29-JULY-2016
SUMMER INTERNSHIP REPORT
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Submitted By:
NAME
ROLL NO.
E-Mail ID
YOUNUS USMAN
D-14-CH-115
younuskk1993@gmail.com
MUHAMMAD AWAIS
D-14-CH-51
engr.awais1451@gmail.com
RAEES PATEL
D-14-CH-111
raees.jawed@gmail.com
ABDUL MANAN KHOKHAR
D-14-CH-119
abdulmananhere@gmail.com
DAWOOD UNIVERSITY OF ENGINEERING
& TECHNOLOGY KARACHI
YUNUS TEXTILE MILL (YTM)
SUMMER INTERNSHIP REPORT
ACKNOWLEDGEMENT
We proudly present our report which is based on Wet processing. For this report we are
extremely thankful to the talented people that worked and helped us in sorting out our circulated
questionnaires and confusion throughout the internship especially we would like to thanks the
skillful personalities and worker whose co-operating was very beneficial & studious for us.
We are also very thankful to,
GM Processing
Incharge of Processing Floor
QC Executive
Management Trainee
Management Trainee
Mr. Rizwan Younus
Mr. Javed Salat
Mr. Imran Sabir
Mr. Farooq Ali
Mr. Usama Bin Adnan
Special thanks to respected Mr.Javed Salat guided us during our internship program.
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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YUNUS TEXTILE MILL (YTM)
SUMMER INTERNSHIP REPORT
PREFACE
In line with recent trends toward high-quality production and diversification in the textile
processing, much efforts are being exerted to improve the performance of mixed fabrics of
natural and synthetic fibers and to introduce the new product with new values.
The report includes information presents a detailed description of the standard latest
working procedure in wet processing on Polyester/Cellulosic blends, CVC, PC fabrics.
As continuous wet processing for polyester/cellulosic blends, CVC, PC fabrics involves a
large variety of fiber substrates, processing methods for pretreatment and dyeing and finishing.
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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YUNUS TEXTILE MILL (YTM)
SUMMER INTERNSHIP REPORT
YUNUS TEXTILE MILL
Yunus Textile Mills (YTM) is the latest addition to the Yunus Brothers Group of
Companies. YTM is a complete vertically integrated textile mill with state-of-the-art machinery
for the home textiles and the garment industry. It is also a major contender in the home textile
and garment export segment of the Pakistani economy. The staff strength at only YTM unit is
around 6,500 employees whereas the Yunus Group employs approximately 15,000 staff
countrywide.
Yunus textile group is a big name in Pakistan export and a winner of above 20 export
trophy from the government of Pakistan for the highest exports from the country as well as the
highest exports in the textile sector.
The group of companies:
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Fazal textile mills limited.
Gadoon textile mills limited.
Lucky cement limited.
International trading.
Lucky textile mills.
ICI Pakistan limited
Yunus textile mill basically deals with home textiles and has following international customers:
Germany:
MGB METRO, KAUFHOF.
USA:
JC PENNY, TARGET, WALL-MART, MARMAXX, KOHL’S, SEARS, LINEN-N-THINGS, BED BATH AND
BEYOND
Italy:
GABEL, CAMAGNOLO
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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YUNUS TEXTILE MILL (YTM)
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Products:
YTM has its own products includes:
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Bed linen.
Curtains.
Bath Shower Curtains.
Kitchen Curtains.
Table Covers.
Blended Fabric.
Cotton Fabric.
Dyed Fabric.
Grey Fabric.
Printed Fabric.
Bleach Fabric.
Mercerized fabric.
FinishedFabric.
FLOW CHART FOR WET PROCESSING
Grey Fabric Inspection
Sewing or Stitching
Singeing
Bleaching
Scouring
De-sizing
Mercerizing
Dyeing / Printing
Finishing
Lab Testing
Sanforising
Calendaring
Final Inspection
Finish Folding
Delivery
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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YUNUS TEXTILE MILL (YTM)
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GREIGH DEPARTMENT
This is the first department of the wet processing industry. In Greigh department inspection of fabric is
done with the help of 10-100% inspection the fabric fault are counted and grading of fabric is done.
Production:
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Machine speed is 100 m/min.
Maximum width run on machine is 126-130 inches.2.25 lacks for three shifts.
Each shift process about average 32000 meter per machine.
GREY DEPARTMENT DEALS:
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To inspect, mend & grade the fabric.
Making lots.
To keep the record of store fabric.
The rejected fabric is sent back to the respected Mill.
Make bath and transfer it to the next department.
Inspection / Grading:
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
The main purpose of the inspection is to check the Greigh fabric
for identify the faults.
Tacoma (Spain) Batch Making: (2003 Model)
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Speed 90-100 m/min.
Tacoma is brushing and batch making machine in greigh department.
Batcher machine is used to made batch of the fabric.
Maximum batching Length:

700-750 a/c to the density of fabric.
Components of the machine:
1. Conveyor belt.
2. Screy.
3. Expanding rollers and guide rollers.
4. Winder.
5. Brush.
The fabric is placed on conveyor belt the pile is threaded through the tension rods and the guide rolls
works on the electronic sensing to run the fabric in center the fabric is than enter the scray than the fabric
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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YUNUS TEXTILE MILL (YTM)
SUMMER INTERNSHIP REPORT
is passed through the expanding roll which expands the fabric to run in smooth through the machine.
After it the fabric entered into the brushing section to brush the contaminants and fluff and fly because
they may create problems in next process especially in dyeing and printing. The fabric is than rolled on a
frame to make our required batch wheel rotates and measure how much fabric is wounded. There are two
Tacoma machines installed in YTM.
Singe De-Size Machine (Osthoff): (1999 Model)
Singeing is the removal of protruding fibers from the surface of the fabric in order to improve their
surface appearance and sharp surface for printing and dyeing and also to remove the size material applied
on to the warp yarns to avoid breaking of warp yarn due to mechanical stress. If not done, this will disturb
the appearance of dyed and printed fabric.
Parameters for singeing:
• Singeing position
• Flame intensity
• Fabric speed
• Distance between fabric and burner
Machine Components:
•
•
•
Guide rollers
Pre drying
Pre rushing
•
•
•
Singeing chamber
Cooling drums
Post brushing
•
•
De-sizing unit
Winder.
2
3
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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YUNUS TEXTILE MILL (YTM)
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Parameters:
Machine name
Made
Max. Width of singe de-size 1
Max. Width of singe de-size 2
Max. speed
Flame intensity
Pressure of the padder
OSTHOFF
Germany
126”
110”
100 m/min
10-16 cm
2.5 bar Flame angles 90,45,90
SCOURING & BLEACHING
SCOURING;
The process of scouring is to make material highly and uniformly absorbent. (i-e the removal of
natural impurities like wax, fats, oils). When oils and fats are heated with a solution of sodium or
potassium hydroxide, they hydrolyzed into glycerol and the alkali salts of fatty acid, these salts of fatty
acid are soaps therefore his particular hydrolysis is referred to as Saponification,
BLEACHING;
Scouring removes almost all the impurities except natural coloring matters which are ultimately broken
down with bleaching agents. Bleaching is necessary for producing white goods either as finished products
or for dyeing pastel shades.
There are two scour bleach machines both the machines are continuous and gives average 2.5 production
per day.
Scour Bleach -2 step (Goller Germany): 2004 Model
The machine is 2 step scour bleach machine with 1-1.2 lack production.
Machine parameters:
Speed
Caustic
H2o2
Stabilizer
Wetting agent
125 m/min
48 Be
50%
KEB
RGN
The fabric after de-sizing is directly carried out on the bleaching machine for the process of washing,
scouring and bleaching. machine parts and their functions and also process on the machine,
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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YUNUS TEXTILE MILL (YTM)
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Scour Bleach solomatic (Goller 1995):
Production of goller solomatic is about 1.23lack per day production.
