Sunteți pe pagina 1din 39

Textile Internship Report

ALOK INDUSTRIES LTD.


Vapi, Gujarat

Submitted by :ANTARIKSH SRIVASTAVA MOHD. SHAHID HASAN MANISH DWIVEDI RAHUL TELANG

BFT- 5

CONTENTS

1.
2.

i Introduction iii

3.Management Profile iv 4.Preparatory Processes 5.Weaving 6.Inspection 7.Process House


8. 9.

1 4 5 7 15 17

Finishing Process Lab

10.

Export Design and Development 19

SPINNING
To basic principal of the process is to understand the concept of spun yarn production, grey fabric(both woven and knitted) production, dyeing, printing and finishing of fabric, textile testing and their quality aspects both technical as well as for commercial purposes. The main purpose is to Get the machinery features, machine and material process parameters available in detail in the areas as mentioned below: Raw material storage and inspection section Detail documentation of the raw materials (fiber/filament) - Its specifications, bale specifications, storage capacity its area measurement and the brief layout. Fiber inspection and test methods followed in the concerned manufacturing unit. Blow room section. Detail information on the opening & cleaning methods followed their timings, type of input/feed system, etc..., mixing/blending ratios and the machineries used for this purpose. Detail information on the input material and the output materials specifications, productions per day per machine, etc... Carding section. Detail information on the carding machine and process. Machine specifications like draft (carding ratio), input weights, wire pin specifications (angle, material, etc...), different rollers in the carding machines, output material specifications (linear density, productions per day per machine, etc...). Drawing section. Detail information on the draft and doubling, machine detail, number of draw frames in use in sequence, production per day per machine, etc... Combing section. Detail information on the combing process and the machines in use with productions. Drawing section. Detail information on the draft and doubling, machine detail, number of draw frames in use in sequence, production per day per machine, etc...

Roving section. Detail information on the roving process and the machines in use with productions.

Ring Frame section. Detail information on the spinning process and the machines in use with productions, output yarn count, etc...

Ring Conner section. All the spun yarns are made into cones, then they are sent for inspection

Yarn Conditioner section. This process is carries out for the better moisture regain capacity of the yarn which will help further in weaving process..

UV section. All the yarn faults, shade variation, etcare all checked in this section.

OPEN END SPUN YARN


RAW

BLOW ROOM

CARDING

RING FRAME

RING CONER

YARN CONDITIONER

UV ROOM for YARN FAULTS PACKING AND DESPATCH

PROCESS FLOW CHART FOR RING SPUN YARN


RAW

BLOW ROOM

CARDING

DRAW FRAME (FOR UNIFORMITY) COMBING

DRAW FRAME NO.2 (FOR UNIFORMITY)

ROVING

RING FRAME

RING CONER

YARN CONDITIONER

UV ROOM FOR CHECKING FOR YARN

PACKING AND DESPATCH

For open ended spun yarns the end product from carding is directly brought on the ring frame. Thus open end yarns are coarser than ring spun yarns.

WEAVING PROCESSES

RAW

WARP

WEAVING PREPARATION WEFT

SIZING DIRECT WARPING KNOTTING SECTIONAL KNOTTING WARPING

DRAWING IN

GAITTING LOOM SHED

INSPECTION

PACKING AND DESPATCH

GREY YARNS The newly constructed fabric as it comes from the mill is called Greige fabrics. It simply denotes to any unfurnished fabrics. The various yarns used in manufacturing of the grey fabric. Mostly Combed cotton yarns are used And polyester yarns are used from the polymer production plant (Alok)

WARPING Conversion of single end packages into multiple end package from cone to beam is called Warping. It is the process of developing warp beams out of creels. The machine unwinds the creels and winds them over the warp beams. They have multiple ends insertion technique. Beam warping is used for long runs of grey fabrics. As an intermediate stage warp beams containing up to 1000 ends are produced. Warping is done by Benninger Warping machine

Benninger Warping Specifications)

Machine

(Technical

Speed- 400-1200 mpm

Creel Capacity(for cone)-1088 ends Production m/day Capacity500000-600000

One stop by sensor at yarn breakage Hydraulic and Pneumatic system Fully Automatic with Touch Screen Warping Beam Flange Diameter-1000mm Beam Width- 2400mm

WEAVING PREPRATORY Weaving preparatory consists of two sections. Direct Warping Sectional Warping

DIRECT WARPING This is carried out when only single colour on yarn is being used. For sing colour fabric.

