SUMMER INDUSTRIAL TRAINNING

Duration: - 18th June to 17th July

AT

SANTEJ, AHMEDABAD
For
Practical fulfillment of the requirement of the degree of

B.Tech.

In Textile Technology

From

GOVT. COLLEGE OF ENGG. & TEXTILE TECHNOLOGY,

BERHAMPORE

WEST-BENGAL-742101
Submitted By:- Arna Chattopadhyay
Arpita Biswas
Raja Das

Guided by – MD ENTAJ SK. SIR

Submitted to –SK. HASMAT SIR

ABOUT ARVIND LTD

HISTORY OF ARVIND LIMITED

In the year 1930, world suffered a traumatic depression. Companies
across the globe began closing down. In UK and in India the textile industry in
particular was in trouble. At about this time, Mahatma Gandhi championed the
“Swadeshi Movement” and at his call, people from all over India began
boycotting fine and superfine foreign fabrics, which had so far been imported
from England. In the midst of this depression one family saw opportunity. The
Lalbhais reasoned that the demand for fine and superfine fabrics still existed.
And any Indian company that met this demand would surely prosper. The three
brothers, Kasturbhai, Narottambhai and Chimanbhai decided to put up a mill to
produce this superfine fabric. Next they looked around for state-of-the-art
machinery that could produce such high quality fabric. Their search ended in
England. The best technology of that time was acquired at a most attractive
price. And a company called Arvind Mills was born.

Arvind Mills started with a share capital of Rs 2,525,000 ($55,000) in the year
1931. With the aim of manufacturing the high-end superfine fabrics Arvind
invested in very sophisticated technology. With 52,560 ring spindles, 2552
doubling spindles and 1122 looms it was one of the few companies in those
days to start along with spinning and weaving facilities in addition to fullfledged
facilities for dyeing, bleaching, finishing and mercerizing. The sales in year 1934,
three years after establishment were Rs 45.76 lakhs and profits
were Rs 2.82 lakhs. Steadily producing high quality fabrics, year after year,
Arvind took its place amongst the foremost textile units in the country
HISTORY AND OPERATIONS
1931 - Arvind Mills Ltd. is incorporated with share capital Rs.2525000
($55000) in Ahmedabad. Products manufactured are dhoties, sarees, mulls,
dorias, crepes, shirtings, coatings, printed lawns & voiles cambrics, twills
gaberdine etc.
1987 - The Company took up a modernisationprogramme to triple the
production of denim cloth and to produce double yarn fabrics for exports.
The new product groups identified were the indigo dyed blue denim, high
quality two-ply fabrics for exports, and special products such as buttasarees,
full voils and dhoties.
1991 - Arvind reached 100 million meters of denim per year, becoming the
fourth largest producer of denim in the world.
1992 - The Company increased the production of denim cloth by 23,000 tons
per day by modernizing the plant located at Khatraj of Ankur Textiles.
1993 - The Company proposed to expand the denim manufacturing capacity
by 85, 00, 00 meters per annum. The Company also proposed to set up a new
composite mill for producing annually 120 lakh meters of high quality
shirting fabrics to be marketed in the domestic as well as international
markets.
1994 - The Company's operations were divided into 3 units viz., Textile
Division, telecom division and garments division.
1995 - The performance of textile division was significantly affected due to
an unprecedented rise in cost of cotton.
1996 Garment division launched ready to stitch jeans pack under the brand
`Ruf&Tuf‟

1997 - The marketing and distribution network of `Newport` brand was

strengthened and the launched `Flying Machine' and 'Ruggers` brand
were strengthened.
The Company reported a fire in the goods go down& folding packing
department in Naroda Road unit of the company.
In 1997, Arvind set up a state-of-the-art shirting, gabardine and knits
facility, the largest of its kind in India, at Santej, Ahmedabad.
with Arvind‟s concern for environment a most modern affluent
facility with zero affluent discharge capability was also established
Arvind Mills sets up the anti-piracy cell for the first time in India to curb
large scale counterfeiting of their highly successful brands Ruf&Tuf and
Newport jeans.
Arvind Mills adopts the franchisee system for the manufacture and
distribution of Ruf and Tuf jeans.
ArvindFashions, doubles its capacity in the state-of-the-art
Manufacturing facility in Bangalore to produce Lee jeans.
1997 was also the year when Arvind mills started facing serious troubles
financially
1998 - Arvind Mills emerges as the world's third largest manufacturer of
denim. Arvind Mills goes live with SAP R/3 ERP package in April 1998
in their new manufacturing unit.

1999 - Arvind Mills sets a two-month deadline for hiving off its garments
division into a separate company and sale of its real estate in Delhi.
2000 - CRISIL downgrades the debenture issues of Arvind, indicating
that the instruments were in default.
2001 - Arvind Mills defaults on a $125 million floating rate note issue
and puts forward a debt restructuring proposal that could significantly
reduce its debt burden and sharply improve its financial health.
Arvind Mills posts a net loss of Rs 44.59 corer for the quarter ended
September 30, 2001.
2003 - For the fourth quarter, Arvind Mills witnesses 280% growth in the
net profit
Arvind Mills Ltd is assigned a `P1+` rating by CRISIL, which indicates a
very strong rating for their commercial paper.
2004 - Company turns itself around showing remarkable improvement in
financial performance.
2005 - For the fourth quarter in a row, Arvind Mills has managed to post
a profit growth in excess of 80 per cent.
Arvind Mills decides to buy entire stake in Arvind Brands from ICICI
Ventures. Arvind Mills does not distribute dividends to its shareholders
Consistently.

