Orientation Report

US DENIM MILLS (Pvt.) Ltd.

Submitted To:
Human Resources Department
US Denim Mills

Submitted By:
Muhammad Waqas Siddiq
Management Trainee Officer
Utility (Mechanical)
 TABLE OF CONTENT

ACKNOWLEDGMENT ............................................................................................................................................................. 3
SAFETY MANAGEMENT........................................................................................................................................................ 4
PROCESS STUDY ...................................................................................................................................................................... 6
Ball Warping ......................................................................................................................................................................... 7
Rope Dyeing.......................................................................................................................................................................... 8
Re-beaming ........................................................................................................................................................................... 9
Sizing ....................................................................................................................................................................................... 9
Weaving.................................................................................................................................................................................. 9
Finishing............................................................................................................................................................................... 10
Inspection ............................................................................................................................................................................ 11
Shade Area .......................................................................................................................................................................... 11
Utility Department ................................................................................................................................................................ 12
Boiler ..................................................................................................................................................................................... 12
Compressor Room ........................................................................................................................................................... 14
Power Generation ............................................................................................................................................................ 16
Humidification Plant ....................................................................................................................................................... 17
Softening plant .................................................................................................................................................................. 17
Mechanical Workshop .................................................................................................................................................... 18

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 ACKNOWLEDGMENT

Though only our name appears on the cover of this dissertation, many people have
contributed to its production. We owe our gratitude to all those people who have made this
dissertation possible and because of whom our graduate experience has been one that we
will cherish forever. Above all Almighty Allah who has always been there throughout this
endeavor and shower His blessings upon us.

I am thankful to Mr. Ghulam Sarwar for his initial lectures on safety management regarding
working at the plant site. Due to him we all are well aware to follow the rule of safety first.
We are thankful to Mr. Usman for his guidance throughout the orientation period and all
the management staff of the production area for briefing us the manufacturing process of
the denim garment.

Our deepest gratitude is to our General Manager Mr. Attique Ahmad and Engineering
department managers Mr. Shahid Younus and Mr. Usman Zahid. We have been amazingly
fortunate to Dy. Manager Mr. Ghawas Mahmood and Asst. Manger Mr. Usman Maalik who
gave us the freedom to explore on our own and at the same time the guidance to recover
when our steps faltered.

We are also thankful to the system staff and all the technical staff who has helped us
throughout our orientation period and has never hesitated to explain our queries regarding
the system operation and maintenance.

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 SAFETY MANAGEMENT

There are different types of fire extinguishers and their uses.

1. Water type:

Suitable on fire of
Wood
Cloth
Paper

2. Foam type:

Suitable on fire of
Oil
Petrol
Paints

3. Dry chemical powder (DCP):

Suitable on fire of
Electric Tension
Highly inflammable liquids
Oil
Petrol
Paints
Wood
Cloth
Paper

4. Carbon dioxide (CO2):

Suitable on fire of
Electric Tension
Highly inflammable liquids
Oil
Petrol
Paints

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 5. Halotron:

Suitable on fire of
Wood
Cloth
Paper
Electric Tension
Highly inflammable liquids
Oil
Petrol
Paints

Use of personal protective equipments (PPEs) is mandatory while at the work site. The
PPEs include safety helmet, safety shoes, and safety goggles, face mask and ear plugs.

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 PROCESS STUDY

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 BALL WARPING
Ball warping is the initial department of Denim production. Warping is the process of
transferring multiple yarns from individual yarn packages onto a single package assembly.
In ball warping ends are pulled from the creels. The yarn then passes through a comb-like
device which keeps each warp yarn separates and parallel to its neighboring ends.

The input is yarn which is procured by the yarn sourcing department from different
industries with collaboration from production planning and control. The output of the ball
warping department is logs also called balls which in turn become the input to the rope
dyeing department. At a time 3 sets are provided by the ball warping department to the
rope dyeing and each set has variable number of balls varying from 10-12.

There are 3 ball warping machines of Griffin Company and have a creel capacity of 540
ends. As an extension phase of increasing production from 2.5 million meters per month to
3.2 million meters per month a new ball warping machine has been installed with a creel
capacity of 480 ends.

A ball warping machine has rather a simple design. The four major components of the
machine are given as follows in the layout diagram.

Creel Vacuum Filter Fly and Comb Head

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 ROPE DYEING
The yarn from the ball warping passes in the dyeing process. Most denim is yarn dyed
fabric with the warp yarns dyed with indigo dye and the filling yarns are left un-dyed.
Indigo dye in its normal form is vibrant blue in color, it is insoluble in water and it will not
dye cotton fiber. To dye the cotton fibers, chemical reduction will take place. In rope
dyeing, ball warps are continuously fed into the rope or chain dyeing for application of the
indigo dyeing.

The process used in rope dyeing is based on dip and oxidation. There are two machines
installed in rope dyeing section. One machine is Morrison made. It has 8 dips and can run
36 ropes. The other machine is of Smartech. It is 11 dip machines and can run 36 ropes.