SECTIONAL WARPING This is carried out when different colours of yarns are used. For checks pattern.

SIZING In order that warp yarns can withstand the complex stresses to which they are subjected in the weaving machine, they are previously strengthened by coating them with a thin film of size, and then drying. Its main purpose is to increase the strength of warp yarn. It is mainly done on 100% cotton. The thread

of 18-28 warp beams are combined at the slashing (sizing) stage and wound on to a weavers beam. The process of sizing is carried out by Benninger Sizing Machine.

BEN- Sizetec (Technical Specifications)

Speed- 40-50 mpm Creel Capacity- 28 warping beam Double Immersion Double Squeezing pair in one saw box. 2 boxes for positive feed system. 12 drying cylinders with 2 pair of wet spilling device. Waxing device Heel Sized beam flange Diameter-914mm Beam width- 3400mm Automatic Size level and Temperature Control Drying Cylinder centigrade Saw Box centigrade Temperature110-140 90

Chemical

Temperature-

SIZE RECIPE Size Recipe consists of the following things Adhesive

Softner Binder

Texoplast, Sonycryl, Ketanol, PVA and mutton tallow are generally used to make the size recipe. Here T.66 PVA is used as an adhesive, Sisco12 as a softener and Sycoluke as a binder.

How Yarn is Sized on the Sizing Machine After preparing the set of warping, they are loaded on the sizing machine creel. Here after tacking each and every warping beams sheet of yarn together at the end of circle zone and will be passed to the pair of saw boxes in 50% + 50% ratio of total number of threads. In saw boxes size chemical is taken.Here each yarn sheet will immerse in the saw box by 2-immersion roller pairs and it will be squeezed by 2- squeeze roller pairs to access size in the yarn. After the saw box zone yarn will be passed from hot drying cylinder zone to make it dry because the yarn was wet by the size chemical. After drying the yarn by cylinder zone to make it dry because the yarn was wet by size chemical. After drying the yarn by the cylinder zone it is passd through the splitting zone to split the threads. After splitting zone yarn is wound on weavers beam to give in loom shed to make the fabric.

DRAWING-IN Before the weavers beam is mounted on the loom, each end is threaded through a heald eye and the reed. It also supports a drop wire. After leasing of beam it has to be given for drawing in department to draw each and every thread through drop pins, heald wires and reed as per the weave/construction of the fabric. The warp unwound from weavers beam passes around the back rest and comes to the heald frames (harnesses), which are responsible for separating the warp sheet for the purpose of shed formation.

It then passes through the reed, which holds the threads at uniform spacing and is also responsible for beating up the last inserted pick. All the threads unite again in the fabric at the point of cloth fell. The cloth then passes over the front rest, round the take up roller, and is wound on the cloth roller.

A drop wire signals the loom to stop immediately after a warp end breaks off. The warp from the beam is then fed onto the weaving zone where it is converted into fabric and this fabric is then taken up on a cloth roll.

LEASING After preparing the weaves/sized beam it has to be given for leasing machine to insert 2-lease in the yarn sheet in 1-3-5-7-9. Countinuous upward thread and 2-4-6-8-10 continuous down thread sequence.

GAITTING

When an entire warp is to be constructed with a new quality yarn Automatic Coner machines (Staubli) are used this process is called Gaitting.

KNOTTING When a new set of yarns are to be brought in they are knotted with the existing set of yarns forming a new sheet.

LOOM SHED The primary motions of loom shed are as follows: Shedding Picking Beat-Up

Shedding is the name given to the motion which moves the heald frames up and down in order to separate the warp sheet into two layers and create a triangle in form of a reed through which the weft can be passed.

