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1) ACKNOWLEDGMENTS
I would like to express my sincere thanks to my supervisors and mechanical team at Kay and Emms
Private Limited for their support and guidance during my internship. Special thanks to the Mechanical
Engineering department for their help.

 Manager Mechanical Department

Sir Saif Ullah Sb

 Mechanical supervisor

Sir Rashid Sb

Each of you played a crucial role in making my internship both educational and enjoyable.

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2) Table of Contents
 EXECUTIVE SUMMARY....................................... 4
 INTRODUCTION..................................................... 4
 INTERNSHIP OBJECTIVES ................................. 5
 INTERNSHIP TIMELINES .................................... 6
 JOB RESPONSIBILITIES & TASKS .................... 7
 CHALLENGES FACED ....................................... 16
 RECOMMENDATION………………………..…18
 CONCLUTION…………………………………...18

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(i) EXECUTIVE SUMMARY
I am thankful to Kay & Emms (Pvt.) Ltd for providing me with this great opportunity which is not only
give exposure to industry but also enhanced my technical and professional skill.

In my four weeks of internship program at Kay & Emms (Pvt) Ltd Faisalabad, I visited different departments
of the organization and learned about the departmental working, working process and different techniques
used in these departments. Kay & Emms is vertically integrated unit from Yarn to Garment.

During my internship at Kay & Emms (Pvt.) Ltd, I worked in the Mechanical Engineering department.
My main tasks included maintaining dyeing, finishing, and sample machines. I also visited the boiler and
compressor units to observe their operations. Additionally, I examined the functioning of pumps and valves
used in various machines. The internship provided me with hands-on experience in machine maintenance and
enhanced my understanding of industrial processes within the textile industry.

I am extremely great full to my department staff members and friends who helped me insuccessful completion
of this internship.

(ii) INTRODUCTION
Established in 1990, today Kay & Emms (Pvt.) Ltd is one of the leading manufacturers of knitted apparel in
Pakistan. With the experience of more than 33 years in the industry, Kay & Emms have served several different
major brands and labels in the US and Europe.
Kay & Emms is capable of producing different styles of men, ladies and children from basic to high fashion
with extensive embellishments. Kay & Emms deals in 100% cotton and cotton- blended fabrics. Fleece,
interlocks, Ribs and cotton-spandex fabrics are strengths of Kay & Emms and several other programs like
jerseys, Piques and thermals are also manufactured every year.
The vertically integrated operations help Kay & Emms to achieve shorter lead times and greater flexibility to
cater to the customers demand and their satisfaction. The factories are producing a range of knitted jersey tops
and bottoms with heavy embellishments for Children's, Ladies and Menswear.
Kay & Emms (Pvt.) Ltd is a leading entity in the textile industry, known for its commitment to producing
high-quality fabrics and garments. The company leverages state-of-the-art technology and advanced
machinery to maintain its competitive edge in the market.
My internship was centered on the maintenance and operational analysis of these machines, which are critical
to the company's production processes.

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(iii) INTERNSHIP OBJECTIVES
The objectives of my internship were clearly defined to ensure a comprehensive learning experience:

 Practical Application
To apply mechanical engineering principles in the maintenance and optimization of textile machinery
such as dyeing machines finishing machines and sample machines.

 Machine Maintenance
To understand and perform routine and preventive maintenance on dyeing, finishing, and sample
machines. The maintenance of machines includes the checking of compressed air lines and steam and
maintain the mechanical losses done by machinery.

 Operational Analysis
To observe and analyze the performance of the boiler and compressor units, focusing on maintaining
optimal operational parameters. This includes the power output and efficiency of boiler and
compressor.

 Technical Expertise
To develop expertise in the operation and maintenance of various pumps and valves integral to the
machinery.

