Professional Documents
Culture Documents
Taken
(WEAVING UNIT)
BY
0
ACKNOWLEDGEMENT
1
SR NO. SUBJECT PAGE
1 COMPANY PROFILE 1-2
4 P.P.C 17-19
6 WEAVING 35-49
8 KNITTING 56-60
9 CP/POY 61-68
10 TEXTURISING 69-74
2
ALOK INDUSTRIES LIMITED
ALOK was established in 1986 as apvt. Ltd. company with 1st polyester
texturising plant being set up in1989. Over the years it has Expanded
into weaving, knitting, processing home textiles and garments. And to
insure q uality and cost, efficiencies it has integrated backward into
cotton spinning and manufacturing of POY through CP route Alok also
provided embroidered products through Grabal alok implex Ltd.
Alok has recently entered the domestic retail segment through a wholly
owned subsidiary Alok retail India Ltd, with a chain of stores named
H&A that offers garments and home textiles at attractive prices.
LOCATION:
Survey no: 17/5/1 & 521/1
Village Rakholi, Sayali
Silvassa: Khanvel road
Silvassa: 396230
(D&N.H) India.
Busines activities:
Alok is a well established, profit making, consistently dividend paying
professionally managed textile company. The company has intergrated
manufacturing facilities for:
• Home textiles
• Apparel fabrics
• Texturising
3
The vertically integrated operation and flexibility to produce in cotton/
polyester/ viscose and blend in various counts has enabled the
customers and thus provide integrated textile solutions.
The total value addition chain in textile and Alok’s presence in the chain
is indicated below:
• Fibres
• Spinning
• Weaving/ knitting
• Processing
• Garments/Home textiles/ Madeup
• Retailing
I.M.S policy
WE, AT ALOK INDUSTIES LIMITED ARE COMMITTEDTOWARDS-
1. Serving our customer to their satisfaction by efficiency reliable
supply of products at most competitive rises and meeting social
objectives and other specified requirement through INTEGRATED
MANAGEMENT SYSTEM.
2. Constantly improving product quality, environment, performance
work environment and services by up- gradation of skill,
knowledge and technology through employee education and
involvement.
3. Ensuring a healthy and safe environmental in and around our
manufacturing plants complying with all applicable legal and
other requirement related to safety, health, environment, social
and quality aspect by setting and reviewing quality, environment,
health, and safety objectives towards continual improvement.
4
4. Enhancing corporate social responsibility by making earnest
endeavors to prevent environment pollution, reduce
occupational, health hazard minimize waste and optimize useof
natural resources.
RAW MATERIALS
• Two types of raw materials means yarns are consumed by the
industry these are (a)-Grey Yarn
(b)-Dyed yarn
• Alok consumed 80% raw materials from his own spinning mill &
20% raw materials from other industry (Near Industries,
Vardhman Industries, Ravali Spinning Ltd,Trident, Dhanlaxmi,
Vasundhara Cotton mills, Sandhya Spinning Mills Abhishek
Industries Limited,Vasundhara Cotton mills Pvt.Ltd, Kallam
Spinning Mills etc.).
5
• The method of raw materials proceeds is:
Then it enter
Then unload
Stocked
Distribute to dept.
6
Party: Saha Mahash Kumar
Mohanlal & Co.
Count: CTN 40 COMB COMP
WVG Midnight
Shade: Midnight
Shade No: YX048717
SORT:
AW00666666XWYDNF
SO No: 3062078182
PO No: 109410078882
LOT No: YD1000334446
STPO: 5100099317 WVG
RW STORE
No of cone: 12
Gross weight: 15.82 kg
Net weight: 15.82 kg
Sap batch: 3011375748
Carton no: VY1000010352
• Sample-2(Grey materrial)
Alok Industries Ltd(Spinning
Div.) Unit-2
Packing slip
100% Cotton Combed yarn
CTN 64 Comb Comp ROCOS
ORG WVG
Count: Y00530
Box: PO10039476
No of cone: 160
LOT No: 2LC100026B
Grade: A
Gross weight: 429.000 kg
7
Tare weight: 29.000
Net weight : 400.ooo
Date: 31.06.2010
Packed by: PP_VIINODS
2500000
2000000
2353071.39
1500000
2208080.50
RANGE OF QUANTITY
1914381.29
1909833.15
1732692.85
1000000
1465009.29
13 87335.91
1135006.91
8
500000
0.00(kg) Aug08 Nov08 Feb09 May09 Jul09 Oct09 Jan10 Apr10 Month
120000
100000
80000
105129.41 kg
113804.31 kg
103197.06 kg
93405.76 kg
95345.27 kg
95345.27 kg
NGE OF QUANTITY
9
60000
40000
20000
Quality Assurance
10
• Running time checking in the loom.