Weft Insertion (picking) is the means by which weft is projected through the shed. This was traditionally done by shuttle, but more recently it is done by projectile, rapier, air jet or water jet. Beating up is where the reed, mounted on sley, pushes the weft in to the fell of the cloth to form a fabric. This requires considerable force, and hence the term beating up.

It is done by rewinding the yarns left over from warping in the rewinding machines from RKJ Automatics.

WEAVING For manufacture of Plain, mass production fabrics Air-Jet looms are the most appropriate technology due to lower operating costs. Weaving is the interlacement of warp and weft yarns. It is carried out on a mechanical machine known as a Loom. It is done by airjet loom (Pecanol) and Dobby loom (Gci) . There are around 1500 Looms. The looms have 4 pick insertion system and advanced techniques like stop motion for faults. The fabrics produced are plain weave, plain sateen, sateen stripe, dobby and micro checks. It has a daily production of about 4,00,000 mts.

JACQUARD LOOMS Jacquard shedding mechanisms are capable of producing large and intricate weave designs that are beyond the scope of dobby shedding mechanisms. In jacquard weaving, it is possible to control every warp yarn individually. Many specialized types of jacquard machine have been developed for weaving particular kinds of fabric, such as terry towels, damasks, and carpets. Most of the rest are general purpose types that are comparatively easy to classify. The most elaborate designs (reproduction of freely drawn shapes, i.e. floral designs) are woven on an intricately constructed loom called the Jacquard loom, and the weave of these fabrics is called the jacquard weave TECHNICAL (Design Capability) For designs that require the reproduction of freely drawn shapes, it is usually necessary for each end in the repeat to be separately controlled. Jacquard machines are used for a wide variety of purposes from ties to carpets. Their patterning possibilities virtually unlimited.

No. of picks/repeat virtually no limit to the number of picks/repeat (i.e. 5000 picks or more) the length of the repeat is limited only by the cost and inconvenience of a very long pattern chain No. of heald frames (or no. of ends/repeat) Jacquard machines are made in a wide variety of sizes to control from 100 to 2000 or more ends per repeat. In conventional jacquard machine field, the spectrum now ranges from 192 through 3200 to 6144 hooks. When a higher no. of independent lift is required two or three jacquard machine is placed side to side. Principal motion in the jacquard shedding. Drive : the mechanism that links the engine to the weaving machine Knives ( set of knives) Selection: needles, springs, card cylinder, and endless paper pattern Lifting: Hooks, neck-cords, harness cords, mails, and weights (spring or elastomer) A Jacquard machine may be divided into three main parts: Jacquard head /engine : Knives, hooks, needles, springs, and card cylinder, endless paper pattern Harnesses : neck-cords, harness cords, mails, and weights (spring or elastomer) The mechanism that links the engine to the weaving machine The jacquard m/c is assumed to have 400 hooks: Eight rows of fifty hooks (8 X 50 ) We suppose there are four repeats of 400 ends, making totally 1600 ends Advantages Tremendous design possibilities, Simpler in principle than dobbies Disadvantages Large scale moving parts makes the machine and its harness relatively costly to install and maintain. Jacquard fabrics are much more costly to produce. Jacquard machines are even more liable to produce faults in the fabric than dobbies. Pattern change is a time consuming process.

Until recently, the jacquard machine had tended to impose limitations (300 picks/min ) Jacquard shedding is normally used only when the cloths to be woven are outside the scope of dobby shedding. The machines involved rapier mechanism (Suzler) DOBBY LOOMS WERE BEING USED MOSTLY FOR SAMPLING.

CAM LOOMS Cam looms have a design capability of producing simple weaves.

Number of Picks/Repeat limited to 8-10 picks/repeat Number of heald frames limited to 8,10-12 ends/repeat

Advantages of Cam Looms

Simple and Roboust. Inexpensive with regard to both initial cost and maintenance Very less likely to cause defects in fabric Impose no limitation on the speed of the loom

Disadvantages of Cam looms Restricted design possibilities Inconvenient for frequent pattern changes

To change the gearing of the cam for a different no. of picks /repeat

DOBBY LOOMS These are more complicated than cam systems but have higher initial and maintenance costs. Dobby looms have the capability of producing more complicated and sophisticated weaves. Due to their complexity, dobby mechanisms are more liable to produce more fabric faults than cam systems.

