CHAPTER I

INTRODUCTION

An internship is a professional learning experience that offers students and recent

graduates an opportunity to gain practical skills and insights in a real-world work
environment. Internships are designed to bridge the gap between academic education and the
professional world, allowing individuals to apply theoretical knowledge in a practical setting.
Interns often work within organizations or industries related to their field of study, providing
them with hands-on experience that enhances their understanding of the industry, its
challenges, and best practices.

Internships play a crucial role in shaping the career paths of students, helping them explore
potential career options, develop key competencies, and network with professionals. The
experience gained through internships is invaluable, as it gives interns a competitive
advantage in the job market, helping them stand out from other candidates. Moreover, many
organizations use internships as a way to identify potential future employees, providing
interns with the possibility of full-time employment after successful completion.

Internships vary in length, structure, and responsibilities, but they are all centred on the idea
of experiential learning. They allow individuals to understand the dynamics of professional
environments, contribute to organizational projects, and gain mentorship from experienced
professionals. The internship experience is a two-way exchange, where interns contribute
their fresh perspectives and ideas, while organizations provide learning opportunities that
prepare interns for their future careers.

OBJECTIVES

Gaining Practical Experience

One of the primary objectives of an internship is to provide interns with hands-on experience
in their chosen field. By working on real-life projects and tasks, interns are able to apply the
knowledge they have gained from academic learning to real-world situations. This practical
experience helps them understand the daily operations of their industry, as well as the
challenges and opportunities it presents.
Developing Professional Skills

Internships help students and recent graduates develop essential skills that are necessary for
success in any professional environment. These skills include communication, teamwork,
problem-solving, time management, and adaptability. By working in a professional setting,
interns learn how to interact with colleagues, manage deadlines, and navigate workplace
dynamics, all of which contribute to their professional growth.

Building a Professional Network

Internships provide a valuable opportunity for interns to connect with industry professionals
and build a network that can be beneficial for their future career. Networking is crucial for
career development, as it opens doors to job opportunities, mentorship, and collaboration.
Interns can establish relationships with supervisors, colleagues, and other interns, which can
serve as a foundation for their future career progression.

Exploring Career Paths

Internships allow individuals to explore various career options within their field of study.
They may discover new interests, strengths, or areas of expertise that they had not previously
considered. This exploration helps interns make informed decisions about their future career,
whether it is pursuing a specific role, further education, or professional certifications.

Enhancing Academic Knowledge

Internships reinforce academic learning by providing a practical context for theoretical

concepts. Interns are often able to see the relevance of what they have learned in the
classroom, which enhances their understanding of the subject matter. Additionally, some
academic institutions offer credit for internships, making the experience an integral part of
the educational journey.
Improving Employability

One of the most significant objectives of an internship is to improve employability. By

gaining work experience, developing skills, and building a professional network, interns
increase their chances of securing a job after graduation. Employers often look for candidates
who have relevant experience, and internships provide a way to demonstrate that experience.

Receiving Mentorship and Feedback

Internships offer the opportunity to receive guidance and mentorship from experienced
professionals. Interns are often paired with supervisors or mentors who provide feedback on
their performance, offer advice on career development, and help interns navigate their
professional journey. This mentorship is invaluable for personal and professional growth, as it
helps interns learn from the experiences of others and improve their skills.

Understanding Workplace Culture

Another key objective of internships is to help interns understand and adapt to workplace
culture. Every organization has its own unique culture, including values, work habits,
communication styles, and expectations. By experiencing this culture firsthand, interns learn
how to integrate themselves into professional environments, fostering a deeper understanding
of workplace norms and behaviours.

Contributing to Organizational Goals

While internships are primarily learning experiences, they also provide interns with the
opportunity to contribute to organizational goals. Interns often work on projects or tasks that
support the mission of the organization. This not only gives them a sense of accomplishment
but also demonstrates their ability to add value to the workplace.
 CHAPTER II

INDUSTRY PROFILE
INTRODUCTION

The spinning mill industry in India holds a prominent position in the global textile market.
With its second-largest spinning capacity of 48 million spindles, India is not only a global
leader but also the market leader in yarn trade, exporting approximately 1.2 million tons of
yarn with a 30% share.

The history of spinning mills in India dates to the early years of the cotton textile industry.
The cotton-growing regions of Rajasthan, Maharashtra, and Gujarat housed most of the
cotton textile sector. Availability of raw materials, market, transport, labour, moist climate,
and other factors contributed to localization. This industry played a vital role in Bombay's
economy at the beginning of the 20th century, but it quickly fell after the country's
independence, largely due to deregulation beginning in the mid-1980s.

India’s textiles sector is one of the oldest industries in the Indian economy, dating back to
several centuries. The industry is extremely varied, with hand-spun and hand-woven textiles
sectors at one end of the spectrum, with the capital-intensive sophisticated mills sector at the
other end. The fundamental strength of the textile industry in India is its strong production
base of a wide range of fibre/yarns from natural fibres like cotton, jute, silk, and wool, to
synthetic/man-made fibres like polyester, viscose, nylon and acrylic.

