TEXTILE INTERNSHIP

TERRY TOWEL DIVISION VAPI

SUBMITTED BY:
PRIYANKA VISHNOI SHIVANGI B.F.TECH SEM V 2011-2015

INTRODUCTION
The textile internship has been completed in Welspun India Limited, Vapi, Gujarat.
The duration of the internship was of three weeks where we had covered nine different departments of textile processing. Familiarized us with the various aspects of a Textile Processing Unit starting from its Organizational hierarchy to the functionality of the various departments. Introduced us to the various brands of machineries available for carrying out the different textile processes to meet global standards.

OBJECTIVES
The textile internship was carried out to develop a clear understanding about the following: Flow process sequence and Technical details on machine particulars of weaving, dyeing, printing, finishing, laboratory etc. Particulars of raw material, intermediate products and final product, process details, product quality parameters. Particulars of the manufacturing environment. Human resource management. Productivity analysis for various processes. The internship helps us to:

To understand the structural and functional constituents of the industry. To adapt to real industrial situations which equips us for decision making in a realistic environment. To strengthen the relationship between the industry and students.

COMPANY AND LEADERSHIP

Overview
Incorporated in January 1985 Fully integrated Home Textile Manufacturer-from spinning to finishing. Manufacturing facilities at Vapi and Anjar in Gujarat. Ranked 1st among Home Textile Suppliers in the US (Source: Home Textile Today) Largest vertically integrated manufacturer of towels in Asia Supplier to 14 of the top 30 global retailers - Walmart, Target, J C Penney, Kohls, Macys, etc. Distribution network in over 32 countries including U.S.A., U.K, Europe, Canada and Australia

Global leadership
Largest terry towel producer in Asia. Worlds 3rd best and 4th largest terry towel producer. Largest specialty polyester filament yarn producer in India. Acquired 85% of Christy UKs leading towel manufacturer & sole supplier to Wimbledon. 80-90 % of products are exported.

COMPANY PROFILE
WELSPUN INDIA LIMITED, VAPI 1st June,1993- Establishment of textile unit at Vapi. Chairman and Managing Director(Welspun Group): Shri.B.K.Goenka. Managing Director(Welspun Global Brands Ltd) : Mrs. Dipali Goenka WELSPUNs VISION We aim to emerge as a global leader preferred by every home serve...with passion grow....@ speed innovate.....with quality excel...with ethics Delighting all stakeholders..... We are...WELSPUN WELSPUNs MISSION We endeavor to reach a leadership position in each Segment / Sector of our Product / Service. We are committed to satisfy our customers by providing best quality and service, which gives the highest value for money. We believe that employees are our most important asset through which we can reach the top in each category of our Product / Service. Therefore, we will emphasize on their continuous improvement through upgrading relevant knowledge and training. We commit ourselves to continuous growth, so as to fulfill the aspirations of our Customers, Employees and Shareholders.

CUSTOMERS
Categories Clubs Mass Merchants Global Clients Costco Sams Club Walmart Target Kohls JCpenny Tjmaxx Ross K-mart Sears LNT BBB Belk Dillards FEdeated Macys FortunOffs IKEA Tommy Hilfiger Nautica Umbra Sheridan Springs Welhome Welspun India Welspun USA

Discount Stores

Speciality Stores

Departmental Stores

Brands

Manufacturer/Importer Own Brands

TERRY TOWEL
Terry towels are woven pieces of fabric either cotton or cotton-polyester that are used to absorb moisture on the body after bathing. Terry towels are generally woven with a loop or pile that is soft and absorbent and is thus used to wick the water away from the body. Most towels have a two selvage edges or finished woven edges along the sides and are hemmed (cut and sewn down) at the top and bottom. The basic structure of towel is divided into these main parts: Plain Hem Terry Bar Body Border Selvedge

CATEGORIES OF TOWEL
SIZE OF TOWEL 33 X 33 30 X 30 15 X 21 41 X 21 40 X 76 50 X 100 60 X 110 60 X 100 70 X 140 76 X 132 CATEGORY OF TOWEL WASH TOWEL WASH TOWEL GLOVES HAND TOWEL HAND TOWEL HAND TOWEL BATH TOWEL BATH TOWEL BATH TOWEL BATH TOWEL

76 X 142
80 X 170 100 X 150 90 X 178 80 X 176 74 X 152 50 X 90 50 X 80

BATH TOWEL
BATH SHEET BATH SHEET BATH SHEET BEACH TOWEL BEACH TOWEL BATH MAT BATH MAT

Process Flow of Welspun India Limited

1. BUYER'S REQUIREMENT

At first the buyer sends his requirement for towel according to feel, look and absorbency. He also specifies the towel design and dimensions.

2. PRODUCT DEVELOPMENT

Nearly 30 pieces are developed as per the buyer's requirement by the product development department. Out of these 6 pieces are sent to the buyer for approval.

3. COMMENT SENT BY BUYER

The buyer may approve the pieces sent to him or may send comments ask for some changes. If some changes are asked for then the towels are re-developed and again send to the buyer.

If the buyer is satisfied with the above parameters then it sends the shade of the towel as per his requirement
4. SHADE SENT BY BUYER

The product development department develops swatches of the shade send by the buyer and also 2 or 3 more shades which is very near to required shade and send to the buyer.
5. LAB DIP

6. SHADE
APPROVAL

The buyer then approves the shade he wants.

7. PREPRODUCTION SAMPLE SENT

The Product development department develops nearly 100 200 pieces of towels as per the buyers specifications in the approved shade. Out of these 12 20 pieces are sent to the buyer.

8. BUYER'S APPROVAL

The buyer approves the towel which meets his standards and this towel serve as the standard towel for reference between the buyer and the manufacturer.

9. PURCHASE ORDER

The buyer sends the bulk order in the form of purchase order to the Head Office in Mumbai.

10. SALES ORDER

The Head Office in Mumbai prepares and give the sales order to the PPC department of the plant through the plant merchandiser.

As per the sales order the PPC makes the production plan along with the material requirement plan. 11. PRODUCTION PLANNING

12. MATERIAL A purchase order is generated for the required yarns and trims and sent to the suppliers. PROCUREME NT

13. WEAVING ORDER

Production order is given to the weaving department.

Weaving happens as per the weaving plan.

14. WEAVING

15. PROCESSING

Processing takes place as per the processing plan.

Finishing takes place as per requirement

16. FINISHING

Final inspection is done by TQM

17. TQM

Dispatch is done
18. SHIPMENT

Time Taken For The Different Processes

NAME OF THE PROCESS
Sample approval (for new orders) Material procurement Weaving Processing and Cut & Sew Inspection & dispatch (also kept as a buffer period)

TIME
15 days 15 days 15 days 10 days 5 days

Note: It must be noted the above stated time period is taken ideal but it is subject to change depending upon design features, raw materials availability and other buyers specifications. The timings are also given keeping in mind the average lots of orders fulfilled and delivered and may change as per the quantity of lot as well.

PRODUCT DEVELOPMENT

Product Development Department

Responsible for developing the samples for the buyers as been specified.
The sampling process is as follows: Firstly 6 of the Fit samples are sent of any shade for the approval of feel, look and absorbency.

Then after the corrections are made if required and approval of the fit sample, shade is sent by the buyer.
Then a lab dip is done and the sample pieces of 5*5 inches of the nearest shades to the one sent by the buyer are sent for shade approval. This number is generally 4-5.

Then the preproduction samples of the desired look, shade, feel and trims are sent to the buyer for approval.
After the corrections are made if required and approval is done, the size set samples i.e. all the required sizes of the same towel are sent to the buyer if desired by the buyer.

Then the bulk order is sent by the buyer after which the product development department issues the order to the production planning and control department for the bulk production.

PRODUCTION PLANNING AND CONTROL

Production Planning And Control Department (PPC)

The role of the production planning and control (PPC) department starts after the approval of the samples has been done and the bulk production has to be taken care of.
The main objectives of PPC department are: Making a plan to be implemented to fulfill the buyers orders. To coordinate with the merchandising department (Head office) to deal with the orders properly. Coordinate with the production department for proper implementation and control over the orders. To coordinate with the grey fabric department for the issue of correct lot of fabric to the processing department on time.

I. Sales Order

II. Material Requirement Plan (MRP)

III. Production Plan

IV. Dispatch Plan

I. Sales Order
Sales order refers to the order placed by the buyer. The sales department issues a standard sales order. The planning in sales order leads to complete information from production of shades and packing information including raw material specifications. A particular sales order gives following basic information: Product quantity Product quality specification.

II. Material Requirement Plan (MRP)

Once the sales order is received, the PPC department estimates, calculates and decides the type, quality and quantity of the required materials for the fulfillment of the order. MRP results in an independent/dependent requirement at each level of the process flow of the production.

III. Production Plan

The production planning refers to the planning for the material specification thatmeets the buyers requirement at each level of production. This plan has 4 major plans as its main production line plans. They are as follows:

Production Plan
Spinning Plan Weaving Plan Processing Plan Cut & Sew Plan

IV. Dispatch Plan

Taking in consideration aforesaid steps, a planned dispatch date is calculated, this planned dispatch date is against the required dispatch date

SPINNING

Spinning Department
The spinning division serves as the first and one of the most crucial divisions in any textile industry. In this unit of 37235 spindles capacity, the raw fibre is converted (spun) into yarns through a series of processes. The main fibre spun in this unit is cotton and its blends along with some other special fibres that include polyester, modal, bamboo, static, etc. The cotton is mainly blended with polyester in the ratio depending on the end use and requirement. Capacity of the spinning division is approximately 55-60 tons per day.
There are mainly two types of spinning processes that are performed: Ring Spinning Open end Spinning

Fibre Procurement
Types of Fibre Shankar 6 Shankar 4 Oganic Cotton Pima Egyptian Giza Wool Noils PVA Bamboo Price Range (Rs. Per Kg) 70-75 57-63 65-70 114-118 102-106 70-75 144-148 148-152 Procured From Gujarat Gujarat Maharashtra,Orissa USA Egypt Imported Imported China Used in Towels, Rugs Towels Towels Towels Towels Towels, Rugs Towels, Rugs Towels

Other types of fibres include Acrylic, LRA, Viscose, Nylon, and Banana etc. Out of the all varieties of cotton only Pima and Egyptian variety is imported. The fibre is usually procured as per the buyers specification in terms of candies where one candy equals 355.62 kg. The fibre usually arrives in bales of 160 kg each and stored in a godown having capacity of 75000 bales. The bales of cotton that are to be spun are then taken from the godown to the spinning unit with the help of the fork lift.

Flow Chart For Yarn Manufacturing Process

Marketing and PPC TT Production Planning SPG Equipment Spares

Purchase

Raw Meterial (Cotton)

Blow Room

Carding

Breaker Drawing

YES

NO (Carded)

Combing UniLap

Combers Finisher Drawing

(Contd..)

SPINNING CARDING PLAN LAP FORMATION DRAWING FINISHER COMBING After the blowroom activity comes In time production of yarn with After the doubling process has to an quality. end, the cotton fiber gets right BLOW ROOM The combed slivers are then After the laps arecans produced the been done, output from the ready for the first sliver formation combined and drawn to form the BREAKER DRAWING cotton isdraw then frames combed. breaker are combined through the carding process. Ensure that fibre procurement The fiber procured has to undergo final condensed sliver that is to is be a Combing is required to produce together to form laps for the Carding is the most important done on sequence of operations prior to the taken to time. the speed frame where The cans filled with sliver are fine yarns through an additional combing process. process which helps spinning foryarn opening of the fibers first roving isthe made. then passed on breaker draw straightening into this operation, fine 4 calendar rollers and large lap to open the flocks to Fibre requisition is done well in and cleaning of the same for trash The combination of several frames from the carding machines. toothed combs continues rollers allow for faultless batt individual fibers, advance in case of blends. removal so that the fibers can cans be slivers is known as drawing. Here, sliver from 6 of these straightening the fibers until they structure, and ensure a secure and process cleaning upblow the room has spun into yarns. The This are doubled into 1 can. are arranged ineliminates high degree of optimal lap construction. impurities, Fibre requisition should be made lines of operation, which are irregularities that would cause too Hence, the output sliver is more parallelism. The regulated automatic lap removing the neps, taking care of the available stock, independent to each other. They much variation if the slivers would compact, fine and ready to go into In this process the short fibers loading safeguards the ideal align the fibers etc, to processed waste and anticipated are: put through singly. the combing process. namely noils are removed. pressure of the lap on basic the lap rollers achieve the yarn rejection. 8 of the combed slivers are The output that comes out of cycle. the during thequality complete build-up and better 1. Blow Room Process for Pure combined together to form 1 combing machine is known as efficiencies in further Procedure cotton spinning condensed sliver by combed sliver or there combed cotton spinning processes. 2. Blow Room Process for Cotton producing longer and thinner which is very fine, smooth, strong Higher the production, the more Fibre requisition. Blends slivers. and used to produce more sensitive becomes the carding Fibre to yarn production. serviceable cotton fabrics. operation greater the danger Delivery and of yarn to weaving or of a negative influence on as quality. processing at Vapi unit the case may be.

Finisher Drawing

YES

NO

Ring Spun Speed Frame Ring Spinning Open End

Auto Coners
YES NO

TFO

Assembly Winding

TFO

Xorella Yarn Conditioning

Storage

Packing in Cartons or Pallets

FINISHER DRAWING SPEED FRAME RING AUTO FRAME CONERS SPINNING OPEN END The combed slivers are then YARN CONDITIONING The condensed slivers which combined andof drawn to form YARN PACKAGING As Conversion the roving yarn small is fed spindles it have been obtained from the A process of spinning which is the final condensed sliver that passes to required from sizea set of cones rollers i.e. the A maximum of 570 cones are finisher draw frames are fed extremely fast and is best is to be taken to the speed The packages of yarns arerollers drafting where the taken tosystem a cylindrical chamber directly from the cans each of suitable for coarser yarns for frame where the first roving made as per the buyers move Waxing at progressively of the yarn higher i.e. Contexxor capacity 20 kg Compact to the drafting the use in denims, towels, yarn is made. specification or are generally speeds. xorella machine in which it is system of the speed frame carpets etc is Open End The combination of several made in the packages (cones or The Re-tensioning top the rubber rollers of the yarn and the to provided with 65 degree through creel to the feed spinning or Rotor spinning. slivers is known as drawing. cheeses) of 1.5kg ,1.89 kg,2.8 the bottom avoid tension steel rollers variations constitute celsius temperature with guide. This process eliminates kg for ring spun yarns and drafting system. almost 90% vacuum Each speed frame rovescause yarn that would packages of 2.5kg,3kg and 3.7 irregularities Then Splicing the yarn as and goes when to the yarn application so that the yarn is to 120 bobbins at a time from too much variation if the kg packages for open end guide required through to join the the nip two roller ends at of the conditioned and attains 120 respective cans. slivers would put through yarns. front. spindles moisture gaining capacity. The main objective of the singly. The conditioned yarn is yarn is wound on thethe spindle roving process is to give 8 of the combed slivers are then packed in two ways: which Cleaning rotates of at the a high yarn speed This process also increases first basic twist to the sliver combined together to form 1to Carton packing which is driven by the spindle the durability of the yarn. hold the short slivers together condensed sliver there by Pallet packing drive. and the resulting product. producing longer and thinner slivers.

Dispatch to TT and Market

Blow Room
The fiber procured has to undergo a sequence of operations prior to spinning for opening of the fibers and cleaning of the same for trash removal so that the fibers can be spun into yarns. The blow room has lines of operation, which are independent to each other. They are: Blow Room Process for Pure cotton spinning Blow Room Process for Cotton Blends For Pure Cotton Spinning: 1. Automatic Bale Opening And Mixing Machine used: Trutzschler Blendomat Bdt 019
The bales of cotton are taken from godown to the blow room and fed to the automatic Blendomat machine. It takes lay downs of up to 27 bales of raw material at a time in two bale groups on each side of the machine. The swivelling take-off tower on its travelling chassis has an optional device that scans the bale contours, thus ensuring uniform take-off. The machine then transports the material to the other machines for further processes through the channel of material transportation and suction tubes.

Look alike model of the Blow Room

2. Automatic Dust Removal, Gravity Trap And Metal Detection

After the cotton has been fed by the blendomat machine into the aero feed suction pipes, the cotton first enters the dust cleaning chambers where the dust is removed by the help of the air suction fans and collected separately in the impurity bags. Then it enters the gravity trap where various foreign materials such as wood pieces, pins, stones, etc are removed i.e. the impurities that are heavier than the cotton fiber are removed in the gravity trap. Then the cotton is passed through a metal detector. The metal shield reliably detects and diverts any metallic particle as small as 2 millimeters, at velocities of up to 33 meters per second. After the fiber is passed through the metal detector, it is transported to the ASTA machine where it gets automatically cleaned as well as opened.

3. Automatic Cleaning And Mixing

Machine used: Asta Machine The material fed to the ASTA is picked up by special pins and passed five times mechanically over the cleaning grid. During the process, the raw material is guided over the integrated dust-extracting filter where dust, fiber fragments and fine trash particles are stripped off mechanically. It has Continuous throughput without nipping and the use of grid knives that results in gentle cleaning. With the flexibility of easy on-going adjustment and multiple assortment operation possible, it gives high cleaning performance and intensive dust extraction that owes to have optimum material utilization.

4. Further Mixing And Opening

Machine Used:Trutzschler Multimixer The cotton fiber from the ASTA is then passed on this machine for automatic mixing and opening of the cotton fiber. The unique three-point blending process enables converting of cotton into a homogeneous blend of tufts with only a single machine. This saves space. The material is fed simultaneously and uniformly to the 8 chambers. The dust in the conveying airis systematically separated from the fibers and sent to the filter unit.

5. Blending And Cleaning Machine used: Dustex Machine

The fiber is then passed on to the Dustex DX- 385,which not only blends and opens the fabric but also does the final cleaning before the fiber is passed on the carding machines. The Dustex DX- 385 is a fine cleanerfor natural fibers. Its maximum production capacity is 600 kg/hour. It can be used without any additional components as a feed machine for cards. The single-cylinder concept permits a wide operating range with no damage to the fibers or excessive loss of good fibers. With the Dustex cleaning process the blowroom activity of a cotton lot comes to an end. Around 2 3 % impurities from the cotton lot is removed during the blowroom activity. After this process, the cotton is passed into the carding system where it isfurther cleaned and the first sliver of cotton is formed

For Pure Cotton Blends:

For the manufacture of blended yarns, the required bales of cotton and other fibers are opened and hand mixed as done in the pure cotton spinning. But now the process will vary and the further processes are as follows:

6. Mixing Bale Opener (MBO)

The hand mixed and open fibers of required type are fed to the throat part of the MBO in a pre-calculated proportion as per the required kind of yarn. The working width of the machine is 1000 mm and its capacity is 250 kg/hr.

7. Blending Machine
The blending machine is used to blend the fibers in homogeneous mixture and least impurities with at least 2 and almost 8 kinds of materials can be blended and can be distributed to different carding trained each with different blend ratio.

Now the fiber coming out of this machine is directly fed to the carding machines for continuous process.

Carding
After the blowroom activity comes to an end, the cotton fiber gets ready for the first sliver formation through the carding process. It is the most important process which helps to open the flocks to individual fibers, cleaning up the impurities, removing the neps, align the fibers etc to achieve the basic yarn quality and better efficiencies in further spinning processes. Higher the production, the more sensitive becomes the carding operation and greater the danger of a negative influence on quality.
Technical Details of the Carding Machine
Speed (current)
182 m/mins 330 m/mins 9000 m 50 kg 0.100 Ne

Speed (maximum) Length of sliver per can Weight of sliver in 1 can Sliver hank

Time to fill 1 can (output)

Efficiency Impurities removed Production per hour (current)

62 mins
79.6% 6% 51.4 Kg

Model depicting structure of Carder

Doubling By Breaker Draw Frame

The cans filled with sliver are then passed on to the breaker draw frames from the carding machines. Here, sliver from 6 of these cans are doubled into 1 can. In other words 6 slivers with hank of 0.100Ne are combined and merged together to make a finer sliver of hank 0.105Ne. Hence, the output sliver is more compact, fine and ready to go into the combing process.
Technical Details of Doubling Machine Speed (current) Speed (maximum) Length of sliver Weight of sliver Input Sliver hank Output Sliver hank Time to fill 1 can (output) Time to fill 1 can (input) Efficiency
645 m/mins 900 m/mins 5500 m 30 kg 0.100 Ne 0.105 Ne 7 mins 15-20 mins 80-85 %
Breaker Draw Frame Machine

Lap Formation
After the doubling process has been done, 22 28 of the output cans from the breaker draw frames are combined together to form laps for the combing process. Each lap of diameter 550 mm, weighing nearly 18.75 kg contains 250 meters of lapped cotton sliver. Only optimal drafting distribution can ensure the best drafting conditions and the resulting fiber parallelization. 4 calendar rollers and large lap rollers allow for faultless batt structure, and ensure a secure and optimal lap construction.

Technical Details of the Unilap Machine

Speed (current)
Speed (maximum) Length of lap Input Sliver hank

115 m/mins 130 m/mins 250 m 0.105 Ne

Output weight of lap

Time to fill the full lap (output) Time to empty 1can (input) Efficiency

75 gms/m
2.3 mins 3 hrs 80-85 %

A Model showing functionality of the Unilap Machine

Combing
Combing is required to produce fine yarns through an additional straightening in this operation, fine toothed combs continues straightening the fibers until they are arranged in high degree of parallelism. In this process the short fibers namely noils are removed. The noil that is removed constitute to about 15 20% of the lapped cotton fibers in case higher counts such as 80s and 100s. These noils are then used to produce yarns of coarser count through open end spinning. The output that comes out of the combing machine is known as combed sliver or combed cotton which is very fine, smooth, strong and used to produce more serviceable cotton fabrics.
Particular
Speed (current) Speed (maximum) Length of sliver Input weight of lap Output Sliver hank Time to fill 1 can (output) Time to finish 8 laps(input) Efficiency Impurities removed (Noil)

Rieter E 62
202.1 m/mins 400 m/mins 6700 m 75 gms/m 0.16 Ne 30-35 mins 2 hrs 80-85 % 20-21%

Rieter E 60
148 m/mins 400 m/mins 3800 m 75 gms/m 0.16 Ne 25 mins 2 hrs 80-85 % 20-21%

Drawing By Finisher Draw Frame

The combed slivers are then combined and drawn to form the final condensed sliver that is to be taken to the speed frame where the first roving yarn is made. The combination of several slivers is known as drawing. This process eliminates irregularities that would cause too much variation if the slivers would put through singly. 8 of the combed slivers are combined together to form 1 condensed sliver there by producing longer and thinner slivers. This draw frame is the final stage drawing system and hence known as the finisher draw frame.
Technical Details of Doubling Machine Speed (current) Speed (maximum) Length of sliver Input Sliver hank Output Sliver hank Time to fill 1 can (output) Time to fill 1 can (input) Efficiency

504 m/mins 900 m/mins 3500 m 0.16 Ne 0.16 Ne 7 mins 15-20 mins 70-75 %

Speed Frame
The condensed slivers which have been obtained from the finisher draw frames are fed directly from the cans each of capacity 20 kg to the drafting system of the speed frame through the creel to the feed guide. Each speed frame roves yarn to 120 bobbins at a time from 120 respective cans. Here the slivers are drawn through the sliver guide by a 4 roller double apron drafting system with 4 top rubber rollers and 4 bottom steel rollers. The main objective of the roving process is to give the first basic twist to the sliver to hold the short slivers together and the resulting product
Technical Details of the Speed Frame Machine Twisting range
10-100 twists per meter (202.54 tpi) Upto 63mm

Fiber length range Time taken to wind one bobbin

The input can capacity The delivered bobbin capacity Speed Thickness of the roving yarn Software used Production per Hour

247.7 minutes(approx)
20 kg 4600 m 1500 rpm 260 mm Easy spin systems 2.07 133704 m/hrs

Ring Frame Spinning

There are two kinds of Ring frame spinning techniques adapted here: Conventional Ring frame spinning COM4 spinning with compacting technique The basic concept behind the two techniques is almost the same but the COM4 spinning has an extra attachment i.e. the primo suction unit which makes it efficient for finer counts and improves the quality and dyeability by removing the trash with the jet of air and holds the fibers as well to improve the efficiency too. As the roving yarn is fed it passes from a set of rollers i.e. the drafting system where the rollers move at progressively higher speeds. The top rubber rollers and the bottom steel rollers constitute the drafting system. Then the yarn goes to the yarn guide through the nip roller at the front. The yarn is wound on the spindle which rotates at a high speed which is driven by the spindle drive. The traveller moves up and down gradually during the spinning process. The traveller has a ring which is always in contact with the high speed running yarn which guides the proper and uniform winding of the yarn on the spindle.

WINDING OF RING SPUN YARN

FUNCTION: Waxing of the yarn Re-tensioning of the yarn to avoid tension variations Splicing as and when required to join the two ends of spindles Cleaning of the yarn Conversion of small spindles to required size- cones PROCESS: The spindles are fed to the magazine of the machines. One of the spindles is automatically taken by the machine for the winding (with air jet and drum rotation mechanism) to the spool keeping the spindle stationary at the bottom. This happens by the synchronized movement of automatically and pneumatically controlled suction arm which takes (sucks) the thread and gripper arm which joins the spool and spindle thread by splicing technology. The splicing is done by untwisting the broken ends of the yarn and then retwisting the yarn to get maximum uniformity. There is a gripper yarn perforator which sucks trash and removes it. The yarn passes through the tension control unit which maintains a uniformity in yarntension Through the head drum guard and drum, the yarn is wound on the required cones.

Open End Spinning

A process of spinning which is extremely fast and is best suitable for coarser yarns for the use in denims, towels, carpets etc is Open End spinning or Rotor spinning. In this process the sliver from the can which has been drawn from a finisher draw frame passes through a sliver guide in the COROBOX unit which guides the sliver to the funnel shaped inlet from where it goes to the housing board. From this unit it goes to the single spiked roller that revolves at a progressively higher speed, thereby opening up the sliver so that the sliver can be fed virtually individually into the spinning operation. This in turn breaks up and opens up the sliver, hence the term open-end. Automatic piecing by the COROMAT unit: The specially designed sensor enabled COROMAT unit senses the yarn movement at the rotor with the help of a laser and then if it identifies any yarn absence in the way it stops and pieces with the two way suction and piecing technology. The lever opens the housing board, sucks up the yarn from the rotor, closes the housing board cover, takes the end of the cone yarn to the navel and again after sucking the yarn from the rotor pieces both the ends by untwisting and re-twisting as and when required. This operation is done twice per defect, if the piecing turns to be unsuccessful; it has to be manually done by the operator.

 Yarn count of the yarn produced is less than 40 s.

Comber sliver is not used. There is no requirement of spool rotation as in Ring frame. So lessens the yarn breakages and knots in it Larger spools can be made (upto 3.7 kg) Better fiber elongation due to progressive rotors and rollers. Less handling time as it is a shorter process and no winding is required Homogenizes the blends better than the ring frame units with the same preparatory techniques

Yarn Conditioning
A maximum of 570 cones are taken to a cylindrical chamber i.e. CONTEXXOR COMPACT xorella machine in which it is provided with 65 degree celsius temperature with almost 90% vacuum application so that the yarn is conditioned and attains moisture gaining capacity. This process also increases the durability of the yarn.

Yarn Packaging
The packages of yarns are made as per the buyers specification or are generally made in the packages (cones or cheeses) of 1.5kg ,1.89 kg,2.8 kg for Ring spun yarns and packages of 2.5kg,3kg and 3.7 kg packages for open end yarns. The conditioned yarn is then packed in two ways: In carton packing, the cartons were manually packed with transparent tape. Each carton may have 3050 cones or even more depending on the buyers specification. In Pallet packing 250 cones are arranged in a 5*5 manner with 10 layers of the same, one above the other with a supporting layer in between. Then the cones are wounded over by polythene sheet . This kind of packing is mainly done for in house transportation. Then the particular packed carton or other form is labeled with the lot number, gross weight, net weight, number of cones, count of yarn, fiber name and content and buyersuppliers name etc.

WEAVING

WEAVING PREPARATORY
The weaving department forms the core of fabric production in a textile industry. In this department our study concerns about the weaving of terry towels i.e. uncut pile weaving. The weaving department has following sub departments in it: Textile design department Weaving preparatory department Weaving department Grey folding department

TEXTILE DESIGNING DEPARTMENT

The objective of this department is to prepare a pattern for the weaving process to achieve the desired effect and look on the fabric as per the buyers specification.It does the following things.

Weaving Preparatory
As per the design and structure specified the design of the towel is made. According to the design the yarn requirement is calculated with the help of the software tools. The required amount of yarn is sourced and then a warping plan is made and is followed.
FORMATION OF DESIGN WARPING PATTERN PLAN

SIZING

WARPING

Sectional warping machine

TRANSPORTATION OF WEAVERSS BEAM TO THE WEAVING DEAPATRMENT

Process Flow
Winding Yarn from the spinning department

Winding

Beam Warping

Sectional Warping

Sizing

Drawing in (Beam Gaiting)

Knotting

Loom Shed

Inspection

Packing

Dispatch

Direct Warping
There are 4 direct warping machines from: Benninger Ben-direct 2 machine Jupiter - 2 machines The cones are placed on the creels and the ends are passed through two pre stationary rods out of which one is stationary and one is movable. These rods are responsible to give proper tension to the yarns. The yarns are passed through a Zig-Zag yarn guide to the gear-controlled cylindrical beam that continuously rotates and prepares the warping beam.

Ben-Direct warping machine

Zig-Zag guides for proper winding

Sectional Warping
There are 5 sectional warping machines from: Benninger (SuperTronic) 1 machine Sucker Muller (hacoba) - 1 machines Vamatex (Servomatic M 08) 1 machine Prashant Gamatex 1 machine Karlmayer 1 machine The sectional warping has a warpers beam in the form of a composite solid made from a drum and a cone of length 3.4 m. Drum density is 400g/dm3. After the cones are placed on the creels and passed through the pre stationary rods and thread control unit and the end guides, the sectional beam rotates at high speed and the beam automatically moves laterally to get a uniformly wound.

Winding of weavers beam from sectional beam

Reed yarn guide separator

Sizing
Sizing is a process in which the warp yarns are stretched and given a size bath, dried and in the process thousands of warp yarns from a warpers beam are transferred into a weavers beam. Sizing is mainly done to increase the strength of the warp yarns that have to sustain the high tension and regular abrasion during the weaving process. The warp yarns are subjected to a stretch of 1%. Sizes like Terrysize UFC, Sizebond WD, Softsize PB, Sizecare CWS and Sizol TDY are used which contain starch based or synthetic like polyvinyl alcohol or a water-soluble acrylic polymer, depending on the fiber content of warp yarns. They are given a bath of a water base sizing solution with a concentration of 1.7% for 1/13 count to 10% for 1/10 count. The input yarn is subjected to maximum tension of 650 N and the output yarn is subjected to maximum tension of 1250 N.

Line diagram of the sizing machine

WEAVING
After the sizing process of the pile and the ground beams, they are manually transported to the weaving looms. The looms present in the weaving department are Airjet looms and Rapier looms. There are a total of 151 looms that were in production out of which 58 are Rapier looms and 93 are Airjet looms.These looms have either Dobby attachment or Jacquard attachment. Out of these 151 looms, 62 have Jacquard and 89 have Dobby. According to the orders coming to the unit, looms are allotted for specific towel weaving.

The weaving unit

Weaving Process
Based on the production plan and the textile design plan, the beams of the pile & ground are gaited on to the loom as specified in the loom plan. Each of the ground and the pile beams carry yarns of length nearly 3000 and 9000 meters respectively. The weft yarns are arranged on the weft feeder/dispenser based on the color pattern. The weft yarns are usually supplied from cones. The design through floppy/ programmer is set on the looms. The loom process control parameters for the functioning of the beams are set, like the reed, the pick, the terry motion, let off, take up etc & weaving starts. It must be noted that for the formation of the pile loops, the speed of the pile beam (let off) is more than the speed of the ground beam. As such the ratio of yarn consumption of ground beam to pile beam is 1:5. Once the cloth roller for winding of the towel is full which can take upto 1200 kg of grey fabric roll, the roll is doffed & sent to the Grey folding area. Before sending to the Grey folding area, relevant production entries are made in the system.

Weaving Mechanism
DRAWING IN Here 16 heald dobby attachments are used for terry towel designing. The pile threads are drawn on four healds, & the ground threads (if the loop formation is to be continuous) on eight healds for a 2 ground-2 pile order of arrangement. 2 healds are used for leno and 2 are used for selvedge. DROP PIN MECHANISM There are drop pins for every single yarn. Yarn is passed through the whole provided in the drop pin. SHEDDING Shedding is the process of division of warp sheet in two layers to create space for insertion of weft yarn.

PICKING Picking is said to be passing of weft yarn through the shed opening.

Picking & creel stand

BEATING UP The weft thread that has been inserted across the warp thread in a shed is pushed upon the fell of the cloth. Fell of the cloth is the position of the last pick in the cloth woven on the loom.
LET OFF It allows the warp yarns to move in forward direction by unwinding weavers beam maintaining a predetermined warp tension. TAKE UP A motor is provided which winds the fabric produced in the loom. WEAVE CONSTRUCTION The Turkish toweling structures form a class of warp pile-termed terry pile in which certain warp threads form loops or curls on the face of the cloth. Only one kind of weft may be used, but 2 series of warp threads, placed on separate beams, are necessary for the production of the cloth- viz. ground threads & pile threads.

Terry Towel weaves construction: red lines represent the pile threads and blue lines represent the ground threads.

TRANSPORT VEHICLES

Warp beam trolley

Pile beam trolley

Doff beam trolley

GREY FOLDING

GREY FOLDING
After the required fabric is woven by the weaving department, each doff is then sent to the next department known as the Grey Folding It is the store house of the grey fabric. It can store about 8000 tons of grey fabric at a time. Inspects the grey fabric for weaving defects and to generate quality reports of the fabric inspected. It also prepares the fabric for delivery to the processing department as per the present requirement or demand. It stores the grey goods in the roll form, until they are issued to the processing. It also mends all the repairable defects prior to rolling & storage. Before sending into the Grey Folding Department, a computer data entry of the details of the fabric doff is made for the Weaving & Grey Folding Department and the data card of the same is fixed on to the doff roll for easy identification. The details entered are: Order no. Sort no / design no. Length of the fabric roll Weight of the roll Total no. Of pieces produced per size.
Grey fabric store

Grey Fabric Inspection Machine

The 100% grey fabric inspection is done in the woven fabric inspection machine with the following features: Inspection table is laminated with adequate number of tube-lights provided beneath and above the glass with variable lighting arrangement. Push button controls are given on the drive box on the right hand side. Cloth can run in FORWARD as well as in REVERSE direction instantaneously. Fabric runs face in/face out Special jogging or inching device is provided to stop the machine at the right location of the defect. Soft start and instantaneous stoppage of fabric.

Automatic stop arrangement to stop the machine at the end of the fabric piece.
Bow bar has been provided in the batching device to open out the creases in the fabric. Perfect tension during the flow of the fabric is provided using guide roll assembly, thus no hassles of nip rolls. Meter Counter is installed in front on platform top for easy reading.

PROCESSING

PROCESSING
Objectives of Processing: To remove the impurities. To increase the lustre and appearance of the fabric. To make the fabric attractive and sellable. To improve the softness and water absorbency of the fabric. To color the fabric of different shade.

Material Flow of Processing

Grey yarn/ Fabric

Dyeing Machine

Hydroextractor

Inspection

Dryer

Rope Opener

Yarn Dyeing
Process: The yarn is loaded in the ECO-BLOCK machine and the program is set that consists of all the steps of scouring, bleaching, dyeing ,soaping and fixing. After the material has been loaded firstly scouring chemical is used i.e. EM clean cp and HTC chemical. The temperature is raised to 80C and is run for 10 minutes. EM clean cp, soda miratol WA and caustic is put and runned for 20 minute at 80 degree C then hydrogen peroxide is added. Temp is raised to 100 degree C and held for 30 minutes . Then the bath is drained , then hexa phosphate is added at 90 degree and run for 10 minutes. In dyeing process first salt and saracol-s is added at 60 degree. Then color solution is added by dosing to avoid more strike of color generally dosing time is 20-30 minute. Then add soda at 60 degree and run for 15 minute then add caustic and run for 15 minute the and run for drain the bath. And give a cold wash to the dyed fabric. Then raise the temp to 60 degree and add acid for neutralization. Run time for acid is 10 minute. Then drain the bath and add miratol that is a soaping agent and raise temp. To 95 degree and run for 10 minute. Then give a hot wash at 80 degree for 10 minute. Then take out material and cut sample and match with standard depth. Then go for softening at temp. 60 degree for ten minute. For heavy shade we do use a fixer before softening at 60 degree for 20 minute. Drain the bath and give a cold wash and unload the material.

Yarn Dyeing Machines

M/c name SAMPLE M/C ECOBLOCK-1 ECOBLOCK-2 ECOBLOCK-3 ECOBLOCK-4 ECOBLOCK-5 ECOBLOCK-6 ECOBLOCK-7 ECOBLOCK-8

Make
Fongs Thies Thies Thies Thies Thies Thies Thies Dalal engg. Pvt.Ltd Dalal engg. Pvt.Ltd Thies Thies

No.of chamber 8 1 1 1 1 1 1 1 1

Addition tank 1 1 1 1 1 1 1 1 1

Pump speed 100 rpm 1440 rpm 1440 rpm 1440 rpm 1440 rpm 1440 rpm 1440 rpm 1440 rpm 1440 rpm

Material capacity 16 kg 146 kg 270 kg 270 kg 270 kg 660 kg 1120 kg 1120 kg 56 kg

Liquor capacity 60 lit. 750 lit. 1500 lit. 1500 lit. 1500 lit. 3000 lit. 6000 lit. 6000 lit. 280 lit.

ECOBLOCK-9
ECOBLOCK-14 ECOBLOCK-15

1
1 1

1
1 1

1440 rpm
1440 rpm 1440 rpm

105 kg
292 kg 292 kg

525 lit.
1500 lit. 1500 lit.

Yarn Dryers
M/c name Yarn Drier-1 Yarn Drier-2 Manufacturer Thies Thies Capacity 300 1236 Tempt. 120C 120C

Yarn Drier-3

Thies

1236

120C

Fabric Dyeing
Process: First take the material and load it in the eco soft machine. Main objective of scouring is to remove the PVA and chemical used is EM clean CP. After this treatment bleaching chemical is added, which includes miratol WA, Tinochloride GI for the bleaching temp. Required temperature is100 degree and treatment time is 10 minutes. Then hydrogen peroxide is added at 100 degree and run for 30 min. Then hot wash is given at 80 degree for 10 minute. After hot wash addition of CAT is done but temp. must be cool down to 55 degree first and then run for 15 minute .CAT is a peroxide killer & needed for good results. In dyeing process first add salt and saracol-s at 60 degree. Then add color solution by dosing to avoid more strike of color generally dosing time is 20-30 minute. Then add soda at 60 degree and run for 15 minute then add caustic and run for 15 minute the and run for drain the bath. And give a cold wash to the dyed fabric. Then raise the temp to 60 degree and add acid for neutralization. Run time for acid is 10 minute. Then drain the bath and add miratol that is a soaping agent and raise temp. To 95 degree and run for 10 minute. Then after ward give a hot wash at 80 degree for 10 minute. Then take out material and cut sample and match with standard depth. Then go for softening at temp. 60 degree for ten minute. For heavy shade we do use a fixer before softening at 60 degree for 20 minute. Drain the bath and give a cold wash and unload the material.

Fabric Dyeing Process

Load Batch Desizing

Bleaching

Neutralization

Check pH, Hardness of H2O & Residual H2O2

Sequestering Agent

Check pH

Dyeing starts

Cold Wash

Acid Wash

Soaping

Softening

Draining

Unload

Processing Laboratory (Testing)

The main function of processing laboratory is to test each and every detail of the lot as per the company requirement including fastness properties and the quality of fabric in terms of strength, feel & handling . All the activities which are performed in the lab on small samples are performed in bulk manner in the processing department. All the calibrations are carried out in the lab. Testing: The objectives of testing are : Shade development Quality Parameter Checking of the in-house material Quality Parameter checking of dyes and chemicals List of machines in lab: Spectrophotometer Dispenser Solution maker IR beaker dyeing machine (Ahiba Nuanace) Light fastness tester Light box Perspiration tester Rota meter (paramount)

Open beaker dyg. Machine Laundrometer Electronic pipette Surface water absorbing testing machine machine Digiflame digital fire retardency tester

FINISH FOLDING

FINISH AND FOLDING UNIT

Finish Folding is one of the most crucial units in terms of productivity. It serves as a final stage of terry towel manufacturing as the towel passing out of this department will bear its final look and appearance that is one of the most important criteria from a buyers point of view . After processing the towels are brought in this unit where each towel is separated from the fabric roll and stitched and packed as per the buyers specification and dispatched. For making bath robes the whole fabric rolls are brought to the bath robe making unit where the fabric is laid according to the marker plan , cut and sew.

The process of the finish-folding department is as follows:

Length Slitting

Checking

AQL

Length Hemming

Cross Hemming

Packaging .Polybag .Carton

Cross Cutting

Embroidery

Dispatch

Length Hemming alteration

Cross Cutting

Length Slitting
The main objectives of length slitting are lengthwise slitting of the fabric into individual pieces and correct slitting of fabric using sensors. Processed fabric is fed from the trolleys that are brought from the processing unit. Rollers are provided to feed the fabric on the cutter. Knives are activated according to the number of parts that have to be taken out from the fabric.
Number of machines Speed (current) Speed (maximum) Efficiency Production per hour (current) Production per hour (maximum) Production per day (current) Production per day (maximum) 3 25 m/min 35 m/min 70% 1470 meters 2100 meters 35280 meters 50400 meters

Technical Details of Length Slitting Machine

Length Slitting Machine

Length Hemming
The main objectives of length hemming are lengthwise hemming of the fabric into individual pieces and correct stitching of fabric using sensors. The fabric is fed lengthwise and the stitching is done on both of its edges in the lengthwise direction. These machines are off Schmale Durate with Pegasus chain stitch swing machine attachment. There a total off 8 length hemming machine performing single needle stitch and 3machines performing double needle chain stitch. The main reason for the usage of chain stitch is that there need not to be any bobbin change after fixed intervals and also,fewer chances of thread breakages. Number of machines 11
Speed (current) Speed (maximum)
Stitches Per Inch Type of stitch Efficiency Production per hour (current) Production per hour (maximum)

15 m/min 20 m/min 9-11 Chain Stitch 70% 840 meters 1200 meters

Production per day (current) Production per day (maximum)

35280 meters 50400 meters

Length Stitching Machine

Technical Details of Length Hemming Machine

Cross Cutting and Hemming

After the length hemming is done the trolleys are sent to the cross cutting and hemming section. There are 10 cross cutting machine and 105 cross hemming machine. Cross hemming machine are single needle lockstitch machine Hem folding and stitching and label attachments are done manually piece by piece.

AQL (Acceptable Quality Level)

100% checking is done manually at this stage to grade the product into different qualities according to the type of defect. Towels are checked for defects as they come out of the cross hemming machines. The defected pieces are graded according to acceptable quality standard. Pieces are forwarded only if they match the standard. A grade - no defects B grade - defects exist but buyer cannot identify. C grade - visible defects, the pieces are sold as downgrades. D grade if the pieces are not sellable because of some major defect. After AQL process the lot of towels is send for packaging.

Bath robe Section

Process Flow For Bathrobe Making
Sleeves and Pocket
Overlock

Top Stitch On Sleeves

Sides Overlock

Inspection and Packaging

Sleeves Hemming

Sleeves attachment

Placket Attachment

Top Stitch On Belt

Pocket hemming

Top Stitch On Shoulders

Label and sleeves seam

Belt Formation

Pocket Join Pocket Overlock (3 sides)

Shoulder Attachment

Top Stitch On Placket

Bottom Hemming Bottom Overlock

Pocket attachment

Loop Making

Specifications
Spreading done manually. Total ply height is 7 inches. No. of lays in a spread = 40 GSM of fabric = 420 If GSM 360 or lays no. of plies = > 70 Production per 12 hours = 550 pieces

At the time of observation: 4 way marker SM size 420 gsm Time taken in laying 0.5 hour Length of ply = 586 cm Width of ply = 232 cm White colour fabric No. of plies = 40

Stitching Defects
The following defects are encountered with during the cut and sew process.
Alter CORNER IN CORNER OUT CORNER OPEN CORNER IMPROPER LOOSE STITCH JUMP STITCH WAVY STITCH DOWN STITCH DOUBLE STITCH UNCUT THREAD LOOSE THREAD RAW EDGE PIPING ROPING PUCKERING SPI JOINT MIS MATCH WRONG THREAD USED FABRIC FACE/BACK Mending NEEDLE MARK P. FOOT MARK SMALL HOLE CONTAMINATION SMAL L SLUBS Stain OIL STAIN SOIL STAIN RUST STAIN INK MARK Reject BIG HOLE BIG SLUB SHADE VARIATION DYE STAIN BOWING MENDING MARK PATCHY DYEING WHITE SPOT DOUBLE PICK MISSING PICK DOUBLE END DRAWING MISTAKE DAMAGE FABRIC REVERSE FABRIC MISSING END BAD DAMAGE SELVEDGE SPOT STITCH MARK MAJOR CONTAMINATION

PLEATS ELASTIC PROBLEM GATHERING OVERLOCK PROBLEM

Packaging
Packaging of terry towels is done as per the buyers requirement. Each buyer has their own specific way of folding the towels and size of the carton in which the goods are to be shipped. The packaging is usually done manually. There are four ways of packing the towel. They are: Solid color solid size This type of packaging contains same colored and same sized towels packed in one carton. Solid color assorted size This type of packaging contains same colored but different sized towels i.e. one piece each of wash, hand, bath, and bath sheet in one carton. Assorted color solid size This type of packaging contains different colored but same sized towels to be packed on one carton. Assorted color assorted size This type of packaging contains different colored towels of different sizes to be packed in one carton. The towels according to the desired category are first packed in poly bags. Poly bags are provided with air holes to allow air-flow. The cartons used for packing are manufactured by local vendors and have handling instructions printed on them.

A carton can usually contain from 6 to 24 towels poly bags and 12 to 60 in case of hand and wash towels as per the buyers requirement. Here once again checking is done. This time the checking is done randomly where 20 to 25 pieces of towels is picked from a group of 100 pieces. If more than two to three pieces are found defective then the entire lot is rejected. This checking process is termed here as FSA or Final statistical audits. It usually takes place after packaging.
Once the lot is approved for shipment they are loaded in trucks for the delivery. An average big container has the capacity of 64 cubic meters that is for example if we take bath towels of the standard size, then 800 cartoons of bath towels and each cartoon containing 12 towels weighing approximate 4 tons can be stored comfortably in one container. Containers are usually of 20 & 40 feet. Everyday there is a shipment of almost 55 60 tons of terry towels. They have 120 employees working per shift.

Cartons ready for shipment

EFFLUENT TREATMENT PLANT

The effluent treatment is designed in such a way to get the maximum out of the available water resources and discharge minimum to the environment creating maximum utilization and minimum impact on the environment. All the liquid waste is treated so that it doesnt harm the environment. The working of the plant is as follows:
Water reaches to the collection tank through under ground drainage system. Addition of alum and decolorizing agent Tertiary purieier. Settlement of sludge and most solutes.

Water goes to the Sreen chamber for the removal of big solid wastes by eiltration to decrease the BOD & COD. Water reaches the homogenizing tank for equalizing temperature, color , pH solid percentage, BOD & COD Water reaches a neutralizing tank where the PH is made normal to 7.5 by adding recycled H2SO4.

Secondary purifeier for sludge settlement

20% of treated water discharged in open agricultural lands & 80% discharged to the water bodies through drainage.

Water is bubbled with atmospheric air @ 800m3/hr for two days.Here bacteria takes oxygen and consumes upto 60 % of dyes in water and decreaes the BOD & COD

The sludge is dumped into the hazardous waste maneill

Water reaches the distribution tank which adds bacteria contained sludge to the water to decrease the BOD and distributes the water to the oxidation tank.

Working of the Effluent treatment plant at WIL, VAPI

TOTAL QUALITY MANAGEMENT

TOTAL QUALITY MANAGEMENT

The total quality management department is responsible for all kinds of quality parameters running in the industry. Although the major objective of this department is to maintain customer satisfying quality level in

Quality of raw materials used Quality of infrastructure and machinery used for production Quality of the finished goods Quality of the working area Quality of human capital and management
The objectives of the TQM department are: To sustain the quality of the goods To satisfy the customer by sustaining the quality parameters crucial to customer and crucial to quality. To develop a system so that factors critical to quality and critical to customer are sustained under all circumstances To ensure that the quality providers also get the quality working environment and are paid accordingly. Working deeply on the factors Crucial to Customer and Crucial to Quality that are considered as the core of the departmental values.

The techniques adapted by the department to meet the objectives are:

Online Quality Inspection: The quality checking happens generally at the entry and the exit level of a particular process. If the quality of the intermediate stages or the condition of the machine or the quality of the materials used is also checked while the process is going on, it is called online checking. Offline Quality Inspection: The checking of the input and output of each process every time is not possible under offline inspection, as there is 100% checking in the offline inspection to eliminate any chance of loophole in quality maintenance. Quality Checking: Randomly selecting the samples and checking them for standards follow up this technique. There is an AQL i.e. acceptance quality level for each and every parameter which varies from buyer to buyer and even the manufacturing company has its own norms. Generally, AQL 2.5, Level 2 is maintained. The final inspection is also done randomly and the evaluation of what has been found as results in those checks are called FSA i.e. final statistical audit that is actually a report of the quality parameters.

RUGS

RUGS DIVISION
Rugs is a general term embracing many coarse woven or plaited fibrous materials used for covering floors or furniture, for hanging as screens, for wrapping up heavy merchandise and for other miscellaneous purposes. Rugs are made both through Power loom & Handloom. Rugs are being widely used in USA and European countries, due to its soft nature. Rugs in this plant is being manufactured by the process of tufting. Tufting is a type of textile weaving in which a thread is inserted on a primary base After the knitting is done, short U-shaped loops of extra yarn are introduced through the fabric from the outside so that their ends point inwards. Production of rugs consists of following processes: 1. Tufting 2. Latex Coating 3. Processing 4. Inspection By TQM 5. Finishing & Packaging

RUGS DIVISION

Rugs Production

Rugs Dyeing

Grey Folding And Raw Material

Tufting Coating and Latex Heat setting and Cabling Cut and Sew Packaging

TUFTING
Tufting is the process of creating textiles, especially carpet, on specialized multineedle sewing machines. Several hundred needles stitch hundreds of rows of pile yarn tufts through a backing fabric called the primary backing. The needles push yarn through a primary backing fabric, where a loop holds the yarn in place to form a tuft as the needle is removed. The yarn is caught by loopers and held in place for loop-pile carpet or cut by blades for cut-pile carpet. Next, secondary backings of various types are applied to render a variety of performance properties. Here are some key steps in the tufting process: Yarn comes from cones on creel racks (or from big spools called beams) into the machine.The primary backing feeds into the machine. Yarn and primary backing come together in the machine (full shot of machine Yarn is fed through needles on a needlebar of a tufting machine. Needles repeatedly penetrate or tuft into the primary backing. The tufted carpet is mended and inspected. Carpet is rolled onto large rolls for the next step (whether its to be dyed or to be backed.)

Tufting in this plant takes place in two ways: 1. Machine tufting 2. Table tufting

Tufting

CUT AND SEW: After the latex coating is done the it is sent for cut and sew. There the roll is spread on the spreading table transferred to the cutting table through air floatation table and cutting is done by automatic Gerber cutting machine. A maximum of 10 plies of spreading is done for the machine tufted roll and 45 plies of canvass roll spreading is done. After the cutting is done as per required design the pieces sent foe edge finishing. It includes either piping the edges or overlocking it as per requirement of the buyer. DYEING: Dyeing is the process of coloring materials by impregnating fiber, yarn or fabric with with dyestuff. Coloration in rugs can be achieved at two possible times in the manufacturing process either by dyeing the fiber or yarn before the fabric is tufted or by tufted or by dyeing the tufted fabric before the application of the secondary backing and backing and the finishing process. Yarn dyed rugs are only washed and dried for finishing whereas grey rugs undergoes undergoes dyeing followed by washing and drying. FINISHING AND PACKAGING : After drying the rugs, finishing is done like trimming of the threads, mending etc. they they are further inspected by the TQM and after their clearance they are ready for dispatch. Inspection is also done at packaging stage.

PROJECT

BEAM FAULTS
S.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 LOOM NO. 62 68 72 52 50 56 59 134 132 112 115 170 75 78 77 80 85 86 165 160 193 178 180 GROUND/PILE P G G P G G G P G P G P P G P G P G P P G,P G P NO. OF CONES 1 1 5 2 1 6 3 1 2 1 2 1 5 1 2 2 1 1 4 1 1,1 1 1 BEAM NO. WP20 WG27 BG21 BP8 BG12 BG35 WG61 KP76 KG29 AP7 HG32 SP3 TP13 TG16 TP3 TG16 TP23 TG29 KP97 KP66 NG51,KP13 NG56 KP28 COUNT 13 KC 2/20 KC 2/20 KC 2/20 KC 2/20 KC 2/20 KC 2/24 KC 11 HYGRO 10 OE 2/20 RC 10 0E 2/24 KH PIMA 2/20 RC 10 OF 2/2O RC 2/24 KC 13 KC 2/20 KC 2/20 RC/SHE 11 HYGRO 10 OE,16 KC 10 OE 11 HYGRO REASON CUT END CUT END CUT END,WEAK ENDS CUT END CUT END CUT END,WEAK ENDS CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END CUT END

DATE: 11.06.2013
SIZING MACHINE B/N-1 JUPITER JUPITER JUPITER JUPITER JUPITER JUPITER B/N-2 S/M B/N-2 S/M B/N-2 B/N-1 S/M B/N-2 JUPITER B/N-2 JUPITER B/N-2 B/N-2 S/M,B/N-1 S/M B/N-2

DATE: 12.06.2013
S.NO LOOM NO. GROUND/PILE NO. OF CONES BEAM NO. COUNT REASON SIZING MACHINE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

68 70 72 69 54 44 41 144 142 112 122 118 128 75 93 170 166

G G G P P G P G G G P G G P P P P

1 1 4 1 2 2 1 1 1 1 2 1 1 1 1 2 4

WG48 SG8 BG21 BP30 BP3 WG37 WP67 KG7 KG9 KG31` SP17 WG22 KG26 TP13 TP30 NG66 KP55

10 OE 10 OE 2/20 KC 2/20 RC 2/25.3 RC(S-6+60PVA) 2/20 KC 2/25.3 RC(S-6+60PVA) 1O OE 2/20 KC 2/20 KC 2/24 KC 2/20 RC 2/24 KC 2/20 RC 2/24 RH PIMA 10 OE 16 KC

CUT ENDS CUT ENDS WEAK ENDS CUT ENDS WEAK ENDS CUT ENDS WEAK ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS YARN ENTANGLED INSIDE OTHERS YARN AT FLANGE CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS B/N-2

S/M S/M JUPITER B/N-2 B/N-2 JUPITER B/N-2 S/M JUPITER JUPITER S/M S/M JUPITER B/N-1 B/N-2 S/M B/N-1

18 19 20 21 22 23 24

159 156 154 192 187 183 177

P P G G P P P

1 4 1 2 1 1 EXTRAENDS -22

KP60 KP53 NG3 NG8 KP85 KP89 KP84

2/20 RC 16 KC 2/24 KC 10 OE 2/24 KC 2/24 RH PIMA 16 KC

B/N-2 B/N-2 JUPITER S/M B/N-2

B/N-2

DATE: 13.06.2013
S.NO 1 2 3 4 5 6 7 8 9 LOOM NO. 52 56 60 59 57 32 150 144 138 GROUND/PILE P G,P G G G G G G G NO. OF CONES 1 3,2 2 3 1 1 1 1 1 BEAM NO. BP33 BG37,BP17 BG28 W646 WG4 WG11 KG5 KG7 KG14 COUNT 2/20 RC 2/20 KC,2/20 RC 2/20 KC 10 OE 10 OE 2/20 KC 10 OE 10 OE 2/20 KC REASON CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS SIZING MACHINE B/N-1 JUPITER,B/N-2 JUPITER S/M S/M JUPITER JUPITER S/M S/M

10
11 12 13 14 15 16 17 18

126
120 118 76 78 97 93 173 160

G,P
P G G G P G G G

1,1
3 1 1 1 1 1 4 1

SG3,SP21`
SP13 SG25 TG10 TG16 TG26 TG31 NG6 NG9

2/20 KC,2/20 RC
2/24 RH PIMA 2/24 RH PIMA 10 OE 10 OE 2/24 RC 2/24 KC 10 OE 10 OE

CUT ENDS
CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS CUT ENDS,WEAK ENDS CUT ENDS

JUPITER
JUPITER,B/N-2 B/N-2 B/N-2 S/M S/M S/M JUPITER S/M

19 20

187 178

G P

1 1

NG26 KP15

2/20 KC 16 KC

CUT ENDS CUT ENDS

JUPITER B/N-1

Beam Type more prone

44% GROUND Pile 56%

Yarn count more prone

6% 3%

1%

3%

7% 1% 2% 2%

23%

13 KC 2/20 KC 2/24 KC 11 HYGRO 10 0E 2/24 KH PIMA 10 OF 2/20 RC/SHE 16 KC 10% 2/25.3 RC(S-6+60PVA) 2/24 RH PIMA

25%

2/24 RC 4%

13%

Sizing machine more prone

10%

29%

B/N-1 JUPITER 31% B/N-2 S/M

30%

Beam faults Cut ends Extra ends Crossings Over dried ends Over sized ends Sizing patch Count mix Sticky ends Migration or entanglement of one layer into other Conclusion Ground beam is more prone in beam faults. Generally ground beams having yarn count 2/20 kc or 10 oeare greatly included in beam faults. Beams made on sizing machines jupiter and sucker muller are more in numbers which have cutends(beam fault). Effect of beam faults Because of cutends we have to use cone /cheese in place of that missed end in the further cause below given problems. 1. Tension variation in the specific ends in the warp sheet. 2. Threading time is more which further lowers down the m/c efficiency. 3. Fabric faults like Variable loop height leads to uneven appearance

Remedies Look into the yarn quality given by spinning department to the weaving preparatory department Tenacity Yarn regularity Package faults Maintain the proper creel tension level in the warping and sizing for different yarn count. Reduce the peak tension level for the yarn count(10 oe,2/20 kc) in the warp sheet on the jupiter and sucker muller sizing machine. Optimise the speed for different yarn counts like low fpe single yarn and more for ply yarn. Proper working of stop motion on warping m/c. Proper temperature maintain in the time zone in sizing m/c. Worker should be more attentive towards warps breakages in sizing m/c. There should no short length of the warp sheet. Maintenance should be properly and regularly checked and maintained and there for the weaving preparatory machines. There should be proper preparation of sizing paste in term of their concentration of sizing material and its cooking time. Seepage of water on warp sheet from the roof should not be there. Operator should be aware about beam faults,its causes and there remedies so that he/she would take corrective action as per his knowledge and experience.

THANK YOU!

BIBLIOGRAPHY
http://www.osthoff-senge.com/en/produkte.html http://www.thiess.com.au/smart-solutions http://schlafhorst.saurer.com/en/products/winding/bobbin-processing/

http://www.noiseandhealth.org/article.asp?issn=14631741;year=2011;volume=13;issue=54;spage=348;epage=355;aulast=Dube
http://welspunindia.com/content.asp?Submenu=Y&MenuID=1&SubmenuID=1 http://www.rieter.com/en/spun-yarn-systems/about-spun-yarn-systems/ http://www.welspun.com/content.asp?Submenu=Y&MenuID=1&SubmenuID=14 http://www.fibre2fashion.com/industry-article/3/297/safety-and-health-issues-in-thetextile-industry2.asp