Dobby has a design capability of producing more versatile designs. No. of picks/repeat virtually no limit, around 5000 picks/repeat No. of heald frames built upto control 2028shafts

There are two types of dobby

Single Lift Dobbies In single lift dobbies, the shed is closed after every weft insertion and the pick is beaten up at the closed shed (center closed shed). The speed of single lift dobbies is limited to 160-180 rpm. All system elements perform their function once every weaving cycle to open a shed and then they return to their original positions before a new cycle. Double Lift Dobbies All new type dobbies are double lift in their operation. Its cyce occupies two picks. The system elements operate once every two weaving cycles but the shed opening is achieved every pick. Most of the motions in dobby occur at half time

loom speed. In dobby mechanisms open shed is produced, and unnecessary and wated movements are eliminated. These are suitable for high speed operations

The dobby mechanisms consists of three principal operations: The drive mechanism The selection mechanism The lifting mechanism

INSPECTION Fabric inspection is the most important process as it is used to analyze the quality of the fabric. Four point system is the most widely used and recognized inspection technique frequently used in the textile industry. It is a technique issued by the American Society for testing and materials with reference to the designation ASTM D5 43093

A maximum of 4 points may be assigned to any one linear yard, regardless of the number or the size of the individual defects. The fabric is inspected after weaving by using the four-points system. There are 9 machines for inspecting the fabric out of which 3 are used for inspecting grey fabric. Four Points Grading System

The maximum number of defects points to b counted against any one linear yard/meter is 4 points. Overall,fabric quality is assessed om the basis of the number of defects points per 100 sq. yard/sq.meter of fabric. Normally fabric rolls containing up to 4048 points per 100 sq. yards are acceptable. Points Calculation- (Total points secred in a roll)*3600/(fabric width in inches *total yard inspected).

After inspection of fabric it is dividing in to five categories, details are :Category A B C D Points in 100 linear meters 0-20 points 21-30 points 31-40 points 41-50 points

It has been observed that 96% of the fabric produced is of A grade while the rest of the 4% is of other grades.

PROCESS HOUSE

BATCHING After the weaving process is carried out the fabric is brought to process house for further processing like singeing, desizing, mercerization, bleaching etc They are made into batches which then goes for processing.
WEAVING

BATCHING

CONTINOUS PROCESS

SINGEING Surface Hair Removal is usually the first stage in a preparation sequence and can be carried out by Singeing. The main objectives of the process of Singeing are: To get rid of the small fibres.

To make the fabric smoother than before. To help the printing ink and dyestuff make deeper impact on the fabric To improve the rubbing and washing fastness of dyed or printed fabric Increased Wettability Improved visibility of fabric texture. Less Pilling Decreased contamination through removal of fluff and lint.

It is a mechanical process that uses a gas flame or a wet plate in order to get rid of small fibers protruding on the fabric surface.It is more invasive than any other method of fibre removal. The most widely used type of Singeing machine allows the fabric to pass at the speed of 60 to 120 meters per minute through a naked flame so the protruding fibers are burnt away.

Singeing is a continuous process carried out on dry open width fabric and maybe done on either one or both sides of the fabric. Immediately after passing through the flame the fabric is quenched by running it through water or a steam box to extinguish any remaining sparks and embers.

The flame position is generally perpendicular to the fabric and only rarely tangential. The fabric is positioned at a distance of 1.5 - 4mm from the end of flame and the mahine is equipped with a suction device under the fabric, which attracts the flame and concentrates the heat on the fabric. Singeing process with the perpendicular flame is the more common one while the one with tangential flame is used for fine fabrics.

DESIZING Desizing is the process of removal of size materials from the warp yarns in woven fabrics by dissolving them. Desizing is generally carried out by either acids or enzymes such that the chemical penetration of fabric at the later stages is not inhibited.

