Summer Training Project
Report & Viva Voice on
“ Marketing Strategy on spun yard production”
Undertaken at
“MANGALMAY INSTITUTE OF MANAGEMENT AND TECHNOLOGY”
Submitted in partial fulfillment of the
requirements for the award of the degree
of
BACHELOR OF BUSINESS ADMINISTRATION
To
CHAUDHARY CHARAN SINGH UNIVERSITY, MEERUT
Under the Guidance of
Ms. SONALI CHAUHAN
Submitted by
DEEWAKAR JHA
BBA V SEM
200992105049
Academic Session –
2022-23
CERTIFICATE
I DEEWAKAR JHA bearing Enrollment No. M- 20015990 from BBA-V Sem. Of
the Mangalmay Institute of Management & Technology, Greater Noida, and U.P,
hereby declare that the Summer Training Project Report entitled " A Study on
Marketing Strategy with Relevance to Vardhaman ” at NOIDA U.P is an
original work and the same has not been submitted to any other Institute for the
award of any other degree.
Date:
Signature of the Student
Certified that the Summer Training Project Report submitted in partial
fulfillment of the requirements for the award of the degree of BACHELOR
OF BUSINESS ADMINISTRATION to CHAUDHARY CHARAN SINGH
UNIVERSITY, MERRUT by DEEWAKAR JHA Roll No. 200992105049 Has
been completed under my guidance and is Satisfactory.
Signature of the Faculty
Name of the guide: SONALI CHAUHAN
Designation:
CERTIFICATE
This is to certify that…DEEWAKAR JHA…a student of Bachelor of Business
Administration(BBA), a class of 2022, from BBA-VSem of the Mangalmay Institute of
Management & Technology, Greater Noida, U.P., Affiliated Chaudhary Charan Singh
University, Meerut bearing
Roll No…200992105049 has undertaken
the
Summer
Internship
at … VARDHMAN TEXTILES … during
18 AUG 2022 to 15
OCT 2022 under my supervision & guidance.He/ She has conducted a study &
completed the Summer Training Project Report Titled “A Study on Marketing
Strategy with Relevance to Vardhman ” satisfactorily.
Signature of the Industry Guide:
Name of the Industry Guide:
Designation:
Address: NOIDA U.P.
DATE:
Acknowledgement
This Internship Proved to bridge the gap between the theoretical and Practical
Aspects of textile Field. It was a great pleasure to be part of Vardhman Group. All
Thanks to my instituteMIMT for providing me the opportunity for getting the practical
knowledge at such an eminent company.
I am very thankful to the whole Vardhman Group for providing me the best possible
facilities and good environment during the period of my internship. I acknowledge
deep gratitude towards each and every employee of the group for providing me with
their valuable time.
I would like to express my deep gratitude to my mentor Ms SONALI CHAUHAN for her
patient guidance$ enthusiastic encouragement and useful critiques of this research work.
I would also like to thank my *batch mates and the faculties of MIMT a for their views
and ideas for the given topic. This proved out to be really helpful for the Project.
TABLE OF CONTENTS
1. Group Profile
2.Spinning processes
3.1eaving processes
4.dyeing processes'
5.different departments with
Process involved
6.learning outcomes
GROUP PROFILE
Vardhman Group is a leading textile conglomerate in India having a turnover of
2344 million. Spanning over 56 manufacturing facilities in five states across India$ the
Group business portfolio includes yarn Geiger and Processed Fabric Sewing
Thread$
Acrylic
Fibre
and
Alloy
Steel.
Vardhman has evolved through history from a small beginning in <:89 into a modern
textile major under the dynamic leadership of its chairman$ S.P.-swal. =is vision and
insight has given Vardhman an enviable position in the textile industry. under
his leadership$ Vardhman is efficiently using resources to innovate$ diversify$
integrate and build its diverse operations into a dynamic modern enterprise.
An Insight into the Vardhman Logo,
➢
The f l a m e signifies the growth of each and every i n d i v i d u a l
associated with it whether he or she is a worker$ an employee$
➢
share holder or a customer.
The @Stick symbolizes cottons which is basic raw material of the core product
➢
of Vardhman Group.
The V stands for Vardhman Group.
MISSION
Vardhman aims to be world class textile organization producing diverse range of
p r o d uc t s for the global textile market. Vardhman seeks to achieve
customer delight through excellence in manufacturing and customer service
based on creative combination of state of the heart technology and human
resources. Vardhman is committed to be responsible corporate citizen.
PHILOSOPHY:
Faith in bright future of Indian textiles and hence continued expansion in
areas @which we know best.
Total customer focus in all operational areas.
Product to be of best available quality for premium market segments through
TQM and zero Defect Implementation in all functional areas. Global
orientation targeting at least 20% production for exports.
Integrated diversification product range expansion.
W o r l d c l a s s m a n u f a c t u r i n g facilities with most modern /HD and process
technology.
Faith in individual potential and respect for h u m a n values.
0nco raging innovation for constant improvements to achieve excellence in
all functional areas.
Accepting change as a way of life.
Appreciating or role as a responsible corporate citizen.
HISTORY
The industrial city of Ludhiana$ located in the fertile malwa region of central
Punjab is otherwise known as the Manchester of India. Within the precincts of this
city is located the corporate headquarters of the Vardhman Group a household name in
Northern India. The Vardhman Group born in 1985 under the entrepreneurship
of Late Lala /rattan chand o swal has today blossomed into one of the largest
Textile
* business houses in India.
At its inception$ Vardhman had an installed capacity of <6$444 spindles$ todayJ its
capacity has increased manifold to over 7 laces spindles. In <:75 the Group enteredthe
sewing thread market in the country which was a forward integration of the
business. Today Vardhman Threads is the second largest producer of sewing thread in
India. In <::4$ it undertook yet another diversification C this time into the weaving
business. The Grey fabric weaving unit at *baddi K=PL$ commissioned in <::4 with a
capacity of 54$444 meters per day$ has already made its mark as a vitality
producer of Grey poplin$ sheeting$ and shirting in the domestic as well as foreign
market. This
was followed by entry into fabric processing by setting up Auro Textiles at *baddi and
Vardhman Fabric at * budhnimadhya Pradesh. Today the group has :44 shuttle
less looms and has processing capacity of :4mn meters fabrication.
In the year the Group has added yet another feather to its cap with the setting
p of Vardhman Acrylics Ltd.$ *Baruch which is a joint venture in Acrylic
Fibre production undertaken with &ar beni and 0xlan of (apan. The company also has
a strong presence in the markets of (apan$ =ong Kong$ Korea$ >K and 0> in
addition to the domestic market. Adherence to systems and a tr e dedication to
) ality has res lted in obtaining the coveted IS- :445 IS- <6445 ) ality award
which is the first in Textile ind stry in India and yet another la rel to its credit.
*'(ns
arn &an fact ring is the major activity of the gro p acco nting for 9< percent of the
gro p t rnover. Vardhman is virt ally a s permarket of yarns$ prod cing the widest
range of cotton$ synthetics and blended$ Grey and Dyed yarns and =and Knitting
arns$ in which Vardhman is the market leader in India. The gro p has twenty one
prod ction plants with a total capacity of over 7.7 lacs spindles$ spread all over the
co ntry. In many of the yarn market segments$ Vardhman holds the largest market
share. Vardhman is also the largest exporters of yarn from India$ exporting yarns
worth more than >SD 575 million.
PERFORMANCE:
D ring the last <8 years$ Vardhman Gro p has recorded <; percent top line growth
rate$ which is higher than the industry average growth rate. The Gro p t rnover has
grown from /s 35; crores in <::9 to /s 9444 crores Kabo t >SD <444 millionL in
54<;C<6. The exports has grown from negligible level in early nineties to /s <944
crores K>SD ;44 millionL in 54<;C<6.
PRODUCTS:
•
•
•
•
•
•
cotton yarn
organic cotton yarn
-rganic Fair Trade cotton yarn
0llitwist yarn
Vortex arn
Sl b arn
Acrylic arn
Synthetic blends
Synthetic +otton blends
Special *lended arn
+ore Sp n arn
&elanges $ =and Knitting
arnGassed &ercerised
arn
&odal arn $ Speciality
arnTencel arn
CUSTOMER FOCUS:
At Vardhman$ each c stomer is special and a constant so rce of inspiration.
Therefore$ the Gro p has leveraged technology to develop a highly sensitive
response system for addressing customer needs. A hightech inCho se sampling
unit and a design studio enable Vardhman to provide customers with the most
innovative products. Vardhman has also implemented enterpriseresources Planning
K0/PL System to provide facilities like online tracking of orders.
HUMAN RESOURCES:
The h u m a n r e s o u r c e development at Vardhman is aimed at enabling
people discover their true potential. The company endeavors to provide
opportunities toexperiment with a strong culture built around talent$ team work$
competitive spirit$ continuous learning$ trust
and transparency.
The
predesignated system of knowledge dissemination across various levels ensures access
to intellect al capital. The knowledge bank facilitates individual growth and
excellence. Vardhman believes that winning leaders are teachers and winning
organizations always encourage andreward teaching. The business processes$
organizational structure and day to day operating mechanism promote teaching for
developing a stream of young leaders.
The calibre and professionalism of its people has helped Vardhman achieve and
maintain its leadership in the competitive environment of today. The Gro p has
initiated a number of human resource development processes to facilitate
consistent improvement in performance$ prod ctivity and effectiveness.
Vardhman believes in continuous learning and adapting to change as a way of life.
Preparing for transformation$ the Group has designed elaborate training and
development programmes that encompass the technical$ managerial$ behavio ral
and
spirit al growth
of
its employees. Vardhman Training and Development
+entre at L dhiana$ caters to the distinct needs of its employees$ where training
programmes are cond cted thro gho t the year by inCho se and external fac lty.
&anav Vikas Kendras and 1 ality +ircles are also similar initiatives where trained
fac lty impart reg lar training$ especially to workmen. Apart from this$ managers
participate in training at some of the best instit tes like the =arvard * siness
School K>SAL$ Instit te of &anagement Development KSwitBerlandL$ IS* and II&s in
India. Vardhman sincerely believes that when technology converges$ people will
make all the difference.
THE SOCIAL DIMENSION:
As a commitment to the society and the workforce$ Vardhman has provided
schools for the children$ f nctional residential complexes for employees and
working women hostels for single women workers. N mero s recreational activities$
sports programmes and c lt ral events d ring festivities are reg larly organised.
