HAWASSA UNIVERSITY

INSTITUTE OF TECHNOLOGY
Declaration
I hereby, declare this final internship report is the result of my work except as cited in
the reference and compiled according to the internship report guideline given.

Name of student: LEWEYE MELISSIE Signature: __________Date: 27/01/2014 E.C

This final internship report has been submitted for examination with my approval as
University advisor.
Advisor Name:YIMER.Y Signature: ________________ Date: 27/01/2014 E.C
Acknowledgment
At first, I must show my gratitude to Almighty God for giving me energy, ability &
capabilities for preparing this report.
I would like to express my gratitude and respect to my honorable company advisor
Mr. MURAD IE in washing and Mr. Daniel, supervisor in washing plant of
Indochine Apparel Company for their constant guidance, advice, encouragement &
every possible help in the overall preparation of this report.
I express my heartfelt gratitude deepest regard to my advisor Mr.Yimer.Y lecturer of
Textile and Garment Engineering Department, who has given me valuable
instructions, constructive criticism and advice regarding to the progress of this work.
I would also like to give thanks to all the organization workers for facilitating me the
whole internship period by allowing soft skill training at the beginning of the
internship program.
I would like to express my sincere gratitude to my hosting company laboratory
technicians, washing plant operators and all of the employees who were very co-
operative with me during internship report.
I am ever grateful to my parents also for their guidance and sacrifice to continue my
study.
Finally, I would like to express my gratitude to all the people who helped me by
providing their valuable assistance and time during this internship program.
 Executive summary
This final internship report covers my three months stay in Indochine apparel PLC.
From June, 2021 up to August, 2021.
It is a clear fact that the Theoretical knowledge in engineering cannot be upgraded
without practical experience in each field of the subject matter. This paper is a written
report about the internship program.
This report is about the back ground of our holding company including its history and
major achievements, our overall internship experience, tasks and the procedures we
followed, the practical and theoretical knowledge we gained including the challenges
we faced while performing those tasks.
The contents of the report have been divided into three chapters and the topics
covered include the company background, our overall internship experience, and the
benefits we gained from the program.
Generally, this internship practice free-thinking me with different theoretical and
practical know-how’s. Chapter one is about background of my hoisting company.
Here brief history of the company; its vision, Mission, main products of the company.
Suppliers, customers, machineries and utilities and other important information of the
company are included.
Chapter two discusses about a project work which I have done on REDUCING
LYCRA(SPANDEX) FIBER BREAKAGE IN DENIM WASHING .The project
contains project title, problem statement, objective of the project, methodology,
identified problems and their solutions and conclusion and recommendations.
Chapter three presents about my experience and my work tasks I performed during
the three-month internship program. There are points which has been finish when I
am performing my work tasks what measures I have taken to those problems and
benefits I have gained from my internship program. The benefits are explained briefly
in this chapter.
Table of Contents

Declaration.....................................................................................................................................ii

Executive Summary......................................................................................................................iii

Acknowledgment...........................................................................................................................iv

List of figures.................................................................................................................................ix

List of Symbols and their Nomenclatures......................................................................................x

List of Appendices.........................................................................................................................xi

1. INTRODUCTION.....................................................................................................................1

1.1. Background of company......................................................................................................1

1.2. Management and organization structure of epic apparel.....................................................1

1.3. Objectives.............................................................................................................................3

1.3.1. General objective...........................................................................................................3

1.3.2. Specific objectives.........................................................................................................3

1.4. Limitation and challenges of company................................................................................4

2. LITERATURE REVIEW...........................................................................................................5

2.1. History of Washing..............................................................................................................5

2.2. Garment Washing.................................................................................................................6

2.2.1. Type of Garment Washing..........................................................................................10

3. GARMENT MANUFACTURING PROCESS........................................................................14

3.1. Introduction to manufacturing process...............................................................................14

3.1.1. The Cutting Department..............................................................................................14

3.1.2. The Sewing Department..............................................................................................14

3.1.3. The Washing Department............................................................................................14

 3.1.4. The Finishing Department...........................................................................................15

3.2. Manufacturing process.......................................................................................................15

3.2.1. The Pre-Production Process........................................................................................15

3.2.2. The Production Process....................................................................................................................16

3.2.3. Post production process.....................................................................................................................16

