority. Opening of grey fabric & random inspection also takes place, defects observe such as hole, knots, oil stain, grease stain, knitting defects etc.

Stitching of small rolls of same quality is being done. Roll wise checking report is made consisting type of defects, meterage, sort number, party name, sales order no. (S.O.), production no. (P.O.).

Trolleys & batch number is issued to Bleaching department.

Description of fabric quality is as follows:

100% cotton fabric. Cotton/Lycra (C/L) blend

Various Design such as: Single jersey, double jersey, Interlock etc. Lot number -C110102219
Quality: - VISC Lycra Shade: - purple Residual H2O2 - Nil Light source: - D-65 Absorbency: - Ok Whiteness Index : - 70 Water Ph: - 7.2 P.F.D. Ph: - 6.9 Enquiry No-180011442/B

First digit of sort number signifies:

If 1 - 100 % cotton 3 - P/C blended Grey fabric received in the form of rolls of different length.

34

Roll length may vary from 1000-1100kg. Sample length may vary from 10-15 g.

Machinery description:
Name Number of machine Make Name of machine Number of machine Make Name of machine Number of machine Make Name of machine Number of machine Make Name of machine Number of machine Make : Stenter for heat setting : Two : NAVIS Arrytex : Bleaching Machine : One : ERBATECH (D64711) Germany. : Padding Machine : One : ROTACENT (Germany). : Dryer : One : Pin Dryer 603 (syntax group) : Compactor : One : Lafer compactor - 705

Man power: Operator/Shift (11 hrs.) Supervisor & helper 2 2 & 10

B. BLEACHING DEPARTMENT
The grey fabric consists of various kinds of impurities like vegetable matter, waxes etc. In this section all of these impurities are removed and whiteness in fabric is imparted. In this department two main steps are carried out:

35

Pre-treatment

Bleaching

i) Pre-treatment
a) Scouring: Scouring is the first process carried out with or without chemicals, at room temperature or at suitable higher temperatures with the addition of suitable wetting agents, alkali and so on. Scouring removes all the waxes, pectins and makes the textile material hydrophilic or water absorbent.

b) Bleaching: The next process of decolorization of greige material in to a suitable material

for next processing is called bleaching. Bleaching of textiles can be classified in to oxidative bleaching and reductive bleaching.

Oxidative bleaching Generally oxidative bleachings are carried out using sodium hypochlorite, sodium chlorite or hydrogen peroxide. Natural fibres like cotton, ramie, jute, wool, bamboo are all generally bleached with oxidative methods. Reductive bleaching Reductive method of bleaching is done with Sodium hydrosulphite, a powerful reducing agent. Fibres like Polyamide, Polyacrylics and Polyacetates can be bleached using reductive bleaching technology. In this step scouring and bleaching are carried out in a single machine. The Benninger continuous pretreatment concepts comprise continuous desizing and bleaching in one cycle with just one steaming process. In one step grey cloth is turned to dye ready fabric. This process is fast, economical and of immaculate quality. Due to this optimized one-level process the operational costs are lowered by approximately thirty percent, and the impact on the environment is significantly lower.
36

Machine Description
Machine Make Model Made In Year Of Mfg No. of machine ERBATECH D 64711 Germany 2008 One

The ERBATECH machine is mainly divided into 5 main parts

1. Parcowash Zone -1
In this initial step the Dust,impurities etc are removed using hot water and steam. All the processes are carried out in a chamber known as parcowash-1. There are 3 chemicals used for pre-washing.

Name of chemical

Working

Sirrix N 2UDI MRZ Temp.

