Raymond The complete Man Since 1925

About company
Almost Nine decades old, Raymond group is in operation since 1925. It is one of India's largest
branded fabric and fashion retailer. It is ranked as second largest branded apparel business in
India. Raymond has under its umbrella on of the prestigious award winning brands like
Raymond, Park Avenue, Colorplus, Parx. Raymond is amongst the earliest direct retail chains in
India and is one of the largest exclusive retail networks in the textile and fashion space in India.
Company has maintained its large India focus, with more than three fourth of revenues from
domestic market. Raymond Ltd, the flagship company of the group, is listed on BSE and NSE.
With a capacity of 38 million meters in wool & wool-blended fabrics, Raymond commands over
60% market share in worsted suiting in India and ranks amongst the first three fully integrated
manufacturers of worsted suiting in the world. Raymond is perhaps the only company in the
world to have a diverse product range of nearly 20,000 design and colours of suiting fabric to
suit every age, occasion and style. Company exports its products to over 55 countries including
USA, Canada, Europe, Japan and the Middle East.
Business activity is manufacturing process of fiber to fabric. Company is fully integrated across
the value chain. Its raw materials handled are wool, polyester. Fabrics made from the fibers are
worsted suiting, Premium suiting. Company has manufacturing facilities in India and overseas
like Vapi, Thane, Nasik, Chindwara, Ratnagiri to name few in India and overseas location of
Indonesia, Romania, Belgium, Portugal and United States of America.
Vapi Plant
Raymond has increased its worsted suiting capacity by 14 million meters, as part of the second
developmental phase of the Vapi plant.
Modeled to meet international standards, the Vapi plant has been set up on 112 acres of lush
green land with Hi-tech machinery such as warping equipment from Switzerland, weaving
machines from Belgium, finishing machines, automatic drawing-in and other machines from
Italy.
Site of Vapi Plant is spread across 112.61 acre land with 94.43 acres of land developed as
industrial area and 18.18 acres of land as residential area.
Location Advantage
Vapi plant is situated in Gujarat a state known for its good governance. The plant is connected
with the market as it is situated on NH no.8 and near to industrial Hub. Water requirement of the
plant is met with the river which flows through this plant location Location has a facility of Ware
House, Folding department, Process & Finishing Plant, Weaving plant, Boiler House with water
treatment plant and raw water tank, Effluent treatment plant and overhead tank.
Location is well connected by Rail & Road and has a Proximity to Mumbai and Thane.
Company has accessibility of skilled manpower who are local residence. There is continuous
availability of water making plant location self-sufficient in its use of water. Company has access
to urbanized and literate people and operates in Multi- culture community with communal
harmony.

Process Flow U Shaped Plant


















Support Function
Quality Assurance, Human resource, Information Technology, Accounting, Design

Plant Workforce
Human resource department is devoted to providing effective policies, procedures, and people-
friendly guidelines and support within companies. Following types of person are employed/
engaged at site:
Wool Scouring
Grey Combing
and Convertor
Dyeing
Weaving and
Mending
Spinning and
Yarn
Re combing
Finishing
Folding
Warehouse
Management staff, Workmen, Fixed period employees, Contract labors, Job contract and Labor
contract. Company has come up with the rule of weekly shift rotation where one day is givn to
an employee as a day of rest so that when he/she start with the new shift timing they are fresh
and energetic to compete the work assigned to them.
This has helped the company in a way that there are no group formation at the work place and no
favoritism chances among the supervisor and the sub ordinates. Work force is distributed as 11
workmen in dyeing, four in ring frame per operator in spinning and 17 in TFO.

Production Capacity
Name of the Department Capacity
Scouring 14000 kg
Grey Combing 7000 kg
Convertor 7000 kg
Dyeing 14000 kg
Recombing 14000 kg
Spinning 7500 kg
Weaving 28000 mtrs
Finishing 65000 mtrs
Folding 65000 mtrs
Warehouse 150000 mtrs

Scouring
It is a process of removing grease and other impurities with hot water, soda ash and detergent. It
is a chemical process carried out in a series of bowls where the wool is washed thoroughly.
The impurities present in wool are
Natural impurities oil, fats, secreted by sebaceous glands of animal skin (wool fat)
Acquired impurities- sand, dust, and vegetable matter.
Applied impurities- raw wool contents 24 to 25 % of impurities
Wool Scouring:
Capacity of the machine is to feed 950 kg of wool per hr.
Clean wool yield: 60 to 65% that depends up on wool quality.


