National Institute of Fashion Technology, Chennai

Textile Internship at

Vardhman Textiles
Baddi (HP)
(26.12.2011- 5.1.2012)

Under the Guidance of:

Mr. T. Murugan An effort By:
(Asst Professor)
NIFT Chaitanya S.P
Keshav Chugh

DFT VI
 OBJECTIVE OF INTERNSHIP

Observations to be made on
Yarn manufacturing and Winding section
Weaving section
Dyeing section

Testing and Quality control sections

 Total Productive Management
8 Pillars of TPM

1. Focused Improvement
2. Autonomous maintenance
3. Planned maintenance
4. Education and Training
5. Initial flow control
6. Quality maintenance
7. Office maintenance
8. Safety health and environment
 SPINNING
Process Flow

REITER Machines

TRUTZSHLER DK 803

RSB 851
REITER Machines
REITER F35 Roving
Frame

REITER Ring Frame F16

Schlafhorst/saurer
 The Blowroom

The Blowroom is the 1st step of yarn production in the spinning mill.
INPUT : Fabric in the form of Bales
OUTPUT : Sliver
 Basic operations
Blowroom
a) Opening
b) Cleaning
c) Dust Removal
d) Blending
e) Even Feeding of material to the card
 Opening Devices
Type Appearance Description

Rollers Small Diameter, Widely used.

e.g.: in STEP CLEANERS

Drums Larger Diameter, little used

e.g.: in MONO-CYLINDER
CLEANERS

Quilted Shaft Shaft with many beater rods,

hardly used
 Cleaning
Cotton contains upto 18% trash,
in most cases ranging from 1% to 7%

Since this Cost is a considerable cost factor, it has to be kept as low as

possible, which requires an assignment

Cleaning Degree = extracted trash*100

--------------------------------------
trash content in fed cotton

Cleaning Efficiency = extracted trash*100

--------------------------------------
Total Extracted Waste
 Dosage Blender

Unimix
Model LB 7/3
By Lakshmi LMW
 The m/c is made up of 3 parts
Storage section,
Intermediate section, and
Delivery section
 Cleaning Machine

MACHINE: REITER UniClean

1. Special Design VIBRATING PLATE

4. Rollers for additional Dusting

5. Servomotor-controlled feeding plates

6. Groove

7. Operating Panel
 Carding

Ensuring that debris is removed while aligning the fibers to make

them easier to spin.

Without carding, cotton thread would be coarse and extremely

fragile.
 BREAKER DRAW FRAME

Parallelize the fibres in card sliver along the sliver axis.

To improve the regularity in linear density of card sliver by doubling.

Improve sliver quality.

To achieve the correct amount of blending.

 COMBING

17-18% of short fibres are removed

Removal of neps

Parallelization of fibres

Kitty Level is Reduced

 ROVING
The function of the speed frame is to attenuate the sliver and to form
a suitable supply package for the ring frame.

Twist + Strength + Winding

 SPINNING

To draft the roving until the required fineness is achieved

To impart strength to the fibre, by inserting twist

To wind up the twisted strand (yarn) in a form suitable for storage

Transportation and further processing.

Spinning Machinery
Weaving: Process Chart
 Work Flow
Customer
CPDC Vardhman

Marketing Team

CPDC
Located at Mahavir Textiles

Central Design Technical

Pilot Plant
Cell (CDC) Department

R&D(Small Length
Bit Loom
Sampling )
 Sectional Warping

Several sections are wound in sequence and parallel to each other on a

dresser or on a drum
the warping sections are as many as necessary to obtain, with the available
creel capacity, the total number of threads composing the warp
The warping speed is about 800 m/min, while the beaming speed is about
300 m/min
 Calculations
Before carrying out warping, following calculations are necessary:

If the calculation does not give an exact number, the last section will
be produced with a number of threads lower than the other sections,
Or the number of threads composing each section will be reduced.

so as to get all sections with one and the same number of thread,
 Sizing

A complementary operation which is carried

out on warps formed by spun yarns with
insufficient tenacity
 Preparation of weaving Machines

Requirement of Style Change Drawing-in:

consists of threading
the warp yarns
through the drop
Drawing - in
wires, the healds and
the reed

