CHAPTER – I

INTRODUCTION TO THE INDUSTRIES

India is the second-largest producer of raw silk in the world after China. The country has a unique
distinction of being the only country producing five different types of silks in the world. Mulberry silk is
produced predominantly in southern states of Karnataka, Tamil Nadu, Telangana, and non-mulberry
varieties (Vanya silk) such as Tussar is produced in Chhattisgarh, Jharkhand, Odisha, and West Bengal.
Moga silk is specific to Assam state and Eri silk is grown in Meghalaya and Nagaland. Mulberry silk
constitutes nearly 70 per cent of the total silk produced in India with Karnataka leading the production of
mulberry silks.

Realizing the huge employability potential spawning across the value chain of the silk industry, that
could put the country on economic growth trajectory, the Government of India established the Central Silk
Board (CSB) soon after the country attained Independence, and with it a series of policies. With low capital
requirement and remunerative nature of production from rural on-farm and off-farm activities, and an ever-
growing culture bound domestic market, silk industry has been central to the socio-economic development
of large agrarian population, providing employment to 9.4 million people in rural and semi-urban areas.

With sericulture activities spread across 52,360 villages, the Indian silk industry is one of the largest
generators of employment and foreign exchange for the country. India enjoys a unique global position in
terms of producing all the commercially useful varieties of silk.

Highlights

The states of Karnataka (8,219 metric tonnes), Andhra Pradesh (6,550 metric tonnes), West Bengal
(2,002 metric tonnes), Tamil Nadu (1,185 metric tonnes) and Jammu & Kashmir (141 metric tonnes) were
the major producers of mulberry silk in India during 2012-13. In the same year, Jharkhand (1,047 metric
tonnes), Chhattisgarh (381 metric tonnes), Odisha (99 metric tonnes) and the North-eastern states produced
non-mulberry or wild silks.

In India, the silk industry generates employment for approximately 7.6 million people (2012-13),
which includes farmers and small households.
Key Markets and Export Destinations

In 2012-13, Indian silk exports stood at US$ 410 million. The readymade garments of silk formed the
largest segment, generating around 58 per cent of the export earnings from silk, while natural silk yarn,
fabrics and made-ups accounted for around 38 per cent of the silk export earnings.

The US and the UAE are the major export destinations for Indian silk goods, generating combined
earnings of around US$ 122.6 million in 2012-13. The UK, France, Italy and Germany are the other major
export destinations. The segments that are exported in the silk sector include natural silk yarns, fabrics,
made-ups, readymade garments, silk carpets and silk waste.

Indian Silk Export Promotion Council

The Indian Silk Export Promotion Council (ISEPC) has initiated programmes for the growth and
development of the silk industry. ISEPC organises trade shows and fairs across the world to promote trade
with different countries. The council also facilitates meetings between exporters and potential customers.

Zari (or jari) is an even thread traditionally made of fine gold or silver used in traditional Indian,
Bangladeshi, and Pakistani garments, especially as brocade in saris etc. This thread is woven into fabrics,
primarily silk, to make intricate patterns and elaborate designs of embroidery called zardozi. Zari was
popularized during the Moghul era; the port of Surat was linked to the Meccan pilgrimage route which
served as a major factor for re-introducing this ancient craft in India.
 Zari is basically a brocade of tinsel thread meant for weaving and embroidery. It is manufactured by
winding or wrapping (covering) a flattened metallic strip made from pure gold, silver or slit metallized
polyester film, on a core yarn, usually of pure silk, viscose, cotton, nylon, polyester, P.P., mono/multi
filament, wire, etc. Nowadays, it can broadly be divided into three types. Real zari, imitation zari, and
metallic zari.
Real Zari is made from fine silver or gold thread is drawn from silver or gold alloys, which is flattened by
passing it under equal pressure rotating rollers.

The flattened silver threads are wound on the base yarn that is usually made of silk. These spools
with silk and silver threads are further flattened for electroplating. The threads are then plated with gold by
the process of electroplating. The lustre of the gilded threads is further increased by passing them through a
brightener. These threads are then wound on a reel.

In ancient times, when precious metals were cheaply and easily available, [citation needed] only real
zari threads were produced. Due to industrial revolution and invention of electroplating process, imitation
techniques came into existence to cut the cost of precious metals. As copper is the most malleable and
ductile metal after gold and silver, silver electroplated copper wire replaced pure silver. Various modern
colours and chemicals are used to create/impart a golden hue instead of pure gold.

The precious metals and copper too became dearer due to huge demand in various modern
industries. Thus, a cheap and durable alternative was invented with non-tarnishing properties. Metallic zari
came into vogue replacing traditional metals like gold, silver & copper. This non-genuine modern zari is
light in weight & more durable than earlier editions. Also, it has the sought after properties of resistance to
tarnishing and knotting.

Imitation zari is made when copper wires are drawn from copper alloys. It then undergoes a similar
process, except in this case, they are electroplated with silver and then wound around the base yarn and
reeled. This type of zari is less expensive than pure zari, as silver electroplated copper is more economical.

Metallic sari is a modernized version of ari and it replaces traditional metals like gold, silver and
copper. It is resistant, durable, and light in weight. It is non-tarnishing and maintains its lustre for a
considerable period.
Quality of pure Zari:

245 grams of Zari is called one mark. It contains 191 grams of silver (78 percent), 51.55 grams of
silk (21 percent), and 2.45 grams of gold (1 percent).

Zari Thread:

Zari (or jari) is an even thread traditionally made of fine gold or silver used in traditional Indian,
Bangladeshi and Pakistani garments, especially as brocade in saris etc.
There are types of zari thread:
 Imitation Zari.
 Gold Zari Threads.
 Half Fine Zari Thread.
 Silver Zari Threads.
 Nylon Zari Thread.
 Kasab Zari Threads.
 Dapka Zari Thread.
 Polyester Zari Thread.
 CHAPTER – II

ORGANISATION PROFILE

Tamil Nadu Zari Limited is a State Govt company, incorporated on 06 Dec, 1971. It's a public
unlisted company and is classified as ‘company limited by shares.

Company's authorized capital stands at Rs 50.0 lakhs and has 68.8% paid-up capital which is Rs 34.4
lakhs. Tamil Nadu Zari Limited last annual general meet (AGM) happened on 26 Sep, 2017. The company
last updated its financials on 31 Mar, 2017 as per Ministry of Corporate Affairs (MCA).

Tamil Nadu Zari Limited is majorly in Manufacturing (Textiles) business from last 52 years and
currently, company operations are active. Current board members & directors are DHARMARAJAN
PARTHASARATHY, PALANISAMY MUTHUSAMY, THIRUMALAI NARASIMHAN VENKATESH,
USHMAN MOHIDEEN MOHAMED MASOOD, BOOMA, RAJENDRAN and RAMACHANDRAN
KRISHNA MOORTHY.

Company is registered in Chennai (Tamil Nadu) Registrar Office. Tamilnadu Zari Limited registered
address is INDUSTRIAL. ESTATE, ORIKKAI, KANCHEEPURAM TN 631502 IN.

The Tamil Nadu Zari Limited, Kancheepuram was registered as a public limited Company in the
year 1971 under the Companies Act 1956. The Tamil Nadu Zari Limited was started for the purpose of
producing and supplying quality "Zari" to the Co-operative handloom weavers of the silk industry and to
reduce the dependency on the unorganized producers of Zari from Surat, who were monopolizing the trade
hitherto.

At present the Tamil Nadu Zari Ltd is engaging in the production of zari and serves Silk Handloom
Weavers Co-operative Societies all over Tamil Nadu.

SHARE CAPITAL AND MANAGEMENT:

All the shares and the administrative control are vested with the Government of Tamil Nadu.

 Authorized Share - Rs. 50.00 lakh

 Capital Paid up Capital - Rs. 34.40 lakh.

The Government of Tamil Nadu holds the entire shares of the Company, and our corporation is
being managed by a Board, nominated by the Government from time to time. The Commissioner of
Handlooms is the Ex-Officio Chairman of the Corporation, and the present Board of Directors are:

 Deputy Secretary, H.H.T.K Department, Chennai.

 Deputy Director Finance (BPE) Department, Chennai.
  General Manager (Production), T.N.H.W.C.S Ltd (Co-optex), Chennai.
 Principal Scientist, CECRI, Karaikudi,
 Managing Director, Tamil Nadu Zari Limited, Kancheepuram.

The Company had declared and paid dividend to Government from the financial year 1990-91 to
2020-21 amounting to Rs. 180.37 Lakh as against the share capital of Rs.34.40 lakh. The Company also re-
paid the entire principal amount of Rs.25.00 Lakh XRF Government Loan during October 2017 and the
outstanding interest amount of Rs.23.66 lakh during October 2018.

The Company is certified under the ISO 9001:2000 since the year 2000, transited to 9001:2008
from the year 2010 and transited to ISO:9001: 2015 from the month of December 2018.

OBJECTIVE OF THE DEPARTMENT:

 To bring a greater number of handloom and powerloom weavers into cooperative fold by
enrolling them into weaver’s cooperative societies.
 To provide continuous employment opportunity and fair wages to the cooperative weavers
throughout the year.
 To implement the Government Programmes and Schemes like
 Free Supply of Uniforms to School children.
 Low-Cost Sarees and Dhoties Schemes.
 Production of Cloth required for Old Age Pension Scheme and Srilankan Refugees.
 Deendayal Hath Kargha Protsahan Yojana Scheme.
 To implement various Handloom Development Schemes for cooperative societies.
 To implement various welfare schemes intended for the cooperative weavers.
 To provide raw materials and other infrastructure to primary weaver’s cooperative societies.
 To market the Handloom cloth produced by the handloom weaver’s cooperative societies through
Co-optex and various marketing complexes assisted by the department.
 To extend working capital loans to weavers outside the cooperative fold through Tamil Nadu
Handloom Development Corporation Limited.
 To control and monitor the purchase of Silk, Zari and Cotton besides ensuring the quality.
 To protect the overall interest of the Handloom Weavers, Power loom Weavers and Textile Industry
and to work for the harmonious growth of all the above three sectors without affecting the interest
of each sector.
ORGANIZATIONAL SET UP:

Secretary to Government, Head of the Administrative

Handlooms, Handicrafts, Textiles and Department of the Secretariat.
Khadi Department.

Director of Handlooms and Textiles Head of the Department

The Director of Handlooms and Textiles is assisted by the following Officers: -

At Head Office:

 Joint Director (Handlooms)

 Joint Director (Uniform)
 Joint Director (Textiles)
 Financial Adviser & Chief Accounts Officer.

The entire State is divided into 18 Circles and each Circle is under the Control of a Deputy Director of
Handlooms and Textiles / Assistant Director of Handlooms and Textiles who are in-charge of
implementation of the various welfare and developmental programmes of the Department at the field level.
Enforcement offices are also set up at Salem, Tiruchengode, Erode, Tiruppur, and at Madurai.
 CHAPTER – III

DEPARTMENTATION
Mention how many departments are functioning under TN Zari Ltd.

Purchase / Production / Marketing & Sales / Accounts etc. are required

There are Four Departments are under the TN Zari Limited:

 Purchase Department
 Production Department
 Accounts Department

PRODUCTION DEPARTMENT:
Stage – I

 Dyeing of Cotton yarn or silk, or Art silk yarn.

 Melting of Silver (Raw).
 Preparation of Silver wire bars.
 Hammering of Silver bars to form an elongated rod.
Stage – II
Drawing of silver wire of different gauges, coarse, medium, fine, and superfine in Pawtha and Tania
wire drawing units (From an ounce of silver into 3000 yards) of silver wire.
Stage – III
Flattening the wire in flattening machine (CHAPAD)- The flattened silver is called badla.
Stage – IV
Wrapping of flat silver wire on Pure silk, Art silk or Cotton on wrapping machine (Bitai
Machine) to make real zari thread. - The thread is called Ruperi Zari Thread
Stage - V
Electroplating of Pure gold (24 carat) on real zari thread (Sona Gilit Bakda).
Stage - VI
Gold plated real zari thread is wound on reel (Flattened or Round Zari).

There are some machines involved in production:

 Flattening Machine.
 Electro Plating Machine.
 Reeling Machine.
 FLATTENING MACHINE:

A flattening machine, also known as a roller or flattener, is a mechanical device used to flatten or level
materials such as metal sheets, paper, textiles, plastics, and more. It is commonly used in various industries,
including manufacturing, printing, metalworking, and processing.

The machine typically consists of two or more cylindrical rollers or plates arranged parallel to each
other. The material to be flattened is fed between these rollers, and the pressure exerted by the rollers
compresses the material, reducing its thickness and creating a flat surface. The number of rollers and their
configuration can vary depending on the specific application and the type of material being processed.

Flattening machines are essential in processes where the uniform thickness or smoothness of the
material is critical. For instance:

 Metalworking: In metal fabrication, a flattening machine is used to flatten metal sheets or plates, ensuring
uniform thickness and surface smoothness required for subsequent processes like welding or cutting.
 Printing Industry: In printing, especially in offset printing, a flattening machine helps to flatten paper or
cardstock to improve print quality and reduce paper curling.

 Textile Industry: Flattening machines are used in textile manufacturing to flatten woven or knitted fabrics,
ensuring consistency in thickness and surface before dyeing or printing.

 Plastic Industry: Plastics manufacturers use flattening machines to produce flat sheets or films of
consistent thickness, which are then used for various applications like packaging or laminating.

 Woodworking: In some woodworking applications, flattening machines can be used to flatten and level
wooden boards, ensuring they are smooth and even for further processing.

The flattening process is essential to meet quality standards and achieve the desired characteristics
of the material being processed. Modern flattening machines often incorporate automation and advanced
controls to enhance efficiency and precision during the flattening process.
ELECTRO PLATING MACHINE:

An electroplating machine, also known as an electroplater or electroplating equipment, is a device used in

the process of electroplating. Electroplating is a technique used to deposit a thin layer of metal onto a
conductive object (known as the substrate or workpiece) by using an electric current. The purpose of
electroplating can vary from providing decorative finishes to improving the substrate's properties, such as
corrosion resistance or conductivity.

The basic components of an electroplating machine typically include:

 Plating Tank: A container made of non-conductive material (such as plastic or glass) that holds the
plating solution, also known as the electrolyte. The plating solution contains metal salts of the metal
to be deposited.

 Anode: A metal electrode that serves as the source of the metal ions for deposition. The anode is
made of the same metal that is to be plated onto the workpiece.
  Cathode (Workpiece): The object to be electroplated, which is usually made of a conductive
material like metal or a conductive plastic.

 Power Source: A direct current (DC) power supply that provides the electrical energy to drive the
electroplating process. It connects to both the anode and the cathode, completing the circuit.

 Electrical Conductors: Cables or wires that connect the power supply to the anode and cathode,
allowing the electric current to flow through the plating solution.

The electroplating process works as follows:

 Preparation: The workpiece to be plated is thoroughly cleaned and prepared to ensure good
adhesion of the plated metal. This may involve cleaning, degreasing, and surface activation.

 Immersion: The workpiece is immersed in the plating tank, and the anode is also placed in the same
tank, but not in direct contact with the workpiece.

 Electric Current Application: The power supply is turned on, and a direct current is applied. This
causes metal cations from the anode to dissolve into the electrolyte as metal ions.

 Metal Deposition: The metal ions in the electrolyte are attracted to the workpiece's surface, where
they gain electrons and are reduced to form a thin layer of metal, adhering to the workpiece.

 Finishing: After the desired thickness of the plating is achieved, the power supply is turned off, and
the plated workpiece is removed from the plating tank.

Electroplating machines come in various sizes and configurations depending on the specific application
and the size of the workpieces to be plated. They play a crucial role in industries such as manufacturing,
automotive, electronics, jewelry, and more, where metal plating is required for various purposes.
REELING MACHINE:

A reeling machine is a device used to wind or reel materials, such as wire, cable, yarn, thread, or
film, onto a spool or reel in an organized and controlled manner. The primary purpose of a reeling machine
is to facilitate the storage, transportation, and subsequent use of the material in an efficient and convenient
manner.

The design and features of reeling machines can vary depending on the specific application and the
type of material being handled. However, some common components and functionalities of reeling
machines include:

 Reel or Spool Holder: This is the core component of the machine that holds the empty or partially
wound spool or reel onto which the material will be wound.

 Material Feed Mechanism: The reeling machine is equipped with a system to feed the material
onto the reel in a controlled manner. This may involve pulleys, rollers, or guides to ensure proper
alignment and tension of the material during winding.

 Tensioning System: A tensioning mechanism is often employed to maintain appropriate tension in

the material as it is being wound onto the reel. This helps prevent slack or over-tensioning, which
could cause issues during subsequent use.
 Winding Control: Reeling machines may have features to control the winding speed and layering of
the material on the reel. This ensures even and smooth winding without causing any defects or
irregularities.

 Length Measurement: Some reeling machines are equipped with length measurement devices to keep
track of the amount of material being wound onto the reel accurately.

 Safety Features: To prevent accidents and ensure safe operation, reeling machines may have safety
interlocks, emergency stop buttons, and other safety mechanisms.
Reeling machines are used in various industries, such as wire and cable manufacturing, textile
production, film, and packaging industries, and more.

For example:

 In wire and cable manufacturing, reeling machines wind the finished cables onto spools for easy storage
and transportation.

 In the textile industry, reeling machines are used to wind yarn or thread onto bobbins or cones, which
are then used in weaving or knitting processes.

 In the film industry, reeling machines are used to wind films onto reels for distribution and
projection in theaters.

Overall, reeling machines play a crucial role in efficiently handling and managing materials, making
them ready for use in subsequent processes or for transportation to end-users.
 CHAPTER – IV

SUMMARY OF WORK
DONE

DATE WORK DONE

30.5.2023 I was given a short information about ZARIES and the

background of Tamil Nadu Zari Limited.,
31.5.2023 Got an overview about various machines involved in silk
thread weaving and production
1.6.2023 Worked in the stores department to know the procedures of
receiving the raw materials and storing it.

2.6.2023 Storing process was continued and got to know the entry
procedures in the stores records.
3.6.2023 Visited the Testing lab to know the process of strength and
content testing.
4.6.2023 Got engaged in the process of sliver strength test- practical
attempt by me.
5.6.2023 I did the sliver content test in the lab – Practical session
6.6.2023 Learned about manufacturing process and material, machine
organization.
7.6.2023 Loaded the sliver wire in flattening machine – Learned one of
the process involved in silk thread weaving and making.
8.6.2023 Worked in old electro plating machine
9.6.2023 Learned about new electro plating machine.
10.6.2023 Visited reeling department and learned to
Operate reeling machine.
11.6.2023 Operations continued in the reeling machine

12.6.2023 Visited packing department and packed zari – Manual process

only and no machines are involved in packing.

13.6.2023 Learned to maintain petty cashbook and general ledger in

accounts department.
14.6.2023 Staff taught me the basics of tally accounting software
15.6.2023 Learned about entry of vouchers and report generation in tally
16.6.2023 Learned the quality control aspects of silk production.

17.6.2023 Interaction with the supervisors and employees to know about

their working conditions and satisfaction of job.
 CHAPTER – V
CONCLUSION

This internship that I underwent in Tamil Nadu Zari Limited, Kancheepuram has been an especially
useful experience for me. I can safely say that my understanding of the job environment has increased
greatly. I was much inclined to do the internship in Tamil Nadu Zari Limited because of the reason that I
could afford my contribution to our family business and I also have a plan to expand the business as I hail
from Kancheepuram. However, I do think that there are some aspects of the job I have to work on. Also,
the technical parts of the job were a bit difficult and needs more practice. The two main things that I
learned after my experience in this firm are the importance of time management and being self-motivated.