Sequesting agent Water hardness controller Wetting Agent 70oc

37

2. Impregnating:
In the main Bleaching zone the fabric is impregnated with chemicals for subsequent troublefree steaming process. The design ensures that a high liquor exchange is achieved. The chemicals are distributed immediately at the right place in the fabric. The chemicals added are as follows: Chemical used H2O2 Sifa M MRZ Caustic soda Sirrix N Temp. Working of chemical Bleaching agent Reaction Stablizer Wetting agent Swelling,cleaning agent Sequesting agent 97 oc

3. Steaming:
In the steamer the chemicals react with the fibres themselves and the accompanying substances. The combination steamer with tight strand cloth runs and plaiting on a roller bed permits reaction times of 1 to 60 minutes. An automatic steam conditioning and regulating station guarantees constant conditions and an air free atmosphere. In this machine steaming time was 13-14 minutes. The steam is used in the following conditions: Temperature of steam mix: 102oc

4. Washing:
The chemicals which have been made soluble by steaming, are washed out. The high washing effect of this machine is achieved through exact liquor segregation and counter-flow guidance. It has been designed for especially low power and water consumption. Final washing is done in 4 subsequent chambers. Compartment No. Set Temperature (in deg C) 90 90 90 Actual Temperature deg C) 90 94 63 63 60 Length of fabric that can be treated (in m) 27 30 28 28 28

(in

1 2 3 4 (chamber 1) (chamber 2)

38

5. Neutralizing
In this chamber ph of fabric is maintained.

Working parameters
Speed Dwell time Inject steam flow Impecta nip pressure Steamer temp Steamer content Pick-up(%age) Steam flow in steamer Steam pressure Water pressure Air pressure Pre-washer flow Post-washer flow Acid dosing 70mt/min 15min. 500kg/hr 0.5N 1002c 1200 m/min 75 1200kg/hr. 3.5kg/cm 5kg/cm 7.0kg/cm 5.0lt/kg of fabric 5.0lt/kg of fabric 4-5 PH

Operator Helper Production/machine/day

2 4 80,000 90,000 mts.

C. DYEING DEPARTMENT

Dyeing is the process of imparting colors to a textile material through a dye (color). Dyes are obtained from flowers, nuts, berries and other forms of vegetables and plants as well as from animal and mineral sources. These are known as natural dyes. The other class of dyes is known as synthetic dyes. These are based on a particular type of chemical composition. Some of these dyes are- Acid (Anionic) dyes, Basic (Cationic) dyes, Neutral- Pre metalized dyes, sulfur dyes, vat dyes, reactive dyes, pigment dyes etc.

39

Colour is applied to fabric by different methods of dyeing for different types of fiber and at different stages of the textile production process. These methods include Direct dyeing; Stock dyeing; Top dyeing; Yarn dyeing; Piece dyeing; Solution pigmenting or dope dyeing; Garment dyeing etc. Of these Direct dyeing and Yarn Dyeing methods are the most popular ones. Dyeing is defined as the application of dye to fibers (according to their affinity) to have desired colour. Every natural or synthetic fiber varies in affinity or capacity to take the dyestuffs. Dyeing is done at fabric stage. Main types of fabrics those are dyed are: 1) 100% cotton fabric 2) L/C blend (A) DARK SHADE DYEING In dark shade dyeing of cotton cloth we use Reactive dyes are used. And the machine used is Cold pad batch and soaper.

Cold pad batch (CPB) M/c Description

Machine make No. of m/c Cloth capacity ROTACENT/Germany/ One 1100mt

Working parameters (Kuster)

Speed dye capacity Nip level Nip pressure(Bar) Dye temp. Temp. of pedding Colour: alkali ratio Trough PH 44 m/min. 1250 lt. 100% L:M:R 0.4:1.5:0.4 30c 25 4:1 10.5-11.5

Dyeing recipe
Colour Ever. Yellow LX Ever Red ED3B Ever Blue ED G.P.L. 2.5 30.70 6.30

40

Auxiliary
Material Lionil UH Caustic lye Soda ash G.P.L. 1 7 18 Total amount 0.125 lit 0.875 lit 2.250 kg

Process of Cold Pad Batch is as follows:

Fabric is passed through the cold rollers to keep the temperature of the fabric even so that the classes of dyes used are better reactive . Then fabric is passed through the Padding mangle where the colour padding takes place. The color recipe used here is 1 part Sodium Silicate as fixing agent and 4 parts of colour. speed here is 44Mts./min. The fabric is then sent for rotation of 8 hours. The time allotted is the dwelling time and within this time the colour fixing happens and the fabric absorbs the dye equally. And at the end fabric is sent on the washing range where the fabric is washed and dried on the drying range.