3.3. Raw materials used for production process........................................................................................25

3.4. Production procedure of garment.......................................................................................26

3.5. Quality and working parameters............................................................................................................28

3.5.1. Working parameters....................................................................................................28

3.5.2. Quality parameters......................................................................................................30

3.6. Auxiliary or Downstream manufacturing process.............................................................32

4. MATERIAL AND ENERGY BALANCES.............................................................................41

4.1. Material balances................................................................................................................41

4.1.1. Mass balance on washing machine.............................................................................41

4.1.2. Material balance on extractor machine.......................................................................42

4.1.3. Material balance on dryer machine.............................................................................43

4.1.4. Material balance on boiler...........................................................................................44

4.2. Energy balance...................................................................................................................46

4.2.1. Energy balance on dryer machine...............................................................................46

4.2.2. Energy balance on boiler.............................................................................................48

5. ENVIRONMENTAL AND SOCIOECONOMIC ANALYSIS...............................................51

5.1. Environmental analysis:.....................................................................................................51

5.2. Social Analysis:..................................................................................................................52

6. CASE STUDY..........................................................................................................................53

6.1. Challenges and problems of company/industry facing currently.......................................53

6.2. Case Study on Installation of Organic Rankine Cycle (ORC)...........................................55

6.2.1. Background.................................................................................................................55
 6.2.2. General objective.........................................................................................................55

6.2.2.1. Specific objectives....................................................................................................55

6.2.3. Statement of the problem............................................................................................55

6.2.4. Possible solutions that can address the above problem...............................................56

6.3. Literature review................................................................................................................56

6.3.1. Organic Rankine Cycle...............................................................................................56

6.3.2. Working Principles......................................................................................................57

6.4. Methodology......................................................................................................................58

6.4.1. Heat source..................................................................................................................58

6.4.2. Working fluid selection...............................................................................................58

6.4.3. Modeling of Organic Rankine Cycle components......................................................60

6.4.4. Payback period............................................................................................................61

6.4.5. Mathematical analysis.................................................................................................61

Expander calculation.............................................................................................................63

6.5. Result and Discussion........................................................................................................64

6.6. Conclusion..........................................................................................................................64

6.7. Recommendation................................................................................................................64

6.8. New Findings or New Knowledge’s that I experienced in my stay at the

hosting company.......................................................................................................................65

7. CONCLUSION.........................................................................................................................66

8. RECOMMENDATIONS..........................................................................................................68

REFERENCES.............................................................................................................................69

APPENDIX...................................................................................................................................70
List of table

Table 3.1 working parameters and the effect............................................................. 28

Table 3.2 quality parameters and their effect ............................................................ 32

Table 4.1 Material balance on washing machine ....................................................... 42

Table 4.2 Material balance on extractor machine. .................................................... 43

Table 4.3 Material balance on the dryer machine ........................... ......................... 44

Table 6.1: The thermo-physical properties of the working fluid .............................. 59

vii
List of figures
Figure: 1.1 organizational structure of Epic Apparel……………………………...... 2

Figure 2.1: garment washing process flow diagram ................................................. 13

Figure 3.1: hand scrapping ......................................................................................... 18

Figure 3.2: ozone washing machine........................................................................... 19

Figure 3.3: washing machine .................................................................................... 22

Figure 3.4: The e-flow machine ............ .................................................................... 23

Figure 3.5: extractor machine ............... .....................................................................

24

Figure 3.6: drying machine ................. ............. ....................................................... 24

Figure 3.7: production procedure of garment ............................................................ 27

Figure 3.8: wood boiler ............................................................................................. 36

Figure 3.8: water treatment plant ............................................................................. 39

Figure 3.9: compressor................................................................................................ 40

Figure 6.1 Flue gas exhausted from steam generating boiler ..................................... 54

Figure 6.2 Schematic of organic Rankine cycle ........................................................ 57

