Presented By: Avinash Mishra Diksha Sikarwar

Ravikant Rashmi

Saurav Suman Somalika Banerjee

Vishal Kumar

TEXTILE INETRNSHIP

CONTENTS

• Objectives • Company Profile • Spinning• Knitting • Dyeing • Printing • Quality control • Conclusion

OBJECTIVES To study in the functioning of the following

departments of Textile industry:-

1. Fibre storage section 2. Yarn manufacturing and Winding section 3. Knitted Fabric manufacturing section 4. The Dyeing and Printing section 5. Testing and Quality control section

COMPANY

The companies visited:- • SCM Textiles Spinners (Thekkalur ,Tirupur). • Aathava knitting( SCM garments Pvt Ltd) unit

(Thekkalur , Tirupur). • SCM Textile Processing Mills (Erode).

COMPANY PROFILE

• Started in the textile town of Tirupur, in 1962.• Founder Shri. Kulandaival madaliar.• SCM Textile Spinners is a unit of TCS( The

Chennai Silks). • SCM Textile Spinners was started in 2003 in

Tirupur.

BRANDS

• Fanujaa ( Jewellary )• Dhoolikas ( Jewellary )• Madras yarn – SCM textile Spinners ( exports to

U.S.A , Italy , Germany , Hong kong Singapore , Iran , Srilanka , Egypt , Taiwan , Mauritius .)

• Vivaga – Saree ( Silk )• Bublee – Kidswear • KKV – Dhoti

RAW MATERIALS Imported Cotton Varieties • o PIMA (USA) • o GIZA 86, 88 (Egypt) • o SUDAGIB (Egypt) Indian Cotton Varieties • o SH (Gujarat) • o ORGANIC COTTON (Maharashtra) • o MECH (Madhya Pradesh) • o DCH-32 (Maharashtra) • o MCU-5 (Gujarat)

GODOWN STORAGE CAPACITY • Variety SH – 1859 bales – from Gujrat .• Variety MECH – 400 bales – from M.P.• Variety DCH32 – 286 bales–from Maharashtra.• Variety Organic –1759 bales – from

Maharashtra. • Variety MCU-5 – 4074bales – from Gujrat .• TOTAL STOCK ( no. of bales ) – 8378

SPINNING• Blow room • Carding • Combing • Drawing • Ring spinning frame • Winding

BLOW ROOM • To open the compressed bale of cotton. • To extract impurities and other foreign matters

from cotton by opening and beating. • INPUT - Bale weight – Above 250 kg Relative humidity maintained in blow room

(preparatory) – 55-60% .• OUPUT - uniformly mixed, clean cotton in the

form of chute feed or compressed layer of cotton called lap.

A blow room line carries out the following processes :

• Opening -opening hard pressed bales of cotton• Cleaning - Extract impurities with the least

amount of lint loss .• Mixing - different varieties of cotton are

generally mixed thoroughly to get a proper blend .

• Lap forming - The loose cotton passed through the blow room machinery is converted into regular sheets called laps .

• MACHINE USED - Bale plucking: Lakshmi UNIMIX LMV • Production upto 1500 kg/hr • Working width is 2300mm • Traverse speed upto 3-12 meters/min • Bale lay down upto 350 bales • No. operators = 2 people

CARDING

• To open the flocks into individual fibres • Cleaning or elimination of impurities• Elimination of dust • Elimination of short fibres • Fibre blending • Fibre orientation or alignment • Sliver formation • Input - Cotton in the form of lap • Output - Carded sliver

• Feed System• There are two of kinds -Lap feed system in which fibers are formed

into a lap or compact sheet

-Chute feed system in which flocks are transported pneumatically

• Principle -Short fibers creating hairiness are to be

removed -Cotton introduced in flocks is obtained as

slivers -Faults like naps and hook ends can be

rectified later -Rollers fixed at certain distances eliminate

short fibres

TOTAL 55 Machines, arranged in 5 linesMachine Name- LMW-Lakshmi LC 300A

COMBING• To produce an improvement in yarn quality, the comber

must perform the following operations: - elimination of short fibers -elimination of remaining impurities -elimination of naps

• The basic operation of the comber is to improve the mean length or staple length by removing the short fibres.

• Input -Ribbon Lap

• Output -Combed sliver

• Machine – LMW• Model no. -LK250ILK54

• The sequence of operation is- - Feeding of the lap by feed roller - The fed lap is gripped by the nipper - The gripped lap is combed by circular comb -The detaching roller grips the combed lap and moves

forward -Top comb comes into action to further clean the lap.

The short fibers are removed. -Nipper opens and receives a new bit of lap. -Brushes that clean the circular comb.

DRAWING

• Through doubling, the slivers are made even • Doubling results in homogenization (blending) • Through draft, fibres get parallelized • Hooks created in the card are straightened • Through the suction, intensive dust removal is

achieved • Input - Combed or carded sliver • Output - Drafted sliver

• Machinery • LMW LRSB85I/DO/6 • Positively driven creel calendar rollers • By changing the calendar rollers (thickness),

the count can be changed. • Length of sliver – 4500-6000 m/can • Machine speed – 200-400 m/min

• Autoleveller is an additional device which is meant for correcting the linear density variations in the delivered sliver by changing either the main draft or break draft of the drafting system, according to the feed variation

SPEED FRAME

• Reduces the thickness of the sliver into roving, imparts twists and winds it around a bobbin.

• The main function of speed frame is to make roving from the draft sliver that has strength to withstand the tension variations at ring frame.

• Input - Sliver • Output - Roving

MACHINE - Lakshmi LFS 1660V Speed frame • In this machine, the top rail is fixed and the

bottom rail is moved up and down for builder action.

• Aprons are present in the third drafting roller. • Separate photocell is used to correct the

tension on the roving. • Tension controller varies the speed of the

inverter motor. • Doff weight – 2.5 kg

RINGFRAME SPINNING

• It reduces the thickness of the roving to the desired yarn count by means of drafting rollers. It influences mainly evenness and strength.

• It imparts twists into the yarn thus strengthening it and preventing short fibres from protruding.

• Input - Rove • Output - Bobbin

• Mechanism• Traveller and spindle together help to wind

the yarn on the bobbin. • The shape formation of the package (cop)

takes place with the help of cam • There is always a triangular bundle of fibers

without twist at the exit of the rollers; this is called as spinning triangle.

• The length of the spinning triangle depends upon the spinning geometry and upon the twist level in the yarn

Machine name- Lakshmi LR 6/5 No of machine- 53 (22+22+9) No of spindles- 1200

WINDING

• Objective - To remove yarn faults - To make bigger package (60 gram bobbins

to 2 kg cones) by splicing -Lubrication of yarn

• Input -Cop

• Output -Cone

Machine: 2Ic USTER quantum with SIRO 338 with USTER quantum with SIRO Model: MURATEC -SCHLAFHORST

YARN-STORAGE AND PACKAGING• Process: • Conditioning is done for humidifying cotton in

order to increase its strength• The cones obtained are exposed in a container

for around 1 hour at 58-65 deg. Celsius. • The huge container has a capacity of about

500 cones at a time. • Cones are tested for any stains or shade

variation under ultra violet rays.

• The packing is done here in three different ways. They are:-

• Packing in Carton Boxes(For regional and local markets)

• Packing in Bags(For regional and local markets)

• Packing in Pallet packing(for export)

KNITTING• Tirupur is best known for knitting industries • Known as the knitting capital of india• Aathava Knitting under SCM Garment Ltd is

one of the biggest manufacturer of knitted fabrics in the state

• Employs 100 people• Capacity of 10 tonnes of knitted fabric per

shift per day

• There are basically four categories of knitted fabrics produced in SCM:-

1. Single Jersey 2. Rib 3. Rib interlock

Knitting Machines

• Total number of machines: 71 • Machine manufacturers: Terrot (Germany) • Meyer and Cie (Germany) • PaiLung (Taiwan) • Year China (China)

These machines have varying diameters from 18 inches to 38 inches. All machines are equipped with auto stop motions for needle and yarn breakage. Latch needles from Groz Beckert are used for knitting on circular machines

Quality control in Knitting• Fabric inspection is carried out for identifying

various defects in knitting. These are performed on inspection tables made locally.A total of 5 machines are used for this purpose – three 75 “ wide, one 105 “ and one 100 “ wide.

• Organic cotton fabrics are inspected on a separate machine.

• 4 point system of fabric inspection is followed for quality control.

DYEING• SCM Textile Processing Mills in Erode • Process flow • Lot opening -Fabric is reversed as during knitting the front

side goes behind on take-off roller• Grey fabric inspection -Here inspection of fabric takes place for

defects and crossed checked for further defects• Scouring

• Bleaching • Checking pH (process before pH =5.5-6) • Dyeing (pH = 7-9) • Shade checking • Soaping (95 degree Celsius for 15-30 minutes) • pH stabilization + finishing Grey Storage: • Storage on racks with capacity for 80 tonnes of

fabric. • Five open reprocessing sheds to store fabrics in

between the processes.

Machine Details Machine make: THIES Number of operator: 1operator and 1 assistant per machine Total number of machines: 7 Capacity: 1080 kg/batch

Polyester Dyeing: • Temperature: 130 degrees • Pressure: 2kg/cm2 • pH: 4 - 5 • Dye: disperse dye • Time: 2 hours Cotton Dyeing: • Temperature: 60-80 degrees • Pressure: atmospheric pressure • pH: 10.8 – 11.4 • Dye: Reactive dyes • Time: 45-75 min

• JIGGER DYEING

• First the fabric is wound around one of the rollers; during dyeing the fabric is passed through the dye bath and rewind on to the second roller.

• When all the fabric is passed through the dye bath the direction of movement is reversed, this would be repeated until the dyeing is completed. During dyeing tension is imparted in length of the fabric.

• Suitable for delicate fabrics & light wt. Fabric.• Low liquors ratios (1:2 to 1:6) the consumption of

chemicals and energy is low. • Knitted and stretch woven fabrics cannot be used

• Machine Details • Machine make: Swastik (India) • Number of operator: 1 operator per 2 machines • Total number of machines: 13 • Production: 20,000 m/ 13 machines/ day • Speed of the machine: 60 m/min • Roller pressure: 70 – 75 Kg/cm² • Maximum Temperature: 80º C

PRINTING

• SCM Textile Processing Mills in Erode.PROCESS FLOW • SAMPLING (COMPUTER ART DESIGN) • STRIKE OFF FOR SAMPLING (SMALL SCREEN

DEVELOPMENT) • PARTY SAMPLE APPROVAL • BLD (BRIGHT LIGHT DUPLICATE) • ROTARY SCREEN EXPOSING • PRINTING

ROTARY SCREEN PRINTING • The respective screens are mounted on the

rotary heads • Selected squeegees are inserted and

connected to the respective colour pumps • The fabric to be printed is fed to the blanket

and gets printed by the respective screens in continuous manner

• The printed fabric is conveyed through dryer and plaited

Machine details: • Machine make: Stomac • Machine width: 70 inch • Numbers of colours possible: 12 • Numbers of operators: 1 operator and 4

assistants per machine • Printing speed: up to 80 meters/minute

PIGMENT PRINTING • Pigment printing is one of the simplest direct

styles, which is applicable to all class fibres • Since the pigments are insoluble colouring

matters, they are physically applied by means of binders.

DISCHARGE PRINTING• Discharge prints are fabrics that are dyed a

solid colour prior to printing. • The design is applied by screen or roller with a

chemical a reducing agent which removes the colour of the originally dyed fabric.

TESTING AND QUALITY CONTROL

Yarn Testing • SCM Textile Spinners own an in house testing lab

for the purpose of yarn testing.• Materials tested in this lab include cotton fibre,

sliver, roving and yarn from the spinning unit.• The lab is ISO 9001:2000 certified and also

conducts testing for external manufacturers on behalf of SITRA(South India Textile Research Association).

The equipments in this lab include the following: • PREMIER ART HIGH VOLUME INSTRUMENT • USTER AFIS PRO • USTER TESTER 4 • TENSOJET TENSILE TESTER • STATEX WRAPREEL • STATEX TWIST TESTER • STATEX TRASH SEPARATOR • CSP SYSTEMS • YARN APPEARANCE BOARD WINDERS

1. PREMIER ART HIGH VOLUME INSTRUMENT • Premier Art HVI is the most advanced instrument

for testing of fibre properties. • It measures strength, elongation, micronaire,

maturity ratio, percentage of maturity, Fineness, UV-Status and colour Rd+b.

2. USTER AFISPro • AFISPro or Advanced Fibre information system is

an equipment used to test various parameters of the fibre obtained from sliver or lap.

• The weight of the samples to be tested should be between 0.40gm and 0.60 gm

3. USTER TESTER 4 • Uster Tester 4(UT4) is an evenness tester that uses

sensor technology allows a simultaneous measurement of the most important quality parameters. Sliver, roving or yarn can be tested at speeds of up to 400 m/min.

4. TENSOJET TENSILE TESTER • Tensojet tester is used to determine the tensile

strength of individual yarns. • The test is carried out after the tpi of the yarn is

determined. • The testing capacity of the USTER® TENSOJET is 24

running kilometers of yarn per hour.

5. STATEX WRAP REEL • Wrap reel equipments are used to prepare yarn

skeins for measuring the count and strength of skeins (Lea).

• An A.C. motor drives the reel at a constant speed.

• The reels are made up of Stainless steel for accurate measurement and stability

• Upto 10 yarn skeins can be reeled at a time

AUTO LAB DISPENSER: Data Colour-Auto Lab TF It is a fully automated robot which makes small dye sample in small quantities. It uses the recipe generated by the computer.

CONCLUSION

• After seeing the processes happening in industry , we got a closer view of each and every process and machine equipments and got working knowledge of everything.

• The problems which are faced in textile industry from lower level till higher .

• Management of the workers , process , equipments and product .