• Yarn testing
Here mainly the raw materials that coming from different sources
are checked and compared with company standard. If satisfies
then run in loom and If not then reject and return. The apparatus
that use for this testing are:
11
shows the types of faults. There are two types of dots: green for the
nominal fault an red for untolerable faults.
OBSERVATION:
400
250
150
12
A B C D
100
F G
45
0.1 1 2 4 8 32
cms
-30
-45
H I
USTER TENSOJET 4
This is the latest model USTER SINGLE YARN TESTER. This is used
for measuring the single yarn strength, R.K.M.(Resikilometer) &
their variation.
Testing speed:-100 to 400 Mt/min
Test method:- ISO 2062, DIN 53834, ASTM D:-1578 JIS
For 60 count yarn pretension wt 4.92 gram-force, Maxᵐ
Load 2KGF.
USTER TESTER 5
This is the latest model of USTER EVENNESS TESTER.
This machine is used for measuring the mass variation in the sliver,
roving & yarn also for hairiness index of yarn.
Testing speed is 25 to 800 Mt/ min.
Test method:- ISO 53817
13
The yarn is wound on the black board with the help of winder machine.
According to the count of the yarn the wraps/inch is decided. The result
are decided by the ASTM method.
Cotton count Tex count Warp ASTM board Pulley set
INCH CMS
1 to 12 590 to 50 20 8 1 A
12 to 24 50 to 25 22 9 2 B
24 to 36 25 to 16 26 10 3 C
36 to 50 16 to 12 32 13 4 D
50 to 75 12 to 8 38 15 5 E
75 to 135 8 to 4 48 19 6 F
CSP SYSTEM
14
By this system mainly different of yarn count strength product
measured.
Purpose:- To determine the count & strength.
Principle:- Works on the principle of constant rate of elongation.
Lot size No of cones No of leas Total no of leas
to prepare
Above 4000 kgs 15 15×2 30
Above 1000 kg to 4000kgs 10 10×3 30
100 kgs to 1000 kgs 5 5×3 15
Less than 100 kgs 2 2×3 6
PPI*23.25
Weft =
Weft count(Ne)
Therefore
Fabric GSM = Warp GSM + Weft GSM
BY GSM CUTTER:
Cutted fabric is weighted and multiplied by 100
FABRIC TEAR STRENGTH TESTER:
This instrument is used for testing the tear strength of the
fabric in warp and weft way.
15
Elmatear digital tear tester.
Used for measuring fabric tear strength.
Testing capacity – 6400 gms
CONDITIONING SYSTEM:
CONDITIONING BOX:
2.Bottom %: Up to 1.5
3.Yarn tension
6. Shed checking
16
Sizing:
1. Roller heardness
6. RH %
7. Viscosity
8. Size pick up %
LOOM:
1.Tpes of breaks
2.Fabric effect
3.Fabic width
4.Loom setting
5.Humidity
6.Temparature
7.Efficiency %
17
PROCESS CONTROL STUDIES
1.WARPING:
Direct warping
Sectional warping
2.SIZING:
The various studies performed in Sizin are –
3.WEAVING:
The various studies performed in weaving are –
Snap round
18
Loom stoppage study
Quality round in order to check quality of
fabric on running loom.
Humidity verification
3.FOLDING:
Two activities are being performed in folding depertment
Mending of fabric
Grading of fabic
PRODUCTION PROGRAMME
20
Weave : Dobby MCNO:AIRJET_PIC74.8”6CLRDOBY
Picks/inch:80 Shade:
Reed space: 66inch Insetion: 1
Reed: 68/4 Grey width:64”
Meters: 888 SIZ. MTRS: 1003
Delivery Date: 23/06/2010 Desk loom no.:
SORT MASTERING
In sort mastering each new design is given new sort number for quick
identification.