*esides these$ the +ompany r ns medical camps to meet the health re) irements
of the people.
Sri A robindo +ollege of +ommerce and &anagement in L dhiana and the
A robindo P blic School at *addi K=imachal PradeshL are stellar examples of how
Vardhman is involved in providing
specialised ed cation and improving
competence levels in the society at large. /esponding to the call for incl sive
growth$
Vardhman
Programme for socially
at enhancing
Gro p
has
started
a +apability
0nhancement
Training
nderCprivileged st dents on reg lar basis. The training aims
the employability of n derCprivileged st dents belonging
to
sched led castes$ sched led tribes and other backward classes
The Vardhman Gro p made earnest efforts to increase the income of cotton
growing farmers by imparting training to them on vario s aspects of cotton
c ltivation through @Village Adoption Programme . As a res lt of these efforts$ the
cotton prod ctivity of the adopted villages increased manifold and has crossed the
national cotton prod ctivity average.
ENVIRONMENTAL CONSCIOUSNESS:
Decreasing green belts and ever increasing poll tion has become the bane
of moderniBation. Vardhman has always made a conscio s effort not only to
preservethe environment aro nd s b t also to contrib te its mite towards b ilding a
better world. A corollary of this conscio sness is visible in the best poll tion control
devices and practices. Vardhman has also increased green cover across all
man fact ring nits. Going f u r t h e r $ Vardhman g r o u p actively pioneered the
setting C p of Nimb a Greenfield P njab Limited$ a company dedicated to solid
waste treatment$ storage and disposal in the State of P njab$ India.
QUALITY MANAGEMENT TECHNIQUES
At Vardhaman vitality management techniques are given a lot of credit and are
followed religiously. One of the major quality management technique followed by
them is Total Productive &maintenance KTP&L.
Total Productive &maintenance is a maintenance program which involves maintaining
plants and shipment. The goal of the TP& program is to markedly
increase production while$ at the same time$ increasing employee morale and job
satisfaction.
TP& brings maintenance into focus as a necessary and vitally important part of the
business. Down time for maintenance is scheduled as a part of the manufacturing day
and$ in some cases$ as an integral part of the manufacturing process. The goal is to
hold emergency and non scheduled maintenance to a minimum.
TP& starts with 9S. Problems cannot be clearly seen when the work place is
norganiBed.
+leaning
and
organizing
the
workplace
helps
the
team
uncover problems. &aking problems visible is the first step of improvement.
to
&otal Productive Maintenance instructions and
methods have been put up in the actory to
OR$ANI6ATIONA& STRUCTURE
+hief &anaging
Director
MR2 S2P2 OS3A&
0xec tive Director
MR2 SACHIT JAIN
ViceCPresident
K+ommercial H
AdministrationL
+hief
&anager
0xec tive$
-fficers H
Staff
&anagers
KAcco ntsF=/F+osti
ngF+ommercialL
0xec tive$
-fficers H
Staff
Vice President
KProd ctionL
MR2VINEET PAN4E*
Asst. Vice
President
K0ngineeringL
MR2 4HEERAJ
MEHTA
+hief &anager
KGorstedL
MR2 J2S2
RE5HI
0xec tive$
-fficers H Staff
Prod ction
S pervisors
Gorkmen
Senior &anager
KSpinning < H
Spinning 5L
&anager KDye
=o seL
MR2 VASANT BISEN
MR2 ATU&
VERMA
0xec tive$
-fficers H Staff
0xec tive$
-fficers H
Staff
Prod ction
S pervisors
Prod ction
S pervisors
Gorkmen
Gorkmen
AUTO SPINNING MILLS
➢ PROUDUCTION
DETAILS
Number o production halls ; 2
7N(& 1 #< 551'
Manufacturing activity rage Cotton #both carded > combed' and core spun
with 5ycra.
7nit Capacity=
•
•
0/)/00 spindles
Production o yarn per day= 14)999 kg
Product Range=
•
19s?49s
7N(& 0
0'
Manufacturing activity= Sliver preparatory and sample line
7nit Capacity=
•
spindles
Production o sliver per day= @)999 kg
Product Range=
•
7N(&
5ycra) compact) compactAlycra) slubAlycra) slub) Blends
#< 55
'
Manufacturing activity= Cotton and Lycra #bulk orders'
7nit Capacity=
•
spindles
Product Range=
•
5ycra) slub) ancy yarns
7N(& /
Manu acturing
/'
ctivity= 6pen? end yarn
7nit Capacity=
10/8 rotors
Production o yarn per day= 10)999 kg
Product Range=
•
4s?09s
7N(& 2
Manu acturing
2'
ctivity= Compact #:lite' spun yarn
7nit Capacity=
•
1/024 spindles
Production o yarn per day= /999 kg
Product Range=
o
/9s?099s
PROCESS FLOW OF COTTON SPINNING
Opening
H
Sorting
&ixing
arding
PreC+ombing
+ombing
Draw
Frame
Speed
/ing
Frame
Frame
Ginding
+conditioning
Packing
BLOWROOM
OPENING SORTING AND MIXING
This process involves opening of fibre bales and opening tufts of cotton into
smaller tuftsand removal of foreign materials. &ixing and sorting is done to,
➢ reduce the cost of raw materials
=ave a uniform distribution of different types of cotton
➢ &roisterer the cotton and allow them to open p
While mixing it should be considered that fibers should have identical properties like
length$ strength etc. Price$ color and grade of cotton should be of approximately
same )vitality. -optimum amount of different varieties s houl d be
mixed to keep the
)vitality p to the mark. Soft waste should be added as per requirement.
Mi:inning The material from the compressed bales are torn into small flocks
manually and stored into the mixing room for <5 h ou rs . &meanwhile$ the
fib ers absorb the moisture from the air and get conditioned. -il and water are
sometimes used in the mixing room and they are sprayed on the mixed lot. The
mixture helps to moisturize the material and reduce the fly and fluff in the mixing room.
Offsetting It is the procedure in which the compressed bales are broken into
small tufts which is done manually. +examinations are sorted out in this process.
Tec)nic'l S-eci;ic'tions ;o( Cotton
i.
Cotton Varieties Used
(C;6 K34EL
ii.
SC8 K;4EL
59 x <3 x 6:
<89C<34kg
Bale Size
Bale Weight
Cotton V'(ieties P'('mete(s
P'('mete(s
Staple Length (mm)
Strength (gm/tex)
Elongation (%)
icronnaire
Reflection $egree (Rd)
Brightness (B)
J73#
S7<
57 5:
;4 ;<
9.<C9.5
6.7C9.4
35 38
7C:
5:C;4
;4C;<
9.5C9.;
;.7C6.5
38C74
7C:
Tec)nic'l S-eci;ic'tions ;o( Pol=este(
;: x 59 x 6:
644 kg
66mm
<.5 Dtex
*right
Bale Size
Bale Weight
Length of i&re
Count of i&re
Lustre
Tec)nic'l S-eci;ic'tions ;o( Ac(=lic
64 x 56 x 68
;44C;94 kg
64mm
<.; Dtex
*right
Bale Size
Bale Weight
Length of i&re
Count of i&re
Lustre
$odowns wit)in t)e Mills
S
R2
NO2
1
$O4O
3N NO2
&EN$T
H >in ;t?
3I4TH
>in ;t2?
AREA
>in
MATERIA& STORA$E
sq2
Ft2?
<<6
<84
79
<;844
Acrylic Fiber$ Nylon Fiber$
2
3
83A
<49
<44
<44
84
84
8444
8444
Polyester Fiber
Acrylic Tow
Acrylic Tow H Fiber
#
99
39.5
84
69<5
All
Types
of Filament
1
;;
;9
<49A
88
88A
;3
74
39
<44
84
6;
88
:4
74
84
65
94
66
3544
8444
8444
5954
5<94
5:46
arns
/aw +otton
/aw +otton
Grey arn
Grey arn
Grey arn
Grey arn
1
8;
88
63
;<45
Grey
arn
1
86
88
63
;<45
Grey
arn
1
;8
<95
69
8764
All types of waste
S
$O4O3N
@
<
D
1
2
3
R2
NO2
1
NO2
&EN$T
H >in ;t2?
3I4T
AREA
H >in ;t2? >in
MATERIA& STORE4
sq2
Ft2?
S.T.CII
:9
:5
7364
/aw +otton
2
Godowns KAL
S.T.CII
:9
:5
7364
/aw +otton
3
Godowns K*L
S.T.CII
:9
:5
7364
/aw +otton
#
Godowns K+L
S.T.CII
9:
63.9
5749
/aw +otton
Godowns KDL
In the blowroom$ input is being fed in the form of cotton bales and the output appears
in the form of flocks. The main function of blow room is the opening$ cleaning and
mixing of bale.
The main identifiable impurities are being removed by the machines at the farming
stage$ the process is called ginning. Ginning process removes the main impurities
like seed coats$ hair$ stones$ plastic$ jute$ cords etc. After ginning cotton bales are
formed in the compressed form. 0ach bale weighs approx <34 kg. Sometimes$
imported bales weigh even to ;44 kg.
The blow room of >NITCI consists of 5 lines, LineCI and LineCII. 0ach line is formed by
the lay down of bales in the form of stack one over another$ approximately 94 in
number.
&ixing can also be done at this stage by creating a lay down which consists of two or
more varieties$ in the approximate ratios$ according to the endCprod ct re) irement.
Blowroom= 5aydown o cotton bales be ore mi ing and sorting
Machine used
UNIFLOCK
CONDENSER
Unifloc A-10
&manufacturer, /I0T0/
This machine is used pluck the flocks out of the laid down bales$ basically with the
help of section. It consists of a takeC p unit which is connected by vacuum. It has
5 types of rollers, < beater roller and 5 stripper roller.
The 5 stripper rollers consist of metallic blades on its surface$ which penetrate inside
the bales for better grip on both the sides.
In between are the main rollers i.e. the beater rollers$ which again have got spikes on
its s rface. Its main f nction is to open the compressed bales and p l u c k o u t the
fibers$ so that they can be s cked by the pne matic action.
Traversal speed of take C p nit M <4.9m min
+apacity of the machine M <444kg hr
In addition$ the workers also pick the noticeable trash by hand like, hair$ j te$ plastic$
paper$ stones
etc.
they
also
open
the
b nch
of
fibres
man ally.
done by the 7nifloc Machine.
TRANSPORTATION PIPES:
The flocks pl cked in >niflock through ch teCfeed system$ Kthe pipes tili Be
pne matic action to pass on the pl cked fibresL get more opened$ while travelling
through the d ct. In between there is also a metal detector which detects the
presence of any metal pieces inside the flocks and the damper diverts it into the
waste bag.
The standpipes have been given color coding,
Sr.
No
<
+olo r +ode
F nction of Pipeline
Diameter
of Pipes
KmmL
Green
&aterial
;44
Transportation
5
;
6
Location
*l e
ellow
/ed
In all machines K*lowroom and
+ardL
Gaste Transportation 554$;44$9 &F+$ +VTC;$ +omber
94
&icrod st
Transportation
;44
LVSA$ +VT ;$ SP F$ +ard
Fire Diversion
;44
&F+$ &P&$SPCF$ +ard
In case of spark inside the F*K pipes d e to friction metal particles$ the entire
material inside the d cts is diverted o tside the nit for preventing the fibre from
spreading.
CONDENSER:
&manufacturer, Tr tBschler
-nce the material has been passed through the metal detector$ it goes to the
+ondenser where the heavy particles are sucked and they fall down. This$ in this
way the material is further cleaned.
MAXI FLOW:
&an fact rer, Tr tBschler
The material is dropped in the machine by gravity t h r o u g h the +ondenser
andadvances with the beater action. The d st and contamination is separated and
falls
down. The material is removed from the maxi flow with the help of s ction from the
maxi machines.
SEPARATOR:
&an fact rer, Tr tBschler
=eavy Particle Separator is simple e) ipment working on aeroCdynamics principle.
The machine removes contaminations in the mixing s ch as metal parts and other
heavy imp rities which may otherwise ca se damage to expensive blow room and
carding machinery.
sta= <eavy particles are separated in this machine be ore they go to MPM?
/ and MPM?4.
MPM:
&an fact rer, Tr tBschler
The m ltiCmixer ens res a good blending at the beginning of the spinning process
which is essential for a
niform distrib tion and representation of all fibre
components into the yarn crossCsection. This needs to be achieved d ring the
spinning processes as it cannot be achieved by the later processes alone. Proper
blending avoids variation in r nning conditions$ yarn strength$
niformity and dye
takeC p. The m ltiCmixer is s ally available in 6$ 8 or 7 chambers. In Vardhman$
there were two lines one containing the 8 chamber &P& and the other containing an
7 chamber &P&.
CVT-
&an fact rer, Tr tBschler
This is another machine which is sed for cleaning of the material. First of all$ the
feed roller feeds the material inside the machine. Then it passes through three
spikes beater of increasing spike intensity$ which carries o t the opening. It has a
colo r contamination sorter K++SL.
Gidth of the machine, <844mm
+apacity, 844C 744 kg hr
SECUROMAT:
&an fact rer, Tr tBschler
Foreign fibre detection takes place at the end of the blowroom line and directly
before the cards$ where the opening degree of the fibres has reached a maxim m
val e$ the foreign parts$ however$ still exist in a coherent form.
The separation of the foreign parts is effected by means of ;5 compressed air
noBBles K<4L distrib ted over the total working width of <844 mm$ which can be
individ ally controlled by pne matic valves$ in fact exactly at the point where a
foreign part is located on the s rface of the needle roll.
CARDING
Manufacturer Lakshmi reiter
machines :10
Manufacturer:trutzschler
The carding process essentially involves the opening of fibre aggregates by working
between two closely spaced surfaces covered with inclined wires. The main
objects of carding are,
➢
➢
➢
➢
➢
To carry further process of fibers opening to a state of fibre individualization
To remove neaps$ tiny limps of fibers
To deliver a continuous sliver for f u r t h e r processes.
To remove impurities from the material by individual fibre separation.
To enable parallelization of fibers.
The carding machine is supplied with cotton flocks through FBK ducts
continuously. The cotton then traverses through the rollers. The material is fed inside
with the help of feed roller which is located above the feed plate. The feed roller is
followed by the
lickerCin cylinder.
There is a lickerCin under casing and back plate below and in front of the rollers
respectively. under casing is a perforated plate which is responsible for collection of
the waste removal from the card. *sack plate is positioned between the lickerCin and
cylinder. Front plate is positioned between cylinder and the doffer. *oth have spikes
and perform the same function as that of the set of cylinder and flats.
Flats are clothing on the rollers which is in the form of spiked belt. There are <45
flats of which about 65 are in working position at time of contact with cylinder.
cylinder moves very fast as compared to the flats. Due to this movement$ the best
fibres are straightened$ made parallel and opening and cleaning is performed.
The back plate and front plate reduces the loading on the cylinder. The voids
between the cylinder$ clicker and cylinder$ doffer are thus covered by front and back
plates.
The cylinder is having the main function of opening and cleaning the fibers.
The main function of the differ is to collect the fibers from the cylinder and deliver
them in the form of a web. The function of the clicker is breaking and opening of thetuftsof
cotton and pass them onto the cylinder without retaining any of them.
To get optimum performance from the various elements of a card$ it is essential to
use the right type and right combination of wire clothing. The metallic wire particulars
which could influence the carding process are, wire width$ wire point density$ tooth
angle$ shape and height.
+arding performance can be improved by increasing the number of teeth cross wise
along the width of the card. This has led to the development of finer rib wires. The
diferclothed with a wire which has a higher trapping and holding power than the
cylinder wire. Thus it has a greater point density than cylinder wire.
Carding Machine
M'c)ine S-eci;ic'tions
Cylinder Speed
Licker in Speed
$offer Speed
lat Speed
Cylinder $iameter
Licker in $iameter
Can $iameter
Can eight
694C944 rpm
<<44C<544 rpm
59C;4 rpm
55C59 cm min
<5:4 mm
594 mm
56
65
Tec)nic'l S-eci;ic'tions
Linear $ensity of Lap
ed
Rate of eed
Length of Sli*er/Can
Weight of Sli*er/Can
Linear $ensity of Sli*er
+roduction/min
+roduction/hour
+roduction (kg/hr)
644 gm m
944 gm min
9944 m
58 kg
6.7 gm m
79 m min
9<44 m hr
59 kg hr
PRE-COMBING
Within the overall spinning process$ the combing operation serves to improve
the raw material. Its use in the production of medium$ medium fine and fine yarns
enables a positive effect to be exerted primarily on the following yarn characteristics,
➢
➢
➢
➢
➢
yarn evenness
yarn strength
+leanliness
Smoothness
Visual appearance
0limination of short fibers produces an improvement mainly in the staple length
of the fibre$ but it also affects the fineness of the raw material. Since nil is on average
finer than the original raw material$ the micromanage value of the combed sliver is
slightly higher than that of the feed stock. The various machines used are,
&an fact rer, Lakshmi
It is the preparatory process for combing. The basic p rpose of this machine is to
mix different card can slivers$ for homogeneo s mixing to ens re
the fibers. It is
niformity among
sed to convert the leading hooks into trailing hooks. It also eliminates
wastes. Drafting arrangement – 6 8
MACHINE SPECIFICATION
Linear $ensity of Sli*er ed
Rate of eed
Weight of Lap $eli*ered
Weight of Bo&&in
Net Weight of aterial
Length of Lap
Linear $ensity of the Lap
Time taken for one Lap
$eli*ery Speed
$eli*ery in gm/min
+roduction in kg/hr
Ri
6.7 gm m
39C<54 gm min
<4.69 kg
<.59 kg
:.5 kg
<94 m
8<.;; gm m
<94 seconds
84 m min
;83:.7 gm min
554.36g hr
on &'- M'c)ine
&an fact rer, Laxmi
It the second step in the preCcombing process. In this machine the fibers are evened
o t.
Production o ribbon laps
Unil'- m'c)ine
This machine performs the combined f nction of sliver lap and ribbon lap. Its major
advantage is that it takes less time than the two machines combined.
COMBING
manufacturer, Lakshmil,
Number of &achines, :
The main objectives are,
➢
➢
➢
➢
0limination of short fibres
0limination of remaining imp rities
0limination of large proportion of neps
Straight and paralleliBation of fibres
The inp t of this machine is 7 laps. The waste of coming is termed as @noil @.
The lap is passed through a top comb which has got 58 needles or pins per cm. The
functionof this top comb is to catch the short fibers out of the lap. It is followed by another
brush roller which consists of plastic bristles on its surface to catch the fibers flying
around. After the combing action$ the laps pass through three sets of rollers$ of which
top ones are covered with rubber and bottom ones are made of steel. The material
then passes through a condenser acting as a guide and calendar roller to form a
sliver. Top clearer is present in the machine to take care of the fly being
generated.
M'c)ine S-eci;ic'tions
Num&er of eads
Length of achine
Width of achine
Loading of Rollers
Can $iameter
Can eight
7
9.<8: m
<.;<7 m
Pne matically
<7
64
Tec)nic'l S-eci;ic'tions
Noil +ercentage
eed Lap Weight
eed Lap Width
eed Lap $iameter (max)
$eli*ery Speed
Length of Sli*er in One Can
Time Taken for One Can
Output/ achine
Nips/min
7C59E
85.9 gm m
;44 mm
694 mm
;5 m min
6444 m
<59 min tes
<8C64kg hr
;44
DRAW FRAME
manufaturer, Lakshmi
The main objectives are
➢
➢
➢
➢
➢
Parallelization and e)libation of fibers.
Do bling
*lending
/emoval of hooks
reducing the co – efficient of variation among the fibers
There are two types of dr a w fr a m e s ,
Single in which one can is formed from do bling of 8 slivers.
Double head in which two cans are formed. 0ach can is from do bling of six slivers.
main features of /S* d r a w f r a m e are,
It is e)sipped with a tomatic can changer system.
➢ It features an auto leveller. A particular fineness value for the sliver is being set in the
machine. Variation of O
➢
K<C9L E from the reference value$ for a set time$ say ; sec$ is sensed by the
displacement sensor. The sensor converts this variation into the pulse form at sends
the signal to control the feed accordingly. If the thickness is increased$ feed is
reduced and viceversa
➢
➢
It is e)sipped with top and bottom stripper for cleaning top and bottom roller.
Machines specification
LD- 8
Num&er of $eli*eries
Can Changing System
Roller Weighing
Calendar Rollers Weighing
Can $iameter
Can eight
Top Roller $iameter
Calendar Roller $iameter
5
A tomatic
Pne matic
Pne matic
<7
64
;7.5 mm
85 mm
/S* 79<
594C394 m min
54C94 gm min
;:.5 mm
A tomatic
6.7C6.:5 gm m
$eli*ery Speed
Rate of eed
Top Roller $iameter
Can Changing System
$eli*ered Sli*er Weight
Com-'(ison
S2
No2
<.
