REPORT OF TEXTILE INTERNSHIP

AT
ALOK INDUSTRIES LTD.
Submitted By:
Ashutosh Vatsa
Kr Prame!dra Si!ha
Pa!"a# Patha"
Susha!t Kumar
Bat$h %&&'()*+ semester VI
National Institute of Fashion Technology
P,ot !o )-+ Se$tor(.+ Khar/har+ Na0i 1umbai+
1aharashtra+ .)&%)&
) 2 P a / e
ACKNOWLEDE!ENT
3e 4ish to e56ress our /ratitude to e0erybody 4ho has assisted i! ,ear!i!/ 6ro$ess
duri!/ this i!ter!shi6 There are ma!y to 4hom e56ressio! o7 /ratitude is
i!e0itab,e+ but there some s6e$ia, 6eo6,e 4ho has to be /i0e! 6romi!e!$e+ 4ithout
4hom 4e 4ou,d !ot ha0e rea$hed the $o!$,usio! o7 this 6ro#e$t so 8ui$",y a!d
e9$ie!t,y
3e 4ish to tha!" our Pro7essor+ :r AK Khare 7or 6ro0idi!/ this 4o!der7u,
o66ortu!ity+ $ha,,e!/i!/ a!d moti0atio! 3e are a,so tha!"7u, to our ;ourse
;oordi!ator 1r TS Pra"ash a!d our te5ti,e 7a$u,ty 1s Abo,i Nai" 7or their su66ort
a!d /uida!$e
No amou!t o7 <ratitude is ade8uate 7or 1r :i,i6 B =i4ra#"a+ 1a!a/i!/ :ire$tor+ A,o"
I!dustries Ltd+ 7or his $o!se!t i! a,,o4i!/ us to $o!du$t our i!ter!shi6 i! their
0e!erated i!stitutio!
3e e56ress our dee6 i!debted!ess to 1r 1a!o# 1o!do,+ HR ma!a/er a!d 1r
A"shesh Kar!i"+ HR e5e$uti0e 4ho /uided a!d su66orted us throu/h e0ery sta/e o7
our i!ter!shi6
3e a,so 4ish to tha!" a $ou6,e o7 se!ior ma!a/ers as ,isted be,o4 7or their te$h!i$a,
/uida!$e a!d assista!$e duri!/ i!ter!shi6
1r S S Ai$h+ ;EO+ Va6i P,a!t
1r Ri!"u Nath+ VP+ HR+ Trai!i!/ > :e0e,o6me!t
1r Ar0i!d Sharma+ VP+ PP; :e6artme!t
1r B1 ;hauha!+ Head+ Ra4 1ateria, Stora/e(<rei/e
1r :aya!a!d Ra!a+ Head+ Ra4 1ateria, Stora/e(:ied Fabri$
1r Sa!#ay Bas"ar+ Head+ Si?i!/ :e6artme!t
1r A< Kurie!+ Head+ @ua,ity Assura!$e :e6artme!t
1r :ee6a" <eedh+ 3ea0i!/ P,a!t I Head
1r PK :as+ 3ea0i!/ P,a!t IV Head
1r Pradee6 Sharma+ 3ea0i!/ P,a!t V Head
1r Asho" =a,e,a+ 3ea0i!/ P,a!t VI Head
1r A!oo6 Si!/h+ 3ea0i!/ P,a!t IX Head
1r P ;hatto6adhyay+ 3ea0i!/ P,a!t VII Head
1rVi!ay Te!du,"ar+ 3ea0i!/ P,a!t III Head
1r Te" Si!/h+ I!s6e$tio! > Fo,di!/ :e6artme!t
1rPradee6 Bhatt+ Pa$"i!/ > :is6at$h :e6artme!t
3e ta"e this o66ortu!ity to e56ress our aAe$tio! to4ards our 6are!ts 7or their
$o!siste!t 7aith a!d su66ort
Ashutosh Vatsa
Kr Prame!dra Si!ha
% 2 P a / e
Pa!"a# Patha"
Susha!t Kumar
Contents
)& I!trodu$tio!
%& Ob#e$ti0e o7 I!ter!shi6
*& S$hedu,e o7 I!ter!shi6
.& S6i!!i!/
.) B,o4 Room
.% ;ardi!/
.* ;ombi!/
.. :ra4i!/
.- Ro0i!/
.B Ri!/ s6i!!i!/
.C O6e! e!d s6i!!i!/
.D 3i!di!/
.' ;o!ditio!i!/
.)& Pa$"i!/
-& Po,ymeri?atio!
-) ;o!ti!uous Po,ymeri?atio!
-%) Partia,,y Orie!ted Ear!
-%% Te5turi?atio!
-* Fu,,y :ra4! Ear!
B& 3ea0i!/
B) 3ar6i!/
B% Si?i!/
B* :e!ti!/ a!d :ra4i!/ I!
B. 3ea0i!/
C& Pre6aratory 6ro$ess 7or :yei!/ a!d Pri!ti!/
C) Si!/ei!/
C% :esi?i!/
C* Pre( Treatme!t Ra!/e
C. 1er$eri?i!/
D& Fabri$ a!d yar! dyei!/
D) ;o,d Pad Bat$h
D% ;o!ti!uous :yei!/ Ra!/e
D* Be!!i!/er Pad Steamers
D. :yed Fabri$ 3ashi!/
D- Ear! :yei!/
'& Pri!ti!/
)&& Fi!ishi!/
)&) Ste!ter
)&% Sa!7orisi!/
* 2 P a / e
)&* ;a,e!deri!/
)&. 1i$rosa!di!/
)&- Brushi!/
))& Testi!/ a!d I!s6e$tio!
))) Ear! Testi!/
))% Fabri$ Testi!/
))* :e7e$ts i! Fabri$
. 2 P a / e
".# Int$o%uction
B F Te$h FA66are, Produ$tio!G is a . years $ourse 7o$usi!/ o! a66,i$atio! o7
te$h!o,o/y i! a66are, 6rodu$tio! Te5ti,e bei!/ ra4 materia, 7or a66are,s is
/i0e! ade8uate em6hasis i! the $ourse I!6uts o! te5ti,e ma!u7a$turi!/ are
s6read to three semesters To $om6,eme!t a!d to $om6rehe!d the $,ass
room tea$hi!/+ a % 4ee"s i!ter!shi6 a7ter V
th
semester i! te5ti,e se$tor is a
6art o7 the $ourse I!ter!ees did this i!ter!shi6 at A,o" I!dustries Ltd at their
Si,0assa a!d Va6i 6,a!ts duri!/ %%
!d
:e$ember %&)) H .
th
=a!uary %&)% The
$om6a!y 6roI,e is e!$,osed as A66e!di5 I
&.# O'(ecti)e of Inte$nshi*
The mai! ob#e$ti0e o7 this i!ter!shi6 4as to ,ear!
The 6ro$ess o7 s6u! yar! 6rodu$tio!+ diAere!t 8ua,ities o7 yar!
6rodu$ed a!d reaso!s 7or 0ariatio!
<rey 7abri$ Fboth 4o0e! a!d "!ittedG 6rodu$tio!+ de7e$ts asso$iated
4ith it a!d treatme!ts $arried out o! it de6e!di!/ u6o! its 6ro6erties
:yei!/+ Pri!ti!/ a!d Fi!ishi!/ o7 7abri$+ Te5ti,e testi!/ a!d their 8ua,ity
as6e$ts both te$h!i$a, as 4e,, as 7or $ommer$ia, 6ur6oses
- 2 P a / e
+.# Sche%ule of Inte$nshi*,
B 2 P a / e
C 2 P a / e
D 2 P a / e
-.# S*inning
Ra. !ate$ials
;otto! $omes i! ba,e 7orm o7 ba,es+ the 4ei/ht o7 this ba//y stru$ture is
about %B- K/ The diAere!t 0arieties o7 $otto! ,i"e BT $otto!+ $o!0e!tio!a,
$otto! ,i"e Su6ima 7rom JSA+ <i?as 7rom E/y6t+ Im6orted $otto! 7rom
$o!tami!atio! 7ree ori/i!+ Or/a!i$ a!d Or/a!i$ Fair trade $otto! are used 7or
yar! ma!u7a$turi!/ The sta6,e ,e!/th 0aries 7rom %Dmm to **mm
' 2 P a / e
The ra4 $otto! is 6ro$ured 7rom the o6e! mar"et+ 6rimari,y 7rom states o7
<u#arat+ 1aharashtra a!d A!dhra Pradesh ;otto! is a,so im6orted 7rom
E/y6t A! a0era/e !i!e mo!ths i!0e!tory o7 ra4 $otto! is mai!tai!ed
6rimari,y 7or yar! ma!u7a$turi!/ A,o" 6romote $o!tra$t 7armi!/ a!d buyi!/
$otto! i! bu,"
-." /lo. Roo0
O'(ecti)e
To o6e! the $om6ressed ba,e o7 $otto!
To e5tra$t im6urities a!d other 7orei/!
matters 7rom $otto! by o6e!i!/ a!d beati!/
To a,,o4 6assa/e o7 $,ea! $otto! either as KuAy mass or as ,a6 F$hute
7eed or ,a6 7eedG to the !e5t ma$hi!e
In*ut
Ba,e o7 $otto!
Ba,e 4ei/ht H A0era/e %B- "/
Re,ati0e humidity mai!tai!ed i! b,o4 room F6re6aratoryG H --(B&L
Out*ut
;,ea! o6e! $otto! Iber
A b,o4 room is the area o7 a s6i!!i!/ u!it 4here o6e!i!/+ $,ea!i!/+ mi5i!/
a!d ,a6 ma"i!/ o7 $otto! Iber ta"e 6,a$e o! ma$hi!es The $otto! is
re$ei0ed i! the mi,, i! a hard 6re(ba,e 7orm 4hi$h $o!tai!s se0era, im6urities
The b,o4 room ma$hi!ery 6er7orms
7u!$tio! o7 o6e!i!/ hard 6ressed ba,es o7
$otto! a!d $,ea!i!/ the $otto! o7
im6urities Trash a!d 7orei/! matter is
e5tra$ted 7rom the $otto! 4ith the ,east
)& 2 P a / e
amou!t o7 ,i!t ,oss The amou!t o7 4aste e5tra$ted 4ou,d de6e!d o! the
amou!t o7 trash i! the mi5i!/
At A,o" I!dustries Ltd+
JNIFLO;K automati$ ba,e
o6e!er ma$hi!es are used to
o6e! ba,es The ba,es bei!/
o6e!ed are 6,a$ed ,e!/th4ise or
$ross4ise o! both sides o7 the
ba,e o6e!er+ a!d the ta"e(oA u!it $a! 6ro$ess u6 to 7our diAere!t
assortme!ts The ma$hi!e o6e!s the ba,es i! mi$ro tu7t 7or eAe$ti0e $,ea!i!/
a!d dust e5tra$tio! This ma$hi!e /i0es the out6ut o7 u6 to ).&&"/Mhr
These mi$ro tu7ts 6ass by 6i6es usi!/ 6!eumati$ 7or$e :ust 6arti$,e are
remo0ed ma!ua,,y as 4e,, as usi!/ ma$hi!es
Visio! shie,d a!d ma/i$ eye+ are the ma$hi!e used i! A,o" 7or dete$ti!/ o7
dust 6arti$,es
1ision shiel%: this ma$hi!e uses a! u,tra0io,et ,i/ht sour$e+ $ombi!ed
4ith a ,i/ht dete$tor+ to ide!ti7y 7orei/! bodies
!agic eye, This ma$hi!e $a! dete$t 4hite $o,ored a!d di9$u,t to
ide!ti7y by !a"ed eyes sy!theti$s ,i"e Po,y6ro6y,e!e+ i!de6e!de!t,y o7
o6ti$a, b,ea$hes or 6o,ari?atio! eAe$ts
)) 2 P a / e
INFRASTRUCTURE
1a$hi!es used i! b,o4 room:
S. No. !achine2E3ui*0e
nt
4u$*ose No. of !achines2
E3ui*0ents
" A "" UNI5oc Ba,e O6e!ers .
& 6ossi T7E 1ISION
S7IELD !4I8
7orei/! Iber
dete$tio!
D
+ / "" UNIclean 6re($,ea!ers %
- / "& UNIclean 6re($,ea!ers %
9 / :# UNI0i; b,e!ders .
< / :" UNI0i; b,e!ders .
: / <# UNI5e; I!e $,ea!ers -
= A := UNIsto$e 7eeder )
Ta'le ", !achine Ca*acity in /lo.$oo0
-.& Ca$%ing
;ardi!/ is "!o4! as the Nheart o7 s6i!!i!/O This 6ro$ess is do!e 7or the
i!di0idua,i?atio! o7 the $otto! Ibers The Ibers a7ter this 6ro$ess /et
arra!/ed i!to 6ara,,e, 7orm 7rom ?i/?a/ arra!/eme!t
O'(ecti)e
) To o6e! the Ko$"s i!to i!di0idua, Ibers
% ;,ea!i!/ or e,imi!atio! o7 im6urities
* E,imi!atio! o7 dust
. E,imi!atio! o7 short Ibers
)% 2 P a / e
- Fiber b,e!di!/
B Fiber orie!tatio! or a,i/!me!t
C S,i0er 7ormatio!
In*ut
;otto! i! the 7orm o7 ,a6
Out*ut
;arded s,i0er
Waste
F,at stri6es
Li$"er
;y,i!der Ky
;arded s,i0er is either dire$t,y used i! O6e!(E!d S6i!!i!/ or used 7or 7urther
6ro$essi!/ 7or ri!/ s6i!!i!/ At A,o" I!dustries Ltd+ ;(B& $ards ma$hi!es are
used 7or $ardi!/ S6eed o7 $ardi!/ ma$hi!e is -&"/Mhr
There are t4o ty6es o7 7eedi!/ to the $ards+
La6 7eed system( Ibers are 7ormed i!to a ,a6 or a $om6a$t sheet
;hute 7eed system( Ko$"s are tra!s6orted 6!eumati$a,,y
)* 2 P a / e
At ALOK I!dustries ;hute Feed system is used
The ad0a!ta/es a!d disad0a!ta/es o7 ;hute Feed system are as 7o,,o4s:
A%)antages
) Hi/h 6er7orma!$e i! $ardi!/ due to hi/h de/ree o7 o6e!!ess o7 7eed 4eb
% Labor re8uireme!t is ,ess due to !o ,a6 tra!s6ortatio! a!d ,a6 $ha!/e i!
$ards
* For hi/h 6rodu$tio! $ards+ o!,y $hute 7eedi!/ system is suitab,e
Disa%)antages
) Li!ear de!sity o7 the 4eb 7ed to the $ard is !ot as /ood as ,a6
% The i!sta,,atio! is !ot Ke5ib,e
* Auto ,e0e,er is a must 7or $o!tro,,i!/ 4ei/ht 6er u!it ,e!/th+ he!$e
i!0estme!t $ost a!d mai!te!a!$e $ost is more
). 2 P a / e
4$inci*le of Ca$%ing,
Short Ibers 4hi$h are res6o!sib,e 7or hairi!ess a!d redu$tio! i! stre!/th
are to be remo0ed
;otto! is i!trodu$ed i! the 7orm o7 Ko$"s a!d obtai!ed i! the 7orm o7
s,i0ers
At $ardi!/+ the 7au,ts ,i"e !e6s+ hoo"ed e!ds $a! $ome These 7au,ts $a!
be re$tiIed at the ,ater sta/es
Ro,,ers used i! the $ardi!/ ma$hi!es are I5ed at $ertai! dista!$e that
deI!es the mi!imum ,e!/th o7 Iber re8uired This e,imi!ates shorter
Ibers but a,so /i0es rise to hoo"s FIbers he,d by 7ro!t ro,,ers 7orm trai,i!/
hoo"s 4hi,e Ibers he,d by ba$" ro,,ers 7orm ,eadi!/ hoo"sG
INFRASTRUCTURE
1a$hi!es used i! ;ardi!/:
!achine 0o%els No Of 0achines
Riete$ C <# ca$%s .*
-.+ Co0'ing
3he! the Iber is i!te!ded 7or I!e yar!s+ the s,i0er is 6ut throu/h a!
additio!a, strai/hte!i!/ $a,,ed $ombi!/ ;ombi!/ is the 6ro$ess 4hi$h is
used to u6/rade the ra4 materia, It i!Kue!$es the 7o,,o4i!/ yar! 6ro6erties:
) Ear! e0e!!ess
% Stre!/th
* ;,ea!!ess
. Smooth!ess
- Visua, a66eara!$e
I! additio! to the abo0e+ $ombed $otto! !eeds ,ess t4ist tha! a $arded yar!
be$ause the short Ibers are remo0ed
4u$*ose of Co0'ing,
)- 2 P a / e
I! order to 6rodu$e a! im6ro0eme!t i! yar! 8ua,ity+ the $omber must
6er7orm the 7o,,o4i!/ o6eratio!s:
) E,imi!atio! o7 short Ibers
% E,imi!atio! o7 remai!i!/ im6urities
* E,imi!atio! o7 !e6s
The basi$ o6eratio! o7 the $omber is to im6ro0e the mea! ,e!/th or sta6,e
,e!/th by remo0i!/ the short Ibers Si!$e I!e!ess o7 short Ibers F!oi,G is
,o4+ the o0era,, mi$ro!aire o7 the s,i0er a7ter $ombi!/ is hi/h Be$ause o7
$ombi!/+ Iber 6ara,,e,i?atio! i!$reases
In*ut
J!i(La6
Out*ut
;ombed s,i0er
PRO;ESS
For $ombi!/ s,i0er 7rom the $ardi!/+ it is 6assed throu/h 6re($omber dra4i!/
a!d the! throu/h the u!i(,a6 to /et sma,,er ,a6 o7 $otto! These ,a6s are the!
7ed to $ombers to /et s,i0er+ 4hi$h has ). L to )D L o7 shorter sta6,es
remo0ed 7rom it
)B 2 P a / e
JNI,a6 E *% $ombi!/
6re6aratio! ma$hi!es
I! this o6eratio!+ I!e(toothed $ombs $o!ti!ue strai/hte!i!/ the Ibers u!ti,
they are arra!/ed 4ith su$h a hi/h de/ree o7 6ara,,e,ism that the short Ibers
are $ombed out a!d $om6,ete,y se6arated out 7rom the ,o!/er Ibers
INFRASTRJ;TJRE
!achine 0o%els No Of 0achines
JNI,a6 E *% $ombi!/ 6re6aratio!
ma$hi!es
D
E B- $ombers *.
-.- D$a.ing
)C 2 P a / e
O'(ecti)e
Throu/h doub,i!/+ the s,i0ers are made e0e!
:oub,i!/ resu,ts i! homo/e!i?atio! Fb,e!di!/G
Throu/h dra7t+ Ibers /et 6ara,,e,i?ed
Hoo"s $reated i! the $ard are strai/hte!ed
Throu/h the su$tio!+ i!te!si0e dust remo0a, is a$hie0ed
Auto,e0e,,er mai!tai!s abso,ute s,i0er I!e!ess
In*ut
;ombed or $arded s,i0er
Out*ut
:ra7ted s,i0er
The mai! out6ut o7 dra4i!/ is a more u!i7orm s,i0er 4ith u!i7orm
massM,e!/th distributio!
4ROCESS
I! this 6ro$ess si5 s,i0er are $ombi!ed
to/ether The $ombi!i!/ o7 se0era, Ibers 7or
the dra4i!/+ or dra7ti!/+ 6ro$ess e,imi!ates
irre/u,arities that 4ou,d $ause too mu$h
0ariatio! i7 the s,i0ers 4ere 6u,,i!/ throu/h
si!/,y
)D 2 P a / e
The dra4 7rame has se0era, 6airs o7 ro,,ers+ ea$h ad0a!$ed set o7 4hi$h
re0o,0es at a 6ro/ressi0e,y 7aster s6eed Ea$h o7 7our set o7 ro,,s ru!s
su$$essi0e,y 7aster tha! 6re$edi!/ set The ,ast set ru!s a66ro5imate,y si5
times as the Irst setP $o!se8ue!t,y+ s,i0er $omi!/ out is the same si?e as
ea$h o!e o7 si5 /oi!/ i! but is atte!uated to si5 times the ,e!/th 6er mi!ute
The s,i0er is !eat,y $oi,ed a/ai! i! ro0i!/ $a! by $oi,er head The s,i0er is
!o4 mu$h more u!i7orm a!d Ibers mu$h more !ear,y 6ara,,e,
:ra4 7rame $o!tributes ,ess tha! -L to 6rodu$tio! $ost o7 yar! But its
i!Kue!$e o! 8ua,ity is 0ery bi/+ be$ause dra4i!/ is the I!a, 6ro$ess o7
8ua,ity im6ro0eme!t i! the s6i!!i!/ mi,, a!d 8ua,ity o7 dra4 7rame s,i0er
determi!es the I!a, yar! 8ua,ity
INFRASTRUCTURE
!achine 0o%els No Of 0achines
S/>D -# '$ea?e$ %$a. f$a0es )D
RS/>D -# auto le)ele$ %$a. f$a0es )'
)' 2 P a / e
-.9 Ro)ing
O'(ecti)e
Redu$es the thi$"!ess o7 the s,i0er i!to ro0i!/+ im6arts t4ists a!d 4i!ds it
arou!d a bobbi!
The mai! 7u!$tio! o7 s6eed 7rame is to ma"e ro0i!/ 7rom the dra7t s,i0er
that has stre!/th to 4ithsta!d the te!sio! 0ariatio!s at ri!/ 7rame
In*ut
S,i0er
Out*ut
Ro0e
4u$*ose of Ro)ing,
S,i0er is thi$"+ u!t4isted stra!d that te!ds to be hairy a!d to $reate Ky The
dra7t !eeded to $o!0ert this is arou!d *&& to -&& :ra7ti!/ arra!/eme!ts o7
ri!/ 7rames are !ot $a6ab,e o7 6ro$essi!/ this stra!d i! a si!/,e dra7ti!/
o6eratio! to $reate a yar! that meets a,, the !orma, dema!ds o! su$h yar!s
He!$e+ ro0i!/ 7rame is used
PRO;ESS
The $a! o7 s,i0er 7rom dra4i!/ 7rames is 7ed bet4ee! three sets o7 dra7ti!/
ro,,s Ea$h 7o,,o4i!/ set o7 ro,,s ru!s 7aster tha! 6re$edi!/ sets This 6u,,s
s,i0er a!d thi!s it do4!+ ma"i!/ Ibers !ear,y 6ara,,e, :ra4i!/ out a!d
t4isti!/ ta"e 6,a$e u!ti, the $otto! sto$" is about the diameter o7 a 6e!$i,
,ead
%& 2 P a / e
The s6i!d,e tur!s Kyer a!d is dri0e! at a $o!sta!t s6eed The 7ro!t ro,,s are
set at a s6eed that /i0es stra!d $omi!/ out o7 the ro,,s a 6redetermi!ed
!umber o7 tur!s o7 t4ist 6er i!$h as it mo0e a,o!/ bet4ee! ro,,s a!d Kyer
The bobbi! is dri0e! by a sour$e se6arate 7rom /ear that dri0es s6i!d,e a!d
Kyer The bobbi! is re/u,ated to tur! automati$a,,y at a s6eed su9$ie!t,y
7aster tha! Kyer+ 4hi$h $auses ro0i!/ to 4i!d o! bobbi! at same rate as it is
de,i0ered by 7ro!t ro,, To this 6oi!t+ o!,y e!ou/h t4ist has bee! /i0e! the
sto$" to ho,d the Ibers to/ether
INFRASTRUCTURE
!achine 0o%els No Of 0achines
F "9 $o)ing f$a0es .ith "<#
s*in%les each
)D

