Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
NATIONAL INSTITUTE OF
FASHION TECHNOLOGY,
MUMBAI
Acknowledgement
We would also like to thank NIFT, Mumbai for giving us this opportunity and facilitating our
internship.
We would like to thank BSL, Bhilwara unit for giving us the opportunity to undergo training in
the textile department and for extending their support towards us all throughout our
internship.
It was a great learning experience throughout to see one of the most well planned and
advanced textile units. We take the opportunity to thank all the people who guided us through
the entire process and made our training a success by sharing their knowledge.
We are grateful to our College mentor Mrs. Kavita Pathare, for guiding us at every stage and
making this project a success.
We would like to thank Mr. R.d. Jat, Manager H.R. and Admin at BSL, Bhilwara, without whose
support and guidance the internship couldn’t have been completed satisfactorily.
Amandeep Singh
Rishi Raj
Sheetal Choudhary
B.F.Tech(AP) - V
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4
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TABLE OF CONTENTS:
2. OBJECTIVE 8
3. COMPANY PROFILE 9
4. LEARNING 10-23
APPENDIX
1. ORGANIZATIONAL BREAKDOWN 24
2. SPINNING 24-36
3. WEAVING 37-48
4. PROCESSING 49-58
5. MARKETING 58-60
6. EXPORT DEPARTMENT 61
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INTRODUCTION
The journey of the LNJ Bhilwara Group began in 1961 when the Group founder, L. N.
Jhunjhunwala established a textile mill in Bhilwara, Rajasthan.
Today that single textile mill has expanded into several textile mills; the Group has diversified
strategically and stands proud as a multi-product and service conglomerate. Industry pioneers in
many cases, we have also established ourselves one of the top 50 Indian business groups.
The marriage of traditional values and foresight has combined advancement while retaining our
core. Hence, while expanding our original business of yarn, we have moved into manufacturing
fabric, technical textiles, automotive fabric, knitted and ready-to-wear garments and now denim.
Opportunity is the window to the future and we are looking out of it. We have diversified into
areas that few players have ventured into... Graphite Electrodes, which has been forward-
integrated into sponge iron and steel billets business is one such example. We also have the
largest single site graphite electrode manufacturing plant in Asia.
Self-reliance is our mantra. The success of our first hydro captive power plant led us to set up
India's first merchant hydro power plant. Today, the group's power business is flourishing with
five projects already under its belt and is well on track towards producing 1500 / 2000 mw by
2012. Our in-house power consultancy firm consolidates our position in this segment.
Integrating the Group with the times and aligning with market forces has always been a keystone
of our strategy. Today, a group company features among the top ten BPOs in the Healthcare
sector. In addition, our IT support company is making strides in a technology-intensive market
and we are in the process of consolidating our interests in this sector.
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OBJECTIVE
The textile internship was carried out to develop a clear understanding about the following:
Flow process sequence and Technical details on machine particulars of weaving, dyeing,
printing, finishing, laboratory etc.
Particulars of raw material, intermediate products and final product, process details,
product quality parameters.
Particulars of the manufacturing environment.
Human resource management.
Productivity analysis for various processes.
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COMPANY PROFILE:
BSL LTD. Ltd., established in 1971 at Bhilwara, Rajasthan has emerged as a strong global player
producing over 18 million meters of fabric every year. BSL LTD. is equipped with state-of-the-art
technology. Right from raw material sourcing to product finishing, meticulous attention is paid
to detail at every stage of production. The emphasis is to achieve shorter lead times and
greater efficiency by following the proven processes of integrated yarn preparation, spinning,
weaving and finishing.
The Dawn
In the days when the idea of manufacturing poly-viscose suitings was a unique concept in India,
the second member of the LNJ Bhilwara Group, BSL LTD. was born in the desert state of
Rajasthan. The year was 1971 and the town where this happened was Bhilwara.
Over the years, with the belief that there are no shortcuts to excellence, at BSLLTD. BSL has
moved from strength to strength.