The baBasic purpose of desizing is:

Removal of added impurities like starch Weight Loss Improved Wetability

The recipe for desizing is: For Pad Batch : Beisol - 4 g/l (Enzyme) Felosan APF SPZ 4g/l (Wetting Agent) Heptol ASC 2g/l(Chelating Agent)

For Pad Steam (yarn dyed): Felosan APF SPZ 4 g/l (Wetting Agent) Heptol ASC 2 g/l(Chelating Agent)

Beisol (Enzyme)

- 3.5 g/l

For Pad Steam : Heptol EMG 0.5 g/l(Chelating Agent) Felosan APF SPZ 4 g/l (Wetting Agent) Beisol HTS - 3.5 g/l (Enzyme)

Need for Desizing Insufficient desizing can lead to resist areas in printing, reduced color depth, hard fabric handle, poor absorbancy and reduced degree of whiteness.

The singeing machine is combined with desizing machine of Osthoff. The fabric comes from warehouse in Palette form or roll form in an open width form.

PREBRUSHING SINGEING

POST BRUSHING

DESIZING

BATCHING

Singeing & Desizing process in OSTOFF machine.

BLEACHING Bleaching is used to whiten fabrics and yarns. Bleaching is the process of removal of natural pigments and vegetable impurities. Its main objective is to make the good to be suitable for dyeing and printing with pale or bright shades. The scouring process of cotton removes the wax and the majority of other impurities, leaving the material in a more absorbent condition, but scouring only partially removes cotton seed and husk, and has little effect on any natural coloring matter that may be present in the fiber.

Bleaching completes the purification of the fiber by ensuring that seed and husk are fully broken down and removed and that coloring matter is destroyed or at least converted to colorless products. The bleaching of cellulosic fibers is carried out with oxidizing agents ussuallyone of the following:

Hydrogen Peroxide (H2O2)

Sodium Hypochloride (NaOCl)

The process conditions during bleaching vary with the type of agent used. Once bleaching is complete, the bleaching agent must be completely removed, either by thorough washing through the use of enzymes.

The bleaching range is called the Continuous Bleaching Range by Benninger. It includes Washing range, Steaming sectiotn and a bleaching machine.

Washing Machine Extracta Steaming Machine Extracta Bleaching Machine Ben-IMPACTA


INJETCTA

EXTRACTA

BENIMPACTA STEAMER

WASHER

VDR (VERTICAL DRYING RANGE) BATCHING

Recipe and Working conditions Hydrogen Peroxide(50%) 50ml/kg Caustic Soda 25ml/kg Seq. Agent 3ml/kg Stabilizer 12ml/kg Dwell Time 20 min Machine Speed 80m/min Steaming Temp 98oC

MERCERIZING Mercerization is the process which is only applicable to cellulosic fibers, and in cotton particular. The main purpose of the process is to alter the chemical and physical properties of the fibers. The treatment is carried out by using Caustic Soda (28-30 Be), which determines the contraction and swelling of fibers, they become translucent and increase their tensile strength, but reducing their flexural and torsional strength.

Typical working line on a chain mercerization machine

The bean like section of the fiber becomes first elliptical and then circular, allowing a better reflection of light with a consequent increase of lusture.

Mercerization process is carried out on Cotton fabric and results in: Increased luster Strength Affinity to dye Resistance to mildew Lint reduction

Procedure of Mercerization process

Pad 22-25% NaOH at 100%wpu Dwell Time 30-40 sec. Stretch to Greige width on chain stenter Wash to < 3% NaOH and release Acid sour, rinse and dry.

PRETREATMENT

IMPREGNATION

VDR (VERTICAL MERCERIZATIO DRYING IMPREGNATION STABILIZER EXTRACTA N

RELAXATION

Mercerization process in BENNINGER

DYEING Dyeing is employed to give an all over shade to the fabric. Coloration of dyeing involves the use of dye stuff which are capable of reacting and combining with textile fibre molecule, usually when in a water solution, and usually with other auxiliary chemicals to enhance the process.