Flow of fabric in Cold Pad Batch Machine

ERBATECH SOAPER
The washing range primarily is used to wipe out the superficial colour absorbed by the fabric and then send to the finishing department.

The process of Washing Range is as follows:

The dyed fabric is washed with the counter flow of water at 98 degree of temperature. Then the fabric is washed in soap solution in two chambers. Then again the fabric is passed through water.

41

And finally the fabric is passed through acetic acid where it is neutralized and then the fabric is dried as the acetic acid is volatile in nature thus it does not require any further washing. After the fabric is passed through the drying range it is drying in Pin Dryer and sent to finishing department. Excellent results have been obtained with the pad batch (cold) system utilizing high reactivity dyes. Dyers have experienced many benefits, Some of which are listed ahead: 1. Reduction in waste loads in effluent 2. Low capital outlay. 3. Low energy requirements. 4. High production speed 5. Less labour requirement. 6. High colour yield 7. Outstanding productivity. 8. Excellent dye penetration and levelling characteristics. 9. Rapid fixation 10. Substantial overall cost savings (dyes, chemicals, labour, water. The fabric undergoes less turbulence during the cold pad batch dyeing process, and therefore retains a smooth, uniformly coloured appearance with added luster and a soft touch and drape. It is also brighter in shade, has superior wet fastness properties, and has a better look and feel.

D. FINISHING DEPARTMENT
Finishing is the final series of operations that produces finished textile fabric from greige goods. Finishing operations are predominantly wet operations requiring large amounts of thermal energy for water heating and drying. Finish is applied on the textile material by different chemical and mechanical means. The finish to be applied on textile material depends upon the end use of the fabric.

OBJECTIVES
To improve the appearance of fabric To increase the whiteness To provide anti-shrink properties To provide soft feel to the fabric To increase the width of the fabric To improve dimensional stability. Average production shift = 4 ton. No. of Stenters = 2 Machine name: Mahlo (Mechanical Finishing)
42

PROCESS FLOW IN FINISHING DEPARTMENT GREY BLEACHING PADDING BATCHING SOAPING DRYING SANFORIZING

MACHINERY IN FINSHING DEPARTMENT

STENTER(NAVIS Arrytex) PIN DRYER -603 (syntax group) SANFORISER(Lafer-705) 2 1 2

STENTER PROCESS AT STENTER MACHINE OBJECTIVES

Heat Setting Resin Finish Water Repellant Finish Soft Finish Stretching Skew, Bowing

43

Working parameters (temp. in C)

Chamber Light shades Med. & dark Shirting wt. White goods Bottom wt. RFD(stretching) Heat setting 1 120 120 100 100 100 150 210 2 130 130 100 120 120 160 210 3 140 140 110 130 130 170 210 4 150 160 110 140 140 180 210 5 150 160 120 150 150 180 210 6 160 170 120 150 150 180 210 7 160 170 120 150 150 180 210 8 160 170 120 150 150 180 210 9 160 170 120 150 150 180 210 10 170 180 120 150 150 180 210

Specification of Machine (stenter)

No. of chambers Length of one chamber Heating system Model Working width Threading length Speed Trough cap. Equipped 10,10 3 mt. Thermic oil (300C) NAVIS Arrytex 180 cms. 75 mt 5- 100 mt/min. 50 lt. Mahalo system

Different parts of stenter : Brushes after pinning: Since the pinning shoes only bring the fabric on to the tips of the
pins, the function of the subsequent brushes to press the f/c fully on to the pins. The brushes are mounted on a pivoting lever, which after releasing a locking handle, can be moved to the non operational position or working.

Vertical feed roller: The feed roller is located right ahead of the pinning or clipping
positions. It can be moved to various positions by means of pneumatic cylinders. Steam spray cleaning unit clips/pins: Some time finish chemicals such as softener etc. cling or stick to the pin over a period of time softener, residue of glue & condensates can build up on the needle bars & clip tables the steam spray cleaning unit for pin chains or combination chains can be used.

44

Brushes for needles: Over a period of time softener residue of glue & condensates can build
up on the needle bars &clip tables, impairing the function of the stenter chain. The residue must therefore be removed at regular interval by actuating the brush system. Main track guide selvedge feeder: The width of the in feed track is controlled by the selvedge feeder when there is no f/c in the m/c the chain track run with the activated feeders swung fully increases. Rotary compensator: Is used even running speed it is infinitely pneumatic variable so that necessary longitudinal tension can be produced in the f/c Rotary tensioner it can be infinitely by hand so that requisite longitudinal tension can be created via f/c friction. Break roller: When unbreaked the break roller is driven by f/c. actuating the pneumatic break slow the roller movement & thus increase the f/c tension. My-cock bent stretching (curved roll): The bent stretching to prevent fold & stretches out the edges of the f/c.depending on the type & design of the f/c ,the adjustment angle of the stretching roller can be varied while the f/c is running. Lifting device: The liquor can be lowered pneumatically so that internal element in the trough is easily accessible. This facilitates threading in of the f/c& simplifies the cleaning of the trough & internal element. Matex three roll padding mangle system: The rolls are press together by two pneumatic cylinder thereby pressing excess liquor out of the f/c. Spreading roller: This roller has severe like profile running out to the left & right. Drawing screens: The screens prevent fluffs, threads etc. carried by the f/c from entering the air circulation system. The screens are located on the suction duct depend on the type & design /the m/c may be equipped with fixed base screens which can be removed after opening the service doors or with auxiliary screen which can be removed during the m/c operation. Integrated suction ducts: The m/c is equipped with an integrated suction duct. The exhaust air volume can be regulated via mechanically adjustable air valves. Rip cord switch: The safety system comprised a ripcord switch located at the outlet of the stenter. Pulling the ripcord trips the emergency stops function for the whole m/c. Master switch: When the master switch is in the Zero position, all power to m/c is switched off. In this operation the master switch can be locked with a pad lock to prevent restarting. Compressed air maintenance unit: A separate maintenance unit is provided in the control desk to prepare the compressed air for the mangle pad. The maintenance unit consists of filter with water trap a compressed air oilier & shut off tap. Pinning unit: The function of two pinning unit is to position the fabric selvedge as closely & uniformly as possible in line with the pressed overfeed on to the tips of the pins on the rubber brush roller & the continuous shrink belt underneath. Heating system: It is based on the oil circulating heating .the machine should be heated up only with the stenter chains running. in the same way, the heated machine Should never be left for prolonged periods with the stenter chain stationary. for this reason heating is automatically switched off when the machine is stopped on machine, without bypass flaps, when the machine is empty, the air circulation fan & suction fans must continue to run for approximately 15 min. after switching off the heating in order to condensation of the vapour treatment chamber monforts stenter are therefore adequate control reserve. the large heating capacity allows the circulating air in Monforts stenter to be heated up very quickly from room temperature to the
45

desired temperature .for physical reasons the circulating air heats up more quicker than the steel construction, so steel parts can therefore still be cold even when the circulating the air has already reached the desired treatment temperature when starting the machine, cold before the beginning of production, heat up the range without fabric to 250c at least one hour. After one hour the desired temperature can be set. Cooling zone: The fan draws in the ambient air & blows it via the nozzle system as top & bottom air current on the fabric. The fabric is carried on the air current.

Sanforizing machine Objective: The purpose of this machine is to provide the fabric with relaxation
shrinkage so that it does not shrink during later washings. This finish also increases the lusture and softens the handle of the fabric. The main function is to give shrinkage in the warp direction and fix it, until the next home wash, to avoid that the fabrics have any dimensional variation (shrinkage), and also improving the touch of fabric.

(B) SOFT FLOW DYING PROCESSH.O.D. - Mr. VINAY PRODUCTION/ SHIFT- 4Ton
So the fabric initially in the open form goes through the following path before it is made into a finished usable material.

Bleaching Dyeing Finishing Folding Made Ups

46

Machinery description: MACHINE USED FOR SAMPLE

Name Number of machine Make CAPACITY : DYING MACHINE : SIX : KRSNA, SCLAVOS, KROMSON : 6kg. , 10kg. , 18kg. , 40kg. , 40kg. , 80kg.

MACHINE USED FOR BULK

Name Number of machine Make : DYING MACHINE : NINE : SCLAVOS

CAPACITY : 360kg. , 360kg. , 540kg. , 540kg. , 720kg. , 180kg. . 280kg, 1500kg. , 1500kg. FINISHING MACHINES Name : DRYING MACHINE Number of machine Make Name Number of machine Make Name Number of machine Make Name Number of machine Make : TWO : LAFOR : STENTER : ONE : BRUCKNER : COMPACTOR MACHINE : TWO : LAFOR, SANATA COMPACT : ROLL CHECKING MACHINE : TWO : RAMSONS, ALMAC

PROCESS OF DYEING:-

Filling 7liquor (i.e. 7lit for 1kg)

Tank-2(wetting agent + caustic soda)

47

Tank-1(H2O2) Transfer to tank and hold for 15 min at 95oc

Wisdom rinsing

Drain

Filling soft water (2lit/kg) Rinsing at 60oc

Aciding for 5 min

Killer agent for 10 min (B.F.S.P.) Then rinsing at 0oc

Check Ph Then unloading and drain Filling soft water 4lit/kg and heat at 50oc Dyeing chemical

Levelling agent Check hardness

Colour dosing Hold time 10 min

48

Salt transfer Increase temperature about 80oc at 1.5o gradient Holding time 30 min

Water in tank -2 for soda Cooling about 60 oc at 1.5o gradient Hold time 15 min

Dosing of soda Hold time 15 min

Check hardness Hold time 45 min

Drain

Filling 2lit/kg Check Ph Heat at 50oc Rinsing at 50oc (8 lit/kg.) Rinsing at 50oc (12 lit/kg.) Water filling in tank 1
49

Acid transfer 8 min hold time

Soft water filling 2 lit/kg. Tank 2 water for soaping Check Ph

Transfer soaping agent from Tank-2 Hold at 95oc for 10 min Cooling about 80oc at 2o temperature gradient

Rinsing at 13 lit/kg Rinsing at 70oc at 12 lit/kg Rinsing at 0oc at 2 lit/kg

Check clarity

Drain

Unload

50

Finishing: Stenter (Buckner) Open width fabric

From Dyeing machine Dryer at 140oc Tubuler fabric

Compactor Sanata compact Syntex

Compactor KST-500 Lafor

Roll Checking ALMAC

Roll Checking RAMSONS

CHAPTER -7 SEQUENCE OF CUTTING DEPARTMENTS IN PRODUCTION

THE RAW MATERIAL OF CUTTING IS FINISHED DYED MATERIAL. FIRSTLY WE DONE SPREADING BY LECTRA M/C. SPREADING IS DONE TWO TYPES. FIRST IS MANUAL SPREADING&SECOND IS AUTOMATIC SPREADING. SPREADING LAYER WIDTH CAN NOT BE MORE THEN 4. AFTER SPREADING WE PREPARE MARKER FOR MINIMISE THE WASTE. AND THEN WE DOING CUTTING BY LECTRA CUTTING M/C.

THE FOLLOWING REQUIREMENT FOR CUTTING ARE USED.

