THE WORKING PROCESS OF MACHINERIES OF A TEXTILE PROCESSING DIVISION FOR FINISHING FABRIC

University Institute Of Engineering And Technology, Panjab University, Sector 14, Chandigarh

Submitted By: Manish Parmar

ACKNOWLEDGEMENT Gratitude is hardest of emotions to express and often dose not find adequate words to convey all that we feel. I owe gratitude to several people who helped me in my course of project. If I were to sit down to map out all the contributors who have given time and shared their views to make this project possible, it would be an impossible task. First of all I would like to thank the Almighty God for making me an instrument to prepare this report. I dont have any word to express my gratitude towards Mr. P.K. BHATT (DGM, P&A). He in true words is the guiding light behind the working of division, his indispensable cooperation, and advice and for granting me permission to do my training in RSWM Ltd. Banswara. I express my heart felt thanks to my project guide Mr. R.N. Nirmal (HOD Engg.) .Special thanks are due to Er. B.P. Singh & Er. Pankaj Gupta for providing me with detailed guidelines of Machinery despite of their hectic schedule. I also thank all the employees of HR Deptt. specially Mr. H.S. Shaktawat. Finally, yet importantly I would like to give my special thanks to Mr.SOURABH JAIN and all other employees of RSWM. Without the support of all these, this project would not have been a success. This is not just a report that I carry with. But it gives my personality some new dimensions and a better outlook of corporate world with a diverse vision, a new horizon to plan my future. It gives me a boost to think big and aim for the best..

MANISH PARMAR

COMPANY PROFILE

INTRODUCTION OF THE COMPANY

Name of the concern Locations: Regd. Office Corporate Office

RSWM LTD Kharigram, P.O. Gulabpura-311021, Bhilwara, Rajasthan. Distt.

Bhilwara Towers,A-12, sector-1, Noida-201301 (U.P.) Kharigram, P.O. Gulabpura-301021, Distt. Bhilwara, Rajasthan. Lodha, P.O. Banswara-327001, Rajasthan. Mordi, Banswara-327001, Rajasthan. Mandpam, Bhilwara-311001, Rajasthan. Rishabhdev-33802, Disstt. Udaipur, Rajasthan. Ringas, Distt. Sikar, Rajasthan. Bidadi, Banglore, Karnataka.

Works

Constitution

Public Limited Company

Date of Incorporation

17/10/1960

Lines of Manufacture

Manufacturing of synthetic, blended, grey/dyed yarn, cotton mlange yarn, and cotton blended yarn and fabric under the brand Mayur. Now also entered into Garment Business.

RSWM LTD, the flagship Company of the LNJ Bhilwara Group. RSWM Ltd is primarily engaged in the manufacture of synthetic, blended, mlange and specialty yarns and fabrics.

RSWMLtd is a premier company of the Group, with a turnover of Rs.775 crore (US$ 177 million). RSWMLtd is exporting a complete range of yarn and fabric to over 60 countries worldwide, giving RSWMLtd a markedly visible presence across the textile world.

The manufacturing capacity of the Company is upwards of 81,000 MT of Yarn per annum from its five units - Gulabpura, Banswara, Mandpam, Rishabhdev and Ringas located in Rajasthan. RSWMLtd also manufactures 12 million meters of fabric per annum at its Gulabpura unit.

All the plants are equipped with state-of-the-art machines and Captive Power Generation facilities. RSWMLtd is the first composite textile mill in India to be accorded the ISO Certification. The Company also enjoys a prestigious Three Star Export House status and, over the years, has received several Export Awards from SRTEPC. The companys leadership in the textile industry is exemplified in the equity that their brands enjoy in the Indian market - place - Mayur Suitings .

To enhance its operating capacity, RSWMLtd has acquired Jaipur Polyspin Ltd. for manufacturing of Synthetic Blended Yarn. RSWMLtd has also acquired a state-ofthe-art process house at Mordi, Banswara Rajasthan.

Global Presence RSWMLtd exports a complete range of yarn and fabric to over 60 countries across Europe, South Africa, Australia, Korea, Belgium, Singapore, Italy, Egypt and the Gulf countries. With nearly 30% of RSWM's production exported, the Company has a significant presence in the world of textiles. RSWMLtd has also been recognized as a Golden Trading House by the Government of India having won the prestigious SRTEPC Export Award for several consecutive years. This makes the Company truly global, yet truly Indian. RSWM'Ltds Gulabpura unit has the distinction of being India's first composite textile mill to be accorded the coveted ISO 9002 and IS/ISO 9001:2000 certifications. ISO-certified Quality circles function across all units. Total Quality Management (TQM) has been implemented at the Banswara unit. The Group has a highly specialized Yarn Development Center, pilot plants and a Design & Development Studio for Fabric at Gulabpura,

A Promise to our Heritage The 60s. A decade of tumultuous change, hope and promise saw John F. Kennedy take over as the President of the United States; the civil rights struggle; Woodstock and Neil Armstrong on the moon. The same decade saw the seeds of enterprise sown in the desert sands of Rajasthan, in 1961. Starting a small textile unit with 12,500 spindles - manufacturing Carded Cotton Hosiery Yarn, RSWM added another 13,000 spindles for Synthetic Yarn. This made RSWM the pioneer of Viscose and Polyester spinning on the modified Cotton System and Dyed Synthetic Fiber. This began the spinning of a superlative success story. Today, the Company has installed over 2,42,000 spindles and over to weaving machines, with a product range that includes Polyester / Viscose Yarn and Fabric, Flame

Retardant Fabric, Specialty Tencel and Lycra Blends. RSWM has also built Mayur Suitings into one of India's top textile brands.

A Promise to Deliver For us, it is not enough to manufacture the finest Blended Yarn, Cotton Mlange Yarn and Synthetic Yarn and Fabric. The real goal is to ensure that the finished Yarn and Fabric reach our customers on time, every time. Over the years, we have evolved proven procedures. Our Centralized Production Planning Cell (CPPC) has an experienced team of time conscious production planners. All plants are computerized, which is a key tool towards productivity enhancement, information dissemination and development. VPN links connect all plants and offices with all shipment points continuously tracking shipping movements, ensuring timely delivery. ERP systems have been implemented across the board. The use of Palletized cartons are a standard practice, with direct delivery on containers, proving that we mean business, and giving us the means to deliver.

A Promise to Care We are an equal opportunity employer, making no distinctions between genders, religions, castes or ethnic origins. Our work force is representative of India's multicultural identity and rich and diverse social fabric. Our staff's welfare is not about corporate ethics but enlightened self-interest. For us they are an investment in building our business. Fostering a healthy work-culture helps us retain our competitive edge. Workers in all our plants enjoy a host of facilities and benefits... housing, Medicare, co-operative stores, banking, loans, children's education, sports and recreation. We are committed to the enhancement of the professional skills of our workers and managers. We organize training workshops regularly and send our Engineers and other key personnel abroad to keep abreast of global trends in technology, product mix and design. Continuous training has seen RSWM emerge as the cradle of leadership

within the group. Most of the CEOs of the group companies began their careers here as trainees. The other focus area is the development of in-house capabilities in maintenance and servicing. This helps ensure low downtime. To facilitate this, our engineering talents are deputed to our machinery suppliers' plants to master maintenance and servicing issues.

A Promise to the Earth In a culture, where the earth is referred to as Mother, caring for the environment is ingrained. In caring for the earth we are committed to leaving our children and the generations to come a clean, green earth. A promise that we live by and live up to in everything we do. At every step in the manufacturing process, we employ eco-friendly processes not just to abide by laws but also to sustain and take forward the 'green' traditions that form a rich part of our heritage. Effluent treatment is carried out using the latest state-of-the-art technology. All the water used in fabric dyeing and finishing is recycled for use in the process-house and in horticulture. We are continuously greening all our plants, residential and other facilities, planting thousands of saplings every year. Our environmental care is executed with an eye for detail. The Banswara unit has over 42,000 square meters of greens, with over 50,000 plants having been planted on the campus and an exquisite 11-acre orchard surrounding an artificial lake. The Banswara unit was accorded the best plantation award in Rajasthan. So while we 'do' yarns and textiles, we 'think' environment.

A Promise to Perform When we make a promise, we back it with all that we have - resources, infrastructure, technology and will power. In the final analysis, what counts is the way an organization raises up to any challenge and its performance.

State-of-the-art manufacturing facilities at Gulabpura, Banswara, Rishabhdev and Mandpam in Rajasthan are backed by modern testing equipment and stringent quality checks on process parameters and quality. All units and offices have implemented Enterprise Resource Planning (ERP) Management Systems ensuring timely delivery schedules. All these plants have captive in-house power generation, avoiding production downtime due to power-cuts. These facilities are totally self-sufficient in power. RSWM, Banswara, is the first textile unit in India to implement Total Quality Management (TQM) in 1997. This was made possible by empowering the team at the unit to work seamlessly together, forming one cohesive entity, driven by a single goal... that of ensuring and maintaining the highest quality, resulting in brilliant overall performance.

A Promise to be One RSWM LTD 's integrated units are spread across the state of Rajasthan, each handling specialized processes, from raw fiber handling to final product delivery, on time every time. Each process smoothly collaborates with the next, ensuring a legacy of supreme quality.

Every Team Member is highly trained in all the latest trends and technologies. Together they drive themselves to work efficiently around the clock.

THE LNJ BHILWARA GROUP

The LNJ Bhilwara Group, founded in 1961, has today grown into a strong global presence worth Rs. 2049 crores. The Group has been nurtured into a successful growth track by the able guidance of the Founder and Chairman-Emeritus, Mr. L. N. Jhunjhunwala. Currently, the LNJ Bhilwara Group stands as one of the largest firms on the corporate horizon in India with over 20,000 employees and 21 production units positioned at strategic locations across the country. The Groups export earnings comprise of 46% of the Groups turnover.

RSWM(parent company of LNJ Bhilwara Group) is a professionally managed, progressive and growth oriented company with business interests in Yarn, Fabrics, Garments and Denim. It is one of the largest producers and exporters of polyester viscose blended yarn in the country. The company operates around 3,60,000 spindles and produces 1,00,000 MT of yarn per year.

RSWM possesses strengths and expertise to deliver Indias largest quantities of grey, dyed and mlange yarn, while specializing in technical fabric. It is equipped with inhouse fabric weaving and processing facilities, with an installed capacity of 12 million metres per annum. Modern technologies and world-class skills have enabled the company to produce the finest quality adhering to stringent international norms. The company has state-of-the-art garment unit for global customers with a capacity to deliver 13,000 units daily.

RSWMs leadership is exemplified in the equity that it enjoys in Indian as well as international market. RSWM has acquired 50 equity stake in SISA S.A. Spain that will enhance its presence in higher value added international yarn market. An expansion plan of Rs. 900 crore has been initiated by RSWM in order to expand its horizons.

Its Denim and 46MW Captive Power Plants have commenced opetation. As a significant milestone of its expansion plan, RSWM International B.V. Holland is incorporated as a 100 subsidiary of the company. It has also announced the acquisition of Cheslind Textile Ltd., a Bengaluru based textile unit.

The fabric division is the plant where finishing of the fabric is performed. During this process of finishing the fabric is being passed through various machines which brings fine quality to the fabric. In this division the fabric is being brought to improved quality and the roughness of the fabric is being removed. Then the fabric is being washed to get clean. And if any other modifications to be done to fabric like the widening of the fabric, more smoothening of the fabric etc. are being done in this division. And the machines being used for these operations are very larger occupying large space. Their operations being skilled so the machine has to be maintained for its good performance and greater output of fabric from this division. The fabric is also being rolled and fold which is being a packing process to get final dispatch is also performed in this division. This division being very large generally has a high temperature. Every machine here has high working temperature, therefore care has to be taken. The machines here are being operated carefully.

1. SINGEING MACHINE The first process involved in the finishing of the fabric is known as singeing. In this process the fabric is passed through flames at a fix speed. Through this process the roughness and the fiber in the fabric is being removed. The temperature of the flames and the speed at which the fabric is passed through flames can be adjusted according to the quality of the fabric. In this process the machine involved consists of various cylindrical rollers for the movement of the fabric. Various guiding rollers and tension rollers are used so that the fabric easily passes through the flames and no harm can be cause to the fabric. After passing through the process of singeing the fabric obtained is of a good quality. The direction of the flames are horizontal, they are so adjusted that horizontally flames are applied to the vertically moving fabric from both the sides of fabric. Number of singeing machines in fabric division: 1 Outstanding Features: Singeing on both side of the fabric with four pass arrangements on two burners. Heavy duty burners with S.S. Strips. Lower gas consumption due to complete combustion of the fuel. Blue flame with high intensity. Auto-stop of flame on power failure.

Technical Specifications: MODELS : Z/E 1 & Z/E 2 Working-width : 1000 mm. to 3500 mm. Speed of the machine : 60 mts./min. to 100 mts./min.

Fabric Entry Device

Singeing machine has a perfect fabric feeding device with a pneumatic cloth guider,
positively driven nip, pneumatic compensator for tension free passage. A scray for

holding fabric for continuous running during changing over the batch roll with a number of stainless steel guide rolls is also provided.

In the singeing machine platter is being attached at the portion where the fabric comes out from the machine to plat the fabric. The machine has various parts interconnected according to the process of singeing of the fabric.

2. Second process involved is the washing process. Two types of fabric are being washed in this process: First which has to be colored and second one which is already colored. The machines being used for washing and dyeing of the fabric are being large in size occupying large space. Steam being used for washing purposes makes the temperature higher at the working place, therefore care has to be taken. a. JUMBO JIGGER MACHINE For washing of the fabric jigger machine is being used. This machine is of two types: Jumbo jigger and Pacific jigger. The fabric which is already colored and has to only wash is washed in Jumbo jigger machine. This machine is used only for washing. The liquid solution which is used for washing contains water being mixed with various chemicals according to the type of fabric. The various chemicals being mixed with water are sodium hydroxide{caustic soda},hydro sulphade, auxiliac acid, hydrochloric acid and scouring chemicals. The chemicals are added to hot water according to the type of fabric which has to be washed. The machine consists of various rollers which are connected with the chain drive system which is connected to the shaft of the motor which causes the movements of rollers. Mainly five rollers are being used in jumbo jigger machine, in which two are tension rollers which are used for tightening of the fabric. This machine has a open system and the functioning is manual. The machine can be used both for forward and reverse process. Amongst five rollers one roller is being dipped in a big tub which is known as guide roller. The tub is filled with the solution used for washing, it also contains a way for the steam inlet. Number of jumbo jigger machines in fabric division: 4 This jumbo jigger machine comes with following salient features: cast-iron frames rigidly connected by means of cast-iron tie bars. differential gear box. each batching roll fitted with breaks shoe stainless steel liquor tank provision for drain, overflow provided. perforated steel pipe for direct heating coil for indirect heating below the guide rolls. 3.H.P./ 7.5 h.P. Standard electric motor fitted below the gear box.

drive by `v` belts totally enclosed. reverse forward starter with panel box. starters provided on either side of the gear box.

b. PACIFIC JIGGER MACHINE For the fabric which has to be washed as well as colored and dyeing is washed in pacific jigger machine. It is used both for washing and dyeing. This machine has a closed system. It is packed. And the functioning of this machine is automatic. For washing of the fabric the rollers move by the power produced by the hydraulic system. Number of hydraulic type jumbo jigger machines used in fabric division: 8 Technical characteristic :

Slow start/stop. Trough is entirely built in stainless steel AISI 316. The door of machine pneumatically lifted & lowered. To observe inside of the machine large windows are provided. The doors and windows are sealed with special gasket against steam escape. To prevent dripping of condensate there are steam coils in the hood. Dye liquor circulation by means of pump this circuit is used for better leveled dyeing or switching the flow on the spray pipes for more efficient washing or raising. Dye liquor filter out side the machine with large filtering surface. Service tank for dye stuffs & chemicals. Semi or fully automatic with microprocessor (optional).

This machine is also known as hydraulic type jumbo jigger machine.

HYDRAULIC TYPE JUMBO JIGGER MACHINE

3. HTHP MACHINE The third process for finishing is also a washing process. In this the fabric which is already colored is washed in a machine known as High Temperature High Pressure machine. The process of washing in this machine is similar to process of that of the Jumbo jigger machine but HTHP {High Temperature High Pressure} machine has a large capacity then Jumbo jigger machine. Also if the HTHP machine is in good condition and functioning is perfect then both scouring and dyeing of the fabric can be done through this machine. After washing through this process the fabric gets smoothen and the hardness of the fabric is being removed. This machine is a closed machine in which the fabric is washed inside the machine and the system is closed. The temperature at which the fabric is being washed is varied according to the quality of the fabric. Certain features of HTHP machine are as follows: Applicable to jig dye all kinds of thick, thin, terylene, chemical fiber, real silk fabric under the normal temperature and pressure. Can take the place of a normal printing and dyeing machine to print all kinds of textiles such as natural silk, man-made silk and caprone. With such characteristics as structure in reason, good security, large capacity and convenient service.

Heavy duty stainless steel low pressure high volume centrifugal circulation pump. Machine body and major wetted parts made of stainless steel of best quality AISI 316L highly corrosion resistance steel. Thickness 3mm to 5mm. Lifter reel driven by frequency inverter controller motor. High thermal gradient heat exchanger for fast heating and cooling. Magnetic level indicator. Large diameter nozzle.

Semi and fully automatic version with advanced microprocessor control.

4. RELAX SCOURING MACHINE Relax scouring machine is also used for finishing of the fabric. This machine is generally used for the scouring purpose of the fabric. Number of relax scouring machines in fabric division: 1 The different parts of the machine are being listed below: Light nip number 1 {perforated box 1} Light nip number 2 {perforated box 2} Relax zone: this is the zone where the fabric is being kept in the relax mode for around one minute and the washing of the fabric takes place. Washer box number 3 Washer box number 4: in this box we neutralize the fabric and check its pH Washer box number 5: in this box also we neutralize the fabric and then check is pH Washer box number 6 Heavy nip

Special Features The use of modern manufacturing technology has laid the path to new ways of ensuring high quality products with great savings in cost and working times. The methods used in this range that includes textile scouring machines, textile bleaching machines, scouring machines, bleaching machines are aimed at all the bleaching processes that have to treat a wide range of goods with different chemical/physical properties. The versatility is the result of an automatic system which gives easy control and above all the ability to reproduce the results Preparation of white fabric Preparation of fabric to be printed Preparation of fabric to be dyed

The sourcing and bleaching line, textile scouring machines, textile bleaching machines, scouring machines, bleaching machines has been manufactured to the most recent requirements in technology with a level of reliability that ensure meeting of production schedules. The care employed in the manufacturing process ensures the machine will last for a long time and maintenance cost will be reduced to a minimum.

Special selection of components for work in steam and chemical condition Fabric Entry Device

Relax scouring machine has a perfect fabric feeding device with a pneumatic cloth
guider, positively driven nip, pneumatic compensator for tension free passage. A scray for holding fabric for continuous running during changing over the batch roll with a number of stainless steel guide rolls is also provided. Pre-Washing Compartment Close type washing compartment with big diameter guide rolls with mechanical seal to avoid leakages. In built intermediate squeezer, quick bath exchange due to small liquore content, economic use of washing liquore due to consequent counter flow, precise temperature regulation with direct or indirect heating system. Gentle, but intensive removal of dissolved size and impurities sticking to the fabric surface respectively fibre structure, crease free and low tension fabric transport. Impregnating Fabric is impregnated with chemicals for subsequent trouble free steaming process. The design ensure that a high liquore exchange is achieved with an initial moisture contents of 70% and add-on of 50 to 80%. The cloth exits with a liquore content of 120 to 150%. This is ideal for single stage sourcing and bleaching process. Chemical Dosing System An automatic system that doses the pure products ensures that the concentration level is kept constant. The circulation and feed system in the impregnator guarantees the highest concentration uniformity and stability and the lowest liquore top up coefficient. The chemical station consists for each chemical, feed pump, inductive flow meter and control valve. Metering of the chemicals in ml/kg based on the fabric throughout means that a defined quantity is added. If more water is brought in with the fabric then the addition of water controlled on level is reduced. The following data should be entered in the dosing PLC display: Fabric weight per running meter Top-up recipe in ml/kg of fabric Initial filling in liters according to total volume

Steaming In the steamer, the chemicals react with the fibers themselves and the accompanying substances. An even penetration of the applied chemicals is essential for uniform preparation of the cloth. For this purpose the first part of the tight strand section is vertical movement of fabric on top bottom rolls, the big roll diameters are essential for creaseless fabric run and short distance between the top bottom rolls, Creasing may be caused also by roll driven with uneven torque. Texfab steamers are equipped with frequency controlled intermediate drives. For even penetration fabric run in light strand section require a reaction time of about 45 seconds before plating on bed. A plating system in full width open condition on to the conveyor bed. A cloth spreading device ensure excellent transfer to the washing section.There is a non-drip false ceiling inside the chamber with a steam pipe to ensure that any water droplets

will evaporate. Large tempered glass doors are on the sides.

Steam conditioning in the Steamer Chemical treated fabric undergoes efficient washing to remove the dissolved dispersed 6r emulsified impurities. All close type washing. compartment with big diameter rolls with mechanical seal to avoid leakages, inbuilt intermediate squeezer, quick bath exchange due to small liquore content, precise temperature regulation with direct steam injection. Crease free and low tension fabric transport. Control Panel The bleaching treatment line, textile scouring machines, textile bleaching machines, scouring machines, bleaching machines with all its safety and control device ,can be accurately set and the data can be recalled for future production needs. The control system is based on a state-of-the-art PLC installed in a dust proof A.C. cabinet. All production recipes are memorized and can be recalled when the same production cycle is required

5. VERTICAL DRYING RANGE MACHINE The forth process for finishing is the drying process. The fabric being washed is then dried. The machine being used for drying is known as vertical drying range machine. The machine is a large machine consisting of sixteen cylinders which are filled with steam. These cylinders have a coating of Teflon over it. Each cylinder is connected with gears. These gears are interconnected through chains and thus the rotations of these cylinders are due to the chain drive system. Multi cylinder vertical drying range is suitable for intermediate of final drying of fabrics. Number of vertical drying range machines in fabric division: 2

Salient features:

Sturdy structure

High polished non-magnetic stainless steel cylinders to give high efficiency. Range is equipped with rotary joints, siphon, copper flexible pipes, vacuum breaker and other accessories. D.C. drive & compensator for synchronization with mangle or washing range. (Frequency drive is optional) High efficiency low radiation losses. Entire machine is on one common base of the same level, thus abating necessity of erection & alignment. Every cylinder hydraulically tested up to 120 PSI to get working pressure of 60 PSI. Suitable for drying all kinds of fabrics. For better performance cylinders are equipped with a drain valve to remove condensate before starting. Teflon coated cylinder for special purpose drying.

In the VDR machine various rollers are being fixed which are used for various purposes like guiding, tension etc. The speed of the cylinder attained maximum is 60 m/s.

6. STENTER MACHINE The fifth process of finishing of the fabric is of widening of the fabric. This is done with the help of stenter machine. The temperature maintained in this machine is generally 180 C. The stenter machine is used for both natural fiber and chemical fiber, and both for weaving and knitting fabrics. The stenter machine is mainly used for heat setting process of open width knitted and woven fabrics made of cotton, mixed cotton or chemical fibers. Number of stenter machines in fabric division: 3 Amongst the three stenter machines being used 2 machines are six chambered machines and one is eight chambered machine. Technical parameters: working width :rail 2400mm, 2600mm, 2800mm(standard),3000mm,3200mm. mechanical speed:10~100m/min overfeed rate:-20%~+50% rail type: non-lubricated steel rail clip type: pin, clip, combination heating method: heat transfer oil, natural gas(220 centigrade) power:193kw(8chambers) thermo supply:1500mcal/h

Main equipment: infra-red centering , mangling, manual weft straightening , lower overfeeding, uncuring, overfeeding and pinning, edge gumming, drying and heat setting, cooling, selvage cutting, platting, PLC and HMI control system.
Fabric Entry Device

Stenter machine has a perfect fabric feeding device with a pneumatic cloth guider,
positively driven nip, pneumatic compensator for tension free passage. A scray for holding fabric for continuous running during changing over the batch roll with a number of stainless steel guide rolls is also provided.

STENTER MACHINE

7. CALENDAR MACHINE After passing through the stenter machine the fabric comes to calendar machine. This machine is used to make the fabric light in nature and used for improving the quality of the fabric. Calendaring may be defined as the modification of the surface of the fabric by the action of heat and pressure. The finishing from the calendar machine is obtained by passing the fabric between the heated rotating rollers when both speed of rotation and pressure applied are variable. Number of calendar machines in fabric division: 1 The surface of the rollers used can be either smooth or engraved to provide the appropriate finish to fabric. These rollers are made of various materials from hardened

steel to elastic thermoplastic. Platter control device is also attached at the outcome of the calendar machine to plat the fabric. In the calendar machine two rollers with a coating over the surface which are at a high temperature are provided with some distance between them which gets cover up by a roller whose shaft is connected with the motor and the surface of the roller is in contact with the two coated rollers. The rotation of the shaft make all the three rollers rotate. Pressure can be applied to the three rollers in contact. The speed of the rotation and the pressure applied are controlled by the computer. Components: tension rollers: these are used so that the fabric moving along the rollers does not get loosen up guiding rollers: these are used so that the width of the fabric does not get shrink or the fabric remains plain motor: it is used to give rotating energy to the shaft of the middle roller
Fabric Entry Device fabric feeding device with a pneumatic cloth guider, positively driven nip, pneumatic compensator for tension free passage. A scray for holding fabric for continuous running during changing over the batch roll with a number of stainless steel guide rolls is also provided.

Through the pressure being applied the fabric gets a smooth silky touch and its gets compressed. Because of the compression of the fabric the thickness of the fabric gets reduced. Also the air permeability gets reduced because of the closing of the threads. Many more other objectives are being covered by the calendar machine like increase in luster, decrease in the yarn slippage, increase in opacity of the fabric and surface patterning by embossing.

8. ZERO-ZERO MACHINE Zero-zero machine is also used for the finishing process of the fabric. After the calendar machine the fabric comes to zero-zero machine. In this machine the fabric is made smoother and lighter with the help of steam. Number of zero-zero machines in fabric division: 1 This is a large machine working on a high temperature. This machine contains a large steam box above which are two cylindrical rollers which are connected with each other through a rubber belt. Tension has been provided on the middle of upper part of the belt through a large cylinder known as guiding cylinder in which steam is present. This tension makes the rubber belt to dip into the steam box. The fabric is then being passed from bottom of the guiding cylinder. Two tension rollers are being attached near the two sides of the guiding cylinder so that the fabric does not get loosen up.
Fabric Entry Device fabric feeding device with a pneumatic cloth guider, positively driven nip, pneumatic compensator for tension free passage. A scray for holding fabric for continuous running during changing over the batch roll with a number of stainless steel guide rolls is also provided.

ZERO-ZERO MACHINE

9. CF MACHINE CF machine is also used for the finishing of the fabric. Here CF stands for Conti Fit machine. In this machine silicon belt is used. Hydraulic pressure is applied to the cylinders which caused their movement and the fabric is passed through high temperature steam. The general temperature maintained in the CF machine is 130 C. In this the fabric gets removed from various chemicals, gets more smoothen and of a fine quality. This machine is related to the finishing of good quality of fabric. By changing the hydraulic pressure we can get different types of finishing {shining} in the fabric. Number of Conti Fit machines in the fabric division: 1 Different parts of this machine are as under: Hydraulic power belt: pressure is 150kg/sq-cm. we use HLP 46 for this power pack. Silicon pressure belt: this belt has the variable pressure as per the requirement of the fabric. The pressure generally varies between 60 to 120 kg/sq-cm. SS roll: here SS stands for silicon steel roll. It is an effective and a direct heating roll. Humidifier Platter control device: its work is to plait the fabric.

10. KD MACHINE KD machine is the final process of finishing. The maximum pressure in KD machine can be 2.5 kg f/sq-cm. In KD machine the fabric gets more loosen up. Number of KD machines in the fabric division: 1 In this machine a roll of three cylinders are being used. Three processes take place here. First is the loading of the fabric on the cylinder, then second process is the ironing of the fabric and the final process is the unloading of the fabric from the cylinder. The three processes take place at a time on the three cylinders. When the first cylinder gets loaded by the fabric at a time the second cylinder gets into the steamer and the ironing of the fabric is done and the third cylinder gets unloaded and the fabric gets collected and is being platted through the platter control device. In this process ironing of the fabric is done. The fabric then is measured and packed for the distribution. This machine also has a high working temperature. Following are its some components: Tension rollers: tightening of the fabric. Guiding rollers: maintenance of the length and width of the fabric. Cylinders: These cylinders contain steam inside them. These are used for loading, ironing and unloading purposes. Motor: used for the movement of the cylinders and their rotations. Platter control device: to plat the fabric. Valves: for steam pressure control. Slider: to slide the cylinder into the large cylindrical portion for ironing. This machine has a computerized system. The pressure and the temperature of the system are variable, also the sliding movement of the cylinder is controlled by the computer. Description of drums: 3 drums, 670 mm drum diameter & 2000 mm drum length 1300 mm autoclave diameter. Stainless steel autoclave

K.D MACHINE

11. ROLLING MACHINE This machine is being used to make the rolls of the finished good quality of the fabric. Number of rolling machines in the fabric division: 1 The fabric after the KD machine is brought here so that the rolls of the fabric can be made. These machines are small in size as compared to KD machine. This machine just make the rolls of the fabric.

12. FOLDING MACHINE Here we fold the finished fabric and then send it to the next department for the final dispatch. Number of folding machines in the fabric division: 2 Here we have seen two different types of folding machine which are listed below: Single fold machine: in this machine the folding is done in such a way that the fabric is packed with a single layer made folding.

Double fold machine: in this machine the folding is done such that the fabric gets covered up by its two layers.

13. SEWING MACHINE These machines are used to sew the fabric. This machine helps for the connection of fabric so that the fabric gets easily entered into the machine one after the other which saves a lot of time and helps in greater production.