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TEXTILE PROCESS TRANING REPORT
- 1. INTERNSHIP DURATION: 11-JUNE-2018 TO10-JULY-2018 SUMMER INTERNSHIP REPORT Department – processing SUBMITTED TO :- Mr. ASHOK PANDEY (H.R., HEAD) SUBMITTED BY:- Mr.ROHIT SINGH (B.tech 3rd Year, NITRA)
- 2. ACKNOWLEDGEMENT We would liketo express our sincerest gratitude towards Alps Industries limited, Meerut for providing us the best facility and working environment during our training period, at your esteemed organization. We are grateful towards each and every employee of the Alps Industries limited, Meerut for providing us their most valuable time and experience. It is indeed a great pleasure for us to express our profound and sincere thanks to Miss. Swati Yadav (Asst. Executive, HR) for his co-operation. We would like to thanks to Mr. Naseem Ahmed (Processing Head), and Mr. Benami Singh (Asst. Manager, HR) for giving their valuable time and attention during our training. Their instructions proved to be quite beneficial during the training period. We pay our special thanks to Mr. Ram Kumar (Executive, Processing Lab) and Mr. Harendra Chaudhary (Processing Lab Incharge). We thank all of them for providing us a friendly and stress free learning environment in Weaving and Designing department. Our association with the Alps Industries limited over the past 1 month has been immensely fruitful and we sincerely hope that this association will continue. Thank you Alps,Approved by:- Mr. ASHOK PANDEY (H.R., HEAD) Alps Industries Limited
- 3. CONTENT Page no. History ofcompany 4 Mission 5 Our group companies 5 Company profile 6 Flow chart 7 Processing department 8-9 Singing 8 Ready for dyeing (RFD) 9 Dyeing & printing department 9-15 Jigger Jet Soft flow Printing machine Finishing department 15-21 Mechanical finish Other department 21-23 Hot melt machine Foam lamination machine Final inspection 23-25
- 4. History of Company 1962-Alps Industries was promoted by Mr. KK Agrawal, a Textile Engineer & started manufacturing of Home Furnishing textile products, primarily for domestic markets, including five star hotels. 1974- Commenced exports to USA, Europe and Far East. 1989- Managing Director Mr. SandeepAgarwal, joined the company in the year 1974. Started interior décor products like Venetian & Vertical Blinds, Curtain Rods in our Brand-Vista, in collaboration with Levolor of US for domestic market as well as exports. 1995- IPO with 2.3m Equity Shares. Listing on both BSE & NSE. 1996- Set up integrated Textile Mill with in-house Spinning, Weaving, Processing, Cut and Sew Operations. 2007- Set up Spinning plant at Haridwar with 88,000 spindles comprising of latest state of the art compact yarn spinning frames from Toyota and Reiter. 2009- Set up state of art Weaving and Processing unit in Meerut including Foam Back & Blackout coating for Window Treatments & Hot Melt Processing for Mattress ticking fabrics, etc.
- 5. MISSION To achievea leading position in environment friendly textile products To create top of the mind brand recall for its products To pursue innovation of new products To strengthen market reach in both the domestic and international markets so as to fully capture emerging opportunities To reach the customers directly for improved responsiveness to changing customer preferences To introduce own brands for home furnishing products in the international market Position, both in domestic as well as the international market Group Companies:- Vista Offer complete range of home furnishing products for decorating your windows & floors. Vista, the market leader in Interior Fashions is well known in the market for its world class quality and continuous innovations.
- 6. Le Pashmina Offernew range of Pashmina Shawls. Company profile Name of the company: Alps Industries Limited Address of Registered Office: Alps Industries Ltd, 57/2, Site IV Industrial Area, Sahibabad, Ghaziabad-201010, Phone no.-0120- 4161700
- 7. Supporting departments HumanResource Department Engineering Department MIS Department Quality Control Department General Store Department Accounts Department Designing Sampling
- 8. FLOW CHART GREY FABRIC SINGEING(when required) READY FOR DYEING(RFD) DYEING DRYING (BY STENTER OR ZERO ZERO) FINISH FOLDING PACKING OR DISPATCH In the following context brief introduction of all departments is given:
- 9. Grey Fabric The Rawmaterials are Cotton, Polyester, Polyester/Cotton and Polyester/Cationic used. The Grey fabric procurement is from various sources and from various industries and stored in fabric Godown. PROCESSING DEPARTMENT SINGEING: Objective:-To remove the protruding fibres from the surface of the grey fabric with the help of burning flame. This process is mainly used for cotton fabric. SINGEING MACHINE: Company Of Machine:-PoongKwang Machine Co. Ltd. Korea Year Of Manufacturing:- 2008/12 Speed Of Machine:- Max. 100m/min Distance from flame:- 5mm RFD (Ready For Dyeing) Objective:- The main objective of RFD is to make the fabric suitable for dyeing. RFD(BLEACHING AND SCOURING) CHEMICALS USED-- 1. Scouring agent (Caustic Soda)
- 10. 2. Bleaching agent(Hydrogen Peroxide) 3. Wetting Agent(for proper wetting of material) 4. SequestingAgent(it make water soft) 5. Stabilizer Agent(it improves stability of hydrogen peroxide at high temp.) 6. Lubricating agent(for ease mobility in jet or soft flow m/c) 7. Peroxide Killer(it removes the peroxide from material after process) PROCESS PARAMETER 1. For cotton on jigger , temperature is 90-95 cent. And in jet is 110 cent. and time is 155 minute. 2. For p/c blend temp. is 100-110 cent. 3. For polyester temp is 100 cent. And time is 90 minute. DYEING After RFD next process is DYEING. For cotton dyeing REACTIVE DYE is used and for polyester DISPERSE AND CATIONIC DYE IS USED. Cotton dyeing is done in jigger and polyester dying is done on jet or soft flow. The machinery plays an important role in processing. To get even and better results in dyeing process, the machinery used in dyeing should be fulfill the all following conditions to utilized the
- 11. following form ofenergy • Chemical • Thermal • Mechanical • Fluid The machine used for dyeing purpose in "Alps Industries fabric dyeing section are almost fulfill the that requirement. The machine used for dyeing are "High temperature, High pressure dyeing machines. These are fully automatic machines(jigger) which are operated by fully computerized control panel. Two types are machines are mainly used in fabric dyeing section: • jet HTHP dyeing Machine • Soft flow HTHP dyeing Machine • Jigger dyeing machine(closed and open) JIGGER MACHINE Jigger m/c--- In ALPS industry both manual and automatic jigger are use for dyeing The jigger provides a v shaped stainless steel vessel for containing the dye liquor.
- 12. A pair ofupper guide rollers, a pair of immersion rollers at bottom of vessel and two draw rollers to pull the fabric through the dye liquor The dye liquor heated by direct heating by use of steam, a perforated steam pipe located bottom of vessel. The cloth is wound on draw roller such that cloth is between under tension and without creases. One END is said be completed when the entire cloth rolls travels' from one draw roller o another through liquor. END should be in EVEN. This forward and backward travel of the fabric enables it to pick up more and more dye liquor. From time time the cloth checked for shade to see whether dyeing is over. After dyeing is over the dye liquor is run out from the vessel, which is then filled with cold water. The fabric is rinsed well in the over flowing water through as many ends as are required to wash it free of the dyeing chemicals and wound on to a draw roller from which it can be taken for drying or other treatment. 1. It is usual to run the fabric at least six ends in a standard dyeing cycle. 2. The M:L ratio of jigger is usually about to 1:5 or less. 3. The M:L ratio is increases during process because of direct heating. 4. Now a days closed jigger, hthp jigger used. Closed jigger is very useful in dyeing of cellulosic fiber with vat and sulfur dye. Also used in polyester fiber dying with carrier method at a temp.
- 13. of 110. Inhthp jigger temp can be rises to 140 cent. 5. IN jigger both rfd and dying process performed. JET DYEING MACHINE JET M/C--- This m/c is more efficient and quicker. The basic principle of jet involves movement of both liquor and fabric. This liquor is forced through a narrow jet or venturi and this cause its velocity to increase dramatically. Them/c consists of a main dyeing vessel, which stores the fabric and dye liquor a jet, a heat exchanger, a circulation pump and a cloth reel as the main parts. 1. The heating system is indirect by use of heat exchanging system. 2. The maximum temp. attainable is 140 cent. 3. Any kind of fabric that has dimensional stability the forces of circulating liquor through the jet can be dyed on this kind of machine. 4. In spite of its obvious advantages jet dying m/c suffers from limitation that a fabric with poor dimensional stability can not be dyed because fabric would be distorted its shape.
- 14. SOFT FLOW MACHINE SOFTFLOW M/C--- A soft flow jet dyeing m/c is suitable for dying a wide range ofknitted and woven construction of fabric in rope and open width form up to 98 cent. In soft flow m/c only a part of the dye liquor passes through jet so its velocitythrough jet will be low . Even if the fabric transports has low dimensional stability itwill give gentle treatment at the jet and no distortion would be occur. 1. The M:L is 1:10. S.No MACHINE NAME MODEL CAPACITY MANUFACTURER 1. Soft flow KEMPL KRSNA-300 300 kg INDIA 2. Soft flow KEMPL KRSNA-1000 1000 kg INDIA 3. Soft flow BRAZZOLI HT 1 X C3 300kg ITALY 4. Soft flow BRAZZOLI HT 3 X C3 900 kg ITALY 5. Soft flow KEMPL KRSNA 10 kg INDIA 6. Soft flow KEMPL KRSNA 10 kg INDIA 7. Soft flow KEMPL KRSNA 10 kg INDIA 8. Soft flow KEMPL KRSNA 100 kg INDIA 9. Soft flow KEMPL KRSNA 100 kg INDIA 10. JET 1 CIRCULAR HISAKA H-200 50kg JAPAN 11. JET 2 CIRCULAR HISAKA H-200 360kg JAPAN
- 15. 12. JET 3SAMILL SIDC-2200 500 kg KOREA 13. JET 4 SAMILL SIDC-2100 250 kg KOREA 14. JET 5 KEMPL 250 kg INDIA 15. JET 6 KEMPL 250 kg INDIA 16. JET 7 KEMPL 250 kg INDIA 17. JET 8 KEMPL 150 kg INDIA 18. JET 9 KEMPL 150 kg INDIA 19. JET 10 KEMPL 100 kg INDIA 20. JET 11 KEMPL 100 kg INDIA 21. JET AMJ AMU 30 kg INDIA 22. JIG. No-1 SUNG MOOUF15P23 700 kg KOREA 23. JIG. No-2 SUNG MOO UF15P23 700 kg KOREA 24. JIG No- 3 SUNG MOOUF15P23 900 kg KOREA 25. JIG. No- 4 SUNG MOO UF15P23 900 kg KOREA 26. JIG. No- 5 GILL ENGINEERS 700 kg INDIA 27. JIG. No- 6 GILL ENGINEERS 700 kg INDIA 28. JIG. No- 7 JUPITER ENG. WORKS 500 kg INDIA 29. JIG. No- 8 JUPITER ENG. WORKS 500 kg INDIA 30. JIG. No- 9 JUPITER ENG. WORKS 500 kg INDIA 31. JIG. No- 10 GILL ENGINEERS 250 kg INDIA
- 16. 32. JIG. No-11 GILL ENGINEERS 250 kg INDIA 33. JIG. No- 12 GILL ENGINEERS 250 kg INDIA 34. JIG. No- 13 GILL ENGINEERS 250 kg INDIA 35. JIG. No-14 POWER BUILD LIMITED 500 kg INDIA 36. JIG. No- 15 POWER BUILD LIMITED 500 kg INDIA 37. JIG. No- 16 250 Kg INDIA 38. JIG No- 17 250 Kg INDIA 39. PRINTING MACHINE (KLIEVERIK Heli B.V.) NETHERLAND FINISHING DEPARTMENT Machines Used:- 1. Rope Opener 2. Stenter 3. Zero Zero Machine 4. Calendering Machine 5. Shearing Machine 6. Pitching Machine Other Machines:- 1. Hot Melt Machine 2. Foam Lamination Machine 1. ROPE OPENER
- 17. Objective:- Mainly usedfor the opening of fabric after dyeing for further finishing process of the fabric. Company Of Machine;-HanayamaKoyga Co. Ltd. Japan Year Of Manufacturing:- 2008 Speed Of Machine;- Max 100m/min 2. STENTER Objective:-Stenter machine is not only a dryer but also used for many other purposes. Here knitted and woven fabric in open width form is treated. This multipurpose machine is used for the following processes. Drying Heat Setting Width Control Curing Finishing Chemical application Selvedge Printing Weft Straightening Padding Mangle Flocking No. Of Stenter used in Industry:-4 1. Stenter 1:- 8 Chamber 2. Stenter 2:- 8 Chamber 3. Stenter 3:- 10 Chamber 4. Stenter 4:- 4 Chamber FLOW CHART Under Feed Roller
- 18. Over feed Roller PinningDrum Photocell sensor Hot Chamber Cooled Chamber Delivery Roller Dancing Roller Cooling Cylinder
- 19. Batching Roller For polyesterpressure used is 3.5 kg, temperature is 1600 C and width can be increased up to 5cm. For cotton pressure used is 3kg, temperature is 1800 C and width can be increased upto 20 cm. Company Of Machine:-Sun-super S, South Korea Year of Manufacturing:- 2008 Speed of Machine:- 13 mt/min 3. ZERO ZERO MACHINE Objective:-It is the Controlled compression shrinkage or pre-shrinking of the fabric by passing the fabric into rubber unit. This process forces the yarns closer together and the fabric becomes thicker and heavier and the dimensional stability of the fabric improves. This process is also called “sanforization”. BEFORE SANFORIZING AFTER SANFORIZING