In the beginning of rope dyeing process the ropes are passed through a scuver box which
removes all sorts of contaminants like waxes, oils and dirt from the ropes.

Creel Section Size Box Coating Cylinder Dry Cylinder

Coiler
Section

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 RE-BEAMING
Once the warp yarns are rope dyed it is then necessary to change the yarn alignment from a
rope farm to sheet form before entering the next process which is sizing. The process of
converting the rope yarn into sheets is called re-beaming. Re-beaming involves pulling the
ropes of yarn out of storage tubes and moving them upward to a guiding device. This
upward travel allows the ropes to untangle before nearing the beamer head.

SIZING
The main purpose of the sizing is to encapsulate the yarn with the protective coating. The
material used for coating is starch. This protective coating reduces yarn abrasion that takes
place during the weaving operation and reduces yarn harness preventing adjacent yarns
from entangling with one another at the weaving machine. Also, this protective coating
keeps the indigo dye from rubbing off during the weaving process.

Creel Section Scourer Box Dyeing Section Coiler

Section

WEAVING
Denim fabrics are woven by interlacing two sets of yarns perpendicular to one another in
fabric form. Yarns in the machine direction are called warp yarns or warp ends and these
are interlaced with filling yarns or weft. The sequence or order of interlacing the two sets
of yarns can be varied to produce many different weave designs. The finished fabric
construction is determined by the number of warp and filling yarns per square inch or
centimeters.

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 FINISHING
The finishing of denim fabrics is done different paths that involve singeing machine,
mercerizing machine, pad steam, sanforizing, pad skew and stenter. There are 5 processes
through which these machines are utilized.

Singeing Pad Skew Sanfo

Singeing Mercerizing Pad Skew Sanfo

Singeing Mercerizing Over Dye Pad Skew

Sanfo

Singeing Over Dye Pad Skew Sanfo

Singeing Mercerizing Coating Pad Skew

Sanfo

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 INSPECTION
From weaving section each denim fabric is tested initially in the QA lab. 2m sample cloth is
tested for the all requirements to be met as laid down by the customer. Once the sample is
cleared the production of that denim garment is resumed. In inspection section the finished
denim garment is tested for any defects during the production process. Customer
requirement code is followed during the inspection procedure. It is a 4 point American
system. And the fault length is marked in terms of points. The fault point scheme is as
follows.

Fault Length Points

(in)
3 1
36 2
69 3
9 1m 4

Then the points are allotted per 100 square yard of the denim fabric and on the basis of
which the product is either marked A grade or B grade product. The formula is given as:

3600
=

SHADE AREA
After inspection the fabric is sent to shade area they make record of cloth samples and after
stitching pieces of cloths they sent it for washing according to standard sheet and customer
requirement. Washing is done to change shades and to remove chemicals and hazardous
materials from fabric completely. Here Hunter lab machine measures the color of the fabric
shade. From here packing list is finalized.

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 UTILITY DEPARTMENT
BOILER
The boilers are used to generate steam which is provided in the process hall for the wet
process machines. The list of wet machines is as follows:

1. Rope Dyeing # 01, 02

2. Sizing # 01, 02
3. Pad Steam
4. Finishing
5. Mercerizing
6. Stenter # 01, 02
7. Sanforizing # 02
8. Washing

Besides the usage in wet machines in the process hall the steam is also provided in the
compressor rooms for the chillers. Steam is also provided for the HFO day tanks and a
steam is also provided to the LPG plant where it is provided to the evaporator.

The steam generated in the boiler room is saturated steam at almost 8 bar and 174 oC. The
boiler room is provided with 4 main boilers and 3 waste heat recovery boilers. The
specifications of the main boilers are as follows.

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 Boiler # 01
Descon Package Type
Made
Boiler Model 2003
Combustion Fuel Natural Gas, HFO
Heating Surface 4443 sq. ft
Capacity 15 Ton

Boiler # 02
Robey Lincoln Package
Made
Type Boiler
Combustion Fuel Solid Fuel
Heating Surface 3900 sq. ft
Capacity 10 Ton

Boiler # 03
Made Loose Boiler
Combustion Fuel Natural Gas, HFO
Heating Surface 4700 sq. ft
Capacity 16 Ton

Boiler # 04
Made Robey Loose Boiler
Combustion Fuel Natural Gas, HFO
Heating Surface 4700 sq. ft
Capacity 05 Ton

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 COMPRESSOR ROOM
Compressor room has 8 compressors installed in the vicinity to meet the demands of
compressed air utility in the process hall and mostly in the weaving shed to operate the air
jet power looms. The air produced by the compressors in the compressor room is first sent
to the air receiver tank from where it is being sent to the air dryers. From the air dryers the
compressed air is sent to the discharge header which sends compressed air to the process
hall with a 14 line for the weaving shed and 4 line for the process hall. The common exit
discharge pressure is 6.3 bar.
Compressors

Air Receiver
Tank

Air Dryers

Process Hall and

Weaving Shed

The compressors installed and their specification data is provided as follows:

1. ZH-7000 (Atlas Copco)

It is a centrifugal compressor with three stages; operate on oil free method and
produces compressed air at 7.7 bar maximum pressure. It operates at 2980 rpm. It
has a capacity of 96m3/min and is powered by a motor of power 560 kW. ZH-7000
is water cooled by the closed circuit water.

