NATIONAL INSTITUTE OF FASHION TECHNOLOGY

C. A. Site No. - 21, Sector-1, 27th main road, HSR Layout Bangalore.

TEXTILE INTERNSHIP REPORT ON

BHARAT VIJAY MILLS, KALOL NORTH GUJARAT.

SUBMITTED BY: ISHITA PANDEY NEENU SUKUMARAN RANI TREASA JOSEPH RASHMI AGARWAL

ACKNOWLEDGEMENT
At the outset, we wish to express our gratitude to everybody who has assisted in formulation of this report. There are a many to whom expression of gratitude is inevitable, but there some special people who has to be given prominence, without whom we would not have reached the conclusion of this project so quickly and so efficiently. We wish to thank Mr. A.K. Khare and Mr. Shivalingam for providing this wonderful opportunity, channeling and motivation. No amount of Gratitude is adequate for Mr. Rahul Patel and Mr. Amit Patel for their consent in allowing us to conduct our internship in their venerated institution. We express our deep indebtedness to Mr. M. K. Chaturvedy, the Human Resource Manager who guided and supported us through every stage of our internship. We also wish to thank Mr. H.J Shah, Mr. Daxesh Lala, Mr. Mukesh J. Shah, Mr H. M. Raval, Mr. Atmaram Patel, Mr. Siraj, Mr .Subhash G. Patel, Mr. Ravin Mehta, Mr. G. C. Bairi, Mr. Sunil Tailor, Mr. Ganesh Aher and Mr. Ravin Mehta for their technical guidance and assistance. We take this opportunity to express our affection towards our parents for their consistent faith and support. Ishita Pandey Neenu Sukumaran Rani Treasa Joseph Rashmi Agarwal

INDEX
PREFACE 1. INTRODUCTION TO BHARAT VIJAY MILL 2. DEPARTMENTS i) OPERATIONS a) SPINNING b) YARN DYEING c) WEAVING d) GREY FOLDING e) CORDUROY f) PROCESSING g) FINISH FOLDING h) SQC i) PRODUCTION PLANNING AND CONTROL j) LABORATORY k) ENGINEERING l) ETP ii) ADMINISTRATION a) RETAIL SHOP b) GENERAL ADMINISTRATION c) HUMAN RESOURCE DEPARTMENT d) PERSONNEL iii) MARKETING a) MARKETING b) DESPATCH c) DESIGN DEPARTMENT iv) PROCUREMENT a) PURCHASE b) STORES

c) WASTE d) COTTON DEPARTMENT v) FINANCE a) ACCOUNTS 3. CONCLUSION ANNEXURES .

exposure. To study the working environment of the industry 2. group work and experimentation. To study the Organisational Structure We have tried our best to sum up the total work process of the industry through observations and interactions. . The textile intership at Bharat Vijay mills is evidently the experience which provided the spectrum of psychophysical knowledge and experience. The real life experiences gathered through the period helps the pupil to learn practical aspects and application of theoretical knowledge.PREFACE The blend of the practice and principle. Gujarat. To study the departmental processes and their interrelation within the organization 3. the composite unit expresses a strict environment which breeds exclusive expansion and development. Located at a centre of rich culture and nationalistic history. As a internee at Bharat Vijay Mills we assume our engrossment of an amount of this superior order and management. Our Major Objectives of study were: 1. It provides a huge positive impact on the student in the spheres of interpersonal skills.an industrial internship project transforms the classroom student into a multidimensional internee.

1 INTRODUCTION .

Zodiac. through continuous product and technological innovation. BVM’s 80% of textile production consists of shirting and 20% consists of suiting and corduroy. BVM has been the undisputed leader in varied product mix for the last 70 years with a continuous expansion of its product range. Allen Solly. quality and services. Peter England. BVM’S MISSION: Belief in strong customer orientation. a composite textile mill.1. . Their renowned buyers are Madhura garments. BVM is a vertically integrated plant having its own spinning to finishing facilities. is their major end buyers. high-rise business buildings and innumerable vehicles ranging from the latest sleek limousines to three-wheelers. is the commercial capital of Gujarat. the present management took over. Bharat Vijay Mills (BVM). San Francisco etc.. With an infusion of motivation and enduring commitment to excellence the mill expanded. glittering shopping malls. customer orientation and a focus on cost effectiveness. it has had a colourful history dating back to antiquity unlike the new metropolitan city. The textile division consists of 350 staff members and 1800 workers BVM’S VISION: To achieve global presence in Textile business. a town 30 Km in North of Ahmedabad (India). In 1956. initially operated on a very modest scale at Kallol. It has numerous fashionable hotels. It has grown into 50 million US$ group turnover with a dedicated work force of 1600 people in the textile division. one of the fastest-growing cities in western India. Today. Corduroy & Bottom Weight. Located on the banks of the Sabarmati River. Since last 20 years it has established a name in global market with its Yarn Dyed / Piece Dyed Shirting. INTRODUCTION Established in the year 1931. THE GEOSPHERE: Ahmedabad.

During the Sultanate. giving it the sobriquet 'Manchester of India' over a hundred years. Soon enough. As of October 2005.started functioning as a textile division of Sintex industries. the rulers encouraged the merchants. including accommodation. the demand for more urban facilities. a commercial city. and the entire infrastructure considered essential to modern life. who named it after himself. and burgeoning industries reflects some of these changes. the city now known as 'Ahmedabad' was founded by Sultan Ahmed Shah. the chimneystacks of these modern composite mills covered almost the entire skyline. HISTORY OF BVM:   1931-1970’s. its crowded streets. which produced exquisite textile and other artifacts for the Imperial Court at Delhi. The main characteristic of Ahmedabad is that it continues to remain. An imperial atelier was located here. . The spinning mill is scheduled for commissioning by end 2006. members and crafts in come to Ahmedabad and make it a flourishing commercial and industrial city. With the phenomenal increase in population. construction work has been initiated and equipment suppliers were appointed. Indian entrepreneurs established textile mills in Ahmedabad.400 million. as it was in the beginning. Bharat Vijay Mills is expanded spinning mill from 18 million mtrs/yr to 24 million mtrs/yr at Kalol in Gujarat. Plans are also on the anvil to set up a readymade garment facility with an investment of Rs. Today's city. and a major center of trade. began putting a tremendous strain on the existing civic amenities. Over a hundred years ago. Even in those days. 90s . experts contributed to Ahmedabad's prosperity A hilarious Ahmedabadi is renowned for his spirit of enterprise. It is no surprise therefore that Ahmedabad continued to grow.manufacturers of sarees. 1970’s – 1980’s – (while the textile industry faced business/ market crisis) joined with Sintex (plastic manufacturing company) and sustained the crisis by manufacturing Sintex plastic tanks  Since 1980s. with its teeming millions.Looking back in 1411.

M.co.in www. Kalol.sintex-india.com Type of industry: Composite mill consisting of spinning. India Phone: (91-2764)23731(6 lines). 20793 Fax: (91-2764) 20436 E-mail: bvm@sintex. weaving and processing HEADS OF INSTITUTION: Chairman: Dineshbhai Patel Vice Chairman: Arunbhai Patel Managing Directors: Mr. Amit Patel President Operation (production): Mr.) 382721.G. GENERAL INFORMATION Name of the industry: Bharat Vijay Mills. Chathurvedy . Ashok Mehta Human Resource Manager: Mr. Rahul Patel Mr. K. Divided into both textile and plastic with textile consisting of the 1/3 rd of the income. 20246. North Gujarat Address: Bharat Vijay Mills (Textile Division of Sintex Industries Ltd) Kalol (N.

Sashidharan Procurement Manager Mr. R. IS.M. Rathore Organization Chart Managing Directors President Operations Spinning Weaving Yarn Dyeing Engineering Grey Folding Processing Finish Folding Lab SQC PPC Design Corduroy Ware House Personnel T. Public Relation Security Retails Shop Power Plant General Administration Excise President Admin.Administration Manager: currently vacant. Sharma CFO L.C. President Marketing Marketing Despatch President Procurement Purchase Stores CFO Finance Accounts Secretarial HRD. K. K. R. MIS . I. Marketing Manager: B.

ORGANISATIONAL HIERARCHY Managing Director President General Manager Deputy General Manager Senior Manager Manager Deputy Manager Senior Executive Trainee (Qualif: B.Stipend Rs.4500 – 15.Tech.5 lakh meters of corduroy .000) Worker (ITI) PRODUCTION STATUS 56000 meters/day of shirting fabric 1. Sc/Diploma/B.

30s. Chambray's in plains as well as dobbies l Bottom-weights with different weaves End use of Products • • • • • • Men's Wear Top And Bottom Formal As Well As Casual Skirts Jackets Shorts Furnishing Count range In English(Ne)-12s.PRODUCT On the product front. l Corduroy for bottom-wear as well as shirting from 4 Wales to 21 Wales per inch l Yarn Dyed stripes. .24s.50s. company has added various bottom weight qualities in singles as well as in doubles in addition to existing products like corduroy. The product range also covers Men's and Ladies apparels and furnishing etc. yarn dyed and solid dyed shirti ng's which helps the company to supply widest product range coupled with small and large quantities of products to meet the demand of garment manufacturers/exporters.20s.40s.45s and 60s.16s. Fil-a-fil. Checks.2/80s and 2/100s in 100% Cotton and in Poly/Cotton and Poly/Viscose Blends-40s.

2 OPERATIONS DEPARTMENT .

And then it has been sent for even moisture distribution. After all these processes this bale cotton gone to traders and textile mills receives these bale cotton from traders. OPERATIONS DEPARTMENT 2. As soon as the cotton arrives at the mill after ginning process in large bales weighing about 500 pounds (225 kg) each it is been kept for 24 hours.2. After this hydraulic pressing is done and cotton is been tested for the quality control. of the cotton plant. I. and ribbon like with a wide inner hollow (lumen). I. a. twisted. SPINNING The cotton fiber grows in the seedpod or boll. Each fiber is a single elongated cell that is flat. the remainder consists of natural impurities. And then spinning process starts:- Fan which distributes moisture (Stack of bales kept after hydraulic pressing) (Even moisture distribution is been done through the bale cotton) (Bale cotton kept for 24 hrs rest before blending) .It is composed of about 90 percent cellulose and about 6 percent moisture. The outer surface of the fiber is covered with a protective wax like coating which gives the fiber a somewhat adhesive quality.

The rapidly whirling beater blades take off small tufts of cotton. leaves. OPENING STEPS: Lint cotton falls on apron and passes between feeder rolls to beater cylinder. Some of the cotton stays on apron. The cotton knocked back by roll and continues to chum and blend until picked up again by apron.1. 2. WHY IT’S BEEN DONE?It is necessary in order to loosen hard lumps of fiber and disentangle them. and any remaining seeds. Mechanical bale pickers pluck thin. Conveyor belt passes cotton to another type of beater. Cotton falls on conveyor belt and is carried to next process. WHY IT’S BEEN DONE?It is necessary so as to obtain uniformity of fiber quality. and loosen up the mass. cleaning is required to remove trash such as dirt. even layers of the matted fibers from each of a predetermined number of bales in turn and deposit them into a opening machine where the fibers are loosened) . Apron moves cotton to blending apron. From beater the cotton passes to a conveyor and is carried to (Cotton going through the picker. The two screen rolls are made of screen material and air is sucked out of them by fan. knock out trash. This draws the cotton from beater and condenses it on the surface of the screen rolls from which it is taken and passed on by the small rolls. Blending apron has sharp spikes the raise cotton until part of it is knocked off by the roll. Air suction through cotton takes out dirt and trash. Another roll strips off cotton that was not knocked back by previous roll. burrs. BLENDING STEPS: Cotton is passed from bales and then to apron.

MPM-8 – it has got 8 chambers. The kind and number of cylinders or beaters. employed depend upon the type of cotton that is being processed. So that it will affect the fabric. (Mixing of diff cotton bales) (Formation of lap) (Laps formed) Here fibers are rolled into roller at the same time they are pressed also. The fiber is mixed and passed to an opener. after homogenous mixing all will be the same. trash falls through a series of grid bars.hopper. So. Generally used for homogenous mixture of fibers like while harvesting some cotton are from matured plants and some are not. it still contains small tufts with about two-thirds of the trash. As the mass of fiber passes through the opener. It may be conveyed as lap. Time taken to roll one lap:40s Count 50s Count 20s Count 600 sec 666 sec 500 sec . GBR. The commonly used porcupine beater revolves about 1000 revolutions per minute. As the cotton is opened.Here the cottons are fed for homogenous mixtures and for removing dirts. When the cotton emerges from the opener. cylinders with protruding fingers open up the limp and free the trash.

The straightening process puts the fibers into somewhat parallel CARDING. (Lap is been fed into carding machine) (Carding process taking place) . disentangles the fibers . and they must be straightened. This web is drawn through a funnel shaped device that molds it into a round rope like mass called card sliver. and arranges them in a relatively parallel manner in form of a thin web. the remaining impurities must be removed. As the cylinder rotates. the cotton is pulled by the cylinder through the small gap under the brushes. CARDING PROCESS: Before the raw stock can be made into yarn. the teasing action removes the remaining trashes. Card sliver produces carded yarns or carded cottons serviceable for inexpensive cotton fabrics. the fibers must be disentangles. The work is done by carding machine. The lap is passed through a beater section and drawn o rapidly revolving cylinder covered with very fine hooks or wire brushes slowly moves concentrically above this cylinder.3.

This results in a relatively narrow lap of compactly placed staple fibers. and then into can. to a sliver of smaller diameter without falling apart. DOUBLING PROCESS: After carding. several slivers are combined. The sliver may be passed from one can to combing for further removal of foreign matter and parallelization of fiber or directly to drawing. coiler head. The doffer comb vibrates against doffer cylinder and takes lint off in a filmy web that passes through condenser rolls. 4. The cotton follows large cylinder to doffer cylinder. or drawn out. which remove lint from large cylinder. . The compactness of these fibers permits this cotton stock to be attenuated.(Card sliver formed) STEPS: The lap from pucker unrolls and feed roll passes cotton licker in roll (covered with saw toothed wire).The licker in roll passes fiber against cleaner bars and gives it up to large cylinder which passes between the thousands of fine wires on surface of cylinder and on flats.

thus almost one fourth of the raw cotton becomes waste. in turn. produces a smoother and more even yarn. In this operation. This operation as much as 25% of the original card sliver. is identified with consumer goods of better quality.5. COMBING PROCESS: When the fiber is intended for fine yarns. the sliver is put through an additional straightening called COMBING. are combed out and completely separated out from the longer fibers. (Combing process) . The combing process forms a comb sliver made of the longest fibers. The combing process. quality cotton goods carry labels indicating that they are made from combed yarns or combed yarns. therefore. called noils. Since long-staple yarns produce stronger. which. fine-toothed combs continue straightening the fibers until they are arranged with such a high degree of parallelism that the short fibers. smoother. and more serviceable fabrics.

STEPS: Her six cans that were filled at cards feed each drawing from delivery. The sliver is neatly coiled again in roving can by coiler head. the machine automatically stops. thereby producing longer and thinner slivers. or drafting. each advanced set of which revolves at a progressively faster speed. Each of four set of rolls runs successively faster than preceding set. where rollers similar to those in the drawing frame draw out the cotton further. The sliver is now much more uniform and fibers much more nearly parallel. This prevents making uneven yarn later. The spoons are connected so that if any one of the six slivers from can should break. The last set runs approximately six times as the first set. consequently. This action pulls the staple lengthwise over each other. where it is given its first twist and is then wound on bobbins. sliver coming out is the same size as each one of six going in. After several stages of drawing out.6. process eliminates irregularities that would cause too much variation if the slivers were pulling through singly. the condensed sliver is taken to the slubber. but is attenuated to six times the length per minute. (Drawing process-6 cans of comb sliver been fed) (After drawing process) . Here the slubbing is passed to the spindles. DRAWING PROCESS: The combining of several fibers for the drawing. The draw frame has several pairs of rollers. The sliver is now ready for roving frames.

only enough twist has been given the stock to hold the fibers together. Roving is the final product of several drawing out operations. STEPS: The can of sliver from drawing frames is fed between three sets of drafting rolls. The bobbin is driven by a source separate from gear that drives spindle and flyer. The operations are identical. The front rolls (nearest flyer) are set at a sped that gives strand coming out of the rolls a predetermined number of turns of twist per inch as it moves along between rolls and flyer. it will break apart easily with any easy pull. ROVING PROCESS: These bobbins are placed on the roving frame. The bobbin is regulated to turn automatically at a speed sufficiently faster than flyer. There are two stages of roving. intermediate and fine. Roving has not tensile strength. but each machine yields a finer product than the stock is received. To this point. where further drawing out and twisting take place until the cotton stock is about the diameter of a pencil lead. It is a preparatory stage for the final insertion of twist. This pulls sliver and thins it down. The spindle turns flyer and is driven at a constant speed. . Each following set of rolls runs faster than preceding sets.(Inner arrangement-helical) (Cover) (Spring + helical structure) 7. which causes roving to wind on bobbin at same rate as it is delivered by front roll. making fibers nearly parallel.

the yarn may be reeled into skeins for bleaching or may be wound on cheeses. The ring frame. From bobbin roving is fed between set of drafting rolls to draw strand down to its final desired size. which is general in use. SPINNING PROCESS: The roving. is placed in the spinning frame. ring frame and mule frame. where it passes through several sets of rollers running at successively higher rates of speed and is finally drawn out to yarn of the size desired. and its constant spinning action provide a fast operation. whirling thousands of revolutions per minute.(Bobbin) (Speed frame-back side) (Speed frame-front view-120 bobbins) 8. for example. or spools. Its hundreds of spindles. The bobbins of yarn are removed for such processing as may be desired. The spindle turns bobbin at a constant speed. intermittent operation. and (3) by winding the yarn on bobbins-all in one operation. is more suitable for the manufacture of cotton yarns in mass production. STEPS: The principle of spinning is same as that used in roving except that the operation is more refined and a ring and traveler are used instead of the flyer. such as worsted. The tension caused by drag of traveler causes yarn to wind on bobbin at same rate of speed as it delivered by rolls. for ultimate weaving. the mule frame is required because of its slow. . The front set of rolls is adjusted to deliver yarn at a speed sufficient to insert desired mount of twist as strand moves along. The ring frame is faster process. Spinning machines are of two types. The ring spinning frame completes the manufacture of yarn (1) by drawing out the roving (2) by inserting twist. on bobbins. but produces a relatively coarse yarn. for very fine yarns. The traveler glides freely around ring.