NO. OF TABLE USED IN CUTTING 6. TYPES OF TABLE (1) LECTRA TABLE (2) MANUAL TABLE. TYPES OF FABRIC SINGLE JERSEY, LYCRA, VISCOSE, RIB (1/1, 8/4, 2/2). CUSTOMERSARA LEE, CAN, NIKE, HANS, CARREFOUR. PRODUCTION OF ONE SHIFT 60,000 PIECE.

51

NOTE
THE CAPACITY OF SPREADING M/C IS ABOUT 100KG. THE BUTTER PAPER IS USED FOR TO FIND THE NO. OF ROLL ON SPREADING LAYER. TWO TYPE OF KNIFE ARE USED IN THE CUTTING M/C. LECTRA CUTTING M/CBEND KNIFE. MANUAL CUTTING M/CSTRIPE KNIFE.

FLOW CHART

DYED FABRIC COMPACTOR PACKING CUTTING DEPARTMENT 4 LAYING (SPREADING) CUTTING (LECTRA M/C) TROLLY STORAGE (FEEDING DEPARTMENT) PRINTING

52

CHAPTER -8 SEQUENCE OF GARMENT DEPARTMENTS IN PRODUCTION

GARMENT:-Garment is the final product obtained. It is the final outcome of all the
processes; it is mainly constrained with the sewing.

PRODUCTS OF GARMENT DIVISION:- Men undergarment, ladies innerwear etc. MAJOR BUYERS: Carrefour Marinopoulos.SA, HANES, LINGRIGE. These are the buyers
which give the order for manufacture of the garment.

TYPE OF MACHINES USED AND THEIR MANUFACTURERS:

1. 2. 3. 4. 5. 6. 7. over lock machine (YAMATA-JAPAN) lock stitch machine (BROTHER and SUNSTAR-CHINA) cover seam machine (YAMATA-JAPAN) Bartech machine (BROTHER-CHINA) F.S machine (YAMATA-JAPAN) Attach elastic chain lock

MACHINE DISCRIPTION:
1. Over lock machine- there is a needle and two loops, with the combination of the above two they form 10 taka in an inch. It is used for elastic attach. 2. Lock stitch machine- there is a needle and a luper. It is similar to the sewing machine used at homes. 3. Covers seam machine- it is basically used to attach the fly folding. In this machine there are two needles and a luper. 4. Bartech machine- It provides taka at the specified point not on the entire fabric area. It is done in order to provide strength and extra extensibility. 24 takas are provided in one operation by this machine. 5. F.S. machine- The basic operation of this machine is to sew two or more heads of fabric. It is also used for fly attach. There are four needle and two lupers. 14-15 takas are provided in an inch by this machine.

53

6. Attach elastic machine: in this machine there are three needles and a luper. This machine is used to attach elastic, this elastic provide the required extensibility to the fabric. 7. Chain lock machine- The interlacement of the thread form a chain at the time of sewing. It has a luper and two needle.

SPECIFICATION PROVIDED BY BUYERSSIZE SPECIFICATIONS:SSMALL28-30inches 32-34inches 36-38inches 40-42inches

M- MIDDLELLARGE-

XL-EXTRA LARGE-

STYLE SPECIFICATION:1. STYLE- 7460-P4 SM-MD- 9.5 inches L4-XL- 10.5 inches 2. STYLE- 7694-P4 3. STYLE- 5624-P4, - 7795-P4/AB -7470CM -7480-P4 V4, C4, 4B/7690 V4, AS, AT

TYPE OF NEEDLE IN CARREFOUR BUYERSNAME OF THE MACHINE TYPE Folding,5T,Cover seem Pullar, C/S Open elastic, all Hat Lock All over lock Zigzag Bartek FS, Full att, net folding Lock stitch TYPE OF THE NEEDLE TV X3 MODEL NO. OF THE NEEDLE 60/8,65/9,70/10,75/11, 90/14 60/8,65/9,70/10,75/11, 90/14 60/8,65/9,70/10,75/11, 90/14 65/9,70/10,75/11 65/9
54

DC X1 DP X5 UY X113 DB X1

THREAD USED IN GARMENT DIVISION:

*TEX-18 (Colour-black, white, navy blue)

*Texturized polyester Filament *CFP Textursed Oeko-tex standard 100 Shirley.