Experience
Product profile covers material ranging from wool, wool-blended and premium lightweight
fabrics, to wool modal, Trevira wool and other specialized fabrics blended with Lycra, Silk,
Linen, Tencel etc.
Rewards
BSL’s commitment to quality through technology and human ingenuity, has earned BSL
numerous laurels and awards like ISO 9002 quality certification besides the National Certificate
of Merit for outstanding export performance.
Learning
1. Vortex yarn has a two-part structure: a core surrounded by wrapper fibres. The number of
wrapper fibres compared to the fibre core is higher compared to the air jet spinning. During
yarn formation, the leading ends of the fibers are directed towards the yarn core and the
trailing ends wrap around the core fibres.
Less shrinkage of fabric: Due to structural difference the shrinkage problem is very less
in the fabric of vortex yarn.
Better evenness of fabric: In the VORTEX yarn after drafting, the fibers passes through
the air, through the jet nozzle, the most of the short fibers wrapped around the parallel
long fibers, this results in even yarn & ultimately the even fabric.
Better life of fabric: VORTEX yarn have high degree of resistance for pilling, so can bear
much more number of washings with out deteriorating the fabric quality & life.
Sizing: The even and deeply penetrated sizing, because of better absorption property,
results in better efficiency at loom and less consumption of sizing material also. The low
hairiness surface of VORTEX yarn also results in better loom shedding, ultimately the
less breakages and the better efficiency, even with the slightly low strength.
Stitching: As the VORTEX yarn have less spirality problem and good resistance against
deformation, which make it ideal for stitching of fabric.
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http://www.muratec-vortex.com/vortex01.html
Plain selvedges
Tape selvedges: Tape selvedges are made of heavier yarns or ply yarns, which provide
greater strength.
Fused selvedges: These selvedges are made on fabrics of thermoplastic fibres, such as
polypropylene, nylon, etc., by pressing a hot mechanical element on the edges of the
fabric. The fibres melt and fuse together, sealing the edges.
Leno selvedges: The leno selvedges are obtained by binding the wefts with strong
additional threads working in leno or gauze weave and by eliminating through cutting
the protruding weft ends. Half cross leno weave fabrics have excellent shear resistance.
Tucked-in selvedges: In tucked-in selvedge, the fringed edges of the weft yarns are
woven back into the body of the fabric, the weft density is doubled in the selvedge area.
Staublis SAFIR S30 automatic drawing-in machine is a drawing-in machine that travels along the
stationary warp beam as it draws the filament yarn into the healds and reed.
High drawing-in rates. The drawing-in capability exceeds 2,00,000 ends per 24 hours.
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Filament warps with or without lease and with a warp density exceeding 100 yarns per
cm can be drawn easily.
4.Warp Stop-Motions
Warp stop-motion stops the loom in the event of an end break. The system is activated by the
lightweight metallic drop wires which have profiled shape. The large slot at the top is for the
movement of the reciprocating bars which are used in both mechanical and electrical warp
stop-motions.
In case of mechanical warp stop-motion , one reciprocating bar moves between two
stationary bars. The bars have profiles like step waves. The sideways movement of the
center bar is equal to the width of a step. In case of an end break, the drop wire will lose
support from the tight yarn and will fall due to gravity. If it falls to the lowest possible
height, then the reciprocating movement of the center bar will be affected and the loom
is stopped.
In case of electrical stop-motion, the drop wire acts as an element that makes or breaks
an electrical circuit. In case of warp break, the drop wire will complete an electrical
circuit and activate a solenoid. The solenoid will attract a bar which will be hit by the
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knock-off lever.
5. Melange Yarn:
Melange yarn is a blend of different colored fibers to develop various shades in the yarn.
Different in ratio of fibers in the blend alters the uniqueness of spun melange yarn.
Blended Mélange Yarn: yarn in which different fibers are mixed/blended together in a
certain fixed ratio for instance PC (Polyester: Cotton blend) 50:50, PV (Polyester
:Viscose) 80:20, CV(Cotton :Viscose) 60:40.