The darkness or lightness of color in dyeing is known as the depth of shade. This depends on the quantity of dye used in the ratio to the fiber weight. The textile material is moved in the solution of dyestuff, then the dye is attracted to the material and seen that the liquid gradually loses its color whilst the textile materials become deeply dyed.

Classification of dyes Dyes may be classified into a number of ways, including color, intended use and chemical constitution. There are basically five types of dyeing processes namely: Reactive VAT Disperse

Reactive dyes are called so because their molecules react chemically with the fiber polymers to form a covalent bond. The dyestuff thus becomes a part of the fiber and is much likely to be removed by washing. It is suitable for man-made and natural cellulose fibers, synthetic fiber and natural protein fiber. It is used to dye dark shades. Reactive dyeing is done by E-Control, CPB and Pad Steam (COLD PAD BATCH)

VAT dyeing means dyeing in a bucket or VAT. Vat dyes are insoluble in water and incapable of dyeing fibers directly. Both cotton and wool, as well as other fibers can be dyed with VAT dyes. These have excellent wash and light fastness properties. It is usually very bright and hold up better when bleached. Vat dyes are costly and demands addition of costly chemicals, makes the process still costlier. Vat dyes are developed by the process of steaming. Vat dyeing is done on Pad Dry Pad Steam (PDPS)

Pigment dyes are not water soluble and adhere to the surface of the fabric which is done by heat setting. Pigment dyeing is done on Pad Dry Cure (PDC)

Disperse dyes are mainly used for dyeing of polyester. These are insoluble in water and acidic pH is required by the fabric for dyeing. Dyeing is carried out at high temperature and pressure. Disperse dyes have good crocking and light fastness. Disperse dyes are used for dying CVC (Chief Value Cotton) Pad Dry Cure & RC (Reduction Clear) is used for Disperse dyeing.

Winch dyeing machine is one of the oldest known machine in rope form processing for all circular knitted goods. It has a capacity of around 1000 yards. During the operation of winch, the tension exerted on the fabric is far less than that on the

jigger dyeing machine. Also known as Beck dyeing or Box dyeing. It retains much of its original softness of hand and fabric fullness.

The list of dyeing machines in the industry is as follows:

Pad thermosol (PIGMENT) o Speed 40m/min o Mangle 2/1/2 bar (L/M/R)


o

Temperature 130-170oC

Cold Pad Batch Dyeing (BATCH DYEING) o Speed 40m/min o Mangle 35/35/35 (n/mm) o L/M/R 2.9/1.6/2.9 bar o Batching 10hrs.

Continuous Dyeing Range (Benninger)


o

Speed 65-70m/min

o Mangle 24/24/24 n/bar CVC dyeing on (Polyester Dyeing) o Speed 40m/min o Mangle-1/2/2002 bar
o

PAD

THERMOSOL

Temperature 110o-220oC

PRINTING Printing can be defined as localized application of dye or pigment in a paste form to generate a pattern or design on the fabric. It is simply called localized dyeing. It is single or multicolor application on one side of the fabric at selected portions only. The printing paste is applied in dry form.

The main steps in printing process are as follows: Preparation of print paste Printing of Fabric Drying Fixation of Dye-Stuff Washing off

The printing method used in the unit is ROTARY SCREEN PRINTING. Fully automatic flat-screen machines cannot be described as operating continuously, because their printing action is in fact intermittent. Continuous movement of the fabric has been achieved by moving the screens along with the fabric while printing (the American Precision Midas machine, for example, is of this type), but the use of rotaryscreen machines has proved to be a simpler and more economical means of achieving this goal. In rotary-screen printing, continuous rotation of a cylindrical screen while in contact with the fabric ensures genuinely continuous printing. Print paste is fed into the inside of the screen, and during printing is forced out through the design areas with the aid of a stationary squeegee. In the case of flexible-blade squeegees, the rotation of the screen in contact with the stationary blade builds up the pressure to force the paste through the screen. This