ARVIND LIMITED PROFILE

Venture into the world of RENOVISION Search any dictionary and you
won‟t find the word. We had to coin it. It means a new way of looking at issues
Of seeing more than the obvious. It is our corporate philosophy. The time -
1931, The event - the Swedish Movement . The result - non availability of fine
and superfine fabric in the Indian market.

At this juncture, The Arvind Mills was set up with the pioneering effort of
the Lalbhai brothers. With the best of technology and business acumen Arvind
Mills became a true Indian multinational having chosen to invest strategically,
where demand was high and quality required was superlative.
Arvind Mills the flagship company of Rs. 20 billion ($ 498 million) Lalbhai
Group. Arvind Mills has set the pace for changing global customer demands for
textiles and has focused its attention on selected core products. Such a focus
has enabled the company to play a dominant role in the global textile arena.

With its presence across the textile value chain, the company endeavors
to be a one-stop shop for leading garment brands. Fore vision and Technology
has brought Arvind to be one of the top three producers of Denim in the
world, and on its way becoming the Global Textile Conglomerate. Arvind is
already making its presence felt in Shirting’s, Knits and Khakhis fabrics apart
from being all set to create ripples in the ready to wear Garments world over.

GROUP OVERVIEWS
The Lalbhai group, founded by the 3 Lalbhai brothers - Kasturbhai,
Narottambhai and Chimanbhai - in 1908, has grown to become one of India's
most diversified business houses, with a significant presence in the textiles,
ready-to-wear, chemicals and telecom industries in India.
Each company in the group, in its own way, pursues a single mission - to be the
benchmark in its' industry. To achieve this, it has been tied-up with a variety of
companies . all world leaders in their respective fields.

ARVIND FABRICS-:
ARVIND BRANDS-:
Arvind has single handily developed a multi-billion denim market in India. The
brands fostered by Arvind include,
Lee &Arrow for the super-premium segment,
Flying Machine &Excalibur for the premium segment,
Newport for the economy and Innovative ‘Ruf&Tuf’for the mass market.
The company had recently made a foray into children segment by introducing
Lee Youth, Ruggers Kids & Newport Kids. Similarly in tie-up with Cluett
Peabody.
10
BUSINESSES
Fabric
Denim
Shirting
Khakis
Knitwear
Voiles
Garment Exports
Shirts
Jeans
Arvind Brands (owned)
Flying Machine
Newport
Ruf&Tuf
Excalibur
Arvind Brands (licensed)
Arrow
Lee
Wrangler
Gant U.S.A.
Sansabelt
Izod
Cherokee
Technical Textile
Filtration Fabric
Belting Fabric
Canvas Fabric
Coating Substrate
Protective Clothing
Automotive Textile

ARVIND MILL TODAY

A ONE STOP SHOP FOR ALL COTTON FABRIC REQUIREMENTS
Arvind‟s product ranges spans the entire gamut of cotton fabrics Arvind
limited manufacture world class denim, high value shirting‟s, Bottom
weights (gabardines/chinos) and Knit fabrics.
Arvind limited existing relationship with global brands such as Marks &
Spencer, V.F Corporation, Calvin Klein, GAP, Benetton, Polo, Esprit,
Tommy Hilfiger, Hugo Boss & Liz Claiborne.
Arvind Limited present in 70 countries across the world.

As considered India‟s biggest textile house that has products tailored to fit
virtually every segment of the consumer market. The brands fostered by
Arvind include Lee & Arrow for the super-premium segment, Flying
Machine & Excalibur for the premium segment, Newport for the economy
and innovative „Ruff & Tuff‟ for the mass market. This is not all. Arvind
recently made a foray into children segment by introducing Lee Youth,
Ruggers Kids & Newport Kids.
Arvind well known for its global dominance, with an annual turnover of
$ 251 million FY 98 accounts for more than 75% of the total denim
manufactured in India. Arvind limited is the world‟s 3rd largest
manufacturer of denim and largest denim exporter and roll out 120 million
meter every year.
Arvind invests more than $130 million in technological innovation over last
five year alone, Arvind has taken a quantum lead over its rivals.
Arvind has 251 types of yarn in its stock.

Some of them are :

Anmol comp I-siro 103

Aml comp I-siro 103
Anmol slub MP1
Achal slub MP1
ACL Slub 2M48
AML Tencil M13
Achal Tencil M 138
ACL carded 2Pm37
ACL Spandex 70D 2PM34
AACL Spandex 70D 2PM49
Spandex 40D tencil
AML Lycra 20D 103
Vardhaman Spandex 70D A05
Mahima 24 RKM L 919
Ashoka Black
Nahar 24Rkm L04
ACL CBC 67/33 M7
Trident combed organic L268
Ambica Giza comp CHNN
Polyspun ganesh GR0002
AURO COTTON WOOL PW5 L45 I SIRO
Texrise
AML HT JA1
COMPANY PROCESS FLOW CHART :