DEFECTSBroken, MS MT, Strain, shade, hole

CHECKINGIf there is oil stains then the fabric is rejected

SPOTTINGChemical, steam and air pressure is used to clean the spotting. The chemical is usually washing soda. If there is a spot found in fabric or garment then the garment can be rejected.

PACKING:
After all the above mentioned operation the garment are packed to exported to the buyers.

55

CHAPTER -9 SEQUENCE OF KNITTING DEPARTMENTS IN PRODUCTION

M/ C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

TYPE RIB RIB RIB RIB 8 LOCK 8 LOCK 8 LOCK RIB 8 LOCK INTER RIB INTER RIB RIB 8 LOCK 8 LOCK RIB RIB

MODAL FV2.0 FLDR FLDR I 1108 FIL 8AE FIL 8AE FIL 8AE I 1108 OV 2.0 INOVIT 2.0 INOVIT 2.0 I 1108 OV 2.0 OV 2.0 I 1108 I 1108

MAKE MAYER &CIE FUKUH ARA FUKUH ARA TERROT FUKUH ARA FUKUH ARA FUKUH ARA TERROT MAYER &CIE MAYER &CIE MAYER &CIE TERROT MAYER &CIE MAYER &CIE TERROT TERROT MAYER &CIE MAYER &CIE

M/C 1 JAPAN JAPAN GERM ANY JAPAN JAPAN JAPAN GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY

TYPE RIB 60 60 54 84 84 84 54 96 60 60 54 108 108 54 50 96 96

MODAL MAKE FV2.0 30 30 30 30 33 33 30 30 30 30 30 34 34 30 30 30 30 MAYE R&CIE 18 18 18 18 18.24 18.24 18 24 18 18 18 18 18 18 18 20 20,24,2 8

CAPACITY 350d 400d 400d 300d 450d 500d 500d 300d 360d 350d 350d 300d 550d 550d 300d 300d 400s 400s

FLEECE MBF 3.2 FLEECE MBF 3.2

56

19 20 21 22 23 24 25

SINGLE JERSEY RIB

MV4 3.2 I 1108

MAYER &CIE TERROT MAYER &CIE MAYER &CIE MAYER &CIE MAYER &CIE LAXMI TERROT MAYER &CIE FUKUH ARA MAYER &CIE FUKUH ARA MAYER &CIE TERROT TERROT TERROT TERROT TERROT TERROT TERROT TERROT TERROT TERROT TERROT

FLEECE MBF 3.2 FLEECE MBF 3.2 SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY TERRY RIB MV4 3.2 MV4 3.2 S 296

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

MPU 1.6 FLDR

GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY INDIA N BASED GERM ANY JAPAN GERM ANY JAPAN GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM

96 54 96 96 84 96 96

30 30 30 30 26 30 30

28 18 20,24,2 8 20,24,2 8 24,28 20,24,2 8 24,28

400S 300d 400s 400s 350s 400S 250s

48 60 96 84 96 64 64 64 64 64 64 100 100 100 100 109

30 30 30 33 30 36 36 36 36 36 36 36 36 36 34 34

24 18 20,24,2 8 18,24 20,24,2 8 18 18 18 18 18 18 18 18 18 28 28

300s 400d 400s 500d 400s 450d 450d 450d 450d 450d 450d 600d 600d 600d 550s 550s
57

FLEECE MBF 3.2 8 LOCK FIL 8AE

FLEECE MBF 3.2 RIB RIB RIB RIB RIB RIB RIB RIB RIB SINGLE JERSEY SINGLE I3P154 I3P154 I3P154 I3P154 I3P154 I3P154 I3P284 I3P284 I3P284 S296-1 S296-1