Sort no Type of fabrics
10001-19999 100% cotton
20001-29999 Viscose
30001-39999 Pet
40001-49999 Organic cotton
50001-59999 Dyed yarn
60001-69999 Slik fabrics
21
WARPING
The main object of this department is to collect a no. of warp ends
from creel & to wind them in to a sheet on doubled flanged beam in
such a manner that the threads are parallel to each other.
OPENING OF CURTONS
CREELING
DENTING
22
TYING UP OF ENDS ON THE BEAM
AFTER COMPLETION BEAMS CREEL ENDS ARE CUT AT THE CREEL & CHANGE
SECTIONAL WARPING
TECHNICAL INFORMATION:-
BEN-TRONIC
• Machine designation:
BEN-TRONIC sectional warping machine.
PRASHANT GAMATEX sectional warping machine.
• Model: movable.
• Creel capacity: Ben-Tronic-960 cones , Prashant Gamatex: 3
m/c:672cones & 2 m/c 720 cones.
• Useful widths: 2200, 2600, 3000,3400,3800,4200 mm.
23
• Machine weight: approx 1100 to max 1400 kg.(depending up on
useful width)
• Temp. : 10c-max 40c.
MACHINE DATA:-
• Warping speed: max 800m/min.
• Warping winding tension: 600N.
• Beaming speed: 400m/min.
• Beaming winding tension: 1500N (min 100N)
VERSOMAT:-
• Make: BENNINGER
• Creel capacity: 480 cones.
• Tensioner: Disc type tensioner.
• Sensor: electrical sensor.
• Max speed: 800mt/min.
• Drum width: 2200mm.
CALCULATION:-
• Total no of ends=7068
• EPI×PPI=108×100
pattern No.of ends total
A 120 3540
B 30 900
C 30 888
D 30 870
E 30 870
24
• Total no of section=29
• 1 section0f 108 ends
• Section width=total pattern end/E.P.I=240/108=2.22
• 1 operator/machine/shift.
• 1 jobber boy/machine/shift
• 3 creel boy/2 machine/shift
In direct warping the warp thread directly wind in a beam from the
creel. Here no need of any other cylinder before winding.
GENERAL INFORMATION:-
25
TECHNICAL INFORMATION:-
GENERAL OBSERVATION:-
26
2 BEN- 250m/min 330dan 1088 936 60s 220cm
DIRECT
3 BEN- 600m/min 250dan 1088 1074 60s 220cm
DIRECT
4 BEN- 800m/min 200dan 1088 976 40s 220cm
DIRECT
5 BEN- 800m/min 200dan 1088 1076 60s 220cm
DIRECT
6 BEN- 300m/min 250 dan 1088 1018 60s 187cm
DIRECT
7 BEN- 650m/min 200dan 1088 966 80s 220cm
DIRECT
8 BEN- 900m/min 550dan 720 558 20s 187cm
DIRECT
9 KARL 700m/min 300dan 680 595 40s 187cm
MAYER
10 KARL 800m/min 6oodan 720 648 20s 187cm
MAYER
CALCULATION:-
Where,
A=length in sizing
13%=this is considered shrinkage
50mt=this is considered as sizing waste
Waste planning:-
13%extra=30 count
27
15%extra=20count
20%extra=below 20count
TYPE OF FAULTS:-
• Slubs.
• Foreign matter.
• Thin places.
• Thick places.
• Bad piecing
• Bunch.
• Slough off- packing fault.
1 supervisor/shift
1 operator/machine/shift
16creel boy/shift
1 fitter/shift
6helpers for beam carrier
WARPING:-
100 HOUR: Cleaning
Monthly:- Greasing, oiling.
3 Weekly:- Cleaning, checking attain major problem.
Cleaning is done by blow air of different parts as follows
Complete machine
28
Wind air
Guide roll
Pressure roll
Terapezoidal threaded assembly
Limit switch assembly
Checking:- Oil level of hydrolic
Screw connections
Drive belts
Beam position
Cylinder pressing device
Comb traverse Device
Oiling & greasing of all moving parts.
Sizing department
The main object of sizing to improve the weavability of the fabric by
increasing the strength of the yarn using size paste. The strength of the
yarn is increased up to 25%. The other purpose is to reduce the
hairiness of the yarn and make the warp as a warp sheet.