(Ring Frame) SPINNING PROCESS FLOW CHART CARDED BALE OPENING COMBED BALE OPENING POLY/COT BALE OPENING OF 100%POLYESTER STACK MIXING WITH TINT COLOR BLOW ROOM STACK MIXING STACK MIXING BLOW ROOM PRE OPENING CARD BLOW ROOM CARD BREAKER DRAW FRAME FINISHED DRAW FRAME SPEED FRAME CARD DRAW FRAME PASSAGE OF POLYESTER DRAW FRAME BLEND PASSAGE P+C PRE COMB LAP FORMING P/C BLEND 2nd PASSAGE RING FRAME COMBER WINDING WINDING POST COMB P/C BLEND FINAL PASSAGE (3rd ) .

O RING FRAME RING FRAME WINDING WINDING WINDING WINDING PARALLEL WINDING PARALLEL WINDING T. CV% of count .F.M) LAP WEIGHT LAP LENGTH GRAMMO METER TOLERANCE LIMIT 12S TRUMAC New 11 20 44.PARALLEL WINDNG WARPING SPEED FRAME SPEED FRAME T.2 90 300 + or – 300gm YARN QUALITY PARAMETERS 1.P.F.4 450 + or – 300gm 20S TRUMAC New 11 20 56 400 + or – 300gm 40S 50S TRUMAC TRUMAC Old 11 20 61 330 + or – 300gm New 11 20 66.F.6 300 + or – 300gm SYNTHETIC LR Old 9 13.O T.O PROCESS CONTROL PARAMETER MIXING MAKE (m/c form) SHELLROLL (R.

R. T P I Raw material faults 16 class faults(A to D) Long thick faults(E+F+G) Long thin faults(H+I) Objectionable fault(A4+B4+C3+C4+D3+D4) 7. Classimat faults o o o o o 6. CV% of strength 3 .P 4 .S. CV% of single yarn strength 10. neps) & yarn hairiness.U% & imperfection ( thin. 5. CV% of elongation END USES o o o o Yarn dyed fabric Corduroys pile fabric Bottom weights fabrics Dobby fabrics & poplins . Single yarn strength (gm) 8.2.M 9.K.C. thick.

COMBING Laxmi-Reiter Laxmi-Reiter Laxmi-Reiter Laxmi-Reiter Laxmi-Reiter Laxmi-Reiter 1 1 2 2 4 2 2 4 4.S.INSTALLED NAME OF THE MACHINE Trutzschler blow room line with two finisher scutchers New trutzschler blow room line with one finisher scutcher Old synthetic blow room line with one scutcher Pre filter & fine filter unit CVT – 3 Roving waste opener Bonda waste opener Bale braker Mixing bale opener(MBO) Trutzschler DK-740 card Trutzschler DK-780 cards Trutzschler DK-780 cards Waste collection system R.OF MACHINE 1 1 1 1 1 1 1 1 1 8 4 4 1 1 4 4 6 1.BLOW ROOM TRUMAC TRUMAC Laxmi-Reiter TRUMAC TRUMAC TATHAMS TATHAMS PLATTS Laxmi-Reiter 2.G grinder complete High speed comber E7/4(old) High speed comber E7/4 High speed comber LK-250 Lap former E 2/4A Lao former E2/4A High speed comber LK-250 HS draw frame DO/6 model HS draw frame padmatex – 720 HS RSB – 1 draw frame HS RSB – D – 30 draw frame Speed frame TS-15 model MAKE YEAR 1992 2000 1978 1998 1999 1960 1960 1946 1989 1997-98 1998 2000 1998 2000 1991-92 1995-96 1998-99 1994 1997 2002 1989 1992 1998 1999 1992 NO.SPEED FRAME TEXTOOL .DRAWING Laxmi-Reiter Padmatex RIETER RIETER 5.CARDING TRUMAC TRUMAC TRUMAC TRUMAC PERFECT 3.

T.250 COMBER SLIVER LAP L.Speed frame TS-15 model Speed frame LF-1400 Speed frame LF-1400A Speed frame LF-1400A Ring frame MEI Rig frame DJ-50N MODEL Parallel winding m/c Parallel winding m/c Super doublers T.WINDING/DOUBLING/T.K.DRG LR GS SPEED FRAME MEI RING FRAME (12) T.O LAKSHMI3 SME – E 7/4 LAYOUT OF SPINNING DEPARTMENT LK 250 COM BER MIXING ROOM L F 1400 S F P.RING FRAME MEI TEXTOOL KAMITSU KAMITSU NMM VEEJAY SME – 2 7.O BLOW ROOM LINE TEXTOOL Laxmi-Reiter Laxmi-Reiter Laxmi-Reiter 1994 1989 1997-98 2000 1989 1992-93 1964 1971 1978 1999-2000 1 4 2 1 4 50 1 1 1 3 6.F.ROLL SHOP1 SECTION SME - 7.F.PJ 50N RING FRAME (34) T 151 SPEED FRAME WMM SUPER SPINNER RING FRAME(6) T.SAGAR 1972 1960 1998 SLIVER LAP 1980 1992 1989 1 1 1 1 1 1 .250 COMBER BLOW Cot mounting m/c ROOM LINE Cot mounting m/c Cot mounting m/c Cot buffing m/c TRUMAC DK 780 CARD Cot buffing m/c S draft TRUMAC DK 740 Cot bercolising m/c C&C DRONSFIELDS VIRAJKA RSBDRG SABAR E 7/4 COM DENIMACBER H.K.T. DJ50N RING FRAME(16) WEAVING SECTION SPINNING OFFICE DOUBLING MACHINES T F O KAMITSU WINDING WINDING DEPARTMENT L F 1400 SPEED FRAME E 7/4 &L.T.

and heather mixtures.2. Yarn dyed fabrics intended for laundering must be quite colorfast. it is described yarn dyeing. Cloth made of dyed yarns is called yarn dyed. Yarn dyed fabrics are usually deeper and richer in color. . are usually woven with a colored warp and white filling. for example. There are several methods of yarn dyeing. plaid. The purpose is to have the dyestuff penetrate to the fibers in the core of the yarn. shepherd’s check. I. stripes. this is similar to the penetration of the fibers in stock dyeing. seersucker. Other combinations of different colored yarns are checked gingham. or bleeding could occur. B YARN DYEING When dyeing is done after the fiber has been spun into yarn. The primary reason for dyeing in the yarn form is to create interesting checks. and plaids with different –colored yarns in the weaving process. Chambrays.

Package-dyed yarns are more suitable for woven fabrics. However. it is the more commonly-used method. In a commercial dyeing machine seven hundred packages are tightly packed on a number of spindles which are arranged vertically on a hollow base (the carrier). whereas skein-dyed yarns as more suitable for knits and carpets where a fuller bulk is more desirable. package dyeing can be performed on a much larger scale and with more uniform results.After loading. the dye-liquor is circulated through wound packages of yarn until the dye is evenly exhausted. the carrier is dropped into a seating in the dyeing tank.Yarns can be dyed in the form of skeins or packages. PACKAGE DYEING MACHINES In these enclosed machines where dyeing under pressure can take place. according to need. through which the dye-liquor is circulated. Carrier Spindle Yarn package Main tank (Carrier inserting into the main tank) . The dye-liquor is pumped through the packages in either direction. Consequently. or other types of holders and the packages formed are then mounted onto a perforated rod (spindle) or tube. The yarn is wound onto perforated tubes or springs.

to dye loose fibers. In any case. Modern package dyeing machines are made to operate at low liquor ratios. This is achieved by eliminating the external expansion tank. color etc. with the proper modification. Packages that are too loosely wound may collapse during the dyeing process. the packages must be wound as uniformly as possible. o Then in hang form dyeing take place . tops and sliver. and warp yarns. The sample given is generally known as eskloon (handkerchief shape). In dyeing warp yarns. o It is then checked in lab. a single perforated cylinder of the yarns fits into the seating of the dye tank. However. There they will check it in a particular design like how many threads they need. Therefore. MAIN STEPS INVOLVED IN YARN DYEING Yarn dyeing is done in mainly two stages:1) DEVELOPMENT o Customer gives sample with its all specifications like count. Many times the packages are Carriage by a covered protective bag which acts as a filter to prevent deposits of insoluble dye and other impurities on the yarn. packages that are too tightly wound may interface with the circulation of the dyeliquor. Sudden pressures changes should be avoided to prevent possible distortion of the packages. newer package dyeing machines have the capability of controlling both flow and differential pressure.These type of machines are also used.

date is fixed. o So we generally use spring winding so that more yarn can be wounded as well as gives uniform winding. .1 Receives soft package from winding department o Yarn packages from winding department been received. But if the quantity of shade required is very less like 2 warp yarns in long intervals then shade variation in the cone can be tolerated. SPRING o Uniform dyeing not possible if we use paper corn winded Yarn. o CYCLE OF YARN DYEING PROCESS 2. o There is a spring attached to the yarn package which helps in shrinking the yarn package. Depending on load. capacity. records of number of chemicals and recipe kept o If its not correct they will re-produce or re-process. constraint.o Approval from buyer. o If approved go for bulk order 2) BULK ORDER o Production Planning Department takes charge of bulk order.

2. o These spindles are attached to a carrier. o Recipe is been made according to development stage.3 Dyeing . o The main principle behind this is mechanism of compression.C department dyeing is been done. These rods have small pores in it which allows movement of dyeing chemicals in and out during dyeing process. But it again depends on compression mechanism. o Compression is done according to :-design :-density package :.2 Loading yarn packages to carrier o These packages are put in a carriage in compressed form. o There is long cylindrical rod –spindle in which spring wounded yarns are been kept. o As per availability of recipe and P. In one 400 kg carrier there can be almost 61 spindles.o It basically helps in loading process.vessel height in which these yarns are been dyed. There is a pressing device which compresses the packages. 2.P. o In each spindle there can be maximum 11 yarn packages can be kept.

. Capacity is 5-6 tones/day After dyeing process almost double amount of water is present inside the package. :-Main tank It’s the main tank in which carrier is been put.o The dyeing machine consist of::-Microprocessor It depends on light. Then water comes down due to gravity. There is another system known as automatic dosing system. And tube passes from this tank to main tank through which chemicals pass through. :-Closing tank In this chemicals are been put. medium. reactive dyes.-in –out and out-in 9-10 hrs is taken for dyeing 1 carrier. o o o o o o o First they put the carriage in the main tank in which 900 liters of water is been filled. There are mainly two stages. dark. In this chemicals are put in different tank according to color we want program is been feeded and the chemicals are taken automatically from these tanks and recipe is made. Then chemical is put into chamber which later goes to closing tank. temperature Water coming out from bottom of spindle and spreads out. Programming done-according to chemicals. water. All details are feeded onto the processor and locked. as per the requirement one program is used.

Example. In that situation we use dummy spindles which is covered with the steel for the equal distribution of pressure of water in all the spindles. It consists of a l oading device in which yarns are kept. Dummy spindles are plain rod which doesn’t have holes in them so that when dyeing process takes place water is not wasted in and out through these spindles. 2. So these rods block the movement of water in and out through the spindle. Then this is put into a . There are carriers known as dummy carriers. So.Suppose in a 100kg m/c we want only 80 kg yarns to be dyed. And if we use the simple porous spindles then most of the colored water will try to come out of that spindle because the pressure applied is very less in those spindles. These carriers consist of dummy spindles. This is been removed through a hydro extractor. We have to put all the spindles but we cant waste 20 kg of dyed yarn. And it also helps out in shade variation problem. variation in color may arise.4 Hydro extractor After dyeing yarn contain almost double amount of water.In-out Out-in Porous spindle (The rod is made of steel and no holes present n it so that it controls the movement of water in and through.) Dummy spindle In same vessel we can have different capacity.

0mm 5. which create an electromagnetic field.chamber. Through radio frequency further drying is been done.7 m/h 11. Shade matching If the shade is not matching this can be rectified by reprocessing it.get split.7 A 2.H+ and O. Therefore H+ and O. Levelness of package From 2 cheese to 1 cone Dyes generally used are vat.Dryer (Radio Frequency Dryer) After hydro extracting there is still some amount of water present inside the yarn. like 2 yarn packages are winded in one cone to check for the shade variation among different yarn packages.speed Anode Ja Grid Ig 283.This start vibrating and create energy. Electrode Conv. the yarn packages are winded in a cone.5 R. Inside this chamber the load rotate in a speed of 1700rpm. Due to the centrifugal force water comes out. Colors used:- .polar molecules are been produced. reactive dyes.4 A After the drying process. In this temperature has to be controlled and also height between these electrodes and yarns have to be maintained. TYPES OF DEFECTS 1. 2. 8 yarn package in 1 floor Total 2 floors present 2. Time taken is 10 minutes.I n this dryer machine electrodes are present.F.

⇒ IND BROWN BR ⇒ IND GREY 4B ⇒ INDOLIVE T ⇒ IND OLIVE GREEN B ⇒ NOV BROWN 2G ⇒ NOV PURPLE LR ⇒ NOV BROWN P ⇒ NOV OLIVE R ⇒ NOV YELLOW 5G ⇒ NOV JADE GREEN XBN ⇒ YELLOW 3RT ⇒ IND NAV BLUE VH ⇒ IND BLUE BC ⇒ IND BLACK AC ⇒ BLACK BLWUWU RED DYES ⇒ CRIMSON HEXL ⇒ YELLOW HEXL ⇒ NAVY HEXL ⇒ BLUE HERD ⇒ BLUE HEXL ⇒ BLUE HEGL ⇒ RED HEXL REACTIVE DYES .

PREPARATORY PROCESS FOR WEAVING: The yarns as manufactured and packaged after spinning are not in the optimum condition to enter the looms directly so as to produce fabrics. it was found to be much difficult to raise alternate warp threads and lower the others. using a hand-loom. Using a shuttle. weft yarn is threaded widthwise. Package size. In early times.2. The weft could then be carried between them in a straight line. C. WEAVING Cotton yarn can be made into cloth by knitting or weaving but weaving is by far the most important and the only one used here. The position of the warp threads was then reversed and the weft sent back in the opposite direction. I. Weaving is carried out on a loom where warp yarns run lengthways from back to front. build and other factors make it necessary for the yarn to be further processed to prepare it to be .

handled efficiently during fabric manufacturing. The yarn package as it comes from spinning must be repackaged to meet the particular needs and demands of fabric manufacturing. Various steps for preparatory process of yarn for weaving are as follows: WINDING (WARP WINDING AND WEFT WINDING)

WARPING

SIZING

DENTING AND DRAWING-IN

1.) WINDING
warping machine. REQUIREMENTS: • • • •

WEAVING

OBJECTIVE: To transfer yarn from spinner bobbin to another suitable package for

The fault level in the yarn must be reduced to an acceptable level. The yarn must not be damaged in the winding process. The package size, shape and build must be suitable for particular end use. The package size should be controlled to meet the particular economic requirement. MACHINERY:

i) AUTOCONERS: These are machines used to remove impurities, irregularities, and imperfections like thick or thin places, slubs, nebs or loose fibers from the yarn

obtained from spinning. There is a special feature called ‘auto-doffing’ in all of these. In this mechanism, after the yarn package finishes, another package automatically drops and the winding process continues. Doffing capacity = 60 doffs per hour. Weight of the yarn = yarn length/ (1694* yarn count)

There are three types of autoconers used in the winding department: a.) MURATEC MACHINE CONER 138 : Separation of electrics, pneumatics and No. of machines = 2 No. of spindles in each machine=60 b.) SCHLAFHORST AUTOCONER 238 : Single( individual) spindle machine • • • Automatic splicing. Uniform tension Electrode sensors are present No. of machines = 2 No. of spindles in each machine=60 c.) SCHLAFHORST AUTOCONER 338 : Sensor-controlled winding process. • Uniform yarn tension. measured in terms of micro and millimeters. • Variopack: For stretchable yarns, to achieve uniform tension without destroying the shape. mechanics

This is the latest machine with the following features: • Ecopack: Exact length measurement. Accuracy is

• Cradle pressure: Proper compact package to maintain uniform density. • Speed: Fastest machine fully computerized. No. of machines = 2 No. of spindles in each machine=60 ii) SAMPLE WINDING MACHINE: VERSA WINDER Here, the length of yarn to be winded can be feeded and after the length is achieved, the machine automatically stops. Number of machines = 1 Number of winders in each machine = 6 GAS YARN SINGEING MACHINE: Every yarn has a different level of hairiness. To avoid this, yarn singeing is done. A mixture of certain volume of gas and air at a certain speed and temperature is used in the burner. As the yarn passes through the burner, only the protruding fibers get singed. Yarn singeing is generally done for stripe qualities, where the ground is of the same color. TYPES OF YARN PACKAGES: Cone : this comprises of one or more threads, which are laid very nearly parallel to layers already existing in the package. It may be tapered in both sides and package weight varies from 1-2 kgs. Cheese : This consists of a single thread, which is laid in the package at an appreciable helix angle so that the layers cross one another to yield stability. It is generally in cylindrical form and weight varies from 1-2 kgs.