2. ZR-315 (Atlas Copco)

It is a rotary screw type compressor with two stages; operates on oil free method
and produces compressed air at 7.5 bars. It operates at 1485 rpm. It has a capacity
of 56m3/min and is powered by a motor of power 315 kW. ZR-315 is water cooled
by the closed circuit water.

3. ZR-250 (Atlas Copco)

It is a rotary screw type compressor with two stages and it operates on oil free
method. It has a capacity of 46m3/min and is powered by a motor of power 250 kW.
Compressor room has three ZR-250 compressors installed. ZR-250 compressors are
water cooled by the closed circuit water.

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 Two of the ZR-250 compressors have variable speed drive and are referred as VSD1
and VSD2, because they can vary their rpm depending upon the load conditions. The
maximum rpm they can achieve is 3000 rpm although they operate normally at
2600 rpm. Thus VSD1 and VSD2 are more energy efficient. Maximum pressure that
can be achieved is 8.6 bar. The third one is called ZR-250 fixed because its motor
rpm cannot be varied. It operates at 1485 rpm and a can produce compressed air at
max pressure of 4.5 bar.

4. GA-22 (Atlas Copco)

It is a rotary screw type compressor with single stage; operates on oil injected
method produces compressed air at 10 bar maximum pressure. It operates at 2940
rpm. It has a capacity of 35m3/min and is powered by a motor of power 22 kW. It is
air cooled compressor. There are two GA-22 compressors installed, one is available
in the compressor room and other one is installed in the process hall.

5. NR-75 (Ingersoll Rand)

It is a rotary screw type compressor with single stage and it operates on oil injection
method. It has a capacity of 15m3/min and is powered by a motor of power 75 kW.
NR-75 is air cooled by the radiator sort of method.

The dryers installed in compressor room are as follows:

1. FD 2000
2. FD 1000
3. MD 1000
4. CDx65L

All of the dryers work on the principle of vapor compression refrigeration cycle and are
used to remove the moisture from the air. It must be noted that there are losses in the air
pressure during the drying process of the air.

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 POWER GENERATION
US Denim Mills Power house utilizes three different means for power generation:

1. Gas Gensets
2. Diesel Gensets
3. LESCO

Power Plant Details:

05 Gas Gensets Jenbacher 5.3 MW, 400V

05 Diesel Gensets Caterpillar 5.6 MW, 400V
LESCO Independent Feeder 11KV, B3
03 Step Up Transformer SIEMENS 3x2500KVA,
11 MV Panels Areava 11KV, 630A, 25KA
02 Distribution Transformer Climax 2x2000KVA, 11KV/400V
01 Distribution Transformer Siemens
2000KVA, 11KV/400V

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 HUMIDIFICATION PLANT
There are 5 humidification plants installed in US Denim Mills. Four of them were installed
by Best Air Engineering Group and one is installed by the LUWA. The humidification plants
are referred:

1. Ball Warping (Best Air)

2. Re-beaming (Best Air)
3. Weaving Shed # 01 (Best Air)
4. Weaving Shed # 02 (Best Air)
5. Weaving Shed # 03 (LUWA)

The purpose of the humidification plant is to maintain the temperature and humidity level
at a certain required level. The required temperatures in weaving shed are 27oC Wet and
24oC Dry with a relative humidity of 77%.

SOFTENING PLANT
The softening plant is used to remove the hardness of the water caused by the calcium and
magnesium ions. The technical data of the softening plant that installed at US Denim Mills is
as follows:

Quantity 2
Capacity 75 m3/hr
Service time 10 hrs
Regeneration time 2 hrs
Output regeneration 750 m3
Resin volume 1825 liters
Regeneration mode counter current flow
Regenerant NaCl
Regenerant concentration 10%W/W NaCl
Regeneration level 200kg salt/ liter resin
NaCl consumption per regeneration 360kg (100% W/W)

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 MECHANICAL WORKSHOP
The mechanical workshop provides services of welding, machining, plumbing, wood work
and paint work. Mechanical Workshop is equipped with the following equipment to assist
in metal and work works:

1. Lathe Machine 6ft

2. Vertical Drill Machine 4 ft
3. Vertical Drill Machine 6 ft
4. Wooden Planner
5. Welding Plant Single/Two phase
6. Welding Plant Single phase
7. Welding Plant Two phase
8. Welding Plant Three phase
9. Argon Welding Plant
10. Saw Blade
11. Double end pedestal grinders x 6

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