Professional Documents
Culture Documents
Toaz - Info Project Report On Textile Industry PR - 23r
Toaz - Info Project Report On Textile Industry PR - 23r
Textile Industry
2 ACKNOWLEDGEMENT
6 FACILITY LOCATION
9 BIBLIOGRAPHY
Textile Industry Is One Of The Leading Textile Industries In The World. Though Was
Predominantly Unorganized Industry Even A Few Years Back, But The Scenario Started
Changing After The Economic Liberalization Of Indian Economy In 1991. The Opening Up Of
Economy Gave Much Needed Thrust To Textile Industry, Which Has Now Successfully Become
One Of The Largest In The World.
Indian Textile Industry Largely Depends Upon The Textile Manufacturing And Export. Its Play
A Major Role In The Economy of The Country. Indian Textile Industry Is Also The Largest In
The Country In Terms Of Employment Generation.
Indian Textile Industry Can Be Divided Into Several Segments, Some Of Which Can Be Listed
As Below:-
Cotton Textile
Silk Textile
Woolen Textile
Readymade Textile
Hand-Crafted Textile
Jute And Coir
3|Pag e IGNOU
In the production system there are following types of production system can be used for the
conversion of raw material into the finished goods.
➢ Project
➢ Job shop
➢ Batch production ( disconnected line)
➢ Assembly line
➢ Continuous flow
➢ Cell manufacturing (group technology)
The textile industry using the JOB-SHOP or BATCH PRODUCTION techniques for the
production.
The Weaving Process Is Characterized By Long Planning Horizons And Relatively Slow Speed
Of Machines, Very Long Setup Times, Very Large Production Batches, And Mixed Order And
Stock-Based Production. On The Contrary, The Warp Making Process Is Characterized By Short
Planning Horizons And High Speed Of Machines, Short Setup Times, Small Production Batches
And Only Orders-Based Production. The Above Phases Pose The Most Complex Production
Scheduling Problems.
JOB-SHOP techniques:-
In the job shop machinery used mostly general purpose to produce the goods.
Highly skilled labor is needed for this type of production system to handle and operate the
machinery.
Textile production systems may be treated as a succession of local problems, one per each
production phase. The coherence of these local problems should be taken into account by
“material requirements planning” or “just-in-time” approaches.
4|Pag e IGNOU
INTRODUCTION:-
Products are the goods and services produced and processes are the facilities, skills, and
technologies used to produce them. Production function or operation function is the primary
function of an industrial enterprise. It is also known as conversion process or transformation
process which transforms some of the inputs (raw material and components) into outputs which
are useful for the consumers.
5|Pag e IGNOU
6|Pag e IGNOU
FIBER PREPARATION:-
Raw Cotton Contains Cotton Fiber Along With
Small Plant Parts And Field Trash That Are Not
Removed By The Ginning Process. At This
Stage, The Cotton Fiber Has A Coating Of Oils
And Waxes That Make It Hydrophobic. Raw
Fiber Is Suitable For Making Nonwovens To Be
Used In Industrial Products In Which
Absorbency And Aesthetics Are Not Important.
In Some Cases, Nonwoven Fabrics Made With
Raw Fiber Can Be Wet Processed In the Same
Manner As Woven And Knitted Fabrics
SPINNING:-
The Spinning Machine Takes The Roving, Thins It And Twists It, Creating Yarn.
In Mule Spinning The Roving Is Pulled Off A Bobbin And Fed Through Rollers,
Which Are Feeding At Several Different Speeds. This Thins The Roving At A Consistent
Rate. If The Roving Was Not A Consistent Size, Then This Step Could Cause A Break
In The Yarn, Or Could Jam The Machine. The Yarn Is Twisted Through The Spinning Of
The Bobbin As The Carriage Moves Out, And Is Rolled Onto A Cop As The Carriage
Returns. Mule Spinning Produces A Finer Thread Than The Less Skilled Ring Spinning.
