Textile Internship Report

Satadeep Datta.
Bala Murugan
Muhammad Ali K.
 Company Profile
• Company name :- Arthanari Clothing Private Limited
• Incorporation Stage :- 02 December 2003.
• Type of Company :- Non-govt company and is registered at Registrar of Companies, Coimbatore.
• Authorised share capital :- Rs. 70,000,000
• Paid up capital :- Rs. 50,500,000.
• Products :- Wholesale of household goods.
• Address :- 68/2B, Manalkadu Erumapalayam Salem, T.N. - 636015
• Company Identification Number :- U51311TZ2003PTC014963
• Email-ID :- sashikumar@arthanariclothing.com
 Objective
The Objective of our textile internship at ACPL was to understand the concept of
preparatory processes, weaving, and finishing of fabrics. As well as textile testing
and quality aspects both technical as well as for commercial purposes. Our first
step was to find out about the profile of the corporation and their primary
dealings. We further dealt with the way to the various stages of production. We
have seen the different stages of textile manufacturing from the preparatory
processes to the final dispatch. We understood the importance of each of theses
stages in textile manufacturing. Also we got to know about machinery feature and
machines used for the entire processes.
PLANT LAYOUT

Organisational
Structure
 Processes
Winding

Warping

Sizing

Drawing

Weaving

Grey Section

Singeing

Scouring, entering, crabbing, and heat-setting

Sanforization

Quality Control

Inspection

Final Dispatch
 Preparatory Processes
Yarn Produced in Spinning Mills are packaged in small packages,
thus winding is done to convert smaller packages into bigger and
suitable packages.
Warping is transferring many yarns from creel of single-end package
forming parallel sheet of yarn wound on to a beam or section beam.
ACPL mainly deals with two types of warping.:-
1. Sample Warping
2. Sectional Warping
 Checkpoints

Whether the cones are creeled as per plan?

Whether the feed material is as per plan.

Whether the empty beams are in good condition?

Whether the stop motions and brake are functioning properly?

Whether the length set is as per plan.

Whether the machine is giving the required production and efficiency? Etc..
 Sizing
Warp Sizing is the process of giving a protective coating on the warp yarn to minimise yarn breakages
during weaving operation.

It Prevents the warp yarn breakage due to abrasion with neighbouring yarns or with backrest, heald eye
and reed.

It improves the yarn strength by 10 to 20% though it is not the primary objective of sizing process.

Giving a sized film on the circumference of the yarn body (proaction of the yarn), thus making thin
places stronger.

In, ACPL for small orders they use sample sizing machine and bulk orders are done in Benninger
sizing machine.
 Manual Drawing
• Yarn drawing is the process of passing the warped yarns through the appropriate
eye of the heddles of a harness.
• Attached to these harness frames are a series of wires that are called heddles.
The heddles have openings that can be compared to the eyes of needles.
• Feed: Warped yarns
• Delivery: Drawn yarns
• Yarn drawing is done manually with the help of a hook that helps in pulling the
yarns through the eyes of the heddles.
There are total 3 in machine for drawing. Minimum of two workers are required in
Beam:
1) Drawer 2) Reacher
Problems Observed.
1. Postural defect of the operators working in this section.(Sitting in a small stool
without any back rest and the spinal cord inclined at an angle of 60 to 80 degrees.)
Abstracts Information:
1. The operators working in this section and contract based operators and earn Rs 3
per Ends. And one frame has 650 Ends.
 Drawing to Weaving
Working Process for Weaving :-
• A minimum of 2 workers are required to shift the beam from the
drawing frame to the Power Loom.
• In the industry it took nearly 7 hours to change and shift the
beam.
• Then after the installation and initial testing handover of charge
takes place.
• Indicator lights to be checked for identifying the type of problem.
• For every 3 power looms there is one operator.
• Design Sheets are used for communication of fabric information.