42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY

S296-1 S296-1 RELANI T II RELANI T II RELANI T II RELANI T II RELANI T II RELANI T II RELANI T II RELANI T II S296-1 BW S296-1 BW S296-1 S296-1 S296-1 S296-1 S296-1 S296-1

TERROT TERROT MAYER &CIE MAYER &CIE MAYER &CIE MAYER &CIE MAYER &CIE MAYER &CIE MAYER &CIE MAYER &CIE TERROT TERROT TERROT TERROT TERROT TERROT TERROT TERROT

ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY GERM ANY

109 109 114 114 114 114 114 114 114 114 115 115 115 115 115 115 115 115

34 34 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36

28 28 28 28 28 28 28 28 28 28 28 28 24,36 24,36 24,20 24,20 24 24

550s 550s 550s 550s 550s 550s 550s 550s 550s 550s 400s 400s 650s 650s 650s 650s 650s 650s

58

FLAT KNITTING MACHINES/ TAPE MACHINE

31 32 33 34 35 36 37 FLAT MACHINE FLAT MACHINE FLAT MACHINE FLAT MACHINE TAPE MACHINE FLAT MACHINE FLAT MACHINE CMT 211 CMT 211 CMT 211 CMT 211 STOLL STOLL STOLL STOLL VARITEX SMA 121J FLYING TYGER SMA 121J FLYING TYGER GERMANY GERMANY GERMANY GERMANY INDIAN BASED TAIWAN TAIWAN 6 6 6 6 6 HEAD 6 6

KNITTING INSPECTION MACHINES

1 2 3 4 INSPECTION MACHINE INSPECTION MACHINE INSPECTION MACHINE INSPECTION MACHINE CALATOR GUVEN CELIK GUVEN CELIK CARDWELL

TYPES OF FABRIC
SINGLE JERSEY SINGLE JERSEY ELASTANE 1X1 RIB LYCRA 2X1 RIB LYCRA SINGLE PIQUE LYCRA DOUBLE PIQUE & LYCRA HONEY COMB 3T FLEECE 2T FLEECE TERRY FABRIC TWILL FABRIC SINGLE JERSEY DRIFIT SINGLE PIQUE DRIFIT

TYPE OF LYCRA CREORA DUPORIT(1) 1U025 (2) ELASPANE

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TYPE OF NEEDLES GROZ BACKERT HIGHER COST(AVG.RS.27) SAMSUNG -CHEAPER COST(AVG.RS.15)

TYPE OF KNITTING OIL CASTROL-LOW COST VICKERS HIGH COST

COST

NEEDLE COSTRS.0.25/KG OIL COST RS.0.35/KG POWER COSTRS.2.5/KG

REJECTION LYCRA STITCH/LYCRA OUT 30-40% NEEDLE LINE 30-40% SETTING 5-10% OTHERS 10-35% NOTE

SINGLE JERSEYONLY SINKER & NEEDLES (NO. OF SINKER=NO. OF NEEDLE) DOUBLE JERSEYNEEDLES [ NO OF NEEDLES = DIA X GAUGE X 3.14 ]

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CHAPTER -10

TIME OFFICE

It is the initial and final stage for the worker. The function of time office is to record keeping (record for rest, leave) and to keep the record of the attendance.

The function of the time office is to maintain the workers in shift as per requirement of the shift.

The function of the time office is to keep the record of overtime and give extra benefit to that worker.

Thank You

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UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE Kanpur

A REPORT ON SUMMER VACATION PRACTICAL MILL TRAINING AT PRATIBHA SYNTEX LIMITED

(20.07.20011 TO 02.08.20011) Submitted To: Mr. GOPAL DIXIT (UPTTI KANPUR) Submitted By: SANJEEV SINGH (0804463031) VIRENDRA KUMAR KANAUJIYA (0804463042) SATYAJEET LENKA (2904463002) BRANCH TEXTILE ENGINEERING

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