PROCESS FLOW CHART
Warpers beam
Leasing
Denting
29
Loading empty weavers beam
General information
• Make: Benninger zell
• Model: Bensizetec, synchro 4
• Maximum Creel capacity: 24
• No of Machines: 9(normal width=3, wider width=4, sectional=2)
• Country : Germany
• Type of creel: magazine creel
• Creel breaks: breaks stripes with pistons
• Beam break: hydrolic
• Double size box: for more than 55 warp cover factor it uses to
better size.
Mechanical information
• No. of sow boxes: 2
• Size roll: 2+2
30
• Type of sow box: 2 dip 2 nip
• Moisture control: PLEAVA RIB
• Microprocessor: SIEMENS TOUCH
• No of drying cylinders: 8 per drying cylinders, 4 main drying
cylinders. Teflon coating is on drying cylinders to avoid sticking of
ends.
• Drying cylinder pressure:3.5 bar
• Wax box: to improve the softness & reduce hairiness of the yarn.
• Leasing zones: diameter of bigger lease rod=60mm & small lease
• rod = 35 mm
• Pneumatic beam pressing system.
• Beam pressing roll: length=340 cm, Diameter=8 cm
• Sizing level = 140mm
31
• Fan motor: 0.26kw
• Brake and clutch: 3.5kw
• Cold mixer
• Cooker
• Storage
• Cooking time:1hr
• Sow box: 14 inches
• No. of cold mixer:3(no.1=1000lt, 2,3=2000lt)
• No. of storage tank:8
32
• First starch and PVA are taken and it is mixed with water and cold
stirring is done for 10-15 min.
• This paste of water and starch is passed to cooker where the
steam is injected to this paste and hot cooking is done for 13 min.
• After 30min the temp. is kept around 100 -110 .
• Then this mixture is passed into storage tank where softener is
added and then continuous cooking is done as per the req.
• If there is a blend or synthetic material is there then add antistatic
agents.
• Example of ratio of ingradiant:
33
Arbor screw shaft
All points of drying cylinder
Chain of positive drive
Tensioner of positive drive
Screw shaft of immersion roller
All bearing
2. Weekly maintenance:
• Cleaning:
Complete machine by blowing air
Saw box by hot water
Pneumatic control cabinets
Electrical control cabinets
• Checking:
Pressure gauge of steam line
Working of all steam traps cylinder
Spiral cable of handy
Leakage of air from all pneumatic line
34
Man power of the sizing
Auto Drawing in
Technical information
• Made : Stabuli
• Model : Delta 110
• No of machine: 5
• Performance:
Drawing in capacity: upto 3-4 warps in 8 hr
Drawing speed: 100/140 ends/min
Over all performance depend upon: M/C specification,
count, no. of yarn ends/ warp, etc.
• Max warp width: 230 cm
• Flange dia: max 1200 mm
• No of warp beam:1
35
• Heald width :2.2/2.5/5.5 mm
• Heald length: 260-382
• Heald thickness: 0.23-0.38 mm
• Heald type : simplex and complex
• No. of frames: max 20
Beam knotting
If on the loom there is same quality is running then the new beam is
knotted with the running beam.
• Made: Staubli
• Model: topmatic
• Speed :500 ends/ min
• Time required: upto 1 hr
• No. of workers: 2
Beam gaiting
• Tying frame trolley is used to tear beam drawing in dept. to loom
shed.
• Manufacturer: to do company
36
• No of workers for gaiting: 4
• Time required: 1- 1.30 hr
37
WEAVING DEPARTMENT
There are mainly 9 units in weaving dept. The loom distributes in that
dept. are as follows:
UNIT WIDTH NO. OF TYPE OF M/C
LOOM LOOM MANUFACTURER
38
9C Normal 80 Airjet Toyota
9D Normal 110 Rapier Optimax
The looms that find in this dept. is mainly two type according to
shedding:
AIRJET LOOM: Here weft is inserted by air that comes from the nozzle.
Drawing in
Beam knotting/gaiting
39
Cut the fabric & unload the cloth roll
General information
PICANOL AIRJET
• Pre winder:
Name : Picanol Omni 2231 plus
Model no.: IRO 2231 P19.3.
Total pressure capacity: 2
Heald wire details: 331mm-j type
Eye size: 8*2.5mm
• Drop pin detail:
40
Dimension: 165mm*11mm*0.5mm
Weight: 0.5 grms per drop pin
• Production: 680m/day/loom (appx)
• Model:
False Selvage Cutter: B161126
Main nozzle: Picanol BE300623
Filling detector: BE 154883
Filling detector sensor: BE157859
• Various mechanism:
Let off.: Positive let off. Motor is used. A gear provide
motion from one side to another.