 CHAPTER ONE

1.1. Brief History of the Company

1.1.1. Introduction
Hawassa Industrial Park was inaugurated in 2016, in the presence of the Ethiopian
Prime Minster Haile Mariam Desalegn and 18 companies from 11 countries. It is the
biggest industrial park of its kind in Africa. It will host textile and apparel industries
on a total of 140 hectares. When the park fully operated it can hold 60000 workers.
The park is fitted with a zero liquid discharge technology facility with a daily capacity
of 11 million liters of effluent, a system which is also expected to be replicated to
other industrial parks across the country. The industries hosted in the park started
exporting products in March 2017. Indochine apparel plc operates a vertical supply
chain for the sourcing, manufacturing and designing of apparel. Indochine apparel plc
is winner of 2013 Drapers Awards. Formed in 2004, Headquarters is located in
Hangzhou in China. 2016 estimate sales volume around US $ 80 million and also in
Sri Lanka it has around 5500 workers in 2016, producing 720,000 pieces /month Orit
Apparels is Sri Lanka’s No.1 denim specialist manufacturer. The core strength of the
company lies in their single minded dedication to the art of denim and a knowledge
bank of organized design teams that are engaged in developing new washing
techniques and quality finishes. Since its inception over 15 years ago, denim apparel
has grown phenomenally and today boasts of an impressive list of global Clients. This
apparel company is a fashion forward player in the sourcing industry. Design studio
locates London, New York, Los Angeles, cologne, Melbourne, shanghai. They have
around there five office the main office located in Sri Lanka, Myanmar, India,
Pakistan and Ethiopia. In Ethiopia the company found in Hawassa industrial park. Its
employeer number is 2100.

Park. Shade #9, 10 & 11, from Addis Ababa to Hawassa, 278.31 km
 F IGURE 1.1 I NDOCHINE

1.1.2 T HE PRIMARY OBJECTIVE OF THE F ACTOR

 To achieve and receive a profit

 To provide excellent quality and host dealing to its customer
1.2 Vision
To be worldwide competitive on apparel industry and to be an influential
New member of the apparel industry

1.2 MISSION

 Complete transparency of operation

 Strong support for customer initiative
 Team work that challenge processes for further improvement
 1.2. FLOW CHART OF PRODUCTION

Merchandise office Order receiving

Ware house Receiving material, test & inspection fabrics,
deliver to line or cutting
Sample room and CAD(design) Sample making, making marker & pattern,
Cutting Cutting, numbering
CPU Embroidery and first operation
Quality control Inline qc, end line qc, final qc
Sewing Sewing, trimming
Washing Washing department
Finishing Qc, poly bag, tagging, packing
Final good store Packing in to carton
TABLE 1.1 FLOW CHART OF PRODUCTION

1.2.1 PROCESS FLOW OF THE COMPANY

Order receiving Sample making and Fabric store and
room cad room inspection room

Trims and Spreading and Bundling

accessories store cutting department
department

CPU Sewing department Quality assurance

department

Washing department Finishing department

Final good store

FIGURE 1.2 PROCESS FLOW CHART OF THE COMPANY

Indochine Apparel Plc in Ethiopia is a Ready-made garment manufacturer, that provides the
following products: Shirts & Blouses, Denim & Jeans, Trousers & Shorts, T-Shirts & Polos.
Established in the year
 ORGANIZATIONAL STRUCTURE

CEO

COO

HR IE Production Finishing Washing Cutting Quality

manager manager Manager manager manager manager manager

Assistant Assistant IE Assistant Assistant Assistant Assistant Assistant

HR manager production finishing washing cutting
quality
manager
manager manager manager manager

DETAIL ABOUT EACH DEPARTMENT

FABRIC STORE
Fabric storehouse actual are where the fabric for production is receive or
dispatched for processing. Beside storage the fabric store department is also
responsible for the inspection of good receives by it.
. STORAGE
Rack system of storage is followed i.e. packages are stored in two areas:
1. Check fabric
2. Unchecked fabric
They are further segregated on the basic of style no. and lot wise. The fabric rolls
are put in rack manual way. Such systematic maintenance of the store makes it
easy to make the fabric whenever needed in future.
FABRIC INSPECTION
The fabric being the main contribution to development of our final product i.e. the
garment, it is very important to control its quality indicated by the no. of faults and
various present in it. Identification of these objectionable variations and faults right
at the initial stage to reduce the production time. So once the fabric is in- house it
is immediately sent on a pilot and trolley assembly to inspection.
4 POINT SYSTEM:
4 Point system for fabric inspection is widely used in apparel industry for fabric
quality inspection.
1. Fabric inspection method or preparation.
2. Criteria of giving penalty points based on defects and defect length.
3. Calculation method of total penalty points for total defects found in a fabric roll.
4. A Check sheet or format for recording data.
5. Knowledge of different types of defects (how a defect looks and its
appearance).
Criteria for giving penalty points

The penalty evaluation points have been given for different length of fabric defect

and dimension of holes.