The decentralised power looms/ hosiery and knitting sector form the largest component of the
textiles sector. The close linkage of textiles industry to agriculture (for raw materials such as
cotton) and the ancient culture and traditions of the country in terms of textiles makes it
unique in comparison to other industries in the country. India’s textiles industry has a
capacity to produce a wide variety of products suitable for different market segments, both
within India and across the world.

To attract private equity and employee more people, the government introduced various
schemes such as the Scheme for Integrated Textile Parks (SITP), Technology Upgradation
Fund Scheme (TUFS) and Mega Integrated Textile Region and Apparel (MITRA) Park
scheme.
Tamil Nadu, in particular, is a major hub for spinning mills in India. According to Business
Standard, It boasts a significant number of spinning mills, with approximately 2,032 mills out
of the total 3,542 mills in the country. Highest in the country. The major cities with spinning
mills in the state are Coimbatore, Salem, Tirupur, and Erode.

Super Spinning Mills Limited, Bannari Amman Spinning Mills Limited, RG Spinning Mills
Private Limited and Sri Balaji Spinning Mills are some of the top spinning mills in Tamil
Nadu.

Next on the list is Gujarat. According to Times Of India, the state has 120 spinning mills out
of which 75 are in Saurashtra. Other major cities with spinning mills in Gujarat are
Ahmedabad, Surat.

Sanvi Spinning Mill Pvt. Ltd, Shri Muniveer Spinning Mills, Vaibhav Ginning & Spinning
Mills Pvt Ltd and Marutinandan Spinning Mill are some of the top spinning mills in Gujarat.

Maharashtra is third on the list and has Mumbai as the largest centre in India, having 63 mills
out of the state's total of 122 mills. Other major cities with spinning mills in Maharashtra are
Nagpur and Solapur.

Trimurty Spinning Mills Pvt.Ltd, Sanjay Gandhi Coop Spinning Mills, Suryaamba Spinning
Mills Limited and GTN Spinning Mills are some of the top spinning mills in Maharashtra.

Other than these states Andhra Pradesh, Karnataka and Manipur have a considerable amount
of spinning mills.

Growth and Development of Spinning Mills

The spinning sector in India has witnessed significant growth and development, driven by
policy reforms and technological advancements. Policy changes that began in the 1980s and
1990s were extremely important in boosting technical efficiency and global competitiveness,
especially in the spinning industry.

These reforms paved the way for the modernization and expansion of spinning mills in the
country. India's spinning segment is modernized, with approximately 35 to 40 percent of
spindles being less than 10 years old. The industry has embraced technological
advancements, and during 1989-98, India was the leading buyer of spinning machinery,
accounting for 28% of global shipments

This modernization has contributed to the industry's competitiveness on the global stage.

The Tamil Nadu government has several schemes for spinning

mills, including:
 Technology Upgradation Fund Scheme (TUFS)

This scheme provides a 2% interest subvention for investments in technological upgradation

and modernization in spinning mills.

 Tamil Nadu New Integrated Textile Policy 2024

This policy includes a special scheme for technological upgradation in the spinning sector,
with a 6% interest subvention over the next 10 years.

 PM Mega Integrated Textile Regions and Apparel Parks (MITRAs) Scheme

This scheme aims to streamline the textile value chain by integrating spinning, weaving,
processing, and garment manufacturing into one location.

 TANSPIN

This organization provides technical and other assistance to member mills for the selection,
purchase, installation, and maintenance of equipment.

 Pradhan Mantri Jeevan Jyoti Bima Yojana (PMJJBY)

This scheme provides a death benefit of Rs. 2,00,000 to the family of a deceased weaver.

The Tamil Nadu Budget 2024 also includes other announcements for the textile industry, such
as:

 Development of the PM MITRA Park in Virudhunagar

 A textile park in Salem

 Higher capital subsidy for investments in technical textiles

 Establishment of 10 mini-textile parks in Erode, Karur, and Virudhunagar

 Setting up of a research and business development centre for technical textiles

What are the Different Types of Spinning Mills?
Different mills use different spinning techniques and are hence known for that. Composite
mills are relatively large-scale mills that integrate spinning, weaving, and sometimes fabric
finishing, all under one roof.

In other major textile-producing countries, composite mills are common. However, in India,
they now account for only about 3% of the output in the textile sector. It's important to note
that while spinning mills themselves use different spinning techniques, the classification of
spinning mills is typically based on factors like size, production capacity, and the type of
fibres
used.

1. Ring Spinning:

Ring spinning is the most popular and worldwide used spinning technique. In this method,
fibres such as cotton, wool, or flax are drawn out into a roving, which is then attenuated by
using drawing rollers. The attenuated roving is then looped and twisted around a spindle that
is housed inside a separately revolving ring flyer. The spindle imparts a twist to the fibre
strand, and the yarn is wound onto a bobbin due to the traveller and ring combination. Ring
spinning is a continuous process, and the yarn produced is of high quality and strength.