RAW METRIAL

SPINNING

YARN DYEING PROCESS

PREPARATORY

WEAVING
WARPING SIZING
SINGEING

DESIZING

MERCERISING

STENTERING

CURING( USING RESIN)

SANFORIZING

BRUSHING

CSP-INSPECTION
YARN DYEING PROCESS FLOW CHART:

GREIGE YARN
PACKAGE

SOFT WINDING

SCOURING & BLEACHING

HOTWASH

COLDWASH

NEUTRALISATION

DYEING

HYDRO
EXTRACTION

RF DRYER

RE
WINDING
SOFT WINDING:

The soft package winding is the most important pre dying operation, which directly
affects the dyeing quality.
Soft winding is performed in order to produce a package with necessary porosity
for dye liquor to penetrate and uniform density.
Two types of package holders are generally used :
 Spring - The dye springs are most commonly used package holder, on which
the yarn is wound. It offers the advantages such as reusability, compressibility
and making a perfect column after pressing. Dye springs offers much lesser
resistance to the liquor flow through the packages. Due to high compression
possibility the dyeing machines can be loaded to a higher capacity. The density
of each package is 360 gm/cc (approx).
 Perforated Plastic Tube – This type of package holder is generally used for
lycra yarns and for double directional dye liquor flow through the packages.
There is greater wastage of yarns during dyeing because of lesser penetration
of dye liquor to the core of the PP tube. The density of each package is 380
gm/cc (approx).

Machines used – (SSM) : 23 Machines, No of heads: 48.

(PRECIFLEX):12, No of heads: 50.

(FASTFLEX):9, No of heads: 60.

BASIC DYEING CONCEPT :

DYE : DYE IS A COMPONENT WHICH CONTAIN A COLOUR BEARING GROUP NAMED

CHROMOPHORE & A COLOUR INTENCIFING GROUP NAMED AUXOCHROME.

AFFINITY : ATTRACTION BETWEEN TWO ITEMS.IT MEANS THE PREFARENTIAL

ATTRACTION OF THE DYE FOR THE FIBRE RATHER THAN FOR THE SOLUTION OF
THE DYE BATH.

SUBSTANTIVITY:IT IS AN ATTRACTION BETWEEN THE FIBRE AND THE DYE

UNDER DYEING CONDITION WHEREBY DYE IS SELECTIVELY EXTRACTED FROM A N
APPLICATION MEDIUM BY THE FIBRE.

EXHAUSTION: THE PROCESS, IT INDICATES THE AMOUNT OF DYE THAT HAS

MOVED FROM THE SOLUTION INTO THE FIBRE UNDER DYEING CONDITION.

M.L.R : RATIO OF THE WEIGHT OF THE FIBRE TO BE DYED AND THE TOTAL
VOLUME OF THE FIBRE.

SHADE PERCENTAGE: THE QUANTITY OF DYE TAKEN FOR A DYEING EXPRESSED

AS A PERCENTAGE OF THE DRY WEIGHT OF THE FIBRE TO BE DYED.

FIXATION:FORMATION OF THE FINAL BOND BETWEEN THE DYE AND FIBRE.

EXPRESSION:IT INDICATES THE PERCENTAGE INCREASE IN THE WEIGHT OF DRY

FIBRE AFTER PADDING.

LEVELLING AGENT: THEY ARE USED TO PRODUCE UNIFORM,EVEN DYEING ON

TEXTILE MSTERIALS.

ADSORPTION: DISTRIBUTION OF THE DYE STUFF ON TO THE SURFACE OF THE

FIBRE.

ABSORPTION: DISTRIBUTION OF LIQUOR CONTAINING IS DYE STUFF ON TO THE

WHOLE OF THE FIBRE THAT IS ON TO THE SURFACE AND INSIDE OF THE FIBRE
SURFACE.

DESORPTION: TRANSFER OF THE DYE STUFF FROM THE SURFACE OF THE FIBRE
INTO THE LIQUOR.

DIFFUSION:BY THIS PROCESS, DYE MOVE FROM A SURFACE OF THE FIBRE INTO
THE FIBRE ITSELF AND VISE VERSA.
 AUXILiARY NAME SUPPLIER
& FUNCTION
SL AUXILARY SUPLIER FUNCTION
NAME
1 LIZOL NUTRA VVM CHEM COMPANY NUTRALIZING
AGENT
2 MIRAZEN MIRACHEM INDUSTRY LEVELLING
MER AGENT
3 LENETOL CRODA PVT LTD WETTING AGENT
HPED
4 METAXIL CRODA PVT LTD SOAPING AGENT
AWS
5 SODIUM HYDRO TRANSPETS SILOX PVT LTD REDUCING
SULPHITE AGENT
6 SODA ASH GHCL LTD FIXING AGENT
7 ALKALI VEERAJ INTERNATIONAL LLP FIXING AGENT
SOLUTION
8 BIOCAT EPN GENESYS BIOCHEM PEROXIDE KILLER
9 LUBSHINE ROSSARY BIOTECH LTD SOFTNE
SOFT LQ R
10 HYDROGEN SAMATOR BLEACHING
PEROXIDE AGENT
11 SELSOFT 32 BRITACEL SOFTNE
R
12 LENETOL FFC CRODA PVT LTD DEFOAMER
13 GREEN ACID ROSSARY BIOTECH LTD NUTRALIZING
AGENT
MACHINES OBSERVED

