Textile Internship Report: Ocm Private Limited Textile Unit, Amritsar

JANUARY 2021
TEXTILE INTERNSHIP REPORT

25 DEC 2020 - 7 JAN 2021
OCM PRIVATE LIMITED

TEXTILE UNIT, AMRITSAR
PREPARED BY
JYOTI RAWAL
DEPARTMENT OF FASHION TECHNOLOGY

BATCH 2018-2022
NATIONAL INSTITUTE OF FASHION TECHNOLOGY
KANGRA
TEXTILE INTERNSHIP REPORT 02
ACKNOWLEDGEMENT
I would sincerely like to thank OCM Private Limited for giving me the opportunity to
learn in the textile industry as an internee, and for extending their support
throughout the internship period. I would also like to thank the HR, Ms. Amandeep
Kaur and our industry mentor Ms. Kanika Mahajan for guiding us and providing us
valuable feedback throughout the internship period.
I would like to extend my heartfelt gratitude to the HOD of all the departments
studied to help us go through the processes in detail with the help of a provided
person.
I would also like to thank my department, ‘Department of Fashion Technology’ and

my faculty mentor Mr. Pavittar Punit Singh for arranging the industry internship and
providing me an opportunity of industry exposure.
Lastly, I am grateful to NIFT Kangra, for giving me an opportunity for industry

research in the curriculum and providing the required facilities.
03
TABLE OF CONTENTS
Acknowledgement...............................................2
Objective of the Textile Internship.................5
INTRODUCTION
Company Profile..................................................6
Brands and Departments...................................7
Department H.O.Ds.............................................8
Production Department......................................9
Designing Department.....................................10
Designing Sector........................................10
Flow Chart of domestic sector.................10
Production Planning and Control..................11
DYEING DEPARTMENT...........12
HTHP Mahine....................................................14
Hydro Extractor.................................................14
Radio Frequency Dryer.....................................14
Back Washing Machine....................................15
Fabric Dyeing.....................................................15
Jet Dyeing...........................................................15
Soft Flow Dyeing Machine..............................17
Jig Dyeing...........................................................17
SPINNING DEPARTMENT......18
Gilling..........................................................19
Blending......................................................20
Combing......................................................20
Auto leveller...............................................21
Drawing.......................................................21
Roving..........................................................21
Steaming.....................................................22
Assembly Winding.....................................22
POST SPINNING SECTION.....23

List of Machines................................................23
Assembly Winding.............................................24
TFO.......................................................................24
Steaming.............................................................25
04
WEAVING DEPARTMENT......26
Warping..............................................................26
Drawing In..........................................................27
Weaving...............................................................28
Warp Stop Motion.............................................29
MENDING DEPARTMENT......30
Weaving Defects..............................................31
FINISHING DEPARTMENT.....32
Singeing......................................................32
Scouring......................................................33
Crabbing.....................................................34
Milling.........................................................35
Shearing......................................................35
Decatising...................................................35
Super Finish................................................36
INSPECTION.............................38
Process Flow in Inspection.....................38
Defects in Fabric.......................................39
Four Point System....................................39
Checking of Dimensions..........................40
Folding........................................................41
Packing........................................................41
Warehouse..................................................42
Yarn Warehouse.........................................43
Quality Assurance......................................44
S.W.O.T. Analysis.......................................47
Suggestions................................................48
Conclusion..................................................49
OBJECTIVE OF THE TEXTILE INTERNSHIP
The objective of our textile internship at OCM Pvt. Ltd. was to understand the concept
of spun yarn production, grey fabric production, dyeing and their quality aspects
technical as well as for commercial purposes.
Our first step was to learn about the profile of the company and their basic dealings.
We further dealt with the way the company handles the raw material and sends it
through to subsequent stages of manufacturing. We were to learn about the various
stages in the entire process of textile manufacturing, the importance of each of these
stages, the machinery features, machine and material process parameters .
COMPANY PROFILE
OCM India Limited, popularly known as OCM, a leading Multi National

Company, is a unit of International Textile Group. A British company for
manufacturing high quality carpets established it in 1924. OCM, then known
as Oriental Carpet Manufacturers, have enjoyed the highest goodwill for this
fine quality and vibrant designs both in home and foreign market.
In 1972, the British Company

divested its holding and Mr.
S.K Birla, belonging to the
renowned business family-
of India, assessment its
control and since then OCM
has become a synonym for
quality suiting. In fact, OCM
is the first worsted mill in
India to get ISO-9001
certification. The company
has its edge not only in
domestic market hut is also
exporting to several
countries like Canada, USA,
Middle East and others.
OCM is one of the India’s most modern and composite worsted mills, it has the
facility to execute all stages of production via spinning, weaving, dying, and final
finishing.
High quality yarn manufacturing in state of the art spinning plant takes the shapes of
fabric on improved waving machines from Germany and Belgium. Finally, with the
sprinkle of the finishing effects, the high class fabric is presented to the Indian and
international connoisseurs adding one more feature to their scintillating personality.
OCM began its illustrious pursuit over 80 years ago, with the manufacture of
handmade carpets and carpet yarn and was gradually transformed to worsted fabric
manufacturing.
From fiber to finished fabric, the mill is completely vertical and offers customers a
varied product range from the finest worsted fabrics for tailored garments to diverse
blends for a sportier look. The mill has a stellar reputation for maintaining color
continuity - especially in the segment of suit separates - empowering the end
customer with the ultimate in buying flexibility.
The company has been declared as the largest export of woollen fabrics from India
five times in the last seven years. At the domestic front also, OCM has been very
successful and ranked among the top five players in Indian textile market.
BRANDS
DEPARTMENTS
DEPARTMENT H.O.Ds
PLANT HEAD............................... MR. SHALENDRA PANDEY
DYE HOUSE................................. MR. ASHISH SHARMA
DESIGNING.................................. MR. AMAR SUKHWAL
SPINNING.................................... MR. M.P. SINGH
WEAVING..................................... MR. SANDEEP
FINISHING................................... MR. PARAMJIT BHARADWAJ
WAREHOUSE................................ MR. L.G. RAJESH
MENDING AND INSPECTION......... MR. J.N. MANDA