%) 2 P a / e
-.< Ring S*inning
Ri!/ Frame /i0es the I!a, out6ut 7or s6i!!i!/ ie yar! The 6rodu$ti0ity o7
the 7a$tory is determi!ed by the out6ut o7 the ri!/ 7rame
O'(ecti)e
It redu$es the thi$"!ess o7 the ro0i!/ to the desired yar! $ou!t by mea!s
o7 dra7ti!/ ro,,ers :ra7ti!/ arra!/eme!t is the most im6orta!t 6art o7 the
ma$hi!e It i!Kue!$es mai!,y e0e!!ess a!d stre!/th
It im6arts t4ists i!to the yar! thus stre!/the!i!/ it a!d 6re0e!ti!/ short
Ibers 7rom 6rotrudi!/
Pa$"i!/ it i! a more easy to ha!d,e 6a$"a/e
In*ut
Ro0e
Out*ut
Bobbi!
4ROCESS
The ri!/ 7rame+ 4hi$h is /e!era, i! use+ is more suitab,e 7or the ma!u7a$ture
o7 $otto! yar!s i! mass 6rodu$tio! Its hu!dreds o7 s6i!d,es+ 4hir,i!/
thousa!ds o7 re0o,utio!s 6er mi!ute+ a!d its $o!sta!t s6i!!i!/ a$tio! 6ro0ide
a 7ast o6eratio!
The ri!/ s6i!!i!/ 7rame $om6,etes the ma!u7a$ture o7 yar!:
) By dra4i!/ out the ro0i!/
% By i!serti!/ t4ist
* By 4i!di!/ the yar! o! bobbi!s(a,, i! o!e o6eratio!
%% 2 P a / e
The 6ri!$i6,e o7 s6i!!i!/ is same as that used i! ro0i!/ e5$e6t that the
o6eratio! is more reI!ed a!d a ri!/ a!d tra0e,er are used i!stead o7 the
Kyer The ro0i!/+ o! bobbi!s+ is 6,a$ed i! the s6i!!i!/ 7rame From bobbi!
ro0i!/ is 7ed bet4ee! set o7 dra7ti!/ ro,,ers ru!!i!/ at su$$essi0e,y hi/her
rates o7 s6eed a!d is I!a,,y dra4! out to yar! o7 the si?e desired to dra4
stra!d do4! to its I!a, desired si?e
The s6i!d,e tur!s bobbi! at a $o!sta!t s6eed The 7ro!t set o7 ro,,s is
ad#usted to de,i0er yar! at a s6eed su9$ie!t to i!sert desired amou!t o7
t4ist as stra!d mo0es a,o!/ The tra0e,er /,ides 7ree,y arou!d ri!/ The
te!sio! $aused by dra/ o7 tra0e,er $auses yar! to 4i!d o! bobbi! at same
rate o7 s6eed as it de,i0ered by ro,,s
The bobbi!s o7 yar! are remo0ed 7or su$h 6ro$essi!/ as may be desiredP 7or
e5am6,e+ the yar! may be ree,ed i!to s"ei!s 7or b,ea$hi!/ or may be 4ou!d
o! $heeses+ or s6oo,s+ 7or u,timate 4ea0i!/ 3here it 6asses throu/h se0era,
sets o7 ro,,ers
INFRASTRUCTURE
!achine 0o%els No Of 0achines
Reite$ ++" $ing s*inning 0achines .ith "&## %)
%* 2 P a / e
s*in%les each
Reite$ K --" Co0fo$ S*in 0achines .ith "&##
s*in%les each
B*
-.: O*en En% S*inning
Featu$es,
Hi/her Produ$ti0ity ( it i!$reases the 6rodu$ti0ity a!d redu$es the $ost
o7 ma!u7a$turi!/
Lar/e Fi!a, Pa$"a/e ( The I!a, 6a$"a/e si?e has $o!ti!ued to i!$rease
The I!a, 6a$"a/e si?e is im6orta!t be$ause it redu$es tube $ha!/e
7re8ue!$y a!d thus redu$es id,e time 7or $ree,i!/
Less 6o4er $o!sum6tio! ( Jsi!/ i!di0idua, motors a!d e,e$tro!i$
$o!tro,s 7or ea$h o7 the 0arious dri0es o7 the ma$hi!e ma5imi?e e!er/y
e9$ie!$y a!d mi!imi?es do4!time
In*ut
;arded s,i0er
Out*ut
O6e! e!d s6u! yar!
4ROCESS
S,i0er is 7ed i!to the ma$hi!e a!d $ombed a!d i!di0idua,i?ed by the o6e!i!/
ro,,er The Ibers are the! de6osited i!to the rotor 4here air $urre!t a!d
$e!tri7u/a, 7or$e de6osits them a,o!/ the /roo0e o7 the rotor 4here they are
e0e!,y distributed The Ibers are t4isted to/ether by the s6i!!i!/ a$tio! o7
the rotor+ a!d the yar! is $o!ti!uous,y dra4! 7rom the $e!tre o7 the rotor
The resu,ta!t yar! is $,eared o7 a!y de7e$ts a!d 4ou!d o!to 6a$"a/es
O6e! e!d s6i!!i!/ ma$hi!es $a! ru! u6 to )+ .&+&&& r6m The 6rodu$tio!
rates o7 rotor s6i!!i!/ is B(D times hi/her tha! that o7 ri!/ s6i!!i!/ a!d as
the ma$hi!es are 7ed dire$t,y by s,i0er a!d yar! is 4ou!d o!to 6a$"a/es
ready 7or use i! 7abri$ 7ormatio! the yar! is a ,ot $hea6er to 6rodu$e
%. 2 P a / e
INFRASTRUCTURE
Number o7 rotors: -.%.
-.= Win%ing
Pa$"a/e obtai!ed 7rom ri!/ 7rame is bobbi! 4hi$h ho,ds a sma,, amou!t o7
yar! It is !ot easy as 4e,, as $o!0e!ie!t to tra!s6ort the $o6s 7rom o!e
6,a$e to other Se$o!d,y+ these 6a$"a/es $a!Ot I!d a!y use i! 4ea0i!/ 4here
a ,o!/ a!d $o!ti!uous su66,y o7 yar! is re8uired He!$e+ si5 bobbi!s are
$ombi!ed to ma"e a $o!e This is do!e by Auto$o!er
4u$*ose
Q To remo0e yar! 7au,ts
Q To ma"e bi//er 6a$"a/e FB& /ram bobbi!s to % "/ $o!esG by s6,i$i!/
Q Lubri$atio! o7 yar!
In*ut
Bobbi!
Out*ut
;o!e
4ROCESS
:uri!/ 4i!di!/+ 0arious 7au,ts su$h as !e6s+ thi$" a!d thi! se$tio! are
remo0ed
The ma$hi!e is $o!tro,,ed by $om6uter Si5 bobbi!s are arra!/ed i! a sta!d
that $a! be rotated The yar! 7rom a si!/,e bobbi! is ta"e! by the ma$hi!e
It is 6assed throu/h a 4a5i!/ rod that 6ro0ides 4a5 The!+ it is 6assed
throu/h e,e$tri$ yar! $,earer a!d s6,i$i!/ u!it This u!it $o!tai!s se!si!/
de0i$eFo6ti$a, a!d $a6a$ita!$e basedG that dete$ts the 6rese!$e o7 a!y 7au,t
,i"e thi$" or thi! 6,a$es+ $o!tami!atio!+ hairi!ess+ !e6 7ormatio!+ 4ea"
%- 2 P a / e
6,a$es Su$h 6,a$es are $ut or s6,i$ed a!d the t4o e!ds o7 the yar! are tied
i!to a ti!y "!ot
A te!sio!i!/ de0i$e mai!tai!s the te!sio! i! the yar! a!d thus he,6s i!
mai!tai!i!/ u!i7orm te!sio! 4hi,e 4i!di!/ the yar!
INFRASTRUCTURE
!achine 0o%els No Of 0achines
!u$ata &"C .in%e$s D.
-.@ Con%itioning
The !orma, moisture $o!te!t o7 $otto! is arou!d B(B-L A7ter $o!0erti!/ to
yar!+ $otto! has o!,y .L o7 moisture A $o!ditio!i!/ ma$hi!e im6arts
re8uired amou!t o7 moisture a!d stre!/th to the yar!s It uses steam+ hi/h
tem6erature a!d 6ressure Steam 6e!etrates i!to the materia, a!d i!$reases
the stre!/th o7 the yar! I7 $o!ditio!i!/ o7 yar! is !ot do!e+ 6rob,ems ,i"e
s!ar,i!/ a!d e!d t4ists $a! o$$ur
4u$*ose
I!$rease 4ei/ht a!d stre!/th o7 the $o!e
I!$rease absor6tio! $a6a$ity o7 dyei!/ a/e!ts
%B 2 P a / e
%C 2 P a / e
-."# 4ac?ing
1ai!,y there are t4o ty6es o7 6a$"i!/ methods:
) 4allette 4ac?ing H ;o!es or $heeses 4ra66ed i! 6,asti$ are 6,a$ed o!
to6 o7 o!e a!other a!d the e!tire 6a$"a/e is 4ra66ed i! 6,asti$ The
ma5imum !umber o7 ,ayers 6ossib,e is )%
% Ca$ton 4ac?ing H ;o!es or $heeses are 4ra66ed i! 6,asti$ a!d 6a$"ed
i!to baseboard bo5es :e6e!di!/ u6o! the $o!e or $heese 4ei/ht+ the
si?e or $a6a$ity o7 the $arto! 0aries
There is a!other ty6e o7 6a$"i!/ method 4hi$h is based o! $ustomer orders+
4hi$h is $a,,ed $arto! 6a,,et 6a$"i!/ I! this method o7 6a$"i!/+ $arto!s
a,ready I,,ed 4ith $heeses or $o!es are 6,a$ed o! to6 o7 ea$h other i! ,ayers
a!d the! the e!tire 6a$"a/e is 4ra66ed i! 6,asti$
%D 2 P a / e
9.# 4oly0e$iAation
%' 2 P a / e
9." Continuous 4oly0e$iAation
In*ut,
PTA F Pure Tera6the,i$ A$id G
1E< F 1o!o Ethy,e!e <,y$o, G
TiO% F Tita!ium :io5ide G
:E< F:i ethy,e!e <,y$o, G
Sb%O* F A!timo!y Trio5ide G
Po,ymeri?atio! i!0o,0es rea$tio! o7 PTA FPure Tere6hthe,i$ A$idG a!d 1E<
F1o!o Ethy,e!e <,y$o,G to 7orm Po,yethy,e!e Tere6htha,ate FPETEG
Out*ut,
Po,yethy,e!e Tere6tha,ete FPETEG
4ROCESS
This 6ro$ess i!0o,0es t4o ste6s rea$tio!
Este$iBcation, This is the Irst ste6 o! 4here PTA a!d 1E< 4ere
$o!ti!uous,y mi5 i! a s6e$iI$ ratio a!d 7ed i! to the I st rea$tor $a,,ed
EsteriIes Rea$tio! ta"es 6,a$e 0i/orous,y i! 6rese!$e o7 heat The
i!termediate 6rodu$t 7ormed is $a,,ed as mo!omer The by(6rodu$t
7ormed duri!/ rea$tio! is 4ater+ 4hi$h $o!de!sed a!d se!t to or/a!i$
stri66i!/ $o,um! 4here or/a!i$ im6urities are stri66ed a!d bur!t i! boi,er
The 4ater is se!t to Efuent Treatment Plant FETPG
4oly>con%ensation, 1o!omer is subse8ue!t,y 6o,y($o!de!sed i!to other
t4o rea$tors $a,,ed 6o,y($o!de!satio! rea$tio! 4hi$h is se$o!d ste6 o7 the
rea$tio! Be7ore 7eedi!/ mo!omer to 6o,ymeri?atio! se$tio! diAere!t
additi0es added su$h as TiO%+ Sb%O*+ a!d :E< I! 6o,ymeri?atio! rea$tio!
mo!omer u!der/oes 6o,y $o!de!satio! u!der hi/h tem6erature a!d ,o4
6ressure to 7orm 6o,ymer
*& 2 P a / e
This 6o,ymer is $o!ti!uous,y 7ed to POE s6i!!i!/ 6,a!t+ F:E s6i!!i!/ 6,a!t
a!d ;hi66er
*) 2 P a / e
9.&." 4a$tially O$iente% Ca$n
I! me,t s6i!!i!/+ the Iber(7ormi!/ substa!$e ie 6o,ymer $hi6s is me,ted 7or
e5trusio! throu/h the s6i!!eret a!d the! dire$t,y so,idiIed by $oo,i!/ The
6o,ymer is me,ted at hi/h tem6erature > 6ressure a!d 6um6ed throu/h a
s6i!!eret FdieG 4ith !umerous ho,es Fo!e to thousa!dsG as 6er de!ier
re8uireme!t
The mo,te! Ibers are $oo,ed by the he,6 o7 8ue!$hi!/+ so,idiIed+ a!d
$o,,e$ted o! a ta"e(u6 4i!der Stret$hi!/ o7 the Ibers i! both the mo,te! a!d
so,id states 6ro0ides 7or orie!tatio! o7 the 6o,ymer $hai!s a,o!/ the Iber
a5is This 6ro$ess o7 stret$hi!/ the Iber is $a,,ed dra4i!/ :ra4i!/ is
ty6i$a,,y a$$om6,ished by 6assi!/ the I,ame!t arou!d a series o7 drum or
ro,,s Ea$h drum is i!$reased i! s6eed to stret$h the I,ame!t
INFRASTRUCTURE
POE ) R )-& 1etri$ To!s 6er :ay F1TP:G > )& ,i!es
POE % R *&& 1TP: > )% ,i!es
*% 2 P a / e
9.+ Fully D$a.n Ca$n
Fu,,y :ra4! Ear! FF:EG is 6rodu$ed by a 6ro$ess simi,ar to POE ma!u7a$turi!/
e5$e6t that the yar! is 6rodu$ed at hi/her s6i!!i!/ s6eeds $ou6,ed 4ith
i!termediate dra4i!/ i!te/rated i! the 6ro$ess itse,7 This a,,o4s stabi,i?atio!
throu/h orie!tatio! a!d $rysta,,i?atio!
4ROCESS
Ear!s are 6rodu$ed by a $o!ti!uous 6o,ymeri?atio! 6ro$ess
A,, $riti$a, yar! 6ro6erties su$h as te!a$ity+ e,o!/atio!+ Jster 0ariatio! a!d
boi,i!/ 4ater shri!"a/e are $,ose,y mo!itored a!d $o!tro,,ed
;o!tro,,ed i!ter,a$e e!ab,es the yar!s to be t4isted or si?ed i! subse8ue!t
o6eratio!s F:E is mai!,y used as 4e7t or 4ea0es i! ma"i!/ 7abri$s F:E $a!
be "!itted or 4o0e! 4ith a!y other I,ame!t yar! to /et 7abri$ o7 0arious
diAere!t 0arieties
It is mai!,y used i! Home Fur!ishi!/ Fabri$s+ Fashio! Fabri$s+ :e!im+ Terry
To4e, a!d others
INFRASTUCTURE
F:E R %&& 1TP: > )% ,i!es
** 2 P a / e
9.&.& Te;tu$isation
The mo,e$u,ar stru$ture o7 Partia,,y Orie!ted Ear! FPOEG is !ot orie!ted a!d
has 0ery hi/h e,o!/atio! It $a!!ot be used dire$t,y 7or t4isti!/+ 4ea0i!/ or
"!itti!/ To stabi,i?e the POE a!d ma"e it usab,e 7or the subse8ue!t e!d(use+
te5turisi!/ is do!e
Te5turisi!/ is a thermo me$ha!i$a, 6ro$ess to ma"e POE more suitab,e 7or
ma!u7a$turi!/ o7 7abri$ by 6erma!e!t re(orie!tatio! o7 its mo,e$u,ar
stru$ture a!d 6ro0idi!/ better a!d su6erior te5ture to the yar!
4ROCESS
The POE threads are Irst 6assed throu/h a yar! 7eed de0i$e 4here it is
stret$hed to the re8uired de!ier
It the! /oes throu/h the Irst heater 7or i!itia, set(u6
It is the! 6assed throu/h a $oo,i!/ 6a!e, a!d a 7ri$tio! dis$ u!it 4here
it is t4isted a!d u!t4isted about %-(*& times
It the! 6asses throu/h a!other set o7 ro,,ers stabi,i?i!/ heater a!d the!
throu/h a third set o7 7eed ro,,ers a!d the! I!a,,y throu/h oi, ro,,ers
J,timate,y the yar! is 4ou!d o! the 6a6er tube ru!!i!/ o! the ta"e u6
ro,,er
The yar! !o4 be$omes suitab,e 7or t4isti!/+ 4ea0i!/ Fo!,y 7or 4e7tG
a!d "!itti!/
For ma"i!/ the yar! suitab,e to use as 4ar6 yar! Fi! 4ea0i!/G+ roto yar! is
6rodu$ed For 6rodu$i!/ roto yar!+ i!ter,a$i!/ #ets are Itted !e5t to se$o!d
set o7 7eed ro,,ers i! the yar! 6ath
;om6ressed air 4ith about %- to *& "/ 6ressure is b,o4! 4hi,e 6assi!/
throu/h the #ets+ 4here i! the I,ame!ts are i!tert4i!ed by a series o7
6res$ribed short 6eriodi$ $om6a$t !odes F!i6sG 4ithout $ausi!/ a!y radia,
*. 2 P a / e
disarra!/eme!t o7 the I,ame!ts The yar! be$omes suitab,e 7or usi!/ as
4ar6 yar! 7or 4ea0i!/ a66,i$atio! It a,so e,imi!ates do4!stream o6eratio!s
,i"e t4isti!/ or si?i!/ thereby redu$i!/ $ost o7 4ar6 yar! 7or 4ea0i!/
a66,i$atio!
The I!ished 6rodu$t so obtai!ed is the! 4ei/hed o! e,e$tro!i$ di/ita,(
4ei/hi!/ ma$hi!es to as$ertai! the 8ua!tity ma!u7a$tured
The 8ua,ity as6e$t is a,so ta"e! $are by dra4i!/ a ra!dom sam6,e o7
te5turised yar! 7rom the ,ot ma!u7a$tured a!d the same is tested o!
,aboratory e8ui6me!t 7or $ou!t a!d 8ua,ity assura!$e Therea7ter+ the $o!es
*- 2 P a / e
are 6a$"ed i! $arto!s a!d so,d either to 0arious 4ea0ers domesti$a,,y or
e56orted 7or ma!u7a$turi!/ o7 7abri$
<.# Wea)ing
*B 2 P a / e
<." Wa$*ing
The 6ro$ess o7 arra!/i!/ a $o!0e!ie!t !umber o7 4ar6 yar!s that $a! be
$o,,e$ted i! a sheet 7orm a!d 4ou!d o! to a 4ar6erOs beam
There are t4o ty6es o7 4ar6i!/ methods 7o,,o4ed:
:ire$t 4ar6i!/ Fbeam 4ar6i!/G
Se$tio!a, 4ar6i!/ F6atter! 4ar6i!/G:
:ire$t 3ar6i!/ Fbeam 4ar6i!/G: It is used 7or ,o!/ ru!s o7 /rey yar!s+ si!/,e
$o,our yar!s a!d sim6,e 6atter!s o7 $o,oured yar!s It $a! be used to ma"e 4ar6
sheets The tota, amou!t o7 $o,oured yar!s i!0o,0ed is ,ess tha! )-L o7 the
tota,
:ire$t 4ar6i!/ ma$hi!es are !ot $om6uteri?ed
No o7 dire$t 4ar6i!/ ma$hi!es R * FJUPITER)
Su$tio! de0i$es are 6ro0ided i! bet4ee! 4ar6i!/ ma$hi!es 4hi$h su$"
a,, the u!4a!ted $otto! Ibres Kyi!/
Se$tio!a, 3ar6i!/ F6atter! 4ar6i!/G: It is used 7or short ru!s es6e$ia,,y 7or
7a!$y 6atter! 7abri$s 4here the amou!t o7 $o,oured yar! is more tha! )-L o7
the tota,
Se$tio!a, 4ar6i!/ is a 8ui$" 4ay to 4ar6 a ,oom 4ith a se$tio!a, 4ar6 beam
a!d is best suited 7or 0ery ,o!/ 4ar6s F)- yards or moreG+ a!y si?e or sty,e o7
yar! a!d % i!$h re6eats Fmost se$tio!s o! a se$tio!a, 4ar6 beam are %S 4ideG
It is !ot 0ery 4e,, suited 7or mi5ed 4ar6s 4ith ma!y or ra!dom yar! $ha!/es
It a,so re8uires more s6a$e a!d e8ui6me!t tha! other 4ar6i!/ methods (
s6oo, ra$" 4ith bobbi!s+ bobbi! 4i!der+ a!d s,ey hoo" a!d a te!sio! bo5 or
4ar6i!/ 6add,eM/uide
*C 2 P a / e
4ROCESS ( Se$tio!a, 3ar6i!/:
3ar6 is 4i!ded o!to s6oo,s Fbobbi!sG ( O!e s6oo, 6er ea$h 4ar6 e!d
6er %S o7 4ar6 O!,y o!e se$tio! o7 se$tio!a, 4ar6 beam is 4i!ded at a
timeI7 the 4ea0i!/ is set at )% e6i+ a!d the se$tio!a, 4ar6 beam
se$tio!s are %S+ %. bobbi!s o7 4ar6 are !eeded i! the s6oo, ra$" F%S 5 )%
e6i R %. 4ar6 e!ds+ he!$e %. bobbi!s 6er %S se$tio!G
The s6oo, ra$" is 6ositio!ed behi!d the ,oom
The 4ar6 is $e!tred a!d !umber o7 4ar6 se$tio!s is $ou!ted For a %DS
4ide 7abri$+ the $e!tre ). se$tio!s are used F%DS di0ided by %S se$tio!s R
). se$tio!sG
A $ord is tied to the 4ar6 beam i! ea$h o7 the se$tio!s used
A 4ar6 e!d is threaded 7rom ea$h bobbi! throu/h the te!sio! bo5 or
4ar6i!/ 6add,e The te!sio! bo5 or /uide shou,d be atta$hed to the ba$"
beam to he,6 i! 4i!di!/ the 4ar6 e!ds o!to ea$h se$tio! 4ith e0e!
te!sio! The bu!d,e o7 4ar6 e!ds is "!otted as $,ose to the e!d as
6ossib,e
Be/i!!i!/ at either o7 the outside se$tio!s o7 the s6e$iIed se$tio!s+ the
$ord is tied 7rom the 4ar6 beam to the "!otted 4ar6 e!ds usi!/ a $,o0e
hit$h "!ot Starti!/ at o!e side a!d I,,i!/ se$tio!s i! order strai/ht a$ross
the beam 4i,, 6rodu$e 7abri$ 4ith 4ar6s ti/ht o! o!e e!d a!d ,oose o! the
other Simi,ar,y+ starti!/ at the $e!tre a!d 4or"i!/ to4ards the ed/es 4i,,
6rodu$e 7abri$ 4ith ri66,ed ed/es
The beam is tur!ed+ 4at$hi!/ $are7u,,y to see that the se$tio! I,,s e0e!,y
I7 the 4ar6 6i,es u6 u!e0e!,y+ 6ositio! o7 the te!sio! bo5 is ad#usted Ea$h
re0o,utio! o7 the beam is $ou!ted as Irst se$tio! is I,,ed A,, the other
se$tio!s shou,d be I,,ed 4ith the same !umber o7 tur!s to a0oid te!sio!
6rob,ems i! the 4ar6
*D 2 P a / e
i 3he! the se$tio! is 7u,,+ a 6ie$e o7 mas"i!/ ta6e is 6,a$ed a$ross the 4ar6
e!ds to "ee6 them i! order The ta6e ta"es the 6,a$e o7 a $ross The 4ar6 is
the! $ut o!e i!$h beyo!d the ta6e The ta6e is 6i!!ed i!to the I,,ed se$tio! to
se$ure it
ii The te!sio! bo5 or 6add,e is mo0ed to the other outside se$tio! a!d I,,ed
iii 3he! a,, the se$tio!s are 7u,,+ 6i!s are remo0ed 7rom ea$h se$tio! a!d 4ar6 is
6u,,ed o0er the ba$" beam to4ard the sha7ts
i0 Thread the ,oom is threaded as 7or 4ar6i!/ ba$" to 7ro!t Fhedd,es are
threadedP the reed is s,ayed a!d tied o!to the 7ro!t a6ro! rodG
INFRASTRUCTURE
The se$tio!a, 4ar6i!/ ma$hi!es are 7u,,y $om6uteri?ed
;ree, $a6a$ity R BC%
He!$e+ !o o7 se$tio!s R BC%M F!o o7 e!ds 6er se$tio!G
No o7 se$tio!a, 4ar6i!/ ma$hi!es R ' FPRASHANT <A1ATEX+ SJ;KER
1JLLER AN: =JPITERG
FEATJRES:
Se6arate 4ar6i!/ > beami!/ stru$ture
Hydrau,i$ :is$ Bra"es
;o!sta!t Beami!/ Te!sio!
:i/ita, M <ra6hi$ O! Li!e :is6,ay 7or desired 6ro$ess data
So,id stee, drum ( :y!ami$a,,y ba,a!$ed
Fre8ue!$y 0ariab,e AM; dri0es
Hydrau,i$ do9!/ > do!!i!/ de0i$e
*' 2 P a / e
Auto se$tio! ad0a!$i!/
;o!sta!t 4ar6i!/ a!d beami!/ s6eed
Lost e!d memory > auto sto6 duri!/ beami!/
O! Site Pro/rammi!/ Fa$i,ity
I!di0idua,,y ;o!tro,,ed Te!sio!er Ty6e mode,
.& 2 P a / e
<.& SiAing
The mai! 6ur6ose o7 si?i!/ is to im6ro0e stre!/th a!d abrasio! resista!$e o7 the 4ar6
yar!s by $ausi!/ the Ibres to adhere to/ether to ma"e smooth a!d to ,ubri$ate the
4ar6 yar!s so that there is mi!imum 7ri$tio! 4here they rub to/ether 0arious 6arts i!
the 4ea0i!/ 6ro$ess
Si?i!/ I!/redie!ts:
A%hesi)es, 1odiIed star$h Fte5o6,astG+ 7abri$ /,ue+ thi! 0o,ume star$h+ Potato
star$h+ star$h 7rom $or!+ 4heat+ ri$e+ et$+ ;arbo5y, methy, $e,,u,ose F;1;G+ Po,y(0i!y,
a,$oho, FPVAG+ Po,yester resi! Fa$ts as bi!derG
Lu'$icants, 1i!era, 4a5es+ oi,s+ 0e/etab,e 4a5es a!d oi,s+ a!ima, 7ats
A%%iti)es, Sa,i$y,i$ a$id+ ?i!$ $h,oride+ 6he!o,+ emu,siIer+ so7te!ers+ Po,yethy,e!e
/,y$o,
C7E!I
CAL
"<Te -#CO
L
-#
REC
9# <# :# &# "<OE Sa0*
le
siAing
Te;o*la
st
.& -& -& C& B& -& %& C& DDD
41A B B )& )& )& )- TTT )& =
Fali;los
e
%- %- %- TTT TTT TTT B& %& DDD
SeycoB
l0
. B B )% )- )- . B +
!.
Tallo.
- - - - - - - . +
4e*
"###
)&& )&& )&& )&& )&& )&& )&& )&& DDD
L1 -# ) TTT TTT TTT TTT TTT TTT TTT DDD
Wate$ "9EE "-.9E
E
"-.9E
E
"-EE "-EE "-EE "-EE ":EE "##
Ta'le &, Che0ical Co0*osition of siAing fo$ %iFe$ent ty*es of ya$ns.
)OOR *CC- ,itres
INFRASTRUCTURE,
.) 2 P a / e
SUCKER MULLER HACOBA 4ith PL; de0i$eF 6ro/rammab,e ,o/i$ $o!tro,G: No
o7 ma$hi!es R .
JUPITER F No o7 ma$hi!es R *G
AMBICA F No o7 ma$hi!es R %G
.% 2 P a / e
TEC7NICAL DETAILS,
Feedi!/ de0i$e : Obtai! a /ood 6oi!t o7 /ri6 7or the 4ar6 This $om6rises o7 the
7o,,o4i!/ 6arts:
Pressure ro,,er
;arrier ro,,er
F,oati!/ ro,,er
;o!tro, brid/e
Rotary s4it$h
<uide ro,,er
;o!ta$t,ess s4it$h
S8uee?i!/ ro,,ers
Automati$ s8uee?i!/ ro,,er $o!tro, F PL;G
!EASURIN AND CONTROL DE1ICES FOR DEREE OF SIGIN
I7 de/ree o7 si?i!/ is too hi/h or ,o4+ ris" o7 thread brea"s is i!$reased
:e/ree o7 si?i!/FLG R USaFLG V KFLGW M F)&&LG P 4here Sa R Si?i!/ ,i8uor
ta"e u6
It is the ratio o7 the ,i8uor ta"e! u6 to the 4ei/ht o7 u!treated yar! K R
;o!$e!tratio!
It is measured by a re7ra$tometer
Facto$s AFecting Deg$ee of SiAing,
;o!$e!tratio!
Vis$osity o7 si?i!/ ,i8uor
.* 2 P a / e
Tem6erature o7 si?i!/ ,i8uor
S6eed
S8uee?i!/ 6ressure
<.+ Denting an% D$a.ing H In
A,, the 4ar6 threads ha0e to be threaded throu/h the hea,d eye,et a!d its /a6 i!
the reed 6rior to 4ea0i!/ The hea,d is the 6art o7 the ,oom that is used to mo0e
the 4ar6 threads u6 a!d do4! The threads 6ass throu/h eye,ets o! the hea,d
For a sim6,e 4ea0e 6atter! a,ter!ate eye,ets are mo0ed u6 to raise the
$orres6o!di!/ 4ar6 threads+ a!d the threads bet4ee! are mo0ed do4! 3he!
the shutt,e tra0e,s ba$" their 6ositio!s are re0ersed
INFRASTRUCTURE,
)G STAUBLI DELTA 2, The :ELTA %&& is a hi/h(6er7orma!$e dra4i!/(i!
i!sta,,atio! It is used 4here0er hi/h 6rodu$tio! 6er7orma!$e+ a 4ide Ie,d o7
a66,i$atio!s+ a!d ma5imum Ke5ibi,ity are re8uired The :ELTA %&& dra4s(i!
4ar6 yar!s dire$t,y 7rom the 4ar6 beam 4ith ) or % sheets+ a!d o6tio!a,,y u6 to
. sheets
%G STAUBLI DELTA !!: These dra4i!/(i! i!sta,,atio!s are desi/!ed 7or 4ea0i!/
mi,,s 4ith medium dra4i!/(i! re8uireme!ts The :ELTA ))& a,so ha!d,es dro6
4ires a!d is a u!i0ersa, i!sta,,atio! Furthermore+ a modu,e is a0ai,ab,e that is
s6e$ia,,y desi/!ed 7or dra4i!/(i! $ourse yar!s :ra4i!/(i! ta"es 6,a$e dire$t,y
7rom the 4ar6 beam 4ith ) 4ar6 sheet+ or o6tio!a,,y 4ith % 4ar6 sheets
:ELTA ))& %&&
:ra4i!/(i! s6eed Fe!dsMmi!G )&&M).&V %&&
Number o7 4ar6s i! Dh F$a G %(- .(D
3ar6 4idths FmG %*M .&M
B&
%%M %DM
.&
Number o7 4ar6 sheets ) F%VG % F.VG
Reed de!sityF teethM dmG -&& -&&
1a5 !umber o7 7rames F=M;( %& %D
.. 2 P a / e
hea,dsG
1a5 !umber o7 7rames FO(
hea,dsG
)B %&
1a5 ro4s o7 dro64ires TTTT D
Number o7 dro64ire 6aths TTTT %
:ra4i!/(i! e,eme!t Hoo" Ra6ier
Ear! $ou!t ra!/e Fte5G *(%-& *(**&
Se3uence of Functions,
Ba!d /ri66er starts the dra4i!/(i! se8ue!$e be7ore a,, modu,es are ready
7or dra4i!/(i!
I7 reed modu,e is !ot ready+ it re6orts a7ter reed test
<ri66er e!ters the de!t F$a! be sto66ed i7 reed modu,e is !ot ready+
other4ise $o!ti!ues its 7or4ard motio!
Hea,d modu,e re6orts at hea,d test I7 it is !ot ready+ ba!d /ri66er is
sto66ed be7ore 6assi!/ throu/h hea,d eye I7 it is i! ready state+ /ri66er
mo0es o!
:ro6 4ire modu,e re6orts at dro6 4ire test I7 it is !ot ready+ ba!d /ri66er
is sto66ed be7ore 6e!etrati!/ eye o7 the dro6 4ire I7 ready+ /ri66er
mo0es o!
Ear! su66,y modu,e re6orts at yar! test I7 it is !ot ready+ ba!d /ri66er is
sto66ed be7ore e!teri!/ yar! ta"e o0er I7 ready+ the /ri66er $o!ti!ues its
motio!
A7ter yar! ta"e o0er+ ba!d /ri66er 4hi$h /ri6s the yar! 4ithdra4s
Ba!d /ri66er 4ithdra4s 6ast the dro6 4ire a!d hea,d 6ositio!s
:ro6 4ire a!d hea,d distributio! systems mo0e o!
Reed tra!s6ort e!sures the reed 6ositio!
Ear! e#e$tors are a$tuated i! 6ositio! NeO a!d N7O Fi! the dia/ramG
O!e dra4!(i! $y$,e is o0er
.- 2 P a / e
<.- Wea)ing
It is a method o7 7abri$ 6rodu$tio! i! 4hi$h t4o disti!$t sets o7 yar!s or
threads are i!ter,a$ed at ri/ht a!/,es to 7orm a 7abri$ or $,oth The other
methods are "!itti!/+ ,a$e ma"i!/ a!d 7e,ti!/ The ,o!/itudi!a, threads are
$a,,ed the 4ar6 a!d the ,atera, threads are the 4e7t or I,,i!/ The methods i!
4hi$h these threads are i!ter( 4o0e! aAe$ts the $hara$teristi$s o7 the $,oth
;,oth is usua,,y 4o0e! o! a ,oom+ a de0i$e that ho,ds the 4ar6 threads i!
6,a$e 4hi,e I,,i!/ threads are 4o0e! throu/h them "e#t is a!
o,d E!/,ish 4ord mea!i!/ Sthat 4hi$h is 4o0e!S A 7abri$ ba!d 4hi$h meets
this deI!itio! o7 $,oth F4ar6 threads 4ith a 4e7t thread 4i!di!/ bet4ee!G
$a! a,so be made usi!/ other methods+ i!$,udi!/ tab,et 4ea0i!/+ ba$"(stra6+
or other te$h!i8ues 4ithout ,ooms
The 4ay the 4ar6 a!d I,,i!/ threads i!ter,a$e 4ith ea$h other is $a,,ed the
4ea0e The ma#ority o7 4o0e! 6rodu$ts are $reated 4ith o!e o7 three basi$
4ea0es: 6,ai! 4ea0e+ sati! 4ea0e+ or t4i,, 3o0e! $,oth $a! be 6,ai! Fi! o!e
$o,our or a sim6,e 6atter!G+ or $a! be 4o0e! i! de$orati0e or artisti$ desi/!s
4ROCESS AND TER!INOLOC,
I! /e!era,+ 4ea0i!/ i!0o,0es usi!/ a ,oom to i!ter,a$e o7 t4o sets o7 threads
at ri/ht a!/,es to ea$h other: the 4ar6 a!d the 4e7t Fo,der 4oo7G O!e 4ar6
thread is $a,,ed a!d a! e!d a!d o!e 4e7t thread is a 6i$"+ the 4ar6 threads
are he,d taut a!d i! 6ara,,e, order+ ty6i$a,,y i! a ,oom o7 4hi$h there are
ma!y diAere!t ty6es 3ea0i!/ $a! be summarised as a re6etitio! o7 these
three a$tio!s:
Primary 1otio!s
Se$o!dary 1otio!s
Tertiary 1otio!s
Primary 1otio!s:
Shedding: 3here the e!ds are se6arated by raisi!/ or ,o4eri!/ hea,d
7rames Fhedd,esG to 7orm a $,ear s6a$e 4here the 6i$" $a! 6ass
Picking: 3here the 4e7t or 6i$" is 6ro6e,,ed a$ross the ,oom by a! air(#et+ a
ra6ier or a shutt,e
.B 2 P a / e
Beating-up or battening: 3here the 4e7t is 6ushed u6 a/ai!st the 7e,, o7
the $,oth by the reed
.C 2 P a / e
Se$o!dary 1otio!s:
Let of Motion: 4here the 4ar6 is ,et oA the 4ar6 beam at a re/u,ated
s6eed to ma"e the I,,i!/ e0e! a!d o7 the re8uired desi/!
Take up Motion: Ta"es u6 the 4o0e! 7abri$ i! a re/u,ated ma!!er so that
the de!sity o7 I,,i!/ is mai!tai!ed
Tertiary 1otio!s:
The sto6 motio!s: to sto6 the ,oom i! the e0e!t o7 a Thread brea" The t4o
mai! sto6 motio!s are the
3ar6 sto6 motio!
3e7t sto6 motio!
Others are:
Tem6,e
Le!o Sto6
;at$h ;ord Sto6
3aste ;utter
The 6ri!$i6a, 6arts o7 a ,oom are:
The 7rame
The 4ar6(beam or 4ea0ers beam
The $,oth(ro,,
The hedd,es a!d their mou!ti!/+
The reed
The 4ar6(beam is a 4oode! or meta, $y,i!der ba$" o7 the ,oom o! 4hi$h the
4ar6 is 4ou!d The threads o7 the 4ar6 e5te!d i! 6ara,,e, order 7rom the
4ar6(beam to the 7ro!t o7 the ,oom+ a!d are atta$hed to the $,oth(ro,, Ea$h
thread or /rou6 o7 threads o7 the 4ar6 6asses throu/h a! o6e!i!/ FeyeG o7 a
hedd,e The 4ar6 threads are se6arated by the hedd,es i!to t4o or more
.D 2 P a / e
/rou6s+ ea$h $o!tro,,ed a!d automati$a,,y dra4! u6 a!d do4! by the motio!
o7 the hedd,es I! the $ase o7 sma,, 6atter!s the mo0eme!t o7 the hedd,es is
$o!tro,,ed by X$amsY 4hi$h mo0e u6 the hedd,es by mea!s o7 a 7rame $a,,ed
a har!essP i! ,ar/er 6atter!s the hedd,es are $o!tro,,ed by a dobby
me$ha!ism+ 4here the hea,ds are raised a$$ordi!/ to 6e/s i!serted i!to a
re0o,0i!/ drum 3here a $om6,e5 desi/! is re8uired+ the hea,ds are raised by
har!ess $ords atta$hed to a =a$8uard ma$hi!e E0ery time the har!ess Fthe
hedd,esG mo0es u6 or do4!+ a! o6e!i!/ FshedG is made bet4ee! the threads
o7 4ar6+ throu/h 4hi$h the 6i$" is i!serted
The ra6ier(ty6e 4ea0i!/ ma$hi!es do !ot ha0e shutt,es+ they 6ro6e, the 4e7t
by mea!s o7 sma,, /ri66ers or ra6iers that 6i$" u6 the I,,i!/ thread a!d $arry
it ha,74ay a$ross the ,oom 4here a!other ra6ier 6i$"s it u6 a!d 6u,,s it the
rest o7 the 4ay Some $arry the I,,i!/ yar!s a$ross the ,oom at rates i!
e5$ess o7 %+&&& meters 6er mi!ute 1a!u7a$turers su$h as Pi$a!o, ha0e
redu$ed the me$ha!i$a, ad#ustme!ts to a mi!imum+ a!d $o!tro, a,, the
7u!$tio!s throu/h a $om6uter 4ith a /ra6hi$a, user i!ter7a$e Other ty6es
use $om6ressed air to i!sert the 6i$"+ a!d others sma,, 6ro#e$ti,es They are
a,, 7ast+ 0ersati,e a!d 8uiet
The ha!d,oom 4ea0er si?es his 4ar6 i! star$h mi5ture 7or smoother ru!!i!/
He 4ar6s his ,oom F,oomed or dressedG by 6assi!/ the 4ar6 threads throu/h
hedd,es o! t4o or more har!esses The 6o4er 4ea0erOs ,oom is 4ar6ed by
se6arate 4or"ers I! o6eratio! the 4ar6 threads are mo0ed u6 or do4! by
the har!esses $reati!/ a s6a$e $a,,ed the shed throu/h 4hi$h the 6i$" 4i,,
6ass The har!esses $a! be $o!tro,,ed by $ams+ dobbies or a =a$8uard head
The raisi!/ a!d ,o4eri!/ se8ue!$e o7 4ar6 threads i! 0arious se8ue!$es
/i0es rise to ma!y 6ossib,e 4ea0e stru$tures:
P,ai! 4ea0e: 6,ai!+ a!d ho6sa$"s+ 6o6,i!+ taAeta+ 6ou,t a!d /ros/rai!
T4i,, 4ea0e: these are des$ribed by 4e7t Koat 7o,,o4ed by 4ar6 Koat+
arra!/ed to /i0e dia/o!a, 6atter! %M) t4i,,+ *M* t4i,,+ )M% t4i,, These
are so7ter 7abri$s tha! 6,ai! 4ea0es
Sati! 4ea0e: sati!s a!d satee!s
.' 2 P a / e
;om6,e5 $om6uter(/e!erated i!ter,a$i!/
Pi,e 7abri$s: su$h as 0e,0ets a!d 0e,0etee!
Both 4ar6 a!d 4e7t $a! be 0isib,e i! the I!a, 6rodu$t By s6a$i!/ the 4ar6
more $,ose,y+ it $a! $om6,ete,y $o0er the 4e7t that bi!ds it+ /i0i!/ a 4ar6
7a$ed te5ti,e su$h as re$$ %ea&e
;o!0erse,y+ i7 the 4ar6 is s6read out+ the 4e7t $a! s,ide do4! a!d
$om6,ete,y $o0er the 4ar6+ /i0i!/ a 4e7t 7a$ed te5ti,e+ su$h as a ta6estry or
a K'l'm ru(