 SIZE OF DEFECT PENALTY POINTS

Length of defects in fabric (either length or width)

Defects up to 3 inches 1
Defects > 3 inches < 6 inches 2
Holes and openings(largest dimension)
1 inch or less 2
Over 1 inch 4

FORMULA TO CALCULATE TOTAL POINT PER YARD

In 4 point system fabric quality is evaluated by unit points/100 sq.yds.

Points/100sq.yds = Total points in roll *3937

Fabric length in MTR * fabric width in inch

Example: A fabric roll 120 yards long and 46 inch wide contains following defects

4 defects up to 3 inch length 4x1 4 points

3 defects from 3 to 6 inch length 3X2 6 points

2 defect over 9 inch length 2X3 6 points

1 defect over 9 inch length 1X4 4 points

1 hole over 1 inch 1X4 4 points

Total defect points 24 Points

Therefore, =24*3937/109.72*46

Points/ 100 sq. Yards = 18.72 points

120 yards in MTR – 120*.9144 = 109.72 MTR

Fabric Relaxation

Fabric relaxation is performed for a certain period. This time is varied from fabric to
fabssssssssric. But the minimum time of relaxation is twelve (12) hours. This time
also may

vary according to the buyer‟s recommendation.

Trims store

Trims store as the name suggests is a department, which acts as a storehouse for

accessories. It is the place where all the accessories required in an export house,

are stored. Right from sewing thread, needles to packaging material mike poly

bags and taps etc. all are stored in the accessories store.

CAD department

Computer Aided Design (CAD) becomes an essential tool for pattern making and

related jobs in garment industry. In apparel industry CAD Software is used for

pattern making, Grading of pattern, marker making and digitizing manual patterns.
Marker making

A marker is a diagram of precise arrangement of pattern pieces for size of specific

style that are to be cut from a single spread.

Marker making is a process of developing a diagram which is superimposed on the

top of a ground of superimposed piles as a guide for cutting these plies.

It determines the most efficient layout of pattern pieces for a specific style fabric

and distribution sizes.

Spreading department

Spreading is the process of smooth layering of fabrics in superimposed layers of

specified length.

Cutting department
Cutting means to separate out different garment process from the lay of fabric with

the help of cutting template and devices. It is done to get required shape in
different no. or as a whole to make a complete product. The first stage in the

manufacture if garment is the cutting of material into the necessary pattern shapes.

These patterns are joined to form a garment when large amount of garment style

has to be cut, a lay is created, which consist of many piles of fabric spread one

above the other. Now all the pattern pieces for all sizes are from this lay. The main

objective of the cutting dept. is the cutting of garment parts accurately and

economically and in sufficient value to keep the sewing room supplied with work.

Fusing
Fusing is also carried out in the cutting room itself. The parts to be fused are

separated from the bundle. The fusing material (like interlining) is cut according to

size of the component to be fused. The component along with the cut fusing

material are kept between to paper sheets and the pack is passed through the fusing

machine by means of temperature and pressure fusing takes place at particular

speed and for a particular time. The pack comes out at the other end on conveyors

and the pieces are removed and re-bundled.

Numbering

After cutting the cut pieces are shorted out size and shade wise. All the components of

the same size are brought together. And they are numbered with Numbering machine.

This numbering process is an important factor. As it prevents the garments parts form

mix up. The sorted pieces are now ticketed. Ticketing is the process of marking the

cut components for shade matching precision and sequence identification. The seal

number maintains cutting number, size number, serial number.

Bundling

The checked components of one style and in one size are now clubbed and bundled

using tie. The size of bundle depends upon the requirements of the production

plant. Each bundle will contain pieces of same style and same size only. These

pieces are stored in racks made beneath the cutting table. The cutting department

issues the amount required by the production dept. as and when ask for. The cut

component may be issued in instalment or all at once as the needs of the

production dept. against the job order.

Embroidery Room

Each embroidery machine have its own CPU which have to been control every

activity/operation/ of machine.