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(iv) INTERNSHIP TIMELINES
Week 1-2:
Starting my internship at Kay & Emms (Pvt.) Ltd was an eye-opening experience. The first week
was all about getting to know the mechanical staff and their roles, as well as familiarizing myself
with the machines used in the industry. I toured the facility, learning about the dyeing, finishing, and
sample machines that are the backbone of the textile process. A visit to the mechanical workshop
was particularly insightful. The workshop housed essential tools like Lathe Machines, Drilling
Machines, Shaper Machine and Welding Plants, which are critical for maintaining the factory’s
operations. Understanding the layout and the function of these machines was key to grasping how
everything fits together in a large-scale manufacturing setting.

In the second week, I got into the nuts and bolts of how these machines actually work. I learned
about the principles behind dyeing, finishing, and printing processes, and how each machine
contributes to producing high-quality fabrics. A significant part of this week was dedicated to
understanding the boiler and compressor systems. These systems are the lifeblood of the machinery,
providing the necessary steam and compressed air to keep everything running smoothly. By the end
of the week, I had a good grasp of how these connections work and their importance in the overall
process.

Week 3-4:
The third week was where things got really hands-on. I participated in the maintenance of dyeing,
finishing, and drying machines, which was both challenging and rewarding. One of the highlights
was working on the STENTER machine, which is vital for drying and setting fabrics. I also had the
chance to maintain the MARIO CROSTA machine, which is used for giving fabrics a brushed or
raised finish—a key step in adding texture and softness to the material. These tasks allowed me to
apply what I had learned in the first two weeks and contribute to the team’s efforts.

In the fourth week, I dived deeper into the operation of the facility’s boilers and compressors. These
are water tube boilers with a combined capacity of 20 tons, crucial for generating the steam needed
for various processes. I also learned about the compressor unit, which includes three compressors—
two of which are always in operation, providing a steady 220 KW of power. Additionally, I spent
time at the ETP (Effluent Treatment Plant) and R.O. (Reverse Osmosis) plants. The ETP is essential
for treating the wastewater from the dyeing process, ensuring it’s safe to release back into the
environment, while the R.O. plants purify water for use throughout the facility.

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 (v) JOB RESPONSIBILITIES & TASKS
Throughout my internship, I was responsible for a range of tasks critical to the smooth operation of the
company's machinery:

 Dyeing Machines:
Performed preventive maintenance on dyeing machines, ensuring minimal downtime and consistent
fabric quality.
 Finishing Machines:
Assisted in the maintenance and troubleshooting of finishing machines, contributing to the
enhancement of product finishing processes.
 Sample Machines:
Worked on sample dyeing and drying machines, gaining insights into the intricacies of sample
production and quality control.
 Boiler and Compressor Units:
Observed and analyzed the performance of the boiler and compressor units, focusing on
maintaining efficiency and safety standards.
 Pumps and Valves:
Conducted examinations and routine checks on various pumps and valves, ensuring their proper
function and longevity within the system.

 DYEING MACHINES
Dyeing is the process of coloring textile materials like fibers, yarns, or fabrics. This involves soaking these
materials in a dye solution, where the dye gets absorbed, giving the textile a new color. Dyeing can happen
at different stages of making textiles—whether the material is still in fiber form, spun into yarn, or already
woven into fabric. The main goal is to get the desired color that stays vibrant and doesn’t fade easily, even
when washed, exposed to sunlight, or rubbed.
There are various machines used at Kay & Emms for Dyeing Process. The list is given below, in these
machines some used as samples for fabric dyeing. Their capacity is different for different machines such as
MCS machine has capacity of 800 kg.

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 MCS Dyeing Machine

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 Fong Sample Dyeing Machine

Inlet tower (1), End cover (2)

Main shell (3)

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 Fong Sample Dyeing and Finishing Machine

Industrial Barrel Washing Machine

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 FINISHING MACHINES
Finishing processes aim to alter the surface of a manufactured part in order to achieve a particular
characteristic.
Textile finishing involves changing some quality of a textile (a yarn or fabric) after it has been manufactured.
It can be done through the use of methods such as bleaching, mercerizing, waterproofing, singeing, and dyeing.
Finishing department at Kay & Emms comprises automatic hydro-extractors for the removal of moisture
from dyed fabric, computerized tensionless dryers for instant fabric drying, soft-setting and calendaring
machines for systematic soft-setting and rolling of fabric, fully computerized compaction machines for
complete shrinkage control, and panel wash machines and tumble dryers for panel washing the fabric to give
minimum shrinkage value. 40 tons of fabric can be finished in the Finishing department per day.

Types of finishing machines at Kay & Emms (Pvt.) Ltd

 SLITTER MACHINE
Slitter machine is used for tubular knit fabric to make it in open form. in open form fabric finishing
line; slitter machine is used after hydro- extractor, de-watering and drying machine.
Slitting is a process that is applied for cutting the tubular fabric through the intended break Wales’s
line on lengthwise direction prior to stenter processing During slitting, it is required to be aware
about the cutting line otherwise, fabric faults can be occurred there.

Objectives of Slitting:

Following objectives are achieved by the slitting machine

1. To open tube fabric according to specific needle mark.

2. To prepare the fabric for next stentering process.

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 Function of the Slitting Machine:

1. Used to remove excess water after pretreatment and dyeing

2. To slit the tube fabric by the knife for opening of the fabric and ready for stentering.
3. Delivered fabric increase Free State
4. Before squeezing balloon is formed with the help of compressed air passing by a nozzle or air
sprayer.

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 STENTER MACHINE:
Stenter is the most expensive and important fabric drying and finishing machine. Stenter is a
machine or apparatus for stretching or stentering fabrics. It is also known as a ‘tenter’ in the woollen
industry. The purpose of the stenter machine is to bringing the length and width to pre-determine
dimensions and also for heat setting and it is used for applying finishing chemicals and also shade
variation is adjusted. The main function of the stenter is to stretch the fabric widthwise and to
recover the uniform width.

Stenter machine consists of two endless auto-lubricated driven chains, typically 40 to 60 m in length
carrying pins or clips to hold the fabric edges while passing through a number of hot-air chambers (3–5,
each of about 3 m). Hot air is directed onto the fabric equally from above and below. A stenter has the
provision for overfeeding the fabric to allow required shrinkage during heat setting of fabric while the
width is increased to the precisely specified value by the chains. The use of clip stenter has declined because
of the difficulty of applying overfeed. The stenter speed ranges from 10 m/min for heavyweight furnishing
fabrics to 100 m/min for lightweight dress-goods.

The speed also depends on the processes carried out in stenter namely:

 Drying,
 Heat setting,
 Weft straightening,
 Curing after application of finishes.

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 RAISING MACHINE

Raising or Napping is the finishing process that raises the fibers on a fabric to produce a mat of fiber
ends, or nap. It may be used on knit or woven textiles made of staple fibers, such as wool and cotton,
or with fibers cut to staple length and spun into yarns such as silk, rayon and polyester. Napped
fabrics are usually made with loosely spun yarns in the filling direction (weft) so that the fibers can
easily be pulled out to form the nap. Raising is also used for certain knit goods, blankets and other
fabrics with a raised surface.

In raising finishing process a hairy surface can be given to both face and back of the cloth providing
several modifications of the fabric appearance, softer and fuller hand and bulk increase. This
enhances the resistance of the textile material to atmospheric agents, by improving thermal insulation
and warmth provided by the insulating air cells in the nap. The fuzzy surface is created by pulling the
fiber end out of the yarns by means of metal needles provided with hooks shelled into the rollers that
scrape the fabric surface. The ends of the needles protruding from the rollers are 45° hooks; their
thickness and length can vary and they are fitted in a special rubber belt spiral-wound on the raising
rollers (Figure 1). These rollers are generally alternated with a roller with hooks directed toward the
fabric feed direction (pile roller), and a roller with the hooks fitted in the opposite direction
(counterpile roller).

The machine also includes some rotating brushes, which suction-clean the nibs in pile and counterpile
directions. Actually the trend goes towards a ratio of raising rollers/pile rollers equal or 1/3. The two series

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of rollers have independent motion and can rotate with different speed and direction thus carrying out
different effects .

1. Roller;
2. Rollers equipped with hooks;
3. Fabric;
4. Nib cleaning brushes;
5. Fabric tension adjustment

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(vi) CHALLENGES FACED

One of the biggest challenges I faced was understanding the stenter machine's operations in the textile
industry. At first, the machine seemed quite complicated, with its many control mechanisms and the need to
monitor every parameter precisely. On top of that, I noticed that the cloth wasn't fitting perfectly on the pins
of the stenter machine, which caused problems during processing. This was frustrating, and I knew it needed
to be fixed to keep the production running smoothly.

Thankfully, I had a great team to support me. My supervisor was always available to provide guidance and
answer my questions. They helped me break down the complex parts of the machine into manageable tasks,
making it easier to understand how everything worked together.

Working alongside the senior fitter was incredibly valuable. They shared their extensive experience and
showed me the best practices for troubleshooting and maintaining the machine. Their hands-on approach
taught me how to identify and resolve issues quickly, especially the problem with the cloth not aligning
correctly on the pins. Observing their techniques and asking for advice whenever I was stuck made a big
difference in my learning process.

The assistant fitter also played a crucial role. They helped me with the day-to-day adjustments and
maintenance tasks, providing additional support when things got busy. Their willingness to collaborate and
share their knowledge created a positive and encouraging work environment. Together, we worked on fine-
tuning the machine, ensuring that the cloth fit perfectly on the pins and that the machine operated smoothly.

With the support and guidance of my supervisors and fitters, I took the time to really learn the ins and outs
of the machine. I also spent a lot of hands-on time troubleshooting and making adjustments to solve the
issue with the cloth not aligning correctly on the pins. It wasn't easy, but through practice and persistence, I
finally got a good grasp of how everything worked.

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Another challenge was coordinating the maintenance work without disrupting the production schedule. This
required careful planning and clear communication with the team to ensure that everything was done

efficiently. My supervisor helped us organize the maintenance tasks, while the senior fitter and assistant
fitter ensured that each step was carried out correctly. Despite the difficulties, I was able to overcome these
challenges and contribute to the smooth operation of the stenter machine.

Working with such a supportive team not only helped me overcome technical challenges but also made the
entire experience more enjoyable and rewarding. Together, we ensured that the production ran smoothly and
efficiently, maintaining high-quality standards in our textile products.

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(vii) RECOMMENDATION
During my internship, I noticed a few areas where some improvements could make a big difference. Here’s
what I suggest:

1. Providing Hostel Facilities for Interns:

One key area for improvement is the lack of hostel facilities for interns. Offering a place for interns to stay
would not only make it more convenient for those coming from different cities but also show that the
company values its trainees. This could attract more talented interns and make their experience more
comfortable and focused.

2. Introducing Lunch Facilities for Interns:

Another area to consider is providing lunch facilities for interns. Having an on-site lunch option would save
time and allow interns to stay energized and productive throughout the day. This small addition could
greatly enhance the overall internship experience by making interns feel more supported and cared for.

These recommendations are aimed at improving the overall internship experience at Kay & Emms (Pvt.)
Ltd. By addressing these areas, the company can create a more welcoming and supportive environment for
future interns.

(viii) CONCLUSION
My time as an intern at Kay and Emms Private Limited has been incredibly valuable. Over the course of
my internship, I gained hands-on experience with textile machinery, learning how to maintain and operate
these complex systems. This experience allowed me to apply what I’ve learned in school to real-world
situations, giving me a much deeper understanding of the mechanical aspects of the textile industry.

Beyond just technical skills, this internship helped me grow as a professional. I learned how to solve
problems under pressure, work effectively as part of a team, and communicate clearly with colleagues.
These lessons have not only made me more confident in my abilities but have also prepared me to tackle
future challenges in my career as a mechanical engineer.

Overall, this internship has been a crucial step in my journey, equipping me with the practical knowledge
and skills I need to succeed in the industry. I’m grateful for the opportunity and feel ready to take on new
challenges in the future.

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