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 INTERLOOP

VISION:
CONTENTS
 INTRODUCTION OF PROJECT

DIGITAL SOCK PRINTING IS A REVOLOUTIONARY TECHNOLOGY IN PRINTING. NOW, WE CAN

PRINT THE SOCKS TO 360 DEGREE VERY EASLY.
THIS PROJECT WILL EXPLAIN MY 3 MONTHS WORKING ON DIGITAL PRINTING.
DURING THIS PERIOD I WAS INVOLVED IN THE EXECUTION OF TWO ORDERS OF 360 DEGREE
DIGITAL PRINTING.
I WILL EXPLAIN WHAT I HAVE LEARNED DURING THIS PERIOD AND ALSO WHAT DIFFICULTIES
WE HAVE FACED DURING THIS PERIOD.
 MACHINE INTRODUCTION

Inks jet printer works on the phenomena of Piezo-Electric Technology.

Epson's proprietary inkjet technology uses a Piezo crystal at the rear of the ink reservoir. This is rather like a loudspeaker
cone that flexes when an electric current flows through it. So whenever a dot is required, a current is applied to the Piezo
element which then flexes and, in so doing, forces a drop of ink out of the nozzle.
 CONTI.
AN INK TANK (BLACK) SUPPLIES THE INK DISPENSER (GREEN) THROUGH A NARROW TUBE BY CAPILLARY ACTION.
A DROPLET OF INK FROM THE TANK SITS WAITING AT THE VERY END OF THE TUBE.
WHEN THE PRINTER CIRCUIT (NOT SHOWN) WANTS TO FIRE AN INK DROPLET, IT ENERGIZES TWO ELECTRICAL
CONTACTS (RED) ATTACHED TO THE PIEZOELECTRIC CRYSTAL.
THE ENERGIZED PIEZOELECTRIC CRYSTAL (DARK RED) FLEXES OUTWARD (TOWARD THE RIGHT IN THIS PICTURE).
IT SQUASHES AGAINST A MEMBRANE (DARK BLUE), PUSHING THAT TOWARD THE RIGHT AS WELL.
THE MEMBRANE PUSHES AGAINST A HOLE IN THE INK DISPENSER (GREEN), INCREASING THE PRESSURE THERE.
THE PRESSURE FORCES THE WAITING INK DROPLET FROM THE TUBE TOWARD THE SUBSTRATE.

o
 CONTI
GEARS DRIVEN BY AN ELECTRIC STEPPER MOTOR TURN ROLLERS THAT ADVANCE THE ROLLER TO ROTATE ALONG WITH
THE PRINTER HEAD.
A FLEXIBLE RIBBON CABLE CARRIES PRINTING INSTRUCTIONS FROM THE ELECTRONIC CIRCUIT INSIDE THE PRINTER TO
THE INK CONTAINERS (INKJET PRINTERS CONTAIN CIRCUITS THAT TRANSLATE THE INSTRUCTIONS FROM YOUR
COMPUTER INTO PRECISE MOVEMENTS OF THE PRINT HEAD. THERE'S USUALLY A SINGLE, LARGE CIRCUIT BOARD
SOMEWHERE IN A PRINTER WITH ALL THE COMPONENTS MOUNTED ON IT, INCLUDING THE CONTROL
SWITCHES, LED DISPLAY LIGHTS, AND VARIOUS CONNECTIONS TO THE PRINTER MECHANISM AND POWER SUPPLY.)
PLASTIC AND RUBBER ROLLERS PINCH THE PAPER TIGHTLY SO IT CAN BE MOVED THROUGH THE PRINTER WITH
ABSOLUTE PRECISION.
A STURDY METAL RAIL GUIDES THE PRINTER HEAD AS IT MOVES BACK AND FORTH.
SPIKED WHEELS AT THE FRONT OF THE PRINTER HELP TO GRIP THE PAPER SECURELY AND MOVE IT PRECISELY.
THE PRINT CARTRIDGE PRINTS FROM LEFT TO RIGHT THEN REVERSES THE PRINT INFORMATION AND PRINTS BACKWARDS
FROM RIGHT TO LEFT. THIS IS KNOWN AS BIDIRECTIONAL PRINTING AND ALLOWS PAGES TO BE PRINTED MUCH FASTER.
 WORKING MECHANISM OF MACHINE

THE SOFTWARE APPLICATION YOU ARE USING SENDS THE DATA TO BE PRINTED TO THE PRINTER DRIVER.
THE DRIVER TRANSLATES THE DATA INTO A FORMAT THAT THE PRINTER CAN UNDERSTAND AND CHECKS TO
SEE THAT THE PRINTER IS ONLINE AND AVAILABLE TO PRINT.
THE DATA IS SENT BY THE DRIVER FROM THE COMPUTER TO THE PRINTER VIA THE CONNECTION INTERFACE
(PARALLEL, USB, ETC.).
THE PRINTER RECEIVES THE DATA FROM THE COMPUTER. IT STORES A CERTAIN AMOUNT OF DATA IN A
BUFFER. THE BUFFER CAN RANGE FROM 512 KB RANDOM ACCESS MEMORY (RAM) TO 16 MB RAM,
DEPENDING ON THE MODEL. BUFFERS ARE USEFUL BECAUSE THEY ALLOW THE COMPUTER TO FINISH WITH
THE PRINTING PROCESS QUICKLY, INSTEAD OF HAVING TO WAIT FOR THE ACTUAL SUBSTRARE TO PRINT. A
LARGE BUFFER CAN HOLD A COMPLEX DESIGN OR SEVERAL DESIGN.
 CONTI.

THE PRINT HEAD STEPPER MOTOR USES THE BELT TO MOVE THE PRINT HEAD ASSEMBLY ACROSS THE
SUBSATE .
THE MOTOR PAUSES FOR THE MEREST FRACTION OF A SECOND EACH TIME THAT THE PRINT HEAD SPRAYS
DOTS OF INK ON THE SUBSTRATE AND THEN MOVES A TINY BIT BEFORE STOPPING AGAIN.
THIS STEPPING HAPPENS SO FAST THAT IT SEEMS LIKE A CONTINUOUS MOTION.
 CONTI.

MULTIPLE DOTS ARE MADE AT EACH STOP. IT SPRAYS THE CMYK COLORS IN PRECISE AMOUNTS TO MAKE
ANY OTHER COLOR IMAGINABLE.
AT THE END OF EACH COMPLETE PASS, THE R STEPPE ROLLER MOTOR ADVANCES THE ROLLER A FRACTION
OF AN INCH.
THIS PROCESS CONTINUES UNTIL THE WHOLE SUBSTRATE IS PRINTED. THE TIME TO PRINT ONE SOCKS VARY
BASED ON THE COMPLEXITY AND SIZE OF ANY DESIGN THE .
ONCE THE PRINTING IS COMPLETE, THE PRINT HEAD IS PARKED . MOST PRINTERS TODAY USE INKS THAT ARE
VERY FAST-DRYING, SO THAT YOU CAN IMMEDIATELY PICK UP THE SHEET WITHOUT SMUDGING IT
 PROCESS FLOW OF DIGITAL PRINTING

Bleached Pretreatment Hydro Drying

socks extraction

Washing Curing Printing

and Finishing

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 PRETREATMENT
RECIPE

Chemicals Concentration (g/l)

Sodium Alginate 10

Soda Ash 20

Glauber Salt 30

Urea 150
CONTI
 REACTIVE DIGITAL PRINTING
RIP THE DESIGN TO BE PRINTED ON ULTRA PRINT SOFTWARE BY TAKING THE SIZE OF THE SOCKS AFTER ADJUSTING IT ON
MACHINE AXIAL ROLLER.
MEASURE ITS WIDTH.
MEASURE ITS HEIGHT (ROUNDNESS).
NOW ADJUST THE TWO LASER INDICATORS (PRESENT ON THE TOP OF AXIAL ROLLER) AT THE START (WELT) POINT AND
END (TOE) POINT OF THE SOCKS FOR CONTINUOUS PRODUCTION OF THE NEXT SOCKS.
THE NEXT SOCK SHOULD BE ADJUSTED ACCORDING TO LASER SETTINGS.
NOW MOVE THE HEAD FORWARD TO CHECK THE HEAD HEIGHT.
HEAD SHOULD NOT BE SO CLOSE TO THE SOCKS SURFACE THAT IT TOUCHES ANY LOSES FIBER OR CONTAMINATION
PRESENT ON THE SOCK SURFACE, SECONDLY IT SHOULD NOT BE AT MORE HEIGHT THAT THE IMAGE LOOKS BLURRY,
LOWER THE HEAD HEIGHT MORE SHARPNESS AND EXCELLENT COLOR DEPTH IS OBSERVED.
HEAD IS THE MOST SENSITIVE PART OF THE MACHINE SO IT SHOULD HAVE TO BE PROTECTED FROM DUST AND TOUCHING
WITH THE SOCKS OR ANY HARSH SURFACE.
CONTI..
 CONTI.

IT IS OBSERVED THAT ROOM TEMPERATURE AND HUMIDITY HAS A GREAT EFFECT ON THE INK
BEHAVIOR IT SHOULD BE OPTIMIZED TO 20 TO 25 C TEMPERATURES AND 50% TO 60%
RELATIVE HUMIDITY.
TEMPERATURE ABOVE 25 C CAUSES A LOT OF PROBLEM TO HEADS. IT REMAINS ON THE HEAD
SURFACE AND BLOCK THE NOZZLES TO SPRAY. THEREFORE THE HEAD STATUS IS NOT CLEARED,
ALTHOUGH A LOT OF STRONG OR NORMAL CLEANING IS DONE.
 CURING
AT FIRST PUT ON THE STEAM FOR SOMETIME WITH THE OPEN DOOR OF OVEN TO REMOVE ANY CONDENSATION PRESENT
IN THE PIPES.
LOAD THE TROLLEY AND CLOSE THE DOOR.
PUT ON THE STEAM FOR 4 MINTS WITH THE EXHAUST FAN OFF.
AFTER STEAMING INSTANTLY PUT ON THE DRY HEAT FOR 20 MINS, IT HELPS IN DRYING THE SOCKS AS THEY GOT
COMPLETELY WET WHEN DIRECT STEAM IS APPLIED. FURTHER MORE IT ALSO HELPS IN CURING.
IN CASE OF DRY HEAT WE GOT AN OPTION TO PUT ON THE EXHAUST IN THE SAME TIME WITH HOT AIR BUT WE DO NOT
USE THAT OPTION FOR HEATING THE EXHAUST IS PUT OFF DURING HEATING.
IN CASE OF STEAM, WE HAVE DIRECT INSERTION OF PRESSURIZED STEAM THEREFORE THERE COULD BE AN ISSUE OF
DROPPING ON THE SOCKS HANGED IN THE LOWER PART OF TROLLEY SO TO AVOID THAT COMPLETE REMOVAL OF
CONDENSATION IS REQUIRED FROM THE STEAM PIPE.
AFTER STEAMING THE PIECES BECOME COMPLETELY DRY AND READY FOR WASHING. EVERY REACTIVE PRINTING NEEDS TO
BE WASHED TO REMOVE ALL THE UNFIXED DYE PRESENT ON THE SURFACE OF THE SUBSTRATE. IN INTERLOOP WE USE
DIFFERENT PARAMETERS TO WASH THE SOCKS. 19
CONTI..
 Machines Capacity ( No of Manpower
Garments Per Month)
Cotton Web 624
Softwood 210
STITCHING:
Cotton Web 525000
Softwood 130000
Cotton Web 814
Softwood 200+

Small Front Back

Parts Panel Panel Assembly
Machine Capacity
Tenello 8 100kg
Yilmack 4 80kg
Barrel 7
Front loader 4
DENIM WASHING:
50kg
80kg

Denim
Washing
Garment
Dry Process
( GDP)

Garment
Wet Process
( GWP)
 DENIM DRY PROCESS

WISKERING:

SCRAPPING:
 DENIM DRY PROCESS:
TAGGING OR KNOTTING:

TIEING:
 DENIM DRY PROCESS:
DISTRESS OR DESTROY:
 DENIM DRY PROCESS

PINKY:
 DENIM DRY PROCESS:

3D WASH:
 DENIM WET PROCESS:

ENZYME WASH:
 DENIM WET PROCESS:

BLEACH WASH:

RINSE WASH:
 DENIM WET PROCESS:

ACID WASH:

RANDOM WASH:
 DENIM WET PROCESS:
TINT WASH:
 FINISHING:

Pre quality
Quality
Packing
FINISHING:
 INDUSTRIAL ENGINEERING
MAJOR DUTIES OF IE DEPARTMENT

Make P.P meeting

Negotiation with Garment Analysis if Fabric, trims and
Merchandiser accessories are in Production Target
SAM Calculations
house.

Set Machine Continuous

Layout Line Setting Line Balancing production
meeting

Production report Piece Rate Collecting Preparing

analysis Calculation production data production report
 TYPING SKILLS:
Typing Speed ( WPM)

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33 33 33
32 32 32
31 31 31 31
30 30
29 29
27 27 27
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25

TYPING SPEED

28/8/2016 29/8/2016 30/8/2016 31/8/2016 1/9/2016 2/9/2016 3/9/2016 5/9/2016 6/9/2016 8/9/2016
9/9/2016 16/9/2016 17/9/2016 18/9/2016 19/9/2016 20/9/2016 21/9/2016 22/9/2016 23/9/2016 24/9/2016
EXCEL SKILLS:
CHANGE MANAGEMENT TRAINING WORKSHOP:
Lean Management

Dialogue Approach

Identify the Problems In Product Development

Identify The Reasons For Delay in Product

Development

Measuring And Reducing Lead Time In Product

Development

Development Of Problem Solving Approach Through

Dialogue Approach
 SUGGESTIONS:
Daily Evaluation

More Lectures

More days in Cotton Web

Washing

Meetings With Higher

Management
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ANY QUESTION

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