Sewing Section

Sewing is an operation by which the fabric cut panels are joined together by thread

and gets the shape of a garment. Main responsibility of this department is to stitch

fabric together in a standard way that it meets the needs of a buyer as a garment

2.1 Garments Wash:

The garment was is a new technology in the garment trade. Normally washing mean
cleaning something. But in the garment trade, only cleaning of garments is not
the garment wash. Garment Washing is a technology which is applied to
change or modify the outlook, appearance, comfortable, and design of garments.
The wet washing process of garments to create a better look or effects by normal
wash or rinse wash, pigment wash, caustic wash, silicon wash, enzyme wash, stone
wash, stone enzyme wash, bleach wash and acid wash. In dry washing process, the
most important finishing treatment for garments is done to impart scraping, spraying,
whiskering, damages, spots, rubbing and tacking on garments or denim products.
Washing process applied a combination of wet or dry process on raw sample to
develop certain effect in the garments and measured the change of mechanical or
physical properties due to application of different wet or dry washing process. Wet
washing process is the most important finishing for garment to improve the outlook
which influences the chemical properties of garments on the other hand; dry washing
process is the most important finishing for garment which influences the mechanical
properties of garments. A number of combinations of dry washing process are carried
out on denim to get desired effect. Wet and dry washing process is most widely used
to get the chemical and mechanical properties on garments by replacing the
conventional process.

Machine used in plant washing

Sample washing machine  Washing machine (Side loading)
(Horizontal or
 Tagging machine
vertical)
 Washing machine (Front loading)
 Dryer machine (Steam or ga
 Steam chamber for crinkle

  Grinding machine.
 Hydro extractor machine  Sand blasting Gun
 Sand blasting chamber  Boiler

 Chemical mixture machine  Laser draw

 Spray gun and dummy  Submersible pump

 Industrial oven (Gas or electric)   Generator

Screw compressor
 Ozone
The function of chemicals used in washing plant

Enzyme: The action of enzyme during enzyme wash it hydrolysis the cellulose. At first it
attacks the having projecting fibers and hydrolyzed them. Then it attacks the yarn portion
inside fabric and party hydrolyzed the yarn portion. As a result, color comes out from the
yarn portion and faded affect is produced.
Detergent: Chemical character is fatty alcohol polyglycol ether in an aqueous, glycolic
solution. Detergent is widely applicable in the continuous and discontinuous pretreatment of
all types of fiber and their blends. To remove impurities, mineral oil contamination and sizes
from the garments.
Acetic acid (CH3COOH): Acetic Acid is used to neutralize the garments from alkaline
condition and to control the pH value in wash bath.
Antibackstaining: Antibackstaining is used to prevent the staining on weft yarn of the denim
(white yarn), white pockets of garment, levels, and contacted fabrics of garment and
increased the brightness of fabrics; it is also acts as anticreasing agent.
Bleaching powder: Bleaching powder is an oxidizing agent. It is used in washing plant for
color out from the denim garments. We can achieve deferent shade of color on garment
(Dark, medium, light shade).
Sodium hyposulphite: Sodium hyposulphite is used to neutralize the garments from chlorine
bleach.
Caustic soda: Caustic created the role in bleach technique without color change the garment
and has a good cleaning power. It is work as fading affect or old looking affect come rapidly
on garments.
Soda ash: Soda ash creates alkaline medium for the breakdown of pigment dye. Soda ash
help to uniform bleaching action on bleach bath. It has a cleaning power and help color
fading effect of garment. It is used also for color fixing in dye bath.
Sodium bicarbonate: Sodium bicarbonate is used in washing plant in the bleach bath with
bleaching powder for denim light shade because easily color out with in shot time. As a
result, production increase and costing is low.
Potassium permanganate (PP): Potassium permanganate is used in acid wash with pumice
stone for color out from the garments. It is used also spray chamber by nozzle for color out
(whitish affect) from the garments.
Flax softener (Cationic, Nonionic): Softener is used to make the garments treated textiles a
surface feel that is both sickly and soft and also provides excellent lubricating properties.
Micro emulsion silicon:Amino Silicon is a textile finishing agent consisting mainly of
amino modified silicon. When applied on fabrics, it gives durable softness, lubricity, elastic
handle, antipilling, dimensional stability, tear resistance and fabric to be cut and sewn more
easily allows and improving wear and easy care properties.
Sodium chloride (salt): It helps to exhaust dye in to the fiber.