- 20. 1 - Drawroller (fabric entry). 2 - Water spray unit. 3- Steaming drum. 4 - Skewed fabric straightening roller. 5 - Clip type 6 - Rubber blanket shrinking unit. 7 - Felt calendar. 8 - Felt drying cylinder. 9 –Plaiter Company Of Machine:- RONSON Date of Manufacturing:- 2008/11 Speed of Machine:- Max. 50m/min 4, SHEARING MACHINE Objective:-Suitable for general shearing of Woven and knitted fabrics fulled fabrics, non- woven fabrics made of natural or synthetic fabrics, for manufacture of Velvet, Blankets, Velour's, Plush, Lace. Linings, Fur imitations, Furnishings, Floor Covering. No Cloth tension irregularities by an adjustable driven brake roller and appropriate appliance o the large draw roller. Featured in compact design and rationalized structure.
- 21. FLOW CHART Knitted Fabric GuideRoller Steam Roller Scroller Roller Cutting Roller Glober Pressure Embry rubber Company Of Machine:-Mario Crosta Year Of Manufacturing:-2008/11 Speed Of Machine:-3.5m/min
- 22. 5. PITCHING MACHINE:- Objective:-Themain objective of pitching machine is to polish the fabric with the help of continuous rollers to make the fabric smooth and shiny. Company of machine:- PARAS Ltd. Year Of Manufacturing:- 2013/12 Speed Of Machine:- Min 13m/min OTHER MACHINES 1, HOT MELT MACHINE Objective:-The main purpose of hot melt machine is to coat the required fabric with other fabric with the help of chemicals. The chemicals are padded with the help of hot rollers due to which both the fabrics are attached. Company Of Machine:-World F.L.Y Co. Ltd. Year Of Manufacturing:- 2008
- 23. Speed Of Machine:-10 m/min Roller Temperature:-100 C Chemical Temperature:- 100 C Pressure:- 3 kg Chemical used:- FE-93 2.FOAM LAMINATION MACHINE Objective:-These are double belt presses with integrated contact heating and cooling. The materials that are laminated are heated very gentle. Due to the long heating zone the materials are laminated perfectly with high bonding strength. Right after the heating the materials can be pressed together or calibrated to a set thickness with the pressure rollers. To stabilize this compound the materials a cooled down before they exit the double belt press. With the flat gap between the belts and the precise height adjustment even rigid plates with a thickness of up to 150mm can be laminated. Company Of Machine:- Year Of Manufacturing:-2008 Speed Of Machine:- Max. 20m/min Distance from flame:-23 mm Pressure On Fabric:-2.5 bar Pressure of Net:- 2.4 bar Touch with Flame:-15 sec Note:-The gas used to burn the flame is LPG.
- 24. Final Inspection Object –To remove the defects manually by mending. Following are the defects found after processing- Black line on coating Black stain Bowing Chemical stain Coating knot Color patch Color stain Color sublimation Crack Crease mark Handling stain Insects stain Moon mark Oil stain Pin hole in fabric Rope mark Shade variation Short width Uneven dye Warp patta Weft patta
- 25. Number of machines– ALMAC – 6 YASH – 2 Speed of machine – 20m/min Year-2008 o CALEMARD FRANCE M/C:- Object-To cut selvedge and remove coating defect and black coating mark. No. of machine-1 Speed- 30 to 40 m/min NOTE- Thinner is used to remove black coating stain and oil stain. Quality Assurance Department Object-To check quality of fabric. List of testing equipment in this department are as follows- Air permeability tester De Matia Flex Tester Sublimation Fastness tester Martindale abrasion tester Light fastness tester (Suntest CPS) Yarn examination tester TPI tester Wrap reel Unistretch 500
- 26. Spray test Thankyou so much for giving me this opportunity