Non‐Blended Mélange Yarn: Yarn in which there are no different fibers blended
together, but different colored fibers of same type are used to make the yarn e.g. 100%
cotton dyed yarn.
Environmental: Dyeing fibre before spinning, thus can keep its energy saving, emission
reduction and environmental protection.
Fashion: Melange yarn can present multiple colours on one single yarn, which gives it
rich colours, slenderness and tenderness. Textile made of melange yarn has a certain
ambiguous cyclical effect.
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Shade variation
Melange yarn is widely used in warp and weft knitting machines, various V-bed knitting
machines, and winding machines, etc. Melange yarn is applicable to underwear textile, casual
wear, sportswear, shirts, business suites, socks and all sports of cloth products, as well as bed
lines, towels, decorative fabrics and other home fabrics products.
6..Carding section:
Carding is the one of the most important process in spun yarn manufacturing, because it
determine the quality of yarn. This is the process, by which fiber are prepared to manufacture a
yarn. In this process, fibers are opened at almost single, removal of dust, trash, neps and short
fiber to produce a continuous strand of fiber called sliver. Carding machine is called mother or
heart of spinning, because it prepares the fiber in such a way, which is ready to manufacture
yarn because disentanglement, cleaning and intermixing of fiber are happened here.
Objects of carding:
Carding machine mainly consists of feeding unit, taker-in, cylinder, doffer and a set of revolving
flat-bar. The surface of taker-in, cylinder, doffer and flats are clothed with pin or wire.
The product of carding machine is called sliver. Sliver is a thick untwisted continuous rope of
fibers, which is uniform in weight per unit length and suitable for subsequent process. The
English count of card sliver is 0.1-0.14
Recent development
Metal detector
Auto leveling
Continuous suction
Tensioning Device:
Tension is applied on
yarn on the basis of its
strength. Weight
washers of different
weights are there.
8.Weft Mixing:
When a uni-color yarn fed from a single package, more or less apparent weft barriness
are produced on fabric surface.
This is due to the variation in yarn count, colour, tension or weft density.
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In uni-color weaving, filling is supplied from at least two or more packages for the
production of some plain fabrics.
The individual picks are regularly alternated.
This is called weft mixing.
9.Weaver’s Knot:
10.Warping calculations:
Or,
Weight of warp in pound × count × 840
=……………………………………………………….. (Yds)
Number of ends
Or,
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Or,
Length of warp in yards × number of ends
=…………………………………………………………
Count of yarn
Or,
Count × weight in pounds
= …………………………………………
Length of warp in hanks
Or,
Total length of yarn on the beam in yds
=……………………………………………………
840× weight in lbs
Solution:
Here,
Yarn count= 40s,
Length of yarn in yds= 14000,
Weight of yarn in pounds= (242-62) =180 pounds,
No. of ends in warp=?
So,
Number of ends in the warp,
Count × weight in pounds × 840
=…………………………………………
Length of warp in yds
40×180×840
=………………………
14000
=432
Example-02:
Calculate the beam count of the yarn on a set of 6 slasher beams, each of which contains 525
ends of 120000 yds at a weight of warp on back beams is 12000 pounds.
Solution:
Here,
Length of warp in yds= 120000,
Weight in pounds= 12000,
Number of ends= (525×6)= 3150,
So,
Beam count,
Length of warp in yds × no. of ends
=…………………………………………………
840× weight in pounds
120000×3150
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=………………………….
840×12000
= 37.5s
11.FABRIC COST
cost of a fabric depends on:
At any given instance lets assume the basic costing of Shirting fabirc.
= 2.7456 kgs
= Total mtrs x reed space x picks per inch x wastage % x denier of weft/ 9000000
= 2.376
Therefore
= 2.7456 + 2.376
= 5.1216 kgs for 100 mtrs
= (2.7456 x 5 ) + ( 2.376 x 7 )
= 13.728 + 16.632
= (0.3036 + 0.30 )
= 0.6036 + 30%
Weaving Calculation for weaving looms differ from different types of machines .But the Basic
calculation remains the same .
