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GUL AHMED TEXTILES No 8 Internship Report Sfdac
GUL AHMED TEXTILES No 8 Internship Report Sfdac
NT
We proudly present our report which is based on PRE-
1
.
∞ M.SHARIQ (shariq_1988@live.com)
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∞ WAQAS MAQSOOD (Vicky_textilian@hotmail.com)
Dated: 21 august 2009
TABLE OF CONTENTS
OBJECTS PAGE
NOs.
COMPANY INTRODUCTION
PROCESS FLOW
BATCHER MACHINE
MERCERIZATION
TESTING LAB
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INTRODUCTION
The group began trading in textiles in the early 1900’s. With all it’s know-
how and experience .Gul Ahmed Textile Mills Ltd. was incorporated as a
private limited company, in the year 1953. In 1972 it was subsequently
listed on the Karachi Stock Exchange. Since then the company has been
making rapid progress and is one of the best composite textile houses in
the world. The mill is presently composite on 8 units in Karachi with an
installed capacity of approximately 130,296 spindles, 223 wide width air jet
looms, and a state of the art wet processing and finishing unit.
Gul Ahmed’s fine textile products represent a unique fusion of the century
old traditions of the east and the latest textile technology of the west. The
purest of cotton fibers, produced from the fertile lands of the Indus Valley,
are spun, woven and processed into the finest quality cotton and blended
products through a combination of latest technology, skills and
craftsmanship of this traditional industry.
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In this report we have emphasize on a couple of factors, the highlights are
process flow, plant design and lay out, process parameters etc,
PROCESS FLOW
PLANNING
PRODUCTION
PROGRAM GREY ISSUEANCE
PRE TREATMENT
-- SINGEING -- SINGEING
-- DESIZING -- DESIZING
-- SCOURING -- SCOURING
-- BLEACHING -- BLEACHING
-- EQUALIZING -- EQUALIZING
-- MERCIRIZING -- MERCERIZE IF
REQUIRED
-- EQUALIZE
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After 100% inspecting the material, the fabric is graded as per according to
number of defects, then goes for mending or rejected while the selected
material is transformed into a batch type of package with the help of batcher
machine.
BATCHER MACHINE
Batcher machine is used to made batch of the fabric. The fabric is rolled on
a iron roll which is fixed on a `A` frame arrangement. It is made for easiness
in carriage while processing and for accumulating a large length of fabric at
one package without spoiling fabric.
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IT is a very simple process. The pile of fabric is placed before the
machine .The pile is threaded on the tension rods and through the guide roll
it enters into the scray where it is lifted upward with the help of compensate
roll where it further goes into the tension rods and from the tension rods it
passes through the expander roll . Here the fabric is expanded along width
wise . Then after expander roll pendulum arm is introduce, it is an important
part of the machine the running of the fabric is maintain smooth as well as
the width of the fabric is maintain by the automatically moving its arm let
suppose if the fabric falls on the right side of the pendulum arm it will move
towards left side so that the width remains the same. After this component
again the two expander rollers with pendulum arm is further introduce to the
fabric, and after that the fabric is wound on the A shape frame to form our
required batch with the help of winding arm. Now the batch is ready to face
the next and important process, which is singeing process.
Singeing position
Flame intensity
Fabric speed
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Distance between fabric and burner
Moisture in the fabric coming for singeing
If any of the above parameters are not optimal, the result may be faulty
singeing.
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MAIN COMPONENTS OF MACHINES
1. Tension rods
2. Guide or Measuring rollers
3. Brush rollers
4. Singeing box
5. Chemical tank or Desize box
2. Guide Roll :
Fabric is then passed over the guide rollers for
feeding the fabric in to the brush rollers. In this roller the meter counter is
also working for counting the length which is continuously feeding from the
batch.
3. Brush Rollers:
Before singeing the fabric is brushed tolosen and raise
the fiber ends and moved rapidly normally about 100m/min.
