TEXTILE INTERNSHIP

PRAKASH WOOLEN AND SYNTHETIC MILLS LTD.

NH9, Joya, Uttar Pradesh 244221

BACHELOR OF FASHION TECHNOLOGY

DEPARTMENT OF FASHION TECHNOLOGY
NATIONAL INSTITUTE OF FASHION TECHNOLOGY, NEW DELHI

MONAAL SINGH
DFT 5
 DECLARATION

I, Monaal Singh declare that the report on Textile Internship at

Prakash Woolen and Synthetic Mills Ltd., submitted towards
the partial fulfillment of the degree of Bachelor of Fashion
Technology, is our original work and no part of the report has
been copied from any other report or any other work by
someone else. Immediate and accurate references along with
acknowledgements have been given if however, any material is
taken from any published source.

MONAAL SINGH
 ACKNOWLEDGEMENT

I, Monaal Singh student of National Institute of Fashion

Technology, New Delhi thankful to Mr. Omkar Dongre (GM) and
Mr. Ankit Mishra for their continuous support and guidance
throughout my internship as my mentor. I am also thankful to
the HODs of the various departments for helping me
understand the process and work flow for the company. I would
also like to thank the staff at Prakash Woolen and Synthetic
Mills Ltd. for readily co-operating with me, whenever needed. I
am also thankful to my internship mentors at National Institute
of Fashion Technology, New Delhi, Prof. Bhavna Verma who
has been of constant support during the entire duration of the
internship. I am most grateful to the almighty god for his
continual showing of blessings.
 ABOUT THE COMPANY

Prakash Woollen Mills specializes in the production of Mink

Blankets and Bed Covers. Our manufacturing unit boasts of
state-of-the-art machinery based on the most advanced
technology which has been specially imported for our
production facility. We have streamlined facilities for knitting,
dyeing, processing, printing, finishing and packaging. The
complete facility is backed by the team of highly skilled and
experienced workforce, who ensure zero defects at every stage
of production.
Prakash Woollen Mills Limited, was established as
manufacturing concern of Woollen Blankets, the Company
rapidly honed the skills of the trade. Latter on our skills that
were amply showcased in our helped us to go into backward
and forward integration and become a composite unit. In three
decades of its existence the company has acquired the
capacity to manufacturing over one million of Mink Blankets per
annum and today is one of the largest composite units of Mink
Blanket.
Prakash Woollen Mills Limited was incorporated on 23rd Day of
August 1979 in the name and style of Prakash Woollen Mills
Private Limited. The Company was converted into a Public
Limited Company on the 14th May 1993 by the efforts of his
Executive Directors and Senior Management.
Prakash Woollen Mills Limited, was established as
manufacturing concern of Woollen Blankets, the Company
rapidly honed the skills of the trade. Latter on our skills that
were amply showcased in our helped us to go into backward
and forward integration and become a composite unit.
 The name of the company has been changed from Prakash
Woollen Mills Limited to Prakash Woollen & Synthetic Mills
Limited with effect from 27th Day of July 2015. In a strategic
move Prakash Woollen & Synthetic Mills Limited entered into a
field of Mink Blankets the diversification of this product was
achieved with technical assistance from South Korea and
China who are the leaders in Mink Blankets. The entire project
and the technology have been imported from Korea and China
is of the latest state of art technology.
In four decades of its existence the company has acquired the
capacity to manufacturing over 2.4 million of Mink Blankets per
annum.
Prakash Woollen Mills Limited already has its presence in
domestic market with a strong dealer network and over the
years has gradually increased its presence across the globe
and today is the symbol of quality and familiar name in Blanket
Industry.

COMPANY PROFILE

Name of Company Prakash Woolen and

Synthetic Mills Ltd.
Factory Location and Address NH9, Joya, Uttar Pradesh
244221
Year of Establishment 1993
Business Activities Blankets Manufacturer
Website http://www.prakashwoollen.co
m/

LOCATION

INFRASTRUCTURE
We have a well established infrastructure that stretches over
our widely spread out facility in Moradabad , Uttar Pradesh. Our
technically advanced production facility plant is equipped with
the latest technology available for knitting, dyeing, cutting,
processing and printing, and packaging. The technologically
advanced machines enable us to meet the varying demands of
our customers with finesse and meet our deadlines effectively.
The team at Prakash Woollen Mills comprises of highly
experienced workforce of designers, technicians, professionals,
and managers that execute all the processes using the best in
technological advances in the industry. Our creative designers
with a passion for fashion and innovative styles always come
up with fresh and trend setting styles for our Mink Blankets. All
the processes are carried under the supervision of highly
qualified professionals and managers, who ensure highest
quality of products and services.
Prakash Woollen Mills lays special focus on research &
development in order to evolve with the emerging trends,
technology and consumer needs. This consistent commitment
to market and design research has resulted in path-breaking
new products, thus raising the standard of the Indian Mink
Blankets industry.

OVERVIEW OF THE COMPANY

MINK BLANKETS

Prakash Woollen Mills specializes in the production of Mink

Blankets and Bed Covers. Our manufacturing unit boasts of
state-of-the-art machinery based on the most advanced
technology which has been specially imported for our
production facility. We have streamlined facilities for knitting,
dyeing, processing, printing, finishing and packaging. The
complete facility is backed by the team of highly skilled and
experienced workforce, who ensure zero defects at every stage
of production.
In a strategic move Prakash Woollen Mills Limited entered into
a field of Mink Blankets the diversification of this product was
achieved with technical assistance from South Korea and
China who are the leaders in Mink Blankets. The entire project
and the technology have been imported from Korea and China
is of the latest state of art technology.
Prakash Woollen Mills Limited already has its presence in
domestic market with a strong dealer network and over the
years has gradually increased its presence across the globe
and today is the symbol of quality and familiar name in Blanket
Industry.