7|Pag e IGNOU
MULE SPINNING RING
SPINNING
WEAVING:-
8|Pag e IGNOU
Cloth Is Usually Woven On A Loom, A Device That Holds The Warp Threads In Place
While Filling Threads Are Woven Through Them. A Fabric Band Which Meets This
Definition Of Cloth (Warp Threads With A Weft Thread
Winding Between) Can Also Be Made Using Other
Methods, Including Tablet Weaving, Back-Strap, Or Other
Techniques Without Looms.
DYEING:-
The Most Commonly Used Processes For Imparting Color To Cotton Are Piece Dyeing
And Yarn Dyeing.
In Piece Dyeing, Which Is Used Primarily For Fabrics That Are To Be A Solid Color, A
Continuous Length Of Dry Cloth Is Passed Full-Width Through A Trough Of Hot Dye Solution.
The Cloth Then Goes Between Padded Rollers That Squeeze In The Color Evenly And Removes
The Excess Liquid. In One Variation Of This Basic Method, The Fabric, In A Rope-Like Coil, Is
Processed On A Reel That Passes In And Out Of A Dye Beck Or Vat.
Yarn Dyeing, Which Occurs Before The Cloth Is Woven Or Knitted, Is Used To Produce
Gingham Checks, Plaids, Woven Stripes And Other Special Effects. Blue Dyed Warp Yarns, For
Example, Are Combined With White Filling Yarns In Denim
Construction.
PRINTING:-
Colored Designs On Cotton Cloth Is
Similar To Printing On Paper.
9|Pag e IGNOU
A Typical Printing Machine Has A Large Padded Drum Or Cylinder, Which Is Surrounded By A
Series Of Copper Rollers, Each With Its Own Dye Trough And Doctor Blade That Scrapes Away
Excess Dye. The Number Of Rollers Varies According To The Fabric Design, Since Each Color
In The Design Is Etched On A Separate Roller. As The Cloth Moves Between The Rotating
Drum And Rollers Under Great Pressure, It Picks Up Color From The Engraved Area Of Each
Roller In Sequence. The Printed Cloth Is Dried Immediately And Conveyed To An Oven That
Sets The Dye.
FINISHING:-
Finishing, As The Term Implies, Is The Final Step In Fabric Production. Hundreds Of
Finishes Can Be Applied To Textiles, And The Methods Of Application Are As Varied As The
Finishes.
Cotton Fabrics Are Probably Finished In More Different Ways Than Any Other Type Of
Fabrics. Some Finishes Change The Look And Feel Of The Cotton Fabric, While Others Add
Special Characteristics Such As Durable Press, Water Repellency, Flame Resistance, Shrinkage
Control And Others. Several Different Finishes May Be Applied To A Single Fabric.
CUTTING:-
The Fabric Is Then Cut With The Help Of Cloth Cutting Machines Suitable For The
Type Of The Cloth. These Can Be Band Cutters Having Similar Work Method Like
That Of Band Saws; Cutters Having Rotary Blades; Machines Having Reciprocal Blades Which
Saw Up And Down; Die Clickers Similar To Die Or Punch Press; Or Computerized Machines
That Use Either Blades Or Laser Beams To Cut The Fabric In Desired Shapes.
Sewing:-
It Is The Most Important Department/ Section Of A Garment Manufacturing Industry. Sewing
Machines Of Different Types Are Arranged As A Vertical Line To Assemble The Garments.
10 | P a g e IGNOU
Sequence Of Types Of Sewing Machine Arrangement Depends On Sequence Of Assembling
Operations. Number Of Sewing Machine Per Line Varies From 20 No.S To 60 No.S Depending
On The Style Of The Ga4rmnet To Be Produce. Production Pr Line Pr Hour Also Varies From
100 To 150 Pieces Depending On Specific Circumstances. Number Of Sewing Machine
Arrangement Per Line May Be Up To 60 Depending On Design And Output Quantity Of
Garment.
PRIMARY ACTIVITIES
Raw Product Storage
Waste Bailing
Opening
Carding
Spinning
Warping
Slashing
Weaving
Inspection
Packaging
Warehousing
Shipping
SECONDARY ACTIVITIES
Unloading
Fork lifting
Unwrapping
Cutting Ties
Waste Bailing
Feeding
Removing Lint
Movement Of Card Cans
11 | P a g e IGNOU
Movement Of Drawing Cans
Spinning Yarn
Warp Filling
Winding Yarn Onto Beam
Supplying Beams
Preparing Loom Beams
Storing Loom Beams
Hoisting
Producing Fabric Rolls
Inspecting Fabric
Cutting Fabric
Wrapping
Loading
SUPPORT ACTIVITIES
Eating
Relaxing
Storage
Personal Hygiene
Supervision
Maintenance
Air Washing/Conditioning
Lint Removal
Quality Control
Testing
Training
Monitoring
12 | P a g e IGNOU
FACILITY LOCATION
Plant location may be understood as the function of determining where the plant should
be located for maximum operating economy and effectiveness. The selection for locating
a plant is most important factor which influences the industry.
Any industry has ttry to locate their plant near by the market place, where transportation
facility available, labour force, raw material, power…etc
13 | P a g e IGNOU
Popularly Termed As The Textile State Of India, Gujarat Has One Of The Most Flourishing
Textile Industries In The Country. Also Said To Be The Manchester Of The East And The Denim
Capital Of India The Textile Industry In Gujarat Contributes Almost 3% Towards The GDP Of
India. India Holds A Major Portion Of Global Textile Market Share. Textiles In Gujarat Are
Responsible For Contributing A Major Share Of India's Art And Crafts.
It Is Also Among The Oldest Industries In The State. Due To Its Perfect Combination Of Skilled
Labor, Vast Variety Of Raw Materials, Seamless Blend Of Yarns And The Use Of Traditional
Techniques The State Produces The Finest Range Of Textiles.
One Of The Major Factors Behind The Success Of The Textile Industry In Gujarat Is That The
State Has Managed To Preserve Its Old Tradition And Culture.
The Textile Industry In Gujarat Involves Quite A Sizable Chunk Of The Population. Brands Like
Arvind Mills, Parag And Praful Belong To Gujarat. More Than 90% Of The Polyester Used In
India Is Produced In Surat. The Two Major Textile Manufacturing Cities In Gujarat Are
Ahmedabad And Surat. Both These Cities Together Account For Almost 50% Of The Total
Textiles Produced In Gujarat.
Textiles in Gujarat
BANDHEJ:-
Bandhej Is The Name Given To The Tie And Dye Fabric Of Jamnagar, Mandvi And Bhuj. The
Art Of Bandhej Is Known For Its Typical Designs And Patterns. These Are Often Used In
Wedding Outfits When They Are Called Gharchola Odhni And Sarees.He Tie-Dyed Fabrics Or
The Bandhej Of Gujarat Are Certainly The Best Of Its Kind Produced In India Also Lso Known
As Bandhani Or Bandhni.The Cost Of The Bandhej Of Gujarat Rests Not Only On The Quality
Of The Fabric, But Also On The Number Of Times It Has To Be Tied And Dyed As Well As The
Intricacy Of The Pattern.
MATANI:-
Matani Or More Popularly Called Matani Pechedi Or Mata-Ni-Pachedi Are Made By The
Vaghris For The Purpose Of Various Rituals. They Employ A Combination Of Block Printing
For The Outline Of The Pattern As Well As The Painting Of The Mordants.The Matani Is
Actually A Tribute To The Mother Goddess Durga.Matani Reflects A Passion Among The
Gujaratis For Colors And A Vision For The Intricate Designs And Forms. It Is The Expression
Of An Artistic Personality As Well As Rich Cultural Heritage.
16 | P a g IGNOU
e
PATOLA:-
The Patola Silk from Patan Is Very Popular And One Of The Largest Selling Fabrics In The
Country. The Sarees Are A Mark Of Tradition And Grandeur Depicting Gujarat As A Land Of
Prosperity And Wealth. This Is Unique To Patan And Is Known For Its Utmost Delicate Designs
Woven With Great Expertise And Quality. Gujarat Patola Exhibits A Passion For Color And A
Deep Sense For Design And Form. They Convey A Message Of The State's Rich Cultural
Heritage.
The Indian Textile Industry Today Has Approximately 1200 Medium To Large Scale
Textile Mills In India. 20%Of These Mills Are Located In Coimbatore (Tamilnadu).
The Industry Has 34 Million Cotton Textile Spindles For Manufacturing Cotton Yarn
Which Account For 70 Percent Of India's Textile Exports. (China Has 40 Million Cotton
Spindles.)
Of The Indian Textile Yarn Exports, Almost 80 Percent Come From Coarser Yarns
(Counts Below 40's). Consequently, There Is A Need To Upgrade The Technology.
The Domestic Knitting Industry Is Characterized By Small Scale Units With Facilities
For Dyeing, Processing And Finishing. The Industry Is Concentrated In Tirupur
(Tamilnadu) And Ludhiana (Punjab). Tirupur Produces 60 Percent Of The Country's
Total Knitwear Exports.
Knitted Garments Account For Almost 32 Percent Of All Exported Garments. The Major
Players Include Nahar Spinning, Arun Processors And Jersey India.
EMPLOYMENT OPPORTUNITIES:-
The Indian Textile Industry of India is vast and growing with presence of several national and
international brands. The main segments of the Indian textile industry are Man-made Textiles,
Cotton Textiles including Handlooms, Silk Textiles, Woolen Textiles, Handicrafts, Coir,
Readymade Garments, and Jute.
15 | P a g e IGNOU
Job opportunities are diverse in nature in the textile industry ranging from production, designing,
distribution and sales. The need for manpower for the textile industry is growing to keep up with
the growing demand; fresher’s are finding numerous job opportunities in the textile industry of
India.
The Indian textile industry offers opportunities to fresher's from various academic backgrounds
as nature of job is diverse. A textile engineer must have an engineering background; either B.E.
or B.Tech is preferred
Indian Textile Industry Is Known To Be The 3rd Largest Manufacturer Of Cotton Across
The Globe.
This Industry Of India Claims To Be The 2nd Largest Manufacturer As Well As Provider
Of Cotton Yarn And Textiles In The World
India Holds Around 25 % Share In The Cotton Yarn Industry Across The Globe
India Textile Industry Contributes To Around 12 %Of The World's Production Of Cotton
Yarn And Textiles.
STEPS IN LOCATION:-
in choosing a plant location, the entrepreneur would do well to proceed step by step,
the step being;
There Are Three Classic Approaches To Laying Out The Equipment And Processing Functions
Within A Manufacturing Facility.
Process Layouts Require The Most Movement Of Products From Workstation To Workstation
Since The Equipment Is Arranged Without Regard To The Processing Needs Of Any One
Product. Job Shops Can Attempt To Reduce This Unnecessary Handling, However, By Assessing
Movement Between Various Workstations For Each Product. They Can Then Determine The
Total Number Of Product Movements Between Workstations For All Of Their Products And
Arrange The Different Process Areas To Reduce The Total Number Of Product Movements.
Process Layouts Do Have The Advantage, However, Of Maximizing The Efficiency Of
Machinery Usage. All Products Requiring Drilling, For Example, Are Moved To The Same Drill
Press. Therefore, The Total Number Of Drill Presses Required Is Kept To A Minimum.
19 | P a g e IGNOU
Unlike Process Layouts, However, Product Layouts Maximize The Need For Expenditures On
Equipment. Studies Have Shown That Savings In Process Efficiency Far Outweigh These
Additional Machine Costs. If Cutting Stations Are Required At Several Steps Along The
Processing Route, Product Layouts Would Require Purchasing Separate Saws For Each Step To
Allow The Uninterrupted Flow Of Work Along The Line.
20 | P a g e IGNOU
INDUSTRIAL SAFETY MEASURES IN TEXTILE INDUSTRY
Introduction:-
There Are Numerous Health And Safety (H&S) Issues Associated With The textile Industry.
These Include: Chemical Exposure From The Processing and Dyeing Of Materials; Exposure To
Cotton And Other Organic Dusts, Which Can Affect The Throat And Lungs; Musculoskeletal
Stresses; Noise exposure, Which Can Lead To Hearing Loss; Temperature And Ventilation,
Which Can Lead To Fatigue And Dehydration If Temperatures Are Too High; And Working
Hours And Breaks, Including Access To Food, Drinks And Bathroom Facilities. This Booklet
Reviews Some Key Areas Of H&S In textile Dyeing Such As The Information Present In
Material Safety Data Sheets (MSDS), Fire Hazard Training And Various Other Components Of
H&S.
Health And Safety Regulations Have Been In Place In Textile Industries Across Europe And The
USA Since The 1970s. In England, The Health And Safety At Work Act Was Introduced In The
Early 1970s And The Health And Safety Executive (HSE) Was Formed And Given
Responsibility For Providing The Framework For Workplace H&S. Different Countries Have
Different Standards On H&S Practices And This Booklet Takes Some Of The Key Elements Of
These That Are Applicable To Promoting A Safe Working Environment In The Textile Industry
In Bangladesh.
21 | P a g e IGNOU
CHEMICAL SAFETY
➢ Hazardous Chemicals and their Symbols
➢ Material Safety Data Sheet
➢ Risk Assessment of Chemicals
➢ Health Effects of Dyes and Chemicals
➢ Chemical Storage and Disposal of Waste
➢ First Aid
LABORATORY SAFETY
PROTOCOL
➢ Laboratory Safety Protocol
➢ Factory Floor Safety Protocol
RESPONSIBILITY
➢ Role of The Management
➢ Role of The Factory Staff
23 | P a g e IGNOU
ROLE OF THE MANAGEMENT
The Management Should Regularly Check And Document The National Laws And Regulations
Concerning Workplace Safety. The Management Should Then Develop A Protocol Through
Which To Implement These Laws.
It May Also Be Necessary To Consider The Requirements Of Certain Buyers, Who May Have
Codes Of Conduct That Include Aspects Of H&S, Corporate Social Responsibility And
Environmental Responsibility. The Protocol Given In This Document Should Provide A Good
Basis For This And If Implemented Correctly Could Improve The Safety Of The Working
Environment In Most Factories.
24 | P a g e IGNOU
PROVIDE BASIC NEEDS
Employees Should Be Given Access To Safe Drinking Water As Well As A Clean Area For
Meals. Meals Should Be Taken In A Separate Area Away From The Factory Production. The
Factory Staff Should Also Have Access To A Sufficient Number Of Toilets Of Adequate Quality,
This Is A Legal Requirement And Contained In Most Codes Of Conduct Provided By Buyers.
There Should Also Be Signs Saying “No Food And Drink” In Areas Such As The
Laboratory, Store Room And Factory Floor, And Any Other Areas Where It Is
Not Safe To Consume Food, For Example Because Of The Risk Of
Contamination By Chemicals.
Hazardous Chemicals Should Be Clearly Marked In An Appropriate Language
And With Clear Symbols That People Have Been Trained To Recognise And
Understand.
Heavy Objects Should Be Marked As Such To Avoid Musculoskeletal Accidents.
Substances Or Items That Present A Fire Hazard Should Be Clearly Labelled
With The Universally Recognized Symbol.
Signs Should Be Placed Near Inflammable Substances Stating That It Is Not
Permitted To Smoke Or Have Open Fires.
Showers And Eye Washes Should Be Made Available And Clearly Marked.
Each Employee Should Have Sufficient Appropriate Training And Experience So That They Can
Perform All Their Required Job Activities. Where Relevant Each Employee Should:
• Be Aware Of The Contents Of MSDS And Of Potential H&S Hazards.
• Follow All Protocol In The Safe Handling And Disposal Of Dyes And Chemicals.
•Be Aware Of The Fire Protocol, Where Fire Extinguishers Are And Where The Nearest Exit Is
And Where Assembly Points Are.
• Be Aware Of Where The First Aid Kit Is.
•Wash Hands Before Meals, When Leaving The Work Area And At The End Of The Shift. This
Will Prevent Accidental Ingestion Of Chemicals Or Contact With Eyes.
• Maintain Correct Posture When Lifting Or Carrying Heavy Objects.
• Report All Accidents And Sicknesses To The Manager As Soon As They Occur.
25 | P a g e IGNOU
•Report Any Defects Or Problems With The Machinery That Might Lead To Potential
Accidents.
BIBLOGRAPHY
26 | P a g e IGNOU