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By:
Saakshi Pratishruti
Roll no: B/AP/11/2185
NIFT Kannur
INTRODUCTION
Jaya Shree Textiles ,a Unit of Aditya Birla Nuvo Ltd. is a leading player in Linen and
Wool segment of the Global Textile Business.
Jaya Shree Textiles was established in 1949 at Rishra in Hooghly district of West
Bengal
It has significantly revolutionized the Indian and
foreign textile market by popularizing Linen across a
wide customer base with its brand Linen Club.
Jaya Shree Textiles sells its products in over 50
countries, spanning all the six continents of the World.
The company offers a wide range of products such as
Linen Yarn, Linen Fabric, Worsted Yarn and Wool Tops.
ORGANIZATIONAL STRUCTURE
SBU's
FLAX
SPINNING
LINEN
FABRICS
WOOL
COMBING
WORSTED
SPINNING
SUPPORTING
FUNCTIONS
FINANCE/
ACCOUNTS
HR
IRL
WCM
ENGINEERING/
IT
ORGANIZATIONAL STRUCTURE
DEPARTMENT
MARKETING/
SALES
OPERATIONS
MAINTENANCE
PRODUCTION
QUALITY
CONTROL
PRODUCT RANGE:
Natural, Bleached & Multifold Yarns
Linen Yarn for Weaving
SOURCING:
The fibre is sourced from the best grade Western European Fibre from France and Belgium
for the entire requirement.
1. Suzanne
2.
Lorea
3. Alizee
4. Malina
CARDING
DRAWING
ROVING
WET SPINNING
RF DRYER
AUTOCONER
PACKAGING
BLEACHING
RING FRAME
WINDING
PACKING
The aim of hackling is to clean, untangle and align parallel the bunch of scutched flax, to
separate the fibrous bundles and to start dividing them in order to form a continuous sliver
that is ready for doubling and drafting operations that come next.
Handfuls of strands of flax, weighing 90- 110 gram and held in mobile clamps are fed
manually in the hackling frames.
Moving up and down these clamps convey the fibrous bundles to a double set of combs.
CARDING: Carding continues the cleaning process removing fibers too short for yarns and
separating and straightening the fibers so that they lay parallel to each other. These fibers are
then spread into a thin, uniform web. The web moves into a funnel shaped device (trumpet)
where it is gathered into a rope like mass and formed into the card sliver.
COMBING: The combing process is normally used to produce smoother, finer, stronger and
more uniform yarns.The machines used for combing are as follows:
1. Bi-coiler machine
Make: GC- 14
Production: 18 g/m
2. Comber
Each type has 1 machine and the difference between the two are while GC 15 no 1 produces 18
g/m of sliver, the GC 15 no. 2 produces only 12 g/m of sliver.
DRAWING:
The purpose of drawing is to make yarn more uniform by combing and elongating multiple
slivers, thus eliminating the randomly occurring defects. In this process further attenuation of
fibres and doubling is done.
Several strands of sliver (typically eight to ten) from different carding machines are combined
and conveyed to the drawing machine, where they are pulled together and drawn out into a
new sliver no larger than one of the original single slivers. The loose, rope like strand of fibers
resulting from this process is called drawn sliver
No. of machines: 6
No of fed slivers/head
Doubling no of sliver
8 or 4
8 or 4
17
11
7.3
4.9 or
2.5
1.6 or
0.8
16~24
17~25
17~25
19~26
17~24
ROVING:
MACHINE SPECIFICATIONS
Number of heads
15
Number of spindles
120
into roving.
38.1
38
180-200
bobbin.
No. of machines: 6
160M-615 KW
550
280 X 115 X 38
Overall size
15158 X 3600
Weight
16.6 TON
Count of rove
NM 1.8-3.8
Draft
8.34-12.51
Twist
29-41T/m
833
BLEACHING PLANT:
In bleaching plant the roving materials are bleached in order to remove the natural colour of
the yarn. Bleaching is done mainly by following chemicals:
a. Hydrogen peroxide
j. Securon 540
b. Acetic acid
k. Contavon GAL
c. Sulphuric acid
l. Stabilizer NKC
d. Alfox 200
m. Beta foam KS
e. Soda ash
f. Sodium sillicate
g. Sodium nitrate
h. sodium chloride
i. Caustic flakes
WET SPINNING : The spinnerets are submerged in a chemical bath and as the filaments
emerge they precipitate from solution and solidify. Because the solution is extruded directly into
the precipitating liquid, this process for making fibers is called wet spinning.