PRODUCTION FEATURE

From weaving of blanket fabric to printing, finishing, sizing and

packing, all the processes of making impeccable Mink Blankets
are carried out in-house at Prakash Woollen Mills production
facility. Weaving of blanket fabric from yarn is done in two
different modes; through circular knitting machines, and
through Raschel knitting machines. Grey fabric is printed
thorough automatic Screen Printing machines. Printed fabric is
then finished through various processes, and finally the cutting
of fabric happens to create beautiful, warm and trendy blankets.
This is further followed by the stitching of the sides with satin to
give the blankets the final finish before they go through the
packaging process which is also done in-house at Prakash
Woollen Mills facility.
PRODUCTS

● 2-Ply Mink Blankets

● Baby Blankets
● Fleece Blankets
● Mink Blankets
● Plain and Embossed Mink Blankets
● Soft Blankets

HOME FURNISHING

● 4 Pcs Sets
● Comforters and Comforter Sets
LIST OF PRODUCTS
SOFT BLANKET

The months of mild cold or pleasant seasons like the monsoons

is the time when you might require soft blankets to keep you
cozy. Prakash Woollen Mills has created a range of Soft
Blankets for you to enjoy and cherish the moments of such soft
and cozy weather. Our collection of Soft Blankets will bring
creativity and style to your specific theme of room décor and
furnishing. You can choose from the widest range of colours,
designs and styles that is available in our collection of Soft
Blankets. The Soft Blankets of Prakash Woollen Mills which are
made of 100 percent polyester are extra luxurious and soft. The
full range of Soft Blankets at Prakash Woollen Mills is available
in all the standard sizes. We bring to you, the unbeatable
quality of Soft Blankets at the most affordable price range that
is available in the market. So enjoy your memorable moments
of the soft weather with Prakash Woollen Mills’s Soft Blankets
and make them softer and cozier and more memorable.
Composition - 100% polyester
Size - 200 x 240, 220 x 240, 150 x 220, 160 x 220
PLAIN AND EMBOSSED MINK BLANKETS

If your taste and style of home décor is such that you prefer
plain or embossed blankets to grace your beds, then you are at
the right place. Prakash Woollen Mills, besides creating the
most attractive designs in all kinds of blankets, also boast of an
exquisite line of plain and embossed blankets to keep you
warm when you need to be. The range of Plain and Embossed
Blankets is available in almost all possible colors. Pick the
pieces that go well with your choice of color and room décor
and you can be sure of our Plain and Embossed blankets
adding to the elegance of your beds and bedrooms.
Composition - 100% polyester
Size - 200 x 240, 220 x 240, 150 x 220, 160 x 220
2 PLY MINK BLANKETS

The extra thick, extra soft 2-Ply Mink Blankets are among the
top quality blankets that you will find at Prakash Woollen Mills
collection. Our highest quality 2 Ply Mink Blankets look fresh
and new even after numerous washes and years of use. Well,
that goes for all our blankets and home décor products. That is
the best test of quality of Blankets that their shine and color and
softness do not fade after few washes. The highest quality
products of Prakash Woollen Mills have stood this quality test
for over three decades. Browse through the extensive and
attractive range of 2 Ply Mink Blankets from the collection of
Prakash Woollen Mills and you will have the most sound and
satisfactory , not to mention , warmest sleep of your life.
Composition - 100% polyester
Size - 200 x 240, 220 x 240, 150 x 220, 160 x 220
COMFORTERS AND COMFORTER SETS
Apart from the large variety of Mink Blanlets, Prakash Woollen
Mills also produces stunning Comforters and Comforter Sets to
keep you warm while you sleep or rest in your bed. Available in
different colors, plain and printed , you will find our collection
and quality of Comforters quite endearing. Depending on your
bed size, you can choose the size of comforters which are
available in all standard sizes for twin, king, queen, and full
beds. Comforter covers are also available to keep your
comforters safe for a prolonged use. There is a beautiful range
of Comforter sets also, comprising of a bed skirt, pillow shams
and pillows , if you would like your beds to look completely
color and style co-ordinated in all aspects. Have a look at our
collection and you will never look at any other brand for the
most comfortable, warm and eye catching Comforters.
Composition - 100% polyester
MINK BLANKETS

The collection of Mink Blankets at Prakash Woollen Mills is so

designed that it adds color, warmth, and style to any theme of
room décor. The range of colors, designs and styles is so
diverse in our collection that all kinds of room decor themes find
their perfect match. These blankets are luxuriously soft, cozy
and warm to the core. The elegant color scheme of our
blankets gives them a rich look. The complete range of Mink
blankets at Prakash Woollen Mills is available in all the
standard sizes. We offer the best possible quality Mink blankets
at the most convenient price range available in the market.
Composition - 100% Polyester
Size - 200 x 240, 220 x 240, 150 x 220, 160 x 220
BABY BLANKETS
If you have small babies or small children in your house, they
would require even more special care than the adults to keep
them warm and safe from the cold. Hence, Prakash Woollen
Mills has come up with a cute range of Baby Blankets
especially for your little ones. The collection of Baby Blankets at
Prakash Woollen Mills has been designed keeping in mind the
special needs and nature of babies and small children. Even
the furnishing and room décor of your little babies’ room is quite
unique in its visuals and feel, and our Baby Blankets only
enhance the adorability of their rooms and beds. As children
grow and change at a rapid pace, therefore we have a wide
variety of designs in this section to suit their varying likes. The
softness, size, color combinations and designs of our Baby
Blankets range are all designed with great emphasis on making
our Baby Blankets the most suitable for the temperament of the
little ones. The Baby Blankets from the house of Prakash
Woollen Mills is the best that you can get for your little ones.
Composition - 100% polyester
Size - 200 x 240, 220 x 240, 150 x 220, 160 x 220