is, of course, the converse of flat-screen printing, where the screen remains stationary while the squeegee moves. A typical rotary-screen printing machine is shown in Figure 2.10. The design of most machines follows the pattern established for fully automatic flatscreen machines: an endless driven blanket, screen positions along the top, and blanket washing and drying effected underneath during the return passage. Provision for the use of a thermoplastic adhesive is common on rotary machines, with a curved-surface heating plate to heat the fabric before it is pressed on to the blanket. The cylindrical screens can be much closer together than is possible with flat screens and so the blanket is shorter (for a given number of colours). The fabric dryer, however, must be longer to enable the printed fabric to be adequately dried at higher running speeds. Typically, speeds of 3070 m min1 are used depending on the design and the fabric quality. It is quite possible to run the machine faster than this, the limitations often being the length and efficiency of the cloth and blanket dryers and the difficulty of observing printing faults at high running speeds. Print paste is often poured into flat screens by hand, even in fully automatic machines, but the continuous movement of a cylindrical screen and the restricted access necessitates automation of this operation. The print paste is pumped into the screen through a flexible pipe from a container at the side of the machine; inside the screen, the paste pipe has a rigid structure as it also acts as a support for the squeegee. Holes in the pipe allow the paste to run down into the bottom of the screen; since the paste is pumped in from one end, the holes need to be larger at the end furthest from the pump to achieve an even spread across the full width of the screen. A sensor (level control) actuates the pump when the paste level falls below a preset height. In rotary screen printing, tubular screens rotate at the same velocity as of the fabric. Print paste distributed inside the tubular screen is forced in to

the fabric as it is pressed between the screen and a printing blanket. Continuous Screen Printing Process Fabric glued to blanket Fabric moves under rotating screens Rod or blade squeegee systems Fine adjustments easily made

Machines LAXMI (8 head Rotary Screen Printing M/C) Reggiani (12 head) The Reggiani machinery is highly mechanized and provides prints as well as facilitates the fixation and washing of the fabric simultaneously in one continuous process.

Width of the Screen 3530mm Repeat Size 64, 82, 91 cms

Some chemicals used in the process are : Binder, Luprintol, Ammonia, Urea, Fixing Agent, Luprimol, Latextal, Hydrogen Peroxide, Soap, Acetic Acid.

Printing Recipe Formation Binder ETECO Luprintol PE Liquid Ammonia Luprimol SIG Latextal Hit Urea Color Fixing Agent

Screen Engraving / Screen Development The design is prepared on Photoshop CS2 on 1/1 color with proper pixels. The design is then transferred onto the roller by the following method:

Coating Machine Photoemulsion chemical is applied on to the Nickel Roller. Dryer Chemical is dried in this process Engraving Design(in negative form) is transferred on to the roller Washing Washing is done to remove the excess of chemical for the final design to appear.

FINISHING

The finishing procedure starts when loom state fabrics are delivered from the weaving department, after greige grey inspection. The fabrics are

generally dirty and may contain size, lubricants and waxes from spinning and weaving. The handle will be stiff and lacking volume. The fabrics are weighed, measured, labeled and assembled into batches for processing.

The fabrics must be of the correct dimensional stability for garment making and the correct finished width. Modern finishing machinery is equipped with computer data storage of operating parameters and processing details, video and touch screen display/control to ensure reproducibility of finish. These modern developments help to maintain quality between orders and also reduce operator error.

There are two types of finishing: Chemical Finish Mechanical Finish

Chemical Finish

Stentering is done for width fixation of the fabric by stretching the fabric and applying chemicals in wet form and the drying the fabric at high temperatures such as 120-1400 C because it makes the fabric structure compact. Acetic Acid, MFB are added to the fabric at the statrt of the process. Later on the stenter frame hot gas is blown through the fabric and is exhausted. Then cool water is injected. This process gives the final stability to the fabric. Machine Montfort Montex

Mechanical Finish

Brushing is done for the surface smoothening of the fabric. The continuous brushing of the fabric with metal brushes smoothens the surface . Peaching/Sueding is done for glossy finish to the fabric . Sand paper is constantly rubbed with the fabric. The smoother from the sand paper gets deposited on the face of the fabric giving it a smooth feel.

Machine Optisystem Xetma Lafer microsand

S-ar putea să vă placă și