Buffer: Buffer is used in washing plant for pH control of enzyme bath, softener bath,
desizing bath.

Hydrogen peroxide: Hydrogen peroxide creates the prime role in bleach wash technique. In
alkaline medium, hydrogen peroxide breaks up and gives some perhydroxhyl ion, which
discolor the coloring materials and as a result fading affect is developed. Hydrogen peroxide
is used in scouring, bleaching bath for white or ready for dyeing of gray fabric garments. It is
used also neutralized the garment from alkaline condition.
Stabilizer: Hydrogen peroxide is work a good condition at temperature above 90°c, when
temperature raise to 90°c then break the hydrogen peroxide. Stabilizer is used to protect
break the hydrogen peroxide and peroxide works in bath smoothly.
Fixing agent: Fixing agent is used for unfixed dye to fix on fabrics, when fabric color will be
proper fixing then color fastness and rubbing fastness will be increased.
Catanizer: Catanizer is used in pigment exhaust method processing. Pigment is color not
dyestuff. Pigment colors have no affinity to fabric when catanizer is used in fabric then
increase the affinity between pigment color and fabrics.
Optical brightness: Two types of optical brightener are used in the washing plant, red
brightener and blue brightener. Mainly optical brightener is used for improve the brightness
of garments. Resin: Resin is high efficiency textile resin based on etherified dimethylol
glyoxalin monoureine urea. Resin is used for the creation of semi-permanent creases in
denim and other cellulose fabrics. It is used also cotton and polyester fabric. Fabric retains
soft handle after washing.
Sodium metabisulphite: Sodium metabisulphite is used in the washing plant to neutralize
the garment from potassium permanganate.
Desizing agent: Desizing agent is used to remove mainly starches, waxes, fats pectin’s,
minerals and unfixed indigo dye from denim, twills, poplin and canvas fabrics.
. Type of Garment Washing

Mainly there are two types of washing, such as: Dry or mechanical process and Wet or
chemical process
Dry process or Mechanical washing process

In garments washing, there are some processes which have done without using any chemical
or without using any garments loading washing machine are called dry process or mechanical
process. Sometimes dry process can be done by using mechanical method Types of dry
washing processes applied in garments:
 Scraping  Dama
ges  Spots
 Spraying
 Rubbi
 Whiskering
ng
Hand Scrapping:

Removing to color from the surface of denim garment is called hand scrapping. Here,
fabric is scrapped emery paper in order to get an used effect.
Scraping is a process to remove color from the surface of denim fabric to create worn
out effect on the garments. This effect is done by different methods but it is very
difficult to get even look as per buyer requirements, so experienced operator should
do this process. This process is done before wet washing of the garment. It is done on
garments to get distress look. Fabric is scrapped with different tools in order to get a
used effect. All scraping processes are done manually, so it is difficult to achieve
consistent finishes every time.
P.P Spray:

P.P implies potassium permanganate.In this process chemical is sprayed onto jeans by
a spray gun. The main purpose of this process is discoloration. Spraying is done on
jeans to take a bright effect. Vintage and muddy appearance on denim fabric surface.
And to fix the color and permanent effect on the jeans.
Whiskers

These worn out lines or effects generated by different methods are done mainly on hip
and thigh areas of jeans. Mustaches or whiskers are one of the most important designs
on garment surface. This process is famous for its high quality. It is also cost-
effective. It is most frequently used in small industries especially where the
production is not consistent to style. To get a permanent effect high temperature is
required.
 Damages

Damage or destruction is an art which make denim look unique and used. In order to
achieve favorite vintage look, many damaging processes is necessary. The main
purpose is get different by distressing. This mainly done warp wise to make white
yarn visible. It is done mainly on pocket edges and hem.
Spot

A spot is another kind of dry washing which is done by different method. This is also
depending on fabric types and buyer requirements. Spot is the process by which we
will get the spot or design.
The design is made raw denim color so this process is done at unwashed condition.

