Production process of spinning flow chart:

1-Basic operations in the blow room:

1-opening 2-cleaning

2-THE PURPOSE OF CARDING:

1- to open the flocks into individual fibres. 2- cleaning or elimination of impurities.

3-Combing: 4-Drawing:

Combing is the process which is used to upgrade the raw material. It influences the following yarn quality. Drawing is the final process of quality improvement in the spinning mill.

5-Ring spinning:

The ring spinning will continue to be the most widely used form of spinning machine in the near future, because it exhibits significant advantages in comparison with the new spinning processes.

6-winding:
The winding process therefore has the basic function of obtaining a larger package from several small ring bobbins.

Production process of weaving flow chart:

1-Winding:
The process of transferring yarn from small packages like hank, bobbing etc to a large package such as cones, pirns, cheese etc, containing considerable length of yarn is called winding

2. Wrapining:To wound up fixed length of yarn to a warp beam 3- Drawing: Drawing is the process of passing the yarn through the head frame. 4-Denting :is the process of passing the yarn through the reed. 5-Loom:The weaving machine is technically termed as loom. The loom is a device or
machine in which interlacement of warp and weft yarn is performed and thus fabric is produced

Flow Chart of Dyeing

Inspection of grey cloth Stitching Cropping Brushing Singeing Desizing Scouring Bleaching Souring Washing Drying Mercerizing Dyeing Aftertreatment Finishing Inspection Packing Baling

Flow Chart of Printing

Inspection of grey cloth Stitching Brushing Singeing Desizing Scouring Bleaching Souring Washing Drying Mercerizing Printing Finishing Inspection Packing

Flow Chart of garments:

SL No.

Operation

Job

Method

01

Design/Sketch

It is given by buyers to manufacturers containing sketches including measurements of particular styles Basic block is an individual component of garments without any style of design (without Allowance, Style, Design) When a pattern is made for a particular style with net dimension regarding the basic block along with allowance then it is called working pattern. To make a sample, this will be approved by buyer. After making a sample, it is sent to buyer for approval to rectify the faults After rectify the faults, sample is again sent to buyers. If it is ok then , then it is called approved sample Fabric Costing

Manual/Computerized

02

Basic Block

Manual/Computerized

Working Pattern 03

Manual/Computerized

04

Sample Garments

Manual

05

Approved Sample

Manual

06

Costing

Making Charged Trimmings Profit

Manual

07

Production Pattern Grading

Making allowance with net dimension for bulk production If the buyer requires different sizes, so should be grade as S, M, L, XL, XXL Marker is a thin paper which contains all the components for

Manual/Computerized

08

Manual/Computerized

Marker Making

09

different sizes for a particular style of garments Fabric Spreading To spread the fabrics on table properly for cutting To cut fabric according to marker dimension Sort out the fabric according to size and for each size make in individual bundles To assemble a full garments After sewing we will get a complete garment which is treated with steam ironing & also several finishing processes are done for example extra loose thread cutting Should be approved as initial sample Treated by Polyethylene bag After packing, it should be placed In cartooning for export Ready for export

Manual/Computerized

10

Manual/Computerized

11

Cutting

Manual/Computerized

12

Sorting & Bundling

Manual

13

Sewing

Manual

14

Ironing & Finishing

Manual

15 16 17

Inspection Packing Cartooning

Manual Manual Manual

18

Despatching

Manual

Factors which influence energy consumption:

Such differences may largely be attributed to a multitude of factors, several of which are listed below:

- plant capacity; - rate of plant utilization; - age; - equipment and the manufacturing process adopted;

- integrated or non-integrated operation; - site layout; - overall efficiency of operation; - degree of mechanization of materials handling; - extent of process automation; - wood species, size and moisture content; - product type and mix; - degree of product finishing; - proportion of air to kiln drying; - climatic conditions; - energy prices; - load factor; - steam and power balances; - extent of energy conservation measures adopted; - standard of housekeeping and maintenance. Specialized field Fiber production Spinning Twisting Texture yarn production Weaving Knitting Dyeing Clothing manufacturing others Fuel 67,547 6224 410 220 8510 8007 72551 16,210 12,110 Electricity 56,420 88,244 2560 3210 48867 22625 56420 30,187 23,000 Total 123967 944268 2970 3430 57377 30632 128971 46397 35110 Share 21% 18.4% 0.7 0.6 11.4 6.1 25 9.2 7

Total

191789 331533

1373119

1000

Merits and demerits:

Specialized field Spinning Merits Maximum earn. Maximum engineer required Good yarn if good bails Create bobbin at last Machine work maximum then man. Mostly work on loom Better production Electricity mostly used Latest loom less energy but greater output Less energy consumption Lowest investment Great profit No important electricity Its process easy then other Maximum profit Exports get more profits Low investment then other We start of their business Demerits Production cost is very high Maximum energy consumption Breakage of yarn Maximum energy consumption Breakage of yarn Fault of loom Maximum time required Looms are very expansive Gas is mostly used Boilers are very expansive Chemical used very carefully Electricity require Most time require Salary is very high Machine faults daily

Weaving

Processing

Garments

Improving efficiency of electricity use:

Lighting Due to its nature of operations, the share of lighting in electricity use is relativelyhigh. After the switch from tungsten bulbs to fluorescent lamps achieved considerable electricity savings, electricity-saving fluorescent lamps have been developed and marketed for further improvements, including those capable of reducing electricity use by several percent for the same level of illumination. Electric motor: The textile industry uses a vast number of relatively small electric motors. Notably, while a conventional machine was driven by a single motor with the generated mechanical power transmitted to various parts of the machine in a collective manner, many modern machines utilize multiple motors with a control board controlling the movement of each motor, which is directly coupled to a machine part to drive it independently from others. Electric heating:

In the textile industry, electric heating has largely been replaced by other methods (steam, gas heating, or direct or indirect fired heating) for some time in order to achieve cost reductions. However, since electric heating only requires a small initial investment as a result of convenience and simplicity in equipment construction, it is still used for small capacity local heating purposes.

Improvements in efficient fuel use:

Selection of fuel As is described before, fuels utilized in the textile industry have already gone through a switch-over from coal to oil. More recently, efficient energy use is under investigation, including the revival of coal on the way to a further move from oil to liquefied and city gases, while reflecting various fuel prices. Selection of boiler: By and large, boilers used in the Japanese textile industry have experienced a change from Lancastrian- or Scotch-type tubular or smoke tube to water-tube boilers (natural circulation and forced circulation water-tube boilers and once through boilers). As a result, boiler efficiency has improved from the conventional 60s to 70s of percentage points to as high as the 90s.

Improvement in efficient use of steam:

Piping: The noted feature of steam use in the textile industry is that the amount of steam involved is not so large but the locations where steam is required are widespread so that steam losses due to heat radiation from steam transportation pipes and pressure drops are considerable. Therefore, for steam transportation over long distances, high pressure and small diameter rather than low pressure and large-diameter piping is desired. Steam accumulators: Since live steam is often used in dyeing factories, fluctuations in steam use during working hours are large. On the other hand, since high performance water tube boilers and oncethrough boilers are designed such that water retained inside the boiler is very little, the boiler cannot react to momentary and sudden load changes, while responding to automatically
controlled slow load changes is not a problem.

Recycling of drain So far, after its heat energy is consumed, steam has been drained off. However,in view of energy saving, it is necessary to collect and recycle the heat energy carried by the drain water.