5.
;.
6.
9.
8.
etween RSB
@1 'nd &4O <
-'('mete(
RSB
@1
Num&er of $eli*eries
Can Changer
Creel $ri*ing
$eli*ery Speed (max)
Creel Capacity
Num&er of $ou&lings
Single
A tomatic
negative
744 m min
7
7
&4O <
Do ble
A tomatic
Positive
944 m min
<8
7
SPEED FRAME(SIMPLEX)
MODEL no. – LFC<644 A
&an fact rer – Lakshmi KL&GL
The speed frame performs three major functions,
➢
4(';ting, it is the process where the sliver is attenuated by means of exerting
a pill on it with sets of rollers. This process ensures that the sliver increasesin
➢
➢
length and the mass per nit length is decreased.
Twisting it is the process where the a t t e n d e d sliver is given rotational
twists by means of the rotatory movement of the spindle
Ro0ing, it is the oPTIMUM of the speed frame. It takes a highly r e d u c e d
thickness mass per nit l e n g t h in comparison of the sliver. The roving is
stored on bobbins and these forms the feed package for the ring frame.
The existence of the speed frame is justified by the fact that the sliver cannot be fed
directly to the ring frame$ firstly due to the very high draft requirement at ring frame
and secondly$ due to the very large space requirement in ring frame section.
Therefore$ the need for the speed frame is to impart draft to the sliver to prepare it
for the ring frame and twist to provide strength to roving.
&ain parts of speed frame,
➢
C(eel – =ere$ the cams carrying the D.F. sliver are being placed. The f nction
of creel is to let the sliver reach the drafting Bone$ witho t any obstr ction the
drafting Bone$ witho t any obstr ction. The drafting Bone$ witho t any
obstr ction$ the main parts of creel are as follows,
➢
C(eel (olle(s, it consists of sliver g ides$ which rotate with the help of creel
roller.
➢
Sli0e( g/ide, sliver g ide sho ldn t be worn o t so that the sliver doesn t get
abraised d e to friction.
➢
4(';ting Gone – this is the main portion of the machine$ where the thick sliver
is converted into thinner one by applying appropriate draft. Its main parts are
as follows,
➢
Sli0e( g/ide, the sliver from the creel reaches first to the sliver g ide of the
drafting Bone. This g ide is located on a traverse plate. Its siBe and color
varies acc. To the sliver hank. The g ide sho ldn t be worn o t and no cotton
➢
fibres sho ld be trapped in between.
Bottom d(';ting (olle(s, there are three rollers made of steel arranged at
e) al distances according to the length of the machine,
<.
front bottom r oller
4.
middle bottom r oller
;.
back b ottom r oller
All the other parts of the machine which are re) ired to provide draft to the
sliver rotate with the help of these rollers.
➢
Nose
'( -l'te 'nd s-'ce( – In between the front and middle bottom roller$
lies a plate which is called nosebar plate. -n this plate lies a s) are shaped
piece made of Al$ which is called spacer. The siBe of the spacer varies
according to the roving hank. Its siBe – no. KIn mmL is mentioned over its
s rface itself. This spacer decided the gap between the 5 aprons. In a
machine$ all the spaces sho ld be of e) al siBe and any roving sho ld not be
made witho t spaces$ as it wo ld affect the ) antity of the roving
➢
Bottom 'nd to- '-(on – *ottom apron r ns between bottom roller$ nosebar
plate and tension p lley. The tension p lley provides proper tension to the
apron. In between these two aprons$ the sliver$ after drafting$ forms the roving.
That is why$ it is very important that the aprons sho ld not be worm o t or
loose. They sho ld be cleared p$ time – to time. So that they co ld r n
witho t any obstr ction$ otherwise the no. of breakages can increase and the
) ality can deteriorate.
➢
To- '(m – The arm placed over the bottom rollers is called top arm$ which
consists of ; rollers, front pair$ back pair and cradle rollers. The top arm
presses the top rollers over the bottom ones$ then pne matic press re
beca se of which the slivers$ after passing thro gh the drafting Bone$ take the
form of roving. The top arm sho ld be cleaned reg larly for good ) antity.
➢
S-indle -'(ts
S-indle, spindles are positioned in front of the top arm on a rail. Spindles are
r n thro gh gear mechanism. *obbin and flyer are placed on the spindle. To
rotate the bobbin separately$ the bobbin rail also consists of gears. The bobbin
rail move p and down thro gh Qb ilding motion beca se of which the roving
➢
gets wo nd over the bobbin.
Fl=e(, the part which helps to wind the roving over the bobbin is call flyer. A
Qtwist master is placed over it$ which helps in imparting twist to the roving$
which comes from the drafting Bone. There is a finger on one side of the flyer
➢
which keeps the roving nder press re while it is being wo nd over the
bobbin.
Se-'('to(, the steel plate lying between drafting Bone and flyer is termed as
separator$ which prevents the mingling of broken roving with the ones$ nearby.
&achine sho ldn t be r n when separator is down position.
➢
$e'(ing -'(ts, gears are placed on the right side of the machine$ which are
responsible for providing necessary motion to the different necessary motion
➢
to the different parts of the machine.
F'n it is placed on the left side of the machine. There is a separate motor for
r nning the fan. *elow each delivery lies a s ction pipe$ whose other end
goes to the s ction d ct. Inside the d ct$ there are 5 photocells. *eca se of
the fan$ s ction is generated in the whole d ct. *eca se of which broken
roving gets s cked inside. The moment$ this roving passes in between the 5
photocells$ the machine stops a tomatically. The waste of the fan m st be
cleaned time to time.
Machine
FAU&TS OCURRIN$ IN SPEE4 FRAME
The main fa lts that occ rs in the o tp t of speed frame are as follows
A. 4o/ le (o0ing, when$ one roving breaks and clings to the s rro nding roving$
while the machine is in r nning position.
/easons,
➢
Less amo nt of press re in the s ction t be.
➢
The s ction t be gets clogged beca se of cotton fl ff
➢
Separator is not positioned correctly
*. C/ts in t)e (o0ing,
/easons,
+ ts in the sliver d ring drawframe only
➢
Incorrect – press re of the top arm.
➢
/ bber of top roller is having c ts or worn o t
➢
Gorn o t apron
➢
Gorn o t twist master and flyer finger.
+. Und(';ted (o0ing,
/easons,
➢
Less press re from top arm
➢
Incorrect setting of temperat re and h midity
➢
Incorrect setting of break draft$ ga ge$ spacer etc. according to the
re) ired co nt.
H'(d
in,
o
/easons,
Less press re on back rollers therefore thick roving
➢
➢
high tension on the roving
➢
more twist in the roving than the re) ired amo nt
D. So;t
o
in,
/easons,
➢
less tension in the roving
➢
less twist in the roving than the re) ired amo nt
0. Flied 'nd ;l/;;ed
o
inJ
/easons,
➢
➢
➢
F. St'ined
in calc lation of fly and fl ff from the s rro ndings into the roving
ncovered draw frame cans
not cleaning the racks and trolleys where bobbin are to be placed
o
in,
/easons,
➢
not cleaning the grease or oil on the machine d ring maintenance cleaning
➢
ncleaned hands of the workers
➢
dropping the bobbins on the floor
M'c)ine S-eci;ic'tions
<54
;5 cm
6.7 cm
<644 rpm
;4 m min
; kg
;;
Num&er of Spindles
Bo&&in Length
Bo&&in $iameter
lyer Speed (max )
$eli*ery Speed (max )
ull Bo&&in Weight (max )
$rafting System
Tec)nic'l S-eci;ic'tions
Linear $ensity of Sli*er
ed
$eli*ery Speed
Length of Ro*ing on one Bo&&in
+roduction/hour/spindle
+roduction in kg/hour/spindle
Waste +ercentage
T+0
6.7 gm m
<7 m min
5444 m
<474 m hr
4.335 kg
<E
4.:8
RIN$ FRAME
&an fact rer, Lakshmi
/eiter &odel, D( 9
N mber of &achines, 56
In the /ing Frame department$ yarns of re) ired co nt are made from the bobbins.
=ere$ draft is being provided with the help of rollers and then twist is being imparted
with the help of spindle wo nd$ side by side. So$ the yarns made by this method are
wo nd on the ring bobbin.
Parts of a /ing Frame &achine are as follows,
➢
C(eel – this is the top most part of the machine where the speed frame bobbin
➢
is mo nted. The vario s parts of the creel are ,
Bo
in )olde(, on the bobbin holder$ the simple bobbin holder$ the simple
bobbin is mo nted. It is denoted that the bobbin is mo nted properly and the
holder is not clogged. If it is so$ the roving will not be fed properly and there
➢
might be some tension which can ca se breakage and neps formation.
C(eel (od, it is present between the drafting and the bobbin holder. It acts as
a g ide for carrying the roving. /oving sho ld always come from above the
g ide rod.
➢
4(';ting 6one – This is the most important
one of the machine. =ere the
➢
roving is stretched to from the yarn. Its vario s parts are ,
Ro0ing g/ide, it is sed to g ide the roving to the centre of the roving might
➢
move o tside the roller s rfaces and generate waste. It is mo nted near the
back roller.
Bottom (olls, the machine has three bottom rolls. -n top of the set of bottom
rolls$ there is the top arm. The top arm also has ; rollers and a cradle. The
cradle has spacers.
➢
Bottom '-(on
To- '-(on, bottom apron is mo nted on the middle roller
and cradle of the bottom roller set. Top apron is mo nted on the middle
roller and cradle of the top arm. -n these aprons$ the roving thread opens
p to take the form of final yarn.
S-indle 6one –
➢
S-indle, This is an important part of the machine which rotates with the help
of the spindle tape. This always rotates in the centre of the ring and the
bobbin is lifted on it. If the spindle tape is not tightly$ attached the spindle may
stop.
➢
Ring 'nd Ring T('0ele( , it is a metallic ring on which the traveler holds the
➢
yarn and moves along the periphery. The spindle moves p and down and
hence the bobbin gets filled.
&'-/t )ook 'nd l'-/t ('il, before the thread gets wo nd on the bobbin it
➢
passes thro gh the lap t hook. It sho ld have a proper ga ge.
$e'(ing 6one – this has all the gears and wheels which need to be oiled and
maintained. This area sho ld always be kept covered to prevent the entry of
fl ff.
➢
F'n 6one – this Bone consists of the main motor and the fan. *eca se of the
rotation of the fan at a high speed$ s ction is generated and waste is s cked$
which gets collected in the waste box. Ghen this box gets filled completely$ all
the waste sho ld be taken o t from the box and it sho ld be cleaned so as to
➢
avoid any chance of jamming in the fan and parts malf nctioning.
Jocke= P/lle= 'nd 4(/m P/lle= 6one – the setting of the jockey p lley
➢
sho ld be correct$ otherwise the tape bar wo ld become o t of track. It sho ld
not get jammed$ so it is cleaned from time to time.
O0e()e'd Blowe( 6one – the press re with which the blower throws the air
sho ld not be blocked with fl ff and they sho ld be properly set$ otherwise it
wo ld affect the ) ality.
4i;;e(ent Colo/( Bo
ins 'nd T)ei( Im-o(t'nce
In ring frame$ bobbins of different colo rs are sed like, red$ yellow$ bl e$ white
etc. the colo r of bobbin varies according to the co nt of yarn. Ghile the
prod ction with bobbins of one colo r is going on$ the bobbins of other colo rs
sho ld be sed$ otherwise the mixing of vario s varieties will occ r and ) ality
will get deteriorated. The weight of speed frame bobbin varies from <C <.9 kg$
while that of ring frame varies from 84 – 89 gm.
Ring Frame
M'in F'/lts T)'t Occ/( In Ring F('me
A! BOBBIN FAULTS:
KiL
Ring c/t 'nd
l'ck
o
in Sometimes$ the thread gets c t by the ring and
sometimes it gets c t by the ring and sometimes it gets blackened beca se of the
ring. The main reasons of its occ rrence are,
KiiL
➢
Improper setting of bobbin over the spindle beca se of the
➢
➢
acc m lation of hard waste over the spindle
-cc rrence of do ble roving in the speed frame bobbin
Slight displacement of ring of ring rail.
Bottom s-oiled
o
in, if the yarn in the bobbin comes o t from the
bobbinand gets entangled then it is called bottom spoiled bobbin. Its main reasons
are as
follows.
➢
Improper setting of spindle
➢
Improper setting of bobbin on spindle d e to carelessness
➢
Improper setting of bobbin on spindle d e to tight bottom portion of the
bobbin
➢
KiiiL
KivL
KvL
Improper setting of the reel rail
pper position of the bobbin gets
entangled$ then it is called over filled bobbins. /easons,
O0e( ;illed
o
ins, if the yarn from the
➢
>sing small bobbin than the re) ired siBe.
➢
The machine still keeps on r nning even when doff has been achieved.
So;t
in,
o
➢
Less twist in the yarn beca se of rotation of lower speed d e to any reason.
➢
Less tension of traveller acc. to the co nt.
st'ined
➢
o
in , reason
Not wiping off the oil H grease.
➢ >ncleaned
hands of the worker.
B! YARN FAULTS:
KiL 4o/ le (o0ing,
&ingling of broken roving with the neighboring rovings of the creel.
➢ &alf nctioning of s ction t be beca se of blockage d e fl ff.
KiiL 3e'k ='(n,
➢
➢
-cc rrence of single roving in the speed frame bobbin.
➢
Loose tape
+ t tape
KiiiL *'(n wit) ;l/;;,
➢
Inc lcation of fl ff from the environment into the yarn.
➢
Improper cleaning of the drafting Bone H other parts.
➢ Dirty
speed frame can dr m.
➢ >ncovered
➢ &alf
dr ms cans.
nctioning of overhead blowers.
KivL *'(n sl/ , yarn sho ld be niform in diameter. * t at some places$ the yarn
become f ller$ where twist becomes less and the strength of the yarn red cesJ
which is called sl b.
➢
Improper press re from the top arm.
Apron which is being c t.
➢
Improper setting of the spacer.
KvL Ne--= ='(n, In the blow room$ d e to the formation of b nches of fibres
which occ r on the s rface$ this defect arises. To reg late this$ care is taken
at blowroom$ carding and combing department.
KviL *'(n wit) t)ick 'nd t)in -l'ces, the yarn thickness sho ld be niform
everywhere$ b t when thick H thin places arise in the yarn$ with the length
varying from 7C<4 mm$ then s ch a yarn is called defected. These defects are
meas red by ster machine per Km. eg. R 94E thick place means that the
thickness of the fa lt is 94E more than the act al thickness. Similarly$ C94E
thin places imply that the fa lt is 94 E less than the act al thickness of the
yarn. The yarn with the thin place has comparatively lesser strength.
KviiL
So$ it can break and create more waste and effect the prod ction H ) ality
adversely. Its main reasons are as follows ,
➢
Improper press re of the top rollers.
➢
Apron being c t or dented.
➢
Improper setting of the top arm.
➢ Incompatible
➢
siBe of spaces in relation to the co nt.
Draft applied is not in accordance with the co nt.
The yarn realisation of the cotton fibres comes approximately 73 kg for carded yarns
and approximately 34 kg for combed yarns. This is so as the combing process
removes the short fibres. The noil E Kwaste removal EL for the combing process is
aro nd <3E.
The bobbins from the ring frame m c are collected in containers after their doffing
point has reached. In each container$ a doff slip is p t. This slip is important as it
contains the following details,
➢
Spindle no.
➢
&achine no.
+o nt
➢
Time
➢
Date
➢
Name
This is important as the person loading the bobbins for identifiable fa lts. Also they
are important for co nt identification. After this$ the trolleys are sent to the A toconer
&achines. This has the f nction of forming bigger packages in the form of cones
which can be sed for do bling and then twisting on the T.F.-.
M'c)ine S-eci;ic'tions
Spindle
564 mm
eight
Spindle $iameter at Top
Spindle $iameter at Bottom
$istance Bet1een T1o Spindles
Length of Separators
Num&er of Spindles +er Ring
Spindle Speed (max )
$eli*ery Speed
T+0
rame
<< mm
<9 mm
34 mm
<64 mm
667
<7444 rpm
<7 m min
5<.48 <:.97
WINDING SECTION
yarn produced in the ring frame in the form of bobbins is taken into the winding
section for the formation of large package which is easily transported and various
faults are removed during the winding operation such as thick places$ thin
places and neps.
After winding$ the package should not contain the faults. The strength$ elongation at
break point and appearance should not be altered and the ability of splicing should
be good. The weight of the cone produced is 5.49 – 5.69 kg and <.59 kg as
per demand.
&manufacturer,
Schoolmaster &odel, ;;7
N mber of &achines, 6
For bigger yarn packages
The bobbins are attached on the spools and when the bobbins get exha sted$ new
bobbin is attached man ally after every bobbin change$ splicing is done by the
machine for the identification of the co nts of yarns. The machine follows the
following detection mechanism,
➢
0lectronic sensors which detect the yarn breakage and stop the machine.
This is done thro gh capacitors.
M'c)ine S-eci;ic'tions
84
9
<;
<;44C<844 m min
Pne matic
8
Num&er of $rums on the achine
Num&er of Bo&&ins on the Creel
$istance Bet1een T1o Spindles
$rum Speed
Splicing
agazine Capacity
(nspection o cone in the
utoconer
In this section the cones are kept
nder >V Light for inspection. This is one of the
steps in detecting any yarn fa lts and difference in colo r of the grey yarn.
(inspection comes under uV light
CONDITIONING
+conditioning of the cones is done manually$ i.e.$ room conditioning. The
moist re percent in the cotton yarns comes out to be 3.6E. The material after
conditioning remains for <9C54 min tes outside the conditioning room and final
packaging is donein cartons or pallets according to the re)retirement.
To avoid the loss of moisture from the cones$ two humidifier are provided in
the packing room. *because of these humidifier$ there is an additional gain of
moisture in the yarns on the cones. Increase in the moisture content of the yarn
increases the yarn realization therefore$ the conditioning of the yarns is necessary.
Following are the main objectives of conditioning,
➢
➢
➢
➢
➢
Imparting strength to the yarn
Imparting niformity to the yarn
Imparting evenness to the yarn
Increasing the moist re content in the yarn
Increasing the yarn realiBation
Conditioning room or yarn where sprinklers impart moisture be ore the
cones undergo conditioning in the Dorella Machine.
Dorella Machine=
regaining
set o cones are put in the machine or moisture
PACKING SECTION
According to the requirement of the buyer$ the yarn package is made as cone
or cheese form. Further the yarn packages are packed in the following ways,
✓
P'lette P'cking
This is done on reasonable palettes which are wooden stands on which
the cones are kept in layers. After each layer of cones a cardboard is
placed on
which further cones is placed. The total weight of the palette is approximately
394 kg. This palette packing is more cost effective as the cost incurred is only
of the cardboard sheets and plastic sheets. The following description is
mentioned on each palette.
•
+o nt
Lot no.
Net weight
•
Gross Geight
0xcise no.
•
Date
Palette Packing
✓
C'(ton P'cking
The cones can be packed in cartons. The following description is mentioned
on each carton.
Description
•
+o nt Ne
•
0xcise no.
+arton no.
•
Gross weight
Net weight
Lot no.
&he carton packing is less cost effective as the cartons are not
PROCESS FLOW OF WORSTED SPINNING
F
variety o fibers) depending upon the output) are mi ed so as to make them
uni orm.
&ixing F Sandwich laydown takes place wherein a 49=/9 ratio o regular and high bulk fiber is
KLaydownL
laid.
Gillowing
+arding
F (nput= Small bale tu t) 6utput= 6pen fiber tu t
F Separation o each and
F (ncreasing uni ormity o fibers
Levelling F Parallelising the fibers
KGill *oxL
Simplex F (nput= 7ni orm Sliver) 6utput= Roving
&achine
/ing
Frame
F &he dra t is made according to the count o roving
F Earn is made out o roving.
F Removal o unwanted de ormities o yarn and converting the ring rame yarn into a
A toconer bigger package
+heese F For plied yarns
Ginding
TF-
/eeling
F &wo For 6ne twister where plied yarns are twisted in order to achieve the output.
F :ither the yarn is packed a ter this or it is sent to the dyeing house in the orm o
hanks.
WILLOWING
Number of machines, <
&anmade fibres do not re)tire any cleaning so they are directly made into cards from
their fibre t fts. The primary p rpose of the wallowing machine is to open
p thefibre
t fts into smaller t fts and to mix p vario s kinds of fibres.
This opening is accomplished by passing the material between two beaters. After
this$ material is transported to the cards thro gh a network of pipes.
>nlike the cotton spinning process$ in the worsted process Kwhere we to have to
process only synthetic fibresL$ there is no need of cleaning the fibres as they are
manmade.
Synthetic fiber is ed in the 1illow Machine or opening and
CARDING
&manufacturer, Hibernate$ Latham and
=ergeth &odel N mber, +AC8
N mber of machines, 9
The carding process aims at forming a sliver. The fibres are individ alised by means
of an extensive arrangement of n mero s cylinders. These are arranged so as to
open
p the fibres to the optim m and
ltimately to separate each single fibre.
The carding machines sed are @Thibea Kman fact rerL aero feed cards. These
cards are fed by means of pipes$ which are connected$ to the willow machine.
Inside these machines$ exists a complex arrangement of cylinders of vario s siBes
and this arrangement is designed to optimally open the fibres. The o tp t of these
machines is a sliver$ i.e.$ a loose rope of totally individ alised fibres. This sliver is
stored in cans for transportation to the gill boxes.
3eig)t o; C'(d Sli0e(
Fi (es Used
C'-'cit= o; t)e M'c)ine
;4C;9 kg
<44E Acrylic$
*lends
89.39
kg hr
Nylon$
Polyester
and
Slivers o synthetic fiber coming out o the Carding Machine
LEVELING
&manufacturer, Schlesinger
Numberof &machines, <;
The gill box is the e)divalent of the draw frame used in the cotton spinning process.
=ere the gill box is
sed to form tops or balls$ which form the feed package for the
next stage. The gill box also combs the fibres to achieve the maxim m parallelisation
of fibres. In addition$ the gill box compresses a few card slivers into one sliver so it is
sed for blending different kinds of material into one sliver.
In the gill box$ the combing is done at the @faller arrangement and the delivery rolls
do the calendaring. Th s the sliver prod ced is a blend of many slivers$ i.e.$ is a
blend of different types of materials. According to the properties of the material it may
be given more than one passage thro gh the machine. The sliver prod ced can be
stored in cans or be made into tops as per the re) irement of the next process.
ParalleliHation o fibers in the +ill bo
No. of Faller
Delivery +ans
+an S pecification
Diameter of Top /oll
*ottom Delivery /oll Diameter
Drafting /ange
N mber of +ards fed to the machine
+apacity
5 x 35
<$ 5 o r 6
744 x <<44 m m
74 m m
84 mm
6.<C <<.:
7
GN type, 744 <444kg shift
G+ type, 5444C;444 kg shift
$ra ting inside the +ill bo
thinner and finer
&he sliver becomes
SIMPLEX
Machine
&an fact rer, NS+ N mber
of &achines, ;
&odel N mbers, F&VC;5 K5 n mbersL$ F&C3 K< n mberL
The speed frame performs three major f nctions,
➢
Drafting, it is the process where the sliver is atten ated by means of exerting
a p ll on it with sets of rollers. This process ens res that the sliver increasesin
➢
length and the mass per nit length is decreased.
Twisting, it is the process where the atten ated sliver is given rotational twists
by means of the rotary movement of the spindle
➢
/oving, it is the o tp t of the speed frame. It takes a highly red ced thickness
Kmass per nit lengthL in comparison of the sliver. The roving is stored on
bobbins and these forms the feed package for the ring frame.
The existence of the speed frame is j stified by the fact that the sliver cannot be fed
directly to the ring frame$ firstly d e to the very high draft re) irement at ring frame and
secondly$ d e to the very large space re) irement in ring frame section.
Therefore$ the speed frame imparts draft to the sliver to prepare it for the ring frame
and twist to provide strength to roving.
M'c)ine S-eci;ic'tions
Capacity
aximum Ru&&ing
Bo&&in Length
Tension range &et1een feed roll and
<5
:C58
544 m min
56
64 mm
59 H 94 m m
<44C544 kg spindle hr
<<44 cycles min
564 mm
4.;E to 3.7E
draft apron
Tension range &et1een ru&&ing apron
4E to C<<E
and 1inding roller
Tension range &et1een draft roller and
4E to 8E
Num&er of $rafting Elements
Drafting /ange
aximum $eli*ery Speed
Num&er of Cans
ed
Feed /oll Diameter
Delivery /oll D iameter
ru&&ing apron
RIN$ FRAME
&an fact rer, Ishikawa
N mber of &achines, 58
This is the stage where the yarn is finally formed. The ring frame gives the final draft
and the twist to the roving received from the speed frame.
The mechanism sed consists of three sets of rollers for drafting and spindles for
providing twist to the yarn.
Ring Frame
The process is carried o t with the help of rollers and the roving is drafted to a
re) isite mass per
nit length. It also imparts the re) ired twist to the yarn thro gh
the rotation of the spindle. The spindles have a very high rate of revol tions per
min te. This and some other criteria are adj sted so as to ac) ire a definite level of
TPI$ i.e.$ twist per inch length of yarn.
The inp t in the ring frame is the roving received from the speed frame. This roving
is ltimately converted to @yarn .
M'c)ine S-eci;ic'tions
Num&er of Spindles
$rafting System
Bo&&in Length
Spindle Length
Capacity
644
;
554 mm
564 mm
<5C<9 metric ton day
AUTOCONER
&an fact rer, (ehlafhorjt and & rata
N mber of &achines, 8
The bobbins from the ring frame m c are collected in containers after their doffing
point has reached. In each container$ a doff slip is p t. This slip is important as it
contains the following details,
➢
Spindle no.
➢
&achine no.
+o nt
➢
Time
➢
Date
➢
Name
This is important as the person is loading the bobbins for identifiable fa lts. Also they
are important for co nt identification. 0ach order has a specific colo r bobbin allotted
to its lot. After this$ the trolleys are sent to the A toconer &achines. This has the
f nction of forming bigger packages in the form of cones which can be
do bling and then twisting on the T.F.-.
sed for
Splicing is done side by side as the bigger packages are ormed
M'c)ine S-eci;ic'tions
anufacturer
Num&er of achines
Num&er of
eads in one achine
$iameter of 2arn 3uide $rum
Width of Splicing Cham&er
+ackage $iameter (maximum)
Capacity
(ehlafhorjt
9
84
:9 mm
;.9 mm
;58 mm
7.54kg spindle shift
TFO
&an fact rer, Veejay Lakshmi
&odel N mber, V( <84 =S
N mber of &achines, 6;
This machine is
sed for do bling of yarn. The single yarn in the cone form is
converted into cheese. Two$ three or fo r cones can be
sed to do ble the yarn
witho t applying any twist. This do bled yarn is wo nd on cheese.
This machine operates on the two for one principle of applying twist. The yarn is
gripped at two points d ring twisting before being wo nd on the cones.
The yarn packages in the form of cheese are kept in the containers of the TFtwister. The yarn is threaded and is gripped at one point below the spindle and at the
other point$ which contin o sly rotates and inserts twist. The twisted yarn is wo nd on
the cones. The twist is varied by changing the speed of rotating spindle in the
container which grips the yarn. After the cones are removed from the TF-$ the
following data is mentioned.
➢
TPI
+one Geight
+ stomer
+o nt
➢
& + N mber
M'c)ine S-eci;ic'tions
Num&er of Spindles
Num&er of Spindles/Section
Spindle 3auge
+ot $iameter
T1ist Range
+ackage Type
aximum Length of +ackage (mm)
Spindle Speed
Stop otion
achine Width
achine Length
&wo or 6ne &wister
<87
8
596
<87 mm
5.9C6.; TPI
+heese
<34
<5444 rpm
&echanical
<.< m
5;.; m
CHEESE WINDING
&manufacturer, Sharer Allma
N mber of &achines, 6
This step is carried o t in order to increase the twist of the yarn. The cheeses
prod ced in the a toconer are wo nd onto bobbins sing this machine. A total of <<8
bobbins are prod ced at one go.
Cheese 1inding Machine
REELING
This is the process which is carried o t in order to convert bobbins to hanks
depending pon the c stomer s re) est. 0ach machine has 66 heads for preparing
66 hanks. Geight of the hank also depends pon the c stomer s specifications.
N mber of &achines, <7
Time taken for winding 66 hanks, <4 min tes for hanks of <94 gm each
Reeling is taking place in the <ank to Cone section
PACKING
For worsted sp n yarns$ packing is done in three ways,
➢
➢
=ank Packing KA tomatic packerL
+one packing KPaletteL
+arton Packing
packer
FANCY YARNS
Fancy yarns or novelty yarns are typically made of two or more strands which are
prod ced to provide decorative s rface effects. *ased on the p rpose of yarn$ each
strand is referred to as the base yarn$ the effect yarn or the binder yarn.
The base yarn provides the str ct re and strength$ the effect yarn creates a
decorative detail like loops and knots and the binder yarn is
yarn and the base yarn if binding is necessary.
5?R= Flurry Earn) Boucle Earn) 5oop Earn
sed to tie the effect
Fancy yarns in Vardhman are prod ced by fo r machines,
NEEDLE SPINDLE MACHINE
The effect yarn is c t by a blade so as to prod ce the fl rry effect after which it is
twisted with the base yarn.
&he triangular blade in the Needle Spindle Machine is used
to produce the Flurry effect
Production o Flurr Earn
CROCHET MACHINE
This is a knitting machine which works on the principle of warp and weft yarn. The
yarn is firstly knit and then it is c t by the blade in order to create effects like feather
and knop. It is also
sed to make laces.
Crochet Machine
HOLLOW SPINDLE FANCY TWISTER - EHP MACHINE
0=P machine is a m ltiCp rpose machine which is capable of prod cing most of
the effects. Loop$ caterpillar$ bo cle$ sl b and knop are some of them. These
effects are created by setting the speed of the drafts according to the effect
re) ired. For example$ for a loop effect$ the speed of the draft for base yarn
wo ld be lesser in comparison to the speed of the draft of the effect yarn. This
way more yarn is wo nd aro nd the base yarn in a shorter period of time creating
loops.
<ollow Spindle Fancy &wister
ESP MACHINE
In this machine$ one yarn comes straight passing thro gh the hollow spindle$
which is known as the base yarn$ while the other yarn which is the effect yarn is
wrapped aro nd the base yarn by a twister which moves aro nd the base yarn.