2. Rotor Spinning:

Rotor spinning is a more recent method of yarn formation compared to ring spinning. In this
method, a continuous supply of fibres is delivered from delivery rollers off a drafting system
or from an opening unit. The fibres are then separated by rigorous drafting and collected in a
rotor cup. The rotor spins rapidly, imparting a twist to the fibres, and the yarn is continuously
taken off by the delivery shaft and the pressure roller through the nozzle and the draw-off
tube and wound onto a cross-wound package. Rotor spinning is a high-speed process, and the
yarn produced is cheaper than ring-spun yarn. However, rotor-spun yarns are more even,
somewhat weaker, and have a harsher feel than ring-spun yarns.
3. Vortex Spinning:

Vortex spinning is a relatively new spinning technique that uses high-speed airflow to insert a
twist into the yarn. The process involves drawing out cotton sliver and drafting it to the
desired yarn count via a four-roller apron drafting system. The fibres are then collected on a
perforated drum, where they are twisted into yarn. The vortex spinning technique utilizes
high-speed airflow to insert a twist into the yarn, which greatly increases the rotational speed
of the fibre strand, making the process faster and more energy-efficient. The yarn produced
by vortex spinning is less hairy, has low pilling, and has higher abrasion resistance.

In addition to the main spinning techniques, there are other notable spinning techniques that
contribute to the diverse world of yarn production such as worsted spinning technique and
hand spinning technique.

4. Worsted Spinning:

Worsted Spinning is a specialized technique used to produce smooth and strong yarn. It
involves aligning the fibres parallel to each other before twisting them. Worsted spinning is
commonly used for producing high-quality yarns for fine fabrics, such as suiting materials
and high-end knitwear.

5. Hand spinning

Hand spinning an ancient craft predating industrial mills, uses a spindle or wheel to transform
fibres into yarn. Artisans and hobbyists value its personalized, artistic touch, creating unique,
handcrafted yarns.

6. Air-Jet Spinning:

Air-jet spinning is a technique that uses high-speed airflow to insert twists into fibres,
creating yarn that is less hairy and has unique properties. Air-jet spinning is known for its
high-speed production and energy efficiency, producing yarn wounds about two to three
times faster than rotor yarns and about 20 to 30 times faster than ring yarns. It is used for a
variety of applications, including apparel, home textiles, and industrial textile.

7. Twist less Spinning:

is a technique that produces yarn without any twist. This process produces spun yarn that is
alternatively twisted in S and Z twists, with varying lengths between each twist. Twistless
spinning is used for producing fancy yarns with unique textures and appearances

8. Self-Twist spinning:

Self-Twist spinning is a method where Two strands are twisted and plied in a single step
using the spinning technique to create a two-fold yarn with an even distribution of torque.
The self-twist spinning method is used for producing fancy yarns with unique textures and
appearances.
 CHAPTER III

COMPANY PROFILE
Suriya spinning mills Unit-B is located in Sakthi Co-operative Industrial estate,
Thozhirpettai. This unit was started in the year 2010, and its former unit was started in the
year 2003 by Mr. Venkatasubramaniam. K (managing partner). This is a partnership firm.
The raw material cotton used in this firm is mostly purchased from northern states of India
including Maharashtra and even imported from Australia through yarn agents. The
stock(bale) is stored for nearly one year. This spinning mill has a separate warehouse owned
by the company itself for the purpose of stocking raw materials. The company purchases
long, medium and short fibres. The short and long fibres are mixed for attaining stable
quality. When the count increases the thickness decreases. The existing unit runs at a count
ranging 64-92. The weight of each cone manufactured ranges from 1kg to 1.25 kg. When the
price of the yarn increases the demand for the yarn decreases. So the yarn is purchased in the
months of November to March which is the harvest period and stocked for 6 to 7 months.

VISION

The company’s vision is to step into fabrication and aims to implement doubling which is the next
step of spinning in textile industry.

Strengths
 The quality of the yarn is of grade 1.
 Electricity bill is low as Tamil Nadu Electricity Board detects the charges in exchange
with electricity produced by the windmills owned by the company.
 Proper inventory maintenance
 Efficient labours from the Northern parts of India.
 Own warehouse for storing bulk inventory.
 No power interruption in the peak hours.

Opportunities
 Loans are taken from Small Industrial Development Banking of India for the purpose
of installing machineries.
 The location of this mill is an industrial area so there is no power interruption.
 Surrounded by many stakeholders’ firm’s which always leads to a less logistics
expense.
 Uninterrupted labour supply.

Opportunities:
 The main industrial area of the town provides many business opportunities without
much need for promotion.
 The industrial area provides opportunities for labours recruitment.
 It is easily accessible by all stakeholders.
Threats:
 There are severe threats found as there is no competitors and external factors which
negatively affect the firm.
 The competitors are other yarn manufacturers but shows no deflection impacting in
the loss of the firm.
 The lorry strikes and hike in price of fuel often interfere with the logistics of raw
materials and finished goods.

