TEXTILE INETRNSHIP

Presented By: Avinash Mishra Diksha Sikarwar Ravikant Rashmi Saurav Suman Somalika Banerjee Vishal Kumar

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

Italy . Taiwan . Mauritius . Germany .A . Iran .) • Vivaga – Saree ( Silk ) • Bublee – Kidswear • KKV – Dhoti . Srilanka . Egypt . Hong kong Singapore .BRANDS • Fanujaa ( Jewellary ) • Dhoolikas ( Jewellary ) • Madras yarn – SCM textile Spinners ( exports to U.S.

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) .

P. • Variety Organic –1759 bales – from Maharashtra. • TOTAL STOCK ( no. • Variety MECH – 400 bales – from M. • Variety DCH32 – 286 bales–from Maharashtra. • Variety MCU-5 – 4074bales – from Gujrat .GODOWN STORAGE CAPACITY • Variety SH – 1859 bales – from Gujrat . of bales ) – 8378 .

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

• OUPUT .Bale weight – Above 250 kg Relative humidity maintained in blow room (preparatory) – 55-60% . .uniformly mixed.BLOW ROOM • To open the compressed bale of cotton. clean cotton in the form of chute feed or compressed layer of cotton called lap. • To extract impurities and other foreign matters from cotton by opening and beating. • INPUT .

different varieties of cotton are generally mixed thoroughly to get a proper blend .Extract impurities with the least amount of lint loss .The loose cotton passed through the blow room machinery is converted into regular sheets called laps . Mixing . .• • • • A blow room line carries out the following processes : Opening -opening hard pressed bales of cotton Cleaning . Lap forming .

operators = 2 people .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.• MACHINE USED .

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Carded sliver .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 .

• 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 .

LMW-Lakshmi LC 300A . arranged in 5 lines Machine Name.TOTAL 55 Machines.

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 .COMBING • To produce an improvement in yarn quality. the comber must perform the following operations: .

-Nipper opens and receives a new bit of lap. -Brushes that clean the circular comb. .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.Feeding of the lap by feed roller .The fed lap is gripped by the nipper . The short fibers are removed. -LK250ILK54 • The sequence of operation is.• Machine – LMW • Model no.

Drafted sliver . intensive dust removal is achieved • Input . fibres get parallelized Hooks created in the card are straightened Through the suction.Combed or carded sliver • Output . the slivers are made even Doubling results in homogenization (blending) Through draft.DRAWING • • • • • Through doubling.

the count can be changed.• • • • Machinery LMW LRSB85I/DO/6 Positively driven creel calendar rollers By changing the calendar rollers (thickness). • 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 .

Roving . imparts twists and winds it around a bobbin.SPEED FRAME • Reduces the thickness of the sliver into roving. • Input . • 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.Sliver • Output .

5 kg . • Aprons are present in the third drafting roller. • Doff weight – 2. • Tension controller varies the speed of the inverter motor. the top rail is fixed and the bottom rail is moved up and down for builder action.MACHINE . • Separate photocell is used to correct the tension on the roving.Lakshmi LFS 1660V Speed frame • In this machine.

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RINGFRAME SPINNING • It reduces the thickness of the roving to the desired yarn count by means of drafting rollers. • It imparts twists into the yarn thus strengthening it and preventing short fibres from protruding.Bobbin . • Input . It influences mainly evenness and strength.Rove • Output .

• 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.• Mechanism • Traveller and spindle together help to wind the yarn on the bobbin. 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.53 (22+22+9) No of spindles.1200 .Lakshmi LR 6/5 No of machine.

To make bigger package (60 gram bobbins to 2 kg cones) by splicing -Lubrication of yarn • Input -Cop • Output -Cone .To remove yarn faults .WINDING • Objective .

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

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.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 .

Rib 3. Single Jersey 2.• There are basically four categories of knitted fabrics produced in SCM:1. Rib interlock .

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

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 .These machines have varying diameters from 18 inches to 38 inches.

A total of 5 machines are used for this purpose – three 75 “ wide.Quality control in Knitting • Fabric inspection is carried out for identifying various defects in knitting. • Organic cotton fabrics are inspected on a separate machine. These are performed on inspection tables made locally. • 4 point system of fabric inspection is followed for quality control. . one 105 “ and one 100 “ wide.

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 .

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.• Bleaching • Checking pH (process before pH =5. .

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 .4 • Dye: Reactive dyes • Time: 45-75 min .5 • Dye: disperse dye • Time: 2 hours Cotton Dyeing: • Temperature: 60-80 degrees • Pressure: atmospheric pressure • pH: 10.8 – 11.

• Low liquors ratios (1:2 to 1:6) the consumption of chemicals and energy is low. Fabric. • Knitted and stretch woven fabrics cannot be used . • When all the fabric is passed through the dye bath the direction of movement is reversed. During dyeing tension is imparted in length of the fabric. • Suitable for delicate fabrics & light wt.• JIGGER DYEING • First the fabric is wound around one of the rollers. this would be repeated until the dyeing is completed. during dyeing the fabric is passed through the dye bath and rewind on to the second roller.

• • • • • • • • 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 .

PROCESS FLOW • SAMPLING (COMPUTER ART DESIGN) • STRIKE OFF FOR SAMPLING (SMALL SCREEN DEVELOPMENT) • PARTY SAMPLE APPROVAL • BLD (BRIGHT LIGHT DUPLICATE) • ROTARY SCREEN EXPOSING • PRINTING .PRINTING • SCM Textile Processing Mills in Erode.

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 .

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they are physically applied by means of binders. which is applicable to all class fibres • Since the pigments are insoluble colouring matters. DISCHARGE PRINTING • Discharge prints are fabrics that are dyed a solid colour prior to printing.PIGMENT PRINTING • Pigment printing is one of the simplest direct styles. • 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. • The lab is ISO 9001:2000 certified and also conducts testing for external manufacturers on behalf of SITRA(South India Textile Research Association). sliver. roving and yarn from the spinning unit. . • Materials tested in this lab include cotton fibre.

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 .

maturity ratio.60 gm . PREMIER ART HIGH VOLUME INSTRUMENT • Premier Art HVI is the most advanced instrument for testing of fibre properties. 2. percentage of maturity.1. USTER AFISPro • AFISPro or Advanced Fibre information system is an equipment used to test various parameters of the fibre obtained from sliver or lap. micronaire. • The weight of the samples to be tested should be between 0. elongation. • It measures strength.40gm and 0. UV-Status and colour Rd+b. Fineness.

• The test is carried out after the tpi of the yarn is determined. 4. roving or yarn can be tested at speeds of up to 400 m/min. Sliver. 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. • The testing capacity of the USTER® TENSOJET is 24 running kilometers of yarn per hour. . TENSOJET TENSILE TESTER • Tensojet tester is used to determine the tensile strength of individual yarns.3.

• The reels are made up of Stainless steel for accurate measurement and stability • Upto 10 yarn skeins can be reeled at a time . motor drives the reel at a constant speed.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.

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

we got a closer view of each and every process and machine equipments and got working knowledge of everything.CONCLUSION • After seeing the processes happening in industry . process . • The problems which are faced in textile industry from lower level till higher . . equipments and product . • Management of the workers .

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