Shedding : open shed.
Shed left angle: 24
Shed height: depends on quality, mainly counts.
Cams are used for shedding. Staubli co. positive
shedding max 86 heald shafts with leaving cam.
Picking: Airjet
Profile reed and relay nozzles are used. Main nozzles
auxiliary nozzle, relay nozzles are used.
Main nozzle: 2
Auxiliary nozzle: 2
Relay nozzle: 14 groups (28 relay nozzle, 26 relay valve)
Filling detector: 2
• Nozzle:
Main nozzle: Picanol BE 300623=2
Auxiliary nozzle: 2
Relay nozzle: 14 groups
41
Stretch nozzle: 1
Distance between main and auxiliary nozzle: 100 mm
• Pressure:
Main nozzle: 7 bar
Auxiliary nozzle: 5-8 bar
Relay nozzle left: 9 bar
Relay nozzle right: 9 bar
• Timing of nozzle:
Main nozzle: 85 -20
Auxiliary nozzle: 85 -20
Stretch nozzle: 245 -31
• Loom shed:
Department RH%: 84+/- 2
Air pressure: 7 bar
Shed crossing: 299 +/-3
ELSY crossing: 1 LH=300 +/-3 2LH299 +/-3
By ELSY leno is formed
• Observation:
Sr no. Warp Weft Warp Weft Reed Reed Total Picking Grey Size rpm
cont count blend blend space no. of width pick
ends up%
13641 60S 60S 100% 100% 116/3 129 22416 110 126 9.2 525
SZB CTN CTN CTN CTN
42
15795 80 80 100% 100% 80/5 107 21200 93 104 13.7 500
A COMB COMB CTN CTN
CTN CTN
TOYOTA AIRJET
• Various mechanism:
Let off.: Positive let off with motor
Shedding : open shed.
Shed left angle: 32
Shed height: depends on quality, mainly counts.
Cams are used for shedding.
Picking: profile reed & relay nozzle
Take up: positive take up with motor.
• Capacity of cam : 16 heald frame
• Capacity of E shedding: 16 heald frame
• Maximum haeld shaft: 16
• Selvage: leno+false selvedge.
• Leno: 2 polyester+ textured yarn at both
• Nozzle:
Main nozzle: 2
43
Tandom nozzle: 2,to pass yarn from weft accumulater
Relay nozzle:30,
• Relay nozzle: First 26 nozzle have distance of 26, last four are
40mm. Every 4 nozzle connect with one valve where as last one
have 2 nozzles.
• Motor used :
Main motor
Let off motor
Take up motor
Leno assembly
E shedding motor
For LH cutter motor
Pre winder motor
• Observation:
Sr no. Warp Weft Warp Weft Reed Reed Total Picking Grey Size rpm
cont count blend blend space no. width pick
of up%
ends
62676 40S 40S 100% 100% 108/2 66 8510 80 66 5.3 452
CTN CTN CTN CTN
44
SULZER RAPIER JAQUARD
• Observation:
Sr no. Warp Weft Warp Weft Reed Reed Total Picking Grey Size rpm
cont count blend blend space no. of width pick
ends up%
JQ680 60S 60S 100% 100% 84/4 126.6 10640 50 122 27.8 278
SZB CTN CTN CTN CTN
JQ6797 60 80 100% 100% 68/5 125 10600 104 122 18.3 270
COMB COMB CTN CTN
CTN CTN
45
PICANOL RAPIER JAQUARD
Sr no. Warp Weft Warp Weft Reed Reed Total Picking Grey Size rpm
cont count blend blend space no. of width pick
ends up%
JQ785 60S 80S 100% 100% 68/5 125 21200 104 122 20% 278
CTN CTN CTN CTN
JQ807 60 60 100% 100% 68/5 125 21200 114 122 25% 280
COMB COMB CTN CTN
CTN CTN
46
MAINTAINANCE
• CLEANING:
All types of belt by opening cover.
Leno assembly
Heald frame/heald wires & harness for Jacquard.