Transport and Loading of Beams

and harness onto the Weaving m/c
 Weaving
1. Back rest roller (warp
threads are wound)
2. Support special drop
wires
3. Healds
5. Dents of the reed
8. Slay
6. Motor driving the
take down roller
11. Cloth Beam
 Rapier weaving machines

the most flexible machines on the market

Their application range covers a wide variety
of fabric styles
Their present weaving speed of about 600-
700strokes/min
 Air jet weaving machines

weaving machines with the highest weft insertion performance and are
considered as the most productive

manufacturing of light to medium weight fabrics, preferably made of

cotton and certain man-made fibres

sheets, shirting fabrics, linings, taffetas and satins in staple yarns of man-
made fibres
 AURO TEXTILES
Started in December 2000
Production - 30 lack Meters/ Month
One of the largest fabric processing unit in
Asia.
Has area of 12 acres
Self- sufficient power supply
 AURO TEXTILES
Processes:
Preparatory
Dyeing
Finishing (both piece dyed and yarn dyed
fabrics)
Inspection and Packing
 Departments
Auro Textiles has four major departments

1. Personnel & IR Department.

2. Commercial Department.

3. Engineering Department.

4. Production Department.
 Production

GREIGE SECTION
PREPARATORY SECTION
PERBLE RANGE
NEW PAD STEAMER
MERCIRIZER
DYEING SECTION
TANK COLOUR PREPARATION AREA
PAD DRY
HT STEAMER
THERMOFIX
PAD STEAMER
 FINISHING SECTION
STENTER
SUEDING MACHINE
SANFORIZER
AIRO MACHINE
CURING MACHINE
TECHNICAL SECTION
PHYSICAL LAB
CHEMICAL LAB
PILOT PLANT
INSPECTION AND FOLDING SECTION
PRODUCTION PLANNING & CONTROL
EFFLUENT TREATMENT PLANT
SINGEING

WASHING

DESIZING &
SCOURING

NaClO2 BLEACH

WASHING

H2O 2 BLEACH

WASHING

DRYING ON
CYLINDERS

PLAITOR Preparatory
(Perble) Range
 Perble Range
Section A: Singeing, Combined desizing and
scouring
Section B: Chlorite Bleaching
Section C: Peroxide bleaching
Section D: Vertical Drying Range.

In new Perble Machine, Only Peroxide

Bleaching (3 sections)
 MERCERIZATION RANGE
PARTS OF MERCERIZER RANGE
The mercerization machine has five sections:
Padding Section
Tenter chain
Tenter pit
Washing range
Drawing unit
 MERCERIZATION RANGE
To increase the dye uptake.
To increase the tensile strength of the fabric.
To increase lustre of the fabric.
Better coverage of immature cotton fibers.
To remove crease marks.
To remove naps from the fabric.
To increase the reactivity and absorbency of
the fabric.
 CAUSTIC RECOVERY PLANT
The Caustic Soda used in the processes is
heated and concentrated for reuse
The CRP has an efficiency of 90-95%
The principle of CRP unit is to evaporate the
water from the weak lye.
It helps save money and is less harmful to
environment.
 DYEING
Most important feature of dyeing used is the
continuous dyeing range (CDR)
Consists of Padder Box with a capacity of 50-
60 lts
pad-dyeing method ensures a full penetration
of dye inside the fabric at a relatively low
consumption of dyes, chemical, steam and
water
 Dyes
The cotton and P/C blend fabrics are dyed with
the following dyes

1. Vat dyes for 100% cotton

2. Reactive dyes for 100% cotton
3. Disperse/Vat dyes combinations for P/C blends
4.Reactive/Disperse dye combinations for P/C
blends
 Sample Dye recipe

Reactive (HT Method) PDHT

Dye X gpl
Sanspol AMC 20gpl
Resist salt 5gpl
Sodium bicarbonate 20gpl
Urea 50gpl
 HT Steamer
High temperature steamer is used for the
fixation of reactive dyes on cotton and on
cotton component of P/C blend.
The steam here is used for dual purpose: to
provide heat energy and also to act as a
source of water to transfer rapidly and
uniformly on dyed surface.

FABRIC
STEAMERS PLAITOR
INLET
 THERMOFIX MACHINE
This technique utilizes the high rate of dyeing
achieved at high temperature (commonly in
the region of 210C).

A dyeing achieved in less than one hour at

130C can be attained in 20-60 seconds at
about 200C.
 PAD Steamer

CHEMICAL
FABRIC INLET STEAMER
TROUGH

VERTICAL
13 WASHERS WATER SEAL
DRYING RANGE

PLAITOR
 FINISHING
Stenter
Peaching Machine
Sanforizing Machine
Airo machine
Curing Machine
 FINISHING

CHEMICAL FINISHING
SOFTENING
RESIN FINISH
TEFLON FINISH
ETI(Easy to Iron)

MECHANICAL FINISHING
PEACH FINISH
SANFORISATION
 TECHNICAL SECTION

1. PHYSICAL TESTING LAB

2. CHEMICAL LAB
3. PILOT PLANT
 INSPECTION AND FOLDING SECTION

4 Point system used for Inspection

Fabric divided into A, B, C Grade

Packing done in sizes as per the order or buyer

specification.
Shipping to both buyer/garment manufacturer
PRODUCTION PLANNING & CONTROL
 AURO DYEING
Fiber Dyeing: Cotton, Polyester.
Yarn Dyeing: Cotton. P/C blend, A/C blend

The unit has technical collaboration with

Japanese concern. Most of the machinery is
Imported from Japan.
 Yarn Dyeing
It comprises of five sections:
a) Pre Winding
b) Dyeing
c) Post Winding
d) Conditioning
e) Dispatch
 PRE WINDING
In this section cones of yarn are converted to
soft cheeses for processing.
It is also called Soft package section.
Various counts running 10s To 100s (single
and Double)
 YARN DYEING
Done In HTHP (High Temperature High Pressure)
Dyeing Machines
48 Machines
Hisaka (Japan), Fong (China), Pozzi (Italy)

Machine Package load varying from 50Kg to more

than 500 Kg depending upon model.

Complete Dyeing cycle done in the HTHP machines.

 DRYING
RAPID DRYER
Uses Centrifugal force to extract the excess
liquid out from the soft package.

RADIO FREQUENCY DRYER

Uses high frequency Radio waves to
completely dry the soft packages
 POST WINDING
After processing, yarn is wound onto cones in
post winding section .
Three types of machines are used in this
section.
1. PSM
2. 138 AUTOCONER
3. MACH CONER

Post winding is followed by conditioning of the yarn

 DISPATCH

After conditioning the material is dispatched in cartons.

Following parameters are mentioned on carton.

MILL:
SUBSTRATE:
COUNT:
SHADE N0.
LOT N0:
N0.OF CONES:
DATE:
NET WT.:
GROSS WT.:
 FIBER DYEING
Types of fibers dyed

COTTON
ACRYLIC TOW
POLYESTER
WOOL
MILANGE
 FIBER DYEING
RAW MATERIAL
(Cotton, Polyester, DRYING BALE PACKING
Acrylic)

STAMPING DISPATCH
WASHING

PRESSING CAKE UNLOADING

HYDROEXTRACTIO
DYEING
N
 PRODUCTION PLANNING AND
CONTROL
The main objective of this department is to
execute the orders placed to the organization
by effective scheduling.
They also keep a control over the orders by
daily monitoring at each stage of SPDM,
dyeing and dispatch.
This department has to decide the date for
the dyeing of the particular lot in the bulk
 (R & D)
RESEARCH & DEVELOPMENT has the following
sub departments

a) Quality Control Input

b) Quality Control Output
c) SPDM Section
d) Yarn Dyed Shirting Cell
e) PDC
 (R & D)

Technorama M/c
OBBDM
SPDM
Knitting M/c (Quality)
 Conclusion

Vardhman is one of the biggest names in textiles

worldwide. Our Internship in the company gave us
immense exposure to the processes that take place in the
production of fabric in many forms starting from the fiber
stage up to final packing and despatch to the buyers.

The experience of being a part of such a big company for

even a short time was amazing and helpful in learning
about the different processes in textile manufacturing.

We are very thankful to all the people at Vardhman, Right

from executives to the labourers who selflessly helped us
gather information and explained everything in detail.