Grey Combing
Opening of individual fibers
Elimination of impurities (80-95%)
Elimination of dust from the materials.
Disentanglement of neps.
Elimination of short fiber.
Fiber blending, orientation & sliver formation

GILLING
Parallelisation of fibers.
Reduction in weight per unit length of sliver.
Improving uniformity of sliver material by using multiple passages.
To prepare a sliver of required wrapping for further processing
To lay the sliver into can.
TYPES OF GILL BOXES
Open gill box has a single set of fallers.
Intersecting gill box has multiple sets of fallers.
Rotary gill box has 6 rollers (3 / 3) each having spiked rings.
Line C is for Blending Recombing Gilling.
DEFECTS
The defects in gilling are as follows:
Inadequate pressure on roller
Broken pins or improper density
Improper feelers and improper gilling.
Production 180-240 Kgs/hr

COMBING
Combing is a process followed after the gilling in the grey scouring section for the following
reasons,
To remove short fibers from the material
To remove all vegetable (foreign) matter
To straighten and parallelise the fiber
To remove the neps and
To lay the sliver into cans.


DYEING
DYEING: ( Bellini )
TOP DYEING
Top dyeing is carried out after the first round gilling and combing operations are over for the
sample. In top dyeing at first, sample dyeing is done in which 5 kg of material is dyed in the
laboratory and then after increasing proportions of the chemicals dyes entire bulk required for
dyeing.
Dyes used for wool are modified metal complex, 1:2 Metal Complex, acid milling dyes,chrome
dyes. PET is always dyed with disperse dyes.

GENERAL INFORMATION
Capacity Of Machine Minimum 5Kgs And Maximum 400Kgs
Temperature (Oc) 98 For Wool And 135 For Polyester
Material To Liquor Ratio 1: 20
Time Required
Light Shade - Wool-3 Hr, Poly-4 Hr
Medium Shade - Wool-4 Hr, Poly-5 Hr
Dark Shade -Wool- 5hr, Poly-6 Hr
Extra Dark Shade- Wool- 6 Hr, Poly-7hr
Each dyeing machine is connected with a microprocessor in which various dyeing programmes
are fed as per the material and shade.

RECOMBING
Main function of this process is to proper blending of polyester & wool according to given
proportion & at the same time maintaining the shade by proper mixing of component,
General processes:
55% Poly & 45% wool
65% Poly & 35% wool
38 % wool & 62 % wool
These are the commonly used blends. According to blend dept decides & calculate feeding of
poly & wool.

SPINNING
TOP STORAGE
When the tops coming from combing dept they are stored for conditioning in the trolley.
The conditionings room is enclosed one and humidifiers are installed for conditioning of tops.
The conditioning time is around 24 hrs. After conditioning material is taken for spinning process.

ROVING FRAME
The main objectives of the roving frame are as follows
Attenuation of material
Preparation of suitable package for ring frame.

RING FRAME
The rubbing and roving frame bobbins are brought to ring frame dept. the roving is converted
into yarn by drafting and twisting.
The objectives of the ring frame are as follows
Attenuation and
Twisting and winding on the bobbin.

Factors to be considered in promoting good spinning are as follows
Count of yarn
Position of spindle rail
Correct type travelers and
Satisfactory spindle speed.

WEAVING
SECTIONAL WARPING
OBJECTIVE
To produce weavers beam.
To wind the warp end with equal tension on each and every end.
To produce different colour patterns.
To produce a compact beam (without valleys and ridges).
Sectional warping is done when one needs to produce some design i.e. beam contain some
different colours of yarn then sectional warping is used. In sectional warping, the warp threads
are wound on the warping drum sectionally. After winding on drum it is then taken on weavers
beam.

MENDING
OBJECTIVE OF MENDING
To remove mend able spinning & weaving the defects from the fabric like neps , slubs , Missing
end, loose pick etc
After the mending fabric is delivered to Finishing

FINISHING
Finishing department in Raymond is divided into 3 sections viz.
Grey House,
Wet Finish
Dry Finish
GREY HOUSE
This section is called grey house because all the grey material from the weaving department
after perching and mending is being sent to grey house. It includes grey scouring,heat setting and
singeing.

WET FINISH
This section is known as wet finish section because all the treatments that are carried out on the
material are in wet form that includes rescouring and chemical treatment.
DRY FINISH
This section is called the dry finish section as here the fabric is treated in dry form throughout.
Only mechanical operations are rendered to the fabric in order to enhance its look shine and feel.
This treatment is generally under the influence of pressure and steam

FOLDING
In this department checking of the fabric, cutting and packing take place.
Finish of the fabric approved as per the approved hanger from the product department Shade
checking is done as per the booking hanger
There are two markets
Domestic :- Civil, Exclusive and Stock Lot
Export , RAL, RMG & Institutional
CIVIL
Visual inspection
5 TYPES OF GRADING
1. Good, 2. Second A, 3. Second B, 4. Second C, 5. Second D.