Observations to be made on

o Yarn manufacturing and Winding section

o Weaving section
o Dyeing section o Testing and Quality control sections

8 Pillars of TPM
1. Focused Improvement 2. Autonomous maintenance 3. Planned maintenance 4. Education and Training 5. Initial flow control 6. Quality maintenance 7. Office maintenance 8. Safety health and environment

REITER Machines TRUTZSHLER DK 803

RSB 851

REITER Machine

REITER F35 Roving Frame

REITER Ring Frame F16

Schlafhorst/saurer

The Blowroom is the 1st step of yarn production in the spinning mill.
INPUT : Fabric in the form of Bales
OUTPUT : Sliver

a) b) c) d) e)

Opening Cleaning Dust Removal Blending Even Feeding of material to the card

Type
Rollers

Appearance

Description
Small Diameter, Widely used. e.g.: in STEP CLEANERS

Drums

Larger Diameter, little used e.g.: in MONOCYLINDER CLEANERS

Quilted Shaft

Shaft with many beater rods, hardly used

Cotton contains upto 18% trash,

o

in most cases ranging from 1% to 7%

Since this Cost is a considerable cost factor, it has to be kept as low as possible, which requires an assignment Cleaning Degree = extracted trash*100 -------------------------------------trash content in fed cotton extracted trash*100 -------------------------------------Total Extracted Waste

Cleaning Efficiency =

Unimix o Model LB 7/3 o By Lakshmi LMW

The m/c is made up of 3 parts

o Storage section, o Intermediate section, and o Delivery section

MACHINE: REITER UniClean 1. Special Design VIBRATING PLATE 4. Rollers for additional Dusting

5. Servomotor-controlled feeding plates

6. Groove

7. Operating Panel

Ensuring that debris is removed while aligning the fibers to make them easier to spin. Without carding, cotton thread would be coarse and extremely fragile.

Parallelize the fibres in card sliver along the sliver axis. To improve the regularity in linear density of card sliver by doubling. Improve sliver quality. To achieve the correct amount of blending.

17-18% of short fibres are removed Removal of neps Parallelization of fibres Kitty Level is Reduced

The function of the speed frame is to attenuate the sliver and to form a suitable supply package for the ring frame.

Twist + Strength + Winding

To draft the roving until the required fineness is achieved To impart strength to the fibre, by inserting twist To wind up the twisted strand (yarn) in a form suitable for storage Transportation and further processing.

Customer

Vardhman

Marketing Team CPDC Located at Mahavir Textiles

Central Design Cell (CDC)

Technical Department

Pilot Plant

R&D(Small Length Sampling )

Bit Loom

Several sections are wound in sequence and parallel to each other on a dresser or on a drum the warping sections are as many as necessary to obtain, with the available creel capacity, the total number of threads composing the warp The warping speed is about 800 m/min, while the beaming speed is about 300 m/min

Before carrying out warping, following calculations are necessary:

o If the calculation does not give an exact number, the last section

will be produced with a number of threads lower than the other sections, o Or the number of threads composing each section will be reduced.

so as to get all sections with one and the same number of thread,

A complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity

Requirement of Style Change

Drawing-in:

o consists of
Drawing - in

Transport and Loading of Beams and harness onto the Weaving m/c

threading the warp yarns through the drop wires, the healds and the reed

1. Back rest roller

(warp threads are wound) 2. Support special drop wires 3. Healds 5. Dents of the reed 8. Slay 6. Motor driving the take down roller 11. Cloth Beam

the most flexible machines on the market Their application range covers a wide variety of fabric styles Their present weaving speed of about 600700strokes/min

weaving machines with the highest weft insertion performance and are considered as the most productive manufacturing of light to medium weight fabrics, preferably made of cotton and certain man-made fibres sheets, shirting fabrics, linings, taffetas and satins in staple yarns of man-made fibres

Started in December 2000 Production - 30 lack Meters/ Month One of the largest fabric processing unit in Asia. Has area of 12 acres Self- sufficient power supply

Processes:

Preparatory Dyeing Finishing (both piece dyed and yarn dyed fabrics) Inspection and Packing

GREIGE SECTION PREPARATORY SECTION PERBLE RANGE NEW PAD STEAMER MERCIRIZER DYEING SECTION TANK COLOUR PREPARATION AREA PAD DRY HT STEAMER THERMOFIX PAD STEAMER

FINISHING SECTION STENTER SUEDING MACHINE SANFORIZER AIRO MACHINE CURING MACHINE TECHNICAL SECTION PHYSICAL LAB CHEMICAL LAB PILOT PLANT INSPECTION AND FOLDING SECTION PRODUCTION PLANNING & CONTROL EFFLUENT TREATMENT PLANT

SINGEING

WASHING

DESIZING & SCOURING

NaClO2 BLEACH

WASHING H2O 2 BLEACH

WASHING

DRYING ON CYLINDERS

PLAITOR

Section A: Singeing, Combined desizing and scouring Section B: Chlorite Bleaching Section C: Peroxide bleaching Section D: Vertical Drying Range. In new Perble Machine, Only Peroxide Bleaching (3 sections)

PARTS OF MERCERIZER RANGE The mercerization machine has five sections: Padding Section Tenter chain Tenter pit Washing range Drawing unit

To increase the dye uptake. To increase the tensile strength of the fabric. To increase lustre of the fabric. Better coverage of immature cotton fibers. To remove crease marks. To remove naps from the fabric. To increase the reactivity and absorbency of the fabric.