TRENDS:

 Overhead blower is installed for the purpose of sucking minute dust particles. Clearing dust
enhances the quality of the yarn.
 Humidification plant is installed at each unit which controls internal temperature as
humidification plays a major role in quality.

Evolution

1970 Sakthi Velu Polypack

2003 Unit-A
(Head office)
20112 spindles
2010 Unit-B
27752 spindles
 2019 Windmill
2 M.W (Tuticorin, Palladam)
2022 March
Solar Power Plant 1.5 M. W,
July
1 M.W (Madurai, Virudhunagar)
2023 March
Solar Power Plant
1.5 M. W (Mulanur)
2024 Unit-C
7872 spindles (expansion done), 4992
spindles are under process.

CHAPTER IV

MANUFACTURING PROCESS AT SURIYA SPINNING MILLS

Bale opening:

The bale of cotton brought into the spinning department is first opened for further processes
in blow room. It is done manually here.
Stack Mixing:

The opened bales are mixed.

Blow room:

Basic operations in the blow room are:

➤ Opening

➤ Cleaning

➤ Mixing or blending

➤ Micro dust removal

➤ Uniform feed to the carding machine

➤ Recycling the waste

Blow room installations consist of a sequence of different machines to carry out the above
said operations. Moreover, Since the tuft size of cotton becomes smaller and smaller, the
required intensity of processing necessitates different machine configuration.

Opening in blow room means opening of cotton into small flocks. Technological operation of
opening means the volume of the flock is increased while the number of fibres remains
constant. i.e. the specific density of the material is reduced.

✓ The larger the dirt particle, the better they can be removed.
✓ Since almost every blow room machine can shatter particles, as far as possible a lot of
impurities should be eliminated at the start of the process. Opening should be followed
immediately by cleaning, if possible, in the same machine.

The higher the degree of opening, the higher the degree of cleaning. A very high cleaning
effect is almost always purchased at the cost of a high fibre loss. Higher roller speeds give a
better cleaning effect but also more stress on the fibre.

MACHINE AT SURIYA SPINNING MILLS:

Salient Features:

✔Machine working width is 1600 mm.

✔Infinitely variable production up to 800 kg/hr without opening and cleaning roller and upto
600 kg/hr with opening and cleaning roller.

✔ Additional bypass roller aid for a smooth flow of material when the machine is bypassed.

✔In-built panel with PLC and Inverter helps to monitor the machine parameters.

✔Dynamic change of Lattice and feed roller speeds possible.

✔ Fault annunciations through display.

✔Fibre yield with simultaneous efficient cleaning is up to 2% higher than on conventional

units.
✔Energy-saving due to low air consumption.

✔Pre-cleaning without nipping and the use of mote knives results in fibre-preserving
cleaning.

✔The large dedusting surface ensures intensive dedusting even at high production
performance.

✔Rapid assessment of high cleaning performance and low losses of good fibres by visual
waste checks.

Mixing or blending:

The consistency in yarn quality depends heavily on the homogeneity of the material
composition. The objective of

mixing is to optimize the homogeneity of the material mixture by combining several bales.

Further objectives of mixing are:

✓ Decrease of irregularities in bales of different origin.

✓Economic processing.

✓ Recycling of comber waste.

✓ Effect on the properties of final product.

✓ Reduction of raw material costs.

✓ Usually are fibres stocked in one direction and remove in perpendicular direction.
Perfect and Homogeneous blend is achieved, simultaneous mixing by doublings over an
extended period is achieved.

The cotton bales are opened and premixed by bale opener.

This blend is blown by the material transport fan and conveyed into the feed duct above

the hopper.

The charging of the multimixer starts with the first hopper at the end of the feed duct.

It is filled only to just below the photocell situated in the adjacent hopper, then the closing
flap of the second hopper is opened by push button operation.

Second hopper is charged to a rather higher than the first. The charging level of the hopper
rises uniformly up to the last hopper, which is fully charged, when the last hopper is full the
Closing flap shuts automatically and charging restarts with first hopper, as soon as the level
second hopper has dropped below the Photo Electric cell. Whilst the last hopper is being
charged, material transport is switched on and material in the hoppers starts to drop.

When the charging level rises, more and more of the holes in the perforated plate of the upper
part of hopper are blocked with material. This increases the pressure the conveyor air. Once a
pre-selected pressure is reached, which corresponds to a particular charging level, an
electronic switch closes the flap of this hopper and opens up the flap of the next hopper."

The base of each hopper is closed by a pair of deliver roller which transfers the material
gradually and uniformly to an opening roller. The delivery rollers of the entire hopper are two
variable speed motor with control range up to 1: 6 in this way it is possible to adjust the
output of multimixer to the feed requirement of the subsequent machine.

Opening roller gently loosen the material into tufts and deliver them into the blending
channel from which they are sucked by the subsequent condenser.