2. WARPING
OBJECTIVE: To arrange a convenient number of warp yarns that can be collected in a sheet form and wound on to a warper’s beam.

Warp is winded onto spools (bobbins) One spool per each warp end per 2" of beam is winded at a time.spool rack with bobbins.There are two types of warping methods followed: i) DIRECT WARPING (BEAM WARPING): It is used for long runs of grey yarns. Therefore the spool rack should hold the number of bobbins of warp needed to fill one section of beam at the desired number of ends per warp. It is not very well suited for mixed warps with many or random yarn changes. ii) SECTIONAL fancy pattern WARPING (PATTERN WARPING): It is used for short runs especially for fabrics where the amount of colored yarn is more than 15% of the total. of direct warping machines = 3(JUPITER) Suction devices are provided in between warping machines which suck all the unwanted cotton fibers flying. Only one section of sectional warp . sley hook and a tension box or warping paddle/guide. STEPS FOR SECTIONAL WARPING: i. No. Sectional warping is a quick way to warp a loom with a sectional warp beam and is best suited for very long warps (15 yards or more). Direct warping machines are not computerized. It also requires more space and equipment than other warping methods . It can be used to make warp sheets. any size or style of yarn and 2 inch repeats (most sections on a sectional warp beam are 2" wide). single color yarns and simple patterns of colored yarns. bobbin winder. The total amount of colored yarns involved is less than 15% of the total.

The width of the spread in the tension box reed or guide/paddle should be slightly less than 2" to allow for the width of the pegs on the sectional warp beam. ii. the center 14 sections are used (28" divided by 2" sections = 14 sections). The warp is centered and number of warp sections is counted. If the weaving is set at 12 e. vii. v. The spool rack is positioned behind the loom.p.inch. The tension box or guide should be attached to the back beam to help in winding the warp ends onto each section with even tension. hence 24 bobbins per 2" section). the cord is tied from the warp beam to the knotted warp ends using a clove hitch knot. Starting at one side and filling sections in order straight across the beam will produce fabric with warps tight on one end and loose on the other.A warp end is threaded from each bobbin through the tension box or warping paddle.i. The bundle of warp ends is knotted as close to the end as possible. The tension box or paddle is positioned on the back beam directly above the section to be filled. Note: the bobbins on the spool rack are heavier at the beginning of the warping process. starting at the center and working towards the edges will produce fabric with rippled edges.i. For a 28" wide fabric. . vi. Beginning at either of the outside sections of the specified sections. and the sectional warp beam sections are 2". 24 bobbins of warp are needed in the spool rack (2" x 12 e. iii. This weight makes the first sections tighter than the later ones. It is best to have the tighter sections on the outside edges. = 24 warp ends. There may be a need to put more than one end per dent or paddle hole to achieve this. A cord is tied to the warp beam in each of the sections used.p. Similarly. iv.

The sectional warping machines are fully computerized. this beam is than winded on to a beam by the help of a roller. A long stick is laid across the width of the loom and tied to the sides of the loom to secure. of ends per section) . Length of the drum is marked on it. The warp sections are taped to this stick. The beam is turned. the reed is slayed and tied onto the front apron rod). Length and width of each section of yarn is calculated and each section is warped in a slanting manner on the drum to avoid intermingling of sections. The warp yarns comes from a predefined arrangement of cones as per the color and design of the fabric. pins are removed from each section and warp is pulled over the back beam toward the shafts. ix. x. The tape is pinned into the filled section to secure it. watching carefully to see that the section fills evenly. a piece of masking tape is placed across the warp ends to keep them in order. xii. When the section is full. After all the sections are winded on the drum. xi. no. The warp is then cut one inch beyond the tape. A lace is introduced and tied at the end hooks of the drum after each section of yarns is separated by a rod. The tension box or paddle is moved to the other outside section and filled. Creel capacity = 672 Hence. This beam is called the warp beam. When all the sections are full. The tape takes the place of a cross. position of the tension box is adjusted. If the warp piles up unevenly.viii. of sections = 672/ (no. All the other sections should be filled with the same number of turns to avoid tension problems in the warp. MACHINERY: The sectional warping machine consists of a drum which can slightly shift horizontally as the sections of yarn are being rotated on it. Each revolution of the beam is counted as first section is filled. Thread the loom is threaded as for warping back to front (heddles are threaded.

• Digital / Graphic On Line Display for desired process data . • Constant Beaming Tension Most important and high technological feature only offered by 'Prashant Gamatex' to produce perfect weavers beam to get optimum efficiency for automatic looms. Hydraulic Disc Brakes To ensure gentle but extremely effective stopping of the machine. iii. Extremely convenient in operation and maintenance. of sectional warping machines = 9 (PRASHANT GAMATEX. i. Allowing the machine to be operated with single or multiple creel for higher productivity in respect to capital investment. This division into units provides greater processing flexibility such as. disc brakes are provided on both sides of the drum. New Caliper braking device having sideways installation facilitate easy servicing and settings of brake liners. iv.No. phases. • Easy to reach the warping reel from every position during the different working Facility to add the additional unit like waxing etc. ii. Proportional control of the brakes in our high tech Hydraulic power pack with the help of advance electronics. SUCKER MULLER AND JUPITER) FEATURES: • Separate warping & beaming structure Separate warping & beaming structure ensures smooth vibration free operation at high speed as well as at higher winding tensions. monitors constant tension of the yarn sheet during beaming.

O. which can be easily called back and start the machine without any further delay • Individually Controlled Tensioner Type model Perfect warp beam can only be produced when tension of each individual end is absolutely constant.) having large size Digital display or graphic display is provided for indicating total length. SIZING OBJECTIVES: • To improve strength and abrasion resistance of the warp yarns by causing the fibers to adhere together. or the types of yarn. This increases the overall efficiency of high speed looms. Machine stops automatically before lost end position during beaming to trace and tie the lost end to complete warp. rotation as well as all the messages and fault finding indications in case of machine stoppage. irrespective of warping speed. Frequency variable A/C drives Hydraulic doffing & donning device Auto section advancing Constant warping and beaming speed Lost end memory & auto stop during beaming Broken and lost end during warping can be memorized.Intelligent Operational Panel (I. • • • • • • Solid steel drum . we offer high tech solution to meet all these demand for quality conscious customers. 3. • On Site Programming Facility The design is inbuilt to memorize atleast 100 sets of different programs. package diameter.P. partial length. section width. of section. All lost end data can be monitored on screen at a time and also can take printout of the same.Dynamically balanced. . No.

oils.• To make smooth and to lubricate the warp yarns so that there is minimum friction where they rub together various parts in the weaving process. drop wires. which should be minimized. etc. Potato starch. SIZING INGREDIENTS: Adhesives: Modified starch (texoplast). harness and reed. wheat. fabric glue. They constantly are rubbed together during shedding. vegetable waxes and oils. In the weaving process. take-up. the warp yarns are subjected to rubbing and chafing against various metallic parts of the looms as they are threaded through backrest. emulsifier. Poly-vinyl alcohol (PVA).75 litres . animal fats Additives: Salicylic acid. softeners. phenol.5’’ GREY 50 10 25 6 5 100 ___ 14. shedding and beat up. thin volume starch. Tallow Pep 1000 LV 40 Water 40 6 25 4 5 100 1 15’’ 40COL 40 50 6 25 6 5 100 ___ 14. Lubricants: Mineral waxes. The warp yarns are subjected to tension constantly as well as intermittently during letoff. rice.5’’ 50 70 10 ___ 12 5 100 ___ 14’’ 60 60 10 ___ 15 5 100 ___ 14’’ 70 50 15 ___ 15 5 100 ___ 14’’ 20 20 ___ 60 4 5 100 ___ 14’’ 16OE 70 10 20 6 4 100 ___ 17’’ Sample sizing ___ 8 ___ 3 3 ___ ___ 100 1’’= 37. Polyester resin (acts as binder). starch from corn. Carboxyl methyl cellulose (CMC). Polyethylene glycol CHEMICAL 16Te Texoplast PVA Falixlose Seycofilm M.. zinc chloride. These two reasons lead to increase the end breakage level during weaving.

) FEEDING DEVICE: Obtain a good point of grip for the warp. Sizing machine SE – C has one pair of squeezing rollers.MACHINERY: 1) SUCKER MULLER –HACOBA with PLC device( programmable logic control) No. TECHNICAL DETAILS: 1. 3) AMBICA ( No. of machines = 1 2) JUPITER ( No. of machines = 1) No PLC device is present in this machine. This comprises of the following parts: . Sizing machine SD – C has two pairs of squeezing rollers. of machines = 1) OPERATOR INTERFACE PLC BASED SERVO DRIVE CONTROLLED MULTI-CYLINDER SIZING MACHINE ( JUPITOR).

Measured value is indicated on the scale. Immediately afterwards.Rubber.  Contactless switch: Attached to a roller bearing.  Three type of grindings: rough. It also moves the rollers back together. Carrier roller:carries the warp yarns forward Floating roller: determines the drawing force between carrier roller and first pair of squeezing rollers. Rotary switch : lifts the pressure roller off the carrier roller pneumatically to allow knots or the feed aid to be pulled through when the warp is being fed in. Pulses are transmitted to a second measuring instrument (meter counter or stretch measuring device) located elsewhere. the roller with the largest external diameter must be installed in the last squeezer.  Difference between two sqeezers in the first and second roller should not exceed 0.  The agent reaction time must be kept short to rule out solubilization of the roller surface. the cleaning agent is neutralized and removed with water. The pneumatically operated bridge automatically follows the roller movements. Control bridge : protects the entire arrangement. . These rollers should be brushed down with hot water containing a desizing agent before long periods out of use to wash out all traces of size from the pores. Pressure roller: This has two main functions: Stretch measurement and pulse generation. normal and fine.  When regrinding one of the bottom squeeze rollers on a sizing machine with two squeezers(SD-C).      Guide roller: serves the pupose of length measurement in cases where sizing continues filament yarn.2 mm. 2) SQUEEZING ROLLERS MATERIAL.

If tightened too securely. Stuffing box packing: ‘Kevlar Aramide’ packing code is used. The rollers should be stored at 20 degree centigrade in a dark room and should be lifted only by journals. ii) Can lead to damage of bearings. i) Packing cord coated with Teflon on the backing will burn and sealing effect can be lost. Squeezing pressure is usually set lower for standstill and creep speed than for normal speed. FQ2 V2  Squeezing FQ1 Pressure ( KN) FQ2 FQ1 Speed (m /min) V2 3) SIZING MACHINE HEATING AND STEAM LINES . Automatic squeezing roller control ( PLC) : The pneumatic load on the squeezing roller is increased and decreased according to the operating statuses of the machine. The squeezing pressure control facility allows the squeezing roller pressure to be adjusted depending on warp speed. If the amount of size imparted is more. the pressure of squeeze roller has to be increased and vice-a-versa. The programmable logic control device helps in checking the amount of size imparted to a single yarn. It measures the degree of viscosity of each individual yarn and sends a signal to the squeeze roller.

which in turn heats the size. Heating and temperature control: Heating is done by two systems: i) Direct: By injecting steam directly into the size in the preliminary and main troughs by way of distributor tubes. Temperature is regulated by means of a pneumatically controlled valve.Maximum permissible steam pressure = 3. iii)Condensate and pressure compensation line 5) LEVEL MONITOR IN MAIN TROUGH The liquid level in the main trough is monitored with a bead tube. ii) Indirect: By injecting steam into the double wall of the size trough and thus heating a water bath.  Temperature restriction of indirect heating: Sensor of the control valve is installed in the expanded cross section of pressure compensation line. Water temperature = 80 degree centigrade Size temperature = 70 degree centigrade If internal heating temperature is too high. There is an electro. size can become baked on trough walls. 4) PRELIMINARY TROUGH CONDENSATE LINE The condensate must be able to drain off at zero pressure. If the level falls too low. It consists of: i) Double walled water bath. Temperature of size is measured by a PT 100 temperature sensor in the main trough. A condensate drain is used to prevent the size being watered down. a separate pressure reducing valve and a safety valve must be installed.pneumatic temperature control system.5 bar If the customer wishes to work with lower steam pressures. the system shuts down.  . ii) Sensor of temperature control valve.

REFRACTOMETER MEASURING CUP FACTORS AFECTING DEGREE OF SIZING: i) Concentration ii) Viscosity of sizing liquor iii)Temperature of sizing liquor iv) Speed v) Squeezing pressure ENERGY CONNECTIONS  Steam pressure: Operating pressure = 0. It is measured by a refractometer.5 to 3.MEASURING AND CONTROL DEVICES FOR DEGREE OF SIZING If degree of sizing is too high or low. where Sa = Sizing liquor take up.5 bar  Steam quantity: SE-C = 50 kg/h SD-C = 80 kg/h   Condensate : must drain without back press. risk of thread breaks is increased. K = Concentration. Air pressure : Maximum Operating pressure = 10 bar . Degree of sizing(%) = [Sa(%) * K(%)] / (100%) . It is the ratio of the liquor taken up to the weight of untreated yarn.

Sizing machine layout plan: 3.With squeezing pressure upto:60 KN => 6.15 cubic mt/h (intake) SE-D = 1. It is fitted at the beginning of the dry splitting zone immediately after the dancing roller. motor with a worm gear. d) Lubricant can only be removed via drain cock iii) An applicator roll: a) Made of stainless steel with a specially treated surface.phase a. ii) A tray to contain the lubricant: a) Tray is made of stainless steel and protected from fiber fly and other impurities with cover plates. WAXING DEVICE (PVD) This is used to apply various oils or waxes to the warp after sizing. where the warp is still undivided.5 bar  Air quantity: SE-C = 1. dust and oil.c. iv) if liquid media (oils) are used. b) Driven in properly to the sizing machine’s warp speed by a frequency – regulated liters. This device consists of: i) A melting funnel for solid media (waxes). c) Wax temperature in tray is controlled by a temperature controller and a pneumatic valve.65 cubic mt/h Air must be free of water. it is fed via a transparent bottle with a capacity of 10 . b) The tray has a heating coil for internal heating.5 bar 100KN => 8.

4. The heald is the part of the loom that is used to move the warp threads up and down. The threads pass through eyelets on the heald. When the shuttle travels back their positions are reversed. Some basic terms: . For a simple weave pattern alternate eyelets are moved up to raise the corresponding warp threads. and the threads between are moved down. The reed is like a comb and its purpose is to control the separation of the warp threads. DENTING AND DRAWING – IN All the warp threads have to be threaded through the heald eyelet and its gap in the reed prior to weaving.

0 1 (2*) 500 20 200 200 4-8 2. This process is called denting. 2) STAUBLI DELTA 110 : These drawing-in installations are designed for weaving mills with medium drawing-in requirements. The DELTA 110 also handles drop wires and is a universal installation.8/ 4. MACHINERY: 1) STAUBLI DELTA 200 : The DELTA 200 is a high-performance drawing-in installation. It is used wherever high production performance.3/ 4.times in relation to manual drawing-in thus enabling the required level of processing flexibility. and maximum flexibility are required. Automatic drawing-in machines multiply the productivity of each drawing-in operation 5to 10. Furthermore. The DELTA 200 draws-in warp yarns directly from the warp beam with 1 or 2 sheets. a module is available that is specially designed for drawing-in course yarns.0/ 6. and optionally up to 4 sheets.2/ 2. a wide field of applications. number of frames (J/C-healds) 110 100/140* 2-5 2.0 2 (4*) 500 28 . Main characteristics: DELTA Drawing-in speed (ends/min) Number of warps in 8h (ca. Drawing-in takes place directly from the warp beam with 1 warp sheet. after it passes through the heald. ) Warp widths (m) Number of warp sheets Reed density( teeth/ dm) Max. A warp end is passed through a dent with the help of the reed hook.PREPATORY PROCESS FOR DRAWING-IN: The open space between each wire of the hook is called dent. or optionally with 2 warp sheets.

rows of dropwires Number of dropwire paths Drawing-in element Yarn count range (tex) 16 ____ ____ Hook 3-250 20 8 2 Rapier 3-330 MACHINE CONCEPT: Modular system The different modules of these machines are as follows: 1) Part modules: • • Control cabinet and electrics. 3) Yarn Supply Module: Part modules: • Lifting Device .Max. number of frames (O-healds) Max. Base Frame Main Module Basic Equipment: Function: i) Static auxiliary function ii) Supporting unit for the machine infrastructure iii) Holds electrics and pneumatics. 2) Yarn Drawn –in Module: Function: Serves to guide the separated warp ends through the heald. drop wire and reed.