-& 2 P a / e
Wea)ing> Fa'$ic !anufactu$ing 4$ocess
3i!di!/
3ar6i!/ or beami!/
Si?i!/
:ra4i!/ i!+ Loomi!/
Pir!i!/ FPro$essi!/ the 4e7tG
3ea0i!/
1easureme!ts:
En%s an% 4ic?s: Pi$"s re7er to the 4e7t+ e!ds re7er to the 4ar6 The
$oarse!ess o7 the $,oth $a! be e56ressed as the !umber o7 6i$"s a!d e!ds
6er 8uarter i!$h s8uare+ or 6er i!$h s8uare A! e!d is a,4ays 4ritte! Irst For
e5am6,e: Hea0y domesti$s are made 7rom $oarse yar!s+ su$h as )&Zs to ).Zs
4ar6 a!d 4e7t+ a!d about .D e!ds a!d -% 6i$"s
3ea0i!/ :e6artme!t O7 A,o" I!dustries Ltd:
There are tota, ). 4ea0i!/ u!its i! A,o" I!dustries
Unit Nu0'e$ 4$o%uct
)
3ider 3idth 7abri$
%
* Fi!e ;ou!t 7or Pri!t+ ;hambray
. Ear! :ied FShirti!/ > Suiti!/ Fabri$G
- 3ider 3idth F:e7e!seG
B 3ider 3idth Fabri$ >
C 3ider 3idth Fabri$
D Ear! :ied FShirti!/ > Suiti!/ Fabri$G
'A 3ider 3idth Fabri$
'B
Bat$hi!/F:e7e!se Pur6oseG
';
':
Ear! :ied Fabri$
'E
-) 2 P a / e
Unit
Nu0'e$
!achine Ty*e Nu0'e$ Of
!achines
) Pi!a$o, Air =et Looms 4ith ;am+*.& $msF% 6i$"
i!sertio!G
D&
% Pi!a$o, Air =et Looms 4ith ;am+*.& $msF% 6i$"
i!sertio!G
D&
* Toyota air =et Looms -%
Pi!a$o, Ra6ier LoomF=a$8uardG )%
Su,?er Ra6ier LoomF=a$8uardG )B
. Pi!a$o, Air =et Looms 4ith :obby *%
Su,?er Ra6ier Loom 4ith :obby+%%& $ms &%
Su,?er Ra6ier Loom 4ith :obby+)'& $ms %D
Pi!a$o, Ra6ier Looms 4ith :obby .&
- Pi!a$o, Air =et Looms 4ith ;am 'B
Pi!a$o, Air =et Looms 4ith :obby .D
B Pi!a$o, Air =et Looms 4ith ;am )-%
Pi!a$o, Ra6ier Looms 4ith :obby CB
Toyota air =et Looms 4ith ;am -&
Toyota air =et Looms 4ith ;am %B
C Pi!a$o, Air =et Looms 4ith ;am )&&
Pi!a$o, Air =et Looms 4ith :obby -%
Toyota air =et Looms 4ith ;amF% 6i$" i!sertio!G %B
Toyota air =et 4ith ;amF. 6i$" i!sertio!G )%
D Vamate5 Ra6ier Loom 4ith :obby CB
Toyota air =et Looms 4ith ;am )%
'A A,, ma$hi!es o7 u!it > )B.
Tsuda"oma Air =et 4ith ;am )B
'B Toyota air =et Looms 4ith ;am+ Bat$hi!/ D.
'; Toyota air =et Looms 4ith ;am C)
Toyota air =et Looms 4ith :obby .&
': Pi!a$o, Ra6ier Looms 4ith :obby ))&
'E Pi!a$o, Air =et Looms 4ith ;am ))&
'F Toyota air =et Looms 4ith ;am+*.& $msF. 6i$"
i!sertio!G
)-&
Toyota air =et Looms 4ith ;am+*.& $msFB 6i$"
i!sertio!G
-&
Ta'le +, DiFe$ent .ea)ing units an% Ty*e of 4$o%uct !anufactu$e
/ea0 Length,
Ty*e of Fa'$ic A)e$age LengthI0tsJ
Ca$n Dye% Fa'$ic )D&&
-% 2 P a / e
$ey Fa'$ic %-&&
Wi%e$ Wi%th Fa'$ic *&&&
S*ee% K 4$o%uction,
Sl.
Nu0'e$
Ty*e of Fa'$ic 4$o%uction in
!ts2Loo02Day
S*ee%IR4!J
" Ear! :yed Fabri$ &## 99#
& <rey Fabri$ +## <##
+ 3ider 3idth
Fabri$
":# 9##
Unit 4$o%uction2
Day I0tsJ
ELciency
IMJ
R7 IMJ Count of
Th$ea%
Wi%th of
Fa'$ic
IinchesJ
On
Loo
0
At
Roo
0
" =# =# <9
& =# =# <9
+ :9 =# <9
- &&###>
&9###
=#>=9 =# <9 "&#2&>
"-#2&
:&
9 +-### =# =# <9 +#>"## .i%e$
< :9>=# =# <9
: "9&#<9 =# =# <9 ""<>""=
= =9 =# <9
@A -+### =# =# <9 +#>"## @+
@/ =# =# <9
@C :9 =# <9
@D =9>@# =# <9
@E =# =# <9
@F > > > > > >
Ta'le -, 4$o%uctionN ELciency an% R7 of %iFe$ent %i)isions

-* 2 P a / e
:.# 4$e*a$ato$y fo$ Dyeing an%
4$inting
-. 2 P a / e
$eige Fa'$ic 4$ocessing
<ei/e 7abri$ 7or 7urther 6ro$essi!/ is sour$ed mai!,y 7rom the si,0assa 6,a!t
F'-L o7 the 7abri$ 6ro$essedG
The 6rodu$t mi5 a0ai,ab,e a!d 6ro$essed:(
Fabri$s by 4ei/ht:(Li/ht+ medium+ hea0y
Fabri$s by b,e!d:( Po,y ;otto!+ ;otto! Vis$ose+ ;otto! Ly$ra+ ;otto!
S6a!de5
Fabri$s By 4ea0e:( T4i,,+ P,ai!+ satee!+ sati!+ dobby+ desi/!F=a$8uardG
The 7abri$ is a,ready /raded 4he! it is re$ei0ed %&&& Stee, Ra$"s are there
7or stora/e 7or u6 to %' ,a"h 1eters o7 7abri$ A0era/e ,e!/th o7 7abri$ o! a A(
7rame bat$h is .-&& meters but it $ou,d 0ary o! the <S1 Fabri$ Ro,,s are
o6e!ed a!d $o!0erted i!to A(7rame bat$hes a!d se!t 7or 7urther 6ro$essi!/
o7 si!/ei!/ a!d desi?i!/
:." Singeing
Si!/ei!/ is the 6ro$ess o7 remo0a, o7 6rotrudi!/ Ibers Si!/ei!/ is do!e 0ia
/as Kames 4hi$h $ome i! $o!ta$t 4ith Ibers a!d bur! them
The 7abri$ ru!s 6er6e!di$u,ar or ta!/e!tia,,y to the /as Kames de6e!di!/
u6o! the Iber 6ro6erties a!d thi$"!ess o7 the 7abri$
INFRASTRUCTURE:
There are * ma$hi!es o! 4hi$h these o6eratio!s are 6er7ormed
The ma$hi!e used is XO)t*+, Sen(eY+ 1ode,s: ( VP''(H F% mM$G > .%*%C
3u66uta,+ <erma!y
S6eed o7 Fabri$:
Li/ht 7abri$s: ( )&& ( )%& mtsMmi!
Hea0y 7abri$s: ( B& ( C& mtsMmi!

-- 2 P a / e
PRO;ESS:
The )
st
6hase is the 6re brushi!/+ 4here a
brush is a66,ied i! order to raise the 6rotrudi!/
Iber
The 6ro$ess is $arried out by a66,yi!/ /as
Kame o! the 7abri$+ 7or most o7 the 7abri$P
Kame is a66,ied o! the either side o7 the
7abri$+ 7or some 8ua,ities it is a66,ied o!,y o!
the 7a$e side
The 6ressure o! the 7abri$ is a66,ied i! the
brushi!/ 6hase 4hi$h is /e!era,,y arou!d )% mbar
The Kame i!te!sity $ou,d be redu$ed by a66,yi!/ the Kame at a ta!/e!tia,
a!/,e+ there are . a!/u,ar 6ositio!s
& re6rese!ts !o Kame is a66,ied o! the 7abri$ a!d * re6rese!ts the 7abri$ is
a66,ied at '&
&
) a!d % are 6ositio!s i! bet4ee! & a!d *+ 4here &+ )+ % a!d *
6ositio!s re6rese!ts )%oO$,o$"+ ) oO$,o$"+ %oO$,o$" a!d *oO$,o$" o7 a 4at$h
res6e$ti0e,y
The ,ast 6hase is 6ost brushi!/+ 4here a brush is a66,ied to remo0e the bur!t
Iber 7rom the 7abri$
LEARNIN<:
The ma5imum se!/e i!te!sity o! a 7abri$ $ou,d be 4he! 6arameters are %&
mbar a!d $,o$" 6ositio! is *+ 7or ,i/ht 4ei/ht 7abri$ it is de$reased u6 to D
mbar a!d $,o$" 6ositio! )
These ma$hi!es $a! 6ro$ess u6 to *&+&&& meters MD hrs
I! $ase o7 dobby a!d mi,etta $he$" 7abri$ the 6re(brush 6ressure is *F[M( )G
-B 2 P a / e
:.& DesiAing
It is the 6ro$ess o7 remo0a, o7 star$h 7rom the 7abri$+ mai!,y $arried out by
a66,i$atio! o7 e!?yme Star$h is mai!,y used as si?i!/ a/e!t 4hi,e 4ea0i!/
so hi/h(a$ti0atio!+ hi/h(stabi,ity a!d se,e$ti0e e!?ymes are $hoose! 4hi$h
$a! tar/et o! star$h si?i!/ a/e!t
E!?ymes !eed to be "e6t a$ti0e i! a $ertai! ra!/e o7 6H Fsu$h as 6H - H6H
'G 1ai!,y Aquazym PS-L Enzyme is used I! some $ases Po,y0i!y, A,$oho,
FPVAG is used as si?e materia, a!d it $ou,d be easi,y desi?ed 4ith the he,6 hot
4ater
;hemi$a,s used i! desi?i!/ Pro$ess are as 7o,,o4:(
Wetting agent: ( i!$reases absorbe!$y i! 7abri$
EnAy0es: ( re8uired 7or remo0a, o7 si?es a66,ied to 7abri$s
Chelating agents: ( restri$ts the rea$tio! o7 a!y meta, io! 4ith a!y
added $hemi$a,s
INFRASTRJ;TJRE:
This 6ro$ess is $o!ti!uousP a,, the $hambers are arra!/ed $o!se$uti0e,y i!
order o7 their 6ur6ose

The ma$hi!e has a! im6re/!ati!/ $hamber 7or a66,i$atio! o7 desi?i!/
$hemi$a, o! the 7abri$+ a steam bo5 7or assisti!/ $hemi$a, a$ti0atio! o! the
7abri$+ o!e 7oretra$tra $hamber 7or the remo0a, o7 e5$ess $hemi$a,+ *
-C 2 P a / e
e5tra$ta $hambers 7or 4ashi!/ oA the $hemi$a,s a!d a set o7 ro,,ers to dry
the 7abri$ The tem6erature 7or 4ashi!/ a!d steam bo5 is '-
&
;
4ROCESS:
The 7abri$ mo0es 7rom 6ost si!/ei!/ brush to steami!/ $hamber is to ma"e
si?e materia, s4e,,+ i!side the 7oretra$tra+ the 7abri$ is 7ed i!to a mi5ture o7
e!?yme a!d $he,ati!/ a/e!t+ the e5tra $hemi$a, is remo0ed here o!,y by
ro,,er 6ressure+ the !e5t 6ro$ess o7 remo0a, o7 si?e ha66e!s i!side e5tra$ta+
here there are * $hambers+ i!side these $hambers the 7abri$ is 4ashed 4ith
hot 4ater The !e5t 6ro$ess is 6assi!/ the 7abri$ thou/h the heated
$hambers i! order to dry the 7abri$+ a7ter this the 7abri$ is bat$hed
A3uaAy0 4S>L %(- m,M"/
Felosan A4F *(. m,M"/
Chelating agent I!angle
E;*$essionJ
)&&L
Soa?age te0*e$atu$e '&
&
;
Stac?ing Ti0e B()D hrs
LEARNIN:
The tota, time 7or 4hi$h the 7abri$ remai!s i!side the desi?i!/ ma$hi!e is D(
)- mi!utes
A7ter desi?i!/+ the 7abri$ ,oses about C(DL o7 the 4ei/ht Residua, si?e
materia, is measured i! a u!it $a,,ed TE<3A+ i7 ,e0e, o7 TE<3A is hi/her+
si?i!/ is do!e 6ro6er,y a!d i7 it is ,o4er+ si?i!/ has !ot bee! do!e 6ro6er,y
-D 2 P a / e
:.+ 4$e T$eat0ent Range I4TRJ
Fabri$ 7rom desi?i!/ 6ro$ess arri0es to the PTR a!d is 7ed i!to the ma$hi!e It
is a $om6osite ma$hi!e ra!/e 4here the 7abri$ is 4ashed+ b,ea$hed a!d
dried be7ore it is dyed
The % 6ro$esses ta"i!/ 6,a$e i!side the PTR are s$ouri!/ a!d b,ea$hi!/+ the
6ur6ose o7 s$ouri!/ is to remo0e the 4a5+ dirt a!d other 7orei/! materia,
7rom the 7abri$ 4hi,e the 6ur6ose o7 b,ea$hi!/ is to 4hite! the 7abri$
INFRASTRUCTURE:
The ma$hi!e is $a,,ed BENNIN<ER PTR
There are se$tio!s i! this ma$hi!e as 7o,,o4:
IN=E;TA: Fabri$ is 4ashed 4ith 4ater a!d steam
EXTRA;TA: Remo0e the materia, 6rese!t i!side the 7abri$
I1PE;TA: Paddi!/ o7 7abri$ 4ith 4etti!/ a/e!t+ reser0e a!d stabi,i?er
STEA1ER: Steami!/ o7 7abri$+ a$tio! o7 $hemi$a, o! 7abri$
EXTRA;TA: Remo0a, o7 4a5 a!d dirt 7rom the 7abri$
4ROCESS:
The 7abri$ 6asses 7rom the IN=E;TA a!d EXTRA;TA $hambers Irst+ 4here
4ashi!/ is do!e a!d im6urities are remo0ed+ !e5t+ the 7abri$ mo0es 7rom
I1PE;TA $hamber F;hemi$a, Additio! Ta!"G 4here it is 6added 4ith H
%
O
%
a!d
other $hemi$a,s+ 7rom there it 6asses throu/h steamer 4here at a hi/h
tem6erature the steam is a66,ied to the 7abri$ a!d $hemi$a,s a$t u6o! the
4a5 a!d im6urities
-' 2 P a / e
The $hemi$a, $om6ositio! i! I1PE;TA is ,i"e this:
Che0icals Ouantity I0l2?gJ
4e$o;i%e I7
&
O
&
J %&
Rese$)e .
Wetting agent .-
Sta'iliAe$ .
NaO7 )-
Ta'le 9, Che0ical Co0*osition in I!4ECTA
The Steami!/ tem6erature is arou!d '-
&
; Here i! the steamer H
%
O
%
a$ts as
b,ea$hi!/ a/e!t 4hi,e NaOH is used 7or s$ouri!/+ NaOH a,so 6ro0ides a basi$
medium 7or B,ea$hi!/ A7ter this the 7abri$ is dried a!d bat$hed
LEARNIN:
The e!tire 6ro$ess ta"es D(%& mi!utes to $om6,ete The s6eed o7 the 7abri$ is
CB mMmi! s$ouri!/ a!d b,ea$hi!/ are simu,ta!eous 6ro$esses The 7abri$
$omi!/ out o7 PTR is some4hat basi$ be$ause o7 6rese!$e o7 sma,, amou!t
o7 NaOH The 6ro$ess ha66e!i!/ i!side PTR is emu,siI$atio! a!d
Sa6o!iI$atio! a!d the by6rodu$ts are emu,sio!s a!d 4a5+ /rease a!d dirt
Neutra,i?atio! is $arried out ma!y a times a7ter b,ea$hi!/ i7 the buyer
dema!ds 7or it+ other4ise i7 it is to 6ro$essed 7urther or 6ass throu/h the
mer$eri?atio! 6ro$ess+ it is !ot !eutra,i?ed+ A$eti$ a$id is used 7or
!eutra,i?atio! 6ro$ess
B& 2 P a / e
:.- !e$ce$iAation
1er$eri?atio! is a 6re6aratory 6ro$ess mai!,y used 7or $e,,u,osi$ Ibres 4he!
,ustre is im6orta!t or ,i/ht shades are to be dyed The mai! 6ur6ose o7
mer$eri?atio! is to i!$rease the absorbe!$y+ dime!sio!a, stabi,ity a!d ,uster
INFRASTUCTURE:
Be!!i!/er 1er$eri?er e8ui66ed 4ith the Be!( dime!sa te$h!o,o/y is used 7or
the mer$eri?atio! 6ro$ess There are three mer$eri?ers out o7 4hi$h %
ma$hi!es are based o! the $hai! 6ri!$i6,e+ 4hi,e the third ma$hi!e is based
u6o! $hai!,ess 6ri!$i6,e e5$,usi0e,y used 7or hea0yMbottom 4ei/ht 7abri$s
4ROCESS:
The 7abri$ is Irst 6assed throu/h XRi!si!/ :ro6Y 4here it is 6added 4ith
4ea" ,ye F.&(B& <PLG+ the! the !e5t 6ro$ess is 6assi!/ it throu/h
XIm6re/!atorsY 4here it is 6added 4ith NaOH F%D(*& BeG+ the 7abri$ is di66ed
i! the so,utio! 7or *-(.& se$ be7ore 4ashi!/+ -&(B&L o7 the $austi$ is
s8uee?ed out o7 it+ !e5t+ it is s6read 4ith 4ater to i!$rease the stre!/th
The !e5t is the stabi,i?er ?o!e that 6ro0ides te!sio! to the 7abri$P it is 6assed
throu/h .(- 4asher a!d stabi,i?er at '-
&
; to remo0e the $austi$ matter+ !o4
it is 6assed throu/h a trou/h $o!tai!i!/ /rai! a$idF$ombi!atio! o7 mi!era,
a$idG+ used to remo0e the sma,, amou!t o7 $austi$ materia, ,e7t F-()&LG
The A0era/e 6ro$essi!/ s6eed is B&(C& mtsMmi!
;hemi$a,s used i! the 6ro$ess 7or mer$eri?atio! are:
NaOH F%D(*& BeG
Or/a!i$ a$id
;austi$ soda
B) 2 P a / e
Featu$es:
1er$eri?atio! is a hot 6ro$ess
;o,d mer$eri?atio! 7a$es the 6rob,em o7 !o!(u!i7ormity due to hi/h,y
0is$ous so,utio!
;o!$e!tratio! o7 $austi$( %D(*&Be+ 4hi$h is arou!d %-& /M,
Treatme!t tem6erature is B&
&
;
1a!/,e 6ressure(*-bar
3et 6i$"u6(C-L
)&L shri!"a/e duri!/ mer$eri?atio!
*&&m 7abri$s i!side the ma$hi!e at a time
I! $hai! mer$eri?atio!+ 7abri$ $a! be e,o!/ated 4idth 4ays a7ter
mer$eri?atio!
LEARNIN:
The 7abri$ shri!"s i! this 6ro$ess be$ause o7 the rou!di!/ o7 Ibers 7rom
"id!ey sha6e to $ir$u,ar 7orm a!d be$ause the $austi$ de$reases the ho,,o4
s6a$e bet4ee! the yar!s+ ,usture i!$reases as a resu,t o7 this 6ro$ess
A de!ser 7abri$ 4ou,d ha0e a ,o4er shri!"a/e tha! a !o! de!ser 7abri$
WIDT7 ENTRC /EFORE
C7AIN
AFTER
C7AIN
E8IT
C0s. )-& ).' )-% ).B
Ta'le <, Re%uction in Wi%th %ue to !e$ce$iAation

B% 2 P a / e
=.# Fa'$ic an% Ca$n Dyeing
B* 2 P a / e
Dyeing
;o,d 6ad bat$h FRea$ti0eG H ;otto! Fiber
Pad dry 6ad steam FRea$ti0e+ VATG H ;otto! a!d P; b,e!d
:is6erse o! thermoso, > rea$ti0e o! ;PB H P; B,e!d
:is6erse 0at si!/,e bath H P; B,e!d
E $o!tro, FRea$ti0eG H ;otto! Fiber
=." Col% 4a% /atch
The $o,d 6ad bat$h ma$hi!es are
used 7or a66,i$atio!s o7 o!,y
rea$ti0e dyes There are three
$o,d 6ad bat$h ma$hi!es 7rom
be!!i!/er "!o4! as "usters dye
6ad
The $o,or re8uireme!t o7 a 7abri$
is dire$t,y de6e!de!t o! the
7o,,o4i!/:
The ,e!/th o7 the 7abri$ to be dyed
The 6i$"u6 o7 the 7abri$ i! 6er$e!t
The <L1 o7 the 7abri$F<ram 6er ,i!ear meterG
:yei!/ 6ro$ess ta"es arou!d )B hrs 7or dyei!/ at room tem6erature It $a!
6rodu$e a ra!/e o7 ,i/ht+ medium a!d dar" $o,ours
;PB has a 0erti$a, arra!/eme!t o7 ro,,ers 7or di66i!/ the 7abri$ i! dye
so,utio! The !umber o7 ro,,ers may 0ary 7rom % to . This o6erates i! a
ra!/e o7 -&(B& mtsMmi! The dye to $hemi$a, ratio may 0ary but sta!dard
ratio used is o7 .:)
The 0arious $hemi$a,s used i! the dyei!/ trou/h are:(
Fi;e$ che0icals > Sodium si,i$ate used 7or I5i!/
Reacti)e %yes
B. 2 P a / e
So%a an% caustic
A7ter im6re/!atio! o7 the dyestuA the I!ishi!/ ro,,ers a!d s8uee?i!/ u!it
s8uee?e out the e5tra dye so,utio! These bat$hes the! re8uire I5atio! d4e,,
time 7or 4hi$h the bat$hes are "e6t u!der rotatio! Fto a0oid a!y ,ea$hi!/ out
o7 a!y dyestuAG i! the RF: stora/e /e!era,,y 7or )B hrs
Ea$h ma$hi!e has * dye a!d % $hemi$a, ta!"s 4ith ea$h ha0i!/ a $a6a$ity o7
D&& ,ts A66ro5 6rodu$tio! is %&+&&&(%%+&&&mtsMD hrs
=.& Continuous Dyeing Range,
The !onfo$ts The$0osol is a $o!ti!uous dyei!/ ra!/e i! 4hi$h the 6re(
treated 7abri$s a$ts as i!6ut a!d a $om6,ete,y dyed 7abri$ is re$ei0ed at the
out6ut 4hi$h is the! se!t 7or I!ishi!/ This is mai!,y used 7or the 7o,,o4i!/
ty6es o7 dyes:
:is6erse
1odiIed Vat :ye
Rea$ti0e
There are % mo!7orts thermoso, 4hi$h ha0e simi,ar $o!stru$tio! a!d o!,y
diAer i! the !umber o7 IR dryer ;hamber 4hi$h o!e ma$hi!e has a si!/,e
u!it 4hi,e the other has t4o+ re8uireme!t o7 dryers de6e!ds u6o! the
a66,i$atio! re8uired
The ma$hi!es ha0e a Therme5 hot 7ue, $hamber 4hi$h has %D ro,,ers i! *
$hambers
The 7abri$ is 7ed throu/h the Feedi!/ se$tio! 4hi$h the! 6asses i!to the
3etti!/ u!it 4here it is di66ed i! the a,"a,is re8uired 7or dye I5atio! a!d dye
so,utio! are 6rese!t as re8uired The 7abri$ the! 6asses o! to air 6assa/e
ro,,ers that assist the 6e!etratio! o7 dyes a7ter 4hi$h 7abri$ 6ass i!to the IR
dryer u!its 4here throu/h heat o7 the IR bur!ers 6artia, or 6re(dryi!/ is
6er7ormed 4here u6 to .&L o7 the moisture is remo0ed
Tem6erature is mai!tai!ed at .-
&
;+ the 7abri$ the! 6asses i!to the Therme5
hot(Kue 4here the measuri!/ a!d $o!tro, u!it F$hamber atmos6hereG $o!tro,
the tem6erature a!d the Steam i!#e$tio! u!it 6ro0ides steam 7or heati!/ the
B- 2 P a / e
$hamber A7ter the $uri!/ 6ro$ess the 7abri$ is $om6,ete,y dyed a!d re$ei0ed
at the Out,et se$tio! The s6eed o7 the ma$hi!e 0aries 7rom .-(-& mts Mmi!
a!d /e!era,,y ru!s at %-(*& mts Mmi! at a! a0era/e
/enninge$ The$0osol,
The Be!!i!/er thermoso, is mai!,y used 7or
Vat dye
Rea$ti0e dye
:is6erse dye
The ma$hi!e is mai!,y based o! the 4or"i!/ 6ro$ess 6ri!$i6,e o7 6ad dry 6ad
steam method i! 4hi$h the dye im6re/!atio! a!d dryi!/ is do!e o! the
thermoso, 4hi,e the 6ad steamM$uri!/ is 6er7ormed o! the Be!!i!/er 6ad
steam ma$hi!e
The 7abri$ is 7ed i!to the ma$hi!e by 0arious ro,,ers a s$ray The 7abri$
subse8ue!t,y e!ters the dyestuA trou/h 4here it $omes i! $o!ta$t 4ith the
dye so,utio!+ a66,i$atio! method used is o7 si!/,e di6 si!/,e !i6 The! it
6asses throu/h a! i!termediate air 6assa/e 4hi$h assists i! the dye
6e!etratio! a!d the! 6assi!/ i!to the IR dryer u!it 7or the 6ur6ose o7 6re
dryi!/ 4hi$h $om6oses o7 * u!its a!d * bur!ers heated at /radua,,y
i!$reasi!/ tem6eratures u6 to .-&
&
;
The 6re dryi!/ 6ro$ess he,6s i! remo0a, o7 u6 to .& L o7 the moisture A7ter
6re(dryi!/ the 7abri$ e!ters the thermI5 hot 7ue, $hamber i! 4hi$h the 7abri$
is 6assed a!d dried at hi/h tem6erature a!d hi/h 6ressure+ thus resu,ti!/ i!
a $om6,ete,y dried 7abri$ as the out6ut
To $o!sta!t,y 6ro0ide dyestuA so,utio!s there are - stora/e ta!"s o7 4hi$h .
are dye ta!"s a!d ) is o7 $hemi$a,s o7 . 4ith $a6a$ities ra!/i!/ 7rom -&&(
)-&& ,iters
The dye: $hemi$a, ratio thus is mai!tai!ed at .:) at a! a0era/e
BB 2 P a / e
=.+ /enninge$ 4a% Stea0 !achine
The 6ad steam ma$hi!e ,ies i! ,i!e 4ith the thermoso, ma$hi!e 7or
$om6,etio! o7 the P:PS FPad dry Pad steamG 6ro$ess The Be!!i!/er 6ad
steam ma$hi!e is basi$a,,y used 7or the 7o,,o4i!/ 6ur6oses:(
;o,our de0e,o6me!t
Redu$tio! $,eari!/ i! $ase o7 b,e!ded 7abri$ doub,e bath dyei!/
There are * Be!!i!/er 6ad steam ma$hi!e is a0ai,ab,e 7or the abo0e said
ob#e$ti0es :yes 4hi$h are 6ro$essed i! the 6ad steam ma$hi!e are:(
Rea$ti0e dyes
Vat dyes
;hemi$a,s used 7or rea$ti0e 6ad steam 6ro$ess are:(
Sa,t
Soda ash
;austi$
;hemi$a, 7or 0at dye 6ad steam 6ro$ess is: ( $austi$ hydro
The 7abri$ is 7ed throu/h 7eed ro,,ers i!to the $hemi$a, trou/h 4here a,"a,i 7or
I5atio! $hemi$a,s 7or redu$tio! $,eari!/ are a66,ied o! the 7abri$ throu/h
si!/,e !i6 si!/,e di6 method a7ter 4hi$h it 6asses i!to the booster $hamber
4here the s6e$ia, s8uee?e !i6 o7 the booster /uara!tees a u!i7orm 6i$"u6+
i!de6e!de!t 7rom 6rodu$tio! s6eed a!d 7abri$ 4ei/ht The 7abri$ the! mo0es
i!to the re$ta $hamber 4ith ro,,ers 4here steam treatme!t is /i0e! to the
7abri$ at hi/h tem6erature a!d hi/h 6ressure
BC 2 P a / e
A7ter 4hi$h the 7abri$ 6asses o! to the e5tra$ta $hambers There are '
e5tra$ta $hambers that are used 7or the 6ur6ose o7 soa6i!/+ 4ashi!/+
!eutra,i?atio! a!d redu$tio! $,eari!/ I! Irst t4o e5tra$ta $hambers 4ashi!/
ta"es 6,a$e at room tem6erature I! the 7o,,o4i!/ t4o $hambers H%O% 7or
o5idatio! is added at B&&;I! the !e5t * $hambers soa6i!/ a!d hot 4ash is
do!e I! the $o!$,udi!/ % 4ashi!/ $hambers hot 4ash 4ith !eutra,i?atio! is
at '&('-&$ de/rees The de,i0ery $ustomer $y,i!ders !i6 out a!y moisture i!
the 7abri$ 4ith steam heated $y,i!ders a!d 7abri$ is re$ei0ed i! dried
$o!ditio! as out6ut The 6ro$essi!/ s6eed at a! a0era/e is -& mtsMmi!
=.- Dye% Fa'$ic Washing
The ma$hi!e has i! tota, ' $hambers i! 4hi$h% i!itia, e5tra$ta $hambers are
7or ri!si!/ 6ur6oses a!d I $hamber 7or a66,i$atio! o7 the re8uired $hemi$a,s
duri!/ 6ro$essi!/ !e5t- $hambers are the 4ashi!/ setu6 4hi$h is used 7or
4ashi!/ a7ter the dyei!/ The soa6i!/ is do!e i! t4o 4ays:
;o,d Pad Bat$h 3ash
;o,d 3ash
;o,d Pad Bat$h 3ash:
:e"o, 7bs! a!d a$eti$ a$id mi5ture is used 7or dyed 7abri$s 7rom $o,d 6ad
bat$h the7abri$ is Irst set 7or re,a5atio! a!d 6assed throu/h the heated
$hambers /i0e! as u!der
The 7abri$ is treated 4ith 4ater at *&
O
;+ the! treated 4ith 4ater at .&
&
;+
the! a soa6 so,utio! o7 :E;OL FBSN a!d a$eti$ a$id is a66,ied at B&
&
;+
Norma, 4ashi!/ 4ith 4ater at '&
&
; ta"es 6,a$e i! the !e5t - $hambers+
<ree! a$id o7 !eutra,i?es the 7abri$ at D&o$i! the ,ast !eutra,i?i!/ $hamber
;o,d 3ash:
;o,d 4ash is /i0e! to 7abri$s $omi!/ dire$t 7rom the $o!ti!uous dyei!/
ra!/e The 7abri$ is 6assed throu/h the heated $hambers /i0e! as u!der
The 7abri$ is treated 4ith 4ater at *&
&
;It is the! treated 4ith 4ater at .&
O
;
A soa6 so,utio! o7 Ariea!a, [a$eti$ a$id is a66,ied at -&
&
;Norma, 4ashi!/
4ith 4ater at -&
&
; ta"es 6,a$e 7o,,o4i!/ 4hi$h /ree! a$id o7 )B& /6,
!eutra,i?es the 7abri$ at -&
&
; The ma5imum s6eed o7 the ma$hi!e /oes u6
BD 2 P a / e
to .& mMmi! The se$o!d 4asher has drums i! its e5tra$ta $hambers 4hi$h
are a,so "!o4! as Tri"oKe5P this ma"es it 6re7erab,e 7or medium 4ei/ht a!d
,i/ht 4ei/ht 7abri$
B' 2 P a / e
=.9 Ca$n Dyeing
!ATERIAL FLOW
C& 2 P a / e
Package Winding
Pretreatment
Dyeing
After Treatment
Moisture removal (Hydro Extraction)
Winding
Drying (R dryer)
Soft .in%ing
'B s6i!d,es o! ea$h side
S6eed 0aries 4ith $ou!t:(
I .& $ou!t (C&& r6m
II B& $ou!t( D-& r6m
Pa$"a/e de!sity( *.& /M,
Te!sio! i! 4e7t yar! 6a$"a/e is "e6t hi/her tha! 4ar6 yar! 6a$"a/e
Automati$ s6,i$i!/ o7 bro"e! e!ds
Ca$n %yeing,
Weight of 0achines
I?gJ
No. of 0achines
" .
&9 .
9- -
&-+ *
+&9 %
9+9 )
"#:# %
Ta'le :, Ca*acity of 0achine in te$0s of .eight of ya$n.
C) 2 P a / e
4RETREAT!ENT
At )&&
&
; 7or .- mi!
C7E!ICALS