Rubbing

Rubbing is usually done in combination with spraying. This process allows giving
more contrast and highlighting some part of the garment, especially on waistband or
on top of tacking effect. Rubbing is done for more contrast effect on the fabric
surface. This process focuses tacking effect on the fabric.
WET OR CHEMICAL WASHING PROCESS

Wet or chemical washing process is one of most widely used process, which can be
done by using different types of chemical and garments loading washing machine are
called wet process or chemical process.
Types of wet washing process applied in garments:
 Normal wash or rinse wash  Bleach
wash
 Pigment wash
 Enzym
 Caustic wash
e wash
 Silicon wash
 Stone
enzyme wash
 Acid
wash
 Stone wash

Normal wash or rinse wash

Normal washing is the most common, simplest and popular washing process with
lowest washing cost. It is nearly mandatory from every buyer. In normal wash
manufacturing process, some unwanted materials like dirt, dust and starch are
removed without any shrinkage. By altering temperature, time and detergent quantity
washing effect could be varied in garments surface. Normal washing also known as
different name such as detergent wash, common wash and rinse wash. Rinse wash has
a lot of purposes such as: to remove dust, dirt, oil spot, impurities from the garments.
Remove size materials from the garments, to remove starch presents on the garment
fabrics, for soft feeling to wear the garments after purchasing and to achieve buyer
washing standard.
2.3.2 Desizing wash
Desizing is the process of removing the size material from the warp yarns after the
textile fabric is woven. This is the most important part of denim washing.During
sizing, the warp yarn threads are treated with auxiliary chemicals known as sizing
chemicals which impart the strength, friction resistance during weaving. The purpose
of sizing is to protect the thread by coating. Different types of sizing chemicals are
used like Starch, Modified
starch, polyester, polyacrylates, polyvinyl alcohol, polyvinyl acetate, CMC etc.
During washing, those chemicals must be removed to bring desired look on the fabric.
Its main objectives are given below:
 Removing the impurities which came from fibre or different manufacturing
processes like oil, acedic or alkaline chemicals, dirts, dusts etc.
 Removing the sizing chemicals used in weaving
 Decreasing the crease risk on the garment etc.

Pigment wash

Pigment washing effect is made by pigment dyed or printed garments by pigment

washing method. This process is similar to normal washing process. The aim of this
washing makes fading effect or old looking effect on seam area and also garment
surface. Generally, pigment washing is needed for fading affect or old looking effect
on garment and for soft feeling to wear the garment after purchasing. Caustic wash
Caustic wash generally doing on reactive dye, Sulphur dye, direct dyed or printed
garments and these fabrics are used to manufacture apparels.
Objective of caustic wash
 To fading or old looking effect on garment and seam abrasion affection seam
area.

 To remove the size materials, starch from the garments.

 To increase the color fastness and rubbing fastness.

 For soft feeling to wear the garments.

 To increase the hairiness on garments.

Silicon Wash

Silicon wash is most common and popular washing process. It can be applied almost
all types of fabric such as knit, denim, canvas and twill fabrics. This washing process
gives more softness and elastic hand feel. In silicon washing process, silicon and
softener are used together.
Objective of silicon wash

 It gives durable softness, elastic handle

 It helps to anti pilling affects, dimensional stability and tear resistance

 It helps to fabrics to be cut and sewn more easily allows and improving wears
and easy care properties.
Enzyme wash

Enzyme wash generally cellulose enzyme are used. So they are bio chemical
substances that behave as catalysts toward specific reactions. This washing process is
applied heavy fabrics like jeans and denim. Due to enzymatic abrasion, dye is
released from yarns, giving contrasts in the blue color on denim fabrics surface.
Enzyme washing method almost replaced stone wash. And used to remove the size
materials from the garments and the starch presents on the garments fabrics.
Stone wash

Stone wash is done to produce fading and discolor effect on garments surface by
stone. In stone wash stone are perforated and that are produced from volcanic
explosion. This stones are also called pumice stone.Duringstone washing process,
these stones scrap off dye particles from the surface of the yarn of the denim fabric
which shows a faded, worn out and brilliance effect in the denim fabric.
 Bleach wash

Bleaching of garments means lightening the color of the indigo dyed garments and
apparels are normally dyed with direct or reactive dye. By applying bleaching agent,
color can be removed uniformly from the garment and removal of color have done as
per requirement (as buyer’s provided wash approval). It should be noted that, there
are three categories of bleaching, such as light bleach (where maximum color is
removed), medium bleach and bleach. It is also a separate process, which can be
applied instead of stone washing or together with stone washing.
Acid wash

It is normally done on the garments from heavy fabrics like denim, course canvas and
twill etc. During Acid wash, pumice stones are used. By the action of pumice stones,
irregular fading affect is developed on the garments surface.
Tinting
This is when different dyes have been added to the denim during the washing process.
It follows that different colour dyes create different colour finishes. Commonly used
are Brown and Green tints to give a browned off or green finish.
Brown and Green tints to give a browned off or green finish.