4 PCS SETS
In case you have a large house and you have extensive
furnishing requirements in your house , Prakash Woollen Mills
offers 4 Pieces Sets of exquisite Mink blankets in all sizes and
in a wide variety of beautiful designs , color schemes and
themes. Sogo ahead and stock up your collection with the
warmest , longest lasting and most beautiful 4 Piece Sets of
Mink Blankets available at Prakash Woollen Mills.
Composition - 100% polyester
FLEECE BLANKETS
If you are an admirer of Fleece Blankets, then you will fall in
love with our collection of beautiful fleece blankets the moment
you set your eyes on them and feel the first touch of the Fleece
Blankets of Prakash Woollen Mills. They are soft, warm and
ever so comforting that there is nothing unlike Fleece Blankets
of Prakash Woollen Mills. The creativity that goes into the
making of a Fleece Blanket at Prakash Woollen Mills is
precious and so are the blankets that are made here. Once you
check out our range of Fleece Blankets you are bound to find
the perfect match for your kind of room décor style and also to
suit your personal style statement. So go ahead and pick your
favorite Fleece Blanket from the ever refreshing collection of
Prakash Woollen Mills and make your bedrooms warmer and
cozier than ever.
Composition - 100% polyester
Size - 200 x 240, 220 x 240, 150 x 220, 160 x 220
RAW MATERIALS
The raw material plays an important role for the production of
good quality of fabric. A fabric is made from natural or
manmade fiber or a combination of both.
MANUFACTURING METHOD
Polyester printing mink blanket and its manufacturing
method
The present invention relates to a polyester printing mink
blanket and a method of manufacturing the same, and
more particularly, to weaving polyester yarns at a
constant tension of 30 to 60 g, printing the woven fabrics
at a temperature of 100 ° C to 130 ° C, and printing By
brushing the knitted fabric many times within the
temperature of 90 ~ 140 ℃, it provides a soft touch,
excellent gloss, bulkiness and warmth, and also prevents
the bending and static electricity of brushed piles. It
relates to a manufacturing method.
In general, the printing mink blanket is a knitting process
for making a knitted fabric using acrylic, a printing
process for printing in a variety of beautiful patterns on
the surface of the woven acrylic knitted fabric, and
brushed to enhance the flexibility, bulkiness, and warmth
of the printed knitted fabric. It was prepared through a
brushing process or a mixture of acrylic and polyester
was prepared through the above process steps. Acrylic
mink blankets and acrylic-polyester mink blankets
produced in this process are not only highly warm and
soft to the touch, but also printed on the surface with
various patterns such as animals and landscapes, and
the appearance is very beautiful. However, the
fabrication of mink blankets using polyester-only knitted
fabrics cannot be printed on the surface of mink blankets
due to the dyeing problem of polyester, and the
temperature in the brushing process gives soft touch and
luster to the surface of mink blankets. Due to the curing
phenomenon due to the difference, it was impossible to
prepare a polyester printing mink blanket. As a result, it
is a pity that polyester not only provides soft texture,
excellent gloss, bulkiness, and warmth, but also has
excellent properties than acrylic, i.e., a polyester having
properties that can prevent file bending and electrostatic
phenomena. There was this.
The present invention has been invented to solve the
above problems, and provides a soft touch, excellent
gloss and bulkiness and heat retention as in the
conventional printing mink blanket, as well as properties
that can prevent bending and electrostatic phenomena of
the pile To provide a polyester printing mink blanket
prepared by using only 100% polyester with a polyester,
and a polyester printing mink blanket that can produce a
polyester printing mink blanket under conditions suitable
for the properties of the polyester. There is this.
The present invention relates to a polyester printing mink
blanket which can provide soft touch, excellent gloss and
bulkiness and warmth, as well as prevent bending and
electrostatic phenomena of piles. Knitting process of
weaving polyester knitted fabric on both sides by
applying a fixed tension of 30 ~ 60g to a single yarn of
the polyester yarn; A printing process of printing at a
temperature of 100 to 130 ° C. in various patterns on the
surface of the knitted fabric woven in the knitting
process; The knitted fabric is printed in the printing
process is made of a brushing process to brush
repeatedly by a plurality of times at a temperature of 90 ~
140 ℃.
The temperature control of the printing process is
preferably to use a steam heater to prevent the
phenomenon of the surface of the knitted fabric is
