plant study of alok industries

8/8/2019 plant study of alok industries

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PLANT LAYOUT PLANT LAYOUT

UNDERSTANDING THE BUILDINGUNDERSTANDING THE BUILDING

STRUCTURE AND WORK SPACE INSTRUCTURE AND WORK SPACE IN

TERMS OF AMENITIESTERMS OF AMENITIES



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INTRODUCTIONINTRODUCTION

•• Name of the industry Name of the industry :-Alok Industries Limited

•• Name of the unitName of the unit:- Continuous apparel width processing unit (Dyeing)

•• Location/AddressLocation/Address :- 261,balitha village,Taluka Pardi ,Dist Valsad

• Floor Area covered- 1,60,000 sft(appox).(400x400 ft)

• Setbacks

–– Front and back setbacksFront and back setbacks-- 20ft20ft

–– Side (right and left side setbacks)Side (right and left side setbacks)-- 10ft each side10ft each side



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PROCESS FLOWPROCESS FLOWPreparatoryprocess

Dyeing

Finishing



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Building structure

• The structure of the Alok dyeing Processing building is of shed type

building with simple roof structures on open frames.

• The building has large and clear areas unobstructed by the columns.

• The large floor area provides sufficient flexibility and facility for later change

in the production layout without major building alterations.



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•• Sheds form the uppermost structure of the building which is supported onSheds form the uppermost structure of the building which is supported on

the basic industrial structure of steel/the basic industrial structure of steel/RccRcc pillars and beams.pillars and beams.

•• The distance between each truss structure is around 15 ft and thus theThe distance between each truss structure is around 15 ft and thus the

distance between each pillar on the supporting frame of the truss is at thedistance between each pillar on the supporting frame of the truss is at the

same distancesame distance

•• Sheds types depends upon:Sheds types depends upon:

–– Structural considerationsStructural considerations

•• Be capable of supporting envelop of roof.Be capable of supporting envelop of roof.

•• Be capable of supporting suitable and necessary services.Be capable of supporting suitable and necessary services.

•• Span between the rows of columnsSpan between the rows of columns

•• Head room or clearance requiredHead room or clearance required



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– Design considerations

• Protection against fire

• High wind conditions

• Lighting

• Require compliance with legislation

• Flexibility requirement

• Thermal factor• terrain



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ROOF SYSTEMROOF SYSTEM

•• MultiMulti--span metal roofing type roof is used to join various structures tospan metal roofing type roof is used to join various structures to

make one large structuremake one large structure

•• Sheeting, purlin and supporting roof trusses supported on column toSheeting, purlin and supporting roof trusses supported on column toprovide common structural roof system for the building.provide common structural roof system for the building.

•• The Brittle sheeting such as asbestos sheets are used as the roof coveringThe Brittle sheeting such as asbestos sheets are used as the roof covering

material. The sheets have a thickness of around 4material. The sheets have a thickness of around 4--5 mm.5 mm.

•• The deflection limits for purling and truss have small deflection for theThe deflection limits for purling and truss have small deflection for the

type of sheeting.type of sheeting.



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•• The type of roof covering , its insulating value, acoustical properties, theThe type of roof covering , its insulating value, acoustical properties, the

appearance from inner side, the weight and the maintenance are the variousappearance from inner side, the weight and the maintenance are the various

factors, which are given consideration while designing the roof systemfactors, which are given consideration while designing the roof system..

•• The height of the roof from the flooring is of 30The height of the roof from the flooring is of 30--40 ft because of the nature of 40 ft because of the nature of

operations that take place which involve use of heat and steam and thusoperations that take place which involve use of heat and steam and thus

requiring large escape area for lessening the heating effect on the floorrequiring large escape area for lessening the heating effect on the floor



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Truss type :-Vaulted parallel chords



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•• Pros/advantagesPros/advantages

–– LongLong--lastinglasting lifelife

–– ResistantResistant toto rotrot

–– ResistantResistant toto firefire

–– MinimalMinimal maintenancemaintenance requiredrequired

–– ResistantResistant toto termites/bugtermites/bug infestationsinfestations

•• Cons/disadvantagesCons/disadvantages

–– CanCanbebe denteddented easily easily

–– SusceptibleSusceptible toto rustrust

–– SusceptibleSusceptible toto wind wind damagedamage

–– IndustrialIndustrial looklook may may notnot blendblend with withitsits surroundingssurroundings..

–– SusceptibleSusceptible toto damagedamage formform heavy heavy snowsnow accumulationsaccumulations



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LIGHTINGLIGHTING•• Industrial operations can be carried on most efficiently when adequateIndustrial operations can be carried on most efficiently when adequate

illumination is provided.illumination is provided.

•• The requirements of good lighting are its intensity and uniformity. SinceThe requirements of good lighting are its intensity and uniformity. Sincenatural light is free, it is economical and wise to use daylight mostnatural light is free, it is economical and wise to use daylight most

satisfactory for illumination in industrial plants whenever practicable.satisfactory for illumination in industrial plants whenever practicable.

•• Side windows are of much value in lighting the interiors of small buildingsSide windows are of much value in lighting the interiors of small buildings

but they are not much effective in case of large buildings.but they are not much effective in case of large buildings.