 LABORATORY MACHINES
 VORTEX DYEING MACHINE
 TECNORAMA DOSE & DYE MACHINE
 YARDAGE PRODUCTION MACHINES
 THEN MACHINE
 THIES MACHINE
 FONGS MACHINE
 LABORATORY DYEING MACHINE
MAGNETIC LEVIATED VORTEX DYEING MACHINE
MODEL :HJ-8200 DAL
MAKE :HANG JIE XING
 Sample Weight - 50-200 gms.
 No of dyeing machines in lab – 2x 50g & 2x200g.
 No. of Dyeing Positions – 16 OR 8
 Material: Liquor Ratio - 1: 7
 Dyeing Temperature - 20° C -150° C
 Rate of heating - Max. 5° C/minute and can be controlled

 The circulation of liquor is achieved with the help of Magnetic
levitation and there are no pumps. Circulation can be from
inside-out or outside-in.
 Dye liquor circulation can be inside-out and outside-in and the
duration of each cyclecan be controlled and programmed.
 Conditions in the each dye pot can be individually programmed
separately through micro-processor control. This enables a
user to carry out dyeings with different dye classes under
different dyeing conditions and on different substrates in the
same bath and at the same time.
 Total dyeing programmes available are 100. This is applicable
to each dye pot separately or for the complete set of dye pots.

 Cooling Rate - 0-5° C/ minute
 Power Consumption - 7.2 KW single phase 200V / 60Hz
TECNORAMA

MODEL: DOSORAMA W-ALL

The DOSORAMA W-ALL is an automatic machine for the dispensing of

liquid products. If required, the machine can be equipped with an Automatic
Solutions Maker. The solution maker is able to automatize the process for
the preparation of dyestuff and chemical solution.It is also capable of
automatic loading and unloading of packages..

No of machines in lab: 2
New Tecnorama allows automatic loading and unloading.
Number of dye pots:24
Type: Multi-pipette.
Three main parts:
 Dye and auxiliary chemical bottles
 Robotic arm
 Dyeing pots

The machine software assesses the quantity of product to be drawn into

the pipette by calculating the ratio of the pipette volume to the density of
the product to be dispensed. Accordingly, the precision of the dispensing
operation depends on accurate information regarding the exact density of
the products at the moment of their dispensing.

Yardage machine:These machines are designed to dye a garment size package.The

sample is being come from laboratory and then its being dyed in this machine to get a

garment size yarn and then it is passed to the bulk machines.In Arvind,there are 12

yardage machines in old plant and 22 machines in new plant.the machines are:

 FONGS YARN DYEING MACHINE

 THIES YARN DYEING MACHINE

 THEN DYEING MACHINE

 Machines in yardage and their capacity:

Serial number Machine number Machine name Capacity

1 1 Then 1kg

2 2 Then 1kg

3 3 Then 1kg

4 4 Then 1kg

5 17 Then 1kg

6 19 Then 1kg

7 20 Then 1kg


8 5 Then 3kg

9 16 Then 3kg

10 6 Then 6kg

11 15 Then 6kg
12 18 Then 6kg
13 255 Thies 1kg
14 257 Thies 1kg
15 256 Thies 1kg

16 262 Thies 6kg

17 263 Thies 6kg
18 264 Thies 6kg
19 265 Thies 6kg
20 261 Thies 3kg
21 260 Thies 3kg
22 259 Thies 3kg
23 101 Fongs 1kg
24 102 Fongs 3kg
25 103 Fongs 3kg
26 104 Fongs 3kg
27 105 Fongs 3kg
28 106 Fongs 3kg
29 138 Fongs 6kg
30 139 Fongs 6kg
31 140 Fongs 6kg
32 107 Fongs 6kg
33 108 Fongs 6kg
34 109 Fongs 6kg
35 110 Fongs 6kg
36 111 Fongs 6kg
37 112 Fongs 6kg
38 113 Fongs 6kg
39 114 Fongs 6kg
40 141 Fongs 12kg
41 142 Fongs 12kg
42 143 Fongs 12kg
43 119 Fongs 12kg
44 120 Fongs 12kg

45 201 Thies 1kg

46 202 Thies 1kg
47 203 Thies 1kg
48 204 Thies 3kg
49 205 Thies 3kg
50 221 Thies 3kg
56 222 Thies 3kg
51 223 Thies 3kg
52 224 Thies 3kg
53 225 Thies 6kg
54 226 Thies 6kg
Mostly uses dyes

Reactive Desperse Vat

Sulphur Nomex

Reactive types

HE
• HE01=(0.1% - 0.5 %shades), HE02=(0.51-1)%, HE03(1-4)%,
• HE04=(4-8)%

ME
• ME01=(0.1-.05)%, ME02=(0.5-1)%, ME03=(1-3)%,ME04=(3-
6)%, ME05=(6-8)%
,

HE=(Monochloro dyes,dyeing temp is 80 deg c)

Me=(Heterocloro dyes ,dyeing temp is 60 deg c)

Disperse dye types

Disperse lt
• For light shade

Disperse dk
• For dark shade

Vat dye types

Upto 3% shades

• For light shades

shades between 3% to 8%

• For medium dark shades

above 8% shade

• For heavy dark shades

TYPES OF BOIL:

A boil

• For 0.5% to 8% shades and whitness index is 50 to 65

B boil

• For tensile,vicsose,modal,polyester, MEBLACK

C boil

• For 0.1% to 0.5% and whitness index is 65 to 75

 Recipe for HE01
Steps Chemicals Name Qty(G/L) call2=Hydrogen Peroxide
Lanapex s 0.75

Lenatol HPED 0.6 95 deg for 30 min

Lenatol GLAD 0.2 call2
Caustic
LYE(72*Tw) 4 8

Pre-Treatment Soda Ash 0 call1 Drained

Hydrogen H
Peroxide 4 w
Lizol Neutra 0.5 call1=Lanapex S,Lnatol HPED
Green Acid 0.5 Lenatol GLAD,Caustic LYE
Biocat EPN 0.8

Lanapex s 0.5
Miragen MER 0

Dyeing 60 deg for

Auxiliaries Despolube 0 10 min 80 deg for 20 min 8
Lenatol FFC 0 call5&call6 call5,call6&call7
Cibatex AB55 0.2 Back for salt
Glauber salt 15
Liq Alkali 3.25
Green Acid 0.5 95 deg for 1

Metaxil AWS 0.5 call10

After-treatment AB55 0.2 80 deg for 10 min call11
Cellsoft32 1.2 call9

Fixogen 0
 Recipe for
HE02
N
Chemi a Qty
cals m (G/
Steps Name e L)
Lanap 0.7
ex s 5
Lenato
l HPED 0.6
Lenato
l GLAD 0.1
Causti
c
LYE(72
*Tw) 2.2
Soda
Pre-Treatment Ash 0
Hyd
rog
en
Per
oxid
e 2
Lizo
l
Neu 0.2
tra 5
Gre
en
Aci 0.2
d 5
Bica
t
EPN 0.5
Lan
ape
xs 0.5
Mir
age
n
ME
R 0.5
Despolu
Dyeing Auxiliaries be ACA 0.5
Len
atol
FFC 0
Ciat
ex
AB
%% 0.2
Gla
ube
r
Salt 30
Liq
Alka
li 5
Gre
en
Aci
d 0.5
Metaxil
After-Treatment AWS 0.5
 AB5
5 0.2
Met
axil
AW
S 0.5
AB5
5 0.2
Cell
soft 1.2

Recipe for
HE03
Qty(
Steps Chemicals Name G/L)
Lanapex s 0.75
Lenatol
HPED 0.6
Lenatol
GLAD 0.1
Caustic
Pre- LYE(72*T
Treatment w) 2.2
soda ash 0
Hydrogen
Peroxide 2
Lizol
Neutra 0.25
Green
Acid 0.25
biocat
EPN 0.5
Lanapex s 0.5
Miragen
MER 0.5
Despolub
e 0
Dyeing Lenatol
Auxiliaries FFC 0.2
Cibatex
AB55 0.2
Glauber
salt 60
Liq alkali 5
 Green
Acid 0.5
After- Metaxil
treatment AWS 1
AB55 0.2
Mretaxil
AWS 1
AB55 0.2
Cellsoft32 1.2
o

..

