Brandix College Of Clothing Technology

MILL VISIT
BTL-PANNALA

M.P.ASIRI VIDUL
Which operations are mainly done in dyeing and finishing mill …..

1. Singeing
2. Desizing
3. Scouring
4. Bleaching
5. Mercerizing
6. Prepared for dyeing (PFD)
7. Dyeing
8. Finishing process

In Brandix Textiles Pannala Factory,they mainly do prepared for dyeing (PFD) and prepared for
printing (PFP). They import their raw materials (Gray fabrics) from Pakistan & India.

What are the Fabric types of using BTL ??

 100% cotton
 Cotton/Lycra
 Cotton/Linen
 Cotton/Nylon
 Cotton/polyester
 100% Tencel
 100% Linen

BTL- Plant Overview

Basic process

Raw fabrics------------------------------ Finished Dyed/Printed or PFD (prepared for dye) fabrics.

BTL- Manufacturing process

Manufacturing done at several major steps.

Pre treatment

 Impurities Removal(To remove dust, dirt etc from the fabric)

 Property Improvement
 *  To Convert  fabric from hydrophobic to hydrophilic state. .
*  To achieve the degree of desire whiteness.
Singeing

Singeing is a process by which projecting or floating fibres, stand out on the surface of the fabric
are burned off.

Objects of Singeing:
1. To remove hairy fibres projecting on the surface of cloth and given a smoothen surface.
2. Optical levelness of the dyeing and clean-out lines of a printing design.
3. To increase lusture in the finished fabric.
4. To prepare the fabric for next process.

Advantages:
‡
 Very suitable for back filter in finishing process.
 A certain amount of lusture is produce due to friction between the fabric & hot surface of
curved plate.
 Improved lusture.
 Uniform singeing.
 More effective in case of valvet & pile fabric.

Disadvantage:
‡
 Very difficult to maintain the proper heat control of the plate.
 Only one side of the fabric is singed.
 Discontinuous process so more time taken.
 More labour cost
Desizing

The purpose of a desizing process is to remove sizes that have been attached to warp yarns
during a weaving process. Prior to the desizing process, therefore, the size analysis should be
performed in order to set desizing conditions suitable for the sizes.

Desizing Methods
Different methods of desizing are: A desizing method is selected on the basis of analysis of size ,
type of fabric , eco friendliness , ease of removal , cost of desizing and effluent treatment .

SCOURING:

Natural fibers contain oils, fats, waxes, minerals, leafy matter and motes asimpurities that
interfere with dyeing and finishing. Synthetic fibers contain producer spin finishes, coning oils
and/or knitting oils, Mill grease used tolubricate processing equipment, mill dirt, temporary
fabric markings and the like may contaminate fabrics as they are being produced. The process
of removing these impurities is called scouring. Even though these impurities are not soluble in
water, they can be removed by extraction, dissolving the impurities in organic
solvents,Emulsification, forming stable suspensions of the impurities in water
and Saponification, Converting the contaminates into water soluble components.

Bleaching
Bleaching is chemical treatment employed for the removal of natural coloring matter from the
substrate. The source of natural color is  organic compounds  with conjugated double bonds ,
by doing chemical bleaching the discoloration takes place by the breaking the chromophore ,
most likely destroying the one or more double bonds with in this conjugated system. The
material appears whiter after the bleaching.

Mercerizing
the treatment of cotton with a strong caustic alkaline (NaOH) solution in order to
improve the luster, hand and other properties,was names after its discoverer, John
Mercer.
Mercerization leads to a number of changes in fibre and fabric properties:

• a more circular fibre cross-section

• increased lustre
• increased tensile strength, a major factor for technical textile fabrics
• increased apparent colour depth after dyeing
• improved dyeability of immature cotton (greater uniformity of appearance)
• increase in fibre moisture regain
• increase in water sorption
• improved dimensional stability.

Prepared for dye (PFD)

After mercerizing the fabric is prepared for dye. Purpose of this is give a mechanical finish to
fabric. For that there are 3 finishing methods .

1. Microsand
2. Peach
3. Brushing
Mostly these are depends on customer requirements.

Fabric surface is rub on sand paper roller on microsand method. But this can cause more fabric
damages. In brushing method the fabric is passed through the roller. With series of brushes .
The fabric damages are less in this method than micro sand methods.

Dyeing

Reactive dyes are soluble in water and it goes inside and it can break easily. But vat dyes are
insoluble in water and it has to convert into soluble by using chemicals. After washed again it
becomes insoluble with in the fibre and fixed very well.

There are several methods for dyeing

 CDR – Continuous Dyeing Range

 C PB – Cold pad batch method
 Pad dyeing
 Pad steam
CPB Method is used only for reactive dyes. After dyeing according to CPB method the fabri c is
kept for 24 hours to fixed the dye molecules and also react them with cellulose. After 24 hours
it should be wash to remove the unfixed dye molecules. At that time only we can see the
colour that use to dye the fabric. If there are any colour variations from customers
requirement it has to redye.

CDR method generally use for vat and reactive dye both.

Fabric is passed through a dye bath and dry it by flame during the dying period. And also grow
into increase the width.

Before dyeing they make the dye recopies in laboratory according to customers requirements.

Then they make samples and check weather matching to original fabric swatch.I f it matches
they use the suitable recipe to dye the bulk.

Finishing process

In this they should check the all physical parameters. Otherwise it will finally affect badly for the
garment production. Therefore the finished width, shrinkage and bowing should be controlled
by this can improve the hand feel and increase the strength a little amount.

Quality Process

Separate two pieces 6”,from bottom and end of the fabric and check both them together to
define that it has any colour variations. Then inspect the fabric and grade it as “A” or “B”.