0

Textile internship at Alok Industries, Balitha, Vapi (Processing unit)

Period of internship: - 21/12/2009 to 2/1/2010.

Internship mentor and incharge :-Mr.Dinesh Keswani

Pre-treatment for greige fabrics (dates allocated:- 21/12/2009-22-12-2009)

• Process 1- griege fabric opening
o Purpose:- for opening fabrics and converting into A-frame
batches.
o Number of greige opening machines :- 5
o Speed :- 140 mts/min
o Input and output
o Input :- fabric rolls
o Output:- opened fabrics on A -frame batch

o Target output :- 2.25 lac mts/day

o Average output :- 1.9 lac mt /day
o Grades of fabrics available :- A,B,C,D
o Fabric roll placement style for storage:- cross –layered.
o No. of storage racks:- 2000
o Average length of fabric on a A-frame batch- 4500 mts
o Product mix
• By weight:- light,medium,heavy
• By blend:- PC.CV,CL,CS
• By weave:- twill,plain,sateen,satin
o Number of workers per shift :- 30
o No. of of shifts :- 2
o Total workers:- 60
o Staff shifts :-8* 3= 24
o Workers shifts = 12 * 2= 24
o Next process :- singeing and desizing
Singeing and desizing
o Singeing and desizing performed as a combined process
o Number of available machines:- 3
o Make of the machines :- osthoff senge 42327 Germany
o Model nos.:- VP99-H(2 m/c),VP-99(1 m/c without padding unit )
o Processing speed:- 60-120 mts/min
Light fabrics :- 120 mts/min
Heavy fabrics- 60 mts/min
o Chemicals used in desizing:-
o Wetting agent :- assists increase in absorbency
o Enzymes :- required for removal of sizes applied to fabrics
o Chelating agents :- restricts the reaction of any metal ion with
any added chemicals.

o Target production :- 30,000 mts /day

o Input :- Greige fabric from A- frame roll
o Output :- Singeing and desized fabrics (wet condition)
o Model :- VP-99- H (1) (Greige fabric )
 Singeing chamber- 1
 Desizing chamber:-1
 Pad steam chamber :-1
 Washers/extracta chambers :- 3
 Output A-frame batch
 Output fabrics -wet condition
o Model – VP -99-H(2) (Yarn dyed fabric)
 Singeing :- 1
 Desizing :-1
 Pad steam chamber:-1
 Washers:-3
 Delivery customer with steam cylinders:-1
 Output:-A-frame batch
  Output :- dry/wet condition.

o Model VP-99
o Singeing-1
o Desizing-1
o Washing-3
o Delivery customer-1
o Output- A frame batch

o Washing temperature :- 95 degrees

o Padding temperature :-95 degrees
o Two methods for desizing :
• Rotation desizing :- in this after the chemical application the batch is rotated
at a uniform speed for desizing agents activation and avoid leaching out of
chemicals from the batch.
• Pad steam desizing :- in this the chemical activation is done by rotation in a
steam chamber with a required dwelling time required for chemicals to
activate.
 Pre-treatment range

o Number of pre-treatment range m/c :- 3

Machine 1
o Parts :-
o Feed
o Injecta
o Extracta
o Impacta
o Pad steam unit
o Exxtracta
o Delivery customer
o Output

o Feed :- input of desired fabric from A-frame batch.

o Injecta :- releases high velocity hot water and pressure for partial
removal of sizes.
o Extracta :- used for washing purposes.
o Impacta :-
 H2O2
 Wetting agent
 Stabilizer
 Reserver
 ‘NaoH

o Pad steam unit :- goods remain for at least 15 mins where purpose is
for bleaching & scouring mixture activation .
o Average production rate :- 80-100 mt-min
o Preferable for light and medium weight fabrics.
 Machine 2

Same features as machine 1 but preferable for bottom weight fabric with
more conc. of chemicals in solution.

Machine 3
Preferrable for limp and stretchable fabrics as it has drums in its washers
instead of rollers as in PTR1 &2. It has 2 washers more than other PTR’s.

Mercerization
o Machine name :-Benninger mercerizer
o No. of machines:- 3
o Average speed:- 60-70 mts/min
o Input :- yarn dyed / bleached fabrics
o Output :- mercerized fabric(acidic condition)
o Chemicals used :
o NaoH
o Organic acid
o Caustic soda

o Parts :-
 Chain/Stenter:- temp:- 60 degrees ,pressure :- 80 N
It is used for width stretching and sprinkling of NAOH.
o Stablizer chamber:- Chamber used to sprinkle the
stablizer chemical for assisting in removal of NAOH.
o Washer/steam treatment :- used to wash fabric and
steam treat it. Temp of water-90 degrees, 95 degrees
in steam chamber .
 o Acid chamber :- 95 degrees , ph maintained -5-
6,organic acid used for neutralization and acid is
available in 40 milliliter whose level is auto adjusted.

o Mercerized fabric pH:- 5

o Machine 3 :- mercerizer
Same process as 1 &2 expect chain not present .no width extension
available.
Preferable for heavy weight fabrics as less extension is possible in
these fabrics.

o Mercerized is basically used for :-

o Increase lustre
o Increase strength
o Dimensional stability
 Dyeing

Cold pad batch

o Name of the m/c :- Kusters cold pad batch
o Number of machines :- 3
o Model numbers:- 222.11-1800
o Except poly cott fabrics all fabrics all types can be dyed.
o Only reactive dyes used.
o Speed of m/c:- 50- 60 mts/min
o Color/chemicals trough chemicals:-
o Dye chemicals ratio :- 4:1
o Fixer chemicals used.
o Sodium silicate and Rocoflo - anyone used for fixing.

o Target production:- 20,000-22,000 mts/shift.

o 16 hrs rotation required for batch for color development and avoiding
any type of darining or leaching out of any chemical or dyes.
o Dye trough cleaning steps:-
 Removal of color via gutter line provided .
 Flush clean the trough using water
 All new color solution to the trough.

o m/c 3 has an extra tank placed besides the m/c having a capacity
of15-20 lts.
Number of supply tanks for dyes and chemicals :- 5
3 dye tanks and 2 chemical tanks .
Capacity of each tank:- 800 lts.
For m/c 3 tanks are are as follows :-
 2 chemical tanks- 500 *2
 3 dye tanks -500*3

Washer

o Average production rate :- 50-60 mts /min

o Useful width :- 1800 mm
o Chemicals used :-
o Dekol fbsn -100gpl and acetic acid (for dyed fabrics