Recipe for
HE04
Steps Chemicals Name Qty(G/L)
Lanapex s 0.75
Lenatol
HPED 0.6
Lenatol
GLAD 0.1
 Caustic
LYE(72*Tw) 2.2
Pre_Treatment Soda ash 0
Hydrogen
peroxide 2
Lizol
neutra 0.25
Green acid 0.25
Biocat EPN 0.5
Lanapex s 0.5
Miragen
MER 1
Dyeing
Auxiliaries Despolube 0.5
Lenatol FFC 0.2
Cibatex
AB55 0.2
Glauber
salt 80
Liq alkali 5
Green acid 0.5
Metaxil
AWS 1
AB55 0.2
After Metaxil
treatment AWS 1
AB55 0.2
Cellsoft32 1.2
Fixogen 0
 Recipe for ME01
Chemical
Steps Name Qty(G/L)
Lanapex s 0.75
Lenatol
HPED 0.6
Lenatol
GLAD 0.2
Caustic
LYE(72*Tw) 4
Pre-
Soda ash 0
Treatment
Hydrogen
peroxide 4
Lizol
neutra 0.5
Greeen
acid 0.25
Bioct EPN 0.8
Lanapex s 0.5
Miragen
MER 0
Despolube
ACA 0
Dyeing
Lenatol FFC 0
Auxiliary
Cibatex
AB55 0.2
Glauber
salt 20
Liq alkali 3.25
Greeen
acid 0.5
Metaxil
AWS 0.5
After- AB55 0.2
Treatment Metaxil
AWS 0
AB55 0
Cellsoft32 1.2
Fixogen 0
 Recipe
for ME02
Qty(G/
Steps Chenicals name L)
Lanapex S 0.75
Lenatol HPED 0.6
Lenatol GLAD 0.1
Caustic
LYE(72*TW) 2.2
Pre-
Treatment Soda Ash 0
Hydrogen Peroxi
peroxide de 2
Lizol Neutra 0.25
Green Acid 0.25
biocat EPN 0.5
Lanapex S 0.5
Miragen MER 0.5
Despolube 0.5
Dyeing
Auxiliary Lenatol FFc 0.2
Cibatex AB%% 0.2
Gluaber Salt 45
Liq Alkali 5
Green Acid 0.5
Metxil AWS 0.75
After-
Treatment AB55 0.2
Metxil AWS 0.75
AB55 0.2
Cellsoft 32 1.2
Fixogen 0
 Recipe for ME03
Qty(G/
Steps Chemicals Name L)
Lanapex s 0.75
Lenatol HPED 0.6
Lenatol GLAD 0.1
Caustic
Pre-Treatment LYE(72*Tw) 2.2
Soda ash 0
Hydrogen
peroxide 2
Lizol neutra 0.25
Green acid 0.25
Biocat EPN 0.5
Lanapex s 0.5
Miragen MER 1
Dyeing
Auxiliaries Despolube 0.5
Lenatol FFC 0.2
Cibatex AB55 0.2
Glauber salt 60
Liq alkali 4
Green acid 0.5
Metaxil AWS 1
After-
Treatment AB55 0.2
Metaxil AWS 1
AB55 0.2
Cellsoft32 1.2
Fixogen 1
 Recipe for ME04
chemicals Qty(G/
Steps Names L)
Lanapex s 0.75
Lenatol HPED 0.6
Lenatol GLAD 0.1
Caustic
LYE(72*Tw) 2.2
Pre- treatment Soda ash 0
Hydrogen
peroxide 2
Lizol neutra 0.25
Green acid 0.25
Biocat EPN 0.5
Lanapex s 0.5
Miragen MER 1
Despolube 0.5
Dyeing
Auxiliaries Lenatol FFC 0.2
Cibatex AB55 0.2
Glauber salt 70
Liquid alkali 5
Green acid 0.5
Metaxil AWS 0.75
after-
Treatment AB55 0.2
Metaxil AWS 0.75
AB55 0.2
Cellsoft32 1.2
Fixogen 1.2
 ……………………………………………………………………………
……………………………………………………………………………
…………………………………………………………
Recipe for ME05
Steps Chemicals Name Qty(G/L)
Lanapex s 0.75
Lenatol HPED 0.6
Lenatol GLAD 0.1
Caustic
Pre-Treatment LYE(72*Tw) 2.2
Soda ash 0
Hydrogen
peroxide 2
Lizol neutra 0.25
Green acid 0.25
Biocat EPN 0.5
Lanapex s 0.5
Miragen MER 1
Dyeing
Auxiliaries Despolube 0.5
Lenatol FFC 0.2
Cibatex AB55 0.2
Glauber salt 80
Liquid alkali 5
Green acid 0.5
Metaxil AWS 0.75
After-Treatment AB55 0.2
Metaxil AWS 0.75
AB55 0.2
Cellsoft32 1.2
Fixogen 1.2
 Recipe for DESPERSE LT
Steps Chemicals Name Qty(G/L)
Lufibrol MSD LIQ 0.7
KieralonIRZ LIQ 0.6
Prestogen NKC LIQ 0.15
Pre-Treatment Caustic LYE 2.2
Hydrogen Peroxide 2
Lufibrol 2UD IN LIQC 0.15
Green Acid 0.25
Bactosol Sap Liq 0.15
Lufibrol 2UD IN LIQC 0.3
Metaxil DADLP 0.5
Dyeing
Auxiliaries Cibatex AB45 1
Resist Salt 2
Metaxil Dan 1
Caustic LYE 2
After- Treatment Sodium Hydrosulphite 2
Green Acid 0.5

Recipe for DISPERSE DK

Steps Chemicals name Qty(G/L)
Lanapex s 0.75
Lenatol HPED 0.6
Pre-Treatment Lenatol GLAD 0.1
Caustic lye(72* Tw) 2.2
Hydrogen peroxide 2
Lizol neutra 0.25
Green acid 0.25
Biocat EPN 0.5
AB45 1
Dyeing
Auxiliaries DADLP 0.5
Setamol 0.5
After-Treatment Caustic 2
Hydro 2
 Recipe for NOMEX
Steps Chemicals Name Qty(G/L)
Soda ash 4
Pre-Treatment Lenatol HPED 1
Green acid 1
Citric acid 1.5
Dyeing
Auxiliaries Nomabid 31 2.5
Nomapol n 20
Sodium nitrate 7
After-Treatment Sodium nitrate 7
Sodium nitrate 6
Citric acid 1
 Recipe for VATUPTO3%
Steps Chemicals Name Qty(G/L)
Lufibrol msd liq 0.7
Kieralon liq 0.6
Pre-Treatment Prestogen nkc liq 0.1
Caustic lye 2
Hydrogen peroxide 2
Lanapex s 0.5
Dyeing Auxiliaries Lenatol ffc 0.5
Sodium nitrate 1
Metaxil dan 1
Caustic lye 13.99
Caustic lye 13.99
After -Treatment Sodium hydrosulphite 13.22
Albatex or 1.5
Hydrogen peroxide 2.5
Soda ash 1
Metaxil aws 1
Green acid 0.5
Cellsoft 32 1.2
 Recipe for HEMIG04
Steps Chemicals Names Qty(G/L)
Lanapex s 0.75
Lenatol HPED 0.6
Pre-Treatment Cenatol GLAD 0.1
Caustic soda LYE 2.2
Hydrogen pero peroxide 2
Lizol neutra 0.25
Green acid 0.25
Biocat EPN conc conc 0.5
Lanapex s 0.5
Miragen MER 1
Dyeing
Auxiliaris Cibatex AB55 0.2
Lenatol FFC 0.2
Despolube ACA 0.5
Glauber salt 80
Liquid alkali sol 5
Green acid 0.5
Cibatex AB55 0.2
After-
Treatment Metaxil AWS 0.75
Cibatex AB55 0.2
Metaxil AWS 0.75
Fixogen SCF 1
Celsoft 32 1.2
DYEING PROCESS FOR HE01 & 02