hardened by heat to perform the printing effectively.
In the printing process, it is preferable to use 0.6% of
dye, 1.1% of penetrant, 0.25% of poly softener, and 0.4%
of antifoaming agent with respect to 100 weight of the
manufactured blanket.
The penetrant, poly softener, and antifoaming agent may
be Softener (Conc type), Bubble Eliminator, Penetrative
chemical, or equivalent products, each manufactured by
Hanil Chemical Co., Ltd. (HANIL CHEMICALS CO.).
In the brushing process, the polyester is brushed a
plurality of times while gradually lowering the
temperature from 140 ° C to 90 ° C in order to prevent
hardening due to high heat.
As described above, the polyester printing mink blanket
of the present invention, which is 100% polyester yarn
printed in various patterns on the surface, provides a soft
touch, excellent gloss, bulkiness and warmth, as in the
conventional printing mink blanket, As the surface can be
printed in various patterns, not only the appearance is
beautiful but also the bending and electrostatic
phenomena of the file often occurred in the conventional
printing mink blanket can be prevented, thus extending
the service life. It can be provided. Referring to the
polyester printing method of manufacturing the mink
blanket in more detail as follows.
In the knitting process, using a 100% polyester yarn
made of lightly twisted polyester fiber, weaving machine
(Weaving M / C) through a nacelle double-sided machine
to apply a constant tension of 30 ~ 60g to one of the
polyester yarn on both sides When weaving with a
tension of 30g or less, the degree of injuries is insufficient
to obtain a good effect in the raising process, and when
weaving with a tension of 60g or more, it is difficult to
withstand the force and achieves the desired purpose.
Since it is impossible to do so, it is preferable to be
woven so that a constant tension of the same size is kept
uniform.
The pure white knitted fabric woven in the knitting
process is printed in various beautiful patterns through a
printing process. First, various patterns are designed on
the surface, and then dyes of 0.6% of a suitable color
with respect to the weight 100 of the manufactured mink
blanket , After dyeing and printing the dye penetrant
1.1%, poly softener 0.25%, antifoam 0.4% by using a
steam heater to dry at a temperature of 100 ~ 130 ℃, the
reason for using the steam heater is the polyester It does
not harden by heat, and it makes it possible to implement
printing effectively. In addition, when the set temperature
of the steam heater is less than 100 ° C, the drying is
insufficient and the printing area is easily discolored, and
when the setting temperature is over 130 ° C, the printing
area becomes too hard due to high heat, which makes
the next brushing process difficult. Because.
The printing process is completed by washing polyester
knitted fabrics printed in various patterns as described
above to remove foreign substances attached to the
surface and drying them.
Knitting fabrics printed in the printing process causes a
fluff on the surface in the brushing process, using a
brushing machine (Brushing M / C) in a temperature
range of 90 ~ 140 ℃ to have a soft texture, excellent
gloss and bulkiness and warmth In the first step, at a
temperature of 140 ° C, the next step at a temperature
lower than 140 ° C, the next step at a lower temperature,
and so on, the temperature is gradually stepped down to
the lowest 90 ° C. By raising the surface at the
temperature, the surface of the knitted fabric is a uniform
pile of appropriate length. Here, when the brushing is
performed at a temperature above 140 ° C., the raising
pile cannot be formed due to the hardening phenomenon
of the polyester hardened by high heat, and when the
temperature is lower than 90 ° C., the sufficient raising
file is not formed. Since it is not possible to provide
excellent gloss, bulkiness and heat retention, it is
preferable to carry out a plurality of brushing operations
while lowering the temperature from a high temperature
to a low temperature within the above temperature
range.
By finishing the brushing process, using only 100%
polyester yarn has a soft touch, it is possible to
manufacture a polyester printed pink blanket with
excellent gloss, bulkiness and thermal insulation.
The present invention configured as described above is
woven with a constant tension of 30 ~ 60g in a single
yarn of polyester yarn, printed at a temperature of 100 ~
130 ℃, brushed a plurality of times at a temperature of
90 ~ 140 ℃ polyester printing mink blanket By
manufacturing, the length and distribution of brushed pile
are uniform to provide a soft touch, excellent gloss,
bulkiness and heat retention, as well as no bending or
electrostatic phenomena of piles generated in
conventional printing mink blankets. There is an effect to
provide further improved comfort.