PRODUCTION DEPARTMENT
Designing Department
PPC
Dye House
Spinning
Post Spinning
Weaving
Mending
Finishing
Inspection
Quality Assurance
DESIGNING DEPARTMENT
Design plays a major role in the whole process of fabric making. This section receives first
feedback from the market and after analyzing the various factors, the design is developed and
further processed. This design has been developed keeping in view three seasons i.e.
summer,winter and mid season . They produce about 300 models every season. New designs are
developed based on market trends while modifying some of the old designs.
DESIGNING SECTORS
Designing
Domestic Export RMG
Monopoly
FLOW CHART FOR DOMESTIC SECTOR
Research
Work
Color
Forecasting
Design
Development
Blanket
Pattern
Master
Card
Feeding
on NOW Software
In Export,RMG and Monopoly Sectors samples are made according to the buyers demand
and then production is done.
PRODUCTION PLANNING AND CONTROL
This department plans the production and issues the various plans to different departments and
also controls the whole production process. The main purpose of this department is to control
the time of the material handling by all the departments at the time of production. This
department issues orders to each department and each department works according to its
instruction. It also estimates the amount of raw material required in production and gives
instruction to purchase department so that they could buy the raw material accordingly. It
controls the activities by implementing the rules as per ISO 9001.
Production planning and control (or PPC) is defined as a work process which seeks to allocate
human resources, raw materials, and equipment/machines in a way that optimizes efficiency. In
layman’s terms, PPC helps manufacturers work smarter in allocating internal resources of people,
materials, and machines in order to meet the demands of customers.
DYEING DEPARTMENT
The dye house is one of the most important
units in the plant. The raw wool received is of
white or natural colour and a proper shade is
given in the dye house. The dying process
depends upon the composition and the quality
of the raw materials. Dyes can be used on
cellulosic, protein or synthetic fibre if they
have affinity to them. Acid dyes are used for
wool, silk and nylon and direct dyes are used
for cellulosic fibres.
In OCM 3 types of dyeing are done:

Top dyeing
Yarn dyeing
Fabric dyeing
Polyester Yarn/Tops/Fabric
Disperse Dyeing is done for polyester.
COLUMN 1 COLUMN 2
pH 4-5(Acidic)
Temperature 130 °C
Pressure 4-5 Kg
Time 40 minutes
Wool
Type of Dye: Reactive Dyeing
COLUMN 1 COLUMN 2
pH 4-5
Temperature 98 °C
Pressure 3-4 Kg
Time 40 minutes
There was a testing lab in which samples were tested and also different shades
were made by doing experiments(as required by design department)
Process for dyeing Poly/Wool blends:
The process for poly wool blends is same of that of wool but there are some
extra chemicals added to the solution. They are-
Carrier- it helps to reduce the temperature of exhaustion from 135 deg
celcius to 115 degree celcius.
Wool protector- wool generally gets damaged at 98 degree celsius, but by
wool protector the wool is not damaged till 120 degree celcius.
DYEING DEPARTMENT
Process Sequence for Top Dyeing
Tops Loading in Machine
Rinsing
Addition of chemical through stock tank
Run for Ten minutes
Addition of Dyes
Shade Checking
Addition Rejected Passed
Draining
Soaping
Application of Antistatic Agent and neutralizer
Light Shade Unloading Dark Shade
Hydro Extractor Back Washing
R.F Drier Top Making
Defelting and Top Making
Dispatch
HIGH TEMPERATURE HIGH PRESSURE MACHINES

The machine is used both for fiber and
yarn dyeing. It consists of a stock
tank, dye addition and main dyeing
vessel, which is a cylinder with domed
ends, upper being lid, securely locked
by the sliding ring. There is a cylinder
at the back of the machine which is
operated using the pneumatic press.
There are two pumps, one is the turbo
pump and the other is the injector
pump. Turbo pump is used to transfer
water, chemicals, and dyes, from stock
tank to main vessel. It also helps in
the transfer of liquor during the whole
process. Injector pump is used to
transfer the liquor from dye addition
to dye vessel. The stock tank has a
stirrer.
HYDRO EXTRACTOR
After the dyeing process the tops

and fabrics need to be dried
completely as they stil contain some
amount of water. The hydro
extractor works on the principle of
centrifugal force. The material is
pushed outwards with the help of a
perforated cylinder. There are two
hydro extractors for tops and cones
of yarns.
Different shade tops are loaded
separately.
Wool tops and polyester tops are
loaded differently.
RADIO FREQUENCY DRYER(R.F DRYER)

The material still has some amount of moisture left after being taken out of the
hydro extractor but air/sun drying is not easy.
Hence the RF dryer is used to remove the leftover moisture from the dyed
materials. The process takes about 45 minutes. . Speed for coarser wool is 6.5rpm
and for polyester is 10rpm. Poly Wool blend is only dyed in yarn form. Radio
frequency systems have the capability to accelerate the drying process and short
production time.
During the process the product(yarn/tops) passes through an electrode system

and the powerful voltage breaks the H2O molecule.
Antistatic oils are applied to the material as a textile lubricator.
There are two fans provided for the removal of the moist air. It offers high
volume, high speed and high quality drying.
Tops are left for air drying, this process is also known as conditioning.
BACK WASHING MACHINE

The back washing machine is used to
remove the excessive dye from the
surface of the fibres ( in case of dark
shades only) and also to provide anti
stat oil to the fibre to privilege their
processing in the spinning
department.
FABRIC DYEING
The dyeing of cloth after it is being woven or knitted is known fabric dyeing. The
most dyed fabric is piece-dyed since this method gives the manufacturer maximum
inventory flexibility to meet colour demands as the trends change. The various
methods used for this type of dyeing include jet dyeing, jig dyeing and soft flow
dyeing machines.
JET DYEING
Jet dyeing is a process used for a batch dyeing operations such as dyeing, bleaching,
washing and rinsing. A closed tubular system for transporting the fabric is placed.
The constant commotion helps in better dye penetration. A material roll is provided
which lifts the fabric from the bottom of the dye vessel and feeds to the jet.
DYEING DEPARTMENT
Process Sequence for fabric Dyeing
Loading of Fabric
Washing at room temperature for 10 min
Temperature is raised to 60 degrees
Run for 5 mins color addition
Temperature is raised to 130 degree
Hold for 30 minutes
Cool to 60 Degrees
Drain
Washing For 5 Minutes
Unloading
SOFT FLOW DYEING MACHINE

The soft flow dyeing machine uses
water to keep the fabric moving. The
difference between this equipment
working with a hydraulic system and
a conventional jet is that the fabric
rope stays in rotation throughout the
process cycle (from loading to
unloading). Normal drain and filling
measures do not prevent the
circulation of fluid or substance. The
principle of technology is unique. A
system with which fresh water enters
the vessel through a heat exchanger
in a special exchange area. At the
same time, the contaminated alcohol
passes through the channel without
any contact with the substance or
with the new bath in the machine.
The capacity of the machine is 50 kg.
JIG DYEING MACHINE

The jig dyeing process involved treating the fabric to an open width. The cloth is not immersed
in a dye bath, but instead passed through a stationary dye bath. Upon completion of the first
pass, the cloth is reversed and passed back through the dye bath. To produce gaer colors, the
fabric dye has to go through the bath when a lighter shade is desired. Indirect steam is provided
to maintain the temperature of the bath.
SPINNING DEPARTMENT
Spinning is the twisting technique where the fiber is drawn out, twisted, and wound onto a
bobbin.
Process Sequence for spinning
Raw Material
Gilling
Blending
Combing
Post Combing
Gilling
Auto Leveler
Drawing
Roving
Ring Frame
Auto Conor
Steaming
Assembly
Winding
SPINNING DEPARTMENT
In the spinning mill, the tapes are turned into single yarns by pulling and twisting, and then
turned into spools. For loose fibers 10 to 20 mm long, the new spinning involves several
processes, such as
removing foreign material from foreign fiber

connecting fibers
parallelizing fibers
give them a twist
The method of pulling the fibers out of the mass and turning them into a continuous thread or
yarn is the key to the spinning stranded fiber strands into the yarn and the textile industry. The
yarn is then used to make textiles,
Total no. of workers : 310 for 3 shifts

