SHAHRAJ FABRICS LIMITED FABRIC PROCESSING UNIT

Process Design and Quality Management

Submitted By: Adam Zia Khurram Yar Javed RehmanAkram Saba Javed Hayat Samar Shoaib

Company Profile

Introduction
Weaving
Sales: US$45 Million

Local Sales: Local Buyers, Army International Sales: USA, EU, Chin

Processing

Vertically Integrated

Stitching

Machinery
Weaving

250 Air-Jet Shuttle less Looms Woven Fabric Width Range: 31 160 Inches Capacity: 2 3 Million / Linear Meter Month

Processing

Bleach, Dye, Print, Finish Capacity: 3 Million Meter / Month

Stitching

250 Stitching Machines 4 Quilting Machines Capacity: 2 Million Sheet Sets and 100,000 Sets Bed / Month

Soap Washed

Bleached

Dyed

Fabric Types

Printed

Peach Finish

Crease Resistant

Water Repellant

Mercerized

Anti Bacterial

Production Process

Physical Inspection of Raw Material

Singeing

Production Flow Chart

De-sizing

Bleaching

Mercurizing

Dyeing

Printing

Finishing

Folding

Step 1: Physical Inspection of Raw Material

Gate Pass Assignation: Export / Import Root Card: Delivery Date, Customer Requirements Urgency of Shipment Fabric Checked for Miss-End, Miss-Pick, Double Ends 10% of Inspection

If Own Fabric, Then Rolls sent back, for reprocessing Planning and Production Managers If Outside Supplier Material, than removal of flawed pieces

Step 2: Singeing

Flam e
Fabric Refinement

Heavy Fabric 90 C

Light Fabric
45 C

Gas
Gas Heaters
Oxygenated Air Burns flawed Fibers

Guiders
Fiber Brushing

Lower Limited 90 Meters / Min

Average 100 Meters / Min

Upper Limit 120 Meters / Min

Step 3: DE-SIZING PROCESS

Heating fabric over hot oxygenated air stream De-sizing Box Starch removed through enzymes

Cloth framed on hydraulic rotation machine which makes 10 rotations in a minute

Cloth passed through squeezing machine where linear squeezing and compressing under hydraulic pressure is done

Step 4: BLEACHING AND MERCERIZING PROCESS

Rinsing-Pre Washing The frames loaded on the J box and cloth sent through a set of 3 prewashers and squeezers. First washer tries to achieve maximum temperature of 90 to 95 degrees as fabric temperature is low. Cloth then fed to the hydraulic pressure squeezer in which vacuum is created and suckers take out impurities from the fabric Bleaching Process Cloth fed into a giant steaming unit. Unit contains hydrogen peroxide, caustic catalyst, stabilizer, deironizing agent and wetting agent. Steamer has a temperature of 100 to 102 degrees due to both saturated and dry steam. Usually 200gram cloth takes 15 to 18 minutes before dyeing process can start. Rinsing Post Washers The cloth sent again to an alternate series of five washers and five squeezers. First washer temperature is 85 to 90 degrees Cloth is then passed on to biconduction dryers. Where it is dried through contact with steam filled dryers
Mercerizing Process

PH neutralized before the dyeing process. The fabric moisturized at a very fast pace. Caustic of relevant strength Passes again through a series of post washers and squeezers to remove caustic. PH is neutralized Cloth dried by conduction

Step 5: DYEING PROCESS

Dyeing Process

In the thermodying machine, white cloth frame is loaded on the J-box .

Drying Process

Fabric dried in drying chamber. It contains a fluid which is heated by infrared waves

Padding, Steamin g and Washing

Polyester is removed from the fabric Then sent into the steamer

Drying Process

Cloth dried in Teflon dryers For shade testing, sent to the lab

Step 6: FINISHING PROCESS

Stanter Machine
Finishing Width completion Winding Dying

Step 7: PRINTING PROCESS

Computerized Design Repeat Pattern

Screen Production

Printing

Folding

Computerized Design Repeat Pattern

Screen Production

Printing Folding

QUALITY ASSURANCE
ISO 9001
ISO 2008

ISO 14000
SA 8000

Quality Policy guidelines at Shahraj fabrics includes:

Quality assurance
Regular monitoring of customers requirement and expectations.

Clients satisfaction

Compliance of legal and regulatory environment

Timely delivery/ shipment

Minimize wastage Employees professional competence, constant grooming and development

Striving for excellence

Quality testing at Shahraj fabrics

Water spray test

Conducted to find out water pick up rate in fabric. A sample of the fabric is cut and secured at the start of the test.

A beaker with 250ml of water is placed on the top of the fabric.

The beaker dispels water at a constant rate for 25 seconds. If the criteria for water resistance is met then the roll of fabric is passes, if not then it goes back to get waterproofing.

Lab Test for light fastness and color

The light fastness test is used to determine the color fastness of any type of dyed and printed materials against day light. In this test a sample is exposed to a mercury blinded tungsten lamp inside a chamber.

This test checks for the resistance of the fabric to fading due to exposure to sunlight.
A sample of the fabric is put into the machine and then an ultra bright light is exposed to the fabric. At the end of the test the fading of the fabric is reviewed

Perspiration Tester
The perspirometer is used to check the fading in fabric . A sample is dipped in either water or an alkaline solution and then rested to absorb the liquid. After the test the fabric is checked for the change in color and the degree of staining.

The stacks are then placed under two stainless steel plates.

Martindale Abrasion Test

The abrasion test is used to find out the abrasion resistance of all types of fabrics.

The abrasion resistance is measured by subjecting the sample to a rubbing motion

This test finds out the resistive capabilities of various types of materials.

The materials are then evaluated through direct comparison to actual samples or the lap assistant checks it.

Digital Balance

Spectrophotometer test

Digital balance is used to measure the color according to customer specifications.

The spectrophotometer is used to measure the color density of the dye used in the fabric

The accuracy is in line with the international standards

The machine measures the dye mixture solutions in order to control the color and to measure the density of dye used in the fabric.

Recommendations
Improve the working environment as well as cleaniness Improve inspection methods of raw materials Improve upon chemical waste disposal Demand forecast should be done to achieve full capacity utilization. Organize the departments according to process flow