•• In the processing building the shed roof lighting has been developed in aIn the processing building the shed roof lighting has been developed in a

manner such that it provides a uniform 10% daylight factor by the help of manner such that it provides a uniform 10% daylight factor by the help of

glazing covering 20% roof area.glazing covering 20% roof area.



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• Other than the natural lighting other forms, other artificial sources are also

used.

• LAMPS of Type E 400W Metal Halide and Type E-1, 250W Metal Halide are

used for illumination purposes.

• DESCRIPTION:

– Pendant mounted open clear

– anodized metal housing with interior multi-faceted

– specular reflector, direct distribution. Field adjustable

– light pattern for concentrated to medium to wide

– light distribution for various ceiling height.



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SHED ROOF : continuous strip of glazing covering 20 percent of roof area,10per cent uniform daylight factor.



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• Ventilation of industrial buildings is also important.

• Ventilation will be used for removal of heat, elimination of dust, used air and

its replacement by clean fresh air.

• In the processing unit ventilation is done by means of natural forces such as

aeration.

• The large height of the roof is also used advantageously by providing low

level inlets and high level outlets for air.

VENTILATIONVENTILATION



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• The windows consists of 20% of each wall area

• The windows are of doubled sided slide type

• Windows only act as ventilation and lighting at the floor level ,as its

necessary for the heat generated by processing machines to escape quickly

such that the production floor remains ambient .

• Such quick ventilations are provided by turbo ventilators.



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Advantages of turbo ventilators:- No operating cost, runs on wind energy

Assured 24 x 7 ventilation

Replaces hot air, humidity, stale air, smoke & gas fumes with fresh ambient

air

Improves human comfort level & productivity

Can be fitted to any type of roofing profile

Increased life of roofing sheets

Increase in Productivity.



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CLEARANCESCLEARANCES

• Clearances are distances that are provided between machine to machine and

machine to walls.

• These clearances are provided for various reasons such as –

– Heat

– Walking space

– Amenities connections(water , electricity)

• The clearances are provided such that adequate space could be provided for

proper functioning.



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• The clearances provided depend upon the size of the machine, heat, walking

space requirement.

• Machine to machine clearances(all types )- 10 ft (min),15 ft(max)

• Machine to wall clearances- 10 ft(min).

• Walking aisle space- 10ft

• The walking aisle space is adjusted or coincides with that of the machine to

machine clearances and wall to machine clearances.

• The walking aisle space markings are done by yellow markings such that

these markings are made at a distance from 3 ft from each machine side.



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• The clearances in the finished goods store is around 2 ft from the wall and

rack to rack there is a clearance of 5-8 ft .

• The storage in the griege room is done on rack palletes,the clearances

between each pallet in a rack is 2 ft while the clearances between the racks in

which the pallets are piled is 10 ft on each side of the rack.



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Flow PatternFlow Pattern

Preparatory

operations

Dyeing

operations

Finishing

operations

Raw materials from greige roomRaw materials from greige room

Finished goods to checkingFinished goods to checking



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• The process flow of operation starts from the raw materials entering the

production floor from the griege room• The raw material are processed through preparatory processes such as

bleaching,mercerization,scouring,desizing.

• After the completion of preparatory the dyeing process begins in the dyeingmachines.

• After dyeing the fabric is given the desire finishes using various machines for the

purpose.

• After the finishing the goods are finally checked and eitherstored or loaded in

containers



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FLOORINGFLOORING

• The flooring plays an important role for proper operation and supporting of machinery.

• The processing unit has machinery of heavy machinery category thus theflooring needs to be

– Durable

– Strong

– Resistant to shock ,heat and vibration

– Non slippery

– Easy and cheap to maintain

• The flooring that was used for the complete floor of the dyeing section wasof RCC(reinforced concrete cement) flooring.



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• This type of flooring provides all required properties required to handle theheavy load of the textile machinery .

• The flooring is done in an continuous manner without any sections in theflooring



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Advantages of concrete flooring

Cost• the cost of finishing concrete is comparable to that of other flooring

products, concrete floors will last for decades with no need for replacement,making them the more cost-effective choice.

Durability

• Unlike most other products, a concrete floor will not suffer damage due tomoisture.

• Concrete can also resist damage from gasoline or chemical spills, making itan effective flooring choice

Maintenance• Concrete floors require little to no maintenance, especially if they have been

treated with a sealer. They require only sweeping and mopping to removedust and debris as needed.

• Spills will not damage or stain the surface and need only to be wiped awa

•



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Versatile• It can be stained or etched to resemble tile, stone, marble and many other

floor coverings. It can also be painted, textured or acid-stained to createunique patterns.

Health Effects

• By leaving the flooring exposed, the floors are allowed to "breathe," and moldgrowth is greatly reduced. Concrete is also less likely to trap allergens.



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Bibliography

• Textile internship report at Alok Industries

• http://www.svswindventilators.com/use_of_ventilator.htm

• http://www.designlights.org/downloads/highbay_guide.pdf

• http://www.stroofing.co.nz/st/pdfdoc/lit/roofing/multispan.pdf

• http://www.maplevalleytruss.com/config.htm

• http://www.wolf-system.co.uk/trusstypes.asp



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THANK YOUTHANK YOU

Presented By:

Akriti Sharma(02) Ashish Kumar Annepu(07)

Documents

plant study of alok industries