Micro dust Removal:

Cotton contains very little dust before ginning. Dust is therefore caused by working of the
material on the machine. New dust is being created through shattering of impurities and
smashing and rubbing of fibres. However, removal of dust is not simple. Dust particles are
very light and therefore float with the cotton in the transport stream. Furthermore, the
particles adhere quite strongly to the fibres. If they are to be eliminated, they are to be rubbed
off. The main elimination points for adhering dust, therefore, are those points in the process
at which high fibre/metal friction or high fibre/fibre friction is produced.

Removal of finest particles of contaminants and fibre fragments can be accomplished by

releasing the dust into the air, like by turning the material over, and then removing the dust-
contaminated air. Release of dust into the air occurs wherever the raw material is rolled,
beaten or thrown about. Accordingly, the air at such positions is sucked away. Perforated
drums, stationary perforated drums, stationary combs etc. are some instruments used to
remove dust.
CARDING

"Card is the heart of the spinning mill" and "Well carded is half spun" are two proverbs of the
experts. These proverbs inform the immense significance of carding in the spinning process.
High production in carding to economise the process leads to reduction in yarn quality.
Higher the production, the more sensitive becomes the carding operation and the greater
danger of a negative influence on quality. The technological changes that has taken place in
the process of carding is remarkable. Latest machines achieve the production rate of 60-100
kgs/hr, which used to be 5-10 kgs/hr, up to 1970.

The Purpose of Carding:

 To open the flocks into individual fibres

 cleaning or elimination of impurities
 reduction of neeps
 elimination of dust
 elimination of short fibres
 fibre blending
 fibre orientation or alignment
 sliver formation

CARDING AT SURIYA SPINNING MILLS

The opening effect is directly proportional to the number of wire points per fibre. At the
Taker-in perhaps 0.3 points/ fibre and at the main cylinder 10-15 points/fibre. If a given
quality of yarn is required, a corresponding degree of opening at the card is needed. To
increase production in carding, the number of points per unit time must also be increased.

This can be achieved by:

✓ more points per unit area (finer clothing)

✔ higher roller and cylinder speeds

✓ more carding surface or carding position

Speeds and wire population has reached the maximum, further increase will result in design
and technological problems. Hence the best way is to add carding surface (stationary flats).

Carding plates can be applied at

✓ under the liker-in

✓ between the licker-in and flats

✓ between flats and doffer

Taker-in does not deliver 100% individual fibres to main cylinder. It delivers around 70% as
small flocks to main cylinder. If carding segments are not used, the load on cylinder and flats
will be very high and carding action also suffers. If carding segments are used, they ensure
further opening, thinning out and primarily, spreading out and improved distribution of the
flocks over the total surface area. Carding segments bring the following advantages:

✓ improved dirt and dust elimination

✓ improved disentanglement of neps

✓ possibility of speed increase (production increase)

✓ preservation of the clothing

✓ possibility of using finer clothing on the flats and cylinder

✓ better yarn quality

✓ less damage to the clothing

✓ cleaner clothing

The opening effect is directly proportional to the number of wire points per fibre. At the
Taker-in perhaps 0.3 points/ fibre and at the main cylinder 10-15 points/fibre. If a given
quality of yarn is required, a corresponding degree of opening at the card is needed. To
increase production in carding, the number of points per unit time must also be increased.

This can be achieved by:

✓ more points per unit area (finer clothing)

✔ higher roller and cylinder speeds

✓ more carding surface or carding position

Speeds and wire population has reached the maximum, further increase will result in design
and technological problems. Hence the best way is to add carding surface (stationary flats).
Carding plates can be applied at
✓ under the liker-in

✓ between the licker-in and flats

✓ between flats and doffer

Taker-in does not deliver 100% individual fibres to main cylinder. It delivers around 70% as
small flocks to main cylinder. If carding segments are not used, the load on cylinder and flats
will be very high and carding action also suffers. If carding segemets are used, they ensure
further opening, thinning out and primarily, spreading out and improved distribution of the
flocks over the total surface area. Carding segments bring the following advantages:

✓ improved dirt and dust elimination

✓ possibility of speed increase (production increase)

✓ preservation of the clothing

✓ possibility of using finer clothing on the flats and cylinder

✓ better yarn quality

✓ less damage to the clothing

✓ cleaner clothing

COMBING

Lapping is a preparatory process for combing. The main objective is to flatten the slivers and
obtain a dense lap of fibres to maintain fineness of the combed slivers.

Combing is a method for preparing fibre for spinning by use of combs. It is a technique that
has been used in the preparation of textiles for centuries. Essentially, combing is a process
that helps to smooth and prepare fibres for use in spinning. Combing also helps to separate
short fibres from longer ones, which also helps to make the process of spinning much easier.

While the combs used in this process of fibre preparation do function with a combing action,
the actual devices have no more than a passing resemblance to the combs used on hair. For
textile purposes, the fibre combs are equipped with long metal teeth. Two combs are utilized
in tandem, with one comb holding the strand of fibre in place while the other comb moves
across the surface of the fibre.

Combing accomplishes two tasks at once. As the comb moves through the fibre, it slowly
separates the shorter fibres from the longer ones. Short fibres do not work well in a spinning
operation but may be set aside and processed using a technique known as carding. The longer
fibres are arranged into flat bundles, with all the fibres facing the same direction. These
bundles can then be processed through spinning, creating yarn and thread that can then be
used to weave cloth.
Combing is normally used to prepare a worsted yarn that is made of natural fibres, such as
cotton. In fact, combing cotton is a common process when the fibre is intended for use in
various forms of apparel. The combed cotton will feel smoother to the touch, and also
produce a garment that will wear longer than a garment made with uncombed cotton.

Not all natural fibre

yarns are made by
combing, however,
Woolen yarn is one
example. This type of
yarn is made by carding
the wool only; the
additional step of
combing is not
performed. Carding
straightens some of the
fibres, but not to the
degree that combing
does. The result is a
lighter, stretcher yarn
with more air.

In general, carding is used on shorter fibres, while longer fibres are combed. Many textile
companies will employ both combing and carding in the preparation of fibres for use in
different types of products, such as shirting fabric, towels, sheeting, and other essential
household items.

SEQUENCE OF OPERATION IN A COMBER

 Feeding, lap is fed by feed roller.
 Fed lap gripped by the nipper
 Gripped lap is combed by circular comb
  Detaching roller grips the combed lap and moves forward while the detaching roller
delivers the material, top comb comes into action to further clean the lap.
 While going back, nipper opens and receives a new bit of lap.
 The raw material delivered by the carding machine can not be fed directly to the
comber.
 Lap preparation is a must.

Draw Frame

8 slivers are combined to form one sliver to increase the uniformity and strength of sliver.
Drawing is the process of combining several carded slivers into a single sliver. It eliminates
irregularities that would cause too much
variation if the slivers were put individually.

Blending of fibres can be done by

combining slivers of different fibres. Within
the card sliver is a substantial proportion of
fibres with hooked ends. These hooks are
formed as the fibres are moved along by the
carding machinery. Their presence reduces
the effective length of the fibre, and if these
hooks are not removed the yarn produced
will be weaker. Drawing out removes these
hooks.

TASKS OF DRAWFRAME

 Through doubling the slivers are

made even
 doubling results in homogenization(blending)
 through draft fibres get parallelised
 hooks created in the card are straightened
 through the suction, intensive dust removal is achieved
Defects arising during drawing stages:

 Usable fibres in suction waste.

 Single sliver.
 Cuts in the sliver.
 Improper coiling.
 Improper stock filling.
 Improper functioning of auto levellers.

SPEED FRAME

120 sliver cans in one speed frame. Attenuation- drafting the sliver into roving:

✓ twisting the drafted strand

✓ winding the twisted roving on a bobbin

The slivers are to be thinned out to the level required for the yarn to be spun. This process of
attenuating the slivers is done in several steps on the Speed Frames. While converting slivers
into roving, a small amount of twist is also inserted so that the roving could with-stand the
winding and the unwinding tensions. The roving is would on suitable bobbins. Under
conventional system of fly frames process, the machine use in this department are slubbing
frame, intermediate frames and roving frames. Except as regard the numbers of spindles
speed and dimensions of bobbins, the object structure and machine of all these frames are
practically the same. The attention of the sliver is done gradually at each of these fly frames,
depending upon the draft capacity of the machines. The drafting system employed determines
the quality of the roving produced at the fly frames. All the advantage in technology the
slubbing and roving process is eliminated and the material in processed through only the
passage of fly frames, viz. the caned inner frames.

✓ Fibre to fibre cohesion is less for combed slivers. Rollers in the creel can easily
create false drafts. Care must be taken to ensure that the slivers are passed to the
 drafting arrangement without disturbance. Therefore, a perfect drive to the creel
rollers is very important.

✓ The drafting arrangement drafts the material with a draft between 5 and 15. The
delivered strand is too thin to hold itself together at the exit of the front bottom roller.

✓ Bobbin and flyer are driven separately, so that winding of the twisted strand is
carried out by running the bobbin at a higher peripheral speed than the flyer.

✓ The bobbin rail is moving up and down continuously, so that the coils must be
wound closely and parallel to one another to ensure that as much as material is wound
on the bobbin.

✓ Since the diameter of the packages increases with each layer, the length of the
roving per coil also will increase. Therefore, the speed of movement of bobbin rail
must be reduced by a small amount after each completed layer

✔ Length delivered by the front roller is always constant.

The following parameters are very important in SPEED FRAME. They are

 Feed hank
 Delivery hank
 Twist in the roving
 Roving tension
 Bobbin content
 break draft
 flyer speed
 Drafting system
 Creel and creel draft
 Draw frame slivered can
 Bottom roller setting
 Bobbin height
  Top roller setting
 Breakage rate
 condensers and spacers
 Piecing

RING FRAME:

The last stage in the manufacture of yarn is spinning. In order to convert the roving into the
required counts main operation which are simultaneously carried out off the ring frame are
twisting and winding.

The roving received from the fly. frame department is still much thicker than the thickness
final yarn required. Therefore, the first process on the ring frame is drafting. The other
operation which are done in the ring frames are twisting and winding. The amount of twist
inserted here is larger than at any other previous stage on order to strengthen for the end use
required. The twisted yarn in wound on bobbins.

Hence this process is carried out:

 To draft the roving until the required fineness is achieved

 To impart strength to the fibre, by inserting twist
 To wind up the twisted strand (yarn) in a form suitable for storage, transportation and
further processing.

WINDING
Since bobbins from ring frames are not suitable for further processing, hence winding of
yarns on cones is done.

 First, yarns from bobbins are wound onto cones

 Secondly, if the yarns are to be dyed, then yarns from cones are transferred to soft
package.
 After dyeing, yarns are wound onto cones again for proper unwind of yarns during
warping.

Yarn conditioning

Yarn conditioning, which involves steaming yarn to increase its moisture content, is a process
used in textile spinning mills. The process can improve the moisture content of yarn by 1.5–
1.8%, depending on the yarn and conditioning parameters. The presence of moisture in the
mill atmosphere has a significant impact on the physical properties of fibers and yarns. High-
speed spinning machines generate more friction, thus giving additional heat to the yarn and as
a result of such heat transfer the yarn moisture content is vaporized. For quality reasons, it is
absolutely important to have even distribution of this recuperated moisture throughout the
entire yarn package. The two parameters such as relative humidity and temperature will
decide the amount of moisture in the atmosphere.

 Steam generation: The steam is generated outside the plant and is saturated with cold
steam.

 Evacuation and impregnation: The yarn is evacuated and impregnated with

saturated steam multiple times to ensure that the moisture penetrates evenly.

 Precision sensors: Sensors are used to ensure consistent performance between

batches.

 Fine tuning: The process can be fine-tuned on-site to get the best results for the
specific yarn.

The cones are kept in an enclosed chamber, which shall first be made vacuum by a vacuum
pump. By this, the trapped air between fibres and yarns are taken out. Afterwards live steam
would be allowed to enter the chamber. As the air has been removed, the water molecules can
enter the cavity in the fibres, and the absorption of moisture becomes more effective.
Effects of Conditioning of Yarn:

1. Twist Setting – Preventing Snarling (yarn loops)

2. Better Dye affinity – Eliminating static electricity

3. Influencing the Cloth handle – Preventing crease-proneness

4. High bulking – Humidifying

5. Dye – fixing – De-crinkling

6. Determining residual boiling shrinkage.

Packing
Packing materials: Yarn can be packed in bags, cartons, or pallets. The cost of packing
materials depends on the number of items per package, the weight of the packages, and the
cost of the materials.

Packaging types: Yarn packages can be hard or soft. Hard packages are made of paper cones,
while soft packages can be perforated dye cones or perforated dye cheeses.

Packing labels: Each cone is labelled with information such as the production date, yarn
count, lot number, machine number, and shift number.

Palletization: Yarn packages are placed on pallets and wrapped with stretch film.

FUNCTIONAL DEPARTMENTS

FINANCIAL DEPARTMENT
This department is responsible for maintaining proper accounts of the mill for all the
functioning units A, B and C. Tally software is used for accounting. The staffs of this
department double checks for the payment done for the goods before storing it.
After the arrival of the goods the store manager signs the bill and after the acknowledgement
of the Managing Director or Junior Managing Director the payment is processed and
completed.

For sales, the order is processed after the advance payment. For regular parties the order is
processed with 20% credit if necessary.

Tax Deductible at Source (TDS) and Tax Collected at Source (TCS) is payed before 7 th of
every month. GST for sales is payed before 10th of every month and GST for purchases is
payed before 20th of every month. Advance tax is payed once in every three months before
15th.Balance sheet, Profit and loss account is checked every month for the purpose of advance
tax.

Stock statement and debtor statement is submitted to the bank before 5 th of every month for
the purpose of acquiring working capital fund for 60% of the stock.

Income tax is filed in September end in auditor office and sales tax is filed in December.
Income tax returns is filed every six months.

HUMAN RESOURCE DEPARTMENT

Selection process includes experienced and freshers. Training is given for the labours, and
they work as apprentice for the period of 6 months. During this period, they are offered with
ESI only. After 6 months if the labour is efficient then he is made permanent and offered with
ESI and PF. In case of any accidents, labour welfare expense is claimed by the victim.

The safety measures for the labour includes overcoat, disposable caps and masks. Coffee and
tea are provided twice a day.
 Managing
Director

Junior managing Junior managing

director director

Factory manager Factory Manager

FM1
FM2

Fitters
Electriians
supervisor
Store incharge

Operation manager

Organisational Chart

Bonus:

 Diwali bonus
 Pongal bonus
 Attendance bonus (for full attendance)

Leave:
According to government norms, 9 days will be declared holidays in a year. Weekly holiday
is provided in rotational basis. If the labour is made to work on holidays, then his wages is
doubled for that day.