Factors which effect the production are only two main things .
2) Weaving Efficiency .
RPM means that for every revolution of the motor one pick inserted .
60 signifies the conversion factor of hrs to minutes .
= 600 x 24 x 60
= 864000 picks
Following of Six sigma: The company uses six sigma strategy to increase the production.
Six sigma is basically a set of techniques and tools for process improvement. It seek to
improve the quality of the output of a process by identifying and removing the causes of
defects and minimising variability in manufacturing and business processes.
Employee oriented: BSL is totally employee oriented and has a strong employee union.
Any demand if raised by a minimum of 30% of workers is considered serious.
Refreshment drink for employees: Working in such high temperature is not easy, the
company gives a natural refreshment drink made of camphor, clove, and mint to
workers as a break to keep them calm and cool.
Working condition in processing unit is harsh. High temperature and high humidity, and
smell of chemicals and salt makes it quite difficult for the workers to work. Also there
was some solvents which spills.
Reservation in college for children of officers: As a perk to its officers, company has
reserved few seats in MLVTI college.
Working of design department: We learned how to check the weave and how the design
department works.
Spinning of lycra: Lycra yarns were being produced by core spinning and top spinning
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Applying wax at the time of auto-coner: Wax is applied to yarns to reduce their
fuzziness,
Drafting plan, to increase length per unit weight
Silk weaving
Marketing strategy: The does not advertise much as they focus only on their regular
customers. Majority products are exported.
Workers were only permitted to work in their particular section. They can enter only
after their retina scan was done.
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Appendix
Organisational Breakdown
FOR EXPORTS:
• Discussing of new Ideas for design and new products based on Market Survey
• Blanket Sampling
SPINNING
VISCOSE POLYESTER FIBRE BLENDER BLOW ROOM CARDING BREAKER DRAW FRAME
FINISHER DRAW FRAME SIMPLEX RING FRAME AUTOCONER ASSEMBLY WINDING
DOUBLING & WINDING CONDITIONING INSPECTION & PACKING.
RAW MATERIAL:
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Common raw materials used in synthetic spinning are polyester and viscose. They are received in
the form of bale in grey condition.
There are three godowns for raw material storage in spinning section:
BLENDING:
Different blend composition 65/35, 80/20, 60/40 of polyester viscose blends yarn.
Antistatic Finish:
Chemicals used:
Machinery used:
Feed lattice
Inclined lattice
Delivery roller
Evener roller
Creeper roller
Stripper roller
4 motors are used in the machine:
BLOW ROOM:
1. Opening
2. Cleaning
3. Dust removal
4. Lap formation
Variation:
Lap parameters:
Feed lattice
Creeper lattice
Incline lattice
Evener roll
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Cleaner roll
Steeper roll
Krishner beater
Cage
Shell lattice
Piano roller
Cleaner roll
Steeper roll
Clearance setting:
CARDING:
Licker in
Cylinder
Doffer
Feed roll
Calendar roll
Lap roll
Redirecting roll
Group roll
DRAW FRAMES:
Drawing is a two step process: 1. Breaker draw frame 2. Finisher draw frame.
1. Breaker Draw Frame – During this process 8 slivers produced by carding machine are
parallelized to produce one sliver.
Features of LDO/25
Production capacity for 30s count sliver ( at 85% efficiency ) – 765 kg sliver/shift.
1. Electrical creel stop motion: if broken sliver passes through the pair of drawing frame
the drawing frame will automatically stop.
2. Full can stop motion: if pre-set length of sliver is delivered in the can drawing frame will
automatically stop.
3. If the door of machine is opened while the machine is running the machine will
automatically stop.
4. Calendar roll lapping stop motion: in case of sliver lapping over the calendar roll the
machine will stop.
Features of LDO/6
Production capacity for 30s count ( at 85% efficiency ) – 1100 kg/shift/drawing frame
1. Electrical creel stop motion: if broken sliver passes through the pair of drawing frame
the drawing frame will automatically stop.