. ii) Distributing the drawn-in drop wires between the shafts.• • • Thread Frame Yarn Separation Yarn Supply Function: i) Handling the warp beam and thread sheet ii) Separating and preparing the warp end for drawn. 4) Heald Module: Part modules: • • • • Heald Magazine Heald Separation Heald Distribution Shaft holder\ Stave holder (harness truck) Function: i) Handling the healds from the magazine stack ii) Distribution between the shafts 5) Reed Module: Part module: Reed Transport Function: Reed Handling 6) Drop Wire Module: Part modules: • • • • Drop Wire Magazine Drop Wire Separating Drop Wire Distribution Drop Wire Transport( Harness Truck) Function: i) Magazing the drop wires.in.

 If reed module is not ready. gripper moves on.7) Control Module Part modules: • • Function Keyboard Control Keyboard Function: Controls and co-ordinates the module computers assigned to the main module.  Heald module reports at heald test. gripper moves on.  Gripper enters the dent (can be stopped if reed module is not ready. . band gripper is stopped before passing through heald eye. it reports after reed test.  Drop wire module reports at drop wire test. If it is in ready state. If it is not ready. otherwise continues its forward motion. If ready. SEQUENCE OF FUNCTIONS:  Band gripper starts the drawing-in sequence before all modules are ready for drawing-in. iv) Visualizes the process sequence. If it is not ready. 8) Master System Module Part modules: • • • • Keyboard Monitor Master computer Printer Function: i) Accepts the drawn-in data from the operator ii) Transmits it to the control computer. iii) Manages the operating data. band gripper is stopped before penetrating eye of the drop wire.

Supported on the frame between these two cylinders( warp beam and cloth beam). Yarn supply module reports at yarn test.  Band gripper withdraws past the drop wire and heald positions. If it is not ready.  After yarn take over. the warp yarns are ready to be interlaced by the filling yarns that run in the width of the cloth. the gripper continues its motion.  Reed transport ensures the reed position.  One drawn-in cycle is over.  Drop wire and heald distribution systems move on. Four fundamental operations of weaving in any loom are as follows: • • • • Shedding: raising specific yarns by means of the harness or heddle frame. Classification of power looms used is as follows: Looms . Picking : inserting filling yarns through the shed Beating up( battening) : pushing filling yarns firmly in place by means of the reed. thus producing the woven fabric. the warp beam is mounted at the back and the warp yarns are conveyed to a cylinder called the cloth roll. WEAVING On the conventional loom. band gripper is stopped before entering yarn take over. 5. If ready. band gripper which grips the yarn withdraws.  Yarn ejectors are actuated in position ‘e’ and ‘f’ (in the diagram). which is at the front of the loom and on which the fabric is rolled as it is constructed. Taking up and letting of : winding the finished fabric on the cloth beam and releasing more of the warp from the warp beam.

Within these restraints. which reaches in and takes it across the rest of the way. Yet. or rapier looms. 10. the airjet may not be able to carry the filling across the loom. if the yarn is too heavy. Air jet looms require uniform filling yarns. of looms = 2 RAPIER AIR-JET RAPIER LOOMS: these have a double rapier device that is. Any intricate design or motive can be developed using these looms. one rapier feeds the filling yarn halfway through the shed of warp yarns to the arm on the other side. JACQUARD LOOMS: If the number of harnesses are more than 24. These looms operate at a lower noise level than the shuttle. one on each side of the loom. missile. These rapier looms operate at speeds ranging from about 200 to 260 ppm at about the noise level of missile looms. AIRJET LOOMS: these looms use a jet of air to propel the filling yarn through the shed at rates of up to 600 ppm.000 ends can be individually controlled in this loom MACHINERY: Technical details I ) RAPIER LOOM: PICANOL GTX PLUS . They are more suitable for use with heavier than lighter yarns because the lighter weight yarns are more difficult to control through the shed.DOBBY JACQUARD No. the air-jet loom is effective and can produce a wide variety of fabrics. They can produce a wide variety of fabrics ranging from muslin to drapery and upholstery materials. jacquard looms are used.

ii) Leveling of the machine: leveling is very important for the productivity and life of the machine.Installing the machine: i) Lifting the machine by means of an overhead conveyor or fork-lift truck. The level position of the machine has to be checked in 3 places: on the two frames and on the sley shaft.3 mm/m over both the length and depth of machine. Always. CONECTOR SIGNAL XCOMP 6 7 8 9 10 11 12 SELVEDGE BREAKAGE IMPULSE WARP BREAKAGE START/STOP FILLING BREAKAGE VCOMP RESERVE . Bidirectional communication : loom monitoring is done by the use of connector XCOMP at the bottom of the control box . the right side is lifted first. This has to be done with an accuracy of 0.

Clearance between clutch disc and rotor = 0.3 to 0. until the clutch disc stops slipping. Weave settings for a symmetrical set-up of the warp beam with regard to the machine: A maintenance level. Clearance between clutch disc and brake coil = 0 to 0. in order to obtain a short regular movement of the clutch disc.9 mm.Control clutch: Control of the clutch and brake is obtained by a fixed programmed electric control. Voltage on the clutch and brake coil = 340 V dc Resistance = 10 to 14 ohms. This means that the current in the obtained clutch and brake coil can be changed by the micro-processor.05 mm Starting cycle (weaving): It consists of three phases as follows: • A current which is about 5 times more important than the nominal current is first sent. . • weaving cycle. but can’t be adjusted through keyboard. which is about equal to 3 times the nominal current. about equal to nominal current during the All settings can be carried out without warp beam and with the grippers in the machine. • An intervening over excitation level.

temple profile. Weave settings for an asymmetric set-up of the warp beam with regard to the . • • • • machine: Full set up is same as symmetrical except for that the left hand slide. Filling and waste cutters: Position of the grippers (both left and right hand) Course of the gripper: should be done without a reed in the Position of the gripper openers : sley position = 0 degree Setting of the gripper Reed length (machine without tucking in device) = b + (35 to sley to avoid any damage on the reed or grippers. b = drawing-in width in the reed. filling cutter and tucking-in device are not moved. temple. Where. ii) Position of the first warp yarn in the reed: Machine without tucking in device = 15 to 20 mm Machine with tucking in device = 30 mm iii) Position of the reed: 1mm from the filling guide.Marks on the reed holder Position of the slides The race board The lateral position of the left hand temple support The lateral position of the left hand temple profile Position of the filling guide Position of the right hand temple support Position of the right hand temple profile The temples: height and the lateral position. • The reed : i) 40 mm) (machine with tucking in device) = b + 70 mm.

Filling presentation: There are two types of filling presentations available: • Independent filling presenter type W: i) the left reed dent. Synchronization of the machine.fixed and movable both of which should be lubricated daily. ii) Working: A channel can carry out two types of presentations: a) A single presentation of a channel i) Quickstep is an electronic filling presentor for 2-4-6 or 8 channels.There are two blades. Cutting stroke of the cutter 1mm from the filling guide. Cutters are driven by cam and operate on every pick. Fix blade is 1mm below the filling yarn. Each channel is Position of the filling presentor : first hook at 185 mm from . iii) Setting of the needle depth • Independent filling presentor type Quickstep separately driven by an electric motor. • Tension of the filling clamp • Setting of the filling cutter: both the blades are moved till the fix blade is i) lateral position of cutter blades ii) depth(backrest) position iii) vertical position of fix blade iv) vertical position of movable blade v) cutting movement of the cutter Waste cutter: i) Lateral position of waste cutter : 3mm from fabric selvedge ii) Cutting pressure of the blades iii) iv) Vertical position: tip of the fix blade is 2mm below the fabric. No mechanical drive of the filling presentation and the synchronization with the machine is carried by microprocessor.

bottom shed pulled lower than the guide plate. Quickstep filling presentation is maintenance free and may consequently not be lubricated. required shed height. • Synchronization of the dobby : Sley position should be between 300 and 350 degrees. Tighten the screw on the moving arm/ replace the module unit. Shed height is determined by REASON Power supply is wrong/ wire is not well connected/ no synchronization signal Moving arm and motor shaft are slipping/ motor doesn’t work Motor polarity is connected the wrong way SHOOTING Replace or reconnect the wire/ adjust the clearance between the proximity switch and cam. bottom shed rests on the race board as long as possible. iii) Weave Settings : iv) Trouble shooting N TROUBLE 1 Filling presentor doesn’t work 2 3 Irregular needle movement Position of needle inversed v) Mounting settings: a) Replacing the motor of a module b) Replacing the needle c) Adjustment of needle on motor shaft The shed: • • position of two levers at a distance ‘c’. The warp beam: Position of the bottom shed: improving the gripper flight. Change the wire connections in straight way a) Mechanical b) Synchronization . C depends on harness frame number.b) Presenting the same channel several times.

• Set up of warp beam – i) Symmetrical ii) Asymmetrical Adjusting the position of the warp beam flanges with regard to the warp beam barrel.tension roll and rotating roll. ii) Height and depth of the back rest to be adjusted: For height. Take-up housing Take up rolls and pressure rolls Cloth roll and friction clutch Main oil bath of TU motion parts in Main parts of the take up motor: Warp yarns of bottom shed slightly touch the cross beams of warp stop during open shed. For light fabrics. • Let off (with tension sensor. it should be near to heald frame. ETU electronic take up: Independent servo motor controlled by microprocessor. There is higher position for plain weave/heavy cloth and lower position for silk/ filament yarn. Take up motion • i) ii) iii) TU housing reduces wear and tear. or feeling roller mounted) i) Bevel gears adjusted for let off ii) Spring diameter chosen for different colors • Warp detector : Height and inclination of warp detector should be so that : i) ii) the warp yarns. whip roller should be as far as possible from heald frame and for heavy weights. Depth depends on elasticity of warp yarns. the essential conditions are grain of the fabric. • The backrest: i) Set up of the back rest: Equipped with 2 rolls. warp breakages. Drop wires in the upper shed are lifted as little as possible by .

Gears and chain wheels of the take-up roll should be lubricated.up motion: Following actions to be performed at regular intervals: Oil level in the take-up housing is sufficient to lubricate the gears inside.Reverse take up facility Pick density can be changed through auto. b) Friction clutch can be adjusted to suit the fabric construction. Fixation of the device : i) Device with needles is fixed on the first Aluminium profile( closest to the . • i) ii) iii) Lubrication and maintenance of the take. ii) TU Roll : a) Leads the woven fabric smoothly away from the cloth roll. ensuring even wounding. Pressing force of two pressure rollers on both sides is the same. iii) Cloth Roll and Friction Clutch: a) Woven fabric smoothly and evenly wound onto the cloth roll. change speed. Cloth roll clutch should not get stuck. increase twisting force. the pressure imparted by pressure roller keeps changing. Same tension on both sides should be maintained. b) Depending on the type of fabric. continuity. stability.setting Rotation speed controlled by mp • Functions of the parts: i) TU Housing: transfer drive power. Leno Selvedge Device I) KLOCKER LENO DEVICE: • weaver’s side).

II) LENO HEDDLE OF KLOCKER . a distance of 15mm in the reed is kept between the two groups of leno yarns in case of double leno mechanism. Both plastic pieces can move separately. ii) Phase-II : Needles move upwards and leno yarns move downwards. Both needle yarns are positioned in the bottom shed. ii) The leno yarns are directly drawn in through the two slots of the plastic sliding piece. front piece remains at top with regard to back piece. During weaving. In double leno motion. At the movement of harness crossing. leno yarns are again crossing between needle yarns. front piece remains at bottom with regard to back piece. • Working Principle: Leno yarns are both drawn in through the diagonal slots of the plastic sliding pieces. Upper yarn is drawn through the eye of upper needle and bottom yarn is drawn through the eye of bottom needle.ii) Back lath of the device is fixed on the second profile. For upward motion of pieces. leno yarns cross between needle yarns. During harness crossing. iv) Phase-IV: Needles move downwards and leno yarns move upwards. leno yarns are drawn in at both sides in the same way. One pick is inserted. iii) Phase-III: Needle yarns are positioned completely upwards (in the upper shed ) Leno yarns are positioned completely downwards( in the bottom shed) One pick is inserted. • Drawing.in of the yarns: i) The needle yarns are drawn in through the hole through the side walls of the device. This can be divided into four phases: i) Phase-I: Both leno yarns are positioned in the upper shed. • Harness frames are put on harness crossing for easier drawing in. one leno yarn is straightened so that only one leno yarn is visible in the fabric. For downward motion of pieces. The front piece has a magnet.

all harness frames are placed downwards. Position of the cam Working principle : movement of leno heddle is divided in 4 phases: i) Phase I: At the moment of crossing.• • listings. drop heddle and other listing is pulled upwards. • yarn. For easier drawing-in.( same as phase-II) III) WEAVE SETTINGS • Lateral position of the device: Sley position: On machines equipped with dobby. Drawing in of the yarns : Drop heald yarn is drawn-in through the eye of the drop heald between the two Leno yarn is drawn-in between the two listings in same direction of drop heald yarn. weft is taken along the length of the . a distance of 15mm in the reed between the two groups of leno yarns is maintained. Needle yarn is positioned in front of the drop heald yarn. ii) Phase II : One listing is pulled downwards. • • The shed height: For some fabrics. direction of both the listings is interchanged. In case of double leno mechanism. Fixation of the device. machine is put in position with open shed.( same as phase I) iv) Phase IV : leno yarn slides downward between drop heddle and second listing. drop heddle yarn is positioned above leno Tucking-in Device • After the inserted pick has been beaten up by the reed and when the selvedge ends hold the weft. So the leno yarn between listing and drop heddle will slide downwards. height of leno harnesses is set according to warp yarns. Drop heald yarn is pushed upwards by drop heddle. iii) Phase III: now. Leno yarn is positioned under drop heald yarn. The devices are moved until they warp yarns. Yarns obtain tension and are positioned under yarn guide which is lower than bottom shed.

The reed is also set at a distance of 1mm from the filling guide. No problems occur with fabrics having less picks/inch than ends/inch. so that the drawing-in can be changed between the selvedges and the ground of the cloth. Solution: i) Number of warp ends in selvedge zone should be reduced. The first warp yarn is drawn-in at 30mm from the first left hand reed dent. • Drawing-in of the first warp yarn and the leno yarns: In case of machines with tucking in device.selvedge by gripper. Number of heald wires depends on length of the tucked ends. reed is 70 mm longer than the drawingin of the fabric. ii) The weave in selvedge zone should be changed iii) Thinner warp yarns should be used in selvedge A Dense Warp B Square fabric C Weft Density predominant Reduce warp density by 30% Reduce warp density by 15% Change selvedge weave Use fine warp ends When the machine is equipped with a tucking in device. • Construction: Number of weft ends is doubled on the selvedge edge stroke. extra heald wires should be cut out. risk of warp breakages in the selvedges is greater during weaving and difficulty may occur in the finishing of the cloth coz of construction of selvedge. Hence. With square clothes or clothes having higher weft density. it is advisable to put extra heald wires between the selvedges and ground fabric. It selvedge is perfect. higher tensions are caused in the selvedge because of large shrink. . Weft is then cut between the selvedge gripper and the selvedge ends at 11mm from the first warp end by cutter.

OMNI 800 PLUS Installing the machine • • Unloading the machine Moving the machine : The machine can be moved by means of a crane or fork. it is glued to the floor with a two component epoxy glue.At the right hand side. Leveling the control panel support: Fixing the double warp beam Warp beam bearing poitions Installing the control box PARTS OF THE MACHINE: .3mm/m Two hydraulic lifting jacks A lifting hook which supports front side of the frame. iv. Appropriate lifting beam must be used. Whole length varies from 3760mm to 6470mm. ii. The back side is jacked up by means of the warp beam support. • • • • • Leveling the machine: Auxiliary tools for leveling the machine are : A leveling instrument with an accuracy of 0. II) AIRJET LOOM. Glueing the machine: To prevent the machine from moving due to vibrations. iii. the right hand waste yarn is positioned at 35-40 mm from the last warp yarn. • i.lift track or by wheels.

The following actions can be undertaken without dismantling the movable main nozzle from the machine:- . • Replacing parts: i) Replacing the injectors ii) Replacing the main nozzle module • Channel assignment: It is advisable to use the channel nearest to the reed.The 1131 and 2231 CAN plus Prewinder • • • • • • • Aligning the pre-winder Positioning the balloon breaker Changing the sense of rotation of prewinder 4-pick insertion Replacing injectors Changing assignment Weaving setting The fixed main nozzle: Parts of the fixed nozzle are:- The fixed main nozzle should be positioned such that the line leading from the prewinder drums’ centre to the movable main nozzle is as straight as possible. Injectors are available in different types like conical and cylindrical. The internal operations uniquely identify the different injectors. The fixed and movable main nozzle cannot be exchanged with each other. The movable main nozzle • Parts of the movable main nozzle are:One or more main nozzle modules Injector Air inlet Nozzle extension The filling yarn count dictates which injector and main nozzle body will be used.