The Caustic Soda used in the processes is heated and concentrated for reuse The CRP has an efficiency of 90-95% The principle of CRP unit is to evaporate the water from the weak lye. It helps save money and is less harmful to environment.

Most important feature of dyeing used is the continuous dyeing range (CDR) Consists of Padder Box with a capacity of 50-60 lts pad-dyeing method ensures a full penetration of dye inside the fabric at a relatively low consumption of dyes, chemical, steam and water

The cotton and P/C blend fabrics are dyed with the following dyes 1. Vat dyes for 100% cotton 2. Reactive dyes for 100% cotton 3. Disperse/Vat dyes combinations for P/C blends 4.Reactive/Disperse dye combinations for P/C blends

Reactive (HT Method) PDHT Dye X gpl Sanspol AMC 20gpl Resist salt 5gpl Sodium bicarbonate 20gpl Urea 50gpl

High temperature steamer is used for the fixation of reactive dyes on cotton and on cotton component of P/C blend. The steam here is used for dual purpose: to provide heat energy and also to act as a source of water to transfer rapidly and uniformly on dyed surface.

FABRIC INLET

STEAMERS

PLAITOR

This technique utilizes the high rate of dyeing achieved at high temperature (commonly in the region of 210C). A dyeing achieved in less than one hour at 130C can be attained in 20-60 seconds at about 200C.

FABRIC INLET

CHEMICAL TROUGH

STEAMER

VERTICAL DRYING RANGE

13 WASHERS

WATER SEAL

PLAITOR

Stenter Peaching Machine Sanforizing Machine Airo machine Curing Machine

CHEMICAL FINISHING SOFTENING RESIN FINISH TEFLON FINISH ETI(Easy to Iron) MECHANICAL FINISHING PEACH FINISH SANFORISATION

1. PHYSICAL TESTING LAB 2. CHEMICAL LAB 3. PILOT PLANT

4 Point system used for Inspection Fabric divided into A, B, C Grade

Packing done in sizes as per the order or buyer specification. Shipping to both buyer/garment manufacturer

Fiber Dyeing: Cotton, Polyester. Yarn Dyeing: Cotton. P/C blend, A/C blend The unit has technical collaboration with Japanese concern. Most of the machinery is Imported from Japan.

It comprises of five sections: a) Pre Winding b) Dyeing c) Post Winding d) Conditioning e) Dispatch

In this section cones of yarn are converted to soft cheeses for processing. It is also called Soft package section. Various counts running 10s To 100s (single and Double)

Done In HTHP (High Temperature High Pressure) Dyeing Machines 48 Machines Hisaka (Japan), Fong (China), Pozzi (Italy)

Machine Package load varying from 50Kg to more than 500 Kg depending upon model.

Complete Dyeing cycle done in the HTHP machines.

RAPID DRYER Uses Centrifugal force to extract the excess liquid out from the soft package. RADIO FREQUENCY DRYER Uses high frequency Radio waves to completely dry the soft packages


1. 2.

After processing, yarn is wound onto cones in post winding section . Three types of machines are used in this section.
PSM 138 AUTOCONER MACH CONER

3.

Post winding is followed by conditioning of the yarn

After conditioning the material is dispatched in cartons. Following parameters are mentioned on carton.

MILL: SUBSTRATE: COUNT: SHADE N0. LOT N0: N0.OF CONES: DATE: NET WT.: GROSS WT.:

Types of fibers dyed

COTTON ACRYLIC TOW POLYESTER WOOL MILANGE

RAW MATERIAL (Cotton, Polyester, Acrylic)

DRYING

BALE PACKING

STAMPING

WASHING

DISPATCH

PRESSING

CAKE UNLOADING

DYEING

HYDROEXTRAC TION

The main objective of this department is to execute the orders placed to the organization by effective scheduling. They also keep a control over the orders by daily monitoring at each stage of SPDM, dyeing and dispatch. This department has to decide the date for the dyeing of the particular lot in the bulk

RESEARCH & DEVELOPMENT has the following sub departments a) Quality Control Input b) Quality Control Output c) SPDM Section d) Yarn Dyed Shirting Cell e) PDC

Technorama M/c OBBDM SPDM Knitting M/c (Quality)

Vardhman is one of the biggest names in textiles worldwide. Our Internship in the company gave us immense exposure to the processes that take place in the production of fabric in many forms starting from the fiber stage up to final packing and despatch to the buyers.

The experience of being a part of such a big company for even a short time was amazing and helpful in learning about the different processes in textile manufacturing. We are very thankful to all the people at Vardhman, Right from executives to the labourers who selflessly helped us gather information and explained everything in detail.