Abstract Information
• Salary of the operators:- (9am to 9pm; 7 days a week; Rs530),
(9am to 7pm; 6 days a week; Rs400).
• The Weaving Rooms are like a Chamber with no noise absorption
technique(operators are giving ear buds).
 Shedding :- it is the lifting of some of the
warp yarns, so that the warp yarns that the
warp is divided into 2 sheets. This creates
an opening (a shed) between them for the
weft carrier to pass through

Beating up :- The inserted pick is

consolidated or ‘beaten -up’ into the
fabric when the new pick is punished
into the cloth-fell by the reed.
Picking :- The weft yarn
taken from one side of the
 Grey Section
After the processing of the fabrics from the washing and finishing unit the beams are the carried back for
the final inspection.

Basically 3 processes are happening in this department

1.Roll checking 2.Darning 3.Quality checking

ACPL following 4-Point system for Quality inspection

There are two inspectors to keep continuous watch on fabric for finding the defects. The 4-point

grading system indicates that as per customer requirement defects are allowable up to their levels.

In darning 1 skilled employee is manadatory (person working here was 20years experianced)
 Inspection
•
Grey section department uses 5 roll checking machine to find any defects in fabrics
•
Employee takes 10 to 15 minutes check 200 meter roll.
•
The inspection frame is aligned at an angle between 45 and 60 degrees.
• Speed of fabric on inspection m/c: 20m/min
• Light of 100 Lux and an Inclination of 57
•
Spinning related Defects
Warp Slub, Weft Slub, Thick end, Coarse/fine weft ,Weft bar
•
Preparatory and Weaving related defects ·
Starting mark, Tight end, Weft float, Knot , Moir, Repaired warp, Double end,Knot,Slack end, Size patches
if the roll pass the requirements if some rework needed
Roll
checking

Process flow chart

some necessary reeworks
Darning

After the rewok is done

Quality
 Quality Assurance

Testing Inspection

• In-process
• Final
• Physical
testing
• Chemical
testing
• Shade
testing
• Process
 ATEX
WASHING UNIT
 SINGEING
Singeing is a process applied to both yarns and fabrics to
produce a even surface by burning off projecting
fibres,yarn and fuzz.

The singeing machine used in the ATEX industry was

GAS CYLINDER SINGEING MACHINE.

The industry uses the old model machine [CALICO-

1987]

This machine is manually operated.

Calico gas singeing machine gives the output of 3000

m/hr.

The speed of machines 72-90 m/min depending on cloth

varieties.
 SCOURING & DESIZING(JIGGER
MACHINE)
The jigger machine is one of the oldest types of machine
for scouring, bleaching and dyeing of woven fabric in full
width form.

This industry uses four jigger machines.for the two

machines they uses hot water and remaining two they
uses cold water

It is been process at the 50degree temprature.

Desizing enzyme-->sizing oil & sizing acid

The desizing machines are 15 years old.

It gives an output of 1500 meter in 2 hours

 Sanforizing Process.

Sanforizing is a mechanical finishing process of

treating textile fabrics to prevent the normal
dimensional alternation of warp and weft.

It is also called anti-shrinkage finishing process.

It is a process of treatment used for cotton

fabrics mainly and also for some other textiles
made from natural and synthetic fibres
 In Sanforizing process peaching is been done in this industry to avoid large
amount of shrinking

PEACHING.

Peaching is a finishing process used on the polycotton for drill tops.

After weaving, fabric is stretched while drying.

It's called peaching because it's supposed to make the fabric feel like the fur
on a peach.
The machine used in sanforizing is comct

*In this machine for 1 roll it gives about

3000m.

*Its productivity is 1000 meters/hour.

 BOILERS

This industry uses oil and steam boilers for all the machines.

80% of the usage was with the Oil boilers.

The oil used in the oil boilers was MARK SYNTH. Hi Tech
Therm 60 Heat Transfer Fluid

Main ingredient used in this was silicon green 100%

 Laboratory
CROCKMETER
LAUNDROMETER
PILLING RESISTANCE TESTER
TEARING STRENGTH TESTER
TENSILE STRENGTH TESTER
ABRASION AND PILLING TESTER
ELASTICITY
SHRINKAGE
 Packing & Final dispatch
• Carry out re-inspection with roll checking machine
• Wrapping
• Putting a sticker which gives details like Buyer’s name, meters etc,
• Rolls of approx 150-200 meters
Thank You