Allowances:

Gratuity and pension are payed for the permanent staff after retirement provided that the
labour worked for 5 years.

Work undergoes in 3 shifts (Day/half/Full night) with 150 workers.

Educational qualifications:

 The supervisors must have a degree or diploma in Textile industry.

 The Fitter must have a degree or diploma in mechanical engineering or experience.

Quality control department

Raw material is tested in government testing (research centre). After manufacturing the final
yarn, it is tested with company’s own yarn tester. This raw material is tested by Tamil Nadu
Textile Research Association and expense is borne as yarn testing expense.

Packing department
Each cone is wrapped individually in polythene covers. And for each box 50 cones are
packed if it is 1kg cone and 40 cones if it is a 1.25kg cone. Each box is wrapped with woven
sacs. These packaging materials are bought from their sister concern Sakthi Velu Poly Pack.

Marketing department
The yarn manufactured is not sold directly except for the prominent customers. It is handed
over to yarn or commission agents who sells it to fabric manufacturers . The main agent who
markets yarn for the company is Sri Sai Marketing.

Transportation
 The freight for the raw materials is payed by the company itself.
 For goods sold advance payment is done by buyers and vehicle is arranged by the
company.
  Lorry is the main vehicle used for logistics concerning the regular bulk orders.

Findings and suggestions

1. Operational Efficiency:
The spinning mill's production process is well-structured, with a focus on efficiency
at every stage. From fiber preparation to spinning and winding, each step follows a
systematic procedure to minimize downtime and maximize output.

2. Machinery and Technology:

The mill is equipped with modern machinery such as ring frames, autoconers, and
carding machines. However, there are occasional breakdowns and wear-and-tear
issues that can lead to production delays.

3. Labor and Workforce Management:

The mill relies on a significant number of skilled and semi-skilled workers to ensure
smooth operations. Regular training programs are conducted to upgrade the skills of the
workers, but some gaps in workforce specialization were observed.

4. Quality Control:
A stringent quality control system is in place to monitor yarn consistency, strength, and
other parameters. Nevertheless, occasional discrepancies in quality were noticed due to
machine calibration issues or raw material variability.

5. Environmental Impact:
The mill has implemented some eco-friendly practices such as recycling waste fibers and
using energy-efficient machines. However, there is still a need for better water
conservation and waste management practices.

6. Supply Chain and Raw Materials:

 The supply of raw cotton to the mill is highly dependent on market conditions, and
fluctuations in cotton prices can affect production costs. The mill has multiple suppliers
but faces challenges in maintaining consistent quality of raw materials.

Suggestions for Improvement:

1. Investment in Predictive Maintenance:

Implementing predictive maintenance systems could reduce machinery downtime and
improve overall operational efficiency. Regular monitoring and timely servicing of
machines would prevent sudden breakdowns.

2. Enhanced Worker Training:

While training programs are in place, introducing more specialized training for
workers, especially on modern machinery and technologies, could further improve
productivity and reduce errors in operations.

3. Improvement in Quality Control:

Introducing automated quality control systems for real-time monitoring of yarn
properties could help in early detection of issues and reduce the chances of defective
yarn production.

4. Sustainable Practices:
The mill can adopt more sustainable practices, such as rainwater harvesting, waste
recycling, and adopting renewable energy sources like solar panels to reduce its
environmental footprint.

5. Diversification of Raw Material Sources:

To mitigate the risks of price fluctuations and inconsistent cotton quality, the mill
could explore alternative sources for raw materials or consider sourcing cotton blends
that are more cost-effective and sustainable.
 CHAPTER V

Conclusion

In conclusion, my internship experience at the spinning mill in Tamil Nadu provided valuable
insights into the textile manufacturing process, particularly in the areas of raw material
procurement, yarn production, and quality control. I gained practical knowledge of the
machinery involved, such as ring frames and autoconers, as well as the operational challenges
faced by the industry. This experience has deepened my understanding of how theoretical
concepts are applied in a real-world setting. Additionally, working alongside skilled
professionals has enhanced my technical and managerial skills, which will be beneficial in
my future endeavours in the textile industry.
The internship at the spinning mill in Tamil Nadu has been a transformative learning
experience, providing me with an in-depth understanding of the textile manufacturing
industry, especially in the realm of yarn production. Throughout the internship, I had the
opportunity to observe and participate in various stages of the spinning process, from raw
cotton selection to the final yarn output. This hands-on experience has enriched my
knowledge of the complex machinery involved, such as carding machines, drawing frames,
and spinning frames, as well as the importance of maintaining efficiency and precision in
production. Furthermore, I learned about the critical role of quality control, ensuring that the
yarn produced meets the required standards for further processing. Beyond the technical
aspects, I also gained insights into the management and logistical operations that drive a
spinning mill, including workforce coordination, supply chain management, and cost
optimization. This internship has not only strengthened my practical skills but also provided
me with a clearer perspective on the challenges and innovations within the textile industry,
preparing me for future professional opportunities in this sector.