4. Singeing box :
After brush roller the fabric is moved over arrow of
gas burner to burn protruding fibres.The flame is preferred over hot plate
because flame penetrate in to pores of the fabric. The flame can be set in to
the following conditions;
1. Burner can be set as it touches the tip of the protruding fibers.
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2. Flame touches the cloths directly without deteorating the fabric.
For avoiding the burning of fabric or protecting fabric from the yellowish
shade the flame is composed of 70% of air and 30% of gas. For achieving
the accurate results it is suggested that the flame color should be of light
blue.
Pad @ 90% pick up, Temp 60°C, PH 2-3, Batcher rotation time 4-6 hrs.
1- Application of enzymes
2- Digestion of the starch
3- Removal of the digestion product
The enzymes are only active with in a specific range of PH and temperature.
PH must be maintained by suitable PH stabilizer. Chelating agents are used
to sequester metal ions which may be injurious to the enzymes. Certain salts
may be used to enhance the temperature stability of enzymes.
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After desizing the fabric is batched on roller. The rolling cloth is wrapped in
a plastic sheet to avoid drying of fabric and rotate slowly for few hours (8
hour rotation time for ENZYMATIC DESIZING and 4-6 hour for OXALIC
DESIZING). The batch is then placed on the next process which is the
continuous process of scouring & bleaching.
temp
OILS & FATS + NAOH SOAPS EMULSIFY
WAXES
Waxes are considerably more resistant to soponification than fats, they
forms emulsion when shaken with water containing soap.
BLEACHING;
Scouring removes almost all the impurities except
natural coloring matters which are ultimately broke down with
bleaching agents. Bleaching is necessary for producing white goods either
as finished products or for dyeing pastel shades.
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SCOURING & BLEACHING on
Goller MACHINE
Continue below
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The fabric is passed through the tension rods then the guide roller guide the
coming fabric towards the washing tank for removing all previous
auxiliaries and size paste from it. Then the fabric is dip in to the mechanism
known as DIPSET-1 containing caustic soda, sequesting agent
TGA, wetting agent RGN. In this the main objective of scouring is
achieved and then the fabric is padded and passed through the adopter plate.
The showering of chemical is done, then the doctor plate scrap the fabric.
The fabric is then goes in to the Roller bed steamer, in which fabric is
steamed for about 5-15minutes using temperature 99°c. The steaming
machine is consist of 42 bed roll, that rotate very slowly and push the fabric
forward until it comes to off point. The star roll is used to pull the fabric. It
may be noted that the concentration of chemical and time of treatment for
scouring depend upon the unit-weight and the degree of impurity of the
fabric. The fabric is then goes to the washing range where it the scoure
chemicals is washed off. There is two washing tanks where fabric is washed,
then the fabric is dip in to the DIPSET-2 containing H2O2, sequesting
agent & caustic soda. Then the fabric is pre heated and goes into the
steamer for 5-20 min at 105°c.
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After steaming the bleach fabric is than goes to the washing range of goller
scouring & bleaching machine. The washing range is consists of five
washing tanks. The temperature of first four washing tanks is about 90°c and
the last tank is also used for the neutralization of the fabric. The PH is
maintained to about 6-8 After washing the fabric is squeezed by squeezing
rollers. The fabric is then passed through the bow rollers for expanding the
fabric along width wise. After bow roller the fabric is dried by drying
cylinders. After that the fabric comes down in the scray compensator roller,
after that the fabric is passed through a series of tension rods and bleached
batch is produced by winding on A-FRAME by the wind-arm. Now the
batch is ready for conducting next operation which is mercerizing.
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machine. It is old and time taken operation and the material process in this
machine is of local type.
The fabric from batch is passed through the washing machine and after
washing it goes in to the saturator where the scouring chemical is applied on
fabric. After saturator the fabric is stored in j-box. The time residual of the
fabric is not constant but the approximate time for storing is 1-2 hour and is
different for different material. After j-box the fabric is then washed in two
washing tanks, than after scouring the fabric is then goes in to the saturator-2
for bleaching purpose then the fabric is stored in J-BOX 2(1 hour for PC,
2hour for cotton). After that the fabric is washed in washing range and
transferred in to the white pits chamber for storing in GUL AHMED.