SE#UIN MACHINE
In this machine$ se) ins are added to the base yarn one by yarn or at reg lar
intervals that are set depending on the re) irement. Garlands of se) ins are
loaded on the machine while the base yarn is fed from one side. -nce the
se) ins have been attached to the effect yarn it is twisted along with the base
yarn and finally wo nd on a cone.
SeIuins are kept on the top inside a very long inverted tube rom
where the seIuins are ed into the yarn periodically
ASSI$NMENT7 2
AURO WEAVING MILLS
(n uro weaving mills greige abric is produced.
provided by auro spinning mills.
&he raw material is
&he
uro weaving mills has the ollowing units in the production
department=
•
•
Preparatory unit
/ loom sheds
Folding and inspection unit
Plain) twill) satin) matt) o ord) piIue cord weaves are produced on the
looms.
1e t wise stretch abrics are also produced in uro weaving mills. (n we t
core spun yarns are used in which the core is o 5ycra.
➢
$aily production o
abric per day.
uro weaving mills?
Proc$
9)999 ; 19)999 metres o
flo+ of +$avin#
Win(in#
Warpin#
Warp
Pr$para&ion
Yarn from
pinnin#
$c&ion
Si)in#
Draf&in#*
Dra+in#
Yarn
Pr$para&ion
Loomin#
W$f&
Pr$para&ion
Win(in#
W$avin#
PR:PR &6RE 7N(&
&he preparatory unit has the ollowing sections=
•
•
1arping and rewinding section
SiHing section
$rawing?in section
1 RP(N+
&he process o arranging a convenient number o warp yarns that can be
collected in a sheet orm and wound on to a warperKs beam.
&he aim o warping is winding on one package to a certain number
o warp?ends o a particular length. $uring warping) ends rom many
winding packages are wound on a common package to prepare a +arp
/$am.
R$
ir$m$n&
•
•
•
•
for +arpin#
&he tension o all wound ends must be uni orm and possibly
constant during all the time o withdrawal rom supply packages.
1arping should not impair the physical and mechanical properties o
the yarn.
&he tension should be moderate) to allow the yarn to completely
retain the elastic properties and strength.
&he sur ace o the warping package must be cylindrical.
predetermined length o the warping should be observed.
&he production rate o warping should be observed and it should be
as high as possible.
MACHINES USED
•
•
•
•
1arping machine= benniger ben?direct
No. o machines=
No. o bobbins= 4/9
L 1099 RPM
Running speed L 899?@99 RPM
Creel capacity L 4/9 cones
1arp beam length L 1899 m
PROCESS
(n one warping machine only 4/9 threads can be wound on the warperKs
beam but the number o threads needed in the abric is much more than
that. So the number o threads is divided accordingly in a ratio and a
number o warp beams are created.
( warp must have mK threads) the total no. o ends as divided by a certain
no. NK no. o possibly eIual parts containing pK ends) which are wound on
a warping beam. 7pon warping nK beams with pK ends on each) a set o
beams with a total no. o ends mLp n is ormed which is necessary or
producing the given abric.
For e ample i the number o warp threads reIuired are 19)999. So) 09
warper beams are made each with 299 threads.
PASSAGE OF YARN IN DIRECT WARPING Mac
Creel
in$
Package
E
arn
&
ensioners
E
arn
stop
motion
Sensor
E
arn
guides
Comb
+uide
roller
1arperKs
beam
REWINDING
Rewinding is done to utiliHe the remaining yarn in packages a ter the
completion o warping beam and to orm big packages rom small
packages.
No. o rewinding machines= 1
&ype= drum type winding
SI3ING
&he main purpose o siHing is to improve strength and abrasion resistance
o the warp yarns by causing the fibres to adhere together to make
smooth and to lubricate the warp yarns so that there is minimum riction
where they rub together various parts in the weaving process. SiHing
increases the abrasion resistance o the yarn. So teners are added so the
yarn does not become brittle.
SI3ING C
$mica4
Starch
Binder
•
•
base
So tener
MACHINE
•
•
•
Machine= benniger siHing machine) sucker Muller siHing machine
No. o machines=
Creel capacity= 09
Speed = 102 MPM
Running Speed =
MPM
PARTS OF SI3ING Mac
in$
Creel Hone
SiHe
•
•
•
B
Pre dryer
Final dryer
1a ing Hone
$ry split Hone
Comb
1eaverKs beam
Fac&or Aff$c&in# D$#r$$ of Si)in#:
Concentration
Viscosity o siHing liIuor
&emperature o siHing liIuor
Speed
SIueeHing pressure
•
•
T $ i)$ compo i&ion ($p$n( on man6 fac&or :
•
•
•
•
•
&he fibrous materials which the yarn is made off
&he twist o the yarn
5inear density o the yarn
Spinning method
&he density and pattern o weave o the abric to be produced
&ype o the weaving loom
Count o the yarn
DRAWING7IN
$rawing?in is the consecutive passing o warp ends through the drop
wires) healds and reed. $rawing?in is usually done manually and is time
consuming. $rawing?in is the final preparatory process.
Drop Pin
&he drop wire is a part o warp stop motion designated or stopping the
loom in case o warp breakage.
&he siHe and weight droppers depend on the linear density o the warp
yarn. +reater the warp linear? density) heavier must be the dropper.
Healds
<ealds are designed or the shed ormation on the loom. &hey are
o different designs. &he total no. o healds depends upon the
weaving repeat in the warp) the kind o eed and density o the abric in
the warp.
&he set o the aids on the looms is called harness.
Reed
&he reed is used or controlling the spreading o warp ends throughout the
cloth width and or beating up o the we t to the abric ell
&he number o warp ends drawn through the reed dent depends upon the
structure o the abric.
MACHINE
•
Machine= Stabuli delta 119
No. 6 machines= 1
Speed=
/9?1/9 endsOm ns
LOOM SHED
1eaving involves using a loom to interlace o two sets o threads at right
angles to each other= the warp and the we t #older woo '. 6ne warp thread
is called and an end and one we t thread is a pick) the warp threads are
held taut and in parallel order) typically in a loom o which there are many
different types. 1eaving can be summariHed as a repetition o these three
actions=
•
•
Primary Motions
Secondary Motions
&ertiary Motions
Primar6 Mo&ion
S $((in#: 1here the ends are separated by raising or lowering heald
rames #heddles' to orm a clear space where the pick can pass
Pic8in#: 1here the we t or pick is propelled across the loom by an air?jet)
a rapier or a shuttle
B$a&in#7 p or /a&&$nin#: 1here the we t is pushed up against the ell
o the cloth by the reed.
S$con(ar6 Mo&ion
L$& off Mo&ion= where the warp is let off the warp beam at a regulated
speed to make the filling even and o the reIuired design
Ta8$ p Mo&ion= &akes up the woven abric in a regulated manner so that
the density o filling is maintained
T$r&iar6 Mo&ion : The stop motions: to stop the loom in the event of a
Thread break. The two main stop motions are the
•
1arp stop motion
•
1e t stop motion
The principal parts of a loom are:
&he rame
&he warp?beam or weavers beam
•
&he cloth?roll
•
&he heddles and their mounting)
•
&he reed
MACHINES USED
looms are shuttle less looms that use compressed air to propel the we t
thread.
ir jet looms are used or bulk weaving. (t reIuires an even yarn and good
Iuality o siHing. ir jet looms are used to produce basic weaves.
uro weaving mills have a total o 04/ air jet looms.
➢
Count
range= 9
9
Oe
to
#19)10)1/)14)09) 9)/9)29)49) 9)89'# or lycra'
89s
s ng es)
&otal loom = 04/
looms = 04/
unit 1
airjet
looms
unit 0
unit 3
88 airjet
looms
/8 airjet
looms
unit
/8 airjet
looms
Air9$& 4oom
:;2<==<>=<56@
T
(a8oma
Picano4
To6o&a
T
a8oma 205i
Picano4 OMNI
To6o&a 9$& ;10
T (a8oma 20 i
Picano4 ($4&a7B
T
(a8oma )aB
no&&in#
Process to join warp o new weaver beam with old warp sheet using
knotting machine.
Gai&in#
+aiting is to replace old weaverKs beam) drop wires) healdwires) and reed
with new one.
ir Jet 1eaving=
•
•
•
•
•
Jet looms take the we t yarn across the loom by using high speed air
blast noHHles.
&he drag orce o air carries the yarn rom one side to the other.
&he initial propulsion orce is provided by a main noHHle.
Relay noHHles
noHHles' along the shed produce additional
booster jets to help carry the yarns across the loom.
&he abric width o air?jet loom is normally narrower than rapier or
projectile loom
Jet looms are aster than projectile or rapier looms #picks per
minute'.
<owever) they cannot produce as great a variety o abrics #no
heavy or bulky yarns') nor can they produce as a wide a abric #jets
have less yarn?carrying power'.
Jet looms also do less damage to the warp since there is no abrasion
o this yarn by the jet o air) unlike the projectile or rapier.
Sa ety Measures
•
Be ore starting mOc) keep oneKs hands away rom reed > other loom
parts
For drawing yarns manually) use yarn drawer
*eep emergency button pressed i one has to work on loom
FoLDING AND INSPECTION
(n olding and inspection department the abric produced is inspected on
the basis o / point system and then olded or rolled as per customer
reIuirements and then the bales are sorted on basis o the number
o de ects ound. &he bales are sorted in ) B and $ grades.
Purpose o this department is to check or de ects on the woven abric roll.
&his is carried out on machines where the roll was monitored warp wise
against an illuminated background screen such that the lamina o the
abric was visible > the operator could stop > mark a de ect where he
ound a de ect in the abric.
> poin& INSPECTION S6 &$m
5ength o de ect in abric) either length or width points allotted
7p to
6ver
inch
1
inch. 7p to 4 inch
0
6ver 4 inch upto @ inch
6ver @ inch
<oles and openings 1 inch or less
6ver 1 inch
/
0
/
PROCESS FLOW OF FOLDING an( In p$c&ion
In
p$c&"on
Fo4("n#*Ro4
4"n#
Ba4$
Sor&"n#
Ba4$
Pac8"n#
MACHINES
Inspection Machines
Machine= almac inspection machine
No. 6 machines= @
ROLLING machines
Machine= la mi l /29 # or 5ycra' and la mi rolling machine # or 0 ply and
fine abrics'
No. 6 machines= 0
Folding MA HINES
Machine= la mi olding machine
No. 6 machines= 1
$e ects noted $7R(N+ inspection
Minor DEFECTS
•
Stain
Slub
Contamination
Ma9or ($f$c&
•
•
•
•
Bent pick
$ouble pick
&hick place
Stain mark
6ily we t
1e t distortion
•
Stained pick
&he de ects are marked by tying a thread at the selvage where the de ect
has occurred.
MAHAVIR SPINNING MILLS
Mahavir spinning mills is a part o Vardhman te tiles. &hread as well as
abric is produced in Mahavir spinning mills. Both greige and yarn dyed
abric is produced there.
&he raw material comes rom=
•
•
spinning mill) baddi
spinning mill) baddi
spinning mill) malerkotla
Vardhman abrics limited) budhni.
Vsm) baddi
Vtl satlapur.
1eaving 6F E RN $yed abrics
For the production o yarn dyed abrics the yarn has to be dyed prior to
weaving. Both the warp and the we t yarns are dyed prior to weaving in
the A ro D6$in# Uni&.
&he warp yarns are wrapped on the warperKs beam and sent to auro
dyeing. &he beams are dyed as they are and sent back or weaving. For
the we t packages o yarns are sent to auro dyeing which are dyed in
cheese orm.
ter dyeing the yarns are used to weave checks and plaids.
Preparatory 7nit
(n the preparatory unit the warp yarns are prepared or weaving. &he
preparatory unit consists o
•
•
1arping section and rewinding section
SiHing section
$rawing?in section
1arping S:C&(6N
1 R!(N+
S:C&(6N
$(R:C&
1 R!(N+
S:C&(6
1 R!(N+
Dir$c& +arpin#
(t is used or long runs o grey yarns) single colour yarns and simple
patterns o coloured yarns. (t can be used to make warp sheets. &he total
amount o coloured yarns involved is less than 12P o the total.
Suction devices are provided in between warping machines which suck all
the unwanted cotton fibres flying.
MACHINES
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MACHINE : Moenus Sucker +mbh#+ermany' Comwarp) Beninger
Ben?$irect
No. 6 machines= 0
Creel capacity= Moenus Sucker? 4 0 Beninger? 424
AMBIENT
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ONDITIONS IN $ARPING DEPARTMENT
&emperature range=
Relative humidity=
49?89P
S$c&iona4 WARPING pa&&$rn +arpin#@
(t is used or short runs especially or an cy pattern
amount o coloured yarn is more than 12P o the total.
abrics where the
Sectional warping is best suited or very long warps #12 yards or more')
any siHe or style o yarn and 0 inch repeats #most sections on a sectional
warp beam are 0 wide'. (t is not very well suited or mi ed warps with
many or random yarn changes. (t also reIuires more space and
eIuipment.
MACHINE
•
MACHINE: Benninger Ben?tronic ) Prashant
:SP
1199No. o machines= Benninger?4) PR S< N& +amate ? 0
Rewinding Section
Rewinding is done to utiliHe the remaining yarn in packages a ter the
completion o warping beam and to orm big packages rom smal
packages or selling purpose.
MACHINE
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Machine= P.S. M:&&5:R R:C6 $
No. o machines= 0
Package produced= open wound package
No. o spindles= 49#on two sides'
SiHing section
S(R(N+
S:C&(6N
S(R(N+
*(&C<:N
S(R(N+
<(N:
Si)in#
ITCHEN
SiHe is prepared at the top floor in the siHing kitchen and trans erred to the
machine with the help pipes.
Sizing APPART&S
PR:SS7R:
PR:M(D:R
C66*:R
SIZING ingredients
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•
tSonycryl
Mutton tallow
1ater
*etanol
•
Si)in# MACHINE
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•
No. 6F M C<(N:s=
&sudakoma= 6nly For $irect Beam
Moenus Sucker= Both For $irect > Sectional Beam
Moenus Sucker= 6nly For Sectional Beam.
SIZE PI ( &P percentage
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6pen :nd Earn?8P
Compact Earn?10P
Carded Earn? 14P
Combed Earn? 14P
$R 1(N+?in S:C&(6N
$R 1(N+?(N $:P R&M:N&
V:SS:5
M N7 5 $R 1(N+?(N
7&6M &(C $R 1N+?
(N
1 S<(N+ >
C5: N(N+ S:C&(6N
$rawing?in is the final preparatory process.
done automatically using rapier hook.
•
drawing= <ere drawing is
M C<(N:= Staubli#*6R: ' $:5& ?119
Manual $rawing?in= $one manually to draw warp yarn through drop pins)
heald rames) and reed. &wo workmen=
•
Reacher?in= puts warp in drawing?in pin or needle.
Pinner= <olding drawing?in pins> draws the warp yarns through drop
pins) <eald rames > reed.
5oom shed
&otal loom = 00/
looms = 1/0
Rapier looms = 80
(RJ:& 566MS
#0/A118'
&
#4A
566MS
/A0'
+&D
$6RN(:R +PD
*notting
(t is the process to join warp o new weaver beam with old warp sheet
using knotting machine.
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&ype= grey and dyed yarn
Machine= staubli knotting machine.
ppro imate time= 1?1.2hr.
+aiting
+aiting is to replace old weaverKs beam) drop wires) healdwires) and reed
with new one.
•
Machine= +:N*(N+:R <6B&:D hydraulic gaiting machine.
Tuality assuranceO olding department
•
Mac
(nspection Hone.
Bale sorting Hone.
Bale packing Hone.
in$
Inspection machine
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•
No. o machines=
Manu acturer= 5a mi
Mending ta)le
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No. o machines= 0
Manu acturer= 5a m
Folding MA HINE
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No. o machines= 0
Manu acturer= 5a mi
Rolling Machine
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•
No. o machines= 1
Manu acturer= 5a m
Inspection c*m rolling machine
•
No. o machines= 1
Manu acturer= Navjyot machine works ltd
Ba4$ pr$
in# MACHINE
No. o machines= 1
Manu acturer= 5a mi
$:S(+N $:V:56PM:N&
$esigning plays an important role in marketing.
Vardhman) the
people who are in marketing deal with the customer and gives the
designing department about what is to be made and what is the
demand o the customer. Marketing sector gives the designing
department in ormation regarding the sales.
Vardhman (ndustries creative department mainly deals with the designing
and development o checks and stripes and creative abrics with different
weaves or suiting and shirting. &o achieve this) the unit ollows a certain
procedure.
Process
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•
Samples are made)
Sent to the Customers)
&he demand is identified)
the reIuired design and Iuantity are supplied.
CENTRAL PROCESS DEVELOPMENT CENTRE'
&his is the main head o the design and prototype department o
Vardhman &e tiles. (t has main departments unctioning under it)
1. C$C= Creative $esign Cell
0. P$C= Product $evelopment Cell
Pilot Plant
&he Pilot Plant has
SiHing machines) / warping machines and 14 looms.
&hey deal with all types o yarns such as) Viscose) 5inen) cotton) polyester)
polyester cotton
core spun yarn #CSE') etc.
&he C$C department works on 0 seasons per year. part rom that) they
have the routine development team that unctions throughout the year on
trending designs and trends
PRODUCT DEVELOPMENT CENTER
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Research
Selection o raw material
Process control
Process development
Product testing
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Quality assurances
Specification tests
(INSTRUMENTS USED R&D LAB)
&tension meter) $digital thread counter ) 1eighing scale) Circular
cutter)Stirer &chronometer) Shore hardness tester) Earn appearance
tester)
twist tester) Single yarn strength) tester) Bess lay balance)
$esiccators) Moisture meter) &earing strength tester) 5ea strength tester)
Re ract meter.
AURO TEXTILES
Vardhman grup has stepped into the textile industry with the setup o
7R6 &tiles at Baddi #<.P'. Chie Minister o himachal Pradesh) Mr. Prem
*umar $humal inaugurated it and its production started in
$December 0999.
&he whole plant covers an area 10 acres o land. Since textile field is
new to this group so they had their technical collaboration with the
renowned group o Japan U&6* ( S:N*6V. ll the machinery installed in
plant was imported rom Japan) (taly > +ermany. t present the plant has
the capacity to produce 9 lakh MeterO Month o abric.
&he plant is sel ?sufficient in prospect o the ollowing= ?
•
•
Power Supply as it has its own Power +eneration Plant.
Boiler or steam and)
:Xuent &reatment Plant or the water used in the processing o
abric.
&he plant not only uses the above utilities #power and steam' or its own
consumption but also supply to its sister concerns also as= ?
Po+$r
•
1eaving Mills
199P : port 6riented 7nit
Spinning mills
S&$am
dyeing
VS+M 199 P : port oriented unit
1eaving mills
&he raw material or
7R6 &:D&(5:S Comes rom
•
Mahavir Spinning Mills
+reige abric or piece dyed abric comes rom both uro spinning mills
and Mahavir spinning mills. Earn dyed abric comes only rom Mahavir
spinning mills.
A ro T$ &i4$
1.
0.
.
/.
a fo r ma9or ($par&m$n&
Personnel > (R $epartment.
Commercial $epartment.
:ngineering $epartment.
Production $epartment.
T $ pro( c&ion ($par&m$n& of A ro &$ &i4$ i (ivi($( in&o & $
fo44o+in# $c&ion :
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Preparatory section
$yeing section
Finishing section
(nspection and olding
&echnical section
Preparatory section
&he Fabric rom the mills is received in the ollowing Forms=
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Roll Form
Bale orm
Pallet orm
Firstly the grey cloth is send to technical department where the physical
and chemical testing o grey cloth takes place. ter testing o cloth) all
the reason is written in the dispo sheet by technical department and a
copy o all is send to all the concerned departments and now it is ready
or grey checking which is e amined on grey checking machine.
&hen abric ends are stitched so that a abric batch o longer length is
ormed. &his acilitates that processing can be carried out continuously.
&he abric ends are stitched together with help o stitching machines.
&he abric received by uro te tiles contains many natural and chemical
impurities which have to be removed to increase the dye affinity o the
abric and to add value to the abric.
PROCESSESS DONE in &
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$ PREPARATORY SECTION
6pening and stitching o abric
Pre?treatment
MerceriHation
Mechanical finishes #seuding'
T6p$ of &i&c in# mac in$
&here are two types o stitching machine depending upon the type o the
abric.
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•
P(C* S: MOC= ? 0 &hread #Japan' # or normal finished material'
J7*( MOC= ? 2 &hread #Japan' #those material which are going to be
peached'