Weaving settings: This can be adjusted in two ways: i) Lateral position ii) Depth adjustment • The swinging main nozzle: Switching mechanism Relay nozzles • Arranged over the entire length of the reed. It is open during filling insertion and clamps the filling if insertion doesn’t take place. • • insertion channels. • The filling clamp: there is a filling clamp per channel at the main nozzle inlet. The pneumatic control • Compressed air The more the relay nozzle is turned towards the reed.• Setting the pressure: The pressure can be set on the front left side of the machine. these assist the movable main nozzle in blowing the pick through the reed guiding channel. the lower the yarn flight in the higher the yarn flight in the insertion channel.e. 74mm from one another. in that each group of nozzles is served independently by a dedicated relay nozzle value. i. The second and rest of the relay nozzles are placed at uniform distances. Relay nozzles are fitted to the right of the last warp ends to direct the pick towards the suction mouth • Relay nozzles are divided up into groups.. The pressure of the main nozzle determines the speed of the filling yarn. • • The directional nozzle: To lead the filling in a right direction during the insertion start. the The higher the pressure. .

iv) RIGHT RELAY NOZZLE REGULATOR: Regulates pressure on the RH relay nozzle buffer tank. Auxiliary Pressure = Supply pressure – 1 bar iii) LEFT RELAY NOZZLE REGULATOR: Regulates the pressure on the left hand relay nozzle buffer tank. iv) • i) ii) iii) iv) v) vi) vii) viii) QUICK COUPLING: Pressure from different regulators can be measured by Air distribution : Air to buffer tank fixed main nozzles Air to buffer tank movable main nozzles Air distribution block Air to LH and RH buffer tank Pneumatic unit above movable main nozzle (pneumatic unit) ELCA on buffer tank Parking brake means of a manometer through quick coupling. threading and PFT threading c) Chimney stretching nozzle d) Extraction nozzle e) tucking-in device f) Clamp on main nozzle g) 8 color switching valve This is set for fixed value 6 bar. i) MAIN VALVE REGULATOR: Regulates pressure on buffer tank(s) for main nozzle. Pressure of main nozzle determines the speed of filling yarns. Main distribution block . ii) AUXILIARY PRESSURE REGULATOR: Regulates the pressure for the auxiliary functions: a) pistons of pick finder b) Pre-winder.• Pressure regulators The pressure for the relay nozzles must be set as low as possible with no weaving faults occurring and with a minimum number of machine stops.

temple nozzle mounted on temple support. Transmission of arrival time data to microprocessor. ii) To prevent yarn ends RH side from returning in the fabric. They should be regularly cleaned by alkaline solution. pick finding. On machines equipped with a waste guide. Extraction nozzle blows the filling waste out of the chimney stretching nozzle after the sley beat-up. counter flow Main Nozzle Modules i) For movable main nozzle: Positioned on cross beam ii) For fixed main nozzle: Positioned on power box support behind the left side cover • Temple Nozzle i) Used for a filling detector in front of the reed or next to the reed. To make machine stop when it detects a filling yarn. The filling detector’s function is based on the reflection of a light beam. Filling detector is mounted nest to last warp end. Stretching nozzle is mounted next to filling detector. Filling detectors (in front of reed and next to reed) Functions: • • • To control the arrival of filling yarn at RH machine side. Extraction nozzle blows the filling waste behind the waste guide. Filling cutter . Stretching relay nozzles Waste guide is used to keep long filling waste away from the fabric.ix) • Value block. the stretching relay nozzle is positioned behind the waste guide. Chimney stretching nozzle It ensures that the filling yarn remains stretched during the closing of the shed.

Reed The Dobby The outside cam motion Harness frames The optimum height setting depends on a number of factors like article type. The considerable reduction . the warp threads are drawn through the weaving harness in a perfect manner. Practically all staple fiber and filament yarns can be tied without extensive adjustments. The filling clamp: Used for a better control of the filling TOPMATIC WARP TYING MACHINE • EFFICIENCY: Warp preparation on the TPF tying frame is fast and comfortably.It cuts the filling at the LH machine side at the end of insertion. patented electronic double thread detection of the TOPMATIC PC operates in warps with or without lease. weave. • QUALITY: The unique. Timing of cutting: Time is set around 10 degrees and is adjustable for each channel separately. It is found on left side of the machine next to air preparation of the movable main nozzle. Even at 600 knots per minute. and machine speed(rpm). • • • yarn at the LH machine side.

YARN COUNT RANGE: 0.Mechanical.44 MB. for warps with or without lease KNOT TYPES: .Single or double knots in one machine.5’’ floppy disc drive. • • • • • SPEED: 600 knots/minute. automatic repetition in case of a separation faults. • The controller is equipped with 1. 3.Electronic.Length of knot ends selectable (optional) III) JACQUARD LOOM: TYPE GT511 – II (ELECTRONIC JACQUARD) FUNCTION DESCRIPTION GT511 electronic jacquard adapts 16-bit high performance handler for providing big function and ease of operation. selectable .in double threads and redirected warp threads lead to an increased efficiency of the weaving machine. switch-over control for irregular lease (optional) DOUBLE END DETECTION: . • The dot pattern liquid crystal display has Chinese operation I/F. for warps with lease .2-740 LEASE TYPE: All combinations in one machine.8-500 tex / Nm 2-1250 / Ne 1. DOS compatible. • Maximum speed = 1000picks/ minute .

• Controller has configuration function. • System will automatically start to self test when energized or operated and provide loom’s test program for test weave when djusting the loom. . weft program can be set. • Information in the controller and loom can be preserved. it is not necessary for the customer to remember too much of the procedure.15% . Parameters like warp program. data will not miss when in de-energized state. • Many anti-interference ways to control power interference. if used on special looms. for storing designs transmitted from floppy disc. controller and loom. Therefore. • It has eight LED’s on the panel to display the state of supply. CONTROLLER FASIA: This includes: • • • TECHNICAL DATA: Temperature = -5 to 40 degree Centigrade Relative humidity = 0% to 95% non condensation Power = 110 V +. to edit and weave the complicated JOB.• Memory capacity = 8 MB. which is formed by various kinds of patterns. radiation interference and conduction interference. 45 – 60 Hz Power consumption = 60 watts COMMANDS: Running state: LCD model displays :i) Job number ii) Pattern name iii) Weaved cycles iv) Remaining cycles v) Weave pattern cycles LCD modular 8 LED’s 20 buttons . • Each operation has detailed instruction.

I. d GREY FOLDING Grey Fabric Inspection occurs in fabric inspection for the weaving/ spinning defects. and irremovable defects’ location is noted down and the frequency is noted. There is a roller attatched counter which counts the number of metres inspected and helps in location the position of the defect. The removable defects are removed and noted down. .vi) Current pick vii) Current speed • • Pattern program Application program viii)Pattern application program : a) Pattern directory b) Memory usage c) Pattern conversion d) Return TOP PORTION OF JACQUARD (ATTACHMENT OF HARNESSES) ix) Job list application program : a) Edit b) Weave from first job c) Weave from current pattern d) Weave from designated pick number e) Return • • • Controller configuration Test program Exit 2.

. of machines is 12. Topiwala. of Workers is 50/shift and the no. S." Modern corduroy is most commonly composed of tufted cords. s manufacturers are D. 2 fabric beams are stitched together with a single needle chain stitch machine for acquiring the required amount of the length of the fabric roll. then the fabric is a defective one. Topiwala Enterprise is present.CORDUROY Plaiting Machine Corduroy is a fabric comprised of twisted fibers that when woven lay parallel (similar to twill) to one another to form the cloth's distinct pattern. a "cord. sometimes exhibiting a channel (bare to the base fabric) between the tufts. The no of plaits of fabric folds to be formed can be set in the automatic plaiting m/c. 2 plaiting machines of the make D. Fabric inspection m/c Counter Fabric inspection 2.e. I. No.S. Folding and Plaiting machine 1000/2500/5000 meters of plaited fabric blocks are formed as per requirement fabric passed through 4 sets of rollers cleaning inside the machine. if 30 points/100mtrs of defects are detected. Inspection machine.In 300 mtrs.

8 belts move clockwise and anti clockwise. and are usually favored in colder climates during seasonal periods. Yarn dyed corduroy is manufactured as both bottom (thick) and shirtings (thin). medium. the clothes made from corduroy are considered casual. The density of the cutting rings is 21-28 rings/blades per inch. corduroy is considered a durable cloth. The material is also used in the construction of (sport) jackets and shirts. Pressing and brushing Machine Water sprayed onto the fabric surface once entering the machine. Socially. The cut fabric is collected in plaited batches. The process flow is: Uncut Grey| | Grey uncut brushed (dry conditioned) Grey Cutting (on Cutting Machine) Inspection (Any uncut portion is again cut by razor. the size of the wale. The width of the cord is commonly referred to as "wale". manually) Brush at grey cut(Wet conditioning) Bleaching . Wide wale is more commonly found on trousers. narrow and fine wale fabrics are usually found in garments used above the waist. Two suction tubes are present which continuously sucks in the particles released while cutting. The Basic weave of the corduroy fabric consists of a chain structure in the back of the cloth and an uncut pile formation in the front. The width of the wale makes some uses more common than others.The pile are cut using a circular blade(cutter/knife) and a needle which guides the blde throough the uncut pile loop.As a fabric. Corduroy is most commonly found in the construction of trousers.

18 circular rollers cum brushers roll on the cut grey corduroy for brushing along the grain line. After the brushing the cloth is stretched through a set of 8 cylinders.Dyeing Finishing Corduroy (finish folding)    Production rate of the corduroy dept. moisture is imparted using a fine spray. !6 eccentric rollers are used for further brushing. Corduroy inspection machines are Laxmi. I. tech shivam Industries. for improved softness. pressing)2 nos Bresgres(Bigger brushing machine) Amritsar Brushing Machine  To and fro eccentric motion removes roughness further. Then the fabric is passed through a set of 8 belts moving left and right alternatively. . Vadodara) In the brushing machine.  12 steam cylinders are used for drying after steaming in the first chamber. At a temperature of 50 to 60 digree Celsius. Fabric should have perfect white color before dyeing. 5such sets of belts exist in the brushing system. PIECE DYEING AND FINISHING PROCESSES PREPARATORY PROCESSES: Preparatory processes are used: • • • To improve the wettability for dyeing(for uniform ness and depth of color) To remove the impurities. 2. is 600 to 700 metres/day 8 cutting machines are present The make of the machines are Franz Muller(Germany)(for cutting . 2 sections with 3 rollers and 2 rollers are present before the plaiting. f.

Complete removal is necessary in order to finish.Grey goods must be cleaned before they can be finished. dirt and soil. oils. SINGEING (OR GASSING) AND DESIZING If a fabric is to have a smooth finish. Machine used: OSTHOFF SENGE (GERMANY) Goller singing with impregnation unit type ‘WA’.8 bar Compensator pressure: 2. The . The method of cleaning depends upon the fiber in the fabric. Singing is accomplished by passing grey goods rapidly over gas flames. other additives. at a speed of 100 to 250 yards per minute. Fabric can be singed both face and back side of the fabric. the kind of impurities present. singeing and desizing are one of the first essential preparatory processes. usually two burners to a side. then it is passed through a chemical solution to remove the starch and other chemicals while sizing. called Desizing. dye. leaving an even surface before the fabric passes through other finishing processes. after that the fabric is washed with water to reduce the temperature. Speed of the machine: 79m/min Squeeze pressure: 0. They may contain warp sizing. Especially for achieving the uniform color in dyeing singeing is necessary because protruding fibers causes dullness.0 bar Number of machine: 1 Meter counter production: 46m Process happening: First of all when the fabric from pleating department comes for finishing it is singed and desized in this machine. and print goods effectively. and the construction of the fabric. Singing burns off lint and threads as well as all fuzz and fibers ends.

So the process is continuous. It varies from 8mbr-12mbr. squeezed out in a heavy mangle. the size analysis should be performed in order to set desizing conditions suitable for the sizes. If the fabric is burned then it sense it and the temperature is then controlled in the burner. Desizing: The purpose of a desizing process is to remove sizes that have been attached to warp yarns during a weaving process. Two sides for 1 time Burner pressure: 10. and usually allowed to lie for several hours to allow the enzyme to digest the starch with which the warp yarns were sized. Flame intensity: 10mbar or more. . therefore.fabric collected at the end of the machine in a beam is hot and wet. For fabrics like corduroy the face side is singed two times. Suction unit: In this unit the flames of the burned particles which are left on the fabric are extinguished. Burner: The intensity of the flame depends on the type of fabric. After the cotton cloth leaves the burners. There is a sensor in the machine which detects the temperature of the fabric. only its setting has to be changed for different fabrics. Prior to the desizing process. the fabric can be singed in two ways: One side for two times. There is a temperature indicator on the top which indicates the temperature. A single thread chain stitch machine is used to stitch two different fabrics. Brushing unit: After the fabric is singed it is passed through brushing unit where the burned particles are brushed out. it is pulled through a solution of an enzyme.0 mbar r more. According to roller setting and fabric type.

% • Chemicals used in Desizing: Enzymes: the pH range of the enzymes has to be maintained while desizing. It degrades the cellulose in fabric surface which in turn affect the color of the fabric. Wetting agent Stabilizer Hydrogen peroxide Acetic acid Both direct and indirect heating is given to the fabric.5-1% 0.Desizing temperature: 70 degrees Celsius.3-0. the fabric becomes more faded. There may be difference in the enzymes used. Primary impurities Pectic substance Cotton wax.01-0. .03% Secondary impurities Starch PVA Acrylic size Wax After-wax percentage 4-6% 3-5% 0. Sequestering agent: it removes the metal particles from the surface of the fabric. Cotton fabrics contain primary and secondary impurities as shown in tables below.3% 0. and the purpose of Desizing and scouring is to remove these impurities.4% 0.5% 0. But the softness of the fabric is increased by using enzymes in the chemical. cotton seed oil Protein Ash pigment Percentage 2-3% 0.2-0.5.

The rotation time is given for the enzymes to react with the fabric surface and sizing particles and remove it. especially when the yarns are to be used for fine quality cotton goods. are singed. Turbo rollers are used in this machine for efficiency in washing which creates turbulence while washing through rotating rollers. WASHING RANGE MACHINE: After rotation for 8 hours. Practically all cotton fabrics. of machine: 1 .After desizing the fabric is collected in the beam where the beam is kept rotating for 6-8 hours. Usually such yarns are fully mercerized. One vacuum suction is present in the machine which removes the singing particles from the fabric surface after reaction from enzymes for 8 hrs. except those that are to be napped. the fabric is washed with hot water usually at 95`C. Singing is basically of three types: • • • Roller singeing Plate singeing Gas singeing Singeing may also be done at the yarn stage. and singeing in this case is referred to as gassing. Some of the rollers used for washing have motors. No. Mercerized gassed yarns are sold in the trade as lisle.

This process is necessary if discoloration or stains have occurred during the previous manufacturing processes. such as the tan of linen. the fabric is thoroughly rinsed with slight amount of basic solution to avoid formulation of insoluble silicates. Synthetic fibers.Washing range for reactive dyed fabrics After washing generally wet processing is done. dry processing is done only in few cases. Bleaching is carried out near or above boiling temperature under pressure for one hour or more. destroying color by the application of oxygen. is usually carried out by means of chemicals selected according to the chemical composition of the fiber. or by reduction. Objective: • To remove the natural coloring matters and make the fabric in perfect white with minimum damage to fibers and within the shortest possible time. when they require bleaching. removing color by hydrogenation. All bleaching processes reduce the strength of the fiber. wool and other animal fibers are subjected to such acidic reducing agents as gaseous sulfur dioxide or to such mildly alkaline oxidizing agents as hydrogen peroxide. BLEACHING: Bleaching. Cotton and other cellulosic fibers are usually treated with heated alkaline hydrogen peroxide. After bleaching. Chemical bleaching is usually accomplished by oxidation. may be treated with either oxidizing or . a process of whitening fabric by removal of natural color.

depending upon their chemical composition. It is optional. The pressure and the temperature are decided according to the fabric. The temperature of the cylinders varies from 120`C to 125`C. The fabric is dried through indirect heating from the heated cylinders. . Cottons are frequently scoured and bleached by a continuous system. the temperature also depends upon the type of the fabric and it is maintained automatically and if it is not required then steam is turned off. Chemical unit (called as dip set): The fabric is passed from the chemicals for bleaching and then it goes to the steamer where the fabric is given reaction time at a temperature usually at 98`C. There are four washing chambers.reducing agents. Drying: Depending on the further processes the fabric is dried. Normally wet fabric is preferred over dried. There are total 10 cylinders and the fabric is passed through them covering there surfaces. If the fabric is heavy then the temperature is high and for light weighted fabrics it is low. Washing: After that the fabric comes down to washing unit where it is washed with simple hot water. Bleaching and Scouring CBR (CONTINUOUS BLEACHING RANGE): The wet fabric is feed. There is a camera fixed in the steamer to check for the fabric.

the NaOH concentration in the fabrics needs to be decreased sufficiently when the fabrics leave the tenter. After this process the cotton fibers will swell. untwist and their beam shaped cross section will change into round form giving smoothness to the fabric. The fabric is not dried if it is going for mercerization. It is increased by 15-25% . Change in a cross-section of a cotton fiber during a mercerization treatment. Tension is applied to the fabrics in the machine in the vertical direction with a tension cylinder. it is dried only if it is going for finishing. MERCERIZATION: The treatment of cotton fabrics or garments with a cold concentrated solution of sodium hydroxide for a minute or less is called mercerization. The processing time by the cylinder and the tenter in total is 30 to 60 seconds. and in the horizontal direction with a clip tenter. 1-5 6 7 Swelling process in an alkaline solution Removal of alkali by water substitution After drying Objectives: • To increase the strength. To prevent the fabrics from shrinking after going through the tenter. since the piling on thick fabrics in a wet state leaves creases on the fabrics. Also.The drying process depends on further processes. It is a value added process. the thick fabrics need to be dried promptly.