Production : 8100 kg/day
Storage boxes sourced : New Delhi
RAW MATERIALS:
Blister comes in raw form,In converter Section cutting is done.Dye house sends shade card with
materal and percentage with Issued material.for proper mixing 3 machine are used for better
shade.
GILLING:
Gilling machines is used for blending, drafting, and oiling to make the tops uniform in weight
and length. The machine processes the tops while making the fibers straight and parallel which
increases the uniformity in sliver.
From the back of the machine, the tops are fed.
After passing through the feed
rollers, tops move through the
gilling field which consists of top
and bottom fallers moving in the
same direction as that of top.
Fallers are like combs consisting
of pins whose density can vary
according to the materials being
processed and the stage at which
it is being processed.
The machine head consists of 72
right and 72 left fallers which are
installed alternately( 1 top and 1
bottom).
Faller ends are placed in two chains which drive the fallers and are themselves driven
through gearing arrangement.
Only 22 fallers are in operation at any instant.
The density of pins in the fallers may vary from 3 pins per cm to 9 pins/cm. Low density pins
are round in section while high density pins are flat.
SPECIFICATIONS:
Fallers filled with roller chains 9.5 mm
Number of fallers 2 x 72
Maximum input speed 80 mm
Diameter of drafting cylinder 30mm(small) and 62.5 mm(bigger)
Diameter of top drafting cylinder 80mm
Pin density 3-9pins per cm
BLENDING:
In blending process, two or more tops of same
or different fibers are uniformly mixed
resulting in composition of uniform top. There
are variety of reasons of blending like :
To produce an end product with

characteristics unattainable from one
component.
To produce special effects.
To ensure continuity of supply and avoid
batch to batch variations.
To improve processibilty and spinning
performance.
To exploit advertising/consumer appeal.
Fallers in machine separate fibers from each other and open the tops and mix the fibers properly
to achieve a uniform composition. There is set of four blending machines which through basic
gilling machine principles increase uniformity of required blend. The output of these four
machines has a uniform linear weight of fibers in the top. All these blender vary in pin density in
fallers to separate fibers as we go from one machine to another(4 passages). The blenders while
blending also apply draft on to the fibers tops to control the weight per unit length.
1st passage and 2nd passage – 3 pins per cm

3rd passage – 4 pins per cm
4th passage – 5 pins per cm
COMBING:
After blending, fibers in sliver form are send for combing. In combing process, fibers are made
more parallel, short fibres are removed, front hooks and tail hooks are removed, impurities like
dust and vegetable matter are removed. Numbers of slivers (maximum 24) are fed in to the
machine from the back side through feeding rollers.
After the combing or post combing, waviness of combed tops is removed and tops are
made
into balls to reduce the number of cans required. The tops are continuously
attenuated in weight/length during passage through post combing section. In
post combing, two machines are used-
Gill box- to draft the tops and remove the waviness

Gill box with auto leveler and auto balling component.
AUTO LEVELER
An auto leveler gill box has an exception that it contains a sensor to measure the
thickness (difference) of the sliver and single drafting zone mounted in front of the
head. Any variation in the thickness of the sliver is changed to electrical signal, which
increases or decreases the speed of front drafting zone
DRAWING
This is the machine on which drafting & doubling are carried out. Cardeds liver is not
uniform enough to produce to good quality yarns.Therefore,usually all the cardeds
livers are subjected to Doubling & Drafting on a machine called “DrawFrame”.
ROVING
It is an intermediate process in which fibres are converted into low twist. The sliver which is
taken from draw frame is thicker, so it is not suitable for manufacturing yarn hence roving is
done. A roving is a long and narrow bundle of fibre. Roving is a fibre strand of lesser count than
that of a sliver. It is also having a small twist to keep Fibres together. It is wound on to a package
which is suitable for feeding spinning machinesIn addition to reduction of weight/length of the
tops, a small twist is provided in this machine.
RING FRAME
Ring frame converts the roving into a yarn and simultaneously twist it while it is
wound on a ring bobbin to provide the strength to the yarn to make it stable. In
OCM,there are 44 ring frame machines and they all are of Zinser, company of
France.There is 3 by 3 system for twisting yarn. The drafting zone is divided into three
parts –Back rollers, Middle rollers,and Front rollers.Between the front and back rollers,
there is a condenser which brings the fibres together,so that after drafting they should
not move away from each other.
AUTO CONER
Auto Coner is a highly automated m/c as in this m/c the empty ring bobbin are
automatically replaced, splicer automatically joins the broken ends. More over an
optical sensor equipped with cutters detect the thick and thin places, slubs, neps etc
and splice the broken ends together.All the grooved drums are individually driven and
the length of yarn on package is fixed so that the m/c automatically stops after the
required length of yarn.
STEAMING
After coning , cones are taken for heat setting process. There is a pressure chamber
that is used to sterilize equipment and supplies. When cones are placed inside the
autoclave, they are exposed to high temperature steam. This process is done to avoid
snarling and shrinkage effect which generally comes after giving twist to the yarns
which were being wound in cones. It can be done at any stage of winding.
ASSEMBLY WINDING
After the auto-winding process, yarns are twisted again in which two cones are being
used to make one final cone. The purpose of producing doubled yarns is to improve
yarn uniformity and to increase strength. This is also an essential process to produce
balanced yarn.
It is a two-stage process:
• Doubling – two yarns are twisted to form one single yarn. This process is called as
doubling.
• Twisting – Z twist is given to the yarn while winding it on the final cone.
POST SPINNING DEPARTMENT

The main purpose of post spinning department is to convert the single yarns in to 2 or
3 ply yarns by applying twist to that yarn. For that, the first stage is that of assembly
winding in which two or more packages are wounded on a single package without
imparting any twist on them.
Then the package is sent to TFO where two or more yarns are getting converted into
single yarn by applying twist to them. The twist is imparted with the help of rotation
of spindle on which yarn is getting unwind and the drum speed with which the
package is rotated. The motion is transferred through a pulley, pulley belt and through
gears.
After TFO, yarn is send to autoclave for heat set to set the twist in the yarn. In this,
yarn is subjected to vacuum, steam, and air for setting the twist in it.
Then this yarn is set for conditioning and then the yarn is sent for winding according
to customers requirements.
PROCESS FLOW OF POST SPINNING
Single Yarn from Spinning
Assembly Winding
Two For One Twister (TFO)
Steaming ( Auto Clave)
Conditioning ( 8 Hrs )
Rewinding
LIST OF MACHINE:
Machine Manufacturer Speed
Assembly winding P.S Metler 300m/ min

