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Date 02/06/2015-15/06/2015
Submitted by:
Apoorva
Kavya komal gupta
Pushpa singh
(Nift patna)
Acknowlegdement
At the outset, we wish to express our gratitude to everybody who have
assisted in the formulation of this report. There are many to whom
expression of gratitude is inevitable, but there are some special people
who should be given prominence, without whom we would not have
reached the conclusion of this project so quickly and so efficiently.
We wish to thank Ms. Nilima Regina Topno, the centre coordinator of NIFT
Patna (A.P), for providing this wonderful opportunity, chanelling and
motivation.
Introduction
The internship is the perfect amalgamation of the classroom principles
and practical knowledge that form an integral part of understanding what
is being taught. It gives the students a perfect platform to improve their
interpersonal skills and communication to help them succeed in their
professional career. N.I.F.T gave us this valuable chance to undergo a two
weeks internship at Raymonds Ltd. Chhindwara, Madhya Pradesh.
It was our sincere effort to stand up to the name of our institute and do
our internship with full and complete sincerity.
Primitive people discovered that a succession of short fibres could be
twisted into a continuous yarn. This was probably accomplished slowly
and laboriously at first, but the greater strength thus produced and the
many uses soon found for articles made from continuous yarns led to the
invention of hand implements to aid and improve the process of twisting
and spinning. At the same time it was necessary to invent simple
methods of disentangling, separating and arranging the fibers according
to their length, other than by just using the fingers. Thus, crude methods
of techniques were redefined. In time, long filament strands unwound
from silk cocoons, and still later, filaments formed by chemical synthesis
were made into yarns. Now yarns are also made by integrating the staple
and filament fibers.
Company profile
Name of the company
textile
: Raymond limited,
Division
: Chhindwara
Address
Nagar, Boregaon, tah, sausar
chhindwara- 480106
Head office
tagore marg, civil lines,
:165 Ravindranath
Nagpur 440001,
India
Phone no
226508
: (91-07165)226503 /
Website
www.raymondindia.com
Fax no
: (91-07165)226512
Product type
suiting, shirting
Worli, Mumbai.
Departments covered
RMG
GREY COMBING
DYEING
RECOMBING
WORSTED SPINNING
PV SPINNING
WEAVING
FINISHING
QUALITY CONTROL
RMG
- From outside
- Grey Combing
Viscose TOP
Lenzing TOP
Blended TOP
Acrylic TOP
Casmere TOP
Suppliers Name-
NAME
MATERIAL
TOW-PSF
TOW-PSF-TOP
VSF-TOP
Greasy Wool
Graesy Wool
Greasy Wool
FLAX TOP
Low Pill FibreIts high brittle in fibre which breaks very esasily.
VSF-
USE PSF/USFFor grey dyed fabric VSF we purchase directly from Grasim
Industries (Dope Dyed) and PSF they deliever to their deying department
for fibred deying. Mainly for VSF & PSF they send to their PV/SPG. There
they mix it in a certain rate percentage for the P/V fabric.
Daily avg. consumption. VSF is 1.8Ton and PSF 2.9Ton
TOWTOW is continuous filament(polyester) purchase for making blend
with wool. In TOW it is possible get variable length needed from their
converter machines. Few converter to polyester TOP.
Waste GodownDepartment
P/V Spinning
Waste
P/V Soft
P/V Hard
P/V Sweeping
W/ Spinning
T/W Soft
P/W Hard
P/W Sweeping
Recombing
P/W Soft
R/C Noil
R/C Sweeping
All Wool Soft
Converter
GREY COMBING
Source
Types
Polyester
Source
Types
Denier
Australia
South Africa
17.5, 18.2, 19.0,
21, 22.5, 24.5
Reliance Ltd.
Semi Dull
Trilobal
Low pill
1.5, 2.0, 2.5 3.0
Process flow-
Scouring
Blowing
Carding
3 Pre-Gilling
Top
Formation
2 Post-Gilling
Combing
Impurities In Wool
Fat
Riam
Mud
Process Flow-
CARDING
Objective
Sliver formation
Conversion of width and weight into length
Formation of Web
Individualisation of fibres
Removal of impurities
It is a compulsory process.
Carding Produces Non-Woven fabric.
GILL BOX
Types-
In pre-gilling the output to input ratio is 7:1 i.e. feed given is 7 times
that of delivery. The end roller moves at 7 times higher speed. It
further enlongates the sliver. GILLING IS A ALTERNATIVE PROCESS
USED INSTEAD OF DRAW FRAMES.
COMBING
DOUBLING
MAN-POWER
Carding
Preparatory
Comber
Gill Box
Packer
2 operators of 2
machines
2 operators for 2
preaperatory
2 operators
2 operators
1 operator
CONVERTER
GILL BOX
MACHINES
PROCESS
Carding
Gill Box
Comber
Converter
`
MACHINE USED
Thebbew NSC CS6
Thebbew NSC GC14
Thebbew NSC PB31
Thebbew NSC TP11
Worsted spinning :-
Process Flow of worsted spinning :Top Storage is the first step of worsted spinning then we have gilling 1
,gilling2, gilling3, gilling4 after that it goes with various process like
roving, ring frame ,steaming, auto winding ,s.y.r ,ply winding ,TFO,
Steaming , D.y.r.
Carding:
The carding process for worsted yarn production is intended to disentangle and lay them
as parallel as possible. The fibres are passed between rollers covered with fine wire teeth.
Since worsted yarns, however, should be smooth, the fibers are made to lie as parallel as
this process will permit. Following this operation, the wool goes to the gilling and combing
processes.
Gilling and Combing:
Gilling is carried out before (preparative gilling) and after (finisher gilling) combing. The
preparative gilling is mainly to align the fibers in a parallel direction, further blend the wool
through doubling and to add moisture and lubricants. Whereas finisher gilling is mainly
aimed to remove the mild entanglement introduced to the combed sliver. The carded wool,
which is to be made into worsted yarn, is put through gilling and combing operations. The
gilling process removes the shorter staple and straightens the longer fibers. This process is
continued in the combing operation, which removes the shorter fibers of 1 to 4 inch (25
100 mm) lengths (called combing noils), places the longer fibers (called tops) as parallel as
possible, and further cleans the fibers by removing any remaining loose impurities.
Drawing:
Drawing is an advanced operation which doubles and redoubles slivers of wool fibers. The
process draws, drafts, twists, and winds the stock, making the slivers more compact and
thinning them into slubbers. Drawing is done only for worsted process.
Roving:
This is the final stage before spinning. Roving is actually a light twisting operation to hold the
thin slubbers intact.
PREPARATORY SECTION:When the tops come from recombing dept they are stored for conditioning
in the trolley. The conditioning time is around 24 hrs. after conditioning
matrial is taken for spinning process.
Attenuation in weight per unit length of the sliver.
TO minimize the irregularities and reduce the CV% of material by doubling
of slivers.
OBJECTIVES OF STEAMING :At spinning and twisting the fibres are twisted about their longitudinal
axis. Due to their elastic nature they strive to set back and thus yarn
Doubling section:
The development of short fibers, or staple into yarn when started in terms
of basic manufacturing processes, is as follows; carding, combing,
drafting, twisting and winding. As the fibers pass through these processes,
they are successively formed into lap, sliver, roving and finally yarn.
1)Lap to card sliver by the carding process
2)card sliver to comb sliver by combing process ( if thefiber is ti be
combed)
3)sliver to roving by the drafting, or drawing-out
4)roving to yarn by further drafting and twisting processes
5)yarn reeled on bobbins ,spools or cones by the winding process.
BLOWROOM PROCES
CARDING
COMBING
DRAWING
ROVING
`
YARN
FINISHING:Finishing is the last step of the garment production and all mistakes made
during the process accrue and become a huge problem at this stage. The
Quality Departments also have huge improvement potential and require
special attention.
Process flow for finishing is as follows:
Finishing grey
room
lot making
Singeing
Pre scouring
Post
Scouring
First dry
Heat set
Squeezer
Second dry
Perching/inspe
ction
Shearing
Batching Machine
and cut fibers and collection them in waste bags through pipes.
Brushing is repeated if necessary.
No of machine-1
Shearing: it is used to cut small protruding fibers off the fabric
surface to make it smooth and have better feel. Uses two sets of
blades.
i)Laser blades
ii)spiral cutter
The two baldes meet at a common points where the fabric plies are
in erect position and gets cut through a scissor action. Suction duct
work the same by taking the waste out of the fabrics surface to the
waste bags. Process can be repeated if required or not obtained the
desired smoothness.
No of machines-1
Back coating : it is necessary to provide strength to the plies
attached to the interleshment of fabric structure so that they do not
come out of pulling. This can be done by two methods.
From spraying- manual-inexpensive
Using back-coating machine- automatic-expensive
Coating machine- it consists of rollers and a chemical tray for its
application on the back side of the fabrics. This machine is attached
to the weft straightener at its start and a stenter at its end. Weft
straightener consists of five steel rolls and two banana rolls for
elimination of bow and skews. It is totally computer controlled and
removes the anomaly with the help of five sensing cameras.
Fabric coming from here moves to the main section which consists
of a small roller, a large roller and a chemical tray. The tray is filled
with the chemical (texanate NW) which comes from the chemical
tank attached to the machine. Small roller is half immersed in a tray
and the fabrics passes through the large roller in such a way that
the back side of the fabric touches the small roller. Thus chemical is
applied to the back side through this continuous operation . the
chemical is viscous enough to remain applied on to the surface.
No of machine-1
Make borgaro Toriness italia
After this fabric moves to the stenter machine to dry up the
chemical . temperature is efficiently maintained.
No of machines 1
Make ramoli textile engg.pvt.ltd.
From application- one chemical tank and one large mixing tank is
used .chemical is mixed with water to produce foam in the large
tank. Foam is taken through the pipe to the tray area of the back
coating machie. As the fabric moves through the roller , foam is
WEAVING
Broken end
Broken pick
Floating end
Floats
Loose ends
Loose picks
Missing end
Temple cut
Tight end
Thick in
Weft cut
Softening and p/w for rope scouring . after that second dry is done for
both the materials.
Stenters are used for 1 dry, 2nd dry and softening.
No. of m/c-6
Make corino machine/alba,motex, harish
ROPE SCOURING: The m/c tub is supplied with hot water, cold water
and chemical.a large roller rotates the rope from fabric through
larger grooves into the tub. The processes some have rollers some
have grooves as some have conveyor
No. of m/c -2
Make-local installation
INSPECTION : AFTER SECOND DRY FABRIC IS TAKEN FOR MANUAL
INSPECTION. Stains and objectionable defects like knot, slub,
contamination etc are marked and noted down.
No of m/c- 10
Make- trueshape
PERCHING: slubs ,knot, loose threads and other objectionable faults
are removed.
No. of m/c 15
Make- Trueshape
Shearing ; it is used to cut small protruding fibres off the fabrics
surface . Shearing is a process used to cut off surface fibres on
fabrics. It makes uniform the surface of napped fabrics. Most cut pile
fabrics are also sheared to provide uniform pile height.
DAMPING ; damping is the spraying of tiny water droplets on to the
fabric system through a nozzle system of the m/c. damping is done
only for p/w material.\
1)Scouring / Cleaning
:
Fabric, as it comes from the loom, is dull in appearance. It may have
stains of oils as well as starches, waxes, etc., that are applied to
yarns to make weaving easier. Once the fabric is woven, the
presence of these additives hinders further finishing processes such
as bleaching, dyeing, printing, etc. Therefore, these need to be
removed before sending the fabric for further processing. Scouring
is the process of washing fabric with soap solution. Scouring is the
process of industrial cleaning of fabrics with the help of warm water
and soap solution. It cleans the fabric and makes them more
absorbent.
2) Bleaching:
Many a times natural fibres like cotton, silk and wool are available in
pale / light brown colour. Suppose you have to paint some thing in
light pink colour, unfortunately the brush was not washed properly
and had remains of brown in it. What do you think will happen? You
will not get the pink you wanted. This becomes a problem as light
shades of dyes do not come out well on such fibre colours. To get
exact light shade of the colour, the existing colour has to be
removed. Bleaching is a chemical treatment given to fibres, yarns or
fabric to remove paleness or colour and make them white.
3) Starching / Stiffening:
Starch is generally applied to fabric of fine quality and light weight
or loosely woven fibres. Starching makes the fabric heavier, stiff,
and crisp. It also adds shine and smoothness to the fabric. Cottons
muslin, poplin, cambric and thin silks are generally starched.
Sometimes the loosely woven cotton fabric is starched heavily so
that their quality looks better but the starch comes out with the first
wash and the basic loosely woven structure of the fabric becomes
prominent. Therefore, starched fabric should be examined properly
before purchasing.
4) Calendering:
This is the simplest and the common finish used to improve the
looks of any gray or finished fabric. Similarly, through the process of
Calendering or industrial ironing a fabric is passed through a series
of smooth hot rollers to remove wrinkles and to make it smooth. It
makes the fabric smooth and lustrous, thereby improving its
appearance.
5) ) Mercerization:
The fabric made from cotton wrinkles easily and is difficult to dye. It
is, therefore, treated with sodium hydroxide to make it strong,
lustrous and absorbent. This process is called mercerization. It also
improves the dye uptake of fabrics. Now-a-days this finish has
become a routine finish for all cottons. Even sewing threads which
are used for stitching are mercerized.
6) Parchmentization:
The fabric is different from other cotton fabrics. Yes, it is a thin,
transparent, light weight and stiff fabric and seems to be heavily
starched. But unlike starched fabric, its stiffness remains intact even
after washing. It is not due to a starch but because of application of
a finish called parchmentization.
7) Napping
WEAVING.
Weaving is one of the processes that required in textile in terms of
producing a fabric. From the fiber then become a yarn through some other
process, weaving is a process of interlacing two types of yarn known as
warp or ends (run parallel to the weaving machine known as loom) and
weft or filling yarn (run perpendicular to the loom) to produce a rigid
fabric.
PROCESS FLOW OF WEAVING:
Winding the Warp Threads
The warp, that is, the lengthwise threads in the cloth, must be measured
out to the correct length for my project, and the threads must be kept in
order so that they can be wound onto the loom properly. Since its
awkward to wind a warp with fine threads directly from a skein, I
must first wind the thread back onto a cardboard cone. Then I begin
winding the warp using a warping mill. Each thread follows the same path
(based on a guide thread that is the same length as the warp will be) and
is kept in order through the whole process.
Shedding- The process of separating the warp yarn into two layers by
raising the harness to form an open area between two sets of warps and
known as shed.
Picking- The process of inserting the filling yarn through the shed by the
means of the shuttleless while the shed is opening.
Beating- The process of pushing the filling yarn into the already woven
fabric at a point known as the fell and done by the reed.
To continue the weaving process, there are also two additional operations
are essential:
Warp control (let-off)- The motion that deliver warp yarn to the
from the weaving area at the constant rate that will give the required
pick-spacing and then winds it onto a roller.
Yarn Requirements:
Warp
Weft
Yarn must be wound properly on a suitable package for high speed
unwinding.
Yarn will be carried by shuttle that made up of wood which the pirn
Warping- A process of transfer the warp yarn from the single yarn
PLUSH WEAVING:This department mainly deals with special type of weaving like- curtains,
seat cover for cars, cushion, carpets, sherwani, fabric etc. And it is done
with the help of following machine.