 IN LAB
°C 110
C FOR 20min
100

90

80

70

60
A
50

40

30

20
-5 5 15 25 35 45 min
55 65 75 85 95 105

C = SOAPING FOR 20min D = HOTWASH FOR 10min A& E = COLD WASH FOR 10min

A Dye
B Auxiliary Chemical

DYEING PROCESS FOR HE 03 & 04

 IN LAB
 °C
110
1
100
1 HOLD FOR 45min
90

80

70

60

50 Alkali
40
Drain
30

20 A B
0 10 20 30 40 50 60 70 80 90min 100 110 120 130 140 150 160 170

A Dye
B Auxiliary chemicals

DYEING PROCESS FOR ME 01 & 02

 IN LAB

°C
100

90

80

70
30' HOLD FOR 45min
60

50

40
Alkali
30
Drain
20
0A 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

min

A –Dye & Auxiliary chemicals

DYEING PROCESS FOR ME 03 & 04

 IN LAB

°C
100

90

80

70
HOLD FOR 45min
60

50

40
Alkali
30
Drain

20
0A 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

min

A Dye & AUXILIARY CHEMICALS

AFTER TREATMENT PROCESS FOR HE01 &HE02:

 IN LAB
°C 110
C FOR 20min
100

90

80

70

60
A
50

40

30

20
-5 5 15 25 35 45 min
55 65 75 85 95 105

C = SOAPING FOR 20min D = HOTWASH FOR 10min A& E = COLD WASH FOR 10min

AFTER TREATMENT PROCESS FOR HE03

 IN LAB

110
°C C C
100

90

80

70

60

50

40

30

20
0 10 20 30 40 50 60 70 80min 90 100 110 120 130 140 150

C = SOAPING FOR 20 min

A & D = HOTWASH FOR 10min
E = COLD WASH FOR 10min
AFTER TREATMENT CURVE FOR HE04

 IN LAB
110
°C
100 C C
90

80

70

60

50

40

30

20
0 10 20 30 40 50 60 70 80min 90 100 110 120 130 140 150

C = SOAPING FOR 20 min

D = HOTWASH FOR 10min
E = COLD WASH FOR 10min

AFTER TREATMENT CURVE FOR ME01 & ME02:

 IN LAB

110
°C
100 C FOR 20min
90

80

70

60

50

40

30

20
0 10 20 30 40 50 min 60 70 80 90 100

C = SOAPING FOR 20min

D = HOTWASH FOR 10min

E = COLDWASH FOR 5min

AFTER TREATMENT CURVE FOR ME03:
 IN LAB

110
°C C FOR C FOR
100 20min 20min
90

80

70

60

50

40

30

20
0 10 20 30 40 50 60 70 80min 90 100 110 120 130 140 150

C = SOAPING FOR 20min D = HOTWASH FOR 10min E= COLDWASH FOR 15min

AFTER TREATMENT PROCESS FOR ME04:

 IN LAB

110
°C C FOR C FOR
100 20min 20min
90

80

70

60

50

40

30

20
0 10 20 30 40 50 60 70 80min 90 100 110 120 130 140 150

C = SOAPING FOR 20min D = HOTWASH FOR 10min A & E= COLDWASH FOR 15MINS
HYDRO-EXTRACTION OF DYED YARN PACKAGES

Hydro extractors are machines which are used in the dyeing department. The wet materi
perforated metal, generally stainless steel. The internal drum rotates at high speed thus throw
extractor significantly reduces the energy required to dry any material. The machines used
removing upto 25% water.

R.F DRYER
After dyeing of the packages and beams they are passed through drying machines for fu
machines are used – Pressure Dryer and Radio Frequency (RF) Dryer. The average time tak
and 1-11/2 hrs (RF Dryer). In Pressure Dryer electromagnet generates electricity which further

Machines Used:

Pressure Dryer (Theis)- 3 machines(total)

RF Dryer (STALAM) - 2 machines

Belt speed=6.5
PROCESS FLOW IN CHEMICAL PROCESSING

SINGEING

DESIZEING
(UNMERCERISED
INJECTOR

MERCERIZATION

(IF NOT RESIN

STENTER
(IF RESIN FINISHED) FINISHED)

POLYMERISER

SANFORIZATION

BRUSHING
SINGEING & DESIZING
 MACHINE USED: SINGEING AND DESIZING MACHINE.
 MACHINE MAKE: OSTOFF SENGE, GERMANY.
 MACHINE MODEL: VJ-1994.
 MACHINE SPEED: 95-100m/min.
 FLAME INTENSITY: 13Mbar.
 FLAME TEMPERATURE: 1100’C.
 NIP PRESSURE:1.5bar.
 OBJECTIVE FOR SINGEING:REMOVAL OF
PROTRUDING FIBRES FROM FABRIC SURFACE.
 OBJECTIVE OF DESIZING: REMOVAL OF SIZE
MATERIAL FROM FABRIC.

