NATIONAL INSTITUTE OF FASHION

TECHNOLOGY, MUMBAI

Subject: Textile Chemical Processing Practical-1

ASSIGNMENT NO: 03

Industrial Visit Report

Brief: To develop documentation of all the practical
experiment procedure with samples. To develop of
industry visit documentation report.

SUBMITTED BY: SUBMITTED TO:

AFTAB ALI Dr. Chet Ram Meena
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 INDEX

SR NO. CONTENT PAGE NO

1. Introduction 3

2. Knitting 4

3. Gray Inspection 6

4. Dyeing 6

5. Printing 8

6. Finishing 9

7. Quality control 11

8. Embroidery 12

9. Conclusion 14

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 SUDITI INDUSTRY LIMITED

Navi Mumbai, Maharashtra 400705Address: C-2253/54, MIDC, T.T.C. Industrial

Area, Pawne Village, Behind Savita Chemicals,.

the 20th of February 2017, we the students of TD-4 were taken for an Industrial
Visit to Suditi Industries On Ltd located in Navi Mumbai. Suditi industries was
founded in 1991 as a processing plant. Sudititransforms a basic yarn or fabric, that
is manufactured into usable items, such as apparel, bed linen, etc for individual or
industrial consumption. The further processes are performed in the same
established sector. The main process in this sector includes knitting of fabric,
dyeing, printing, finishing, sewing and embroidery work. In this establishment
Apparel manufacturing is also done. This growth from a processing plant allows
them to control all the processes in the value chain, increasing their ability to
provide standardized good quality products.

Figure No 1: Route from NIFT, Kharghar to Suditi Industries Ltd.

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Abstract:

Certificates like the ISO 9001: 2000, GOTS and OEKO TEX S-100 only
strengthen our reputation in the textile industry and reiterate our mantra for
professionalism and high standards. It is hence a combination of our infrastructure
and experience that enables us to work with some of the top retail brands and
provide them with all their garmenting needs.

Our management team constantly updates itself with new techniques, machinery
and processes, which can be learned or acquired to help strengthen our portfolio. It
is this attitude to constantly grow that has led a processing plant to become a
vertically integrated manufacturing set up. Now, this ambition has culminated into
us creating our own retail brand, Riot.

Riot is a venture started by us a few years ago with the aim of providing the youth
of India fashionable garments of good quality at reasonable prices. It was our set
up that inspired such a decision because we had the chance to eliminate the
tradeoff between quality and cost by managing both in-house.

Reference:http://www.suditi.in/about_us.php

PROCESS
1. Knitting
Equipped with 60 circular knitting machines from–

 Mayer and Cie – Germany

 Vanguard – USA
 Terrot – Germany

These machines have an annual production capacity of 2000 tons and are capable
of manufacturing fabrics like Single
Jersey, Pique, Rib, Terry, Interlocks, Pointelle, Fleece, Jacquards, Autostipers etc.

Circular Knitting:

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The diameter of the machine is 22 m. The yars used are usually cotton yarns.Types
of knits are cotton single jersey, PC single jersey and PKU single jersey. The
number of needls used are 1792 in pairs of 24. Single jersey fabrics are knit on
these machines. Speed of the machine is 6-9 meters per hour. It is usually used to
make t-shirts and other apparel material. It takes 2-2.5 hours to knit 1 role in this
manual machine. The yarns used for knitting are imported from Rajasthan and
Madhya Pradesh.

Rib Knit Fabrics:

These are mostly used in collars and cuffs in garments. Yarns used for these is
Lycra and cotton while. This effect is created by removing needles.

Figure No 2: Vanguard circular knitting machine

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2.Gray Inspection
In this the knitted fabrics are checked for any defects. This process is usually done
manually. Once this step is done, the fabrics goes for dyeing and printing. Fabric
marker is used to write the kilos of weight on the fabric.

3. Dyeing
For dyeing process the machine used is sclavos, safro scale machine. The capacity
of the machine is 250 kg. The fabric dyed to a nuderange in viscose, polyester, etc.
Jigger machine is used for dyeing with a speed of 180 spin in rotation per minute.1
ton machine has 1000 kgs of fabric dyed in it. The amount of fabric fed is always
lesser than the actual quantity to facilitate movement in the fabric. Dyeing is an 8
hour process (which includes softening of the fabric and dyeing) whereas for white
fabrics it takes around 4 hours to complete the process.

The temperature for dyeing varies according to the fabric:

Cotton- 60 degree celsius

Polyester- 110 degree (light colour)

120 degree (medium shades)

130 degree (dark colour)

Silk- 95 degree celsius

Gray fabric is washed and scoured before dyeing with H2O2 followed by
neutralization.

Bleaching Of Cotton

Temperature: 95-130 degree celcius

Time: 1-1.5 hours

Polyester dyeing

Plyester dyeing is done followed by fixatin at 80 degree celcius for 20 inutes.

Meutralization is done using acetic acid.

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Cotton Dyeing:

In piece dyeing, which is used primarily for fabrics that are to be a solid color, a
continuous length of dry cloth is passed full-width through a trough of hot dye
solution. The cloth then goes between padded rollers that squeeze in the color
evenly and removes the excess liquid. In one variation of this basic method, the
fabric, in a rope-like coil, is processed on a reel that passes in and out of a dye beck
or vat. Yarn dyeing, which occurs before the cloth is woven or knitted, is used to
produce gingham checks, plaids, woven stripes and other special effects. Blue dyed
warp yarns, for example, are combined with white filling yarns in denim
construction.
One of the most commonly used yarn dyeing methods is package dyeing. In this
system, yarn is wound on perforated cylinders or packages and placed on vertical
spindles in a round dyeing machine.

Dye solution is forced alternately from the outside of the packages inward and
from the inside out under pressure.Computers are used increasingly in dyeing
processes to formulate and match colors with greater speed and accuracy.

Figure No 3: Dyeing machine

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4. Printing
Long runs of the same fabric design are produced on a roller print
machine operating at speeds between 50 to 100 yards a minute. As many as of 10
different colors can be printed in one continuous operation.
A Polyester cotton can blend fabric is used whose cotton part is burned off. The
machine used is a flatbed screen used to print chemical. The maximum number of
colors possible is 8. The heat is supplied inform of gas. Which concentration is 12-
15 stocks all are given depending in the color. speed is 700 – 800. Meter per hour.
Then the fabric passes through the heating chamber at 140’c.
FOR PIGMENT PRINTING TEMPERATURE:
LIGHT SHADE-120 125’C
DARK SHDE- 150’C
BOTH SHADE-135’C
Screen making:

NYLON net is used for making border frame and the photo chemical 777 is
applied and the screen is kept on dark room from 30 minutes. One screen measure
8*31/2 feet.

Figure No 4: Screen printing. Figure No 5: Drying

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5. Finishing:
Finishing, as the term implies, is the final step in fabric production. Hundreds of
finishes can be applied to textiles, and the methods of application are as varied as
the finishes. The finishing machine is a tub-tex compactor machine. Steam iron
compacting is done. 20 kgs of fabric compacted at a time. Lycra fabric is not cut
inorder to prevent bending from the edges.For finishing of Lycra, stenter machine
is used. It has needles which keep the fabric edge straight and do not let it
bend/roll. The production is 2,600 kg of fabric per day.

Cotton fabrics are probably finished in more different ways than any other type of
fabrics. Some finishes change the look and feel of the cotton fabric, while others
add special characteristics such as durable press, water repellency, flame
resistance, shrinkage control and others. Several different finishes may be applied
to a single fabric.

Equipped with a variety of finishing machines –

1. Relax Drier – Santex, Switzerland
2. Shearing – Textima, Germany
3. Compacting – Tubetex, USA & Santex, Switzerland
4. Raising – Taiwan
5. Peaching – Mario Crosta, Italy
6. Pad, Squeeze and Stretch – Tubetex, USA & Santex, Switzerland
7. Also equipped with Brushing, Tumbling, Stentering and Open Felt
Machines
It is through these machines that they provide their customers with exactly what
they are looking for from finishing winter knits, softening fabrics or even
providing stain repellant and odour eliminating treatments.

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Figure No 6: Dyeing and Finishing machine.

Figure No 7: Stenter Machine.

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6. Quality Control
Serves the purpose of fixing the colour shade demands. Spectometer is a device for
colour mixing. Acturator is a machine that helps fixing the fabric on other
machine. After the measurement for colours is done, the colours are mixed
together in proper proportions. The dispenser auto machine has 36 bottes that have
different colours filled in it.

Figure No 8: Spectometer. Figure No 9: Acturator.

Figure No 10: Colour decoding. Figure no 11: Dispenser auto machine.

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7. Embroidery
For embroidery, TANG machines are used. These machines are Made in China and
imported to India. These facilitate many fabrics to be embroidered at the same
time. Two varities of machines are used, TANG machine in which 7 fabrics are
embroidered at a time and the other TAJIMA machine where 20 fabrics are
embroidered at a time. Satin stitch is used to appliqué fabric patches in the TANG
machine whereas zig-zag stitch is used in TAJIMA machine . The design to be
embroidered is fed in the machine and command for the same is given.

Figure No 12: TANG machine.

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Figure No 13: TAJIMA machine.

Figure No 14: The control panel.

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 8. Conclusion

INDUSRTIAL VISIT IS A IMPORTANT PART OF COURSE WHICH HELPS IN

UNDERSTANDING WHO THE INDUSTRY WORKS .IT IS PRACTICAL EXPERIENCE OF
WHAT IS LEARNED THEORITICALLY IN CLASSROOM

THESE TYPE OF VIST ARE IMPORTANT FOR OUR OWN DEVELOPMENT AND GIVING
US A WIDER RANGE OF INFORMATION ABOUT INDUSTRY.

From this industrial visit we learnt the making and processing of knitted
fabrics. We learnt construction of knitted fabrics and how each step which
includes gray inspection, dyeing, printing and finishing is important for
apparel manufacturing. If even one step among this is missing, the end
result would be affected. We also saw the surface ornamentation done on
fabric once it is sewn and how it enhances the look of the final garment.

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