2. Full can stop motion: if pre-set length of sliver is delivered in the can drawing frame will
automatically stop.
3. If the door of machine is opened while the machine is running the machine will
automatically stop.
4. Calendar roll lapping stop motion: in case of sliver lapping over the calendar roll the
machine will stop.
The stop motion LDO/6 is similar to the LDO/25 the only difference being the LDO/6
starts automatically once the stoppage causing problem is sorted out.
It is done to give further strength and stability to the sliver. The drawn sliver from breaker
draw frame is again drawn. In this process the sliver drawn in the breaker draw frame further
used.
Machinery used:
Function of motors:
In the draw frame auto leveller is used to minimize the yarn tuft variation and it can be
carried out at the first passage or the second passage of the draw frame. The irregularity of the
card feed material is the most important cause for count variation and the other reasons are:
The main function of the auto levelling is to control the weight per unit length of the delivery
material. For this the material is maintained correctly and checked against a free sat level and
take correct action. The auto leveller regulates the hank. In draw frame auto leveller regulates
the feed roller speed as per required.
Electrical creel stop motion: if broken sliver passes through the pair of drawing frame
the drawing frame will automatically stop.
Full can stop motion: if pre-set length of sliver is delivered in the can drawing frame will
automatically stop.
If the door of machine is opened while the machine is running the machine will
automatically stop.
Calendar roll lapping stop motion: in case of sliver lapping over the calendar roll the
machine will stop.
Can change stop motion: After the can is filled and another vacant can is not available
the machine will stop for itself unless the empty can is made available.
SPEED FRAME:
Machine specification:
There are two types of machine.
Type 1.
Make LMW
Model LF 1400A
Year 1994
No. Of spindles 108
No. Of machine 1
Type 2.
Make LMW
Model LFS 1660
Year 2004/2005
No. Of spindles 120
No. Of machine 3
Production-
RING FRAME/SPINNING:
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Maximum draft is employed in the range of 12-14, while it is lower in ring frame, i.e. 6-7. The
amount of twist in the ring frame is very less, the insertion of twist in the roving will help to
with stand the strain, while it is winding and unwinding at the next process.
Make LMW
Model LR6/S
Drafting system 3 over 3
Top roll diameter 32.5 mm
Bottom roll diameter 30 mm
Pressure 20 kg
Motor pulley diameter 152 – 187 mm
Total spindle 480
AUTOCONER:
Objective:
To remove imperfection of spun yarn and make big package in the form of cone.
Technical details
Technical Specifications:
Machine sequence:
Autoconer is fed by magazine containing 6 reserve ring bobbins and one running ring
bobbin.
Automatic cutting and splicing of thick and thin places and restarting of the winding
Its efficiency is upto 95%.
CHEESE WINDING:
Objective:
To wind two or more threads from cone to cheese without inserting any twist.
Machine information:
PS Metler
Make PS Metler
Model F.M.K.S
Manufacturer Peas engineering pvt. Limited
No. Of machine 2
Machine sequence
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DOUBLING:
In doubling twist is imparted to yarn wound on cheese. There are two processes of doubling.
1. T.F.O – In this process twisting and winding on cones is done simultaneously to provide
knot free yarns.
Objective:
Machine specification:
1.
Make Prerna
Model PRN – 225
Manufacture Prerna textile industries
Year 1998
No. Of machines 3
No. Of cones 144
Production capacity – 161.20 kg/shift
Technical specification:
Count TPI
18s 12
30s 17
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40s 20
50s 20.5
Machine sequence:
2. Ring doubling – Here only twist is provided to the parallel wound yarns. These yarns are
the wound in cones at cone winding. At cone winding the yarn is cleared of doubling
defects.