Machine components:
Pre washing:
Chemical padding:
Steaming:
Post washing:
2 chambers for pre washing at 90-98 C.
Chemical padder in which scouring and bleaching chemicals are padded.
The fabric is entered into the steamer 103-108 C for 22 min.
4 chambers in post washing 3. chambers for washing at 70-98 C and last 1 for
neutralization.
MERCERIZATION
OBJECTIVES
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To increase luster.
To increase the affinity for dyes.
To increase the tensile strength.
To give dimensional stability
Use of dye after mercerizing is less
Width control
 After mercerizing increase cost of fabric Rs 2.70 per meter.
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YUNUS TEXTILE MILL (YTM)
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In this process cotton is dipped in a solution of NaOH so that NaOH penetrated in to the fiber and then
NaOH is washed out completely by neutralizing by dilute acid like formic acid. When mercerizing fiber
are examined under microscope. It is seen that each fiber in twisted ribbon like form. After mercerizing
fibers become cylindrical and free from twists.
Process:
After bleaching the Ends/Picks of the fabric are disturbed and also fabric is shrink up to 510%, therefore to regain fabric original width and Ends/Picks fabric is conditioned to be passed through
the STENTER MACHINE, it is also depends upon the material requirement. After pre-stenter the fabric
batch is placed on a mercerizing machine The fabric is passed through a number of guide and Bow rolls.
After that the material is dipped in to the main section, which is a STRONG LYE containing chamber.
The number of chambers in mercerizing machine is different and depends upon the manufacturer of the
machine. In this chamber the material is continuously treated with caustic soda of about 26-30°Be @
60°c. The lye is showered in zigzag manner the fabric is rolled over a number of padder. Load cell are
used to maintain tension to the coming fabric.
If the material is subject able for reactive print mercerization is necessary, whereas on the other
hand for pigment print no mercerize material is required. After strong lye the fabric is passed through
weak lye chamber. The temperature is increased up to 85°c and caustic concentration is decreased up to
7-8°Be, this gradually reduction in caustic concentration stabilize the mercerized material, then in the
stabilizing section caustic concentration is decreased up to 4-3°Be through counter flow of water. The
mercerized material is rinsed and washed and PH is maintained in a washing range. The next stage after
weak lye section is washing. In goller machine there are four chambers as compare to FAISLABAD
MERCERIZE. The temperature of starting chamber is about 90-95°c and last washing chamber contain
room temperature. In continuous washing range of GOLLER MACHINES, neutralization is also alone by
using formic or acetic acid. After neutralization the wet fabric is wound on a batch with the help of
tension and winding arm.
PAD THERMOSOL MONFORTS (2002):
Pad Thermosol is a high temperature dyeing. On pad thermosol we ca get dark shades we are not fixing
the dyes on pad steam we can dye vat, disperse and disperse dyes. In YTM there are two Pad thermosol
machines with 1.2 lack production per day. Pad thermosol 1 has 4 chambers and it is automatic and Pad
thermosol 2 has 5 chambers and it is manual.
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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YUNUS TEXTILE MILL (YTM)
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Types of Dyes applied on Pad thermosol machine:
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Disperse
Vat
Reactive
Pigment
PROCESS SEQUENCE IN PAD STEAM
Batcher 
Screy 
Cooling drums

Drying and curing chamber 
Cooling drums 
Padding 
IR (pre-drying) 
Screy  Batcher
Working of Machines:
The fabric is unwound and then pass through brushing section here the fluff is brushed and fabric is
collected and stored in screy. fabric passes over cooling drums to cool down the temperature of fabric
because when we are dyeing PC fabric then after RC fabric is hot enough. The fabric is then passed
through Kuster padders, two types of pressure used in Kuster padders hydraulic and neumatic.the central
pressure is hydraulic and sides pressure is neumatic.we can adjust the pressure of the padders .
Then there is given I.R system the temperature of I.R is about 60- 50 c. there are two I.R installed the
temperature of first I.R kept 850 c and second 800c.the function of I.R is to remove 30-35% moisture. the
fabric is then passed through the thermos, 5 chambers are provided,
1-2 Drying.
3 Drying.
4-5 Fixation.
The fabric is then passed through cooling drums and finally fabric is collected on a batcher.
PAD STEAM MACHINE :(GOLLER 2000 Germany)
Pad steam is used for dyeing light shades and the fastness properties of the pad steam is better than pad
thermosol. On pad steam fixation of dyes also done. The max temperature of the machine is 100 cand
speed 80 m/min. we can done RC, VAT develop, wet on wet and chemical pad. In pad steam there are
three types of flows,
1-Counter flow
2-Static flow
3-Over flow
In pad steam there are two I.R for high production. We can plant one I.R for normal production. In pad
steam we use urea and steam for increasing the moisture but we use steam in the replacement of urea
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YUNUS TEXTILE MILL (YTM)
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because is less costly then urea also the urea damage the environment. In pad steam there is an E control
or economical control. E-control provide good results but initially produce some variations.
Production of Pad steam is 1 lack per day.
Chambers of Washing Range:
Chamber
Chamber
Chamber
1,2 and 3
4,5,6
7,8
soaping, RC, VAT develop
Hot Washing
Neutralizing
Cylinder dryers:
There are 20 cylinder dryers last 2 cylinders contain water and 18 cylinders contains super saturated
steam 120 C.
PRINTING
There are 3 m/c of REGGIANI having max fabric length 130” and 97” and length is 40 m. on Printing 1
and 2 ,16 colors can be printed and on Printing 3 12 colors can be printed at a time.
Production is 1-1.3 lack per day.
CAM CAD:
The design given by the customer may be on a paper or directly they given a sample fabric to the cad cam
department they scan the design in the computer.
Software used:
•
•
Ram Set
Photoshop
 After the approval of the design by the customer design is sent to the engraving department.
Screen Coating:
The screen is made up of 100% nickel. Screen is coated with coated material SCR 100. Screen is coated
upside down for 15-30 min at high temp over 180-200c and left for dry about 10-30 min.
Screen exposing:
 Wax exposing machine.
Contain black wax which fired on the screen. When light strikes on the screen wax become hard.
 Ink jet.
 Laser exposing.
Laser light bombarded. SCR 102+101 coat is used only curing, exposing and enduring.
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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Screen Developing:
The screen is developed which means only that parts where patterns are printed on screen are removed
from coating while other remains same
Oven Heat (polymerization):
The screen is again oven heated.
Hindering:
The screen is thoroughly washed normally to make sure the patterned area is open i.e. Mashes are not
closed by coating or another dust.
Dried and Heated:
Finally, the screen is heated and dried and sent to the rotary machine
Types of sheets/mashes for screen:
Standard
Panda
Nova
30,40,60,80
100,125,125 V, 155,155 DHL,165 mesh
135,135 DHL, 165,195 mesh.
Process flow:
Entry → Printing → Dryer→ Exit
Components of machine:
•Entry
•Suction
•Flat rollers
•Trolley
•
•
•
•
Printing zone
Sensor
Conveyor belt washing
Dryer
The fabric is passes through guide screen rollers to the suction area here the sucker sucks the fabric fluff
and dust particles. Flats are provided when we use knit fabric. The fabric enters into the trolley where
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YUNUS TEXTILE MILL (YTM)
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PVA is applied to stick he fabric with the blanket belt. The machine is provided with an I.R system and
cambered plate to give temperature to the thermoplastic glue. Then the fabric enters into the printing
zone. The fabric is sandwiched b/w the rollers and the blanket, magnetic system of printing is used.
Color is dozed into the squeegee through pumps automatically. The first screen roller is to press the fabric
and the second gathers the remaining fluff. The printing starts from the third screen. each screen prints a
single color. the number of the screen depends on the type of design. The sensor is used to control the
speed of the blanket. The fabric than entered into compact HC dryer 160-180 c. the dryer has 5 burners.
The dryer has three passages air is blown into the chambers 2 times. Finally, the fabric is collected by a
crank gear mechanism to a trolley.
FINISHING
Stenter machines (Monforts Montex):
The purpose of the stenter machine is to bringing the length and width to pre determine dimensions
and also for heat setting and it is used for applying finishing chemicals and also shade variation is
adjusted.
Components of Machine:
Padders
Weft straightner (Mahlo)
Burners
Heat recovery
Attraction rollers
Circulating fans
Exhaust fans
Winder
Clips
Pins
I.R
Cooling drums
The fabric is collected from the batcher to the screy and then it is passed through the padders where the
finishes are applied and sometimes shade variation is corrected. The fabric is entered into the mahlo (weft
straigtner) the function of the mahlo is to set the bow and also weave of the fabric is griped by the clips
and pins are also provided but the pins has a disadvantage that they pins make holes at the selvedge but
the stretching of the pins are greater than the clips. These clips and pins are joined to endless chain. There
are 8 to 10 chambers provided on the machine each chamber contains a burner and filters are provided to
separate dust from air. The circulating fans blow air from the base to the upper side and exhaust fans
sucks all the hot air within the chambers. Attraction rollers are provided to stretch the warp yarn.
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After stentering we can increase the width of the fabric up to 1.5-2 inch. The speed of the
machine is about 7-150 m/min.3 meters fabric can run in each chamber. Temperature is adjusted that a/c
to the fabric as for,
 PC
210 c
 Cotton
110-130 c
After dyeing 160-170c and after print 130-140c.
Calendaring Machine (KLEINEWEFERS)
Calendaring is an operation carried out on a fabric to improve its aesthetics. Purpose of
calendaring is:
 To upgrade the fabric hand and to impart a smooth silky touch to the fabric.
 To improve the opacity of the fabric
 To compress the fabric and reduce its thickness.
 To impart different degree of luster to the fabric.
 To reduce yarn slippage.
The mechanical finish is done for softness and shining of the fabric or stiffness according to the nature of
the chemical, this process is done after the chemical finishing as per buyer requirement. Speed of the
machine is 10-100 m/min.
 There are two calendaring m/c in ytm
 production of 1 machine is 1.5 lac / day
Components of machine:
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Winder
Metal detector
Seam detector
Rollers (cotton, reclon and steel)
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Anti-static rod
Oscillating roll
Batcher sensor
cooling drum
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SANFORISING MACHINE:
Monforts Sanforizer: (Germany 2003)
The processed fabrics are subjected to elongation during processing. The shrinkage is controlled in the
mercerize and stenter to some extent and it is ultimately brought within the norms in the latest monforts
sanforizer made in Germany. The width ranges from 40cms to 325cms. Sanforising is a mechanical of
treating the textile fabrics to prevent the normal dimension alterations of warp weft, which occur in the
finishing operation; especially those carried on in laundering &allied operations.
 Production / day70,000
 Speed 50 m/min but max is 120 m/min
 Rubber roller length 305- 312
MECHANICAL COMPRESSIVE SHRINKAGE: The fabric is compressed by the contraction of the conveyor surfaces on which the fabric has been made
to adhere. The conveyor takes the form of a rubber belt or sleeve. The outer end expands as it passes over
a roller and at this point the fabric is applied. The surface contracts with it, expansion and contraction are
controlled, precise and predetermined length can be obtained, hence the process is positive.
EVASET PRINCIPLE a specially made rubber sleeve is tensioned b/w roller 2 and 3. A driving roll on
the outside of sleeve and deflects the upper run of sleeve into a reverse curvature, the driving roller 1 is
steam heated.
The outer surface of rubber sleeve is expanded as it moves round the tension roller. The driving roller
nips the fabric into contact with the expanded surface contract on taking up the reverse curvature around
the driving roller.
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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Textile testing lab
The YTM processing laboratory has latest testing equipments for testing fabric, yarn and also shade
matching. the lab is divided into 4 portions.
 Lab dip.
 RND.
 Physical.
 Online Q.C.
Lab Dip:
A lab dip is a swatch of fabric test dyed to hit a color standard. Several lab dips may be submitted for
feedback until the standard is achieved and the lab dip is approved. There is also now a machine used to
read lab dips called a "spectrometer” which will give the same feedback. As not everyone sees color as
well as the next (and you can be tested to see how well you see color) a machine can take out human
error.
RND and Color Matching:
The main functions of RND department are to check all the running chemicals used in the industry and
also to find our troubleshooting and investigate the problem and solve it. They also check new chemicals
available in market which fulfills the running chemical and it is cheaper than the running one. Important
tests conducted by RND portion,
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Whiteness.
CMC.
Formaldehyde test.
Water testing.
Raw material checks.
Barium activity test.
Core pH.
Troubleshooting.
New product assessment.
Degree of de-size.
Absorbency test.
CHEMICAL TESTING
 WASHING TEST:
Sample size= 10x4”
Standard=ISO -105
CO1 CO6
CO1 and CO2 are for the leather garments
CO4 for the Vat dyes
CO6 for the fabric
 SHIRINKAGE TEST:
Sample Size:
For ISO=50x50 cm
For AATCC=38x38cm
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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Standards:
SO-6330 2A-9A
AATCC-135
Washing machine for ISO wascator
Washing machine for AATCC=Whirlpool
Sample is washed in its washing machine and dried. Then, its size is checked and change in size is noted.
Both warp and weft shrinkage is tested.
 pH METER:
It is important machine in any chemical lab to check out the pH.
 PERSPIRATION TEST:
Perspiration test is performed for both acidic and alkaline mediums.2 samples that are sandwiched
between the multi-fiber fabrics are dipped in acidic and alkaline solution. then these fabrics are placed on
perspirometer under a weight of 5 kg for 4 hours for ISO and 6 hours for AATCC. Then the stains on the
multi-fabric are matched with the grey scale.
 HARDNESS TEST:
To check the hardness of water, 1 ml of buffer of pH 10 is added in the sample and is titrated with EDTA.
Eurochrome black t (EBT) is used as an indicator. The point at which the sample gives blue color is noted
and is hardness of water.
Hardness= burette reading * 20
 DETECTION OF IRON PARTICALES:
Iron particles present in fabric create pinholes after bleaching and they appear visible after dyeing. In
order to detect % of iron particles in fabric, 10% of potessium thiocyanide and 5% of nitric acid are used.
Dip the fabric in nitric acid for 5 to 10 min, dry then dip in potessium cyanide solution. The iron particle
on the fabric will appear as red spots and are easily detected.
 Spectrophotometer meter:
Spectrophotometry involves the use of a spectrophotometer. A spectrophotometer is a photometer (a
device for measuring light intensity) that can measure intensity as a function of the color, or more
specifically, the wavelength of light. We can take each and any type of test including shade matching,
CIE whiteness test, Burger whiteness test and also this instrument give us the composition of shade.
Data Color D650 Dual Beam Spectrophotometer.
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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PHYSICAL TESTING
All the physical tests on a textile sample or material is conducted in physical portion of the lab.
The tests conducted by the physical portion are,



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







Tensile strength
Seam.
Abration
Air permeability.
Pilling.
Appearance.
Rubbing fastness.
Washing fastness.
Color fastness.
Water fastness.
Perspiration fastness.
Dry cleaning fastness.
Light fastness
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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Final Folding
Taking samples from each and every roll and faults are detected and the grading is done then
shade is forwarded to the shading department. The rolls are separated in shade wise. The defected fabric
is separated. The grading is done a/c to the customer requirement.
There are two types of machines in YTM namely,
• Rolling machine.
• Flat folding machine.
The rolling machine is used for making the rolls of A and B grade fabrics and other graded fabrics are
separated and folded on flat folding machine.
DAWOOD UNIVERSITY OF ENGINEERING & TECNOLOGY, KARACHI
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