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INDUSTRIAL ATTACHMENT

National Institute of Textile Engineering & Research


(NITER)
Nayarhat, Savar, Dhaka

REPORT ON
INDUSTRIAL ATTACHMENT
Duration (10.12.2017 to 10.02.2018)

WITH
Shohagpur Textile Mills Ltd.
Lakkhon Khola Bondor, Godnail, Narayanganj, Bangladesh.

Supervising Teacher
Sadikur Rahman
Lecturer
Department of Yarn Manufacturing Engineering
National Institute of Textile Engineering & Research (NITER)
Nayarhat,Savar,Dhaka

Submitted By :

NAME STUDENT ID SESSION


Md. Rakibul Islam 140401-065 2013-14
Subir Kar 140401-081 2013-14
Shuvo Sarkar 140401-116 2013-14

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I. Acknowledgement

We are thankful to the Almighty for enabling us to complete the industrial training successfully. We
would like to express our deepest appreciation to all those who gave us the chance to complete this
industrial training.

Our industrial training was carried out at Shohagpur Textile Mills Ltd. a concern of Purbani Group,
located at Lakhhon Khola Bondor, Godnail, Narayangonj, Bangladessh. We express our thanks to
the authorities of Purbani Group of Industries for giving us the official permission for industrial
training.

A special appreciation to Major Md. Mahbubur Rahman (Retd), Deputy General Manager,
Shohagpur Textile Mills Ltd, who gave us the permission to access all required equipment and
necessary materials to complete the industrial training.

A special gratitude to our respected supervisor Md Ali Reza, Production Manager (U-2),
Shohagpur Textile Mills Ltd. for his support, cooperation and constant supervision during the
industrial training at Shohagpur Textile Mills Ltd.

We would like to thank Prof. Dr. Mizanur Rahman, Principal, National Institute of Textile
Engineering & Research (NITER) for giving us guidance and official permission for
internship at Shohagpur Textile Mills Ltd.

A special gratitude to our respected academic supervisor Sadikur Rahman, Lecturer, Dept.
Of Yarn Manufacturing, National Institute of Textile Engineering & Research (NITER).
for his successive instruction, cooperation and constant supervision during industrial training

We would also like to applaud other teachers of our department for providing the base of our
textile engineering knowledge.

Last but not the least we express our special thanks to all the staffs and officers of Shohagpur Textile
Mills Ltd for their co-operation, love, services& support which they offered during our training
period.

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II. Executive Summary /Introduction

Industrial Training refers to work experience obtained during the program of study that is relevant
to professional development prior to graduation. The main objectives of Industrial Training are:

 To experience what it is like to work in a professional organization,


 To increase technical, interpersonal and communication skills, both oral and written,
 To gain a first-hand experience working as an engineering student,
 To apply the technical knowledge and engineering methods to a real-life situation,
 To work with other engineering professionals,
 To observe interactions of engineers with other professional groups.

We got an opportunity to complete 02 months long industrial training in Shohagpur Textile Mills
Ltd. (STML), a concern of Purbani Group. Our industrial training started in Dec 10, 2017 and ended
in Feb 10, 2017. As there were different departments in factory, our 02 months long program was
sub-divided as per following to get us acquainted with all of them-

 2.5 weeks in Maintenance Department.


 2 weeks in Production Department.
 2.5 weeks in Quality Control Department.
 0.5 week in Utility and Electrical Department.
 0.5 week in Administration Department.

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III. Table of Contents

CONTENTS PAGE

Chapter 01: Description of Organization 08-10


Part 1.1: History of Purbani Group 07
Part 1.2: Purbani Group Subsidiaries 07
Part 1.3: Information about Shohagpur Textile Mills Ltd. 07
Part 1.4: Overview on Shohagpur Textile Mills Ltd. 08
Part 1.5: Different Departments of Shohagpur Textile Mills Ltd. 08
Part 1.6: Location of the Factory 09

Chapter 02: Man Power Management 11-16


Part 2.1: Organogram of STML 10
Part 2.2: STML Manpower setup 11
Part 2.3: Job responsibilities of officers 14

Chapter 03: Material Management 17-18


Part 3.1: Sources and different types of raw material 16
Part 3.2: Bale Information 16
Part 3.3: Contaminations of raw cotton 17

Chapter 04: Machine Description & Production Planning Sequence &


Operation 19-56

Part 4.1: Process flow charts of ring spinning yarn production 19


Part 4.2: Machines sequence & descriptions of blow room 20
Part 4.2.1: Flowchart of blow room machines of unit-1 20
Part 4.2.2: Machine descriptions of blow room of unit-1 21
Part 4.2.3: Flowchart of blow room machines of unit-2 24
Part 4.2.4: Machine descriptions of blow room of unit-2 24
Part 4.2.5: Flowchart of blow room machines of unit-3 27

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Part 4.2.6: Machine description of blow room machine of unit-3 28
Part 4.3: Carding machine 33
Part 4.3.1: Carding machine specification & description of Unit-1 34
Part 4.3.2: Carding machine specification & description of Unit-2 35
Part 4.3.3: Carding machine specification & description of Unit-3(Line-1) 36
Part 4.3.4: Carding machine specification & description of Unit-3(Line-2) 37
Part 4.4: Breaker Draw Frame 37
Part 4.4.1: BDF machine specification and description Unit-1 38
Part 4.4.2: BDF machine specification and description Unit-2 38
Part 4.4.3: Carding machine specification & description of Unit-3(Line-1) 40
Part 4.4.4: Carding machine specification & description of Unit-3(Line-2) 41
Part 4.5: Finisher draw frame 41
Part 4.5.1: FDF machine specification and description Unit-1 42
Part 4.5.2: FDF machine specification and description Unit-2 43
Part 4.5.3: FDF machine specification and description Unit-3 (Line-1) 44
Part 4.5.4: FDF machine specification and description Unit-3 (Line-2) 45
Part 4.6: Simplex 45
Part 4.6.1: Simplex machine specification and description Unit-1 46
Part 4.6.2: Simplex machine specification and description Unit-2 47
Part 4.6.3: Simplex machine specification and description Unit-3 (Line-1) 47
Part 4.6.4: Simplex machine specification and description Unit-3 (Line-2) 48
Part 4.7: Ring frame 49
Part 4.7.1: Ring Frame machine specification and description Unit-1 49
Part 4.7.2: Ring Frame machine specification and description Unit-2 49
Part 4.7.3: Ring Frame machine specification and description Unit-3(line-1) 50
Part 4.7.4: Ring Frame machine specification and description Unit-3(line-2) 51
Part 4.8: Auto Cone Winding section 51
Part 4.8.1: Auto Cone Winding specification and description Unit-1 51
Part 4.8.2: Auto Cone Winding specification and description Unit-2 52
Part 4.8.3: Auto Cone Winding specification and description Unit-3(line-1) 53
Part 4.8.4: Auto Cone Winding specification and description Unit-3(line-2) 53
Part 4.9: Heat setting 54

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Part 4.10: Packaging section 55

Chapter 05: Quality Control 57-63


Part 5.1: Quality control system 57
Part 5.2: Plan of quality department 57
Part 5.3: List of testing equipment and their manufacturer and model no 58
Part 5.4: Machine description 58

Chapter 06: Maintenance 64-71


Part 6.1: Maintenance 64
Part 6.2: Maintenance of machineries 64
Part 6.3: Machineries used for maintenance 65
Part 6.4: Maintenance points 66
Part 6.5: Machine maintenance schedule 67
Part 6.5.1: Maintenance for Blowroom 68
Part 6.5.2: Maintenance for carding 68
Part 6.5.3: Maintenance for Drawframe 68
Part 6.5.4: Maintenance for simplex 69
Part 6.5.5: Maintenance for ring frame 70
Part 6.5.6: Maintenance for auto cone winding 71

Chapter 07: Utility Services 72-78


Part 7.1: Generator 72
Part 7.2: Cooling tower 77
Part 7.3: AC Plant 77
Part 7.4: Compressor 78

Chapter 08: Store & Inventory Control 79-81


Part 8.1: Inventory control 79
Part 8.2: Sections of store 79
Part 8.3: Inventory procedure 81

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Chapter 09: Marketing Activities and Cost Analysis 82-83
Part 9.1: Consumers of product 82
Part 9.2: Exporting country 82
Part 9.3: Importing country 82
Part 9.4: Local market 82
Part 9.5: Cost analysis 83
Part 9.6: Marketing strategy 83

Chapter 10: Administration, Account, HRD and First aid 84-86


Part 10.1: Administration 83
Part 10.2: Accounts 83
Part 10.3: HRD department 84
Part 10.4: First aid 86

Chapter 11: Impact of the Internship 87

Chapter 12: Conclusion 88

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CHAPTER ONE

DESCRIPTION OF ORGANIZATION
1.1: History of Purbani Group:
PURBANI is one of the largest & oldest established 100% export oriented Textile conglomerates in
Bangladesh since 1973 and doing business for more than 4 decades with eminence. The group’s first
venture was M/S Purbani traders in 1973. Since 1973, however, the Purbani group has grown into
a leading group of companies in Bangladesh by virtue of its dynamic It is a vertically integrated
textile manufacturing company and title holder of 12 business groups involve in Spinning, Yarn
Dyeing, Fabrics Manufacturing & Dyeing and Ready Made Garments .
The Group includes a number of textile mills that employ approximately 5000 work forces. A
significant contribution to the country’s reduction of unemployment problem.
At present Purbani Group has established itself as a renowned textile manufacturer in the country.
The Group has earned a good reputation among the countries that are involved in the business.
The group is striving very hard to reach its goal that is to be one of the largest textile
manufacturing companies globally.