T.F.O Leewha 22-25m/min
Autoclave (steaming) Stafi -
Rewinding P.S Metler 450 m/min
ASSEMBLY WINDING
This preparatory stage for production of ply yarn consists of winding together 2-3
single yarns on suitable package. It produces ply yarn, which are free from defects
from due to balance tensioning of single yarns. Its main function is to make packages
of required weight. Two processes are carried simultaneously ie. clearing the yarn and
providing a larger feed package. There are two sections- right and left, both sections
containing 60 spindles. Each package is wounded with two or three ends according to
the requirement of the ply of the yarn.
In assembly winding, no twist is provided to the yarn. Also, there is a proper sequence
of threading for proper winding. There is a sensor which senses the breakage of the
yarn and lifts the package from the rotating drum.
To hold and lift the package from rotating drum, there is spring liver mechanism.
The m/c has group drum winder (drum diameter of 90 mm and drum r.p.m of 300). The
speed of m/c is 300 m/min and weight of package formed is 1080 gm.
There were 6 assembly winding machines in OCM.
TWO FOR ONE TWISTER (TFO)

The yarn from the double
package gets twisted like the
roving in the speed frame. Then it
comes out from the central hole
of the disk, moves below to come
out of the outer hole to form a
balloon and gets twisted in a
similar mode to that of ring
spinning. This type of twister not
only gives higher production but
also produce superior quality of
ply yarns .
The twist is imparted with the help of rotation of spindle on which the
yarn is getting unwinded and the drum speed with which the package is
rotated. The motion is transferred through a pulley, belt and gears.
There are four gears,by changing these gears we can change the amount
of twist.
There were 56 TFO machines in OCM.
To find the amount of twist:
T.P.M= Spindle speed / delivery per minute
STEAMING (AUTO CLAVE)
To set the twist and remove snarling, steaming is done to the yarn through auto
calve. The package are packed into perforated basket and entered into an auto clave.
In autoclave, the yarns are subjected to vacuum, then to steam and then twist is set
as fibres get relaxed. The cycle is started according to whether it has to be given a
single cycle or repeat cycle. The choice of cycle depends upon the amount of twist in
the material. The high twist material requires to repeat cycle and the material
containing synthetic fibre can be set with a single steaming cycle only.
Some features of Autoclave machine are:

• 540 kg of yarn can be steamed at a time.
• Steam moves inside out.
• Temperature around 90 degree Celsius.
Conditioning:
After steaming, conditioning is done for about 4 hrs. For wool, around 24 hrs is
spent on conditioning.
Rewinding:
It is done for removal of knots to avoid pin holes in the fabric which are form
during finishing, rewinding on paper cones or material that are not to be used in
the mill.
WEAVING DEPARTMENT
PROCESS FLOW CHART IN WEAVING SECTION
WARPING
The single yarn packages made in winding and spinning are directed for warping. The
warp is a lengthwise thread attached to a loom before weaving begins. Each
individual warp thread in a fabric is called warp-end.The aim of warping is winding
on one package to a certain number of warp-ends of a particular length. During
warping, ends from many winding packages are wound on a common package to
prepare a warp beam, also called warper’s beam.
DIRECT WARPING:
Direct warping is also called high speed warping. In high-speed warping, all
the yarns are wound at once. It is a very high-speed process, and it is used to
make fabric of single colour.
SECTIONAL WARPING:
Sectional warping is done when one needs to produce some design i.e. beam
contain some different colours of yarn then sectional warping is used.
In sectional warping, the warp threads are wound on the warping drum
sectionally. After winding on drum it is then taken on weavers beam. The yarns
which are coming from double yarn room are going for winding for preparing
required amount of package.
Then they are then creeled according to the warp pattern.In OCM, sectional
warping is done.
For example, for 5400 warp yarns 100 cones are wound 54 times. The number
of cones that can be put on the frame at the same time is 225.As wool does not
require any sizing because of its high strength, the need for
producingcomplicated patterns results in the formation of sectional warping in
place of high speedbeaming
DRAWING IN
Drawing-in is the process of drawing the warp yarns through the heald shafts
according to the weave plan.
In weaving, it is necessary to space the warp threads properly in order to get the
required compactness of the cloth.
This is affected by passing the warp yarn through the dents of the reed of
appropriate count so that the cloth woven from the warp may contain the
required number of threads.
This process is conducted manually on an upright frame. One operative is called
the ‘reacher’ and the other is called the ‘drawer’ who sits in front of the frame.
At the start, the reacher takes a bunch of warp threads in his hand, straightens
them up and selects the yarn one by one from one extreme end of the loom beam
in the proper sequence.
By this time, the drawer inserts the hook through the corresponding heald eyes.
At the extreme end of one heald as soon as the hook reaches the other side, i.e.
on the side of the reacher the latter will insert the appropriate end in the eye of
the hook which will be immediately drawn on the other side by the drawer.
DRAFTING DENTING PINNING

DRAFTING
The process of drawing the warp yarn through the eye of heald frames
according to design is called drafting, and the plan which indicates how
drafting needs to be done is called drafting plan. It also denotes the number of
heald shafts required for a given weave repeat.
DENTING
The process of inserting warp threads or ends through the dents of reed is
called denting and the plan that indicates the order in which denting is done is
called denting plan. Usually, two yarns are passed through each dent. Denting
determines more perfectly the width of the woven fabric and the ends per inch
(EPI).
PINNING
It is done to avoid warp defects. Pinning is done separately. Each warp yarn is
passed through one pin individually. If any of the warp yarn breaks during the
weaving process, pin will touch the sensor of serrated bar, then the machine
will stop working automatically.
WEAVING
In weaving technology, loom is the principle mechanical device for weaving. It