WEAVING
The weaving is a process of formation of fabric with
interlacement of warp and weft yarns using a machine called
loom. Warp is a set of yarn in woven fabrics that runs
lengthwise and parallel to the selvedge and is interwoven with
the weft. Weft insertion is done by one of various methods such
as rapier, air jet, etc., for making a pick during weaving. The
process of weaving takes place through the series of different
operations. The material is processed at each level with utmost
care so as to avoid errors and faults of any kind. The quality
control at each stage of weaving process is enormous in order
to maintain efficiency.

WEAVING MACHINE
Actually, the research work on the shuttle loom was dropped in
the first half of the 70’s, with the arrival on the market and the
prevalence of systems using for weft insertion other ways than
the shuttle. The new shuttleless machines are simply called
″weaving machines″, this term implying looms working without
the shuttle.

The weaving machines present following advantages over

traditional looms:

1. Total elimination of any spooling operation

2. Production increase, thanks to the fact that these
machines can work at
high speed, owing to the reduction or elimination of
moving masses
3. Reduction of the shed size, therefore lower tension of the
warp threads
and consequently reduction in the number of yarn breaks
4. Noise reduction thanks to the elimination of the shuttle
pick
5. Automation of various devices.
CLASSIFICATION
On the basis of the system used for weft insertion, the weaving
machines can be divided into:

● machines with mechanical weft

insertion system:
○ by rigid rapiers
○ by flexible rapiers
○ by projectiles
● machines with non-mechanical weft
insertion system:
○ by jets of compressed air
○ by jets of compressed water

Furthermore, the machines can be divided into:

● mono-phase weaving machines (inserting one weft at a

time)
● multi-phase weaving machines (inserting several wefts at
a time)

WINDING
Winding is the process of yarn transfer to obtain a larger
package from several small spinner’s packages. It gives the
possibility of cutting out unwanted and problematic faults,
especially for ring spun yarns. Winding is done to reduce yarn
faults like IPI (Imperfection index i.e. thick places, thin places,
neps, hairiness), slubs, double knots etc. There are two types
of winding machines soft winding and SSM winding machine.
The soft winding machine is used for silk and linen as it has a
roller for soft handle while SSM is used for wool and polyester
blends. There is only one soft winding machine with 48 heads
and 3 SSM winding machines with 55 heads at this unit. Textile
Internship Report 2017 44 12.2 Warping Warping is a process
by which long length of many yarns are winded on a flanged
bobbin to produce a warp beam. Set of warp yarns lay parallel
at uniform specific tension. Beam warping is necessary to
produce long runs of grey fabrics. The weaver’s beam is fitted
in the loom to weave the fabric. The optimum performance of a
warping process depends on the number of end breaks. The
lower the end breaks the better it is for subsequent process
performance. A definite number of warp yarns is wound onto a
beam width and density. Warping may be carried out directly
(direct beaming) or indirectly, in sections (sectional warping).
The warping machines are of two types: a) Sectional Warping
Machines: In sectional warping, equal length of yarn is first
wound in small sections on a drum. From the drum, it is then
transferred to the beam. By this process, we directly get the
weavers beam. It is used for short runs, especially for fancy
patterned fabrics.
b) Direct Warping Machines: It is a high speed warping system
in which the yarn is wound parallel on the weavers beam. All
the yarns are wound at once and simple beam is used. It is
used to make common fabrics in large quantities.

CARDING

Carding is the first stage of mechanical processing of scoured

wool. It is the process of aligning fibers by drawing them
together in a parallel arrangement and making them into a soft,
weak rope of fibers known as carded sliver. Carding performs
many functions including: removal of vegetable impurities (like
burrs) and neps that are left after scouring gradual opening of
wool fibers that get entangled together arranging these
individualized fibers as evenly as possible in a web which will
be condensed in a continuous band (card sliver) which is the
first step towards the final spinning of yarn The scoured wool
passes through the revolving cylinder with an outer belt
covered with fine, short wire teeth that remove vegetable matter
and neps while straightening the fibers. The varying size and
speed of rollers help in breaking of lumps of the fibers, forming
the wool fibers into a continuous form (web) of fine and aligned
wool fibers. After this, smooth steel finger like partitions divide
the web and forms a thin, very weak rope-like strand of fibers
called sliver. This process is known as roving and about 1-
1.2% of waste is generated in this step. The Vapi unit has 2
worsted carding machines from French manufacturer N.
Schlumberger. (Source:W. Simpson and G. Crawshaw, Wool:
Science and Technology, Woodhead Publications) The machine
has the following sections and each section performs a certain
function: Hopper feeder enables the material to be evenly fed
into the machine utilizing the volumetric feed mechanism. Feed
lattice feeds the material into licker - in which opens and cleans
the material tuft. After this the material is passed through the
burr beaters which remove burrs and other vegetable matter.
They have steel blades that run in opposite direction to the card
roller surface. They are used in conjunction with Morel rollers.
The fibers pass through the doffer where the web forms which
is further condensed into a sliver as it passes through a funnel
and between a pair of pressure rollers, the latter running at a
slightly higher speed than the doffer.
SPINNING

Spinning is the twisting together of drawn out strands of fibers

to form yarn. Then, yarn is used to create fabric, which is then
used to make clothing and other products.

MENDING

After the weaving process, mending takes place. It is a value

addition process in which defects incorporated in the fabric
during previous processes are eliminated. Residual defects
from recombing, spinning and weaving reduce the commercial
value of the cloth, even though the quality is good. Hence, it is
necessary to eliminate these visible flaws from the fabric. In this
department, each and every metre of the fabric produced is
perched and mended, necessary markings are done on the
fabric where the defect is observed. Fabric is checked on both
the front and back sides i.e. 100% inspection. Minor defects
such as protruding fiber are corrected on the spot manually;
this is known as general mending. But the major marked
defects are sent for further correction in another room for
mending, which comes under the extra work category.

FINISHING

Textile finishing is a term used for a series of processes to

which all bleached, mended, dyed and certain grey fabric are
subjected before they are put in the market. Finishing
processes are carried out to improve the natural properties of
the fabric. Various finishes applied on fabrics in Prakash mills
are - soft finish, anti microbial, water repellent, wrinkle free.

BLANKET POLISHING MACHINE

This machine is suitable for surface polishing of natural and

chemical fiber, knitted and gregarious fabrics. It is mainly used
for processing of ordinal woolen, blanket, micro velboa and
knitted non-pressed-pile. It also can be used to polish velvet,
cotton fabrics, high pile knitted fabric and man-made fiber. Its
working efficiency is nearly twice as the ordinary polishing
machine.