Washing process flow chart

Garment Garment sent Enter laser
receiving to dry process section

From sewing

hand scraping preparing Garment sent

to
 extracting washing Garment load in
to washing
machine

Quality chacking
drying Back to washing

Send to finishing
department

Figure 2.1 garment washing flow chart

Finishing room
Activity’s that are done in finishing room are

 Ironing: - removing shrinkage, wrinkle & smooth the surface of the garments.
 Labeling: -attach brand on each products
 separate finished & unfinished product
 Trimming; - cut unwanted thread from garment
 Dust particles and trimmed treads removal.
 Folding: - makes depending on the customer order that means for different customers
they use different folding system.
 Final quality checking
  Packaging: -it is the insert or posting of the poly bag to the box (carton).in Arvind
garment factory.
They use different types of packaging system
 The main activity of cartooning room is the packaging of the product size by size.
 Writing size name on each cartoon

o Warehouse room
 Sticker attaching
 Numbering and giving code for each cartoon.
 Product shipment.

1.2. Strength of the Company

 In this industry fabric is produced started from small/inside pant up to trouser are
produced. This is used for minimizing wastage and also used for competitiveness in
national market.

1.3. Weakness of the Company

Some weakness of garment evolution industry is:

 Lack of technical person

 Lack of proper promotional program
 The work can be done by experience, which means there are not educated
person by this field.
 CHAPTER –TWO

1.4. BENEFITS FROM INTERNSHIP EXPEIENCE

 Internship experience
 When I am to do the internship we get different experience. I can develop my
professional interest, and appreciated work experience. When I am finding a finish
that manufacturing company is good and to apply the knowledge I have learned in
the class room to the practical way.

 Benefits I gained from internships

Internship helps me to get experience in my field of study. I was not sure what I wanted to do
when I graduated. So I thought some real life experience would help me solidify my future
striving. The benefit of internship which I acquired during my internship includes the
following.
 Practical skill
  Upgrade theoretical knowledge
 Team playing skill
 Leader ship skill
 Work ethics issue and
 Entrepreneur ship skill
 Inter personal communication skill
 Solving problem in industrial

 Theoretical knowledge
After I have completed my internship program I am able to upgrade my theoretical
knowledge. When I was learned in the class it will be a theory. But after I had completed this
internship program. I have checked that those I have learned in theory are real and are found
in the practical like sewing room

 Practical
During internship program benefited me to have practical skill. Example, how to spread the
fabric, how to cut the fabric by using different machine in garment industry is performed. I
have learned this theoretically and I experienced this practically in internship program and
also able to make practical skill like pattern making and auto cad soft ware

 Garment problem solving skill

Completing this internship program makes me to identify the garment problems and then how
to solve them if happened.
My internship gave the opportunity to apply some garment problem solving skill learned with
in the classroom to real world

 Leadership skill
Doing an Internship made me to build my confidence and knowledge on leadership skill i.e. I
am able work with my workmate and previous goal of the company and become effective
without creating any disagreement with my colleagues.
  Work Ethics Issues and Industrial Psychology
An internship made me to have a strong willing to work. With strong willing to work ethic I
am always committed to the work and will stay until the task is complete. The internship
made me to avoid personal issues on work time and to keep my positive attitude and I
remember that I have smaller tasks to handle previous to my large, more important ones. I
also develop the following things after my internship program,

 Punctuality and accountability to a given task

 Build motivation and work ethics
 Transparency in working once duty etc.
 Internship supports me to act as advisers
 professionals,
 provide recommendations for how to resolve conflicts,
 increase worker productivity, and improve employee morale among other thing

 Internship Communication Skill

At the end of internship program, I am able to identify how employee behaviors and
attitudes can be improved through hiring practices, training programs, and feedback
and management systems physiologists also help organization

2.1 PROJECT TITLE: Reducing indochine apparel denim garment defects to increase
production
BACKGROUND