produces the woven fabric by the insertion of warp and weft yarns.
Types of loom used:
RAPIER LOOM
A rapier loom is a shuttle less loom in which the filling yarns are carried
through the shed of the warp yarns to the other side of the loom by finger-like
carriers called rapiers.
It can be a single rapier, or double rapier.
For a single rapier, a long rapier device is required to extend across the full
width of warp.For double rapiers, two rapiers enter the shed from opposite
sides of the loom and transfer the weft from one rapier head to the other near
the centre of the loom.
The rapier may also be of the rigid rod type or flexible, made of metal or
plastic tapes.
Production speed: 200-260 ppm
Minimum width of rapier loom: 190 cm
The industry uses 80 rapier looms.
Rigid Rapier Loom: The rigid rapier Flexible Rapier Loom: is wound on
is a metal or composite bar usually wheels or placed on semi-circular
with a circular cross section. channels when they are withdrawn
outside the shed. The flexible rapier
can be coiled as it’s being
withdrawn, therefore requiring less
storage space
PROJECTILE LOOM
A projectile loom is also
a shuttle less loom. The
filling of yarn is done by
using a small metal
device resembling a
bullet in appearance with
a clamp for gripping the
yarn at one end, which is
then propelled through
and into the shed.
It has a higher speed
production than rapier
loom. An accommodator
is used to reduce tension.
Maximum width of this type of loom is 540 cm.
Production speed: 300 ppm
27 projectile looms are there in the industry.
These machines have jacquard of 56,40 hooks which are 32 in number and
all machines have dobby attached to them.
These dobby have 20 to 28 shafts.Jacquard is used for monogram on each
side in the form of continuous running strip along the selvedge.
WARP STOP MOTION
The main purpose of warp stop motion is to stop the loom when warp end breaks to
avoid faults. If the breaking of warp thread is not detected, then the loose thread will
tend to become entangled around adjacent thread to break and create faults known
as flat in fabric.
MENDING DEPARTMENT
Mending section corrects any kind
of defects in the fabric. No
specialized machines are used for
this job work. There are menders
and workers in the mending
section who remove the defects.
When woven fabric comes off the
loom, there are some unavoidable
faults and defects in the fabric
which are needed to be removed
before finishing, thus they are
sent to the mending section. Mending is a needle-based skill that involves fixing
various faults that may occur in fabrics. As a result, to comply with the company's
set standards, woven textiles undergo a careful inspection process throughout
which all weaving defects are marked out and then repaired by hand.
In the mending tables there are two tube lights overhead the worker and two tube
lights underneath the mending table. After mending, perching is done to see whether
all the defects in the fabric have been properly checked and mended by the mending
department. The perches have two tube lights underneath the glass panel and two
tube lights overhead the worker.
The fabric from greasy perch is checked on the perches and the defects are removed.
On the perch table and mending table defects like missing pick, missing end, bunches
and knots are corrected. Float, damage, temple cut and wrong draft cannot be mended.
The tools used for mending are-
• Forceps- It is used to pick out and hold threads for mending.

• Erasers- It is used to straighten out pulled or tight threads in the fabric.
• Needles- It is used to repair defects such as missing end, missing pick where filling id
done according to the design of the fabric.
Mending departments has three main operations:

Inspection
Burling
Mending
INSPECTION:
All the fabrics are inspected as soon as it comes from the weaving section. The
objective of inspection is to remove the faults or defects which have been caused by
the loom. This process is also known as perching.
BURLING:
Burling, mainly applied to woollen, worsted, and cotton fabrics, is the process of
removing any remaining foreign matter, such as burrs and, also, any loose threads,
knots, and undesired slubs.
MENDING:
All the breaks in the warp and weft must be repaired imitating closely the weave of
the fabric, provided that the yarns must be equal in count and the quality of the
fabric. The mender carefully works the needle along the line of weft, or warp, or
both and draws the end into place. Mending eliminates defects such as holes or
tears, broken yarns and missed warp or weft yarns.
Total number of mending tables are 74.

Total number of workers in the mending section are 60.
Mending workers are on contract basis.
WEAVING DEFECTS
All possible defects which are created by the loom are being corrected in the mending
department are listed below:
SUM Starting Mark TM Temple Mark

BM Bump Mark HL Hole
BP Broken Pick CH Chappa
PC Pick Out FL Flote
LW Loose Weft FE Floting End
MP Missing Pic LD Loom Dagi
DP Dbl Pic YS Yarn Stain
SN Snall ME Missing End
LS Lesssing CN Contamination
GO Ball Formation SL Slub
WD Wrong Denting KN Knot
WR Wrong Drawing TE Tight End
WP Wrong Patt LM Lever Miss
WE Wrong End MD Missing Dbl
WW Wrong Weft Pat End
WP Wrong Pick TL Tails
WF Wrong Weft AB Abression Mark
WL Wrong Laisan RM Reed Mark
TH Thick Place DM Design Mistake
TN Thin Place NL No Leno
WB Warp Brakes FM Filamentation
CR Crack SE Sec Wrong End
TC Temple Cut SP Section Patta
WC Weft Change
FINISHING DEPARTMENT
After mending, lots are prepared and assembled at one place. The fabric comes to the
finishing department where fabric is treated with chemical and mechanical processes
to achieve desired effects, aesthetic and functional benefits.
THE OBJECTIVES OF TEXTILE FINISHING:

To improve the attractiveness and service ability of the textile materials.
To accentuate/inhibit some natural characteristics on the textile materials such as
softening, de-lusturing, brightening etc.
To impart new characteristics/properties of textile materials such as flame
retardant, water repellent or water proof finishes.
To increase the life and durability of textile materials.
To set the fabric, so that it can be maintained in its shape and structure.
To set the chemicals into the textile materials.To meet up specific end uses.
SINGEING
In Singeing, the protruding fibres(loose
hairs) are removed from the surface of
the cloth, thereby giving it a smooth,
even and clean look, also reducing the
pilling in the fabric.
The singeing machine consist of three
sections:
Brush section – For cleaning of the
dust
Burner – It is attached with LPG for
the removal of extra fluff
Water rollers – It is used to cool
down the warm fabric.
MACHINE USED:
Oshtoff Singeing Machine, Italy.
PROCESS:
The cloth to be singed is passed over a brushing roller so that the
protruding fibres are away from the surface of the cloth.
The fabric is then passed over two burners. These two burners are supplied
with LPG gas. The fabric path is arranged in such a way that both the
surfaces are singed in a single pass.
An exhaust chamber is provided over each burner slot and is connected to
an exhaust fan.
The products of combustion are led into exhaust and taken away from the
machine.
All wool fibres are not singed because when the protein fibres burn hard,
black residue is produced, which is difficult to remove.
SCOURING
Scouring is a process in which we remove the natural impurities, dirt, greasy spots
(from loom) etc. Scouring chemicals are generally acetic acid and soda ash.
OBJECTIVE OF SCOURING:
To remove natural as well as added impurities of essentially hydrophobic
character as completely as possible.
To increase the absorbency of textile materials.
To leave the fabric in a highly hydrophilic condition without undergoing
physical or chemical treatment or damage.
MACHINE USED:
For closed scouring:
Hemmer Machine: 1
Dolly Machine: 5
Mat Machine: 2
For open width scouring:

Zonco: 1
Jigger: 1
CLOSED SCOURING
:
Hemmer Machine:
It consists of two pairs of top
rollers and bottom rollers.
Fabric is passed between these
rollers in rope form. Plates are
provided which can be
controlled pneumatically.
Water inlet and drain valve are
also open and closed
pneumatically. Machine capacity
is 200 kg.
Mat Machine:
This machine is used for both scouring and milling.It is also a rope scouring
machine and consists of two pairs of rollers and four metallic plates; this
machine contains four drain valves and four inlet valves.
A pump is provided in the machine, which brings the chemicals from the
stock tank to the main vessel.
Capacity of machine - 350 kg.
Press of plates during milling- 2 bars
Speed of the fabric- 150-200 m/min( maximum speed is 400 m/min).
Dolly Machine
This machine is used for scouring and width setting of the fabric.
The dolly machine is constructed with two heavy squeeze rollers and guide
rollers.
The bottom heavy roller is driven by a chain pulley drive given from
outside. The top roller rests on this roller with fabric between them in
rope from and is frictionally driven.
A metallic plate is situated under the heavy rollers to catch the expressed
liquor. It is only when scouring is approaching completion that the liquor
is discharged to facilitate quicker and more though rinsing.
The pieces of cloth are made into endless chains in such a way that they
pass through the squeeze rollers.
When the machine is set under motion the pieces will rotate endless.
The top roller is soft rubber coated and the bottom roller is made of hard
ebonite.
In the metallic plate, a steam pipe is provided which is perforated to heat
the water.
Four jets of water at the back side of the machine spray water with force
on to the fabric.
There can be the possibility of processing four ropes together.
Capacity of the dolly machine is 150 kg.
OPENWIDTH SCOURING
This :is a process in which fabric is washed in open width form. Mainly used
for delicate and expensive fabrics.
CRABBING
Crabbing is the setting process of wool. It helps in bringing dimensional
stability to the fabric and eliminates distortions like crocking and uneven
shrinkage.
To set the cloth and the yarn twist permanently, wool fabric is passed over
several cylinders that rotate in hot water and is then immersed quickly in cold
water.
The cloth is held firmly and tightly to avoid wrinkling.
Repetition of the treatment with increased pressure results in setting of the
cloth and the finish.
MILLING
The process of milling fabrics involves the application of friction and pressure
to the fabric while it is running in a hot soapy, acid or alkaline solution.
The objective of milling is to make the fabric fuller and denser as a result of
which the woven pattern becomes more or less obscure.
The milled cloth is suitable for producing a raised finish.
This process is based on the principle that the wool gets shrinked when it is
rubbed in wet conditions and at certain temperature.
After milling, the material is sent to the drying section.
DRYING AND HEAT SETTING

The drying and heat setting both is done by a stenter.
Drying is necessary to eliminate or reduce the water content of the fibres, yarns
and fabrics following wet processes.
The drying process aims at eliminating exceeding water and achieving the
natural moisture content of the fibre. Excessive drying can negatively affect the
final appearance and the hand of the textile.
Machine used – Harish Hot Air Stenter
SHEARING
In a shearing machine there is a spirally wound shearing blade, which revolves
in contact with a ledger blade.
The fabric passes over a cloth rest in front of the ledger blade and the raised
fibres flop against the ledger blade and are cut by the rotary blade.
Suction units are incorporated for cleaning the working units.
Objectives of shearing are-

To clear out the random length fibres and produce a uniform and level pile.
To reduce the height of the wild fibres and prevent pilling.
To produce a certain handle.
To improve the colors and appearance of the fibre.
DECATISING
This process is used for improving the soft handle of the fabric.
The fabric is wound together with an interleaving fabric on a perforated metal
roller so as to form a reasonably thick roll, between each layer of the fabric of
some thickness made of synthetic material.
Mechanism:.
The fabric is compressed between two layers of woolen felt and steam is blown
simultaneously. The fabric acquires body suppleness with an ironing effect on both
the faces. These are due to the swelling of the fibre by steam.
PAPER PRESS MACHINE

It is done to give silk shine effect
or in other words it is a sort of
shine treatment to the occasional
wear fabric.
Paper press machine consists of
electronic cardboard which has a
heating element in it.
Fabric is sandwiched between
these electronic cardboards and
heated for an hour then 250 tons
pressure is created using
hydraulic power and is applied
for 8hours.
Production – 1100 m in 14hours
This machine is used to remove moisture.
Used for costly wool.
ROTATORY MACHINE
This machine gives metal to metal finish.
It consists of metal rollers of 130℃ and metal beds of 118℃.
Fabric passes between the rollers to provide luster to the fabric.
Used for low cost and light weight fabric.
Production – 900m/hr
KIER DECATISING
Prevents wool shrinkage.
KD process gives a permanent finish.
Machine – KD supreme90.
Wool is set at the temperature of 200℃ and pressure 2.5kg/sq.cm.
SUPER FINISH
It has two components – silicon bed and metallic roller.
Metallic rollers are used to give shine and silicon beds provide lustre and soft.
FORMULA 1 PRESS
With a silicone belt.
Double time press machine.
The temperature and pressure for this process is at 135℃ and 90 kg/sq.cm.
Total machines: 2
After finishing, fabric is inspected in the perching machines where

slubs ,knots ,holes and other such defects are inspected.
INSPECTION
PROCESS FLOW IN INSPECTION
Receive material from Finishing Dept.
Back side perching
Face side perching
Measuring table(quality shade check)
Cutting
Weighing
Plaiting
Packing
Final checking
Send to warehouse
In the inspection department,

the fabric from the finishing
department is brought in horse
trolleys. Then the fabric is taken
to the perches. Firstly it is taken
to back side perching, where the
fabric is placed on a machine
with its back facing the operator
or inspector looking for defects
in the fabric. As in general
inspection machines, light is put
on the fabric from the other side
to find the defects easily.
The fabric is inspected for the presence of faults manually and the faults are flagged
according to the faults.
4 types of defects are basically looked upon, they are- clipping, damage, barre and
stain.Six machines are used for the process.
In this process two types of flags are used-
White flag – for presence of minor faults (pin holes, marks)
Yellow flag – for presence of major faults(start up mark, missing pick, damage etc,)
The yellow faults are those faults which cannot be removed from the fabric and have
to be further cut from the fabric. These inspected fabrics are further checked on the
table where the faults are rechecked. The fabric rolls are further processed (cut)
according to the buyers demand. if the fabric length is 15 m and there are 10 white
flags then the amount paid by the buyers will be of 14.90 m only. This means the
buyer is given compensation for this defect as 1% of total meters. Further the
acceptable limit for the white flag is one in every 5m (max).
Production is 2000m per shift per machine.

Total inspection machines are 12.
Total number workers for two shifts are 110.
4-Point inspection system is carried out in the industry.
VARIOUS DEFECTS IN FABRIC

SR. NO. SPINNING PREPARATORY WEAVING PROCESSING
1. Thick places Slack end Missing end Corrugation

2. Thin places Sizing stain Starting mark Water mark
3. Naps Double end Broken end Crease mark
4. Slub Pulling mark Broken pick Stop mark
5. Moiré effect Big knots Short pick Crease mark
6. Cone change Reed mark Single mark
7. Coarse yarn Temple mark Skew impression
FOUR POINT SYSTEM

For the export market, OCM uses the four-point system. The four-point system is issued
by the American Society for Testing and Materials (ASTM). The general tolerance limit
for the presence of the defect is 25 points per 100m roll of the fabric. Again, this
tolerance limit depends upon the buyer as some have strict limits, and some are liberal
in their tolerance level. Generally, the yellow flag faults are not removed for the
export market products because they come under the tolerance level.
SIZE OF DEFECT PENALTY POINTS

3 inches or less 1
Over 3 inches but less than 6 inches 2
Over 6 inches but less than 9 inches 3
Over 9 inches 4
CHECKING OF DIMENSIONS
MEASUREMENT OF WIDTH
Width shall be measured at three different places of the fabric and recorded.
While measuring width, care should be taken: -
To remove the wrinkles/ crease gently from the fabric surface.
To keep the measuring tape straight across the fabric horizontally from
selvedge to selvedge.
To measure the width as far as possible near the centre avoiding the ends.
Not to stretch the fabric while measuring.
MEASUREMENT OF LENGTH
Fabric to be measured for length and actual length recorded. Length is
measured by any of the following methods: -
By passing through meter counter fitted roller.
By manually clipping the fabrics in the fold measuring frame.
By counting the number of meter fold in case of folded fabrics. Care to be
taken to ensure that the folds are of one meter length by measuring a few
folds.
CHECKING OF CONSTRUCTIONAL PARTICULARS

Ends per inch
Ends per inch shall be counted at two places along the width of the fabric and
recorded.
Picks per inch

Picks per inch shall be counted at three places along the length of the fabric
and recorded. Care to be taken while placing the pick glass to see that the edges
of the template should coincide with the yarn. Ends/Picks per inch may be
counted for one inch. Also the picks should not be counted at defective places
like weft bars and cracks.
Weight per square meter

Pieces are to be weighed and recorded for GSM.
Calculation of GSM:
Weigh the individual piece under Inspection and note-down.
Work out the sq.mtrs. of the piece by multiplying the length of the piece in
mtrs. and width of the piece in mtrs.
After measuring and cutting , they place a sticker on to the fabric which contains
information about that fabric, like piece number, shade, weight, length, party to which
it is to be delivered. After this, rolls are made for export fabric and Thaans for the
domestic fabric.
Then the fabric is weighed and then some of the details of fabric and party is
transferred from a white paper to the fabric by help of ironing.
FOLDING
After the fabric is weighed, it is then sent for folding. Two types of fabric folding
are done in the industry- one is cardboard folding and the other is folded in roll
form. Fabric which are used for domestic purposes are folded by cardboard folding
machine and the fabric which is to be sent for export are folded in roll form.
PACKAGING
After folding, fabric
specification tag and
barcode is attached
to each and every
lot, then it is packed
and sent to the
fabric warehouse.
WAREHOUSE
The material from Inspection Department is received in Warehouse and a record is
kept. It is the warehouse from where is material is sent ahead to its market customer
as the challan receipt is issues for the invoice department as well as for the
transportation department , so as to have an estimate figure of cost to be obtained
from the buyer.
The warehousing department follows the listed below steps of procedure:
Scanning of the packed fabric lot
Computer scan of the vouchers & verification of details of the vouchers (using bar
code readers).
Dealer-wise stock maintenance against requirement.
Bill development and issuing of challans ( for invoice, transportation, sales.)
Rechecking of bill with the sales challan copy.
Dispatch to dealer using different modes of transportation.
The vouchers received are checked for any mistake for:
DESIGN
GRADATION
METRES etc. by piece ticket
There is different warehouse for storing export and domestic fabric in OCM.
• In fabric warehouse, both outsourcing and inhouse fabric is stored.

• Fabric stock capacity is nearly 40 lakhs.
• Total number of workers – 30/2 shift.
• Tracking and shipments of fabrics are handled.
• Pest control spray is done to prevent infestation.
• Premium storage boxes are sourced from New Delhi.
• Transportation is mainly done through Safe Express Company.
• Exports fabrics are stored in roll form.
• Domestic fabric is double folded.
YARN WAREHOUSE
Yarns that are obtained from spinning and post spinning department are kept in yarn
warehouse for future use. The yarns are kept in warehouse in organised manner and
some of the yarns are sourced from Mumbai and Rajasthan.
There are total 735 racks.

Capacity is 1,10,000 tons stock.
Total number of workers are 16 for two shifts.
Numbers are allotted according to the colour of the yarn.
QUALITY ASSURANCE
At OCM we observed a separate department dedicated to testing of the fabric. It is
important to maintain a level of quality for every industry or business to get
increased sales and better prospects amongst competitor businesses. As OCM has an
export business also so there are certain quality standards to sustain to ensure
better business globally.
TEARING STRENGTH TESTER

To determine the tearing strength of knitted
and woven fabrics. Capacity up to 6.400Kgs.
With an adjustable cutting knife.
Having three variable capacity 1.600kg,
3.200kg & 6.400kg for different types of
fabrics.
Latest design with modern sophisticated look.
Complete with accessories including three
calibration weights.
Supplied with inspection & calibration
certificates.
SPRAY TESTER (WATER REPELLENCY TESTER)

This test measures the hydrophobic tendency of fabrics by wetting them with water.
MICROSCOPE
Used for fibre analysis or fibre identification. With a maximum resolution of 1000X.
Any type of measurement like length, area, count of any fine textile fibre can be
done. This is the best option for Textile fibre analysis. Enlarged view due to
projection on 360? graduated screen. Supplied with complete accessories including
stage micrometer for calibration. Supplied with calibration & inspection certificates.
DIGITAL TWIST TESTER
Used to determine the twist per

inch/cmSpecially designed for
single yarn, double yarn & open-end
yarns. Smooth precision-engineered
mechanism. 1 & 50gms weight
supplied to give proper tension
during testing. Digital control panel
with LCD display. Complete with all
accessories Supplied with
calibration & inspection
certificates.
TENSILE STRENGTH TESTER

The tensile strength or the breaking strength is tested by three
different methods.
Raveled strip method- In this method, a strip is cut(6 x 20 cm).

Then yarns from the sides are taken out to reduce it to 5 cm
width. This raveling helps to get better results of the strength
than directly cutting 5 cm strip. The ends of the strip are held
by jaws moving away from each other. The reading in the
machine when the strip gets torn is its tensile strength or
breaking strength.
The gap between the load cells – 750 mm
The dimension of the fabric – 40 cm * 10 cm.
This machine also checks the seam strength of the fabric
CREASE RECOVERY TESTER

Small pieces of warp and weft are cut from the fabric. They are kept under weight
for 5 minutes. Then they are hung from a point in the crease recovery tester at 90
degrees. After 5 minutes the scale is rotated at a certain angle, if the crease
straightens up at 140 degrees, then it's good else if it straightens up at an angle
less than 140 degrees then there are less chances of crease recovery in that fabric.
MARTINDALE ABRASION CUM PILLING TESTER

Martindale test is used to measure the durability of fabric.
It is carried out to measure fabric's abrasion resistance. The
fabric that needs to be testes is pulled taut and loaded onto
the lower plates of the Martindale machine. Small discs or
of worsted wool or wire mesh are rubbed against the fabric
in circular motion. The fabric is then checked for any wear
and tear, and the test ends when two yarns break or there is
change in appearance.
CROCKMETER
Crockmeter test is carried out to check the colour fastness to the crockmeter.
To determine the Colour fastness of Textile to Dry or Wet Rubbing as per
ISO/European Standards. Ergonomic latest design with modern appearance with
precision-engineered components. Electronic, resettable LCD Counter. Easy to use,
Polycarbonate Specimen Clamps. Dual Metal Sample Holder for specimen Testing and
Garment Testing. Complete with all accessories including pre-cut (50 x 50 mm) 400
crocking clothes, 16mm Finger and finger clips, blotting papers etc
COLOUR MATCHING CABINET

To match the colours of yarn dyed or printed fabrics or any material.
DYEMASTER
To do sample dyeing with infrared

heating. 200ml twelve beakers supplied
to dye 12 samples together &
temperature up to 140 degree C with
infrared lights.
Eco-friendly equipment, which does not

give any residue & Latest microprocessor
based control panel for temperature &
time. Inside the dye assembly pot moves
at variable speed in both directions.
Stainless steel body & beakers gives rust-
less long life & Smooth, precision
engineered components for exceptional
performance. Special cooling blower for
instant cooling of the bath. Supplied with
all accessories along with tong for
removing beakers. Supplied with
calibration & inspection certificates.
GSM TESTER
This test is the measurement of Gram per Square meter, and one of the most
essential methods of determining the weight of the fabric..
HOT AIR OVEN

The oven controller has Special T/P action to avoid overshooting of temperature. It
has Stainless Steel Inside Chamber, Outer is Mild Steel neatly powder coated.
Complete with Hot air blower and Digital Temperature Indicator cum Controller. It is
used to check the blend percentage. A separate control panel housing all indicators
is provided on the right side of the main body allowing easy maintenance and
accessibility aesthetically designed for long life and comfortable usage. Controlling
Digital Temperature Controller cum Indicator Maximum Temperature Range 105-
1070C Power requirement 220V-240V single phase 1 KW Inside Dimensions 455mm x
455mm x 455mm
S.W.O.T. ANALYSIS
STRENGTHS:
Biggest strength of OCM woolen mills is its latest technology and imported machinery.
High spinning capacity plant in worsted spinning system.
In north India the brand is perceived to be a premium and reliable brand because of its
presence in market for over many decades.
There is no other big industry of woolen fabric in north India.
WEAKNESSES:
The main weakness of OCM is a conventional distribution channel. The company relies
mainly on agents for sales promotion who might neglect their work to earn better margins.
Though the company is selling its product all over India, but it is situated in Amritsar, which
is far from the west and south India.
The company spends less money on advertisement and brand promotion as compared to
other brands.
OPPORTUNITIES:
The company can set up its ready-made unit to increase the utilization of its finished
product.
There is increase in demand of the suiting product in the market due to increase in business
class people.
Due to increased demand of product, there is also demand for quality of product for which
OCM is known in the market.
The other opportunity for OCM is the rural customer because they are not as much targeted
by the big players.
THREATS:
The biggest threat is of the growing popularity of the cotton fabric and thus cotton
producing units in India and abroad.
Raymond suiting has been major competitor of OCM.
The converters i.e. units established exclusively to convert fabric into ready-made garments
pose the biggest threat to OCM, since they usually buy cheaper material of not so known
brands.
SUGGESTIONS
Recruitment of more female staffs
All the information/data are stored in excel sheets and registers that can be done using
software.
Operators should effectively use personal safety equipments like masks, ear plugs, etc.,
wherever required.
The transportation of material from one department to other should be taken care of in a
better manner & done swiftly.
Proper space utilisiation
Adopt CSR strategy
CONCLUSION
From our two weeks of industrial training here in OCM, Amritsar, we have learnt many things
which hopefully mightn’t be imparted anywhere in books or colleges, i.e., with excellence and
perseverance combined with team efforts and morals only, a company can imagine to succeed.
And it gives us immense pleasure to share that OCM is indeed a successful textile company,
setting examples for others to follow and being a guiding light for internees as well as new
fishes in the market to survive(by imbibing in blood their success key).
After this training we have came to know that how fabric is made and what kind of defects are
there in the fabrics and how they come into existence and what are the quality standards for
fabrics.
The strong culture of the OCM does definitely contribute to great extent to the production
capacity of the company. The capacity planning process of the industry is remarkable and does
compel one to pay heed to, if at all one desires to be dream big and be successful.
OCM, India undoubtedly made the two week industrial training program worth and does
enlightened us to extremes.

Textile Internship Report: Ocm Private Limited Textile Unit, Amritsar

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Textile Internship Report: Ocm Private Limited Textile Unit, Amritsar

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JANUARY 2021

TEXTILE INTERNSHIP REPORT

OCM PRIVATE LIMITED

DEPARTMENT OF FASHION TECHNOLOGY

I would also like to thank my department, ‘Department of Fashion Technology’ and

Lastly, I am grateful to NIFT Kangra, for giving me an opportunity for industry

POST SPINNING SECTION.....23

OBJECTIVE OF THE TEXTILE INTERNSHIP

OCM India Limited, popularly known as OCM, a leading Multi National

In 1972, the British Company

PLANT HEAD............................... MR. SHALENDRA PANDEY

DYE HOUSE................................. MR. ASHISH SHARMA

DESIGNING.................................. MR. AMAR SUKHWAL

SPINNING.................................... MR. M.P. SINGH

WEAVING..................................... MR. SANDEEP

FINISHING................................... MR. PARAMJIT BHARADWAJ

WAREHOUSE................................ MR. L.G. RAJESH

MENDING AND INSPECTION......... MR. J.N. MANDA

Domestic Export RMG

PRODUCTION PLANNING AND CONTROL

In OCM 3 types of dyeing are done:

Process for dyeing Poly/Wool blends:

Process Sequence for Top Dyeing

Tops Loading in Machine

Addition of chemical through stock tank

Run for Ten minutes

Addition Rejected Passed

Application of Antistatic Agent and neutralizer

Light Shade Unloading Dark Shade

Hydro Extractor Back Washing

R.F Drier Top Making

Defelting and Top Making

HIGH TEMPERATURE HIGH PRESSURE MACHINES

After the dyeing process the tops

RADIO FREQUENCY DRYER(R.F DRYER)

During the process the product(yarn/tops) passes through an electrode system

BACK WASHING MACHINE

Process Sequence for fabric Dyeing

Washing at room temperature for 10 min

Temperature is raised to 60 degrees

Run for 5 mins color addition

Temperature is raised to 130 degree

Hold for 30 minutes

Washing For 5 Minutes

SOFT FLOW DYEING MACHINE

JIG DYEING MACHINE

Process Sequence for spinning

removing foreign material from foreign fiber

Total no. of workers : 310 for 3 shifts

To produce an end product with

1st passage and 2nd passage – 3 pins per cm

Gill box- to draft the tops and remove the waviness

POST SPINNING DEPARTMENT

PROCESS FLOW OF POST SPINNING

Single Yarn from Spinning

Two For One Twister (TFO)

Steaming ( Auto Clave)

Machine Manufacturer Speed

Assembly winding P.S Metler 300m/ min

There were 6 assembly winding machines in OCM.

TWO FOR ONE TWISTER (TFO)

STEAMING (AUTO CLAVE)

Some features of Autoclave machine are: