SUMMER INTERNSHIP REPORT

ON

SUBMITTED BY:

SHUBHAM KSHIRSAGAR,

G.R. NO. - 150501059,

RAJIV GANDHI INSTITUTE OF TECHNOLOGY,

MUMBAI UNIVERSITY.
 DECLARATION

I, Shubham Kshirsagar, hereby declare that the presented report titled “SUMMER
INTERNSHIP REPORT” is uniquely prepared by me after the completion of 2
weeks as an internee at Kriplon Synthetics Pvt Ltd in Tarapur M.I.D.C., Boisar,
Maharashtra 401504.
I also confirm that the information included in the report is for my academic
requirement and not for any other purpose.

____________________
SHUBHAM KSHIRSAGAR,

G.R. NO. - 150501059,

RAJIV GANDHI INSTITUTE OF TECHNOLOGY,

MUMBAI UNIVERSITY.
 ABSTRACT

From our childhood blanket to our wedding dress, and our favorite worn-out
jeans, fabric plays a major role not only in how we live but also how we feel. The
look, touch and even scent of a familiar piece of clothing can bring to mind a
first love, a cherished vacation memory or simply a sense of comfort.

We also use fabric to express ourselves. Even beyond the world of high fashion
and designer labels, many people even feel that putting together outfits is the
ultimate form of creative expression. We use different clothing styles, colors,
materials and textures to express mood, attitude and personality.

Fabric and clothing also play an important role in religious and social beliefs.
From the earliest recorded history, a person's clothes could give us an instant
glance into their socio-economic status. Where today we hold those designer tags
in highest regard, thousands of years ago, just the fact that one was able to afford
clothing at all was a sign of wealth. Today, many religious orders are readily
associated with certain types of fabric and clothes, from the bright yellow garb of
the Buddhist monk to the heavy black burkas worn by many Muslim females, to
the colorful hand-spun clothing associated with traditional African religions.

Above all, fabric serves a practical function. It protects us from cold and heat, the
rain and the bright sun. We use blankets to cover ourselves as we sleep and woven
rugs to cushion our steps as we walk.

With all of the contributions fabric makes to our everyday lives, many people
don't stop to think how fabric is created. The process of turning natural and
synthetic fibers into cloth is much more complicated than is commonly thought.

In these 2 weeks at Kriplon Synthetics Pvt Ltd, we observed and learned how the
fabric is processed (mechanical aspects) and transformed into the clothing which
we are familiar with.
 Acknowledgement

I am very thankful to Kriplon Synthetics Pvt Ltd for giving me the opportunity to
undertake my summer internship at their prestigious factory. It was a very good
learning experience for me. I am very grateful to every staff member of Kriplon
synthetics, for giving me their valuable time at the site and to explain me about
the ongoing processes.
 TABLE OF CONTENTS

SERIAL NO. NAME PAGE NO.

1 INTRODUCTION 6
2 OBJECTIVE 7
3 OBSERVATION 8
4 TEXTILE WET PROCESSING 9
5 PREPARATION 10
6 PRINTING 19
7 FINISHING 24
8 THERMOPACK AND STEAM BOILER 27
9 SKILLS ACQUIRED 28
10 CONCLUSION AND REFERENCES 29
 INTRODUCTION

Kriplon Synthetics Pvt. Ltd is one of the

leading exporter and manufacturer of diverse range of Suiting, Shirting, Cotton,
Synthetic, and Polyester Fabrics. Their market reach spans across continents from
the Middle and Far East to the Americas to Europe, Scandinavia, Australia, and
Africa. With the help of proficient staff and expert management personnel,
Kriplon is geared towards introducing revolutionary products in the market.
With the state of art facilities, Kriplon is able to customize the production as per
the requirements of the customer in line with global trends. Their monthly
production capacity exceeds 1-million-meter fabric of Suiting and Shirting. All
their products are tested by a host of technical experts to detect the flaws before
the goods are dispatched in the market. The team of quality control inspectors
observes a stringent process of quality checks, where the materials found to have
even slightest of manufacturing defects are immediately rejected.
Kriplon Synthetics Pvt. Ltd. is very well-equipped with all infrastructure
facilities, which enable it produce products as per international standards.
 OBJECTIVE
The objective of this Internship is as follows:
> To appreciate the significance of theoretical knowledge gained in college into
engineering practice.
> To explore and gain experience of the professional aspects and industrial
practices.
> To learn different machining processes used in manufacturing different types
of fabrics.
> To observe and learn working and maintenance of different machines used in
the manufacturing process.
> To observe and learn different methods and processes used for dyeing of cloth.
> To observe and learn different techniques used in printing different designs on
fabrics.
 OBSERVATION
At Kriplon Synthetics Pvt Ltd several observations were made by me during the
training period. The company has a great infrastructure and is well equipped with
modernized machinery necessary for manufacturing of high quality fabrics.

The company has several departments wherein different processes are been
carried out by using different machines in presence of skilled and efficient
workers.

The different departments include:

> Grey Department

> Dyeing Department

> Printing and Designing Department

> Checking and Packing Department

> Chemical Department

> Maintenance and Storage Department

 TEXTILE WET PROCESSING
Sequence of operations in wet processing is as follows –

Textile wet process is made up of three basic steps PREPARATION, PRINTING,

and FINISHING.
 PREPARATION
Preparation consists of entry of grey fabric, singeing and desizing, bleaching,
and mercerization.

Grey Fabric Roll opening machine -

Grey fabric inspection: The inspection and grading of fabric quality is one of
the important functions of Quality Control in the grey or finished state, the
grading of fabric is a difficult task, taking two primary considerations: as the
frequency of effects and the seriousness of defects. The grading has two primary
functions: First, to classify the fabrics according to standard qualities based on
the end-use and costumer demands and second, to supply information as to the
qualities actually being produced.
Singeing and Desizing:

Singeing and desizing form preliminary processes to which grey cloth is

processed are intended to remove cotton ends. Protruding from the surface of the
cloth and certain constituents of the sizing mixture applied to the warp yarns
before weaving.
The preliminary processes are intended to remove cotton ends before weaving.
Since spinning of yarn form short lengths of fibres essentially involves making a
bundle of fibres parallel to each other followed by drawing and twisting, the ends
of some of the fibres are likely to protrude from the surface of yarn, while those
of the bulk of the fibres may be considered as trapped inside the yarn.
When such yarn is used in weaving, these free fibre ends, along with very short
fibre lengths, protrude from the surface of the fabric, giving it a fuzzy appearance.
They destroy the smooth and the lustrous character of the fabric surface. Fabrics
like stain, sateen, poplin, handkerchief cloth etc. are valued for their smooth
appearance. Therefore, in most of the cases, the protruding fibres have to be
removed and this is done by a process called singeing.
Singeing process is as follows:
1. To produce a smooth surface finish on fabrics made from staple fibers first the
fabric surfaces are brushed lightly to raise the unwanted fiber ends.
2. Then the fabric is singed with or passed over heated copper plates or open gas
flames. The fiber ends burn off.
3. The fabric is moved very rapidly, and only the fiber ends are destroyed.
4. As soon as the fabric leaves the singeing area, it enters a water bath or desizing
bath. This stops any singeing afterglow or sparks that might damage the cloth.
Singeing of textile materials is necessary for the following reasons:
1. Cotton materials are valued for their smooth appearance. After the formation
of fabric, it has a fuzzy or hairy appearance due to projecting fibers, thus affecting
the luster and smoothness cotton is known for.
2. Unsigned fabrics are soiled easily
3. The protruding fibers obstruct the subsequent dyeing and printing process.
4. Goods which are to be mercerized are signed to maximize the luster.
5. In fabrics of polyester and cellulosic fiber blends singeing is the best method
to control pilling, sometimes double singeing is done to minimize the pilling.
SCOURING AND BLEACHING:
Scouring is the process by which all natural and adventitious impurities are
removed to produce hydrophilic and clean textile material. It is one of the
important process of wet processing. It is done also for increasing absorbency of
textile material.
Bleaching is chemical treatment employed for the removal of natural coloring
matter from the substrate. Main purpose of bleaching is to ensure a pure and
permanent basic white color fabric.
Both the processes are done on Jigger/Jet/Soft flow Jet/Maxi machines.
Depending on the type of fabric and its quantity, machine is being chosen. These
machines are also used for Dyeing purpose. The fabric (depends) is also dyed
after scouring and bleaching.

Jigger Maxi
Jet:

SOFTFLOW Jet:
Slitter Machine:

If fabric is processed in jet machine, it needs to be

transformed into open form from tubular form.
Slitter machine is used for tubular knit fabric to
make it in open form. In open form
fabric finishing line; slitter machine is used
after hydro-extractor, de-watering and drying
machine.

Slitting is a process that is applied for cutting the tubular fabric through the
intended break Wales line on lengthwise direction prior to stenter processing.
During slitting, it is required to be aware about the cutting line otherwise, fabric
faults can be occurred there.
Objectives of Slitting:
Following objectives are achieved by the slitting machine.

1. To open tube fabric according to specific needle mark.

2. To prepare the fabric for next stentering process.

Function of the Slitting Machine:

1. Used to remove excess water after pretreatment and dyeing.
2. To slit the tube fabric by the knife for opening of the fabric and ready for
stentering.
3. Delivered fabric in crease-free state.
4. Before squeezing balloon is formed with the help of compressed air passing
by a nozzle or air sprayer.
5. It can control the diameter of fabric and GSM and shrinkage by over feeding
mechanism.
MERCERIZATION:
The final step in the preparation is Mercerization of the fabric done using a
machine called Mercerizer.
The Mercerizer contains a chemical solution, including caustic soda (also called
lye), which is kept at moderately low temperatures. The mercerization process
increases the size of the pores on the fabric threads, making it easier for them to
accept color during the dyeing process. Without mercerization, bright, bold
fabrics would not be possible.
Mercerizing also gives cotton cloth increased tensile strength, greater absorptive
properties, and, usually, a high degree of luster, depending on the method used.
After mercerization the fabric is passed through a STENTER machine. This
machine stabilizes the width of the fabric, as the fabric is stretched between pins
on either side of the selvage and passes through a long-heated chamber
Objective of stenter A machine or apparatus for stretching or stentering fabrics.
The purpose of the stenter machine is to bringing the length and width to
predetermine dimensions and also for heat setting and it is used for applying
finishing chemicals and also shade variation is adjusted. The main function of the
stenter is to stretch the fabric widthwise and to recover the uniform width.
 PRINTING
After Stentering, fabric is ready for Printing. The fabric (if required) is dyed to
get uniform color using Jet/Jigger/Maxi/Soft-flow Jet machines depending on
type of fabric and its quantity. Usually polyester fabric is processed in Jet
machines. Printing gives permanent texture and design to the fabric.
Screen-printing is arguably the most versatile of all printing processes. It can be
used to print on a wide variety of substrates including paper, paperboard, plastics,
glass, metals, fabrics and many other materials including paper, plastic, glass,
metal, nylon and cotton. Some common products from the screen-printing
industry include posters, labels, decals, signage and all types of textiles and
electronic circuit boards. The advantage of screen-printing over other print
processes is that the press can print on substrates of any shape, thickness and size.
A significant characteristic of screen-printing is that a greater thickness of the ink
can be applied to the substrate than is possible with other printing techniques.
This allows for some very interesting effects that are not possible using other
printing methods. Because of the simplicity of the application process, a wider
range of inks and dyes are available for use in screen-printing than for use in any
other printing process.
Utilization of screen printing presses has begun to increase because production
rates have improved. This has been a result of the development of the automated
and rotary screen printing press, improved dryers, and U. V. curable ink. The
major chemicals used include emulsions, inks, and solvents, surfactants, caustics
and oxidizers used in screen reclamation. The inks used vary dramatically in their
formulations.

There are two types of print machines, ROTARY and FLATBED and each type
uses different screens.

Flat-screen and rotary-screen printing are both characterized by the fact that the
printing paste is transferred to the fabric through openings in specially designed
screens. The openings on each screen correspond to a pattern and when the
printing paste is forced through by means of a squeegee, the desired pattern is
reproduced on the fabric. A separate screen is made for each color in the pattern.
FLATBED screen print machine:
Flatbed-screen printing machines can be manual, semi-automatic or completely
automatic. One type of machine, which is still commonly found in printing
houses, can be described as follows. The fabric is first glued to a moving endless
belt. A stationary screen at the front of the machine, is lowered onto the area that
has to be printed and the printing paste is wiped with a squeegee. Afterwards the
belt, with the fabric glued on it, is advanced to the pattern-repeat point and the
screen is lowered again. The printed fabric moves forward step by step and passes
through a dryer. The machine prints only one color at a time. When the first color
is printed on the whole length of the fabric, the dried fabric is ready for the second
cycle and so on until the pattern is completed.
In other fully mechanized machines all the colors are printed at the same time. A
number of stationary screens (from 8 to 12, but some machines are equipped with
up to 24 different screens) are placed along the printing machine. The screens are
simultaneously lifted, while the textile, which is glued to a moving endless rubber
belt, is advanced to the pattern-repeat point. Then the screens are lowered again
and the paste is squeezed through the screens onto the fabric. The printed material
moves forward one frame at each application and as it leaves the last frame it is
finally dried and it is ready for fixation.
For flatbed printing the longer the machine the more colors you can print after
printing the fabric is taken up into a drying unit that will completely dry the fabric
prior to being folded and stored in a cart.

ROTARY screen print machine:

Rotary screen-printing is so named because it uses a cylindrical screen that rotates
in a fixed position rather than a flat screen that is raised and lowered over the
same print location. Rotary presses place the squeegee within the screen. These
machines are designed for roll-to-roll (web) printing on flexible materials ranging
from narrow web films to wide-format roll textiles.
This printing method combines the advantages of roller and flat screen printing
techniques. Rotary metal screens are lightweight in contrast to the heavy copper
rolls, and they cost lees. They give color depth that is similar to or as good as that
of flat screens. Prints of various types and intricate designs with shades of up to
twenty colors can be obtained with a high degree of accuracy and sharpness.
Rotaries operate continuously rather than starting and stopping as the flats do.
Production output is considerably higher than it is on flat screen machines.
 FINISHING
After the printing, printed fabric is ready for finishing process.
It consists of Steaming, calendaring, Decatising, sanforization.

Steaming:
steaming the reactive dyes fixes them onto the fabric unless you steam them the
colors will mostly wash away the high temperature steam causes the colors to
react with the cotton and become permanent. This is done using Steaming loop
machine.

After the steaming is completed the fabric is taken to washing machine the fabric
is run through several washing stations each station has a different water
temperature and chemical content as the fabric moves through the washing line
the temperature of the water increases and the amount of chemicals in the bath
decreases the fabric is dipped several times in each washing station. Washing
ensures that all excess dyes are removed and the fabric will meet color fastness
standards.
Finally, the fabric is dried on large heated metal rolls. This is done by calendaring,
decatising, and sanforization.
Dry decatising/decating: Improves luster, appearance, feel as well as preshrinks
the fabric. It may be applied to woven as well as knitted fabrics.
In dry decating, the fabric is passed together with a blanket around a perforated
cylinder. The moist heat causes the fibers to become wrinkle free.
Calendering: Calendering is a mechanical finishing process used on cloth where
fabric is folded in half and passed under rollers at high temperatures and
pressures. Calendering is used on fabrics such as moire to produce its watered
effect and also on cambric and some types of sateens.

Calendaring is a high-speed ironing process that primarily imparts lustre and is

usually the final treatment for the fabrics in the finishing sequence. The basic
principle of calendaring is to expose the cloth to the combined effect of moisture,
heat and pressure until the fabric acquires a very smooth and light reflecting
surface and gets a good lustre. The calendaring effect on the fabric is usually
temporary and disappears after first washing. Semi-permanent lustre is
sometimes achieved by padding fabric in a sparingly soluble polyvinyl acetate
emulsion before calendaring, where the solution acts as a binding agent. More
permanent finish can be obtained by treating fabric with a solution of crease
recovery reagent, followed by drying, calendaring and curing the fabric at about
150 ºC. The calendars are basically an assembly of heavy rolls, alternatively of
iron and paper or cotton that are normally mounted in vertical frames. The rolls
are bearing one on the other under a high pressure that is applied by compound
levers or hydraulic or pneumatic equipment.
Sanforizing/Zero-zero:
Sanforizing is a controlled compressive shrinkage process, which is applied on
woven fabric to achieve shrinkage before making the garments.
After sanforizing the residual shrinkage of woven fabric may be zero. In
sanforizing process shrinkage is achieve by passing the cotton fabric onto a
movable elastic felt blanket is released it assumes a shortened conditional. Thus,
the cotton fabric is forced to conform this compression.

After the finishing processes, the fabric is moved to packaging section where it is
packed and is ready for shipment.
 THERMOPACK AND STEAM BOILER
THERMOPACK/THERMAL OIL BOILER:
A thermal oil boiler fires through a helical coil and generates energy from the hot
products of combustion by heating the coil through radiation and convection. The
coil heats thermal oil or fluid that is pumped through the thermal oil boiler. The
thermal oil heats coils in various types of heat exchangers. Unlike a water or
steam boiler, this heating process does not heavily pressurize the system.
The heated Oil is utilized in stenter machine (as heat exchanger for heating the
fabric) and in boiler (to produce steam).
A thermal oil boiler is nearly always cheaper to operate and maintain than water
boilers. Unfortunately, due to the high pressure required to operate water and
steam boilers, they can become far more hazardous than thermal oil boilers.
Other noticeable advantages are the lack of corrosion, lime deposits and scale that
are common within heated water or steam boilers. This can raise the operating
costs of a water boiler considerably. You should also realize that thermal oil
boilers don’t require makeup water or efficiency draining steam traps.

STEAM BOILER:
It produces steam from water utilizing oil’s heat which is taken from
Thermopack. The steam produced is utilized in various machines within the
factory.
 SKILLS ACQUIRED
As an Intern I got an opportunity to learn and acquire various technical and Non-
technical Skills such as,

TECHNICAL SKILLS:

> Learnt the working of different machines used for manufacturing of fabrics.

> Learnt the different processes that a fabric undergoes before dyeing and
printing.

> Learnt dyeing and printing processes of fabric.

> Acquired knowledge about Thermopack Boiler and Steam Boiler and their uses
in generation of heat for different processes.

> Learnt Gas Cutting of metal.

> Learnt how maintenance and erection of machines takes place.

SOFT SKILLS:

> Learnt about Leadership and Teamwork required to do an effective work.

> Learnt about tactics to maintain discipline and How to deal with workers.

> Learnt how to control quality problems and meet the demands of customer.
 CONCLUSION

It was a wonderful experience working at Kriplon Synthetics Pvt Ltd. I gained a lot
of insight regarding almost every aspect of a plant. I was given exposure in almost
all the departments of the plant. The friendly welcome from all of the employees is
appreciating, sharing their experiences and giving their piece of wisdom which, they
have gained in long journey of work was wonderful. I hope this experience will
surely help me in my future and also in shaping my career.

References-

1. http://kriplon.com/index.php
2. https://www.wikipedia.org/
3. https://home.howstuffworks.com/home-decor/decorating-styles-techniques/how-is-fabric-created2.htm
4. http://textilelearner.blogspot.com/2012/02/introduction-of-calendering-finishing.html
5. https://www.slideshare.net
6. http://www.textileflowchart.com/2015/09/working-flow-chart-of-rotary-screen.html
7. https://www.britannica.com/technology/mercerization
8. http://textilelearner.blogspot.com/2013/01/slitter-machine-object-and-function-of.html