1.2: Purbani Group Subsidiaries:

 Karim Spinning Mills Ltd.


 Shohagpur Spinning Mills Ltd.
 Purbani Rotor Spinning Ltd.
 Purbani Synthetic Spinning Ltd
 Purbani Fabrics Ltd.
 Purbani Yarn Dyeing Ltd.
 Karim Textile Ltd.
 Purbani Fashion Ltd.
 Purbani Agro Processing Ltd.
 Purbani Fisheries.
 Purbani Traders.

1.3: Information about Shohagpur Textile Mills Ltd.:

Name of the Factory Shohagpur Textile Mills Ltd.

Chairman Abdul Hai Sarker

Managing Director Shafiqul I. Sarker (Sohel)

Deputy General Manager Major Md. Mahbubur Rahman (Retd)

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Type Yarn Manufacturing Industry (Ring Spinning)

Head Office Sena Kalyan Bhaban (15th floor),


195 Motijheel C/A, Dhaka.
Factory Location Lakkhon khola Bondor, Godnail, Narayanganj

1.4: Overview on Shohagpur Textile Mills Ltd.:

Nature of the company Private Limited Company.

Number of spindles installed 44000

Product Mix Mélange Yarn, 100% Cotton Mélange, Neps,


Viscose, Inject, Siro, Snow and other Fancy
Yarn
Count Range 20-40 Ne
Production capacity 25 Ton/Day

Establishment 1984

Manpower 1400

Male Employee 650

Female Employee 750

Power Supply Gas generator

1.5: Different Departments of Shohagpur Textile Mills Ltd.:


 Production Department.
 Quality Control.
 Maintenance Department.
 Utility Department
 Store Department
 Administration Department
 Marketing and Sales Department
 Commercial Department.

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1.6: Location of the Factory:

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CHAPTER TWO

Man power Management


2.1: Organogram of STML:
An organizational chart (often called organization chart, org chart, organigram or organogram) is a
diagram that shows the structure of an organization and the relationships and relative ranks of its
parts and positions/jobs. The organogram of Shohagpur Textile Mills Ltd. is given below:

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2.2: STML Manpower setup:

Quality control department:

Designation Current
manpower
Assistant general manager 1
Assistant manager 1
Quality control officer 1
Lab assistant 5
Lab boy/girl 2
Total 10

Maintenance Department:

Designation Current
manpower
Assistant general manager 1
Maintenance officer 5
Assistant Maintenance officer 16
Head fitter 10
Senior fitter 7
Assistant fitter 25
Helper 50
Total 114

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Production department (Unit- 1,2, 3):

Designation Current
manpower
DGM(production) 1 (Unit-1,2,3)
Sr. Assistant General Manager 2 (Unit-1,3 & 2)
Production manager 3
Senior production officer 0
Production officer 8
Assistant production officer 15
Management information system officer 1
Production clerk 3
Supervisor 12
Worker 1100
Total 1145

Administration Department:
Designation Current manpower

Manager (admin) 1
Asst. Manager 1
Admin officer 5
Accounts officer 1
Executive security 1
Security inspector 2
Security guard 32
Pc operator 1
Imam 1
Driver 5
Total 50

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Utility Department:

Generator &Maintenance Designation Current manpower

Manager 1

Engineer 4
Electrical Sub. Assistant engineer 10
Operator + helper 3
Electrician 10
Helper + Loop cleaner 4
Head fitter 1
Work Shop
Helper 10
Sub. Assistant engineer 1
AC
H. fitter + Fitter 1+1
Heat setting Op + Helper 2+2

Store Department:

Designation Current manpower

Manager 1
Store officer 2
Assistant Store officer 1
Store keeper 6
Total 10

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2.3: Job responsibilities of officers:

a) Maintenance manager:
Job responsibilities:
 To ensure all machine safety devices.
 Machine maintenance schedule development.

b) Assistant Quality manager, Quality Control Officer:


Job responsibilities:
 To maintain the quality and process parameters of the yarn production process.
 To plan and monitor the daily activities of quality department.

 To ensure the proper training and motivation of QCA officers and supervisors, lab
assistances etc. up to date to G.M. regularly about the production process as well as the yarn
quality.

c) Senior production officer and Production officer:


Job responsibilities:
 To achieve the target production and ensuring the production from blow room to finishing
 To cheek process parameters lot wise and count wise from blow room to finishing against
standard value.
 To control count mixing, lot mixing of sliver, roving yarn and mixing / Bale management of
raw cotton.
 To control unusable wastage in every stage from blow room to finishing.
 To take the charge from the outgoing shift and hand over the charge to the incoming shift.
 To allow leave of workers & subordinate supervising staffs in systematic way.
 To supervise performance evaluation.
 To maintain doff ticket and control of doffing time in ring section.
 To check attendance.

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d) Maintenance engineer:
Job responsibilities:
 Operation and maintenance.
 Monthly maintenance schedule.
 Local and foreign indents.

e) Maintenance officer:
Job responsibilities:
 Maintenance of boiler, AC plant etc.
 Operating and controlling.
 Machine selection and installation.
 Humidity setting.

f) Admin manager:
Job responsibilities:
 To recruit labor by ensuring that there is no any child or forced labor.
 Punishment and appeal, harassment and abuse – to deal with these matters.
 To keep payroll and attendance record.
 To manage overtime, working hour, wages, breaks, leave, benefits etc.

g) Manager of store:
Job responsibilities:
 Total storage management of raw material, yarn, chemical etc.
 Waste management.

h) Admin officer:
Job responsibilities:
 Responsible person for overall Implementation, review, reporting and corrective action.
 Internal audit and HR management.

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CHAPTER THREE

Material Management

3.1 Sources and different types of raw material: (Fibres)


There are different types of fibres used to produce yarns of various qualities. Those fibres are coming
from different origin and region. Some fibres types and their origin are given below:

Cotton
Brand Name Origin Staple Length Average MIC
CIS Uzbekistan, Russia 36.5mm 4.6
Zambia Africa 29-30mm 4.3
Sankar-6 India 28.5mm 4.0
Benin Benin 27-32mm 4.5
Burkina Burkina 27-32mm 3.5-4.8
Tanzania Tanzania 28.2mm 4.3
Azerbaijan Azerbaijan 27-30 mm 4.4

Viscoses
Origin Staple Length Average denier
India(Black Viscose) 38mm 1.4

3.2: Bale Information :

Binding material used for bales Steel wire


Bale size Height: 59 cm, Length: 95 cm, Width: 80 cm
Bale weight 230 kg
Tare weight 2.6 kg
Bale loading & unloading system It is done by HELI
Bales used in per lay down 47 bales
Bales consumption/day 94 bales

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3.3: Contaminations of raw cotton:


Dirty cotton Piece of plastic
White cloth piece Black cotton
White thread Broken seeds
Colored cloth piece Wooden piece
Colored thread
Leaf
Feather

Other raw materials:


 Coloured Cotton
 Bleached Cotton
 Polyethylene bag

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CHAPTER FOUR

Machine Description & Production Planning Sequence & Operation

4.1: Process flow charts of ring spinning yarn production:

The flow chart of carded yarn is here.

Blow -room

Carding

Breaker Draw Frame

Finisher Draw Frame

Simplex

Ring Frame

Auto Cone Winding

Yarn Conditioning

Packaging

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4.2: Machines sequence & descriptions of blow room:

4.2.1: Flowchart of blow room machines of unit-1:

Bale Opener

MAXI-FLO

Multi -Mixer

CLEANOMAT

Dust X

- SP FPDX
DJjbglkjglkj
U

FD-S

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4.2.2: Machine descriptions of blow room of unit-1:

Automatic Bale Plucker:

Manufacturing Trützschler
Company

No. of M/C 01

Model BO 1600

Manufacturing 2001
Year
Country of Origin Germany

Production 1200 kg/hr

Material used Cotton

Function To open fibre

Fig: Automatic Bale Plucker

MAXI-FLO:

Manufacturing Trützschler
Company
No. of M/C 01
Model MFC
Manufacturing 2001
Year
Country of Origin Germany
Production up to 820 kg/hr
capacity
No of beater 2
Function Opening & Beating,
to remove seed etc.
Fig: MAXI-FLO

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MPM:

Manufacturing Trützschler
Company
No. of M/C 01

Model MPM-10/1600

Manufacturing Year 2001

Country of Origin Germany

Storage capacity 300 kg


No of Blending 06
chamber
Function Homogenous
mixing

Fig: MPM

CLEANOMAT ( CVT1) :

Manufacturing Trützschler
Company
Fig: CLEANOMAT No. of M/C 02

Model BS 987/1600

Country of Origin Germany

Production 800 kg/hr

No. of Beater 01

Function Opening,beating,
cleaning & refining.

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Dust X:

Manufacturing Trützschler
Company
No. of M/C 01

Model DX

Manufacturing Year 2001

Country of Origin Germany

Installed power 0.8 KW


Function Remove the Dust

Fig: DX

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4.2.3: Flowchart of blow room machines of unit-2:

Bale Opener

MBO

ERM

Kirschner Beater

Scutcher

4.2.4: Machine descriptions of blow room of unit-2:

a) Bale Opener:

Manufacturing Perfect
Company
Fig: Bale Opener
No. of M/C 03

Model PB-1200
Manufacturing 2011
Year
Country of India
Origin
Function Opening &
Beating and feed
fibres to other
machines.

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b) MBO (Mixing Bale Opener):

Manufacturing Lakshmi Rieter


Company
No. of M/C 02

Model N/A

Manufacturing 2007
Year
Country of India
Origin

Function Mixing different


fibers properly.

c) ERM:

Manufacturing Lakshmi Rieter


Company

No. of M/C 06
Model N/A
Manufacturing Year 2000

Country of Origin India

Function Separate the wastage


and mix the fibre.

Fig: ERM

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d) Kirschner Beater:

Manufacturing Lakshmi Rieter


Company
No. of M/C 06

Model N/A

Manufacturing 2007
Year
Country of India
Origin

Function To comb and extract the


lighter impurities from
cotton.
Fig: Kirschner Beater

Scutcher:

Manufacturing Lakshmi Rieter


Company
Model N/A

Manufacturing 2000
Year
Country of Origin India

Function To make a lap


sheet and wind on
roller

Fig: Scutcher

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4.2.3: Flowchart of blow room machines of unit-3:

Unifloc

Semi-condenser

Uni Clean
Carding
Multimixer

Codenser
CVT-1

CVT-3
MBO

DX
Line-1
Uni - Blend

Line-2
BO Uni-Store 1 Uni-Store 2 Condenser
MBO

Condenser

 Cotton Processing Line Carding

 Viscose Processing line

Fig: Flow chart of Blowroom of Unit-3

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Machine Specification & Description of Blowroom-3:

a) Unifloc:

Manufacturing RIETER
Company

Model A11

Manufacturing Year 2016

Country of Origin Switzerland

Production rate 1200 kg/hr

Function To open, clean &


blend or mix the fibre.

Fig: Uni floc

b) Uni-Clean:

Manufacturing RIETER
Company

Model B12

Manufacturing Year 2016

Country of Origin Switzerland

Beater roller rpm 780 RPM

Function To beat, clean and


remove the wastage.

Fig: Uni clean

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c) Multi-mixer (Cleanomat):

Manufacturing Trützschler
Company

Model MCM6 / 1200

Manufacturing Year 1999

No. of Chamber 6

Country of Origin Germany

Function To open & mix the


fibre.

Fig: MCM

d) CVT 3 :

Manufacturing Trützschler
Company

Model CVT3(097)

Manufacturing Year 1999

No. of Beater 3

Country of Origin Germany

Function To more beat & clean


the fibre .

Fig: CVT3

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e) Dust X :

Manufacturing Trützschler
Company

Model DX

Manufacturing Year 1999

Country of Origin Germany

Function To remove short fiber


and dust .

Fig: DX

f) BO (Viscose) :

Manufacturing Trützschler
Company

Model BO-1200

Manufacturing 1999
Year
Country of Origin Germany

Function To open, clean the


viscose fibre.

Fig: BO

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h) Uniblend (Viscose) :

Manufacturing Rieter
Company
No of Machine 02

Model A79
Manufacturing Year 2016
Country of Origin Switzerland

No. of feed roller / 01


machine
No. of opening roller / 01
machine
Function To blend the fibers
properly .

i) Condenser :

Manufacturing Rieter
Company

Model A21

Manufacturing 2016
Year
Country of Origin Switzerland

Function to control the width


of the fiber strand.

Fig: Condenser

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j) Uni-Blend :

Manufacturing Rieter
Company
Model A81
Manufacturing Year 2016
Country of Origin Switzerland

No of Chamber 03

Chamber in which 01 & 03


cotton Stored
Chamber in which 02
Viscose Stored
Function To store the processed
Cotton and Viscose.
After all supply the
cotton-viscose mixer to
Fig: Uni-Blend the MBO in proper
ratio.

k) MBO :

Manufacturing Rieter
Company
Model B34

Manufacturing 2016
Year
Country of Origin Switzerland

Function To blend the


different fibers in
given ratio.

Fig: MBO

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Accessories of blow room:
Item Name Quantity
Bale Trolley 8
Wastage Carrier 06
Trolley
Bale Cutter 5
Bale Cleaner 6

4.3: Carding Machine:

Carding is defined as the reduction of an entangled mass of fibers to a filmy web working between
two closely spaced, relatively moving surface clothed with sharp wire points. The carding is the
heart of spinning and well card is half of spun demonstrate the immense significance of carding for
the final result of the spinning operation. The importance of carding is still greater where new
spinning systems are concerned.
The Objectives of Carding are:
 Neps removal,
 Fibre individualization and slightly straightening including parallelization,  Web
formation,
 Cleaning of heavy particles by stripping and carding action.

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4.3.1: Carding machine specification and description:

Carding machine specification and description of Unit-1 of STML:

Trützschler DK-903:

Model DK-903

No. of M/C 05

Manufacturing Year 2001

Country of origin Germany


Production 45 kg/hr
Manufacturing Trützschler GmbH &
company Co. KG.
Fig: Trützschler DK-903

Trützschler TC-03:

Model TC-03

No. of M/C 01

Manufacturing 2016
Year
Country of Germany
origin
Production 85 kg/hr

Manufacturing Trützschler GmbH


company & Co. KG.
Fig: Trützschler TC-03

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Parameters of carding machines:

Technical data & settings DK-903 TC-03

No. of machines 05 01
Feed roller diameter 127 mm 100 mm
Taker in diameter 254 mm 172.5 mm
Taker in speed 930-2200 rpm 1162 -2392 rpm
Taker in PPSI 120, 10° 1) 34, 10º
2) 163, 10º

3) 210, 10º

Cylinder diameter 1290 mm 1287 mm


Cylinder speed 600-900 rpm 500 rpm
Cylinder PPSI 950, 40º 950, 40º
No of flats 104 84
No. of flats in carding action 33 38

Flat speed 342 mm/min 320 mm/min


Flat PPSI 520-550, 5º 525-600, 5º
Doffer diameter 510 mm 700 mm
Doffer speed Depends on delivery Depends on delivery
Doffer PPSI 367, 30º 483, 30º

Carding machine specification and description of Unit-2 of STML:

Model D1/3

No. of M/C 14

Manufacturing Year 1992

Country of origin India

Production 45 kg/hr

Manufacturing company Lakshmi

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Carding machine specification and description of Unit-3 (line-1) of STML:

Trützschler DK-903:

Model DK-903

No. of M/C 05

Manufacturing 2001
Year
Country of origin Germany

Production 45 kg/hr

Manufacturing Trützschler
company

Fig: Trützschler DK-903

Trützschler DK-803:
Model DK-803

No. of M/C 05

Manufacturing Year 2001

Country of origin Germany

Production 45 kg/hr
Fig: Trützschler DK-803

Manufacturing company Trützschler

Fig: Trützschler DK-803

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 Carding machine specification and description of Unit-3 (Line-2) of STML:

RIETER C70L:

Model C70L

No. of M/C 05

Manufacturing Year 2016

Country of origin Switzerland

Production 75 kg/hr

Manufacturing RIETER
company

Fig: RIETER C70L

4.4: Breaker Draw Frame:

The carded sliver is fed in the Breaker Draw Frame. In STML 8 (eight) card sliver cans are fed in
each Breaker Draw frame. More no. of doublings give more removal of irregularity. If the number
of doubling increases, the number of drafting also increased. But more draft leads more unevenness
in the drawn sliver. So optimum doubling should be maintained.

Objectives of Breaker Draw Frame:


 To parallelize and straighten the fibers in card sliver along the sliver axis.
 To reduce the weight variation.
 To reduce hook formation.
 To lay the sliver in can with uniform coils forming a clear center hole.
 Micro dust removal.

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 Specification and machine description of Breaker Draw Frame of Unit-1:

a) Trützschler HS - 1000:-

Model HS - 1000

No. of M/C 02
Manufacturing 2001
Year
Country of origin Germany

Production 130 kg/hr

Manufacturing Trützschler
company
Fig: Trützschler HS - 1000

 Specification and machine description of Breaker Draw Frame of Unit-2

Trützschler HS - 1000:-

Model HS - 1000

No. of M/C 02
Manufacturing Year 2001

Country of origin Germany

Production 130 kg/hr

Manufacturing Trützschler
company

Fig: Trützschler HS - 1000

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INDUSTRIAL ATTACHMENT

a) Rieter RSB-D45 :-

Model RSB-D45

No. of M/C 02

Manufacturing 2016
Year

Country of origin Switzerland

Production 3000m
Capacity
Manufacturing Rieter
company

Fig: Rieter RSB-D45

b) Lakshmi LDO/6 :-

Model LDO/6

No. of M/C 01

Manufacturing 1999
Year

Country of origin India

Production 4000m
Capacity
Manufacturing Lakshmi
company

Laxmi LDO/6

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INDUSTRIAL ATTACHMENT

 Specification and machine description of Breaker Draw Frame of Unit-3 (Line – 1) :-

a) Trützschler HS – 1000:-

Model HS - 1000

No. of M/C 01
Manufacturing 2001
Year

Country of Germany
origin
Production 100 kg/hr

Manufacturing Trützschler
company
Fig: Trützschler HS – 1000

b) RIETER SB-D45 :

Model RSB-D45

No. of M/C 01

Manufacturing 2016
Year

Country of origin Switzerland

Production 130 kg/hr

Manufacturing Rieter
company

Fig: Rieter SB-D45

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INDUSTRIAL ATTACHMENT

 Specification and machine description of Breaker Draw Frame of Unit-3 (Line – 2) :-

a) Toyota DX7A :-

Model DX7A

No. of M/C 02

Manufacturing 1999
Year
Country of origin Japan

No. of Head 2 per machine

No. of 8
Doubling/Head
Capacity 3000m

Manufacturing Toyota
company
Toyota DX7A

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INDUSTRIAL ATTACHMENT

Parameters of breaker draw frame:

Technical Data and settings RSB-D45

Drafting system 4 over 3

No. of head 2

Roller weighting system Spring loaded


Cot roller shore hardness 83º (Carded)
Bottom roller diameter Front roller-35 mm
Middle roller-35 mm
Back roller- 35 mm

Top roller diameter Front roller - 38 mm


Middle roller - 34 mm
2nd Middle roller – 34 mm
Back roller- 38 mm
Bottom roller gauge Front zone - 40 mm
Back zone - 45 mm

Delivery speed 550 m/min


Sliver length/can 6000m
Trumpet size 3.8/4.2 mm

Present of auto leveler No


No of doubling 08

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4.5: Finisher draw frame:


This machine is used both for card and combed yarn. The card and combed sliver both are fed to the
finisher draw frame. If any fault is occurred in this process it cannot be removing in the further
process. The main deference of finisher draw frame to breaker draw frame is the auto leveller. If
sliver mass variation is occurred, then it averages out the mass variation. The auto leveller can
remove maximum about ±25% variation.

 Specification & machine description of FDF of Unit-1:

RSB-D45:

Model RSB-D45
No. of M/C 02

Manufacturing 2016
Year
Country of Switzerland
origin
Production 125 kg/hr

Capacity 4000m

Delivery speed 700m/min

 Specification & machine description of FDF of Unit-2:

a) Rieter RSB-D45:-
Model RSB-D45

No. of M/C 02
Manufacturing 2016
Year
Country of origin Switzerland
Capacity 3500m

Delivery Speed 600m/min

Manufacturing Rieter
company

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b) Toyota : (Double Headed):

Model DX7A

No. of M/C 01

Manufacturing 1999
Year
No of Head 2

Country of origin Japan


Capacity 3500m

Delivery Speed 550m/min

Manufacturing Toyota
company

 Specification & Machine Description of FDF of Unit-3 (Line-1):

Rieter RSB-D45:-

Model RSB-D45

No. of M/C 02

Manufacturing 2016
Year
Country of origin Switzerland
Capacity 3500m

Delivery Speed 600m/min

Manufacturing Rieter
company

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 Specification & Machine Description of FDF of Unit-3 (Line-2):

Toyota DX7A-LT (Double Headed):

Model DX7A-LT

No. of M/C 02

Manufacturing 2000
Year
Country of origin Japan
No. of Head 2 per machine

No. of 8
Doubling/Head
Capacity 4000m
Manufacturing Toyota
company

4.6: Simplex:
The finisher draw frame slivers are fed to the simplex. The sliver is extended and small amount of
twist is inserted. This twist only helps to hold the fiber during winding of roving and unwinding of
slivers.

Objectives of Simplex Machine:


 To draft the sliver to reduce weight per unit length.
 To insert small amount of twist to strengthen the roving to prevent breakage during next
processing.
 To make conical or tapper shape of the bobbin.
 To wind twisted strand on the bobbin.

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 Specification and Description of Simplex Machine of Unit 1:

Toyota FL100:
Model FL100

No. of M/C 03

Manufacturing 2001
Year

Country of origin Japan

Production 2200 m/ Bobbin


Capacity
Manufacturing Toyota
company

Technical Data of FL100:

Drafting system 4 over 4

No of machine 03
No. of flyer 120
Spindle gauge 220 mm
Roving hank 0.80
Roving TPI 1.19
Total draft 8.2
Auto stop motion Yes

Problem indicating lamp system Yes

Top apron size 37×40×1.1 mm


Bottom apron size 38.8×40×1.1 mm

Top clearer cloth size 680 (l)×3(t)×40(w) mm

Bottom clearer cloth size 510(l)×160(w)×3(t) mm

Flyer speed 600-1500 rpm


Top roller + cradle hardness 83º

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 Specification and Description of Simplex Machine of Unit 2:

a) TONG HE- TH496:-

Model TH496

No. of M/C 04

Manufacturing 2016
Year

Country of origin China

Production 2200 m/Bobbin


Capacity
No. of Flyer 130 spindles/machine

Flyer Speed 1100 m/min

Manufacturing TONG HE
company

b) Lakshmi LR 9/AX :-

Model LR 9/AX

No. of M/C 01
Manufacturing 2012
Year
Country of China
origin
Production 2200 m/Bobbin
Capacity
No. of Flyer 120
spindles/machine
Flyer Speed 800 m/min

Manufacturing Lakshmi
company

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INDUSTRIAL ATTACHMENT

 Specification and Description of Simplex Machine of Unit 3(Line 1):-

Laksmi LF 4200/A:
Model LF 4200/A

No. of M/C 03
Manufacturing 2017
Year
Country of India
origin
Production 2200 m/Bobbin
Capacity
No. of Flyer 140 Flyers/machine
Flyer Speed 1100 m/min
Manufacturing Laksmi
company

Technical Data of Laksmi LF4200/A:

Drafting system 4 over 4

No of machine 03

No. of flyer 140

Spindle gauge 220 mm


Bobbin Dia 112 mm
Roving hank 0.80

Roving TPI 1.250

Total draft 8.2

Efficiency 81.7%

Auto stop motion Yes


Problem indicating lamp system Yes

Flyer speed 900-1300 rpm

Top roller + cradle hardness 83º

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 Specification and Description of Simplex Machine of Unit 3(Line 2) :-

Toyota FL100:-

Model FL100

No. of M/C 03
Manufacturing 2001
Year
Country of origin Japan
Production 2200 m/
Capacity Bobbin
No. of Roving 120
Production 4000 kg/day
Flyer speed 1000m/min
Manufacturing Toyota
company

4.7: Ring frame:


The roving is fed into the ring frame to produce yarn. The necessary amount of draft is also needed.
The twist is inserted to improve the strength but excessive twist may decrease the strength. The
traveller is mainly inserted for imparting the twist.

Objective of a Ring Frame Machine: -

 To produce required count of yarn from the supplied roving by the drafting.
 To insert sufficient amount of twist to the yarn.
 To wind the yarn onto the bobbin.
 To build the yarn package properly.

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 Machine specification & description of Ring Frame of Unit – 1:

Rieter G32 V3:-

Model G32 V3

Manufacturing 2016
year

No. of M/C 09

Production 2500 kg/day


Country of Switzerland
origin

Manufacturing Rieter
company

 Machine specification & description of Ring Frame of Unit – 2

Model AD - 2

Manufacturing 2013
year

No. of M/C 27

Production 9000 kg/day


Country of India
origin

Manufacturing Lakshmi
company

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 Machine specification & description of Ring Frame of Unit – 3 (line-1)

Model AD - 2

Manufacturing 2013
year

No. of M/C 14

Production 9000 kg/day


Country of India
origin
Auto doffer Present

Manufacturing Lakshmi
company

 Machine specification & description of Ring Frame of Unit – 3 (line-2)

Model AD - 2

Manufacturing 2013
year
No. of M/C 11

Production 9000 kg/day

Country of India
origin
Auto doffer Connected in 3 machine

Manufacturing Lakshmi
company

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INDUSTRIAL ATTACHMENT

4.8: Auto Cone Winding section:


The Auto cone winding machine is used to make the yarn cone package from ring cops. During
winding, a yarn clearer device is placed onto each drum head of the auto coner machine which
detects the faulty parts of yarn. Then the faulty part is cut& a splicer joins it. Quantum-3 is used as
yarn clearer.
Objectives of Autocone Winding Machine:

 To prepare a big package from ring bobbin.


 To remove spinning faults.
 To improve the quality of yarn.
 To wax the yarn.

 Specification and machine description of Autocone Winding machine of Unit-1:


Autoconer 6:

Model Autoconer-6
No. of M/C 04
Manufacturing year 2017
Production 62 kg/hr
Electric Clearer USTER Quantum 3
Country of origin Germany
Manufacturing Schlafhorst
company
Fig: Auto Cone Winding

 Specification and machine description of Autocone Winding machine of Unit-2:

a) Autoconer 6:

Model Autoconer-6
No. of M/C 04
Manufacturing year 2017
Production 62 kg/hr
Electric Clearer USTER Quantum 3
Country of origin Germany
Manufacturing Schlafhorst
company

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b) Autoconer X5

Model Autoconer X5
No. of M/C 01
Manufacturing year 2014
Production 50 kg/hr
Country of origin Germany
Electric Clearer USTER Quantum
Manufacturing Schlafhorst
company

c) Autoconer

Model Autoconer
No. of M/C 01
Manufacturing year 2009
Production 35 kg/hr
Country of origin Germany
Manufacturing Schlafhorst
company

 Specification and machine description of Autocone Winding machine of Unit-3(Line-1):

Autoconer 338:
Model Autoconer 338
No. of M/C 05
Manufacturing year 2005
Production 40 kg/hr
Country of origin Germany
Electric Clearer USTER Quantam
Manufacturing Schlafhorst
company

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 Specification and machine description of Autocone Winding machine of Unit-3(Line-1):

Autoconer 6:

Model Autoconer 6
No. of M/C 04
Manufacturing year 2017
Production 62 kg/hr
Country of origin Germany
Electric Clearer USTER Quantam 3
Manufacturing Schlafhorst
company

Process parameters of winding machine:

Winding heads 60

Drum diameter 100 mm

Tensioning device Tensor Disc

Yarn speed 1350m/min


Splicing system Pneumatic

Finished package wt. 1.9kg


Electronic clearer USTER Quantum-3

Magazine 9 bobbin feed


Cutter Ceramic

Traverse length 132 mm


Drum type Pac21(Ø100) 2.3 w

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USTER® QUANTUM 3:
The USTER® QUANTUM 3 is a yarn clearing and monitoring system for winding machines
consisting of:
1. Central Clearing Unit 6 (CCU6). One control unit per winder. All settings and operational check
of
each position are made from the Central Clearing Unit.
- Standalone on all winders except Saurer. Schlafhorst Autoconer 6, Autoconer 5, X5
- Integrated with winder Informator on Saurer. Schlafhorst Autoconer 6, Autoconer 5, X5,
as well as Savio Polar and Savio Polar Multi-cone
2. Intelligent clearer measuring heads (IMH) for each winding position.
3. Interface to the winding positions and connecting cables.
The USTER QUANTUM 3 measures yarn quality parameters, including CV, imperfections and
hairiness, using the Q Data feature, correlated with USTER TESTER data. The USTER QUANTUM
3 alarms on different yarn fault and this is defined as cut alarm, quality alarm etc. It alarms on
following faults:
■ Short thick place
■ Long thick place
■ Thin place
■ Count deviation
■ Foreign matters
■ Polypropylene fibres
■ Periodic faults
■ Shade variation
■ Continuous Shade variation
■ Frequent neps
■ Hairiness

4.9: Yarn Conditioning/Heat Setting:


Heat setting is a term used in the textile industry to describe a thermal process taking place mostly in
either a steam atmosphere or a dry heat environment. The effect of the process gives fibers, yarns
dimensional stability and, very often, other desirable attributes like higher volume, wrinkle resistance
or temperature resistance also used to improve attributes for subsequent processes. Yarns tend to have
increased torque just after spinning, cabling or twisting. Heat setting can influence or even eliminate
this tendency of undesirable torqueing.

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Model 1000 KG LPG

Manufacturing year 2014

Country of origin India

Capacity 416 cones

Manufacturing SIEGER
company

Process parameters of Heat setting:


Product Temperature Time

Cotton, Cotton 60ºC 50 min


Melange

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4.10: Packaging section:

Specification of Yarn Packaging Machine:

Model Zancancer

Manufacturing year 2016

Country of origin Italy

Input Capacity 11 cones

Manufacturing Zancancer
company

Measurement of packing bag:


 Length of packing bag = 37 inch
 Height of Packing bag = 48 inch .
 Bag weight = 51.3kg
 A bag contains 24 cones
 Each cone contains 2.04 kg yarn
 Weight of paper cone (24 pcs) = 1.03 kg

Package label:
Package label contains following information:
 Yarn count
 Types of yarn
 Code no
 Lot no
 Factory name
 Date of making yarn
 Weight in kg

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CHAPTER FIVE

Quality Control

5.1 Quality control system:


The quality control department is assigned to maintain consistently uniform quality of the material
in process and various stages of its manufacturing. Shohagpur Textile Mills Ltd. is more concern
about quality.

5.2: Plan of quality department:


 Raw cotton analysis.
 CV% & deviation control of gr/yd and count.
 Setting parameter control (B/R, Card setting, Roller gauge, Draft, TPI, Speed, Yarn clearer
etc.).
 Optimum quality (CV%, Thin, Thick, Neps, H%, Tenacity, Elongation, CSP).
 Wastage control (B/R to finishing).
 Machine fault find out by machine audit and rectification by responsible department (B/R to
Finishing).
 Operation control (m/c, floor cleaning, material handling, lot change, count change and
housekeeping etc.).
 Manpower training (market demand, operation, wastage/quality control, Work procedure,
housekeeping and safety).
 Yarn performance report (Observation market feedback report).
 Continual improvement by R&D.

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5.3: List of testing equipment and their manufacturer and model no:

M/c name Manufacturer Model no No of


machine
Lea strength Tester MAG, INDIA YO261 1

Auto Wrap 10 MAG, INDIA YO121 1

USTER AFIS PRO-2 USA AFIS PRO-2 1

HVI MAG HVT Smile 100 1

USTER TESTER-6 Switzerland YGO41 1

5.4: Machine description:

a)Auto wrap 10:

Specification Details

Machine Name Wrap Reel

Model Auto Wrap 10

No. of M/C 03

Origin India

Fig: Wrap Reel

Function: An auto wrap reel is an automatic device for measuring yarn and making it into hanks of
a standard size. The reel is of a standard size and its revolutions are counted as the yarn is wrapped
around it. A set number of revolutions will be used so that the hank is of a standard size — a skein
or a lea. A skein of cotton would be 80 turns on a reel of 54 inches circumference, making 120
yards.

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b) Lea strength tester:

Specification Details

Machine Name Lea Strength Tester


Model TYT-030

Brand TECHNO
Origin India

No of Machine 1

Fig: Lea Strength Tester

Function: A lea strength tester measures the strength of one lea yarn. One lea means 120 yards.
Strength is a measure of the steady force necessary to break a material and is measured in pound.
The m/c works in constant rate of extension.

c)USTER tester 6:

Fig: USTER Tester 6

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Function: It is used to measure the unevenness of mass (Um %), co-efficient of variation of mass
(CV %), hairiness, imperfection index (IPI), thick- and thin places, neps etc. of yarns, rovings and
slivers. Principles of Uster evenness tester are capacitive principle and optical principle.

d) USTER AFIS PRO-2:

Fig: Uster AFIS Pro-2

This instrument is widely used instrument for neps measurement (Advanced Fibre Information
System) . This equipment has three modules.
 NC Module (Nep classification)
 L & M Module (Length and Maturity)
 Trash Module
Functions: To measure following fiber properties-

-Nep (Cnt/gm) L(n) (%CV)


SFC(n) (%<12.7) L(w) (mm)
Nep (μm) IFC (%)
UQL(w) (mm) Maturity ratio
SCN (Cnt/gm) L(w) (%CV)
L(n) (mm) SFC(w) (mm)
SCN (μm)

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e) HVI:
Specification Details

Machine Name HVI

Model HVT Smile 1000

Brand USTER

Origin India

Function:
The USTER HVT Smile 100 measure the most important cotton fiber properties for cotton classing
purpose (and high throughput for spinning mills). These are length, uniformity, short fiber index,
micronaire, maturity index, strength, elongation, colour & Trash and moisture content.

Feature:
(High Volume Instrument) This equipment is used mainly for bale management. This equipment
contains three modules. They are:
 Micronaire (MIC)
 Length and strength
 Maturity

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Different Test Specifications:


A. Micronaire: Different values of micronaire make difference in fiber grade as follows;
Micronaire values Fiber grade
Less than 3.0 Very fine
3.0 to 3.6 Fine
3.7 to 4.7 Medium
4.8 to 5.4 Coarse
5.5 to higher Very coarse

B. Maturity: The values of maturity index identify the level of maturity as follows;
Maturity Index Description
Below 0.75 Uncommon
0.75 to 0.85 Immature
0.86 to 0.95 Mature
Above 0.95 Very mature

C. Uniformity Index: The uniformity index expresses the ratio of the mean length to the
upper half mean length. It is an indication of the distribution of fiber length within the
fibro gram.
Uniformity Index Description
Below 77 Very low
77 to 80 Low
81 to 84 Medium
85 to 87 High
87 and higher Very high

D. Length: Fiber length in Inches and upper half mean length (UHML) in inches & millimeter
ratio are the main calculative result of length test as follows;
Fibre
length(Inches) UHM (inches) UHM (mm) Code (32nds)
<13/16 <0.79 <20.1

20.1-21.6
13/16 .80-0.85
7/8 0.90 – 0.92 22.9-23.4 29
15/16 0.93 – 0.95 23.6 – 24.1 30
31/32 0.96-0.98 24.4 – 24.9 31

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1 0.99-1.01 25.1 – 25.8 32
1 1/32 1.02-1.04 25.9 – 26.4 33
1 1/16 1.05-1.07 26.7 – 27.2 34
1 3/32 1.08-1.10 27.3 – 27.9 35
1 1/8 1.11-1.13 28.2 – 28.7 36
1 5/32 1.14-1.17 29.0 – 29.7 37
1 3/16 1.18-1.20 30.0 – 30.5 38
1 7/32 1.21-1.23 30.7 – 31.2 39
1¼ 1.24-1.26 31.5 – 32.0 40
1 9/32 1.27-1.29 32.3 – 32.8 41
1 5/16 1.30- 1.32 33.0 – 33.5 42
1 11/32 1.33 -1.35 33.8 – 34.3 43
1 3/8 >1.36 >34.5 44

Wastage:

Section For 100% Cotton For PC or CVC


Blowroom Up to 4% (Dropping-2) 2.5%

Carding Up to 6% (Dropping-1) 3.5%


Breaker drawframe 0.5% 0.5%
Finisher drawframe 0.5% 0.5%
Simplex 1% 1%

Ring 2.5% 1.5%


Winding 0.35% 0.35%

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CHAPTER SIX

Maintenance

6.1: Maintenance:
Maintenance is the combination of all technical and associated administrative actions intended to
retain an item in, or restore it to, a state in which it can perform its required function. Many
companies are seeking to gain competitive advantage with respect to cost, quality, and service and
on-time deliveries. The effect of maintenance on these variables has prompted increased attention
to the maintenance area as an integral part of productivity improvement. Maintenance is rapidly
evolving into a major contributor to the performance and profitability of manufacturing systems.

Objectives of maintenance:
 Minimizing the loss of productive time because of equipment failure.
 Minimizing the repair time and repair cost.
 Minimizing the loss due to production stoppages.
 Prolonging the life of capital assets by minimizing the rate of wear and tear.
 To keep all productive assets in good working conditions.
 To minimize accidents through regular inspection and repair of safety devices.
 To minimize the total maintenance cost which includes the cost of repair, cost of preventive
maintenance and inventory carrying costs, due to spare parts inventory.
 To improve the quality of products and to improve productivity.

6.2: Maintenance of machineries:

Electrical
Preventive Maintenance
Maintenance
Mechanical
Maintenance

Electrical
Maintenance
Break Down
Maintenance Mechanical
Maintenance

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Break down maintenance:


Break down Maintenance is maintenance performed on equipment that has broken down. It is based
on a breakdown maintenance trigger.
Preventive maintenance:
Preventive maintenance is the care and servicing by personnel for the purpose of maintaining
equipment and facilities in satisfactory operating condition by providing for systematic inspection,
detection and correction of incipient failures either before they occur or before they develop into
major defects. This type includes maintenance of machine parts like gear changing.

6.3: Machineries used for maintenance:


The list of machineries used in Shohagpur Textile Mills Ltd. is given below-
 Grinding machine
Carding  Mounting machine
 Brush cleaning machine etc.

 Long cot grinding machine


Draw frame  Flyer washing machine
 Grinding machine etc.
 Cot grinding machine
Ring frame  Cot mounting machine
 Spindle oil change machine etc.

Fig: Grinding Fig: Grinding roller

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6.4: Maintenance points:

S.N. Items need to be checked & serviced

1. Check and tightening all motor terminals.

2. Check and clean pressure sensor and tightening terminals

3. Check and clean the interfacing and data cables.

4. Check and tightening the proximity switch terminals.

5. Inspection, cleaning and tightening all the terminals in the panel.

6. Check and tightening limit switch, safety door guard and the emergency switch.

7. Functional test of the fibre, sliver, roving and yarn detector.

6.5: Machine maintenance schedule:

6.5.1: Maintenance for blow room:

Operations Frequency

Cleaning of dust and collected fly from the m/c Daily


Cleaning of motor air intake screens Daily

Cleaning of flat belts, v-belts and sprockets Every 7 days


Cleaning the brush roller Every 7 days
Checking the condition & tension of flat belt & chain drives. Every 7 days
Oil change in gear motors Every 30 days

Lubrication works of bearing of supporting shaft and tension Every 15 days


pulley.
Cleaning of fibre accumulating from the grid bars and the pins Every 7 days
of the beaters.

Cleaning of the intake grill of the fan cover of the driving motor. Every 15 days

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6.5.2: Maintenance for carding:

Operations Frequency

General cleaning of machinery by the operator. Daily

Checking of stop motion switches Daily

Checking of belt tension and condition Daily

Ampere rating of motor Every 7 days

Checking of doffer to cylinder driving gears Every 30 days

Full setting/re-setting Every 30 days

Dismounting and cleaning of feed coupling plates and web units Every 30 days

Checking of auto leveler Every 30 days

Checking the condition of wire of cylinder, taker-in doffer and Every 30 days

flat combs Every 30 days

Checking the gauge of feed plate to feed roller Every 30 days

Checking the gauge of taker-in to cylinder Every 30 days

Checking the gauge cylinder to doffer Every 30 days

Under casings setting Every 30 days

Checking of trumpet, calendar roller & gears Every 30 days

Checking the bearings & motor shafts Every 30 days

Wire replacement of cylinder, doffer & f1ats. Every I5-18 months

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6.5.3: Maintenance for Draw frame:

Operations Frequency

General cleaning of machine by operator Daily

Cleaning of top roller cots with suitable solvent Daily

Checking the drive/motion of clearer cloth, clearer pad,positive Daily


drive comb, can change drive

Checking the function of oil pump of outer side, gear end s ide, Daily
filling the oil in oil tank

Function of stop motion limit switches etc. Daily

Greasing the top bushes having bearings Every 7 days

Roller gauge checking/resetting Every 30 days

Pressure checking/resetting Every 30 days

Cleaning the bottom fluted roller with wire brushes Every 30 days

Cleaning and polishing of coiler and brush Every 30 days

Lubricating/greasing of the creel roller drivers Every 30 days

Tightening of the loose nuts, bolts, allan screws etc. Every 30 days

Checking the condition of trumpets, sliver guides, clearer tubes Every 30 days
yokes, air pipes grease nipples etc.

Checking of timing belt tension Every 30 days

Backlash checking of machine gears Every 30 days

Checking the eccentricity of top and bottom roller (if needed) Every 30 days

Oil change Every 60-90 days

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6.5.4: Maintenance for simplex:

Operations Frequency

General cleaning of machine by operator Daily

Check functioning of oil pump Daily

Topping of oil Every 15 days

Building motion setting Every 30 days

Top roller cot treatment/greasing Every 30 days

Roller gauge checking/resetting Every 30 days

Centering/alignment the sliver guide, collector and condenser in Every 30 days


relation to cot

Alignment of bottom apron tensioning pulley W.R.I. knurled Every 30 days


roller

Checking & tightening of loose nuts blots etc. Every 30 days

Pressure checking/resetting Every 30 days

Top roller cot grinding Every 30 days

Lubricating oil change Every 60-90 days

Replacement of top roller cots Every 60-90 days

Greasing the top roller arbour Every 360 days

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6.5.5: Maintenance for ring frame:

Operation Frequency

General cleaning of machine by operator Daily

Checking of oil pump Daily

Checking of push-button& motor amperes Every 7 Days

Refilling of oil Every 7 Days

Tension of V-belts and spindle tapes Every 7 Days

Checking of gears & gear meshing Every 20 days

Inverter checking A/C (input & output), D.C Every 20 days

Top roller cots treatment / greasing Every 36 days

Checking of spindle and lappet Every 36 days

Checking of ring rail parallelism Every 36 days

Checking of ring cup block gauge Every 36 days

Building motion setting Every 36 days

Roller gauge checking / resetting Every 36 days

Pressure checking / resting Every 36 days


Bottom roller turning (If required) Every 36 days

Checking of traverse motion, top & bottom rollers/top etc. Every 36 days

Greasing of all bearings, open gears etc. Every 36 days

Checking & tightening of loose nuts, bolts etc. Every 36 days

Top roller cots buffing / grinding Every 90 days

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6.5.6: Maintenance for auto cone winding:

Operation Frequency

Checking and removal of blow cleaner waste Daily

General cleaning of blower motor, filter shaft, motor filter Daily


control box, clipper filters
Measuring head checking Every 7 Days

All micro switch checking Every 7 Days

Gauge checking/resetting Every 7 Days

Drum checking Every 30 Days

Checking of splicing unit Every 30 Days

Spray lubricant for cutters Every 30 Days

Checking of cone sensors Every 30 Days

Spray grease for drive gears/spindle oil for cam shafts Every 30 Days

Checking of drum bearing, splicing bearings, blower shaft Every 90 Days


bearings

Checking of drum brakes, shutter cutters, cassette type joint Every 180 Days
gears, reduction gears

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CHAPTER SEVEN

Utility Services

In Shohagpur Textile Mills Ltd. the available utility services are:

Generator

A/C Plant

Electrical & Electronics

Compressor

7.1 Generator:

M/c Name Model Brand Country of Manufacturing Quantity


Name origin year

Generator VPH 7100 Waukesha USA 2000 2


GSID
Generator VHP 3604 Waukesha USA 2003 1
GSID

Generator 5904 GSID Waukesha USA 2005 1


LTD
Water pump KSB India 2003 4
(Generator cooling)

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STML Power Generation Status at a glance:

Power Consumption
Mill-1 Mill-2 Mill-3 Mill-4 Security Colony Pump Cooling Lightening
Tower
256.90 1344.22 828.72 813.75 16 KW 70 KW 239.20 33.35 17.42 KW
KW KW KW KW KW KW

Generator + REB = 4831 KW

Power Status
Generator (850×2) + (800×2) 3300 KW
Total 3300 KW

Power Capacity
Generator (920×2) + (900×2) 3640 KW
REB 1191 KW

Total 4831 KW

a) Generator specification:
Type Gas generator

Total capacity 920 KW (each)

Frequency 50 HZ

Efficiency 70%

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b) Electrical panel:
M/c Name Brand Country of Manufacturing Quantity
origin year

LT-Panel (4000AMPS) Siemens Germany 2007 3

LT-Panel (3200AMPS) Siemens Germany 2007 3

LT-Panel (200AMPS) Siemens Germany 2007 3

PFI-Panel (500KVAR) Siemens Germany 2007 3

PFI-Panel (700KVAR) Siemens Germany 2007 3


PFI-Panel (900KVAR) Siemens Germany 2007 3

BDT (3200AMPS) Siemens Germany 2007 3

BDT (3200AMPS) Siemens Germany 2007 3

7.2: Cooling tower:

M/c Name Model Country of origin Manufacturing Quantity


year

Cooling tower Thailand 2012 7


350RT

Fig: Cooling Tower

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7.3: AC plant:

M/c name Model Country of Manufacturing Quantity


origin Year

LUWA completer A/C plant DG 05 Switzerland 2010 3 (Unit-1)

LUWA completer A/C plant DG 05 Switzerland 2007 3 (Unit-2)

LUWA completer A/C plant DG 05 Switzerland 2010 2 (Unit-3

LUWA completer A/C plant DG 05 Switzerland 2007 2 (Unit-4)

A/C plant controls the relative humidity in different section during processing of yarn. The most
effective way to humidify a textile plant is to use a compressed air & water spray system. Air
humidity is measured as ‘Relative Humidity. It is defined as the amount of water in a sample of air
compared to the maximum amount of water the air can hold at the same specific temperature.
It’s expressed in a form of ―0 to 100.
Cold air can hold less moisture than warm air, therefore the humidity of air is relative to its
temperature. For example, a sample of air at 10ºc can hold less moisture than the same sample of
air at 20ºc. Even with the same amount of water present in both samples, the warmer sample has a
lower relative humidity as it can potentially hold more moisture than the cold air sample. The
properties like dimensions, weight, tensile strength, elastic recovery, electrical resistance, rigidity
etc. of all textile fibre whether natural or synthetic are influence by moisture regain.
Air conditioning is the process of treating air also as to control simultaneously its temperature,
humidity, cleanliness and distribution to meet the requirements of "conditioned space". An air
conditioning system may use heating, cooling, humidifying, de-humidifying and filtering units of
combination of these depending upon the outside weather.

The capacity of an air conditioning system is directly proportional to the heat load in the system.
The heat load consists of internal heat which is almost constant for textile mills and transmission
heat which varies from time to time and season.
The maximum heat load, which occurs during summer afternoons, determines the capacity of air
conditioning required for a department of the maximum heat load, roof heat load accounts 25% to

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30%. Air conditioning plants are installed to maintain correct ambient condition for spinning process
to work smoothly. Norms of temperature and relative humidity for textile mills are established
through controlled experiments in laboratories and mills.

Relative humidity and temperature in different section:

Section RH Temp
Blow room - Simplex 48-58% 30ºC
Ring section 50-55% 35ºC

Finishing 60-66% 29ºC

7.5: Compressor:
Flow Chart of Compressor:

Motor

Suction Filter/ Air Filter

Compressor

Oil Separetor

Oil Filter

Condenser

Reserve Tank

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M/c Name Model Country Manufacturing Quantity


of origin year
KAESER 2014 4 (Unit 01 & 03)

ELGI E-75 2010 3 (Unit 02)

KAESER Air dryer 2010 1 (Unit 01 & 02)


KAESER Air dryer 2010 1 (Unit 03 & 04)

Parameters of compressor:

Power consumption for a compressor 60 KW/Pcs

Voltage 41 V

Frequency 50 HZ

Capacity 13.6m/min
Normal pressure 5.5 bar

Pressure after compressed 8.6 bar

Fig: Compressor

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CHAPTER EIGHT

Store & Inventory Control

8.1: Inventory control:


Store is the place where every type of raw materials, spares, finished goods are kept in proper
system. Inventory control means the accurate calculation of every type of raw materials, spares,
wastages and finished goods time to time. Inventory control is necessary-
 To know about the required amount of raw material,
 To be continued the production process,
 To find out the profit or loss of a company,
 Stock and stock value for consumption measuring etc.

8.2: Sections of store:

STML store consist of five sections:

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a) Inventory System for spare parts:


In this mills required amount of spears of different machine are stored in mechanical store room.
All the spears are listed in a sheet which is controlled by mechanical and maintenance personal.
Spears are arranged in store room according their size, quantity and requirements.

b) Inventory system for finished goods:


STML supplies its finished yarn to different fabric manufacturing industry. So cone package yarns
are stored for short time in the finishing section. All the delivered yarns are noted on tally khata
according to lot no, count, quantity, buyer ‘s name and other technical parameter.

c)Inventory system for raw material:


 Raw materials partially received from production planning & directly from head office.
 Material receiving & inspection report (MRIR) is prepared. Received quantity is mentioned
and noted down.
 Submitted to Q.C. department. Some are OK & few rejected.
 Entry of data of goods.
 Goods are arranged according to OK or rejected group.
 As per requisition materials supplied & this record is noted down.
 All the raw cotton is stored in godown, near the blow room section.

d)Inventory system for general store:


In general store, there stored-
 Capital equipment’s.
 Accessories.
 Stationary.
 Maintenance parts etc.
All the particulars are labelled and the records of them are noted in record book.

e) Inventory system for waste cotton:


There is a waste cotton godown where hard waste and soft waste are stored. Dropping-1, dorpping-
2, flat strip, noils, bonda waste etc are sorted and stored as per as their usability.

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8.3: Inventory procedure:


 Store requisition
 Store ledger account
 Daily inspection & package report
 Monthly stock & consumption report
 Monthly L/C wise delivery report
 Received delivery & balance stock

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CHAPTER NINE

Marketing Activities & Cost Analysis

9.1: Consumers of product:


The regular consumers of STML product are like,
 Knit Concern.
 Kakado.
 J.S Design.
 Woolen & Wool.
 Keya Spinning mills.
 Metro.
 Aman Tex Spinning.

9.2: Exporting country:

Shohagpur Textile Mills Ltd. does not export yarn directly. They sell yarn to the various export
oriented factory. And after the factories make knitted garments & dyed fabric, then the final products
are exported.

9.3: Importing country:


Raw cotton is imported mainly from Uzbekistan, Tajikistan, Cameroon, South Africa, Australia
Zimbabwe, Tanzania, Azerbaijan, India, Benin, Uganda, Brazil, Zambia.

9.4: Local market:


STML produces not only export quality yarns but also supply yarns in local market.

9.5: Cost analysis:


The management of STML does not provide any information regarding these to the outsiders as per
their managerial policies.

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9.6: Marketing strategy:


Marketing strategy is a very important factors to sale the products to the buyer. If the marketing
strategy is not so developed, it will be very hard to reach the goal. In Shohagpur Textile Mills Ltd.,
mainly senior marketing officers & higher officials deal with the buyer. There are some fixed buyers
of the industry. The buyers give their orders continuously all over the year. By both side
understanding the rate & the order quantity are fixed.
A well-defined marketing strategy has the following characteristics:
 Prompt service,
 Good commitment.
 Good quality,
 Low price or competitive price.

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CHAPTER TEN

Administration, Account, HRD and First aid

10.1: Administration:

Administration department plays a vital role in manufacturing industry. It controls/maintains and


looks after all the task of all departments in industry. It communicates with different department in
regarding company’s target. It is said that, well administration is half success and well management
is the fame of company.
Administration is like a network which spread information, gather information, collect data, recruit
employee & worker, well distribution, try to improve the company’s environment, improve skill by
arranging training and soon. Objective and tasks are:
 To control/maintain and look after,
 To recruit the manpower,
 To improve environment of industry,
 To communicate with owner of the company, local, politician, legal adviser, if face any
unexpected problem,
 To ensure the security of properties and employees inside the factory,
 To arrange training for improving skill,
 To motivate employees and workers and aware about rules and regulations of industry.

10.2: Accounts:
All the financial activities are done by Accounts department. This department is responsible of any
transaction, pay wages, account receivable and payable, to inform to owner, make monthly sheet
and yearly sheet and so on.

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10.3: Fire-fighting:

a) Equipment:
STML installed a modernized fire hydrant system covering the entire area of the factory. Fire
extinguishers of CO2 and ABC gas powder are available in every section of the factory. A fire can
rapidly spare in a spinning mill if it cannot be controlled. Cotton ignited very fast. The worker and
other related person are always ready for any kind of accident with their modern equipment.

b) Fire extinguisher:
There are 3 kinds of fire:
 A class – Solid fire (Cotton, fiber, bamboo, wood etc.)
 B class – Liquid fire (Diesel, petrol, octane etc.)
 C class – Gas fire
And there are five kinds of fire extinguisher:
 ABCE (It can be used in all kinds of fire)
 DCP (Dry chemical powder)
 CO2 (For electrical fire)
 Water type
 Foam type
Here, in STML, there are 200 fire extinguishers, 100 of these are dry powder, 20 of these are
water type, and 5 of these are foam type. There are 50fire house cabinets present in STML.

10.4: HRD department:


Human Resource Development department provides the facilities of employees and workers in
industry. This is also called facilitator department. Tasks of HRD are:
 Need to arrange training program for manpower development.
 To act as a bridge / catalyst / facilitator.
 To co-operate with other departments as per their requirements.

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10.5: First aid:


First aid means primary treatment of any injury. It may be done by doctor, nurse, expert of medicine
and others. The main tasks of first aid team are:
 To provide necessary medicine
 To aware of workers about first aid
 To check up worker’s health
 To send injured to general hospital if needed
 To give proper treatment & medicine
 To call ambulance for serious injured

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CHAPTER ELEVEN

Impact of the Internship

It gives me chance to learn new skills that add to my knowledge base while gaining
confidence in my abilities. Gain industry knowledge first hand from an organization and
professionals. Opportunity to practice communication and teamwork skills. Achieve a sense
of accomplishment by contributing to an organization.

Industrial attachment helps us to learn about the field from the inside and decide if this is the
right career field for us. It also helps us to work alongside in our chosen career area. Along
these, it helps us to observe the work place and see if it matches expectations.

Industrial attachment provides us evidence that I have initiative, are reliable, and have a sense
of responsibility. It helps me to achieve and make chance to apply some of the ideas learned
in school and provide a bridge between school and the professional world .

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CHAPTER TWELVE

Conclusion

As an undergraduate of the National Institute of Textile Engineering & Research we would like to
say that this training program is an excellent opportunity for us to get to the ground level and
experience the things that we would have never gained through going straight into a job. We are
grateful to the Shohagpur Textile Mills Ltd. for giving us this wonderful opportunity. The main
objective of the industrial training is to provide an opportunity to under graduates to identify,
observe and practice how engineering is applicable in the real industry. It is not only to get
experience on technical practices but also to observe management practices and to interact with
fellow workers. It is easy to work with sophisticated machines, but not with people. The only chance
that an undergraduate has to have this experience is the industrial training period. I feel I got the
maximum out of that experience. Also we learnt the way of work in an organization, the importance
of being punctual, the importance of maximum commitment, and the importance of team spirit. The
training program having three destinations was a lot more useful than staying at one place
throughout the whole two months. In my opinion, I have gained lots of knowledge and experience
needed to be successful in a great engineering challenge, as in my opinion, Engineering is after all
a challenge and not a job.

Finally, we like to thank the directors and employees of STML for their support and encouragement
during our training period. By dint of that we have enriched our depth of knowledge on practical.
We believe STML will hold its name and fame in future too. We like to wish Shohagpur Textile
Mills Ltd. all success.

------The End------

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