PACKING:
In packing department the cones produced by Autoconer / T.F.O are checked & then
packed in bags. There are 5 checkers and a large number of packers for this purpose. The
defects, which are checked during packing, are:-
1. Mixing of cones
2. 3-Ply
3. High twist / Low twist
4. Contamination
5. Snarling
6. Winding defect (Ribbon formation)
The standard weight of cone is 2 kgs. Tolerance is± 50 gms. In a bag 32 cones are packed that
is the weight of packed bag is approximately 64 kgs. 8-9 tons cone are packed per day. This is
called loose packing.
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WEAVING
GENERAL PRODUCTION
PRODUCTION
MANAGER SUPRETENDENTS
INSPECTION
INSPECTION
SUPRETEDENTS
QUALITY
QUALITY
VICE PRESIDENT CONTROL
CONTROL
OFFICER
MENDING
MENDING
SUPRETENDENTD
Technical Manager
Production Manager
Maintenance Manager
Maintenance In charge/26 looms – 1
Supervisor/26 looms – 1
Feeder/26 looms – 1
Beam Gaiter/26 looms – 2
Weaver/26 looms – 5
Helper/26 looms – 2
Jacquard master – 1
Jacquard Feeder/shift – 1
Jacquard Helper/shift – 1
FLOW PROCESS
Raw material is stored at the raw material go-down. Polyester Viscose And Polyester Blended
Fabric: - Are created with yarn of finest blends of polyester viscose and polyester-cotton fibers
in the count range of 2/15 Ne to 2/60 Ne.
WINDING M/C
Manufacturer Spindles
WARPING SECTION
There are two models of machinery for the warping drum & beam.
MODEL A:
MODEL B:
Technical Specifications:
2. Model: A – 217
Warping creel:
Technical specifications:
Production information:
Time taken to transfer the warp yarns from drum to beam – 40 mins-1 hours
Sample wrapper
Technical specification:
Defect 1: High variation in tension within and between ends (slack ends).
Remedies: 1. make sure that the end has not come out of the tensioning device.
Defect 2: The surface of yarns, building on the beam, is not even and free, has ridges from one
selvedge to the other.
Cone -> Yarn Guide -> Disc Type Tensioner -> Yarn Guide -> Thread Guide(for thread stop
motion) -> Splitting Rod -> Guide Rod -> Lease Reed -> V-Reed -> Warping Drum -> Weaver’s
Beam(After Warping)
DRAWING-IN SECTION:
DRAWER: he decide the heald shaft and then the passes the ends through dents of reed and
healds wire.
Drop pins are entered after the total process of the entering of the ends through the
Number of rows of Drop pins is one more or less of no. of heald frames in the machine. i.e.
H.F. ± 1
Heald frame specifications:
WEAVING SECTION
Machineries used:
Accumulators:
Accumulator Setting:
Electronic head of Accumulator has one ON/OFF switch & 4 settings are there,
1. Setting of winding Speed by a set screw.
2. Intensity of photocell can be changed according to type of weft yarn Texture or spun.
3. Amount of yarn wound on winding head by altering the position of photocell by the help of
rotating screw arranged with Rack-Pinion system.
4. NT / RT setting.
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Various mechanisms:
PROJECTILE LOOM
RAPIER LOOMS
Picanol:
46
The machine handles practically all types of yarns: spun yarn, filament yarn, fancy
yarn etc.
In the weft the machine processes staple fibre yarns from Nm 0.5-160 and
continuous filament yarns from 5000-10.8 denier.
Weft density is between 0.83-181.5 picks/cm. Maximum weft insertion rate 1200
meter / min. and speed upto 400 rpm.
Can work for upto four different weft colours.
Nominal width 190-540 cm.
Machine design is extremely compact.
Projectile sensor: It is a metallic sensor situated at the receiving side and it senses that
projectile is reaching at correct angle or not.
Let – off sensor: P7100 provides electronic let off. If tension in warp sheet decreases the
sensor senses it by suitable arrangement and motor regulates warp sheet accordingly
Weft sensor: To sense the presence and absence of weft supply at receiving side.