Drop pin & contact bars
Reed & Sley
RH & LH gripper
Tample & ITS ring
47
Load cell
Dobby leaver gear
• OILING:
Dobby leaver bearing
Cloth roll
Weft cutter
• CLENING:
Leno Assembly
Heald fream/Heald wire
Drop pin & contact bar
Reed/Sley
Pre-winder
Main cutteer & selvedge cutter
Temples
Dobby liver & Under motion liver
• CHEAKING:
o OIL LEVEL CHEAKING AT THE FOLLOWING POINTS
Main Tank
Central lubrication
Dobby
o Cloth roll drive & ITS chain
o All types of air & pipes
o All relay valve & main valve
48
• GREASING:
Whip roll-4
Whip roll BKT-2
Cloth roll-2
Sley-2
Dobby Under motion-2
Let-off gear-1
Liver-16
• OILING:
Oiling on Under motion liver
Oiling on heald frame connecting rods
49
Temp. 40 40 50
• Lubricant use:
For jacquard
50
ON LINE LOOM MONITORING STOP CODES:
11 Knotting
12 Gaiting
13 Repairing
14 Maintenance
15 Reed Change
16 Quality Setting
17 Chindi Checking
18 Design Approval
19 Sizing problem
20 No Beam
21 No Weft
22 Electronic Fault
23 Wait For Gaiting
24 Wait For knotting
25 Patteren Correction
26 Redenting
27 Pressure Down
28 Others
51
Different light for indication:
PICANOL
Toyota
52
Inspection & packing
After weaving the fabric is inspected in this dept. to find out the fault in
the fabric. After inspection the fabric is gradified into 7 classes. Then it
packs and export in market. In this dept. there are 18 machine for
normal width and 10 for wider width. The basic tasks are:
• Inspection
• Folding
• Packing
Inspection
Here mainly Four Point American System is applied for inspection. The
method of inspection is:
• Loom beam is fitted
• Fabric is passed through guide roller
• Reach in checking zone
• First check width, EPI & PPI
• Then other problems are checked
• There is a check meter to measure the length
• The report is record in report card where sort no, loom no, count
etc is written.
• The whole fabric is checked.
• Then fabric is gradified.
53
M/C Diagram:
Checking
device
beam
54
Path of yarn Guide roller
Inspection system
In this dept. mainly Four Point American system is used.
Note:
• All color foreign matter should be removed
• All partial defect more than 5mm should be cut.
55
Gradation system
There are mainly 7 grade for fabric. They are:
Grade Pts/100sq Pts/100lnr Pts/100lnr Fabric length
mtr mtr(normal) mtr (wider)
A 15 24 45 >=20 mtr(d)
>=40 mtr(e)
B 22 35 67 >=20 mtr
Chindi 0-25 cm Kg
Fents 25-99 cm kg
56
Name of faults that measure:
COVER SPINNING WEAVING PARTIAL DEFECT
FAULT FAULT
Bumping Coarsepick Ball formation, Crack
Reediness Chocked yarn Black stain Hole
Neppines Color containing Broken end Float
Unevenness count Variation Broken pick Knotting
Hazyness dirty end Bump mark Multiple
Streakiness double weft Broken pattern breakage
Kitty level high twist yarn, Design change Rust stain
knots, neps Design cut Sizing/c stop
moire effect, Double end Tear drop
oily effect Double pick stitches
slub Double weft
slubby effect Fine end
uneven weft Hanging thread
three ply Starting mark
coarse end Thin place
Thickplace
Knots
Lasing in
Leno cut
Less width
Missing end
Nozzle mark
Oily stain
Pulled warp
Reed cut
Short pick
Sizing prob.
Etc.
57
Packing
After inspection, packing is done the steps of packing are:
• Material stag on a moving plate
• Move to wrapper plate & wrapped with plastic
• Blade cut excess plastic
• Punched to next plate where an air suction is done to brief
packing
• Next heat(150 is given to brief packing.
• Final packing is done
58
Packing is done in 3 color plastic: white for grade A,B, green for
organic, Red for C,D,E,F
KNITTING
Knitting is the production of fabric by forming loops with yarn, which
are interlaced in a variety of ways to form the fabric. Traditional hand
knitting , using knitting needles or pins is thought to have existed as
early as the 5th century, although other simpler techniques of inter
meshing and knotting of yarns existed much earlier.
There are mainly two types of knitting:
weft knitting: the loop formed across the weft.
warp knitting: the loop formed across the warp.
Here mainly weft knitting machine is shown.
59
Fabric is produce
General information
• No. of Machine:
Single jourcy=87
Double jourcy=83
Jacquard=9
Flat bed= 17
• Manufacturer : Pai lung, Mayer&cie, Kaeo Heng
• Production: 300 kg/machine/day
• Doffing: after 20000 revulution.
Single jourcy m/c:
• Diameter: 30”
• Gauge : 24
• Feeder use: 90
• Rpm: 28
• Coni rpm :25
• Roll weight: 25 kg
• Conter: 1000
• GSM: 196
Inter lock, double jourcy m/c:
• Diameter: 30
• Gauge: 24
• Feeder: 96
• Rpm: 36
• Coni rpm : avg45
• Roll wt. : 25 kg
60
• Conter :2065
• GSM: 154
Rib, double jourcy m/c:
• Diameter: 30
• Gauge: 18
• Feeder: 72
• Rpm: 34
• Coni rpm : avg15
• Roll wt. : 25 kg
• Conter :2329
• GSM: 172
Jacquard knitting m/c:
Flat knitting:
• Used for make collers and cough of t-sirt
• Latch needle is used
• Maximum width produce: 48”
61
Quality assurance activities
• GSM testing
• Fabric testing
• Stitch lengths
Feed yarn is 1st tested and then dispatched for bulk
Maintaince activity
• Cleaning and setting of m/c: for cotton800000rev, 1600000rev.
• At the time of cleaning cam, needle, dial, gear, shaft everything is
cleaned and clean with oil.
• Oil level is checking.
• There is three fan to remove cotton fly from yarn.
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• Lycra jump
• Pin hole
• Lycra line
• Oil drop
• Shade variation
• White spot
• Yarn cut
• Loop cut
The fabric is then graded in three class.
• Class A= 5 defect/25kg
• Class B= 10defect/25kg
• Rejected=more than10 defect/25 kg
The fabric is then packed. In red pack for sample, white pack for A
grade, and yellow for B grade fabric.
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CP & POY department
CP (Continuous polymerization)
Procedure:
The main raw materials for this process is PTA(poly Teripthelic acid),
and MEG(Mono ethylic glycol). The PTA is found in form of liquid or
solid and MEG is in liquid from. The PTA stores in a large tank call PTA
day bin and MEG is in a small tank. Now this two are mixed at a ratio of
2:1 and form a slurry which in a high temp. converted into a paste of
this two ingredients. Now this paste makes a reaction. This reaction is
an ESTERIFICATION reaction. Here the paste is esterified and as a
product H2O is produced. Then the esterifies paste react with SB2O3.
Now it forms 25% low polymer. This Low polymer at last at vacuum
condition at a temp. of 290 it produce final polymer. Then filtration
is done. Then this is converted directly into the POY by melt spinning
process or into small polymer chips.
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Some important information about this process:
This process is mainly 3 reaction: Esterification, UFPP, Finshing
TiO2 is used here as adhesive.
Sb2O3 is used here as catalyst
The whole process is done at a temp of 280-290
The whole process is done under pressure
The whole process is controlled by the 7 operating consoles with
automatic microprocessor controlled.
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POY DEPARTMENT
• POY (Partially Oriented Yarn) is produced from polymer chips.
• Wet chip hopper:-3kg air pressure also to store the chips for
further process. It also has waste collector system containing
microdust and impurities coming from continuous polymer.
• Vibro feeder:- It is having functions of feeding the reserve chips
kept in hopper.
• Crystallizer:-It drives the chips and remove microdust particles.
• Chips column:- The temperature in the column is around 265° C
and kept for 6 hours and hence it is maintained.
• Dry chip hopper:-From chip column the dry process is done in this
hopper.
• Extruder hopper:- Here chips are melt at 295°C. It has 6 zones
called as manifold. Separate motor is provided for every zone.
• Polymer filter:-It removes dust and clean the polymer chips.
• Spinning floor:-Coolling filament through perforated board.
• Oil pump:-To oil the yarn surface to reduce static change &
microbal attack.
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In this POY department has two unit.
• IN UNIT 1
• IN UNIT 2
Total no of lines:- 12
single line of having 6 heads each head having 10 feeder from where 10
package wound
4×6=24×10=240×12=2880 Package is being produced.
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Production-350 metric ton/day.
M/c Manufacturer- Barmag(Germany)
M/c Name- Wings
Higher denier yarn is being produced in this department.
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Apparatus:- DTI 500
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4 SS 500gm to 2.999kg 3 kg to 4.999kg
5 CLQ 200gm to 499gm 500 gm to 2.999kg
TMT Winders
Existing Proposed
Serial no Grade Wt. range in kg Wt. range in kg
1 1E 10.5kg to 14.250kg 9.750kg to 10.5 kg
2 1A 5 kg to 10.449kg 7 kg to 9.749kg
3 1M 2kg to 4.999kg 5kg to 6.999kg
4 SS 500gm to 1.999kg 3kg to 4.999kg
5 CLQ 200gm to 499 gm 500gm to 2.999kg
Textile lab
Packing Scheduled Testing Packing
Weighment Weighment
Strapping Strapping
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Polymer
GP
Spinneret
Condition Air
Finish Guide
PigTail Guide
Guide 2
Intermingale
line Guide 1
Winder
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TEXTURISING
Texturising is a process of providing an artificial crimp to man-made
fibre to impart properties somewhat similar to natural twist fibres, it
can be provided by melt spinning in continuation by passing it from
crimping machines. It may be gear crimp or false twist texturising. It is a
method of marking the PET yarn wearable. End product of POY is POY
yarn wound on spool the weight varies from 10.5kg-22kgs. The yarn is
very lustrous and not at all comfortable for wearing. It generates static
charges and air permeability of those fabrics is very poor. Here in this
machines the output is made up from the bulk out of flat continuous
POY yarn and termed as Draw Textured Yarn. And this bulk is formed by
spindle running at 850-1000 rpm having 3 discs in zigzag manner. The
flat polyester yarn have covalent linkage with luster is removed by
heater.
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package
Oil roller Guide Package Drum bakelite
GENRAL INFORMATION
• Unit1- 36 machines
• Unit2- 16 machines
• Unit3 - 24machines
• Unit4- 24 machines (Auto Doffing)
• HIMSON – Bhogibhai
• HIMSon – Devananadbhai
• Alidhra- Hansrajbhai
• Alidhra- Babubhai
• Barmarg- China
• Murata- Japan
• Himson- Autodoffing
TECHNICAL DATA
Machine Setting
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Travers speed 375
Temp Primary:200 Secondary:185
Machine data
PRODUCTION DATA
Calculation
Production Chart
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Per day 400 tons produce in this dept.
There are mainly 3 types of products, those produce in the dept. They
are:
• NIM- No intermingling
• SIM- Sub intermingling
• HIM- High intermingling
• First quality
• Printing quality
• Claimless quality
FIRST QUALITY
Defects Knitting Weft G.F.T Micro Roto SIM Export
normal HIM
B.F/Loops 5-6/kg 4-5/kg nil 5-6/kg 1-2/kg 3-4/kg nil
Cross winding 2 2 nil nil 1 1 nil
Oil stain 63 70 70 63 68 66 68
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Nips variation N.A N.A N.A N.A 1/MT 1/MT nil
High oil nil nil nil nil nil Nil nil
PRINTING QUALITY
Defects Weft Roto SIM
B.F/Loops 4-6/kg 3-5/kg 3-8/kg
Cross winding oneside, oneside, oneside,
4-6
Oil stain high high High
Hardness normal normal normal
Slippage nil nil nil
Tight spot 4-6/kg nil nil
Bulk variation Allow Allow Allow
Weak yarn Very less Very less Very less
Winding mistake Allow Allow Allow
Nips variation nil Allow Allow
High oil Abnomal Abnomal Abnomal
CLAIMLESS QUALITY
Defects Weft Roto SIM JOB LOT
B.F/Loops 76/kg 76/kg 78/kg 78/kg
Cross winding Both side, Both Both Both side,
>6-10 side, side, >10
> 6-10 > 6-10
Oil stain Max Max Max Max
Hardness Abnomal Allow Allow Allow
Slippage Allow Allow Allow Allow
Tight spot Allow Allow Allow Allow
Bulk variation Allow Allow Allow Allow
Weak yarn Allow Allow Allow Allow
Winding mistake N.A Allow Allow Allow
Nips variation Allow Allow Allow Allow
High oil Allow Allow Allow Allow
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Mixdenial Max Max Max Allow
For packing 3 color packs are used. Red for C.L quality, Green for
Printing quality, and white one for export quality.
Q.A OF TEXTURISING
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