/io scou$ su*e$ *lus ( S$ouri!/ a/e!t

Lana*e; ( Se8uesteri!/ a/e!t

Caustic so%a

7
&
O
&

/iocatalase ( Pero5ide "i,,er

Ae$onil ( Le0e,i!/ a/e!t

DCEIN
B&( D&
&
; 7or .&(B& mi!
:e6sodye 1S:A ((((( ,e0e,i!/ a/e!t
Soda ash
;austi$ soda
AFTER TREAT!ENT
Soa*ing at '-
&
; 7or )- mi!
Eco*$et AS ((((( soa6i!/ a/e!t
4e$iBl &"# ((((( $atio!i$ a/e!t
EcoB; NF (((((( I5i!/ a/e!t
In to out cycle ti0e (((( * mi!
Out to in cycle ti0e (((( . mi!
!.L.R. :( ):D
Fully 5oo%e% 0achine FHTHPG
Pa$"a/es are hydro( e5tra$ted a7ter dyei!/ to remo0e the e5$ess ,i8uor
This is do!e by $e!tri7u/a, 7or$e
C% 2 P a / e
:ryi!/ is the! do!e i! RF dryi!/ ra!/es
J!e0e! dyei!/ may o$$ur due to 7o,,o4i!/ reaso!:(
Im6ro6er tem6erature $o!tro,
No!(u!i7orm ,i8uor Ko4
J!e0e! 4i!di!/ te!sio!
B,o$"i!/ o7 6er7oratio!s
Im6ro6er dosi!/
Ty*es of Dyeing
I. REACTI1E DCEIN
DE4T7 SALT Ig2lJ SODA I9# MJ CAUSTIC I0l2lJ
\) L %& )& )
)(* L -& - )
*(. L C& - )
.(- L D& - )
]- L '& - )
B,a$" )&& - %
II. 7E %yes
DE4T7 SALT Ig2lJ SODA Ig2lJ
\) L %& )&
)(* L -& )-
*(. L C& %&
.(- L D& %&
]- L '& %&
B,a$" )&& %-
III. 1AT DCEIN
DE4T7 CAUSTIC 9#M
I0l2lJ
7CDRO Ig2lJ SALT Ig2lJ
\) L ). B D
C* 2 P a / e
)(* L )D D )*
*(-L %% )) )D
]- L %B )* %%

La'o$ato$y Testing,
Li/ht Fast!ess
3ash Fast!essF/yro 4ashG
;ro$" meter 7or rubbi!/ 7ast!ess
1u,ti 6re$ise yar! dyei!/ ma$hi!e 4ith ma/!eti$ 6um6s There is !o
i!to out a!d out to i! Ko4
%&& "/ $a6a$ity
Pa$"a/e 4i!di!/ ma$hi!e o7 about )&& "/
K!itti!/ ma$hi!e
I. For sam6,e dyi!/
II. To $he$" 6a$"a/e to 6a$"a/e 0ariatio!

)% to!!es 6er day 6rodu$tio!
C. 2 P a / e
@.# 4$inting
Pri!ti!/ is the te5ti,e 6ro$essi!/ te$h!i8ue 7or ,o$a,i?ed a66,i$atio! o7
dyeM6i/me!t is a desired 6atter! Mdesi/!
The sty,es o7 6ri!ti!/ are $arried out are rea$ti0e+ dis$har/e F4hite a!d
$o,ourG+ a!d 6i/me!t The 6ri!ti!/ se$tio! has its o4! desi/! studio a!d
$o,our "it$he! 7or s$ree!+ dyeM6i/me!t so,utio! de0e,o6me!t
The studio is res6o!sib,e 7or the desi/!i!/ o7 the desi/!s 7or s$ree!s 4hi$h
are re8uired to be de0e,o6ed i! a$$orda!$e to the desi/! s6e$iI$atio!
6ro0ided by the buyer
There are - 4or"statio!s 4hi$h are e8ui66ed 4ith Ramsete III 0ersio! D**
7or desi/! de0e,o6me!t S$ree! 6re6aratio! de6artme!t is the 6ro0ided by
the ready desi/!s a!d its s6e$iI$atio! 7or the 6re6aratio! o7 s$ree!
S$ree! E!/ra0i!/:
A7ter re$ei0i!/ the desi/! de0e,o6ed 7or s$ree!+ 4or" i! the s$ree!
6re6aratio! starts 4ith the e!/ra0i!/ Ni$"e, made Fi!e mesh ready s$ree!
o7 0aryi!/ $ir$um7ere!$es o7 B.&mm+ D)'mm a!d '). mm are a0ai,ab,e
;ST I!"#et 6ri!ti!/ u!it is used 7or the 6ur6ose o7 e!/ra0i!/
;oati!/ o7 the s$ree!s is do!e 4ith the $ombi!atio! o7 three $o!stitue!ts
!ame,y+ Photo emu,sio! Freadymade ,i8uorG+ :i$hromate a!d :isti,,ed 4ater
4hi$h is do!e as 6er the desi/! The desi/! de0e,o6me!t is do!e throu/h the
i!" 4he! the s$ree! is e56osed to u0(,i/ht +$oati!/ harde!s to retai! itse,7
a!d the! 4ashi!/ i! re//ia!i s$ree! 4ashi!/ ma$hi!e to 4ash oA the
u!dried i!"+ thus the i!"ed 6art be$omes the area o7 6e!etratio! 7or the
$o,or 6i/me!t i! the rotary s$ree! Therea7ter the $oati!/ o! the s$ree! is
$ured i! the embee $uri!/ ma$hi!e 7or % hrs at )&&^; A7ter 4hi$h the
s$ree!s are I!a,,y dried i! the 7emate ;,imati?er
The s$ree! 6re6aratio! de6artme!t a,so houses 1ima"i Te5ti,e I!"#et is the
ma$hi!e used 7or di/ita, 6ri!ti!/ :i/ita, 6ri!ti!/ is do!e at a 0ery sma,,
s$a,e 7or o!,y s6e$ia, 6ur6oses A!y ty6e o7 7abri$ $a! be 6ri!ted u6o! usi!/
this ma$hi!e A66ro5imate,y B& mi,,io! $o,ors $a! be 6ri!ted usi!/ this
ma$hi!e Ri6master is the ;A1 used 7or $o!tro,,i!/ these ma$hi!es
o6eratio!s
C- 2 P a / e
AJTO ;OLOR KIT;HEN
Auto $o,or "it$he! is res6o!sib,e 7or ma"i!/ the 6aste 7or 6ri!ti!/ by usi!/
0arious $hemi$a,s > dyes a!d re/u,ar,y su66,y the ma$hi!es as re8uired
The "it$he! has - si,o stora/es 7or urea Fhy/ros$o6i$ a/e!tG+ sodium
bi$arbo!ate+ Potassium $arbo!ate used 7or rea$ti0e 6ri!ti!/ 6aste+ Resist sa,t
Fo5idi?i!/ a/e!tG+ soda ash The si,os su66,y to the automati$ 6re6eartio!
u!it F)&&& ,tsG 7or 6aste 6re6aratio!
Key Ing$e%ients fo$ *$inting *aste a$e as follo.,>
Bi!der: ( )DL bi!der is used 7or dar" shade
BL bi!der is used 7or ,i/hter shade
Lu6rimo, FST<G ( It a$t as so7t!er 4hi$h redu$es hard!ess o7 the 4ater
a!d 6aste so7t
Lute5/e,FHITG ( It a$t as thi$"!er to ma"e 0is$ous 6aste o7 the dye
Fi5i!/ a/e!tFLFG (It a$t as I5er > rubbi!/ 7ast!ess 4i,, i!$rease
Ro!/o,ite FSTG (It a$t as redu$i!/ a/e!t 7or 4hite a!d $o,or dis$har/es
For )&& L $otto! 7abri$ sodium su,6ho5y,ate is used+ 7or b,e!ded 7abri$s _i!$
Su,6ho5y,ate is used
There is a roto mi5 ma$hi!e 7or the $o,our 6re6aratio! 4hi$h is dosed by
$hemi$a, by 0arious dosi!/ systems 4hi$h 6re6are the $o,our 6aste i! ,ar/e
o6e! tubs 4hi$h are tra!s6orted to the ma$hi!e 7or dosi!/ the 6aste to the
s$ree!s
CB 2 P a / e
Te;tile 4$inting
The Te5ti,e 6ri!ti!/ 6ra$tised at A,o" is the rotary s$ree! methods 7or 4hi$h
there are* Re//ia!i rotary 6ri!ti!/ ma$hi!es+ ) La"shmi rotary 6ri!ti!/
ma$hi!e a!d a sam6,e 6ri!ti!/ ma$hi!e 7rom Re//ia!i I! additio! to this
there are T4o Airo,i Loo6 A/ers that are used 7or the 6ur6ose o7 $uri!/
Pre6aratio! o7 $,oth 7or 6ri!ti!/:
The 4et 6re6aratory 6ro$esses are a,, $arried out o!
the Be!!i!/er PTR 4here as 7or "!its itOs do!e i! the
S$,a0os so7t Ko4 ma$hi!es A6art 7rom 4et
6re6aratio!s the $,oth is brushed > sheared o! ,a7er
sheari!/ ma$hi!e by bei!/ 6assed o0er ra6id,y
re0o,0i!/ "!i0es arra!/ed s6ira,,y rou!d a! a5,e+
4hi$h ra6id,y a!d eAe$tua,,y $uts oA a,, I,ame!ts
a!d "!ots+ ,ea0i!/ the $,oth 6er7e$t,y smooth a!d
$,ea! a!d i! a $o!ditio! It to re$ei0e im6ressio!s o7 the most de,i$ate
e!/ra0i!/
Some I/ured 7abri$s+ es6e$ia,,y those 4o0e! i! $he$"s+ stri6es a!d
$rosso0ers+ re8uire 0ery $are7u, stret$hi!/ a!d strai/hte!i!/ o! a ste!ter
7rame+ be7ore they $a! be 6ri!ted 4ith $ertai! 7orma, sty,es o7 6atter! 4hi$h
are i!te!ded i! o!e 4ay or a!other to $orres6o!d 4ith the $,oth 6atter!
Fi!a,,y+ the $,oth is 4ou!d arou!d a ho,,o4 4oode!or iro! $e!ters i!to ro,,s o7
$o!0e!ie!t si?e 7or mou!ti!/ o! the 6ri!ti!/ ma$hi!es
CC 2 P a / e
INFRASTRUCTURE
A rotary 6ri!ti!/ ma$hi!e 6ri!ts desi/!s 4ith e!/ra0ed desi/!s o! a $ur0ed
$y,i!der Substrate here is a $o!ti!uous 7abri$ ro,, 4hi$h is to be 6ri!ted a!d
7urther modiIed i7 re8uired Fe/ die $ut+ o0er6ri!t 0ar!ished+ embossedG
The i!itia, de0e,o6me!t o7 the sam6,es is do!e usi!/ ;A: i! the studio usi!/
4hi$h the s$ree!s are de0e,o6ed a7ter 4hi$h the Re//ia!i sam6,e 6ri!ti!/
ma$hi!e is used 7or 6re6aratio! o7 sam6,es The !orma, 4idth o7 this
ma$hi!e is C&Y It $a! be e5te!ded u6 to )%&OO
La;0i Rota$y 4$inting !achine
J6 to )% $o,ors desi/! $a! be 6ri!ted i! this ma$hi!e The s$ree!s are
mou!ted o! the s$ree! statio!s 6ro0ided+ 7or ea$h $o,or i! the desi/! a
s$ree! is used 4ith the $o,or 6aste bei!/ 6ro0ided i!to the s$ree! throu/h a
6i6e a!d a s8uee?e arra!/eme!t 4ithi! the s$ree!s a66,y 6ressure to e!ab,e
6ri!ti!/ 6aste 6e!etratio!
The 7abri$ is 7ed throu/h ro,,ers to the 6ri!ti!/ tab,e a!d is staba,i?ed i!
4idth by a /uidi!/ system As the 7abri$ 6asses u!der the s$ree! ro,,ers the
$o,ors are a66,ied as 6er desi/! The $a6a$ity o7 this ma$hi!e is %& to )&&
metersMse$o!ds de6e!di!/ u6o! 7a$tors ,i"e desi/! a!d the !umber o7 $o,ors
i! that desi/! a!d the ty6es o7 the 7abri$ F$oarser ta"es ,ess time as
$om6ared to I!er 7abri$G
The ma$hi!e is 6re(e8ui66ed 4ith the u!der(bed 4ashi!/ a!d dryi!/ u!it
4hi$h $,ea!s a!d dry u6 the be,t a7ter ea$h $y$,e A7ter 6ri!ti!/ ro,,ers+ the
dryi!/ u!it dries 6ri!ted 7abri$ i! a -$hamber arra!/eme!t dedi$ated 7or
dryi!/ A7ter dryi!/+ the 7abri$ is se!t to the 6o,ymeri?er 7or I5atio!+ ie the
I5i!/ o7 dyes M6i/me!ts
CD 2 P a / e
Reggiani Sc$een 4$inting !achine
There are * Re//ia!i rotary 6ri!ti!/ ma$hi!es out o7 4hi$h % ma$hi!es $a!
6ri!t u6to )% $o,ors a!d the third ma$hi!e $a! 6ri!tu6to ). $o,ors The
Re//ia!i s$ree! 6ri!ti!/ ra!/e is has simi,ar o6eratio! ru! as that o7 the
La"shmi rotary 6ri!ti!/ ma$hi!e
The o!,y diAere!$e i! both the ma$hi!es is the a66,i$atio! o7 /,ue i! the
Re//ia!i ma$hi!e by a /,ue ro,,er that e!sures that the 7abri$ sti$"s to the
ru!!i!/ $o!0eyor be,t as it 6asses u!der the 0arious s$ree! ro,,ers 7or
$o,oratio!
A7ter 6ri!ti!/ it e!ters the heati!/ $hamber 4here there are - $hambers that
dry the 6ri!ted 7abri$ 4ith hi/h tem6erature a!d 6ressure T4o ma$hi!es out
o7 three ha0e the dryer i! o!(,i!e 6ositio! 4here as the third ma$hi!e has a!
dryer i! o0er head 6ositio! The dried 7abri$ re$ei0ed is the! re$ei0ed i! a
bat$h 7orm or 6,aited F6re7erab,eG a!d the! se!t 7or $uri!/
Technical %etails of Reggiani Rota$y *$inting 0achine
Nu0'e$ of colo$s )% > ).Fma5 %. $o,orsG
4$inting s*ee% *& to .- mMmi! ma5F'& mMmi!G
4$inting .i%th C%Y to D&Y
!ulti $e*eat *$inting hea%s
Isc$een siAeJ
B.& to )%&& mm
S3ueegee syste0 JNIFLJX $o!ti!uous ma/!eti$ Ie,d
Ta'le =, Technical Details of Rota$y Sc$een 4$inting
C' 2 P a / e
"#.# Finishing
D& 2 P a / e
"#." Stente$
It is used 7or: (
I Emu,sio! 6addi!/ 7or 1XL
II For OBA a66,i$atio!
III For heat setti!/
Both 6i! a!d $,i6 arra!/eme!ts are used
Oi, heati!/ me$ha!ism 7or dryi!/
C $hambers i! ste!ter
Bo4i!/ a!d headi!/ ro,,ers at the 7eed e!d to remo0e $reases
O0er7eed: (-L
Fabri$ s6eed: (-&mMmi!
PRO;ESS:
C7A!/ER NO LI7T S7ADE !EDIU! S7ADE DARK S7ADE
) ))&
&
; ))&
&
; ))&
&
;
% )%&
&
; )%&
&
; )%&
&
;
* )*&
&
; )*&
&
; )*&
&
;
. ).&
&
; ).&
&
; ).&
&
;
- ).&
&
; ).&
&
; )-&
&
;
B ).&
&
; ).&
&
; )-&
&
;
C ).&
&
; ).&
&
; )-&
&
;
Defects,
Pi! ho,es
Ee,,o4i!/
Oi, s6ots or soi,i!/
"#.& Sanfo$ising
It is 6re shri!"i!/ I!ishi!/
D) 2 P a / e
Rubber be,t shri!"s the 7abri$ a,o!/ 4ith it
S6eed -& mMmi!
Steam heated ro,,er o0er be,t at ))&
&
;
-& m 7abri$ 7rom i! to out
A7ter shri!"i!/ ?o!e+ there is a setti!/ ?o!e to set the shri!"a/e i!
7abri$
Fabri$ is $oo,ed a!d the! bat$hed
Some shade 0ariatio! may o$$ur
"#.+ Calen%e$ing
Fabri$ s6eed o7 C& mMmi!
E56a!der ro,,ers are used at 7eed e!d
* ro,, system 4ith % $otto! ro,,s a!d o!e stee, ro,,
Tem6erature o7 $a,e!dars ro,,er is C&
&
;
Pressure C& NMmm
Stre!/th redu$es a7ter $a,e!dari!/
It im6ro0es the 7ee, a!d sur7a$e a66eara!$e o7 7abri$
D% 2 P a / e
"#.- !ic$osan%ing
Ro,,ers 4ith diamo!d Amery 6i,e
T4o 6airs o7 ro,,ers
Rou/h( %%& /rades
Smooth( .&& /rades
%. ro,,ers
Lo4er /rade+ hi/her tou/h!ess
%%& /rade ro,,ers mo0e o66osite to the dire$tio! o7 7abri$
.&& /rade ro,,ers a,o!/ the dire$tio! o7 7abri$
Defects,
Pit$h 0ariatio!
Bat$hi!/ Fte!sio! 0ariatio!G
;reases
;S
S6eed ( .B r6m
Fabri$ s6eed ()& mMmi!
Te!sio! o!to ro,, (-& "/
"#.9 /$ushing
Fabri$ s6eed ( )''B mMmi!
%. sma,, ro,,ers o0er a bi/ ro,,
S6eed o7 ro,,ers ())& r6m
Pi,e s6eed ()%- r6m
;ou!ter 6i,e s6eed ())- r6m
It im6ro0es so7t!ess o7 the 7abri$
D* 2 P a / e
Both ba$" a!d 7a$e abrasio!Mbrushi!/ is 6ossib,e
TAPE JSE: IN PA;KIN<
B,a$" H Ro,, 4i,, /o to I!ishi!/
Red H 1i!or de7e$ts a!d it 4i,, a/ai! /o 7or i!s6e$tio!
Ee,,o4 H Pri!ti!/ de7e$ts a!d it 4i,, 7or i!s6e$tio! 7or re$tiI$atio!
AN /N C is the ty*e of co%ing use% to i%entify the *a$ty.
D. 2 P a / e
"".# Testing an% Ins*ection
D- 2 P a / e
Te;tile Testing
Te5ti,e testi!/ re7ers to a,, the testi!/ 6ro$esses i!0o,0ed i! 7abri$
ma!u7a$turi!/+ it ra!/es 7rom Iber testi!/+ Ear! testi!/+ Fabri$ testi!/ a!d
testi!/ 6ro$esses i!0o,0ed i! :yei!/ a!d Pri!ti!/
3he!e0er a! order is $o!Irmed+ it ta"es ) day to a!a,y?e it at A,o"
I!dustries Ltd+ the a!a,ysis is do!e at testi!/ ,ab+ a!d the mai! 6arameters
$o!sidered i! the sam6,e are as 7o,,o4:
1ateria,
3ar6 ;ou!t
3e7t ;ou!t
EPI
PPI
3ea0e Ty6e
Feasibi,ity
""." Ca$n Testing,
The mai! 6arameters tested i! a yar! are as:
;ou!t
Stre!/th H i! Pou!ds
Im6er7e$tio!s: thi$" a!d thi! 6,a$es
Stre!/th : RKm FResista!$eMKmG
;SP : ;ou!t stre!/th 6rodu$t
J Per$e!ta/e : J!i7ormity
I7 RKm o7 a yar! is hi/her+ the yar! has hi/her stre!/th a!d i7 it is ,o4er the
yar! has a ,o4er stre!/th
;SP: it says that 7or a yar! o7 6arti$u,ar $ou!t at 4hat stre!/th a66,ied the
yar! brea"s do4!
I7 JL is hi/her+ the yar! has a ,o4er 8ua,ity a!d there is a ,ot o7 !o!(
u!i7ormity+ but i7 it is ,o4er the yar! is $o!sidered to be more u!i7orm a!d o7
hi/her 8ua,ity
Amou!t o7 1ateria, to be i!s6e$ted is as 7o,,o4:
O$%e$ Ouantity No. of Cones to 'e ins*ecte%
U*to "## ?g % $o!es
"##>"### ?g - $o!es
"###>-### ?g )& $o!es
DB 2 P a / e
-### ?gs an% a'o)e )- $o!es
1a$hi!es used 7or yar! testi!/ are as:
W$a* Reel, the mai! 6ur6ose o7 4ra6 ree, is to ide!ti7y the
$ou!t o7 the yar!
;o!es:Ree, R ):*
S6eed o7 ma$hi!e is )%& RP1+ Le!/th o7 N,eaO is "!o4! a!d
a$$ordi!/,y the $ou!t is measured
Elect$onic T.ist Teste$, The ma$hi!e measures the TPI Ft4ist 6er i!$hG i!
the yar!
/oa$% Win%e$, it is a 4oode! board "i!d o7 testi!/ e8ui6me!t o! 4hi$h the
yar! is 4i!ded+ it determi!es the im6er7e$tio!s ,i"e thi$" a!d thi! 6,a$es+
Ne6s et$ i7 o! the board there is u!i7ormity a!d e0e! distributio!+ it mea!s
that there are ,o4er de7e$ts i! the yar! a!d it has a hi/her 8ua,ity
Uste$ Teste$, It is a! ad0a!$ed testi!/ ma$hi!e by NJster Te$h!o,o/iesO+ it
dis6,ays diAere!t Ear! 6arameters o! a mo!itor ,i"e:
J 6er$e!ta/e
;Vm
Number o7 Ne6s
Hairi!ess
Forei/! 1atter
Uste$ Tenso(et, This Testi!/ e8ui6me!t mai!,y dea,s 4ith Te!si,e stre!/th
a!d eAe$ts o! yar! o! the a66,i$atio! o7 7or$e i! ,e!/th4ise dire$tio! The
ma$hi!e $a! be used to $he$" 6arameters ,i"e:
Te!a$ity FRKmG
Stre!/th o7 yar!
Brea"i!/ For$e
E,o!/atio!
For $ombed $otto! yar! o7 *&Os $ou!t te!a$ity shou,d be more tha! %& RKm
Uste$ Classinat Ouantu0, this testi!/ e8ui6me!t 4hi$h is a 7u,,y
automated determi!es the s,ub a!d $o,or $o!tami!atio!+ it 4or"s at a 0ery
hi/h s6eed o7 a,most -&& 1trsMmi! O! a testi!/ 6arameter it $,assiIes the
de7e$ts i! 7o,,o4i!/ $ate/ories:
DC 2 P a / e
Figu$e, W$a* Reel
& H ) Ne6
) H D S,ub Fshort thi$"G
D H *% S,ub F,o!/ thi$"G
"".& Fa'$ic Testing,
The mai! 6arameters tested o! a 7abri$ are as:
3idth Variatio!
EPI
PPI
<S1
Teari!/ Stre!/th
Im6er7e$tio!s ,i"e thi$"+ thi! 6,a$es
I7 <S1 o7 a 7abri$ is ,o4er the te!si,e stre!/th o7 the 7abri$ is ,o4er The ro,,
to ro,, 4idth 0ariatio! is arou!d ` to ) i!$hes+ 4hi,e i!side a ro,, 4idth
0ariatio! to,era!$e is ) $m+ the mai! reaso! 7or 4idth 0ariatio! i! ro,, is the
6re(treatme!t 6ro$esses a!d dyei!/+ 4idth 0ariatio! is mi!ima, i! $ase o7
/rei/e 7abri$
1a$hi!es used i! 7abri$ testi!/ 6ro$ess are as:
Tensile St$ength, AST1 -&*. FTita!
%
ma$hi!eG+ Sam6,e si?e: %-& V
)&& mm
%
Tea$ing st$ength, AST1 ).%. FE,matear 1a$hi!eG+ Sam6,e si?e: )&& V
B* mm
%
4ic? lass, For EPI a!d PPI $a,$u,atio!
S! Teste$, To $a,$u,ate the <S1 o7 the 7abri$
DD 2 P a / e
"".+ Defects Foun% in Ins*ection De*a$t0ent
S*eciBcations K
A**ea$ance
Wea)ing Relate% Da0ages
Co)e$
Bum6i!/ Ba,, Formatio! Reed ;ut
Reedi!ess B,a$" Stai! Se,0ed/e 3ithout Le!o
Ne66i!ess Bro"e! E!d Short Pi$"
Ha?y!ess Bro"e! Pi$" Si?i!/ Pat$hesM ;rysta,
J!e0e!!ess Bum6 1ar" Si?i!/ Stai!
Strea"i!ess Bro"e! Patter! S,a$" E!d
Kitty Le0e, :esi/! ;ha!/e S,ou/h OA
Fri!/e H Less tha! .mm
Se,0ed/e H Bmm ( Dmm
:esi/! ;ut S,a$"!ess
Dyeing Relate%
Da0ages
:oub,e E!d S!ar,i!/
Patta :oub,e Pi$" Stai!
Shade !ot 1at$hi!/ Tem6,e 1ar" Loose Pi$"
Shade Variatio! Fi!e E!d Tem6,e $ut
J!e0e! :yei!/ Ha!/i!/ Thread 3e7t Bar
Strea"s Starti!/ 1ar" 3e7t :istortio!
S*inning $elate%
Da0ages
Thi! P,a$es 3ro!/ :e!ti!/
;oarse Pi$" Thi$" P,a$es 3ro!/ :ra4i!/
;o$",ed Ear! K!ots 3ro!/ Patter!
;o,or ;o!tami!atio! Lashi!/ I! 3ro!/ 3e7t
;ou!t Variatio! Le!o ;ut Ear! Lot ;ha!/e
:irty E!d Less 3idth Reed mar"
:oub,e 3e7t Let OA 1ar" Ta"e oA 1ar"
Hi/h T4ist Ear! Li/hti!/ Starti!/ 1ar" :obby ,i!e
K!ots Li/ht thi$" 6,a$e =um6i!/ E!d
1oire EAe$t Loom F,y F,oati!/
Ne6s Loo6s 3ro!/ E!d
Oi,y 3e7t Loose Le!o Bi!di!/ Smash
S,ub 1e!di!/ Im6ressio! 4a$tial Defect
S,ubby 3e7t 1issi!/ E!d ;ra$"
J!e0e! 3e7t Ear! No??,e 1ar" Ho,e
Three P,y Oi,y Stai! F,oat
;oarse E!d Pu,,ed 3ar6 1u,ti6,e Brea"a/e
Rust Stai!
Si?i!/ 1a$hi!e Sto6s
Tor! Fabri$
Tear :ro6
Stit$hes
Ta'le @, !anufactu$ing Defects in Ca$n an% Fa'$ic
D' 2 P a / e
$ey Fa'$ic Ins*ection
Fou$ 4oint A0e$ican Syste0
S, No :ama/e Le!/th Poi!t ;ou!t
)& 3e7t 3ise
)) &)Y ( *Y )
)% *Y ( BY %
)* BY H 'Y *
). 'Y a!d abo0e .
%& 3ar6 3ise
%) )M%-
th
o7 the ,e!/th .
*& Partia, :e7e$t
*) R\ - mm %
Ta'le "#, Fou$ 4oint Fa'$ic Ins*ection Syste0
Note:(
A,, $o,or 7orei/! matter shou,d be remo0ed
A,, 6artia, de7e$ts more tha! - mm shou,d be $ut
@ua,ityM <radi!/ F7or mi!imum -&&& meters shi6me!tG
'& 2 P a / e
$ey Fa'$ic $a%ing K Ins*ection
!a$?eting2
$a%e
4ts.2"## s3.
!t$.
4ts.2 "##
Linea$ 0t$s
INo$0al
Wi%thJ
4ts.2 "##
linea$ 0ete$
IWi%e$
Wi%thJ
Fa'$ic
Length
A )- %. .- ]%& mtrs 7or
domesti$
].& mtrs >
abo0e 7or
E56ort
B %% *- BC ]%& mtrs >
abo0e
; *)%- -& '- ]%& mtrs >
abo0e
: No bar \)& mtrs ]) ( \- mtrs ]) mtrs (
\)& mtrs
E No bar ])) ( \%&
mtrs
]- ( \%&
mtrs
])) mtrs (
\%& mtrs
F A,, $o!ti!uous
:e7e$t F4ar6
[ 4e7tG
No bar A,, $o!ti!uous
:e7e$t F4ar6
[ 4e7tG
]%& mtrs a!d
abo0e
< .C C- !i, ]%& mtrs a!d
abo0e
Ta'le "", fa'$ic $a%ation Cha$t
Note: ( A,, remai!i!/ 8ua,ities ,ess tha! o!e meter 4i,, be desi/!ated as
u!der
!a$?et Length 4ac?ing
;hi!di &(%- $m i! "/
Fe!ts %-('' $m i! "/
Fo$0ula,
Poi!ts 6er )&& s8 meters R Tota, 6oi!ts V *'*C V )&&
3idth M Tota, 1eters
') 2 P a / e
Conclusion
The te5ti,e i!ter!shi6 has bee! $om6,eted i! A,o" I!dustries P0t Ltd+ The
duratio! o7 the i!ter!shi6 4as o7 t4o 4ee"s 4here 4e had $o0ered s6i!!i!/+
6re6aratory 6ro$esses 7or 4ea0i!/+ 4ea0i!/+ 6o,ymeri?atio!+ 6re6aratory
6ro$esses 7or dyei!/+ dyei!/ a!d 6ri!ti!/+ yar! dyed se$tio!s a!d I!ishi!/
se$tio!s 3e studied the 0arious as6e$ts o7 a te5ti,e 6ro$essi!/ u!it starti!/
7rom its /rey se$tio! to the 7u!$tio!a,ity o7 the 0arious de6artme!ts
3e 4ere i!trodu$ed to the 0arious bra!ds o7 ma$hi!eries a0ai,ab,e 7or
$arryi!/ out the diAere!t te5ti,e 6ro$esses to meet /,oba, sta!dards The
i!ter!shi6 he,6ed us to u!dersta!d the stru$tura, a!d 7u!$tio!a, $o!stitue!ts
o7 the i!dustry a!d a,so ada6t to rea, i!dustria, situatio!s 4hi$h e8ui6s us 7or
de$isio! ma"i!/ i! a rea,isti$ e!0iro!me!t
'% 2 P a / e