Angle sensor: To stop the loom at correct angle at particular degree
Warp stop motion: Electrical warp stop motion work together with drop pin
attachments
INSPECTION
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Six automated fabric checking machines are used to check the fabric. Chalk is used to mark the
defects. Each machine can check 3000 to 4000 metres of fabric every day.
Grading of fabric on the basis of defect they contain are as follows:
0 -5 defects – A grade
6-12 defects – B grade
13 – 23 defects – C grade
24 and above defects – D grade
MENDING
PROCESSING
PERSONNEL
PERSONNEL GM (P & A)
MANAGER
GREY
FABRIC GM (FABRIC
PROCESSING PROCESSING)
OSPG
PW FINISHING DGM
MARKETING
STORES DY MANAGER
VICE
PRESIDENT PURCHASE ASST MANAGER
FIBRE DYEING GM
TOPS & FIBRE
DYEING MASTER
DYEING
CHEIF
ACCOUNTS
ACCOUNTANT
ASSST BUDGET
COMMERCIAL SR MANAGER COSTING
OFFICER
Its main objective is to store and warehousing of the fabric lot for dyeing and finishing processes.
Fabric lot is supplied along with the lot memo & quality instructions.
Fibre Dyed
Piece Dyed
50
Here fabric is stitched together to get the appropriate length of the fabric and passed for the next
processes.
Scouring
Machineries in uses:
Technical specification:
4. Steam pipes are located at both top and bottom of the chamber.
No. of machines – 2
Jigger
Technical specification:
5. Stem pipes are located at both top and bottom of the chamber.
No. of machines – 16
Jumbo Jigger
Technical specification:
1. They are the high capacity jigger machine and works on the same principle.
No. of machines: 3
1. The machine should be properly cleaned before loading the fabric in machine for
processing.
3. Care should be taken while using the chemicals and should be used according to the
specifications given by the supervisors.
Technical Specifications:
DYEING MACHINES:
At Bhilwara processors limited following two types of dyeing machines are used:
Machinery in use:
PH to be maintained – 4 to 5
The machine is started at 60 ͦ c and is allowed to work for half an hour, the temperature is
increased by certain amount to certain limit at regular interval of time.
Machinery in use:
STENTER MACHINE
HEAT SETTING
SINGEING MACHINE:
Specifications:
Four singeing positions, centring devices, slat rollers, counter rotating scroll rolls
Sequencing unit
Speed – 100 metre/ minute (can be maintained according the fabric requirement)
Model - PF – 2000
Manufacturer – TMT, Italy
Specifications:
3. Two beams have wrapper above them and one of them is vacant.
4. Exit with roll device.
5. Length of fabric rolled at once is 800 metres.
1 roll take half an hour for decatising out which the machine is placed in kier for 15 to 20 mins.
Other 10 minutes are for cooling. It complete the chemical finishes being given to the
fabric by baking the fabric using stem.
CALENDERING MACHINE:
Specifications:
Specifications:
1. No. Of bowls – 6
2. Speed of the machine – 25 to 30 meter per minute
3. Temperature of heating rollers – 15 0 ͦ c
DRYING RANGE:
Specifications:
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The fabric is passed through the soap solution in tank one which washes the fabric. Then it is
passed through a padding mangle which squeezes the water out of the fabric , after that fabric is
passed through 1st set of Teflon coated rollers where 75% of the drying takes place. After that
the fabric passes through the 2nd set of stainless steel roller where the fabric is completely dried
out and a certain level of shine also comes to the fabric.
PROCESS FLOW CHART FOR POLYESTER WOOL AND WOOL WORSTED FABRICS (FIBRE DYED)
Here the fibres, tops(slivers) & yarns are stored. Raw material is stored with its proper detail.
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Fibres (supplied
from spiinning raw
material section)
yarns (supplied
from spinning
section/exported)
DYEING ROOM:
Spring convertor:
Here the cones of yarns are converted into the spring (which is suitable for the carrier of yarns in
dyeing).
Fibre Dyeing
Tops Dyeing
Yarn dyeing.
Wool Scouring.
The machine has specific carriers for each of the above mentioned dyeing processes.
1 kg, 1.5 kg and 2kg carriers are used for fibre and tops dyeing depending upon the
requirement of the quantity to be dyed.
Tops are loaded in the carrier with the help of pressing machine and spindles while yarns and fibres
are loaded and compressed manually in the specified carrier. Then the carriers are placed into the
dyeing machine (with the help of electronic carriers – which hangs the carrier and carry it to the
vessel and place it into the vessel) and water is circulated in the dyeing chamber. The water is
57
heated with the help of steam coils provided at the bottom of the dyeing machine chamber. When
the temperature is raised to 60 ͦ c the dye is added in the chamber (along with acetic acid, leveller
and water softeners) and the temperature is gradually raised according to the specified
requirements. The ph of dye bath is maintained at 4.5-5 during the dyeing process.
Total time consumed for dyeing medium and light shades: 1.45 hours.
The dyed materials are unloaded, with the help of electronic controlled loading/ unloading device,
from the vessel. Then the dyed material goes for the drying.
Tumble Drier (hydro extractor) & Hot Air Drier for tops and yarns.
The dyed fibres/tops/yarns are packaged and sent to the concerned departments as per the
specified requirements.
Uniform dyeing
Reversible pump
Injector pump
DRIERS:
Advantages
58
For those applications that require uniform heating and precise temperature control RF
offers many advantages over conventional drying methods.
Energy efficient
Low maintenance
WOOL TOPS REBALLING & CENTRE PULL PRESSING SCOURING DYEING FINISHING
HYDRO EXTRACTION RF DRYING PACKING DISPATCH
MARKETING
Inspection Activities
1. Information of the Grey Fabric.
2. Information of the Finish fabric.
3. One piece of the random lot is taken and checked thoroughly.
4. Ensuring work instruction.
a) If accepted, sent to the Grading department.
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Grading
Dispatch
The department is concerned with the dispatch of the fabric to the consumers according to
their demands.
1. Finished fabric is received from the folding department.
2. The fabric is checked for details through the challans for details according to the
production instruction.
3. The goods are packed in cartons according to the packing instructions specified.
4. The details of the packed goods are submitted to the excise department for clearance.
5. The balance stock is kept in the racks and the details are entered in the stock reports.
6. The finished fabrics are dispatched.
EXPORT DEPARTMENT:
BSL Export Department deals with the sales in the foreign countries. There are five export officers
who deals with the agents or the customers directly for the export of the suitings and shirtings.
BSL exports its finished products in approximately 55 countries. The major regions in the world
where BSL exports are the Latin America ( Peru, Equador, Chile, etc), Middle East (Egypt, Saudi
Arabia), South Asia (Vietnam, Thailand, Indonesia) and Europe (Spain, Germany). It has been in the
export business since 1987-88.
The export officers travel in various exhibitions and fairs to identify the potential buyers and
agents. Tex World which are held in Paris, France twice a year( February and September ) is
considered to be the Mecca for exhibition for textiles.
The department need an irrevocable letter of credit for the order placement. In case of the risk,
e.g. Export in African Countries, BSL gets the deposit of the part of the money in advance. For the
new customers, BSL sends some sample for their approval. 75-90 days lead time is required for
the export of Fibre dyed fabric and 10 days lead time is required for the export of Piece dyed fabric.
Shipment is done from the Mumbai Office of BSL at Nariman Point. Two types of shipment is done-
Loose Load Container(LLC) and Full Load Container(FLC).
BSL has around 250 companies and retail buyers around the world for e.g. HAGER (U.S.A), JC
PENNY (U.S.A) and C&A (Germany).
The Export Department accounts for about 60% of the annual turnover of the company which is
around 250 crores.
62
BIBLIOGRAPHY
Special thanks to the team of BSL Ltd. Who were very cooperative with us.
http://www.bslltd.com/
http://textilelearner.blogspot.com/
https://www.google.co.in/search?biw=1536&bih=710&tbm=isch&sa=1&ei=Y-
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