RECIPE FOR DESIZEING

CHEMICAL USED FUNCTION CONCENTRATION

BIOGREENE DXTRA ENZYME 1.5
LENATOL ZD WETTING 5.0
AGENT
LENATOL DMCP SEQUESTERI 1.0
NG AGENT
LENATOL RK Liq TH 1.0

LENATOL FCP DEFOAMER 0.2

PROCESS FLOW OF SINGEING AND DESIZING PROCESS

BATCHING

UNWINDING

BRUSHING

GAS SINGEING

BRUSHING

INJECTOR
DESIZING LIQUOR
PADDING

BATCHING

WASHING
 INJECTOR
OBJECTIVE OF MACHINE: TO WASH-OFF DESIZING LIQUOR
FROM THE FABRIC AFTER DWELL PERIOD REQUIRED FOR
DESIZEING IS OVER.

MERCERIZATION
 MACHINE MAKE: BENNINGER, KYOTO.
 DWELL TIME: 35sec, 40sec.
 CONCENTRATION OF ALKALI IN PADDING LIQUOR:
250gpl
 OBJECTIVE OF MERCERIZATION: IMPROVING
LUSTRE, DIMENSIONAL STABILITY, DYE UPTAKE,
TENSILE STRENGTH AND ELASTICITY.

Stenter
 MACHINE MAKE: BRUCKNER (GERMANY)
 TYPE: POWER-PAD
 OBJECTIVE OF STENTER: TO REMOVE BOWING AND
SKEWNESS. FOR HEAT SETTING AND IMPARTING ANTI-
SHRINKAGE FINISH.

POLYMERISER
 MACHINE MAKE: MONFORTS
 MACHINE: KONTINUE FAERBEANLAGE
  MODEL: THERMEX KDC
 OBJECTIVE OF POLYMERISER: CURING AT HIGH
TEMPERATURE TO POLYMERISE THE RESIN AND
CROSSLINK THE MOLECULAR CHAINS FOLLOWED BY
WASHING AND SOAPING TO REMOVE THE UNFIXED
RESIN.
 RESIN FINISH IMPARTS CREASE RESISTANCE AND
CREASE RECOVERY PROPERTY, ANTI-SHRINKAGE
PROPERTY AND IMPROVES RESILIENCE, HANDLE AND
DRAPING QUALITIES.
 TEMPERATURE OF CURING: 120-150’C
 RELATIVE HUMIDITY: 22%

SANFORISER
 MACHINE MAKE:MONFORTS MONFORTEX.
 OBJECTIVE OF SANFORISER: TO IMPART ANTI
SHRINKAGE FINISH FOR PREVENTING NORMAL
DIMENSIONAL ALTERATION OF WARP AND WEFT.

BRUSHING
 MACHINE MAKE: LAFER SPA MACCHINE
TESSILI.
 MACHIHE MODEL: GSM190H2000.
 MACHINE NO.: 3187.
 NO. OF BRUSHING ROLLERS: 2 SET EACH
WITH 24 BRUSHING ROLLERS- 12 IN
CLOCKWISE AND 12 IN ANTICLOCKWISE
DIRECTION.
  OBJECTIVE OF BRUSHING: TO RAISE OR
CREATE A FIBROUS SURFACE WHICH
IMPROVES FABRIC APPEARANCE AND GIVES
THE FABRIC A SOFTER AND FULLER HANDLE.

PROJECT ON SHADE VARIATIONS

IN LAB:

YARN COUNT

40s

2/30s

50s

44s

50s

70s

32s
 2/80s

IN YARDAGE :
PRE-DYEING

M/C NO PH H2O2 HARDNESS

101 6.5 0 1
102 6 0 1
103 6.5 0 1
104 6.5 0 1
113 6 0 1.5
255 6 0 1

POST-
DYEING

PH DOSING TIME PROGRAM RECIPE NO

10.92 15mins HE03 D99231
10.92 15mins HE03 D8370
10.8 15mins ME01 D8373
11.5 15mins HE04 D8374A
10.82 15mins HE01 D9920
10.9 15mins HE03 D7362
PRE-DYEING
M/C NO PH H2O2 HARDNESS
258 6 0 1
260 6.5 0 1.5
264 6.5 0 1.5
203 5.5 0 2
201 6 0.5 1
223 5.5 0 1

POST-DYEING
PH DOSING TIME PROGRAM RECIPE NO
10.92 15mins HE03 D7363
11.5 15mins ME05 D8374
10.8 15mins HE01 D8917
11.02 15mins ME01 D8710
10.8 15mins HE01 D8740
11.1 15mins HE02 D8775

PRE-DYEING
M/C NO PH H2O2 HARDNESS
204 5.5 0.5 1
109 5.5 0 1
110 6 0 1
114 5.5 0 1.5
3 7.5 2 1
17 7.5 2 4
19 7.5 5 3
 POST-DYEING
PH DOSING TIME PROGRAM RECIPE NO
11.06 15mins HE04 D8685
10.92 15mins HE03 D9356
10.8 15mins ME01 D8857
10.84 15mins HE01 D8366
10.8 15mins ME01 D8406
10.42 15mins HE04 D8408
11.11 15mins HE04 D9246

CONCLUSION: