REPORT OF INDUSTRIAL TRAINING

Undergone at

FABTECH PROJECT & ENGINEERS Ltd.(Textile Division), Sangola

Submitted by
Mr.Shriyash Sanjay Dhole
Mr. Ajit Mohan Masal

Under The Guidance Of

Mr. Lokhande.A.S

Department of Mechanical Engineering

Fabtech Technical Campus
College of Engineering And Research Polytechnic (shift), Sangola
2023-2024
Fabtech Technical Campus
College of Engineering And Research Polytechnic (shift), Sangola
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 Department of Mechanical Engineering

Certificate
This is to certify that the Industrial training report has been submitted successfully by,
Mr.Shriyash Sanjay Dhole
Mr.Ajit Mohan Masal
Of S.Y. Mechanical in the partial fulfillment of award of diploma in Mechanical Engineering as
per the curriculum lay down by M.S.B.T.E. Mumbai, during the Academic year 2023-2024.

Date:

Mentor Faculty Industry Expert

H.O.D. Principal

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ACKNOWLEDGEMENT

This work is just not an individual contribution till its completion.

We take this opportunity to thank all for bringing it close to the conclusion. First of all we would like
to thank our guide Prof. Lokhande.A.S For accepting our studentship and continuously assessing our
work providing great guidance by timely suggestions and discussions at every stage of this work.
Thanks to Prof. Narle.D.B Head of Department of Mechanical Engineering for providing all facilities
without which these training work would not have been possible.
We sincerely thank to Prof. Pawar S.L. Principal, Fabtech Technical Campus College
of Engineering and Research Polytechnic (shift), Sangola.
Last but not least, I would like to thanks all the direct and indirect help provided by the
staff of this college, for successful completion of this training.

Mr.Shriyash Sanjay Dhole

Mr.Ajit Mohan Masal

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Abstract

Continuous development and automation has improved the production of Indian textile
industry. As a result, more and more raw materials demands have adversely affect the environment. In
this study the effects of Indian textile industry on environment and human health are reviewed and
concluded that textile mechanical process mainly affects the environment of the workplace by the way
of producing heavy noise and cotton dust, While fiber formation and chemical processing has vast
negative impact on outside world that pollutes land, water, air and emits hazardous byproduct which
indirectly promotes acid rain and global warming.

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CONTENTS

Sr. No. Chapter Title Page No.

No.
01 01 Organization structure of industry &
general layout
02 02 Introduction of industry
03 03 Types of major equipment
04 04 Manufacturing process along with
production planning and control method

05 05 Testing of raw material component &

finished product along with quality
assurance procedure.
06 06 Major material handling products and
material handling procedure.

07 07 Safety procedures
08 08 References

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 Chapter No.01
Organization structure of industry &
general layout

The Textile Sector in India ranks next to Agriculture. Textile is one of India’s
oldest industries and has a formidable presence in the national economy in as much as
it contributes to about 14 per cent of manufacturing value-addition, accounts for
around one-third of our gross export earnings and provides gainful employment to
millions of people. The textile industry occupies a unique place in our country. One of
the earliest to come into existence in India, it accounts for 14% of the total
Industrial production, contributes to nearly 30% of the total
exports and is the second largest employment generator after agriculture. Textile
Industry is providing one of the most basic needs of people and the holds importance;
maintaining sustained growth for improving quality of life. It has a unique position as
a self-reliant industry, from the production of raw materials to the delivery of finished

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products, with substantial value-addition at each stage of processing; it is a major
contribution to the country's economy.. It is a great opportunity for trainee to study
the Organization and learn functions involved and make sure to understand
Theoretical concepts in Practical and Practical concepts in Theory.

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 Chapter No. 02
Introduction of industry
Company started in 1992 by late executive chairman Mr. B.A. Rupnar
Business Type : Exporter / Manufacturer / Supplier
Products : Exporter and Manufacturer Cotton textiles, cotton yarn.
No. of employees : 700
Turnover: 700 core
The textile industry is primarily concerned with the design, production and
distribution of yarn, cloth and clothing. The raw material may be natural, or synthetic using
products of the chemical industry.

Cotton manufacturing:
Cotton is the world's most important natural fibre. In the year 2007, the global yield was
25 million tons from 35 million hectares cultivated in more than 50 countries. [1]There are
five stages:

 Cultivating andHarvesting
 PreparatoryProcesses
 Spinning — givingyarn
 Weaving — givingfabrics
 Finishing — givingtextiles
Synthetic fibres
Artificial fibrescan be made by extruding a polymer, through a spinneret into a medium
where it hardens. Wet spinning (rayon) uses a coagulating medium. In dry spinning (acetate
and triacetate), the polymer is contained in a solvent that evaporates in the heated exit
chamber. In melt spinning (nylons and polyesters) the extruded polymer is cooled in gas or air
and then sets. All these fibres will be of great length, often kilometreslong.

Artificial fibres can be processed as long fibres or batched and cut so they can be processed
like a natural fibre.

Natural fibres
Natural fibresare either from animals (sheep, goat, rabbit, silk-worm) mineral (asbestos) or
from plants (cotton, flax, sisal). These vegetable fibres can come from the seed (cotton), the
stem (known as bastfibres: flax, hemp, jute) or the leaf (sisal). Without exception, many
processes are needed before a clean even staple is obtained- each with a specific name. With
the exception of silk, each of these fibres is short, being only centimeters in length, and each
has a rough surface that enables it to bond with similar staples.

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 Chapter No. 03
Types of major equipment

BALE PLUCKER LA 23/5 – Maintenance

Sr.No. SCHEDULE FREQUENCY
1 Maint.clg& Lubrication 10 Days
2 Trolly wheel front servicing 1 01 Year
3 Trolly wheel front servicing 2 01 Year
4 Trolly wheel back servicing 1 01 Year
5 Trolly wheel back servicing 2 01 Year
6 Gear box oil change 01 Year
7 Take up roller bearing greasing 01 Year
8 Lifting belt change As per requirement
9 Teeth plate replacement As per requirement
10 Material duct alignment 3 Month
11 Conveyor belt alignment 10 Day

CARD LC 333 – Maintenance

Sr.No. SCHEDULE FREQUENCY
1 Maint.clg 10 Days
2 Cylinder 800 T
3 Doffer 800 T
4 Licker-in 250 T
5 Flat 800 T
6 Flat belt As per requirement
7 SFD 800 T
8 SFL 250 T
9 FD9 250 T
10 Full setting 06 Months
11 Cylinder grinding 06 Months
12 Doffer grinding 06 Months
13 Revoving flat grinding 03 Months
14 Coiler gear box oil change 01 Year
15 Top coiler greasing 01 Year
16 Bottom coiler greasing 01 Year
17 Fine feed roller geasing 01 Year
18 Fine feed drive assly servicing 01 Year
19 Cylinder belt tension pulley greasing 06 Months
20 Petrol wash cylinder 01 Month
21 Timing belt tension pulley greasing 06 Months
22 Cylinder brake servicing 01 Year

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 Chapter No.04
Manufacturing process along with production planning and control method

Production Planning and Control:

A planned work brings success. Without planning nothing is completed within the
required time. So planning has its own importance which is intolerable. "Planning"
gives a scheduled task and 'control' completes it successfully. But production
planningand control is not an easy task. Basic working procedure of production
planning and control is given as follows –

1. Taking orders from marketingdivision.

2. Analyzing theorders.
3. Planning for knitting thefabric.
4. Planning for dyeing thefabric.
5. Planning for finishing thefabric.

Cycle of production planning

It is only a basic procedure. It may change according to the type of order. Sometimes,
order is places only for finishing the material or only for dyeing the white goods.
Then some steps are omitted for planningprocedure.

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1. Taking orders from marketingdivision:
Marking division supplies fabric orders to the planning and control division by a
special format.

2. Analyzing theorders:
This section analyzes the orders according to buyers, Order Quantity, type of orders
(i.e. type of fabric, color to be dyed etc.), delivery date etc. Then it selects which M/C.
to use, no of M/C. to use, time required for production etc. This section plans for
required quantity of fabric to be knitted (Order quantity + 12% of Order Quantity),
knitting balance, fabric need to be dyed. Dyeing balance, RFD (Ready for delivery),
RFD balance, delivered fabric and delivery balance.

3. Planning forknitting:
This section plans for knitting production. It selects machine for knit the fabric for
specific type of fabric, type of yarn used, required GSM, width etc. It also gives
delivery data for knitted fabric. It also places orders for buying of yarn from spinning
mills by a specific schedule.
4. Planning for dyeing thefabric:
Production planning for dyeing is called 'Batch Plan’. According to the batch no. And
color, width, style and construction the batch plan is made. For easy understand this
section gives some 'T.' cards. 'T' cards are serialized according to the priority of
delivery. The batches and 'T' cards also serialized as to dye light shade at first and
lastly the dark shades, since faulty shades can be converted to dark color later.
5.Planning for finishing thefabric
Finishing schedule is same us the dyeing. After dyeing the material goes to the
finishing section with the batch plan. Finished data is written to the batch card and is
informed to the planning section. However, this section always enforces to all the
departments to finish all the works within the delivery time given by the buyers. This
section delivers materials by truck, micro, air etc to the customer within the
meantime. Thus it plays a very important role in the success of the company.

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 Chapter No.05
Testing of raw material component & finished product along with quality
assurance procedure.

Textile testing
The quality of a product or process is checked before it is put into large-scale usage.
The quality of the product, its performance, and its reliability are the key factors while
testing is performed. Testing can be defined as the methods or protocols adopted to
verify/determine the properties of a product. It can be divided primarily into two
types: regular process testing and quality assurance testing. Routine testing helps to
streamline the daily process.
Quality assurance testing helps the process or product in the long run to
establish credibility. Testing can also be defined as the procedures adopted to
determine a product’s suitability and quality.
Objectives of textile testing:
The main objective of textile testing are:
 To check the quality and suitability of rawmaterial
 To monitor the production (process control)
 To assess the quality of finalproduct
 To investigate the faultymaterials
 To set standards orbenchmarks
 For R&D (research and development)purpose
 For new productdevelopment
Quality
1. Degree or standard ofexcellence.
2. Totality of characteristics of an entity that bear on its ability to satisfy stated and
implied needs(ISO).
3. The degree to which health care services for individuals and populations increase
the probability of desired health outcomes and are consistent with current
professional knowledge of best practice.
Quality Assurance:
Quality assurance refers to the engineering activities implemented in a quality system
so that requirements for a product or service will be fulfilled. It is the systematic
measurement, comparison with a standard, monitoring of processes and an associated

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feedback loop that confers error prevention. This can be contrasted with quality
control, which is focused on process outputs.
Quality assurance system can be divided into following steps:
On line Quality assurance system and
1. Off line Quality assurance system.
Again on line Quality assurance system can be divided into the following steps:

 Raw materialcontrol.
 Processcontrol.
Tools of Quality Assurance:
Focus on the client(Internal/external): Services should be designed so as to meet
the needs and expectations of clients and communities.
1. Focus on system and Processes: Providers must understand the service delivery
system and its key service processes in order to improvethem.
2. Focus on mesasurement :Analyze processes, identify problems, and measure
performance.
3. Focus on teamwork: Quality is best achieved through a team approach to
problem solving and qualityimprovement
Steps of Quality Assurance:
Self study
1. Strategic planning (vision, mission, objectives andinitiatives)
2. Monitoring &documentation
3. Re-evaluation

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 Chapter No.06
Major material handling products and material handling procedure.

SELECTION OF MATERIAL HANDLING EQUIPMENTS

There are two most important aspects for analysing or solving a material handling
problem are: engineering aspect, and economic aspect. Engineering factors include: the
condition of existing building and plant layout, production processes and equipment’s,
nature of materials and products to be handled, usefulness and effectiveness of existing
material handling equipment. The economic factors include the cost of material handling
equipment, operating costs, repair and maintenance costs and taxes etc. The choice of
particular equipment depends upon specific requirements or the condition of an industry.
For selection of Material handling equipment, the following factors should be taken into
account:
i) Type/shape of materials to betransported:
The size of material, its shape, weight, delicacy and its chances of getting damaged
during handling etc. should be considered.
ii) Mill building andlayout
: The route of material movement, width of doors and aisles, inequality in floor levels,
height of the ceiling, strength of floor and walls, columns and pillars etc. to a great extent
influence the choice of a material handling equipment’s.
iii) Machineproduction
: Different machines have different outputs per unit time. The material handling
equipment should be able to handle the maximum output.
iv) Type of material flowpattern:
A horizontal flow pattern will need trucks, overheads bridge cranes, conveyors etc,
whereas a vertical flow pattern will require elevators, conveyors, pipes etc.
v) Types ofproduction:
The selection of the material handling equipment’s depends a great extent on type of
production such as: mass production and batch production. Conveyors are more suitable
for mass production on fixed routes and powered trucks for batch production.
vi) Otherfactors
: Some other factors also considered during selection of material handling cost are: cost of
material handling equipment, handling costs, life of the equipment and amount of care
and maintenance required for theequipment.

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MATERIAL HANDLING EQUIPMENTS
A wide range of material handling equipments is available in the market; which are
suitable to the most of the industrial requirements. Material handling equipments are
classed as:
Industrial trucks: manual and powered
Cranes: overhead bridge crane, jib crane and gantry crane 3.
Hoists : chain type manual, electrical and pneumatic, 4.
Conveyors: belt conveyors, roller conveyor, drag conveyor, bucket conveyor, pipe line
(pneumatic) conveyor, chain or cable conveyor 5.
Monorail 6.
Slides and chutes 7.
Lift 8.
Tractors and trailers etc. In the textile mills, there are many types of materials viz. raw
materials, purchased components, material in process, finished goods, packing material,
maintenance and repair supplies, scrape and waste etc. These materials are of various
size, shape and specific features. For this purpose, mostly special and some general type
material handling equipments are used in textile industries.
A.Material handling in spinning units
Types of material handling equipments used in the spinning mills are as under [Table 1]:
Table 1:
Material handling in spinning units Process Material Material handlingEquipment
1. from supplier to mill Cotton/polyester in bale form Truck or train orship
2. From truck to store Bale of raw material Manual 2, 3 or 4 wheeledtruck
3. Raw material store to mixing section Bale Manual 2, 3 or 4 wheeledtruck
4. Mixing to blow room line loose cotton Special designed trolleys or lattice orsuction
5. Blow room to card Laps or loose cotton specially designed trolley or Air pipe
conveyor andchute
6. Carding to draw Frame Sliver cans Manual trolley or cans fitted Castrolwheels
7. Draw Frames to Speed Frame Sliver cans Manual trolley or cans fitted castrolwheels
8. Speed frame to ring frame Roving bobbins Manual trolley/Tapa or special designed
trolley
9. Ring frame doffing Ring bobbins Doffing trolleys 10 Ring frame to winding Ring
bobbins Specially designed plastic trolley 11 Winding to packing Cones Big size
plastic trolley or special designedtrolley

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i. From truck to millstores
In the most of the textile spinning mills, raw material i. e. cotton or polyester or viscose in
the forms of bale and other supplies are carried to mills by means of motor trucks. After
arrival of trucks, cotton or manmade fibres bales are manually pushed down on the floor.
These bales are transported with the help of 2, 3 or 4-wheeled industrial trucks/trolleys
(Figure 1&2) for storing in godown one by one. This consumes time, requires more
workers. Sometimes Forklifts (Figures 3) can be used to unload bales (2 or 3 at a time)
directly from trucks, transport and stack them in godowns.

Figure 1: 2-wheeled industrialtrucks/trolleys

Figure 2 : 4-wheeled industrialtrucks/trolleys

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 Figure 3: Forklifts

Figure 4 : Platform trucks

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 Chapter No.07
Safety procedures
Safety Issues in the Textile Industry
There are various dangers and safety concerns regarding the textile industry, most of them
centered around the textile mills and manufacturing. Textile mills are under the risk of:
Fires - These happen due to chemicals and flammable textiles, especially materials like
cotton.
Explosions - Although textile machinery has come a long way, it can break down, have a
short, or bust a circuit just like any other piece of technology.
Machine-related injuries - A lot of the equipment used in mills today is automated, but
not all and not for every country. Many machines are still handled by skilled workerswho
can get their hands and fingers caught, causing a lot ofdamage.
Air pollution - The processing of cotton creates cotton dust due to natural and synthetic
fiber breakdown in the air. This dust is a combination of cotton, chemical pesticides that
were on the cotton, and soil. They all get into the air and then into the lungs of the
workers if they are not properly masked. This can cause serious lung issues for
employees.
Employee deafness - The mills usually have large rooms packed with all of the textile
machinery working at once. The loud machines are damaging to the ear, especially with
constant exposure.
Chemical exposure - Textiles go through several iterations of chemical dipping and
dying for cleaning, finishing, and softening processes. This means that employees are
exposed to these harsh chemicals constantly. A problem with textile mills is that they
have many factors that can combine to spell disaster, like highly volatile chemicals,
flammable materials (some dipped in the chemicals), and electrical and gas-run machines.
If something goes wrong, even if the mill is well taken care of, people can be hurt or
killed.
In countries like Bangladesh, India, and South Africa, the textile mills are still
very dangerous. In 2006, 54 people were killed in Bangladesh and twice those amounts
were hurt due to a boiler explosion that caught the textiles on fire and destroyed the mill.
Unfortunately, buildings and equipment are often not well kept, making incidents like
these somewhat common

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Workers' Rights
Workers have the right to:
Working conditions that do not pose a risk of serious harm. Receive information
and training (in a language and vocabulary the worker understands) about workplace
hazards, methods to prevent them, and the OSHA standards that apply to their workplace.
Review records of work-related injuries and illnesses. File a complaint asking OSHA to
inspect their workplace if they believe there is a serious hazard or that their employer is
not following OSHA's rules. OSHA will keep all identities confidential. Exercise their
rights under the law without retaliation, including reporting an injury or raising health and
safety concerns with their employer or OSHA. If a worker has been retaliated against for
using their rights, they must file a complaint with OSHA as soon as possible, but no later
than 30 days.
How to Contact OSHA
Under the Occupational Safety and Health Act of 1970, employers are responsible for
providing safe and healthful workplaces for their employees. OSHA's role is to ensure
these conditions for America's working men and women by setting and enforcing
standards, and providing training, education and assistance.

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 Chapter
No.08
Referenc
es:

1) https://www.academia.edu/5380018/
MATERIAL_HANDLING_IN_TEXTILE_INDUSTRIES
2) https://www.osha.gov/SLTC/textiles/index.html
3) https://www.osha.gov/SLTC/textiles/index.html
4) https://fashion2apparel.blogspot.com/2017/11/structure-
textiles- clothing-industry.html

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