Specification

Items Data
Nominal width (mm) 2000,2500
Diameter of polishing roller (mm) 370
Rotation rate of polishing roller 300-900Variable
(m/min)
Direction of rotation Forward/Reverse
Polishing temperature Max. 250°C
Speed of fabric (m/min) 9-30
Heating power (kW) 57.6 / 59.7
Heating power (kW) 13.95
Overall L(mm) 4330
dimensions
W(mm) 4530/4730
H(mm) 2750

This high quality MB431 polishing machine is easy to operate

and reliable with the following features compared to the
congeneric machines:

1Single polishing roller double table lathe has good effect. The
polishing roller is possible to run forward and reverse, polish
velvet velludo when anticlockwise and polish velvet plain
clockwise. The working temperature is 75~250°C, controlled by
professional temperature controller, it appears on the numerical
display device. Rectify the deviation of table lathe and belt
automaticly by pneumatic device.
2Control the fabric feeding tension by adjusting the speed of
fore guiding roller and rear guiding roller through exchange
chain pulley.
3Fabric guiding motor and output motor adopt inverters, fabric
speed can be chosen from 9 to 30m/min and it displays on the
numerical display device and can be adjusted directly.
Prakash woolen and synthetic mills ltd. has total 4 polishing
machine.

PRINTING MACHINE

Automatic Magnetic Flat Screen Printing Machine for Polyester

Blanket
It is automatic printing for fabric, such as blanket, flannel, coral
fleece and etc.
Computer servo-system control
Automatic infrared centering device
Independent magnetic base intelligent color
9-10 side/min

Mainly used on automatic printing for fabric, such as blanket,

flannel, coral fleece and etc.
Working width: 2300mm-3200mm(according to order)
Number of color:10(according to order)
Working speed: 9-10 sides/min
Total motor power:84.4kw
Power of magnetic support: 2.3kw*10(10colors)
Overall dimensions(length*width*height):
73800*4200*4460mm(working width 2300mm)

Features
(1)With computer monitoring it could show each printing
process, and easier to learn and master touch-screen operation
system. The servo-system ensures stable and precise
high-volume printing production.

(2)Independent magnetic driven printing trip, intelligent record,

color location setting ans independent frame lifting, suitable for
printing of different kinds of thin and thick fabrics.

(3)Magnetic rod scraping, frequency control digital display,

pressure adjustable, rail tank with water, the exterior surface
are made of stainless steel.

(4)Infrared auto-aligning device ensures smooth and uniform

position feeding of the fabric. Patch roller synchronized with the
conduction band, to ensure to flat the fabric tension-freely, to
achieve the best print result.

(5)The print unit is controlled independently: print route, print

speed and print times of each magnetic could be set
separately.
(6)LMV561 auto-magnetic printing machine inludes cloth
feeding part, cloth duration device, sizing supply system,
guiding belt's transmission and its tension, washing and
pre-heating, penetrating units, magnetic support transmission,
printing frame's vertical movement and touching-screen
controlling system, etc.

(7)Adopt vertical cloth duration device without tension, save the

printing table area.

(8)Gluing method: use magnetic roller or scraper to supply

sizing for belt, supplying width and quantity could be adjusted
conveniently.
(9)Employ permanent magnetic support, with high magnetic,
save power and less maintenance(could choose
electromagnetic support).

(10)Used yaskawa or danfoss operating system.

DRYING

Drying is defined as a process where the liquid portion of the

solution (moisture content) is evaporated from the fabric. This is
done after de-watering of fabric. The water dispersed in a
textile material by a chemical–physical process is generally
eliminated by the action of hot air, which makes the water
evaporate. In textile finishing unit; dryer uses for dry the knit,
woven fabrics and dyed yarn. But the drying process and drying
mechanism of yarn and fabrics is different from one to another.
Drying operations are done by textile drying machine. During
the drying process, it is very important to carefully consider the
way heat is directed on the fabric.

Drying can be done by various methods listed as follows:

1. Heating
2. Blowing dry air on the materials
3. Centrifuging and throwing the moisture out
4. Using radio frequency (RF) waves
5. Using vacuum
6. Exposing to open sunlight and air and so on

In textile manufacturing process and while using textiles, drying

is necessary to eliminate or reduce the water content of the
fibers, yarns and fabrics after wet processes. Drying, in
particular by water evaporation, is a high-energy consuming
step and hence attention is needed to reduce overall energy
consumption by reuse/recycling options.

DRYING TECHNIQUES

Drying techniques may be classified as mechanical or thermal.

In general, mechanical processes are used to remove the water
which is mechanically bound to the fiber. This is aimed at
improving the efficiency of the following step. Thermal
processes consist of heating the water and converting it into
steam. Heat can be transferred by means of convection,
infrared radiation and direct contact and by RF.

Normal drying systems are as follows:

1. The water content of the fiber is initially reduced by

either centrifugal extraction or by mangling before
evaporative drying. The evaporative drying is done by
using dry and/or hot moving air.
2. The water content in hanks is initially reduced by using
centrifugal extraction followed by evaporative drying.
3. The drying of cheeses after wet processing is normally
carried out by centrifugal extraction followed by radio
frequency drying (RFD).
4. The drying of yarn sheet after drying is done normally
by using drying cylinders. In some cases, it is coupled
with hot air drying or infrared drying.
5. The fabric drying in rope form is done by using mangle
squeezing followed by blowing hot dry air.
 6. The fabric in open width is dried by using a chain of
drying cylinders or by using hot air drying after initial
squeezing by mangles.

WORKING PRINCIPLE
After de-watering then the fabric through the dryer. The main
function of the textile drying machine is given below,

1. To dry the fabric.

2. To increase the GSM by over feed system.
3. To control the overfeed system.
4. To control the vibration which increase the G.S.M.
5. To control the shade matching such as for white shade
if need few yellowish or reddish increase temperature
and low speed. If need few red or yellow increase
temperature and low speed.

This machine contains two chambers. Two mesh endless

conveyors are placed lengthwise to the chamber named
conveyor net and filter net, each chamber contain a burner,
which supply hot air. This hot air is guided through the ducting
line by suction fan. There are nozzles placed in between filter
net and conveyor net. When the fabric pass on the conveyor net,
hot air is supplied to the wet fabric to dry it. There are exhaust
fan which such the wet air and deliver to the atmosphere
through the ducting line.

The speed of the dryer depends on the temperature of the

machine and the G.S.M of the fabric. If the machine
temperature is high then machine speed also high and the
machine temperature is low then machine speed also low. The
vibration speed of the machine for heavy fabric is 730 m/min
and normal fabric is 480 m/min.

The temperature of different chambers according to the shade

of the fabric:

Shade Chamber-1 Chamber-2

Light 120oC 130oC

Medium 135oC 140oC

Deep 150oC 170oC

OPERATING PARAMETERS

1. Temperature: Set the temperature between 120oC

-130oC for white and 150oC -170oC for color fabric.
(GSM temperature or moisture content
temperature).
2. GSM: Set the over feed up to 10~20% or as required to
get finish G.S.M.
3. Speed: Set the speed as much as possible
(6~20m/min).

Special Features of Textile Dryer machine:

1. Steam dryer (two chambers ).

2. Vibration occur in heating zone.
 3. Process air pressure switch present.
4. Maximum temperature increase up to 170oC .
5. Steam control switch present.
6. Two burners present.
7. Two conveyor belt is present.

For Polyester Fabric:

Fabric Overfeed Temperature,oC Speed (m/min) Folder

Type % Speed
(m/min)

Light Deep High Low

Color Color G.S.M G.S.M

Single -5% 135oC 115oC 10~12 8~10 4~6

Jersey

Single -5% 135oC 115oC 10~12 8~10 5~6

Lacoste

Polo Pique -5% 140oC 115oC 10~12 8~10 5~6

Interlock -5% 135oC 110oC 6~8 8~9 4~5

Rib -5% 145oC 115oC 4~4.5 4.5~6.0 5~6

Grey -5% 130oC 115oC 6~8 5~5.5 5~6

Mélange
Following things are also considered in case of textile drying
machine:

● If fabric is more redder than the standard one, then

reduce the temperature.
● If fabric is more Yellower than the standard one, then
increase the temperature.
● If fabric is more Bluer than the standard one, then
increase the temperature.
● All this data’s are practiced in mills which may varied
factory to factory.

GARMENT WASHING
The technology which is used to modify the appearance,
outlook comfort ability and fashion of the garments is called
garment washing.

Objects of Garment Washing:

Garment washing is the best touch of a garment. Same type of
garments can produce several effects for several wash.

1. To create wash look appearance, seems the new touch

of fashion.
2. By the washing technique, faded/old, color or tinted
affect .
3. Washing technique creates new fashion such as
tagging, grinding, destroy, blasting, whickering,
permanent wrinkle, deep dye, tie dye, p.p spray, hand
crapping, p.p spoonzing etc.
4. To reduce size materials that imports soft hand feels.
 5. To attraction the customers/buyer by different types of
fashionable washing and market development.
6. Due to washing, shrinkage occurs in the garments.
There is no possibility of further shrinkage of the wash
garments.
7. Any dirt, spot or germ if added in the garments during
manufacturing is also removed due to washing.

Washing machine is the machine used to wash the

various types of clothes without applying any physical
efforts. With washing machine you don’t have to rub the
clothes with hand or squeeze them to remove the water
from them. The washing machine is also called as clothes
washer or simply the washer.

Features of Side Loading Washing Machine:

1. Electrically & mechanically interlocked, S.S.Loading &
Unloading doors.
2. Drive: Heavy duty motor co-ordinates with gear box,
Pully V Belt drive.
3. Electrical Control: Well protected for performance auto
timed, auto reverse & auto digital temperature control.
4. Protective device against single phasing, reverse
phasing and motor overload.
5. Gauge glass cork pair for water level indication.
6. Front display of controls through pilot lamps, push
buttons, water level indication etc.
7. Electric, Steam or thermal fluid heated.
8. Automatic features like auto timed, auto reverse, auto
temperature controller with inching devise.
 9. Side Loading, open pocket, single & Double door, ideal
for larger laundries.
10. Performs all Type of wash with soap, detergent,
bleaching, acid, stone or any chemical wash including
dying.
11. Ideally suited for Denim/Stone Washing, Enzyme
Washing, Garment Dyeing & Bleaching, Softening,
Milling Operation (for woolens).
12. Interlocking system for main door opening for extra
safety.

HYDRO EXTRACTOR:

The hydro extractor is a machine used in the textile processing

industry. These are mainly centrifuges. The wet material is
placed in the extractor, which has perforated metal walls,
usually stainless steel. The inner drum rotates at a high speed
to spray out the water inside. The use of a hydrogenation
extractor greatly reduces the energy required to dry any
material. Hydro extractors usually work by centrifugal force to
generate high gravity and increase the extraction rate of water.
Therefore, the water is separated and the product is obtained in
a dry form.

FEATURES:

(1) Adaptability
Manual or pneumatic opening various basket designs: special
perforations, filter media, modified sizes, separated baskets,
fan-shaped openings for processing tubes.
Variable speed operation
(2) Performance
When loading and unloading, the basket rotates slowly to
reduce the stretching of large and large fabrics.
(3) Reliable and robust
The safety system follows strict international standards.
Various building materials: mild steel, stainless steel.
Some small-capacity dehydrators can also be used in
small-scale production or R&D laboratories.

DYEING
Dyeing is the process of addition of color to fibers, yarns and
fabrics. It is done in a special solution containing dyes which
maybe natural or synthetic, along with chemical materials.
Temperature, pressure and time are three key factors in dyeing.
Wool and polyester cannot be dyed together as they have
different properties and affinity to different dyes. They are dyed
separately. The overall dyeing process takes about 3-4 hours.
Wool Polyester pH 4.5 – 5 4.5 Temperature 900 C 120 0 C Dye
Metal Complex Acid Dyes Reactive Dyes Disperse Dyes Time
30 minutes (only dyeing) 15 minutes (only dyeing) The final
product of combing i.e. 8.5kg tops of wool and polyester, are
the starting products of dyeing. After dyeing they are sent for
recombing. Different combinations are made to achieve the
desired shade. The proportion of dyes and chemicals are
tested to check the functionality of the dye over its application
on the fibers. Before the fibers are dyed in bulk, it is taken
through intensive testing in the laboratory where the samples
for the dye are prepared or selected from the existing records
Since dyeing involves many chemicals, it is hazardous for
health. But this is avoided as the dyeing is completely
automated wherein human intervention and chances of direct
exposure / contact with chemicals are very less. There are 16
staff members and 91 workers in the dyeing department. For
each process, operational control procedures are established to
address safety measures.

RAISING MACHINE

The function of a raising machine is to produce a hairy surface

on a fabric, this effect is made through a series of needles that,
with a mechanism that we will explain later, are penetrating the
fibres, breaking and lifting them.
To better understand the function of the raising machine we
should refer to the geometric figure of the epicycloid, which is a
plane curve produced by tracing the path of a chosen point on
the circumference of a circle, called an epicycle, which rolls
around a fixed circle.
The scheme of a raising machine can be seen in drawing on
the right; a series of rollers, that are called raising rollers, are
placed on a flange with circular settlement, these rollers are
covered by an ordered alignment of needles. The raising rollers
are divided between “pile” and “counterpile” raising rollers,
according to the direction which the needles are plied.
It is now easy to find the similitude with epicycloid when we
consider the points of the raising fillet, the raising rollers that roll
on their axle and that are supported on flanges that are rotating
on their center.
POLISH SHEARING MACHINE:
1. Height position of the shear cylinder and shearing support
can easily touched for operator.
2. Some critical parts are lower height so to achieve whole
machine running stable.
3. Height of shearing can set in touch screen, high efficiency
suction remove away waste piles immediately, 370mm
polishing roller and its auto adjusting of polishing pressure,
all these meet the requirement to produce higher quality
fabrics.
4. Equipped with auto-aligning device, metal detector and
pre-expanding device, ensure fabric feeding smooth and
stable.
5. Whole machine performance are perfected by equipping
the quick disassembly device of shear- pressure and
slide-round shaft block, and high efficiency vortex suction
of polishing roller.
Technical Parameters
● Machine width : 2000mm 2200mm 2800mm
● Working speed : 25m/min.
● Diameter of shearing cylinder : 155mm (900rpm) | 185mm
(700 rpm)Optional
● Grinder Speed : 500rpm
● Number of shears : 18pcs 24pcs (spin to right)
● Diameter of polishing roller (steel) : 320mm
● Rotary Speed : 650rpm
● Heating Power : 49.2kW (2000mm) 52.2kW(2200mm)
57.45kW(2500mm)
● Felt wrap angle : a=0° ~ 55°
● Diameter of driving roller : 220mm
● Diameter of guiding roller : 104mm
 ● Motor Power : 24.93kW(2000mm 2200mm)
26.93kW(2500mm)
● Weight : 550kg
● Overall dimensions (length*Width*height):
3780*4500*3400(working width 2000mm)
3780*4700*3400(working width 2200mm)
3780*5000*3400(working width 2500mm)

WAREHOUSE

The warehouse is spread across an area of 1 lakh square feet

with the capacity of upto 60 lakh metres of fabric. This
department is managed by Warehouse Management System
(WMS) and has 53 company workmen, 110 contract workmen
and 13 staff members. The folded packages are kept in stacks
and shell postings. For shipment, they are packed with HDPE
(High Density Poly Ethylene) bags by the packing machine

QUALITY CONTROL

The purpose of quality control laboratory is to ensure the level

of quality at the different stages of the production. Testing of the
material is done in the fiber, yarn and fabric stages. The
following is the list of tests carried out in Quality Control
Laboratory: 1. Pilling 2. Rubbing 3. Tearing Strength 4. Seam
Slippage 5. Stains 6. Twist 7. Count 8. Elongation and Growth
9. Breaking Strength 10. Yarn Strength 11. Thermal Shrinkage
12. Dry Cleaning Fastness 13. Washing Shrinkage and
Fastness 14. Oil and Grease Recovery 15. Hardness of water
and pH 16. Light fastness 17. Yarn Evenness and Hairiness