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After that passed through DETWISTER to open twist and transforming the
fabric from rope form to open width form, then passed through drying
cylinders and batched on A-frame.
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MERCERIZATION
It is an important operation of the cotton wet processing industry by virtue of
its resultant effects. The effects of Mercerization are as follow.
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FABRIC ROUTE IN MERCERIZING
MACHINE
After bleaching the Ends/Picks of the fabric are disturbed and also fabric is
shrinked upto 5-10%, therefore to regain fabric original width and
Ends/Picks fabric is conditioned to be passed through the STENTER
MACHINE, it`s also depends upon the material requirement. After pre-
stenter the fabric batch is placed on a mercerizing machine.
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The fabric is passed through a number of guide and Bow rolls. After that the
material is dipped in to the main section, which is a STRONG LYE
containing chamber. The number of chambers in mercerizing machine is
different and depends upon the manufacturer of the machine. In this
chamber the material is continuously treated with caustic soda of about 26-
30°Be @ 60°c. The lye is showered in zigzag manner the fabric is rolled
over a number of padder. Load cell are used to maintain tension to the
coming fabric.
If the material is subject able for reactive print mercerization is necessary,
where as on the other hand for pigment print no mercerize material is
required.
After strong lye the fabric is passed through weak lye chamber. The
temperature is increased upto 85°c and caustic concentration is decreased
upto 7-8°Be, this gradually reduction in caustic concentration stabilize the
mercerized material, then in the stabilizing section caustic concentration is
decreased upto 4-3°Be through counter flow of water. The mercerized
material is rinsed and washed and PH is maintained in a washing range.
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WASHING RANGE OF MERCERIZING MACHINE
The next stage after weak lye section is washing. In goller machine there are
four chambers as compare to FAISLABAD MERCERIZE in GUL AHMED,
as it contains only two washing chamber. The temperature of starting
chamber is about 90-95°c and last washing chamber contain room
temperature. In continuous washing range of GOLLER MACHINES,
neutralization is also alone by using formic or acetic acid. After
neutralization the wet fabric is wound on a batch with the help of tension
and winding arm.
IMPORTANT FACTORS
During operation there are numerous factor, which can effect mercerizing
process. Some of them are listed below;
2.Black spots or caustic spots can be produce on the fabric due to air lock
occur in the padder.
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3.If proper neutralization objective is not achieved there is a chance of acid
remains in the fabric, which will result in degradation of fabric.
TESTING LAB
Lab is an important part of any industry because lab gives direction for the
production processes. The lab in GUL AHMED textile is also playing a vital
role in maintaining the production efficient and as per customer requirement.
It works on these criteria by collecting all the important information through
a series of tests performed at set stages. The flow chart ot lab is shown
below,
TESTING LAB
The during production testing is come under the In process section, a series
of tests are performed after bleaching, which are shown in a flow chart wise
manner.
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Process TESTS
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CONCLUSION & RECOMENDATION
Throughout our four weeks training in GUL AHMED textile, we learnt so
many practical things about the pretreatment process. We study function and
importance of pretreatment department and its procedure to do the
production. We perceived about this organization that, it has a strong
departmental structure and this is playing a vital role in the organization
success. The pretreatment department can add up its efforts in the betterment
of organization by reducing errors on consistent basis, as improvement is not
a one day process it’s a slow day by day process.
The attitude of the worker of department is well and proactive towards work
especially MR.Manager, He frequently rounds the department and sure that
every things and every one is appropriate, but it was observed that some
workes are not interested in the company training program.
The organization should also start developing new process and technological
break through for the betterment of the country textile industry and should
provide a plate form for this purpose to the experts and the students as
because the future of the country textile industry is very tough and
competitive to survive.
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