TRAINING REPORT

Abhishek Home Textiles-II

Abhishek Industries Ltd.
Dhaula Complex, Barnala

SUBMITTED BY:
Varun Garg
The Technological Institute of Textile & Sciences
Bhiwani
 ACKNOWLEDGEMENT

We would like to thank Mr. C. P. Punaini, who has been a great support
and guide during our training period. The projects given by him have
proved to be a source of immense learning for us.

We would also like to thank Mr.Lalit Kaushal, Mr. Naresh Kumar, Mr. M.K.
Ghosh and Mr. Puneet Bhatia for their constant guidance and support.

We are also very thankful to all the people working in Trident who co-
operated with us and were a great help during our training.

Varun Garg
 Introduction to trident Group

Trident Group is the second largest terry towel manufacturing and

exporting unit in India. It is a Rs. 15 billion global enterprise in the
business of Yarn, Terry Towel, and Paper & Chemicals. The plant is spread
across 715 acres of land with a state-of-the-art Technology sourced from
Switzerland, Germany and Italy. Abhishek Industries Ltd (ABIL), Barnala
is now on an expansion spree with planned investments in a home textile
plant and sugar manufacturing plant

Trident Group is certified to use Supima Trademark as governed by

Supima Association of America Oeko-Texmark granted by Swiss Textile
Testing Institute for Terry Towels and Yarns thus certifying the eco-
friendliness of the technology. It is one of the largest exporters of terry
towels to international buyers such as Wal-Mart, JC Penny, Franco, Target
Stores, APE, K-Mart, CSC, Gozze, Burlington and Indian corporate like
ITC, Sahara, Jet Airways and Taj Hotels.

To enhance the value proposition to our customers and establish a

collaborative supply chain network the company has gone for
implementation of SAP, to standardize its operations. With this, Trident has
joined the elite group of global enterprises in embracing technologies and
processes for optimizing internal efficiencies and ensuring high quality
deliverables. It has successfully completed the first phase of its SAP R/3
Enterprise Resource Planning (ERP) Solution Implementation. Apart from
streamlining the current business processes and operations, it has also
maximized the production capacity and has helped to achieve faster outputs
in complex new product development. SAP is implemented on gigabit OFC
campus LAN's & across the offices of Trident in India through a Private
OFC networks. As part of Collaborative planning framework, the company
will shortly be extending this network to their business associates. With the
implementation of SAP R/3 and APO, the company has made its advent
into the world of e-business. Its CRM, SCM and B2B Applications and
Business Intelligence Warehousing are deployed on high-end systems
thereby linking all plants, operations, offices, projects, customers and
vendors.

Location: Village Dhaula, Mansa Road, Barnala

Total Area: 715 acres

Facility Comprises of:

• Abhishek Home Textiles Unit 1 (ABIL-AHT 1)
• Abhishek Home Textiles Unit 2 (ABIL-AHT 2)
• Industrial Organics Ltd( IOL)
• Paper & Chemicals Division 1 (ABIL-PCD 1)
• Paper & Chemicals Division 2 (ABIL-PCD 2)
Products
• Terry Towels & Toweling products
Piece Dyed Dobbies,Yarn Dyed Single & Double Jacquards, Undyed
Jacquards, Yarn Dyed Stripes weft inserts & Checks, Terry & Velour
Finish. Beach Towels, Bath Sheets, Bath Towels, Hand Towels, Guest
Towels, Face fringes, Bath Mats, Kitchen Towels & Gloves, Specialty
towels in Zero twist yarn, Egyptian cotton, and cotton with
Model/Tencel Blends.
 TRIDENT BEST PRACTICES

Our Culture

TRIDENT promotes the family culture and hence emphasizes the

importance of transparency, openness, trust and empowerment in the
day-to-day work.

As TRIDENT is on its way to becoming a global organization we have

incorporated certain policies which we feel will give an impetus to the
workflow. These are

TPM

TPM stands for “Total Productive Maintenance” and builds a close

relationship between Maintenance and Productivity, showing how
good care and up-keep of equipment will result in higher productivity.

TPM is a philosophy of continuous improvement that creates a sense of

ownership in the operator(s) of each machine as well as in their
supervisor. We all reach a new attitude of higher responsibility and
 commitment. TPM is to Maintenance very much as Total Quality is to
Production. TPM is another tool to help us reach our projects for the
competitive years to come.

Implementation of TPM at our plant should be

accomplished in accordance with the international
guidelines"

Our focus will be:

• Ease the operation

• Improve the Productivity

• Ease the maintainability

• Make the operation and area Safer!

Once implemented, TPM has just begun... it is an ongoing process of

continued improvement supported by all the team. The members of the team
should communicate with each other on a regular basis to find out how the
process is going and to decide if new improvements should be considered
and, if feasible, scheduled.
FIVE S
What are Five 'S'

Five 'S' are derived from the first letters of the words

SEIRI means Organisation or sorting

SEITON means straighten or prepare correctly
SEISO means Cleanup or Cleanliness
SEIKETSU means Standardisation
SHITSUKE means Discipline

They are five integrated parts of House keeping or work place

Management.

What benefit we get by practising Five 'S'?

A clear work place is high in Productivity

A clear work place is high Quality
A clear work place helps in Cost Reduction
A clear workplace ensures Delivery on Time
A clear workplace is Safe for people to work.
A clear workplace will bring high Morale.
 Abhishek home textiles - 2

Layout of the plant is as follows:

The unit consists of following main sections:
1. Cheese winding
2. T.F.O
3. Soft winding
4. Package to cone winding
5. Package and fabric dyeing
6. Yarn packing
7. Weaving
8. Cutting/Hemming/Packing
9. Shearing

A brief introduction to these sections is as follows:

1.Cheese Winding :

This process is carried out to double the yarn by combining two strands of
single yarns. Yarn supply is on paper cones or cheeses & the two-ply yarn
is wound on to plastic tubes having approx one kilogram of yarn.

The waste incurred is on following basis: -

ϖ Starting of a position, knotting etc.

ϖ Yarn faults, breakage, stains, entanglement, package damage & cuts etc.
It is estimated that for each package of 1 kg, about 20 meters could be
wasted in piece ups including breakages. The wastage is proportional to the
coarseness of the yarn. For heavier yarns the weight of waste will be more.
Wastage because of start-ups, breakages, entanglements & package faults is
estimated to be 0.25% as standard.

2 T.F.O

This process is carried out to twist the cheese wound double yarn to make
twisted two-ply yarn. The final package is maximum 2.0 kgs.

The waste incurred is on following basis: -

● Starting of a position, knotting etc.

● Yarn faults, breakages, entanglements, stains etc.

The wastage is higher if coarser yarn is processed. With improved yarn

quality & reduced breakages the wastage can be reduced to a lower level.
The std. Wastage is 0.25%
3.Soft Winding :

To prepare the yarn package, which can be dyed the material, is wound on
to s.s. wise tube which is compressible & allow the dye liqueur to flow
through the yarn layers from inside to outside & from outside to inside.
The package weight is approx. 1 kg. The amount of waste generation is of
the order of 0.25% under normal circumstances.

4 .Package to Cone Winding :

The dye yarn package on SS. spring tube after dyeing is taken to this
machine to wind the yarn on to paper cones, which is the final product.

The wastage is due to following:

• Start up string up.

• Breakages, entanglement.
• Shade variation portion removal.

To get desired quality package on an average 0.24% waste is incurred. The

reduction is possible with improvement in yarn quality & package dyeing
uniformity.
5. Package & fabric dyeing:

The process has three parts which are pretreatment, dyeing and after
treatment.
Dyeing is carried out in pressure vessels using reactive dyes of vinyl
sulphone and cyanuric chloride he type dyes. The dyeing liquor is forced to
circulate through the package. Before actual dyeing the material has to be
prepared to get good dyeing results. For this it is necessary to do the
following:

• Yarn should be clean, wet, free from impurities, waxes, oils, foreign
matter etc.
• Remove any traces of calcium/magnesium salts.
• There should not be any air present in the yarn or in the dyeing bath.

Treating the material with wetting agent, strong alkali, & bleaching agents
like H2O2.
For lighter shades this pretreatment has to be very thoroughly carried out to
remove all traces of waxes & oils present in cotton. During this process
there is a loss of material in addition to losses due to removal of cotton
waxes etc.
For achieving level dyeing results following factors are to be considered:
v Uniformly of package density.
(A) Material liquor ratio & rate of flow of liquor through the
package.
§ Temperature.
• Exhausting salts.
• Quality of dyes & chemicals.
ϖ Use of clean soft water.

There is no method by which the actual loss in weight of cotton could be

controlled while in process. The estimates are possible by actual
weighments before & after dyeing of each lot. Necessary weighing
arrangements are being planned by installing suitable balance in dye house.
There is no other material wastage in dyeing. In fabric & hank dyeing
process is similar but it does not require the use of pressure because
material is in loose form & offers no resistance to liquor flow.
In dyeing normal material wt. Loss (invisible) ranges between 5.0-6.0%

6. Yarn packing:
The losses could be on two accounts:
ϖ Faulty weighments.
v Lower moisture% in material.
The weighments are done very accurately within + 20 gms. Accuracy &
moisture %age in yarn is maintained at 7.5 to 8.5 % level.
7. Weaving:

In weaving three type of supply package are used normally ground warp,
pile warp & weft.
Weft is used in yarn package form & it could be either in grey or in dyed
form.

Ground warp/pile warp is prepared in beam form in the preparatory section

having following machines:

● Direct warping
● Sizing
● Sectional warping

All beams, which are prepared on direct warping using single yarns, are
taken to sizing machine where weavers beam is prepared by combining 6 to
8 warper beams after applying the size.
Two-ply yarns do not require size application & weavers beams are directly
prepared on sectional warping machine.
The total waste% in preparatory section (direct warping, sizing & sectional
warping) is 1.25%.
Warping operations left out yarn packages on warping creels. With
appropriate planning the left out yarn butts should be within 4% of the
production. This is generally not possible due to various reasons of
production/colour requirements. The left out yarn (remnant) is combined by
rewinding into full packages. Smaller butts will cause more knotting in the
wound package. Larger butts will result into high amount of rewound
(remnant) material. Under normal conditions if the production of same
material/ shade continues these rewound/remnant material is reusable &
generally it is not a waste.

In weaving following are the sources of waste:

● Selvedges cutting.
● Knotting of beams & drawing in/ start up of a new set.
● Yarn breaks.

Selvedge cutting is unavoidable part of shuttle less weaving. For a wide

looms like ours 1.5cm fabric on either side as selvedge for a 300cm wide
fabric weaving accounts to about 0.5% wastage.
Waste generated due to style change/ knotting, denting etc accounts to
additional 1.0% waste.
Total weaving waste (as yarn & selvedge) = 1.5%

Defective fabric which is woven due to negligence & or by machine faults

is additional wastage which has to be controlled. Normally 98% production
is expected to be fault free. Higher % of defective fabric indicated higher
wastage/losses. Another important aspect in weaving/designing is that
fabric gsm should be controlled as accurately as possible within +/- 3%
range. The customer does not pay for the higher GSM & lower GSM is
rejected.

8. Cutting / Hemming / Packing:

Fabric from looms is either sent to fabric dyeing (in case of piece dyeing)
or directly to cutting / hemming section (in case of yarn dyed goods).
Fabric is cut into towels lengthwise & then width wise. Stitching is done on
all sides. The fringes are cut as waste. Fabric at joints is also removed as
waste. Some towels are spoiled by malfunctioning of the machine or
machine operator due to uneven/short selvedge, which leaves no place for
stitching of the border. The total wastage due to all factors is to be
controlled within 1.5%. During stitching the labels etc are also inserted
along as per the customer requirements.
9. Shearing:
The pile fabric (terry towel) is subjected to shearing on one side, which cuts
all the pile (loops) to a certain extent giving a plush (velvet) feel. The
weight loss is generally 11% to get a proper effect on the surface and the
desired towel quality parameters. The working of shearing m/c requires
some length of the fabric at each fresh start up to go waste to carry out
adjustments. Every stoppage may also result into marks to develop on the
surface of the fabric. Depending upon the continuity & uniformity of the
m/c working. Wastages / defective cloth can be reduced but certain
wastages are unavoidable (minimum 11%).
 PROCESS HOUSE

The terry towel division -2 has a highly advanced fully automatic

processing house. Following
• Highly modern Theis dyeing machines.
• Orgatex system to control all the dyeing machines.
• Auto dispensing unit for dispensing the chemicals and dyes into the
machines through MPS-S, MPS-L and MPS-D
• Latest technology fully automatic MCS multiflow machine section.

PRODUCTION:-
Yarn: 7.0 tons/ day
Fabric: 68 tons/ day
PROCESS FLOW CHART FOR YARN

GREY YARN

CHEESE WINDING
SOFT WINDING

TFO
PACKAGE DYEING

HYDROEXTRACTION

RF DRYING

PTC WINDING

WARPING PACKING

SIZING DISPATCH

WEAVING
 PROCESS FLOW CHART FOR TOWELS

WEAVING
GREIGH
FOLDIN

GREIGH INSPECTION
G

LOT MAKING

FABRIC DYEING

HYDROEXTRACTION
PROCESSING

ROPE OPENER

LOOP DRYER

STENTER

SHADE FAIL
LOT
R&D

INSPECTION

SHADE
PASS
 LENGTH CUTTING

LENGTH HEMMING

CROSS CUTTING
FINISHING

CROSS HEMMING

BAR CODE + LABEL

CARTON PACKING

DISPATCH
PACKAGE

DYEING
 INTRODUCTION

In this section, the yarn is dyed in package form. For this purpose HTHP
package dyeing machine is used. The packages are loaded into the carrier
situated in the machine where in to- out & out to- in liquor flow is used to
dye the package. The dyeing is carried out at temperature of 60 to 80 deg
C.. The package dyeing has a capacity of dyeing 6.5 tons of yarn per day

MACHINES USED IN PACKAGE DYEING:

M/c no Make Capacity( kg) Power (k.w.)

1 Theis Ecobloc (Germany) 903 75
2 Theis Ecobloc (Germany) 493 45
3 Theis Ecobloc (Germany) 493 45
4 Theis Ecobloc (Germany) 301 22
5 Theis Ecobloc (Germany) 96 11
6 Theis Ecobloc (Germany) 55 7.5
7 Theis Quattro (Germany) 24(6×4) 3.06
8 Theis Quattro (Germany) 16(4×4) 3.06
9 Theis SPDM (Germany) 1 1.1
 THEIS ECOBLOC PACKAGE DYEING MACHINE

The ecobloc is a high temperature dyeing machine designed according to

the latest technical and technological know how regarding liquor flow,
liquor circulation, dye liquor penetration and economic efficiency due to
the possibility to reverse the liquor flow direction and to adjust the
differential pressure.
Depending upon the kind of material to be processed, the machine operates
with a proven dyeing process at a short liquor ratio of 1:3to 1:6.
Furthermore the liquor level can be raised until the textile material is fully
covered (fully flooded).
A flow reversal allows many functions for instance filling, draining,
reversal of the liquor circulation when dyeing with long liquor, steaming,
hydroextraction using compressed air and rapid drainage via pump.
The speed of the differential pressure build up is infinitely adjustable and
can therefore be adapted to different kinds of material. Electronic
controllers control and regulate all machine functions in conventional
dyeing processes.
The dyeing kier is laid out for a dyeing temperature upto 140 deg C for a
pressure of 5 bars.
All the machines run automatically of the orgatex system in which dye and
chemicals are dispensed automatically by MPS-S, MPS-L and MPS-D.
CONSTRUCTION:
This machine consists of following main parts:
• MAIN DYE VESSEL:
Yarn dyeing machine contains the main dye vessel in which the spindles
are loaded. The cheeses are loaded on to the spindles and dyeing is
carried out using into- out &out to- in flow of the dye liquor. The dye
tank contains heating coils lying at the bottom of the machine. Steam is
used to heat the liquor in the tank.

• ADDITION TANK:
An addition tank is situated near the main dye tank. All the dyes and
chemicals can be fed to the main dye tank through this tank with the
help of feeding system.

• DISSOLVING TANK:
A dissolving tank is also situated near the main dyeing vessel to dissolve
the dye. Addition of the dye liquor through this tank to the dye vessel
with salt in case of dark shades. Similar to the addition tank it also
contains the mixer.

• MAIN CIRCULATION PUMP:

The main circulation pump performs the function of circulating the dye
liquor with into- out &out to- in flow from the package.
• DOZING PUMP:
Dozing pump doses the dye or chemical at a fixed rate to main dyeing
tank with the salt.

• SAFETY VALVE:
Maximum pressure in the machine is kept to be 4 bars. If the pressure
inside the vessel exceeds this value then excess pressure is released by
the safety valve.

• WATER INLET VALVE:

One water inlet valve is attached at the bottom of the machine. It
performs the function of water inlet to the tank.

• WATER OUTLET VALVE:

This is called as drain valve. With the help of drain valve all the liquor is
drained after use.

• STEAM INLET & OUTLET VALVE:

Steam comes for the purpose of heating the liquor. It comes through the
steam inlet valve & goes out from outlet valve. A cold water pipe is
connected to this steam valve for the purpose of cooling.
• AIR PRESSURE VALVE:
Air pressure valve increases the pressure after lid is closed & decreases
the pressure before opening of the lid.
PROCESS PARAMETERS

1. Flow of liquor: In to out (time 4 min)

Out to in (time 6 min)

2. Pressure inside vessel: 2.5-3.0 bar

3. Steam pressure: 6-6.5 bar
4. Water pressure: 3-4
5. Pressure: In to out: 1 bar
Out to in: 1.2 bars

6. Heating system: Indirect

7. Pump efficiency: In to out: 70%

Out to in: 80%

8. Filling height of machine: 165 cm.

9. Material to liquor ratio: 6-7
FABRIC

DYEING
DYEING:
T
Fabric dyeing F
is done by Softflow machines. It is based on the
h M
A both fabric and liquor moves.
principle in which
i C
B
e S
R
s
I 2 types of machines, these are;
In dyeing section, there are
C d

d y

y D e

e Y i

i E n
I
n g
N
g
G:
1. Thies Dyeing machines
m

m a
Make :- Germany
a c

c
Construction: h
- It consist of following main parts:-
h i

• Maini dyeing tank: In this tank, also nknown as KIER, whole process is
done.n All processing steps, includingepretreatment (scouring, bleaching
etc), edyeing, softening and washing are
s done in a single tank.

s
• Stock tank: This tank is used to mix dyes, chemicals and other
auxiliaries inside the main tank.

• Addition tank: In this tank, dyes and chemicals are mixed

homogeneously to make them ready for dyeing etc .

• Operator penal: This is used to operate the machine. It shows the

current as well as previous status of machine.

• Window: it is fitted with sight glass. Direction of flow of fabric can be

viewed from this sight glass. There is a lock fitted at the window, which
automatically locks the window after temperature is raised above 80
degree Celsius to prevent any accident.

• Winch: this is fitted to assist the entrance of fabric to the main dyeing
tank. It can move with speed upto 125m/min.

• Dosing pump: This is used to transfer dyes, chemicals and salt to the
main tank.
• Heat exchanger: It is used to maintain temperature of liquor inside the
main chamber.

• Main pump: It is used for circulation of liquor uniformly inside the

 tank.
• Safety valve: It helps in avoiding the blast inside the main chamber due
to increased pressure. When pressure inside the tank exceeds certain
limit, it automatically opens.

• Pleater : This is used to plait the fabric inside the bath. Pleater
oscillates during the whole running process to pleat the fabric
continuously.

MACHINE OPERATION

The machine is filled to the requested level using a valve. The amount
of water varies depending on the quantity of the fabric to be dyed. The
pump sucks the liquor in from the lower part of the dye chamber. The
pump transports the liquor through the heat exchanger into the nozzles.

The fabric is carried by the transport winch to the nozzle and through the
transport pipe into the rear of the chamber, where it is plaited down. The
liquor flow and the weight of the fabric package take the fabric to the front
and then the transport winch transfers it to the nozzle again.

MACHINES: -
 M/C MAKE CAPACIT NO OF ROPE
NO Y KG ROPES WEIGH
T
1 Theis Ecoflow (Germany) 80 1 80
2 Theis Ecosoft (Germany) 350 1 350
3 Theis Ecosoft (Germany) 700 2 350
4 Theis Ecosoft (Germany) 1450 4 350
5 Theis Ecosoft (Germany) 1450 4 350
6 Theis Ecosoft (Germany) 1450 4 350
7 Theis Ecosoft (Germany) 350 1 350
8 Theis Ecosoft (Germany) 700 2 350
9 Theis Ecosoft (Germany) 1050 3 350
10 Theis Ecosoft (Germany) 1050 3 350
11 Theis Ecosoft (Germany) 1050 3 350
12 Theis Ecosoft (Germany) 1050 3 350
14 Theis Ecomaster(Germany) 1050 3 350
15 Theis Ecomaster(Germany) 1050 3 350
16 Theis Ecomaster(Germany) 1050 3 350
17 Theis Ecomaster(Germany) 1450 4 350
18 Theis Ecomaster(Germany) 1450 4 350
19 Theis Ecomaster(Germany) 1450 4 350
20 Theis Ecomaster(Germany) 1450 4 350

MACHINE PARAMETERS:
S. no Parameter Value

1. Diameter of nozzle 100 mm

 For whites: 3 hrs
For washing: 2 hrs
2. Cycle time
For piece dyeing: 6-8
hrs
3. Pump set percentage: 90%

3 to 4 batches per day

4. Production
per machine

5. Liquor ratio 1:4.5(mostly)

6. Carry over 250%

90 – 125 mt / minute
7. Winch speed (According to fabric
gsm)
8. R.P.M. of circulation pump: 900

9. Heating gradient 3°C/min

10. Cooling gradient 1°C/min

11. Pressure of nozzle 0.4 -0.5 bar

2. MCS dyeing machines : Make -- Italy
Total number of machines – 8
Bulk dyeing machines -- 7
Capacity – 1000kg (1 machine), 1500 kg (6 machines)
Sampling dyeing machines -- 1
Capacity – 50 kg
Parameters (for 1500 kg):
Total number of chambers 6
Pasage time from one chamber to another 1.5 min
Main tank capacity 1000 lit
Stock tank capacity 9800 lit
Number of addition tanks 2
Addition tank capacity 800lit, 1500lit
To start the pump minimum liquor required 3500 lit
Number of filters 10
Breather pump works at 6kg/cm sq
Heating gradient 3deg C/min
Cooling gradient 2 deg C/min
Filling speed 1000 lit/min
loading time 30 min
Unloading time 20 min
Normal drain 3 min
Circulation pump rpm 1110 rpm
Internal reel 110 m/min
Maximum achieveable temperature 140 deg

CHEMICALS AND AUXILIARIES USED IN FABRIC DYEING

Serial Chemical Function
no.
1 Caustic soda lye Scouring agent
2 Soda ash Fixing agent
3 Hydrogen peroxide Bleaching agent
4 Glauber salt Exhausting agent
5 Spectra 197 Soaping agent
6 Depsoluble ACL Lubricating Agent
7 Lenatol S Stabilizer
8 Lenatol DMCP Sequestering
Agent
9 Spectra LD Wetting agent
10 Lenotol HPLF Wetting agent
11 Metazil NZPN Peroxide killer
12 Tuboblanc Optical whitener
13 Sodium hydro sulphide Reducing agent
14 Green acid Mild acid
15 Ultrasil SX Softener
16 Tinozym 44L Bio wash
17 Drimagen ER Levelling agent
18 Edunine NZ-2PX Bio Wash
19 Ultrasil 2D Softener
20 Ultrasil BGX Softener
 DRYING

1. HYDRO EXTRACTOR: -
During hydroextraction, excess water is removed from the fabric rope
.hydroextractor is based on centrifuging principle .the fabric rope is loaded
into the hydroextractor and centrifuged at a rpm of 350 – 450 (according to
fabric quality). The residual moisture content after hydro is between 50% –
60 %. The cycle time is 15 – 20 min.

M/C No. MADE CAPACITY

1 SWASTIK 350
2 SWASTIK 350
3 SWASTIK 350
4 SWASTIK 350
5 SWASTIK 350
6 SWASTIK 350
7 SWASTIK 350
8 SWASTIK 350
2. LOOP DRYING (SEMI DRYING): -

It is used for semi drying. After this operation the moisture content of the
fabric is reduced to 15-17 %. In the loop dryer fabric loops are formed with
the help of a chain and the loops move forward inside the chamber in which
hot air is circulated.
• MAKE NATIONAL ,SWASTIK
• NO OF MACHINES 2 +1
• LOOP LENGTH 55-65 INCHES
• PRODUCTION 10 TONN/SHIFT
• TEMPERATURE 140 – 160 deg C
• MASTER SPEED 35 % FOR TUBMAT
60% FOR BATH, HAND, WASH.

3. TUMBLE DRYER:-
Number of machines – 3
Make ---- Indian
Function --- To dry the fabric completely and to give softer feel

It is a batchwise machine whereas loop dryer is a continous machine.

Differences between tumbler and loop dryer are as follows:

Parameters Tumbler Loop dryer

1. Feel Softer Normal
2. Max. Set Temp 140 deg C 200 deg C
3. Achivable Temp 120 – 130 deg C 160 deg C
4. Nature Batch wise Continous
5. Loading time 12 – 15 min -
6. Unloading time 20 – 25 min -
7. Run time 30 min Depends on speed
8. Speed Depends on run time Max. 28 m/min
9. Max. production 3200 kgs 10 ton
10. Fluff generation More Normal
11. Pile nature Open Flat
12. Steaming option Yes No
13. Manpower needed 1worker 2workers

3. STENTER
The final drying of the rope is done in stenter. After this operation the
moisture content of the fabric is reduced to 3-5 %. There are 4 stenter in the
processing house. The fabric is passed trough the stenter in open width
form. The width of the fabric is adjusted by adjusting the distance between
the chains. The details of the machine are as follows:

• MAKE SWASTIK INDIA LTD and HARISH INDIA LTD.

• NO OF MACHINES 3,1
• TEMPERATURE 170- 190°C
• NO OF CHAMBERS 3
• TYPE clip type
• SPEED 15-30 mts / min depending on the fabric quality
• PRODUCTION 20-22 TON/SHIFT.
 AUTO DISPENSING UNIT

The most important feature of the process house is the auto dispensing
unit .The dyes and chemicals are dispensed automatically to all the
machines with the help of MPS-S, MPS-L and MPS-D, thus reducing the
manpower required for running the machines. Apart from this it reduces the
chances of manual errors. The auto dispensing unit can be divided into 3
parts:
• MPS-S
• MPS-L
• MPS-D
The details of each of them are as follows:
1. MPS-S:
In this section the salt and soda solutions are prepared for dispensing into
the dyeing machines during the dyeing cycle. There are two tanks for salt
and two for soda ash.
The capacity of tanks is as follows:

Salt dosing Capacity

Tank 1 15000 kg
Tank 2 3500 kg

Soda dosing Capacity

Tank 1 3500 kg
Tank 2 3500 kg

Dispensing procedure:
Salt is added in bucket of MPS-S and then it is transferred to the stock tank
with the help of a motor.
When a call comes, required amount of salt or soda and equal quantity of
water is mixed in the mixer tank.
The temperature of the mixer tank is raised to dissolve the salt or soda in
water.
Then the pump pumps the solution into the respective machine.

2. MPS-L:
The MPS-L is used to dispense the chemicals into the dyeing machine. The
unit consists of 26 tanks filled with different chemicals. These tanks are
connected to all the machines through MPS-L pipelines. Whenever a call
for chemical comes, the required amount of chemical is pumped into the
respective machine.
TANK CHEMICAL FUNCTION CAPACITY
NO (liters)
1 H2O2 Weak Bleaching Agent 1396
2 Neutra FAB Hardness Killer 1396
3 Formic Acid Neutraliser(pH setter) 1396
4 Chromofix Fixer
1417
GBCA
5 Ultrasil 2D Softener(silicone) 1498
5A Ultrasil 2D Softener(silicone) 1872
6 Ultrasil SX Softener(silicone) 1872
6A Ultrasil SX Softener(silicone) 1700
7 Spectra 197 Soaping Agent 1546
8 Ultrasil BGX Softener(silicone) 1620
9 Spectra LD Wetting agent 1326
10 Metaxil NZPN Peroxide killer 1630
11 Hydrogen Bleaching agent
1783
peroxide(50%)
11A Hydrogen Bleaching agent 2228
peroxide (50%)
12 Tubingal 7023 Softener(cationic) 1745
12A Tubingal 7023 Peroxide stabilizer 1745
13 Lenetol DMCP Sequestering agent 1827
14 Sabasoft SFC Softener(Non-Ionic) 1340
15 Edunine Softener(cationic)
1745
Aquasoft
16 Lenetol HPLF Wetting Agent 1745
17 Green acid (50%) Organic acid 1745
18A Caustic lye Alkali 2575
18 Caustic lye Alkali 2060
19 Lenapex S Stabiliser 2060
20 Depsoluble ACL Lubricating Agent 2060

3. MPS-D:
The MPS-D unit is used to prepare dye solutions and pump it into the
respective machines. The unit consists of 4 dye dissolving machines. The
operator weighs the required amount of dyes (according to the drug sheet)
and adds it into the machine. The machine automatically takes required
amount of water and the temperature is raised so as to dissolve the dyes
properly. After the completion of dye dissolution, the solution is pumped
into the respective machine.
PROCESS

LAB
Processing lab of AHT-2 has following lab equipments...

• Spectrophotometer (1) :
It is used for Recipe prediction, Cost Management and Quality
Control. In this equipment, sample is inserted and corresponding
information can be taken regarding it. This machine can also be used
for colour matching.
Type: - SF600X
Manufacturer: - datacolor
 COMPUTERIZED COLOR MATCHING

The color of textile product is one of the important parameters which

determine its salability as there is a demand for precise shade control and
its repeatability within acceptable limit of tolerance.

Even today a large no of industries practice visual color matching and

determine color recipe for a given shade by trial and error method.

The foundation of instrumental color measurement was laid in 1931

when CIE (international commission for illumination) defined standard
observer and illuminants. This subsequently led to instrumental match
prediction
(Known as CCM)
SOP FOR EVALUATION OF TERRY TOWELS THROUGH
CCM.

CALIBRATE THE SYSTEM THROUGH DATACOLOR

CALIBRATION KIT

GO TO THE DESKTOP AND CLICK COLOR TOOLS IKON

ENTER THE NAME OF STANDARD

PLACE THE STANDARD ON SPECTROPHOTOMETER AND

CLICK
STANDARD INS AVG BUTTON

MEASURE 3 AVERAGE READINGS

ENTER THE BATCH NAME

 PLACE THE BATCH ON SPECTROPHOTOMETER AND
CLICK
BATCH INS AVG BUTTON

MEASURE 3 AVERAGE READINGS

CLICK THE COLOR COORDINATE IKON AND CHECK

FOR a* AND h VALUES

CLICK THE COLOR DIFFERENCE IKON AND

CHECK THE VALUES OF ∆H AND SEE WHETHER IT LAYS WITHIN
THE PERMISSIBLE LIMIT OR NOT

FINALLY CLICK THE CIE DE PLOT AND LOCATE THE POSITION

OF BATCH W.R.T. STANDARD AS WELL AS
PREVIOUS BATCHES
 FINALLY GIVE THE DECISION PASS/FAIL

● Solution maker(1) :
This machine is used to make stock solutions. 30 % of warm water
is automatically added by machine to raise to required level and dye
is added in the bottle manually. This solution made is then put on the
mixer for 2 minutes. After that, remaining 70 % water is added. Now
solution is ready to be fed in autodispensor.
Type: - Autolab SPS solution maker.
Manufacturer: - Datacolor

• Autodispensor (1) :
It is used for dispensing the dyes and chemicals required for
dyeing the Textile Substrate in lab. This machine eliminates the
occurrence of manual error during dispensing. 120 colours and 7
chemicals can simultaneously be fed into this for recipe formation.
Procedure:-
1. Switch on the machine and turn on computer.
2. Through database, specify the bottle number.
3. Make the solution in solution maker.
4. Place the bottle at its specific place and close the door.
5. Feed the recipe and make their batches.
6. Place the beaker tray on conveyor.
7. Forward the batch.

Type: - Autolab TF.

Manufacturer: - Datacolor.
• Ahiba Dyeing Machines (3) :
This machine is used to dye the samples. In this machine, IR
radiations are used to heat the dye bath to attain temperature required
for dyeing.
There are 3 machines of this type in lab:-
1. Capacity : 19 pots
2. Capacity : 19 Pots
3. Capacity : 14 Pots
 Average Cycle time per batch - 5 Hrs.
Number of Batches per Machine: 4.8
Number of Lab Dips produced per Machine per Day: 8
Manufacturer: - Datacolor.

• Multi –Precise Ahiba Dyeing Machine (1) :

This machine is used to dye 100 gms Yarn in the form of soft
package. Package is loaded inside the machine. Lid is closed properly
and dyeing is carried out according to the program fed into it.

• Hot Air Oven (1) :

This is used for Drying the samples and chemicals to check their
solid content.
Manufacturer: - Paramount.

• Electronic Balance (1) :

This is used to weigh the Samples, Dyes and Chemicals with
accuracy upto 4 decimal places.

• Hot Plate (1) :

This is used for heating of Chemicals, Water and Dye baths.
 • Ph Meter (1):
This instrument is used to check the pH of Liquids.

• Wrap Reel (1):

It is used to make the lees for dyeing Yarn in Ahiba Dyeing
Machines.
Manufacturer: - Innolab.

• Light Box (1) :

It is used to check the shades under different light sources (like
TL84, D65, UV36 etc.) as per the recommendation of customers.
Manufacturer: - Gretag Macbeth.

• Winder (1) :
It is used to wind the soft packages used for dyeing. Programs (0 to
6) can be adjusted according to the requirement.

Manufacturer: - datacolour.

● Technorama Multifastest :
To check the washing fastness, chlorine fastness, hot water
bleeding and many other fastness except crocking fastness and
light fastness at different temperature and pressure.
PROCESS

DEVELOPMENT

CELL
 THE MAIN OBJECTIVES OF PDC SECTION ARE:-

1) TO DEAL WITH PROBLEMS IN DYEING

If any problem in the bulk or lab occurs related to dyeing then it is dealed
by PDC cell and controlled by this section by controlling and studying all
the related parameters of dyeing. For example to get the shade right first
time (RFT) all the parameters related to the process are studied and
controlled.

2) TO DEAL WITH COMPLAINTS

If there are any complaints by the customer then that complaint is dealed by
the PDC cell. This section studies various parameters and reasons related to
that problem. Mostly the complaint arises related to quality of the substrate
and necessary steps are taken to solve that problem for the complete
satisfaction of the customer.

3) TO INTRODUCE NEW DYES AND CEMICALS

If new dye or chemical is to be introducing in the process then testing of
that sample is done in this section. The testing is done through AHIBA
dyeing machine or if necessary then through SPDM section. If the results
are satisfactory then that dye or chemical is introduced into the process.
4) TO INTRODUCE NEW DEVELOPMENTS
New development related to process, shade or the materials are done in this
department.

5) TO DEVELOP VARIOUS METHODS OF COST AND TIME

SAVING
This department introduces various methods of cost and time saving.
By studying thoroughly the related process, which helps in higher
productivity and lower dyeing cost.

6) TO INTRODUCE THE NEW WORK PRACTICES

The PDC section introduces the new method of doing the work so that it
could be feasible and comparatively easier for the worker to do that work.