Stable dimention Machine type: Mercerizing range type “optima” No. of machine: 1 Speed of the machine: 40 m/min-50 m/min Production per hour: 2400 m No. pH is controlled at 4. The fabric should be either neural or acidic but not alkaline. of workers: 3 The machine runs depending on the order Mercerizing zone: Fabric is padded with about 20-25% caustic soda (NaOH solution) containing a wetting agent. Hot mercerization: Where dried fabric is used for the process. NaOH stabilizes the fabric structure. dyes and other chemical finishes. Two types of mercerization are done: Wet on wet: Where wet fabric is used. Washing zone: There are four chambers for washing or four washers. It is not dried. Stabilizing zone: In this section the width of the fabric is stabilized. The temperature of the mercerizing zone is usually maintained at 65`C. NaOH is washed here because less GLP (gram per liter) NaOH is used for washing.5 Water flow in each chamber: 1. To increase the affinity to water.01 /kg .• • • To further enhance the lusture. In the last chamber Acetic acid is dozed to neutralize the fabric before sending it to other departments.

While dyeing. Certain chemicals. PAD STEAM MACHINE: Padding dyes the fabric as it is held at full width. Usually almost all of the dye is consumed. Throughout the dyeing process. The material is run in one operation . There is no sensor in the machine to detect the fabric damage. Achieve acceptable durability of the color to further treatments in production and normal use. Then the dye-bath is prepared by diluting the concentrated dye solution with proper amount of water. the dye solution is circulated through the substrate (fabric) and/or the substrate is moved within the dye-bath. Fastness of the color material to sunlight and multiple cleaning is of prime importance. where it is kept for 30-60 minutes or more. are usually added to the dye-bath before and/or during the dyeing to assist in the proper absorption of the dyes by the fibers. Metal bearings are used in the machine.Rubber is used in the rollers. DYEING: Main objective in the dyeing of textile materials are: • • Color the fibers uniformly. The fabric is passed through a trough containing dye and then between two heavy rollers which force the dye into the cloth and squeeze out the excess. used as dyeing assistance. In a typical exhaust dyeing a concentrated solution or dispersion of the dye(s) in water is made first. Conventional process: The majority of the textile fibers are dyed by conventional batch method of dyeing referred to as ‘exhaust dyeing’. It is generally done on a continuous dye range which can accommodate a large amount of fabric. and the dye-bath is said to be exhausted. the dye is taken up slowly (exhaustion of the dye-bath) by the fibers. according to need. If the rubber is damaged then it will affect the fabric and will leave stains. The temperature is gradually raised usually to temperatures close to boiling point of water.

Water lock: From the steamer which is located on the top of the machine the fabric comes down to water lock where the fabric is cooled. On the sides of steamers there are four tanks having hydro caustic after A-Ring. The steamer is used only if the fabric is dyed from wet dyes. Hydro caustic is used to fix the color on the fabric and also for leveling. Quantity of hydro caustic: 35 gpl (grams per liter) Streamer: After that the fabric goes to the steamer which is located at a higher level where direct heating is given to the fabric. a rinser. then successively into a washer. Machine type: Goller (Germany) Number of machine: 2 One machine is for reactive dyed machine and caustic size where there is no steamer. for a reactive dyed fabric the steamer is switched off because reactive dyed fabrics are kept in rotation for 8 hours and no rotation is required for wet dyed fabrics. and a dryer. The temperature of the fabric has to be reduced so it is washed with water and other chemicals. The temperature of the steamer is usually 100`C. First of all the fabric from the beam is passed through hydro caustic where the hydro caustic is put in a tank. After wet dyeing the fabric is feed to this machine. The fabric stays in the steamer for a minute. into a heat or steam chamber to set the dye. Biancalani PRATO ITALI: used for polishing the fabric. Only steam is present in the streamer. And one machine has steamer which is for wet dyed fabric and caustic size.through a pad. Number of washers: 7 Speed: 60 m/min washer 1 Set temperature(in C ) 40 Real temperature( in C) 56 .

2 3 4 5 6 7 60 60 95 95 70 60 71 71 90 92 83 86 • • • • First and second washer has soft H2O. Also if the shade of the color is changed or a new color fabric is fed then the currently used water is discharged and new water is fed. Fourth and fifth washer contains soap for both wet and reactive dyed fabric. they are known as pulling cylinders. Out of them two cylinders were in the front. Water in the washers is changed if a new lighter shade of the fabric is used after darker shade. Water from seventh washer can be transferred to the first washer. Basically nip rollers are used to remove the excess water in the fabric. Seventh washer contains acetic acid. Third washer has peroxide for wet dyed fabric and if the fabric is dyed through reactive dye then Hexa Meta phosphate (HMP) is used. Basically the cycle which the fabric undergoes in pad steam machine is: Beam A Ring hydro caustic Steamer Final Fabric Hot Cylinders 7 Washers Then it is passed through nip rollers where it is squeezed between two rollers. For drying the fabric for further processes eighteen hot cylinders are used and through direct heating fabric is dried. . Generally water is changed after every 1 or half an hour.

Damper 120 70 5 5 VAT DYES 135 70 5 5 150 80 5 5 150 80 5 5 REACTIVE DYES 180 80 5 5 200 80 5 5 200 80 5 5 200 80 5 5 . I. Fan speed 3.R 5. I.The speed of the machine can be changed according to the fabric type like For Bottom weight fabrics: 45 m/min For shirting fabrics: 30 m/min. Fan speed 3. Temperature 2. Moist 120 50 5 5 VAT DYES 120 130 50 50 5 5 5 5 3+1 21% 0 0 5 5 REACTIVE DYES 120 130 130 0 50 50 50 0 5 5 5 5 5 5 5 5 2+0 45% REACTIVE DYES 120 130 140 70 70 80 5 5 5 5 5 5 3+2 30% VAT DYES 120 130 140 70 70 80 5 5 5 5 5 5 3+3 22% 150 80 5 5 150 80 5 5 VAT DYES 120 135 150 150 70 70 80 80 5 5 5 5 5 5 5 5 30% REACTIVE DYES 170 200 200 200 80 80 80 80 5 5 5 5 5 5 5 5 3+3 40% CORDROY(shirting ) 1. Damper 4. I. Moist BOTTOM 1. Temperature 2.R 5. Moist CORDROY(bottom) 1. Fan speed 3. Temperature 2. Temperature 2.R 5. Damper 4. Damper 4. PDR (PAD DRY RANGE) MACHINE: Parameters: POPLIN 1. Fan speed 3.

Finally the cloth is extracted and dried. It is then rotated slowly for up to 48 hours to obtain uniformity of dye application. The fabric is then washed in a mild alkaline solution to remove the liquor additives and unfixed dyes. Total volume: 586 l Heating mode: heating Temperature 1: 50 C (temperature before adding color) Temperature 2: 30 C (after adding color if more color is to be added after stirring) Mixing time: according to the dye and chemicals used CPB (cold patch batch): This technique is a variation of pad dyeing. Following parameters are considered while preparing the dye: Dissolving volume: 120 l Preparations: 1 Preparation tank: anyone from the four tanks. After the excess liquor is squeezed out by the pad rollers. Moist COLOR KITCHEN: 3+2 30% 2+2 40% In this section colors are prepared for dyeing. The tank who needs the color for the particular machine takes the color from the dissolving tank. Excess liquor is squeezed out on the mangle and the fabric is batched on rolls which . The fabric is immersed in the dye liquor at room temperature. Colors are mixed in a tank. Number of tanks: 5 One dissolving tank and four tanks for different tanks. The dye stuff and alkali are combined in one bath through which the fabric is passed.R 5. Colors are prepared by mixing the dye with water and chemicals.4. I. the roll of fabric is wrapped to prevent drying.

Only colors are imparted to the fabric. no drying of the fabrics happens. Finishing may change the appearance of the fabric. Advantages: • • • This method uses less energy and less water which results in less pollution It is as fast as the continuous range system at less capital expenditure Has the desired stability and rapid fixation while providing reliable and consistent shade.in this unit: Number of machine: 10 Number of workers: 25. Dye or color and silicate caustic are put in trough. liquid is sprayed from one thin roller over a big roller for cooling the fabric. FINISHING PROCESS: Newly constructed fabric is called greige goods or grey fabric.are then covered with plastic sheets to prevent evaporation. and its durability. The goods must pass various finishing processes to make it suitable for its intended end use. It is then subsequently washed. . a trough containing liquid. its hand (feel). two big rollers. First off all the fabric enters a unit containing a cylinder. the second plait of fabric is stitched to the end of first fabric by single needle lock stitch machine.30 per shift Monforts shrinkage range: • In a huge tank plaited fabric is kept where it is continuously fed to the machine. When one plait of fabric gets over. This machine is used for reactive dyes. its serviceability.

or tenter-frame clips. Dhall shrinking range (sunforising machine): Standard shrinkage: 4-5 % Shrinkage in bottom weights: 7% Plaited fabric • • Pre shrinkage In this machine the fabric is passed through two different rollers and steam and it is made to pass through a palmer which is like a thick blancket. which has been set for the narrowest width of the fabric. After being relaxed during dyeing and finishing. After it is passed through this the fabric gets its own shrinkage. +.• • Then the fabric enters a huge unit containing one huge cylinder. Objectives: • • drying of the fabric Evening of the fabric width . 5-6 rollers 1 cylinder 5-6 rollers STENTERING: This process is applied at various stages of finishing. grips the fabric selvedges on entering the machine.3% shrinkage is allowed. Gently but firmly. the fingers stretch the fabric to a predetermined width as is passes down the length of the tenter over live steam and subsequently heat. Chemicals which gets spread over it when it breaks it smoothes the surface. After coming out through the cylinder. Usually the fabric is wet when it is run into a tenter. which dries and sets the fabric. This processes required especially for cotton fabrics. The endless chain of mechanical fingers. all fabrics are coaxed back to normal width on a tentering frame. • • • 00 shrinkage or no shrinkage is there in the fabric after this process.

BRUCKER STENTER Mahlo: weft straightener For checking of the fabric For bow and skew Number of cameras: 4(for identifying bow and skew) There are rollers in the machine which imparts bow and skew to some fabrics. and emerge from the other. There are 10 chambers each with different temperature and the distance between two chambers is 3 meters. Moreover silicon finishing is also given simultaneously for feel improvement. . thus avoiding biased goods. The chains are equipped with clips or pins.This machine basically consists of two endless chains carried in rugged rails with a distance between them that can be adjusted. Primatex FS-100 stenter Strength of the fabric is also improved from Stentering. For example. The fabric stretched here where fan is given to cool the excess temperature while heating. Photo sensors are fixed in the machine for better rest. BRUCKER STENTER: Mahlo machine ii. Harish stenter iii. Every chamber has a fan. There are 4 heating system after Stentering. Stentering is a continuous operation in that the goods enter one end of the frame. No of machine: 3 i. which usually 90 feet (30 m) long. Pin frames are mostly used on woolens or knitted goods. which grip the selvedge of the fabric and carry it into the heated housing where a blast of hot air removes any moisture. clip frames are favored for cottons. for bottom fabric skew is necessary. The frame is equipped with devices that straighten the filling and keep it at right angles to the warp. so the rollers are set according to the amount of skew required.

Its working is equivalent to mahlo type the difference lies in hearting mode. Then effect is given after enzyme washing. TEMPERATURE IN ` C 90 98 101 113 115 107 120 106 109 109 The standard temperature for all kinds of shirting fabrics is 110 `C but for bottom weights it is kept 150 `C. Oil heating system.CHAMBERS 1st chamber 2nd chamber 3rd chamber 4th chamber 5th chamber th 6 chamber 7th chamber 8th chamber 9th chamber 10th chamber • • • • • Every chamber has a fan inside it. Cooling cylinders Moisture controller: 3 small rollers. HARISH MACHINE: • This machine is also used for Stentering. It is necessary for keeping the fabric a little wet also necessary for shrinking the fabrics. Pigment coating machine is attached to it especially for denims and only on one side. PREMATEN MACHINE: • • It has only 4 chambers Oil heating is given . It has only 5 chambers. • • • Moreover bow and skew is adjusted manually. Oils are used for heating. Here gas heating is given to the fabric instesd of oil heating in Mahlo.

Vaco: sprays moisture in the fabric. After the fabric is being processed various types of finishes are given to the fabric according to the intended end use of the fabric. Shrinkage is set here. The • • purpose of this finish is to prevent deformation of the fabric by undesirable and unintentionally introduced folds and rumples. It is basically of three types: Finishing Normal finishing Mechanical finishing Other types of finishing include: • • • Silicon finish Softener finish Wrinkle free finish: These finishes are also sometimes referred to as crease resistance finishes.MONFORT MACHINE: • • • • • Latest machine Rubber unit is present to give pressure. • Mechanical finish which includes peach finish. Chemical finish Water repellant finish: A water repellent fabric is one that will resist absorption and penetration of water for a given period of time. calendaring. raise finish Specific requirement according to the order . Two cylinders are present one big and one small for drying. So the fabric is squeezed inside. After that the fabric goes for cooling. depending upon the length of exposure and the force of water. Pamer unit: made up of woolen blanket. brush.

heat treatment is given where the fabric is passed through a vessel called trough where chemical is put. Dry-cleaning does not impair the finish. The chemical gets bonded with the structure of the fabric while it comes out this result in harsh surface of the fabric so in the final stage softening finish is given to the fabric. Calendar machine: • Gives the fabric extra shine .• • Teflon finish Soil release finish: This finish will facilitate the removal of dirt or stains from fabrics treated with a permanent press finish. and no chemical odor remains. The appearance and feel of the fabric are unchanged. • • • Vitamin E finish Aloe Vera finish Anti-microbial finish: Chemical antiseptic finishes impart a self-sterilizing quality to a fabric. And then through nip rollers which squeeze the fabric. Peach finish (Mechanical finish): Machine type: Zetma (advanced gamatex) Amerising machine: • For smoothening the surface of the machine. The speed and temperature of the machine is maintained according to the fabric type. • • • Uv cut 3X dry finish Durawhite finish etc In chemical finishing.

the process is called pressing. . It gives flammel effect. glossy. Luster increases when the degree of heat and pressure is increased. Calendaring is a final process in which heat and pressure are applied to a fabric by passing it between heated rollers. flat surface is desirable. without pressing. Calendering is not usually a permanent process.• Heating system. and employs heavy. When the fabric is rubbed with these surfaces the yarns of the fabric gets pulled outwards which gives a different feel. heated metal plates to steam and press the fabric. Raising machine: This process is given to the fabric for improving the aesthetic value of it. There are two rollers in the machine and pins are protruding out of the outer surfaces of these rollers. such as most cottons. many linens and silks. a flat surface is not desirable. smooth surface. and various man-made fabrics. Heat is applied through steam. imparting a flat. When applied to wool. Calendaring is applied to fabrics in which a smooth. In such fabrics as velveteen. and the cloth is steamed while in tension.

-Crease.2.Plastic covers are used for packing If the roll length is less than the specified length by the buyers. Processing of the order is done in small parts. Aditya. to the variations After grouping. I. fabric is classified into different categories: 1) Press( as Per buyers requirement) . Requirement sheet comes from party and name of the method includes full detailing. Pantaloon. f. The shipment time also delays with defects and quality issues. A 4 point defect is considered a 2 defect and a 2 point defect is considered as a single defect. etc are major buyers of BVM. sent to checking for packing thela packing –India and Cartons are used for corduroy . tight selvedge. A sample from each roll is taken for shade sorting and grouping The reasons for the major defects (ex. According to size. In 100 mtrs 35 points are allowed. stain) are analysed and a backup report is sent to the concerned department. Acc. Randomly reinspection is done for every 5-10% of the lot and reports are made every day.. FINISH FOLDING 4 point inspection happens in randomly selected samples of the fabric rolls. 4 point defects not more than 4 are allowed in 100metres. there are possibilities of rejection or discount. The packing and transferring data is fed simultaneously into the computer as the processes occur. Zodiac.

  50. 4 chain functions are present in the finish folding department: 1) Inspection 2) Feed back to concerned departments 3) Packing 4) Sampling . ITI trainees are 15 and Unskilled workers are 20. Defects after finishing Dyeing :1) color stain 2) discharge daghi 3) dropping 4) dyed dhabba 5) Dyed tapki daghi 6) Dyed daghi 7) Dyeing crease 8) Dyeingpatches 9) Dyeing patta 10) Dyeing stopmark .2) Press Short length(If length is less than required) 3) Seconds(Continuous) 4) Good cut(Multiples of 1.Sent to aspiring customers if they like the sample.000 metres of fabric are inspected per day. the bulk is ordered.000 mtrs are packed per day No. It is also used for children’s wear. of workers are 78. 50.3. etcmtrs) 5) Fent(45cm to 90 cmlength) 6) Dex(23to 44cm length) 7) <20cm long Chiwndy cleaning cloth 44 varities of type 7 are present.

11) Dyeing other 12) Group 13) Selvedge patta 14) Stitch impression 15) Watermark Bleaching: 1) Abrasion 2) Bleaching other 3) Crease 4) Hairiness 5) Backup Report:-1) hairiness 2) Hole 3) Tappi Daghi Finishing: 1) Abrasion 2) Blanket Impression 3) Bowing 4) Finishing others 5) Finish crease 6) Finish variation 7) Holes 8) Mild stain 9) Selvedge torn 10) Tapki daghi 11) Width variation .

washing properties.  The quality of fabric is checked at grey and finished stages under 4-point grading system. Neps. Chemicals and Dyes Stage-II: Quality control of the Process through surveillance at each manufacturing stage Stage III: Quality control of Final Products Fully computerized & well-equipped in-house laboratory ensures high quality parameters from fiber to finished fabric including all other inputs. Yarns. Grey Fabrics.2.  Well-equipped physical and chemical testing laboratory to check all incoming materials and finished products for their strength and colour fastness. shrinkage and shading. Finally folding and packing department has roll to roll inspection facilities to ensure fault-free longer length quality fabric prior to its delivery to customers. g. Hariness. I. etc.  Moisture meter Aquadon: Portable digital moisture meter %of moisture is measured  USTER TESTER 4 SX has 3sensors: 1) Sensor OH for Hairiness: Uneveness %. as per international norms. SQC QUALITY STANDARDS Stage-I: Quality control of the Input Materials such as Fiber. Relative count. Thin% thick%. Standard deduction(variation) of hairiness. Mass Diagram(cardiogram) 2) Sensor CS: Weighs  .

z&s direction For twist Checking. long length(Total 23 in number) Single yarn strength. TESTING INSTRUMENT FIBRE TESTING.Movement of rolls. coimbatore Star electronics and engineering. Uster UT4-SX and Uster Classimat CMT-3. Coimbatore Ten lab industries Ahmedabad Kamal metal Industries Ahmedabad Good Brand and Co. micronnaire. color. Ltd. 6 spindles KMI computerized electronic tensile tester Af coset electronic count balance model FX-300 Yarn appearance examination machine Kmi electronic twist tester Double yarn twist tester Libra electronic digital weighting balance model 8801M MANUFACTURER Zell wager-uster Switzerland Statex eng. Mattler Kamal metal Industries Ahmedabad Straten eng. product and services.etc Unevenness of sliver Roving and yarn(frequently faulty) Seldom occurring faults like short length. (p) ltd.z&s direction For weight purposes High speed winder machine of Switzerland . Baroda Zell wager-uster Switzerland Zell wager-uster P.   Follows Total Quality Management.3) Conveyer: . ltd England Libra industries Bombay APPLICATION All cotton properties like length. Labourtex Padder. Fully computerized and well equipped in house laboratory ensures high quality parameters from fiber to finished fabric including all other inputs. Data Colour Matching system SF 600.  The Equipment include Uster Hvi 900 Classic. technology. trash Trash% Moisture %of Bale cotton yarn packages. People.S. strength. Ahiba Spectra Dye with Auto dispersing system.S. Uster tester-4(UT-43x) With hairiness module Uster classimat-3 with P. fabric tensile strength Count Checking For ASTM grade(yarn Appearance Board) For twist Checking.Uster HVI-900 and bias software MODEL Cotton trash analyzer Moisture meter Yarn Testing. dryer and pad steam.

Fabric testing count checking instrument Good Brand and Co. ltd England Fabric Count Checking KMI computerized electronic tensile tester .

2.   To arrange production activities as per the requirement of marketing department To plan overtime work in various department.  Monitoring and measurement of processes and product in his area and implementing appropriate corrective action to achieve planned results. Note: 1. Monitoring progress against quality objectives and continual improvement and projects in consultation. The other functions of the PPC includes receiving inspection of all purchased products. whenever necessary in consultation with unit head   Production scheduling and working out raw material requirements. with hold in process and finished items not meeting the requirement and reporting to management. 2. in process and final inspection and testing. reviewing and disposition of nonconforming products during in process and final stages. h PRODUCTION PLANNING AND CONTROL Overall in charge of production activities of all the departments. 3. total operation of production activities. quality of finished products. spare parts etc. Process control and associated activities in all production department/sections. compilation and maintaining the result of defect analysis every month as applied to each manufacturing process. corduroy More Delay in production occurs in rainy and summer seasons Major role in competition with other mills Main strengths of the industry is considered. judicious use of raw materials. I. waste reduction. dobby looms and .

2 19. 6.783 10. currently.38.030 2.5 19.26.4 20. spinning produces 56.80.045 1. satisfaction.231 .17.245 10.15.25.580 11.00.637 2.02.19.29.9 17.695 10.885 10.7 17.798 2.145 1. maintenance. 80% of finishing department is utitlised 10 days in a production season is provided for sampling WEAVING PRODUCTION REPORT 2005 (AUGUST) DATE 1 JAN.5 SIZING (Total meters/ month) 11. 2 SQC persons are involved between the PPC department and SQC.43.71.160 9.99.65.005 9.630 9.4 19.34.8 18.78.453 12.715 11. QC.520 2.60.48.74.615 10. delivery. sales) happens with an Internal Audit.280 9. Monitoring of Process (marketing.54. 7.445 2.25 20. 2 FEB. production.56 17.84.500 11.3 17.738 10.925 10.26.240 10.36.42.58.057 1.086 9.719 LOOM PRODUCTION REPORT: MONTH 1 2 3 4 5 6 7 8 9 PRODUCTION/ MONTH (in meters) 9.366 10.83.82. 8.805 (Beams/day) 18.16.39. purchasing/ stores.42.719 8.000 mtrs per day According to the Customer complaints. 4 APR. 5.14.681 1. because complete coordination is required.930 2.9 16. 5 MAY 6 JUNE 7 JULY 8 AUG 9 SEP 10 OCT 11NOV 12 DEC DIRECT WARPING SECTIONAL WARPING 1.965 1.4. 3 MAR.02.00.

Equalization: It’s a primary treatment. Building maintenance. I. Supernant tank Clarifier Tank . Clarifier tank: Further separation of lighter solids. 3. directorate of boiler and electrical inspectorate. Aeration tank: In this oxidation and removal of odors takes place.00. both internal and external. Reaction Tank: It’s a primary treatment. Maintenance of telephones. Piclic acid is used for slug formation. processing plans and utilities. overall in charge of electric maintenance. i EFFLUENT TREATMENT PLANT: 1. caustic for neutralization of the water. 5. h ENGINEERING The engineering department takes control over the overall maintenance of machineries. Magna Block: Slug and solids present are settled and precipitated. I. Supernant Tank: Complete separation of water 6. Water coming from dyeing section is washed. Liaison work with Pollution Control Board. It is then equalized or neutralized. filter press compresses the slug 8. Overall supervision of security department. 2.10 11 12 10. slug slump collection of solid slug 7.596 _______ _______ 2. 4. 2.

2. LABORATORY A laboratory in the manufacturing industry plays an important role in the production standards of the company. I. j. Chemical processing done at a small scale sampling 3 main activities in lab: 1) Fabric dyeing: Detects absorbency 2) Yarn dyeing 3) Before absorbency and after shrinkage and fastness testing Lab Dyeing has two steps: . A sample production is carried out as per the proposed standards and variations required are analysed as per the practicality.

If shade variation comes it is sent back to dyeing. . Manually. 2. Equipments for testing state of the fabric at the start and the end of the fabric 1) Wagner hot press. 2) Digi washer paramount 3) Washing machines: whirlpool 4) Tumble dryer 5) Oven 6) Tear tester: paramount 7) GSM cutter 8) Crock meter 9) PH meter 10) Microwave oven 11) Hank Preparation machine 12) Labortex padding machine 13) Labortex drying machine 14) Labortex pad steam 15) Data color dispenser: Combined lab dispenser and solution maker and is used for yarn dyeing. IPC department. A Spectrometer scans the color and calculates the spectral value. It is only used for yarn dyeing. values are fed into the computer for the dye recipe and the recipe is combined automatically by the dispenser. 16) Data color CCM-SF600 plus 17) Crease recovery tester Spectra photometer XW-2000 infrared sampling machine: Spectral value of the shade is determined.1. Lab dyeing before order for preparation before order and is matched with lab dip after drying over original fabric pieces. Dye lab and process control lab consists of the following equipments. the concentration not enough for fabric dyeing. RF dyeing: Ready for dyeing H2O2 improves whiteness. Lab to bulk correlation is done after RFD and finishing.

Miele Washing machines 9) IFB Tumble dryer 10) COD Assembly Dark Room GTI mini matcher Dye sampling is same for fabric and yarn. . Cold pad batch for reactive dyes 2. washed and developed 1. Steam pad dry for VAT dyes and light shades 3. The prepared sample is wrapped in paper. Guhaust method: requires high temperature.Dyeing Lab Equipment 1) Color computer matching SF-600 plus(DCI) 2) Ahiba Spectra dye(DCI) 3) DCI combine lab dispenser and solution maker(AUTOLAB YO) 4) Labortex padding mangle 5) Labortex mini dryer 6) Labortex pad steam range 7) Gretage macbeth view box 8) Judge ii view box Process Control Lab Equipment 1) Digiwash laundrometer 2) Tearing strength tester 3) Crock meter 4) GSM cutter 5) AATCC shrinkage ruler 6) Digital Ph meter 7) Wrinkle recovery tester 8) IFB.

Different pieces of fabric are stitched together so that all can be processed at the same time. Dye + caustic +silicate: This recipe is added to the trough of padding mangle machine. then dried in the oven. sample fabric inserted into it. Paramount Tearing strength tester is also present Spectra photometer XW-2000 Infrared sampling machine Data color dispenser ADMINISTRATION .YARN DYEING MACHINE X-W-2000 Infra red sample dyeing machine Fabric is dyed in a separate lab room.

ensuring availability of resources and communicating to the organization the importance of meeting customer as well as statutory and regulatory requirement. RETAIL STORE DJ&C is a major brand of direct buyers of BVM. approves quality. II. UPPERLOOK is an apparel brand of BVM. a.2. GENERAL ADMINISTRATION MANAGING DIRECTOR: Exercises Overall control of all company activities. b. HEAD OF THE DEPARTMENTS: . periodic review of the quality management system. 2. ensures that quality policy and quality objectives are established. II. It has a retail outlet for its fabric in the company premises.

HUMAN RESOURCE MANAGER Responsible for Consolidating training requirements and preparing training calendar based on approved training needs. II. coordinating management reviews. implementation and maintenance of quality management system. Induction training for new entrants. arranging periodical internal audits. reporting on the performance and any need for improvement. 2. Safety and welfare activities. SECOND LEVEL MANAGERS Ensuring development. approval of operational procedures applicable exclusively to the unit. participation in the committee for review and disposition of nonconforming product during various processing stages. (and their revisions. ensuring promotion of awareness of customer requirements through out the organization. overall responsibility for smooth functioning of all departments/sections and other related functions of the unit. Monitoring progress against quality objectives and continual improvement projects consolation with concerned HODs /Section Heads and MR.. also periodic review of progress against established objectives and continual improvement projects. maintaining records of management reviews etc. issue and control of the quality manual.Responsible for setting quality objectives in their areas and obtaining MD’s approval. day to day functions of the unit. THIRD LEVEL MANAGERS Executing various decisions taken by the board and the management. quality system procedures. Maintenance of training records. HUMAN RESOURCE DEPARTMENT • Hire The Best Add Value to Retain . c. resolving and taking appropriate actions on matters of conflicting nature on quality system. Organizing requisite training programs inline with training calendar.

There is a peaceful coexistence amongst the employees. STAFF AND WORKERS Department Spinning Weaving Processing -Yarn dyeing -Bleaching -Dyeing Engineering Lab SQC Sales. BVM workers union for the welfare and representation of the workers.• • Empower to Build Mutual Trust and Opportunity to Grow Induction to BVM value system training imparts Behavior. workers and management. Knowledge and Skill. Culture. Marketing. grey & finish General -finance -accounts 44 26 20 57 78 104 10 0 144 41 19 63 40 Staff 414 862 233 Workers . There exists a union.

. d.. legal matters. Submissions of periodical returns to various Govt. Attend legal matters/court cases i. court cases. liaison works with labor department. Conducting domestic enquiries.Settlement of terminal benefits of retired/VRS employees and those died in service. grievances etc. To supervise the functions of Time Office as well as establishment. MARKETING . civil courts and labor departments. PERSONNEL Overall in charge of administration and personnel department. disciplinary matters etc. labor court. industrial tribunal.2.. PF and other offices. Maintenance of various files in connection with official. II. discipline. initiating disciplinary proceedings against workers/staff. Looking after the duties of office administration.e. Discussing with trade union of factory with regard to production. ESI. inspector of factories. Recruitment and training. departments.

Mr. dealers. Kaushik Pandey is the HOD of marketing . agents. III.2. a. entering into requisite agreements with dealers. etc and present data in the monthly production review meetings  Maintain proceedings of monthly production review meeting and intimate production targets to all concerned  Finalization of sale prices in consultation with management and implements sales promotion schemes approved by managing director  Maintain communication with dealers on progress against indents and coordinating with dealers about the sales activities. MARKETING DEPARTMENT Responsible for overall in charge of marketing activities. franchisees and monitoring their performance  Identifying new products to be produced and also requirements of corporate customers  Consolidate monthly indents from showrooms.

2. III. b. DESPATCH DEPARTMENT
The dispatch department is concerned with the dispatch of the ordered goods and its accounting. The delivery details, the mode and the package details are recorded at this department. The following are the norms, conditions and functions followed by the dispatch department: 1) Carrying forward ex- mill deliveries. 2) Charging of Excise duty and all other government taxes to the customers. 3) Transport, bank commission, Insurance and any other charges are denoted to the buyers to be paid by them 4) If Hundi will be returned, interest will be charged at 30% per annum from the date of hundi and they can even propose to the managing system to cancel all pending contracts of the buyers 5) Settlement of claim of fabric at fabric stage only 6) Verifying the count, pick-reed variation is as per T/C standard 7) Notification to the buyers about delay of delivery. 8) Charging of interest on the goods not taken within 1o days, at 30% per annum.

2. III. c. DESIGN DEPARTMENT
Deskloom The yarn sample which is developed in the lab, is used for development of small swatches using the desk loom which in turn is send to the buyer. If the sample is accepted by the buyer, they produce the bulk order which the PPC manipulates. There exists another sequence of order formation: The buyer provides the design/ weave pattern which is processed by the design section and provided to the deskloom for development, and the same process occurs Either way, the deskloom section plays a very important role in the development of fabric and order of it.   The design of the sample is forwarded from the design section. Sizing machine(small, winding and size spreading ) is present for prearation of the yarn for weaving.  Small samples of the size 6*16 inch are produced woven. Currently, 5 desk hand looms are present which produce 15 samples per day.  Total number workers who work in the design department are 9 to 10.

Design 3 designers and 4 trainees are present in this section who develop the design and the weave structure of the fabric as per buyer specifications or innovative fashion design release. They use CAD for development of the designs: The designs once developed are send to the marketing department who interact with the target customers and sent the report to the PPC who in turn notify the design department about the changes and to develop the final weave structure.   The software use for design development is: TEXTRONICS Dobby designs are developed using individual colors for the warp and weft and providing the intersection points as the dobby design.  A color card is used for detection of the color match.

Denting can also be done in the software(Since creel capacity is 480, the designs are done accordingly).

Scanned picture can be converted into a pixilated digital image which coverts into a jacquard design, the repeat size specified

PROCUREMENT

2. IV. a. PURCHASE
Carries forward purchase activities since from the purchase requisition stage till settlement of payment to the supplier and is responsible for stores activities since from receipts stage to till accounting departments as per their requirement against indents. Service contracts like transportation, calibration, maintenance, annual maintenance contract for computers, scales etc. and looking after day to day correspondence pertaining to stores and purchase department, pursuance of proposal which we sent to SPC for approval.       Approved and completed orders are checked. Vendors are selected from ASL (Approved Select List) Due date for submission of tender is mentioned. Tenders are opened in front of committee members. Comparative statements are prepared. Intenders and user departments are consulted for suitability of the items.

then signature is obtained of inspecting authorities. Maintenance of stock ledger.  Material inspection (MI) and Inspection Report (IR) are prepared. Stock entry separately for accepted/rejected items. STORES Responsible for Receipt and inspection of finished products. SPO (Store Purchase Officer) and UH (Unit . Store department is informed for arrangement of inspections soon after the receipt of items/materials.     2. PO (Purchase Order) is issued after the approval by JPC to the successful tender/supplier. Rejected items are arranged. Issue/receipt of materials:  Incoming items are checked with reference to purchase order details.  The accepted materials are shifted to the reserved/designated locations. Suppliers are pursued for timely supplies. Inspections of rejected materials for fixing discounts and declaring as seconds. IV. Items are kept in designated place marked as ‘A waiting’ inspections. If items are accepted.  Inspection of items by the Quality Control/user department is arranged. b. Separate storage of accepted/rejected items as per the conditions laid down in the procedure.   Test certificate (TC)/ Test Report (TR) is checked.   Proposal sheets are prepared with justifications/recommendations. department heads. then relevant document is sent to accounts department for payment to the supplier as per payment terms. Proposal is placed before JPC (Junior Purchase Consultant) for approval.

 Receipt and pending order quantity are prepared. wastage of materials. Material against complaint indents are issued after obtaining receivers signature. spoiling. consumptions of materials accounts are maintained in prescribed documents/ledgers/registers. In case of rejection. (such as 40s etc. 4.  The sourceing is done through agents and direct deals with trading companies such as vishal trading company. IV. The count of cotton will also depends on the type of fabric order and market conditions. issues.) are consumed. purchase department is informed for rectification and follow up).  2. Receipts. Purchase statements are cashed 2. On an average the cotton fibre consumption is 50 bales per day. Store accounting:  Monthly statements of issues. which is shanker quality. and life of materials.    Entries are made in GIR (Goods Inward Register)..Head).  3. PC (purchase Credit note) is prepared. . Items are checked once in a month. c. Handling: Proper handlings equipments are used ton avoid damage. Storage and Preservation:  Storage and preservation are arranged depending upon type.  A major amount of cotton is sourced from Gujarat (based at ahmedabad and manavadar). Various counts of cotton. quality. consumptions are prepared and sent to Accounts. COTTON DEPARTMENT 100% of the Raw material cotton/ cotton yarn fiber is composite.

. 15-25 kg/day 8. Hard waste perday VAT 4% is added in the costing of the waste . Cotton yarn produced is 125 metric tonne per month(28.    2. PCH qualities are 50s count and are imported from USA. Cool zool 12 rs(50kg per day) 5. Oiling waste 11. MCV 5. etc. 28 2. Gold / silver coated yarn is also bought. Comber waste mixed count 35 rs/kg 4.(12. Colored airjet waste 9. Vardhman. The superior count of yarn bought is 2/80s and 2/100s counts.000 spindles)(upto march 2006) but from march 2006 the spinning mill has been expanded. Ahmedabad cotton waste merchant association dalal within 15 days of tender If the Quantity of waste more the waste is tendered at the rate of 1000 kg/ day(at an average rate of 35 rs/kg) 1. T he deficient yarn quantity is provided by a supplier range namely arun textile. Trumat cuttling rs. d.000 bales were imported recently. Dropping 9-10rs/kg 200kg/day 7. 50KG/DAY 6. The consumption of yarn in april was 200 metric tonne. Fly17-18rs/kg. Luma file 38 rs/ kg 3. IV. Raja palyam mills. Nahar. kkp spinning. WASTE DEPARTMENT The waste generated is tender every month. Cleaning wasters 13/KG. White airjet 10. Soft waste 12. in salem.

59 5.94 WINDNG WASTE 1.09 5.35 1. The waste sales produce around 5-6 crores Rs per year.28 2.41 4.99 4.21 1.96 5.44 2.Ex: Sundar waste.30 1.82 3. WASTE PRODUCTION REPORT: MONTH TOTAL WEAVING 1 2 3 4 5 6 7 8 9 10 11 WASTE 5.12 .60 5.09 1.09 1.12 1.15 1.04 1.04 2.64 2.86 2.39 5.52 5.94 2.39 1. Niranjan waste are the waste buying agents.34 2.9 WEAVING + SIZING WASTE 2.99 5.1 3.3 2.68 LOOMSHED WASTE 3.41 3.63 3.47 6.40 5.32 1.01 5.62 3.10 1.06 3.38 3.26 3.21 1.

the only such association within the industry with a reputed international textile company.44 crore in 2004-05. accounting for 27% of the Company's turnover of which domestic turn over has increased by 62% and production has been grown by 21% over the previous year. V.p.188. The Company serviced brand-enhancing customers like . ACCOUNTS FINANCIAL EXPANSION STATUS The Textile division increased its turnover by 30% to Rs. The previous year was the first full year of working of the expanded capacity of 18 mn metres per annum and the business arrangement with Canclini Tessile S.FINANCE 2.A.61 crores which is grown by 32% over the previous year. Net revenue for the year 04-05 is Rs.194.

Liaison with banks. MIS and other necessary information. Maintenance of accounts relating to corporation. Collecting information from units regarding for cash flow. Participation in committee for evaluation and selection of new suppliers. AG audits/statutory auditors. Value addition: Introduction of value-added products (structured fabrics with higher thread counts in the shirting segment. Preparation of balance sheet. Scrutiny of wages bill and other bills connected to business transactions. PF and ESI office etc .Van Heusen. Allen Solly. Prompt settlement of supplier bill. yarn-dyed corduroy shirting and Pima cotton yarn-based corduroy fabric in the corduroy segment). Peter England. Park Avenue and Pantaloons with larger volumes. Louis Phillip.

15021. There were no Investors' complaints pending as on 01-01-06. Complaints received and disposed off during the quarter were 16 each and no .67 32371. In lacs) .37 4734.34% 66084125 66.04 51053.06 668.39 70913.SINTEX INDUSTRIES LIMITED REGD. 2006 to 31st March.5366.19. AUDITED FINANCIAL RESULTS FOR THE FINANCIAL YEAR ENDED 31st MARCH 2006 (Rs.up Equity Share Capital (face value of Rs. Kalol (North GUJARAT) .each (Rs.46 491.0.58 20077.81 2427.17 42973. hence all related references for the previous year periods have been restated for the sake of comparability.14 7.04 4.23 (1873.has been sub-divided in to Five Eqity Shares of Rs.Near Seven Garnala.07 Year Ended on 31/03/2006 (Audited) [4] 85342.50 lacs) have been converted into 20.44 13 Earning per share of Rs.62 33401.15 1597.FBT) .) -Basic EPS -Diluted EPS 14 Aggregate of Non-Promoter Shareholding .20 9.29 3062.47 2909.47 lacs and for repayments of loans of Rs.81 Quarter Ended on 31/03/05 [3] 24186.10 Notes: 1 The above Financial Results were reviewed by the Audit Committee and were thereafter taken on record by the Board of Directors at its meeting held on April 25.34% 66084125 66.616 equity shares upto 24th April. 2006.56 1053.13 633. Rs.65 1973.26 2825.28 (152.16500 lacs on account of adjustment of Brand Value.24) 17310.000 equity shares were allotted during the period 23rd March.75.91) 5118.50 1290. Further.3070.38 9204.95 88321.29 4086.77 4859.51 5012.subject to approval of shareholders.08 1314. Subsequent to 31st March.56.56.Percentage of Shareholding 61284125 66.67 (2. OFFICE :.93 7.55.02 per share.000 warrants out of 31.10/.51 6781.58 54553.51) 801.96 3.03 304. FCCBs aggregating to US$ 8.7) 5118.17 378. 3 Equity Share of Rs.94 2957.98% 61284125 66.65 (185.Number of Shares .30 1738.02 1847.04 12.77 27004.94 2082.58 2096.5 million (Rs.000 remaining warrants in respect of the said issue are entitled to apply for five equity shares per warrant at any time up to 31st July.06 1 2 3 4 Net Sales / Income from Operations Other Income Total Income Total Expenditure (a) (Increase)/ Decrease in Stock in Trade (b) Consumption of Raw Material (c) Consumption of Stores & Spare parts (d) Staff Cost (e) Other Expenditure Interest Depreciation Profit (+) / Loss (-) Before Tax Provision for Taxation .06 832.31 758.Current Tax (Incl. 2 The Board of Directors have recommended dividend @ 44 % i.76 lacs from proceeds of preferential allotment of equity shares/ warrants up to 31.25) 41486.44 lacs 7 8 Reserve is reduced by Rs.88 per equity share for the year 2005-06.95 8. 2006 5 During the year the Company issued USD 50 million Zero Coupon Foreign Currency Convertible Bonds due 2010.69 2485. The bonds are convertible into 1.98% 61284125 66.39 1734.02 66924.12 6695.34% 5.32 3.66) 4083. 4 62.Deferred Tax 5 6 7 8 1886.66) 9201.53 826.34 Quarter Ended on 31/3/06 [2] 31804.94 602.63 5390.67 (2.45 9739.575 shares at any time upto 14th September. 2 each) See Note :3 Reserve and Surplus (Excluding Revaluation Reserves ) (See Note .03.32 lacs including ongoing capital expenditure of Rs.97 (309. The proceeds have been utilised for capital expenditure of Rs.32.28 1847. 6 The Company has received Rs. 2006 consequent to exercise of 12.85.2/.33 54919.29 1381.54) 30975.000 warrants issued in 2004-05 and outstanding on 31/03/05 at Rs.02 24198.03 7061.382 721.63 2503.each. Particulars Nine Months Ended on 31/12/2005 [1] 53538.75 835.e.50 847.51 2233.68 1847.49 11430.39 378.55 2124.06 19865.44 2978.02 3055.15 Year Ended on 31/03/2005 (Audited) [5] 65871.85 1032. 2006.05 9 Profit After Tax & Before Prior Period Items Excess/(Short) Provision of Taxation earlier 10 11 12 Year(Net) Profit After Tax Paid .37 1973. 2006.9655.40 3.30.93 3908.89 3742.54 5.72 1622.62 43908. the holders of 19.2/.3731.65 (2112.00 7025.2006.65 5530. 2010.26 3068.

67 48871.05 .72 Deferred Tax Liability (Net) (See Note 13-Schedule 20 ) 5703.26 18.12 - Loan Funds : Secured Loans Unsecured Loans 3 4 33822. in lacs BALANCE SHEET AS AT 31ST MARCH 2005 SOURCES OF FUNDS: Schedules Rupees Rupees 2004 Rupees Shareholders' Funds: Share Capital Reserves & Surplus 1 2 1847.Rs.17 33742.44 50719.92 29822.11 1456.23 35.Schedule 20) 1392.18 Share Warrants-Fully Convertible (See Note 6.56 4413.01 35198.66 33840.49 29857.

71 69468.48 Net Block Capital Work in Progress 49344.95 .89 TOTAL Significant Accounting Policies Notes forming part of Accounts and Contingent LIabilites 20 19 91655.65 1922.68 14811.38 13604.33 62951.75 7 8 9 10 10684.67 11572.88 Less: Current Liabilites & Provisions Net Current Assets 11 15780.47 52306.62 14926.95 Fixed Assets: Gross Block Less: Depreciation 5 66942.16 37772.75 7545.34 5686.76 24639.50 Miscellaneous Expenditure (To the extent not written off or adjusted) 12 610.44 17598.52 4445.71 69468.10 11035.11 2962.14 1833.58 48025.65 21992.20 49858.28 319.80 3598.TOTAL APPLICATION OF FUNDS 91655. Loans & Advances: Inventories Sundry Debtors Cash & Bank Balances Loans & Advances 6 16746.39 7831.22 Investments: Current Assets.

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Miscellaneous sales and Export Incentive.46 61619.55 14875. the differing risks and returns. Prefab.Segment Wise Revenue. rent.94 221.91 8777.) . 2 Segment revenue in each of the above business segments primarily includes sales service charges.86 23360. Results and Capital Employed For Financial Year ended 31st March 2006. etc. consistency and integrity of the data entered and updated by it.41 2909.06 3062.96 20775. Segments have been identified and reported taking into account the nature of products and services.55 14875.42 3664.13 602.F.51 66735.26 11430.88 5561.16 5692.32 2485.21 2563.00 54154. profit on sale of Fixed Assets (net).Segment Liabilities) : a) Textile b) Plastics c) Others Total 17482. Name of the compliance officer : Mr.00 0.87 37246.71 9546.15 3090.51 54. Sections. Doors.87 37246.00 0.39 2227.41 7867.44 Quarter Ended on 31/03/06 Quarter Ended on 31/03/05 Year Ended on 31/03/2006 (Audited) Year Ended on 31/03/2005 (Audited) 0. Particulars Nine Months Ended on 31/12/2005 1 Segment Revenue a) Textile b) Plastics c) Un allocated Total Less: Inter Segment Revenue Total Revenue 2 Segment Result Profit/Loss (before tax and interest from each segment) a) Textile b) Plastics c) Un allocated Total Less : Interest Total Profit before Tax: 3 Capital Employed (Segment Assets . No.33 1603. (Rs.66 6507. 3 Figures for the previous year/quarter have been re-grouped / rearranged wherever necessary.43 31901. L.23 115.40 86056.382 721 .02 24128.81 1315.64 141.28 24086.66 24128. In lacs) Sr. SEBI.39 307.40 12175.35 7307. Rathod C.12 14969. fair and accurate (except in respect of errors in or omissions from documents filed electronically that result solely from electronic transmission errors beyond our control and in respect of which we take corrective action as soon as it is reasonably practicable after becoming aware of the error or the omission).40 24932.03 51230.78 36306.06 5268.03 51230. the Stock Exchanges or the NIC do not take any responsibility for the accuracy.79 14339.76 57814.35 2598.M. and the internal financial reporting systems.O & Company Secretary Sintex Industries Limited Kalol (N.32 121. the organization structure.Fabric and Yarn Plastic .26 7061.79 2549.22 6148.44 Notes: 1 The Company is organized into two main business segments.34 1359.78 60786.16 5692.56 826.06 17625.00 24479. Disclaimer clause: The information furnished above is certified by Sintex Industries Limited to be true.88 959.07 3908.40 12175.63 54154. Windows.29 47497.51 6695.01 66735.06 86056.35 31901.00 0.G.85 2082.12 14969. validity.76 57814.79 24086.87 17566.01 19096.75 4734.17 337.00 0. namely: Textile .Water Tanks.

06 25437.66 7061.11 12923.00 739.83 58077.10 12923.17 1000.00 995.35 4921.51) 3366.Equity Shares Tax on Dividend General Reserve Capital Redemption Reserve Balance carried to Balance Sheet TOTAL 0.07 96.50 1290.96 2623.09 EXPENDITURE: Raw Materials consumed Employees' Emoluments Manufacturing & other expenses Interest and finance charges Depreciation 15 16 17 18 31814.14 22.54 436.81 65871.13 7302.74 APPROPRIATIONS: Interim Dividend .71 35.39 52969.66 Earnings per share ( Refer Note 15 of Schedule 20 ) Basic Diluted Significant Accounting Policies 19 35.22 16834.85 72.51 2049.00 11088.00 7533.49 22.60 1000.68 2263.78 126.64 (15.10 10668.23 54727.00 0.25 68797.53 10668.54 5108.04 2646.68 7533.56 1053.72 3055.Preference Shares Proposed Dividend .01 PROFIT AFTER TAX & BEFORE PRIOR PERIOD ITEMS Excess/(Short) provision of taxation of earlier years (Net) PROFIT AFTER TAX Balance brought forward from previous year Profit available for Appropriations 5012.02 1873. in lacs PROFIT & LOSS ACCOUNT FOR THE YEAR ENDED 31 ST MARCH 2005 INCOME: Schedules Rupees Rupees 2004 Rupees Gross Sales Less: Excise duty & Sales Tax recovered on Sales Net Sales Other Income Increase in stock of Finished and Process stock 13 14 71516.14 .26 2825.77 Profit before Taxes Provision for Taxation Current Tax Deferred Tax 758.76 2485.03 61736.00 1500.37 5644.Rs.63 5390.45 49805.10 3381.71 882.15 875.00 21556.78 545.10 1540.05 378.

It is fully geared to offer international quality textile products. CONCLUSION Plant Capacities Overall capacity22 million meters per annum Can deliver finished widths up to 63 inch Plant specifically designed for varied product mix ( 115 GSM to 450 GSM) Can handle 100% Cotton as blended fabric Equipped to provide specialized finishes Testing and QC Lab equipped to satisfy most discerning customers On line quality checking system TECHNOLOGY A tradition of continuous modernization and up-gradation of technology has enabled BVM in becoming globally competitive. manufactured to the latest trends and styles. .Notes forming part of Accounts and Contingent Liabilities 20 3.

Criteria of selecting technology in BVM are: . Electronic Yarn Clearers and other automatic devices.Economizing on water. energy and salt utilization. eco friendly. (Year of Installation . LoomShed 38 Air-jet and 123 Rapier looms from PICANOL. on time and every time. Goller Desizing. bleaching and mercerizing machines.Maximum possible accuracy first time. higher productivity and shorter lead times. .friendly technology . All the machines are equipped with Automatic Splicing. Processing Machineries Selected latest state of the art. 72 more Omni Air Jet looms with the capacity of producing fault-free cloth.Machineries and Capabilities: Winding Section Murata & Schlafhorst.Eco. washing. High level of automation and on-line on-site process control gives high degree of consistency and reproductivity. open-width continuous process system ensuring consistent whiteness / shade across and along the fabric. Spinning Division : 30000 spindles Trumac Blow Room (2000)DK780 Cards (2000) RSB1 Draw Frame from Rieter (1999) LK 250 Comber (2002) LF 1400 Speed Frames Textool Ring Frame (2000) TFO Vijay laxmi (2000) . It consists of pretreatment machineries like the Osthoff Singeing with eco friendly dust free Vibra plus cleaning system. Automatic 238 and 338 models.1999) The existing Rapier looms are capable of producing checks of 4 to 8 colors in weft and are equipped with dobbies which can produce designs up to 22 shafts.

Bruckner and Goller are present.BRUCKNER Cold-pad batch.Goller .dryer ( 1998 ) An excellent management system provides the backbone to the development process .EFFECTA Washer.OPTIMA Chainless Mercerize-Goller Fabric Dyeing Fully computerized German machineries from the Kusters.Goller .Goller desize .Continuous Bleaching .MONFORTS Stenter. All continuous machines with automatic colour kitchens and all level micro processor controls are installed for better productivity and quality in shorter lead time. Dyeing machineries (year of installation) Finishing machineries of the instition.Pretreatment Machineries .KUESTERS ( 2001 ) Pad-dry . Shrinking range .BRUECKNER ( 2001 ) Pad-steam-Goller ( 2001 ) FONG's / STAFFI Yarn Dyeing Machines ( 1998 ) RF.OSTHOFF singing .

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