MACHINE PARAMETERS
Yarn linear density
Twist/meter
Twist direction
Setting(mm)
Yarn ring diameter
Wind height
Spindle speed
Drafting system
300-800Tm
Right Z
180 (front and back roller nip)
55mm
210mm
3700-3800
Single zone, single apron drafting system
with two pressure rollers
Power of motor
Spinning machine drive
Spindle gauge
Spindle quantity
15 KW
0,37
88mm
64, 192, 240, 256
R.F DRYER:
After coming out of ring frame the pirns are in wet condition. It cannot be wound further
without drying them. So, R.F Dryer is used in this case. The lot of pirns are passed through
the R.F Dryer at a temperature of 80 degree Celsius.
AUTO CONER
A winding machine used for automatic packaging of yarns into cone
or cheese form
CONDITIONING ROOM:
In this stage the bigger package wound in the Auto coner machine are stored in a
conditioning room and from there they are sent for packaging.
PACKAGING:
Packaging plays a vital role in marketing a particular product. Here the bobbins are packed
and delivered for further processing or sold to the buyer.
CARDING
PRE-COMB GILLING
COMBING
POST-COMB GILLING
PRESS PACKING
BLENDING:
In this process, the workers manually mix the different sub lots of wool and prepare it to be
fed to the next stage
SCOURING:
It is the process of removal of the natural grease, dust and dirt that are present in wool by
washing. The by-product of this
process is wool grease.
Machine used: Scouring machine
CAPACITY
BOWLS
BOWLS
TEMPERATUR
litres)
E (in degree
5000
Celsius)
5000
65
5000
60
5000
60
5000
55
58
PRESSURE(in
kg/sq.cm)
5.5
CARDING:
No. of machine: 2
Application:
Attenuation and alignment of fibre by drafting through intersecting pinned fallers
Obtaining sliver evenness through doubling
COMBING: It is the process of removal of short fibres and neps from gilled input
material and to make crimped sliver as an output.
No. of machine: 16
Feed/length: 5.8-7.2 mm
Feed gill:
5 PPC- 2pc
6PPC- 3pc
7PPC- 4 pc
Brush setting: 2mm with doffer and to touch last 3 or 4 vario bar for every rotation
PRESS PACKING: It involves the packing of tops and bumps in bale forms for
dispatch.
Bailing press
HDPE Bag
WEAVING SECTION
SECTIONAL WARPING
BEAMING
(incoming inspection
of yarn)
(Warping of yarn
according to pattern)
(Preparation of
weavers beam)
DRAWING-IN
(Drawing of yarn in
heald and reed)
GREY CHECKING
AND FOLDING
WEAVING
BEAM GAITING
(interlacement of warp
and weft yarn)
(mounting of weavers
beam and gaiting)
Yarn Procurement
In this process the yarn is received from the spinning section to be prepared for
sectional warping.
Sectional Warping
Weaving preparatory process involves the process of warping. Sectional warping is done
in the industry. The yarn cones are mounted on a creel which has a capacity of 480
cones.
Machine specifications:
o Features: warp stop motion, when yarn breakS. Here photo electric sensors are used.
o Creeling time: 25-30 min.
o Type of tensioner: Mechanical type (spring plate).
o Adjustment of the tensioner: Manually.
DRAWING: To drive the ends through eyes of healds and dents to feed with the help of
reed hook.
There are total 26 drawing- in m/c for drawing- in beam. Two workers are required-
Drawer
Reacher
MACHINE SPECIFICATIONS
Drop pins- Different weighted drop pins are used for different count
Finer count above 80 low weight
BEAMING
As soon as all the sections are wound on the drum, the weavers beam formation is started
by unwinding the threads from the dresser and winding them all simultaneously on the
weavers beam placed on the chuck. This operation is named beaming.
No of workers required- 2
Beam dimension:
For Rapier: Dia. Of beam- 8.2
Length of the beam- 92
Requirement of worker: 2
End/mm=2.2 mm
Section width=218.8 mm
WEAVING:
The maximum width of the fabric is 153 inches i.e. 390 cm. Other widths of fabric include
A variety of weaves are used such as plain, twill, satin and fancy weave. They also have
attachments for dobby. Plain weave is the most commonly used weave. The department
works in all the three shifts. All the looms are Sulzer Ruti Loom
MACHINE SPECIFICATIONS
Manufacturer- Sulzer Ruti
Model: Rapier- G6200 W 200 N6 SPK
Projectile -P 7200 B 390 N4 SPK, P 7200 W220 N4 SPK
Width of the machines-(rapier)
220cm (34 machines)
200 cm (24 machines)
190 cm (20 machines)
Width of the machines-(projectile)
Double width 153(6 machines)
Single width 85(14 machines)
Speed and efficiency:
Rapier Loom: For yarn dyed-300-350 RPM
For grey fabric- 400(+/-) 20RPM
Projectile: 250-350 RPM
Efficiency of the machine is 70-75 %
DYEING SECTION
SINGEING,DEMINERALISATION &
DWELLING (4 hrs.)
BLEACHING
ON CBR
DRY ON
STENTER
WASH ON
WASHING
RANGE
DRY ON
DRYER
PADDING ON
KUSTER &
DWELLING
CHECKING OF
SHADE
RFD
CHECKING
CALENDERING
DRY ON
STENTER
FINSHING ON
STENTER
WASH ON
CBR
SANFORISING
LAB. TESTING
DWELLING
SINGEING
CBR
DRY ON STENTER
DYE ON PADDING
DWELLING
WASHING
PACKAGING
TESTING
CHECKING SHADE
SINGEING MACHINE:
The purpose of singeing is to remove the loose hairy fibers protruding from the surface of
the cloth or yarn.
Setting Parameters:
Machine Details:
Steam: 6 bar
Threading length: 60 m
Machine Specifications:
No. of chambers: 8
CHAMBER no.
1200
1200
200
Steamer
1800
1800
1200
8a
600
8b
600
min (90 m)
Pressure required:
No. of blower: 12
CALENDARING
The process: calendaring is a finishing process
used on cloth where fabric is folded in half and
WASHING RANGE
The process: After dyeing, the fabric needs to be washed so that the excess colour is washed
off. The fabric is passed through 6 chambers. Second and third chamber contains soap solution.
Machine Specifications
Number of chambers - 6
Threading length 120 m (from entry in the first chamber to delivery width)
JIGGER MACHINE
The jig dyeing process involves treating fabric in open width form.
Jigger consists of a trough, fitted with two rollers known as draw rollers. An immersion roller is
provided in the bottom zone of the trough. Guide rollers are provided for guiding the path of the
fabric.
The fabric in the open-width form is wound on one of the draw rollers, from where it is unwound
and passed into the dye liquor contained in the trough with the help of the immersion roller.
Capacity:-For fabric
For Water
(1).150 Kg
700-800 L
(2).250 Kg
700-800 L
No. of m/c:- 02
Rubber thickness 40 to 65 mm
Jaya Shree Textiles follows stringent quality processes and has the following certifications
to its credit: ISO 9001, ISO 14001, SA 8000, OHSAS 18001 and Oeko-tex 100.
USTER TESTER 5 [ UT - 5]
Application scope: Measurement of Unevenness % and imperfections in yarn, unevenness
% of roving and sliver, Automatic check of all values, diagrams and spectrograms.
Simulation of yarn boards woven and knitted fabrics.
USTER TENSORAPID 4 [UTR - 4]
Application: the USTER TENSORAPID 4 is a tensile testing installation for the quality
control in the textile industry. The determined values for the tensile force and the elongation
percentage
WRAP REEL
Application : Length measurement for determination of yarn count
ELECTRONIC BALANCE
Application : Weight measurement
SPECTROPHOTOMETER
Application : Colour matching and quality control in the laboratory
5. Measurement of core pH
Equipment: Paramount pH meter with 0.1 graduation and buffer solution of pH 4 and 7
Test method:AATCC 81
6. Residual shrinkage percentage
Equipment: Paramount accu shrinkage scale
IFB washing machine
Tumble drier
Flat bed press
Test method: AATCC 135
7. Tensile strength in lbs
17. Method for determining the fire resistance of coated and uncoated textiles