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Weaving, knitting, poy,cp,texturising

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Govt. College of Engg. & Textile Technolgy Berhampore, Murshidabad (2

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Published on Nov 10, 2010

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OMPANY PROFILE 1-2 2 RAW MATERIALS 3-7 3 QUALITY ASSURANCE 8-16 4 P.P.C 17-19 5 WEAVING
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Transcript of "Weaving, knitting, poy,cp,texturising"

1. 1. 0 Report onReport onReport onReport on TakenTakenTakenTaken (WEAVING UNIT)(WEAVING UNIT)

(WEAVING UNIT)(WEAVING UNIT) RAKHOLI, SAYLI, SILVASSA BY Mr. Bultan Sarkar Govt. College of
Engineering & Textile Technology, Berhampore (W.B.)
2. 2. 1 ACKNOWLEDGEMENTACKNOWLEDGEMENTACKNOWLEDGEMENTACKNOWLEDGEMENT
As per course schedule, I have taken Industrial Training at ALOK INDUSTRIES LIMITED, SILVASSA from
29.06.2010 to 26.07.2010.The experience of 28 days was both challenging and immensely valuable. This tanning had
given me the opportunity to learn the entire operational activities of mills. The practical knowledge, which we have
ED ALOK
acquired
was established
over the period,
in 1986will
as definitely
apvt. Ltd.be
company
beneficial
with
to 1st
our polyester
future as atexturising
Textile Engineer.
plant being
At first
se...I am highly thankful to
Mr. R.B Mahapatra(Unit Head) for allowing me undergo the training at the mill. Then I am thankful to Mr. Rinku
Nath(HR Manager), Mr. Dilip Panigrahi and all the H.O.D and supervisors including employees of mill for their kind
co-operation during the course. At the end I am especially grateful to Mr. Debraj Sarkar (T.P.O) for arranging the
training for me and provided me with the required Place: Silvassa From Date: 26.07.2010 Mr. Bultan Sarkar
3. 3. 2 SR NO. SUBJECT PAGE 1 COMPANY PROFILE 1-2 2 RAW MATERIALS 3-7 3 QUALITY
ASSURANCE 8-16 4 P.P.C 17-19 5 WEAVING PREPARATORY 20-34 6 WEAVING 35-49 7
INSPECTION & PACKING 50-55 8 KNITTING 56-60 9 CP/POY 61-68 10 TEXTURISING 69-74
4. 4. 3 ALOK INDUSTRIES LIMITED ALOK was established in 1986 as apvt. Ltd. company with 1st polyester

texturising plant being set up in1989. Over the years it has Expanded into weaving, knitting, processing home textiles
and garments. And to insure q uality and cost, efficiencies it has integrated backward into cotton spinning and
manufacturing of POY through CP route Alok also provided embroidered products through Grabal alok implex Ltd.
Alok has recently entered the domestic retail segment through a wholly owned subsidiary Alok retail India Ltd, with a
chain of stores named H&A that offers garments and home textiles at attractive prices. LOCATION: Survey no:
17/5/1 & 521/1 Village Rakholi, Sayali Silvassa: Khanvel road Silvassa: 396230 (D&N.H) India. Busines activities:
Alok is a well established, profit making, consistently dividend paying professionally managed textile company. The
company has intergrated manufacturing facilities for: Home textiles Apparel fabrics Texturising
5. 5. 4 The vertically integrated operation and flexibility to produce in cotton/ polyester/ viscose and blend in various
counts has enabled the customers and thus provide integrated textile solutions. The total value addition chain in textile
and Aloks presence in the chain is indicated below: Fibres Spinning Weaving/ knitting Processing
Garments/Home textiles/ Madeup Retailing I.M.S policy WE, AT ALOK INDUSTIES LIMITED ARE
COMMITTEDTOWARDS- 1. Serving our customer to their satisfaction by efficiency reliable supply of products at
most competitive rises and meeting social objectives and other specified requirement through INTEGRATED
MANAGEMENT SYSTEM. 2. Constantly improving product quality, environment, performance work environment
and services by up- gradation of skill, knowledge and technology through employee education and involvement. 3.
Ensuring a healthy and safe environmental in and around our manufacturing plants complying with all applicable legal
and other requirement related to safety, health, environment, social and quality aspect by setting and reviewing quality,
environment, health, and safety objectives towards continual improvement.
6. 6. 5 4. Enhancing corporate social responsibility by making earnest endeavors to prevent environment pollution,
reduce occupational, health hazard minimize waste and optimize useof natural resources. RRRRAW
MATERIALSAW MATERIALSAW MATERIALSAW MATERIALS Two types of raw materials means yarns
are consumed by the industry these are (a)-Grey Yarn (b)-Dyed yarn Count range of yarns 6 Ne to 120 Ne
Among these open end yarn 6-20 Ne , Carded yarn up to 30 Ne, Combed yarn 30 to 120 Ne, Compact yarn 30
to 60 Ne, Double yarn range 2/6 to 2/20 & various count of PC,CVC are used as raw materials. Alok consumed
80% raw materials from his own spinning mill & 20% raw materials from other industry (Near Industries, Vardhman
Industries, Ravali Spinning Ltd,Trident, Dhanlaxmi, Vasundhara Cotton mills, Sandhya Spinning Mills Abhishek
Industries Limited,Vasundhara Cotton mills Pvt.Ltd, Kallam Spinning Mills etc.). Daily consumption of raw material
is 120 ton. Total capacity of this godown is 1200-1400 tons Raw materials are stored in godown as Cone &
Chesse in carton or plate according to their Count wise. No of worker in this godown is 45.
7. 7. 6 The method of raw materials proceeds is: Material verified at gate Give massage to operation Verified whether
the order is given or not Then it enter Then check the data Then sample goes to QA to check the quality Then unload
Stocked Distribute to dept. Some samples which is used by Alok Industries Ltd.are given bellow: Sample-1(Dyed
material)toAlok
Industries
Ltd.(Spinning
Date:
on and flexibility
produce
in cotton/
polyester/Div.)
viscose
and28.06.2010
blend in various counts...
8. 8. 7 Party: Saha Mahash Kumar Mohanlal & Co. Count: CTN 40 COMB COMP WVG Midnight Shade: Midnight
Shade No: YX048717 SORT: AW00666666XWYDNF SO No: 3062078182 PO No: 109410078882 LOT No:
YD1000334446 STPO: 5100099317 WVG RW STORE No of cone: 12 Gross weight: 15.82 kg Net weight: 15.82
kg Sap batch: 3011375748 Carton no: VY1000010352 Sample-2(Grey materrial) Alok Industries Ltd(Spinning
Div.) Unit-2 Packing slip 100% Cotton Combed yarn CTN 64 Comb Comp ROCOS ORG WVG Count: Y00530
Box: PO10039476 No of cone: 160 LOT No: 2LC100026B Grade: A Gross weight: 429.000 kg
9. 9. 8 Tare weight: 29.000 Net weight : 400.ooo Date: 31.06.2010 Packed by: PP_VIINODS Grey yarn receiving
from Alok spinning: 2500000 2000000 1500000 1000000 1135006.91 1387335.91 1465009.29 1732692.85
1914381.29 1909833.15 2208080.50 2353071.39 RANGEOFQUANTITY
10. 10. 9 500000 0.00(kg) Aug08 Nov08 Feb09 May09 Jul09 Oct09 Jan10 Apr10 Month AVERAGE DAILY RAW
MATERIAL CONSUMPTION: 120000 100000 80000 95345.27kg 93405.76kg 95345.27kg 105129.41kg
113804.31kg 103197.06kg NGEOFQUANTITY
11. 11. 10 60000 40000 20000 0.00(kg) Nov09 Dec09 Jan10 Feb10 Mar10 Apr10 MONTH Quality Assurance
Quality assurance one of the most important dept. in this weaving section. The raw materials are coming from different
companies. The materials are then checked in this dept. before it sends to different part in the weaving department. If

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finds that the raw materials do not satisfy the standard parameter then that do not run in the loom and returns to the
delivered company. Not only the raw materials, the fabric that made in the company, also check in this dept. before it
sales to customers. This dept. also makes a checking in the loom running time and tells different dept. about their faults
and makes a solution for they are: Yarn testing (Raw materials checking) Fabric testing
12. 11 Running time checking in the loom. Yarn testing Here mainly the raw materials that coming from different
sources are checked and compared with company standard. If satisfies then run in loom and If not then reject and
return. The apparatus that use for this testing are: USTER CLASSIMATE QUANTUM USTER TENSOJET 4
USTER TESTER 5 ELECTRONIC TWIST TESTER AUTOMATIC BOARD WINDER SINGLE YARN
STRENGTH TEST CSP SYSTEM WRAP REEL USTER CLASSIMATE QUANTUM Main purpose is to
measure the yarn faults. Mainly it is measured by graphical method. Here mainly two types of graphs one for
measuring the no. of thick and thin places, no. of neps, etc and other is for different dyed fiber that unnecessarily
entangled with yarn. It also
13. 12 shows the types of faults. There are two types of dots: green for the nominal fault an red for untolerable faults.
There is one cone winder machine where maximum 12 cones are wounded. 100km is wound in one cone for
measuring faults. The winding speed is near about 400-800 rpm. In the time of winding the fault is optically observed
and plotted in graph in this instrument. OBSERVATION: LENGTH 50.1km 22.3km WEIGHT 0.46kg 0.17kg
COUNT 40s 80s TOTAL NEPS 3449 2903 SHORT THICK 153.7 420 LONG THICK 4 13.7 THIN FAULTS
45.9 276 OBJECTIVE FAULTS 12 67.9 DIFFERENT DYED 45 44 TOTAL FAULTS 3698 3664 E 150 400
250
14. 13 0.1 1 2 4 8 32 USTER TENSOJET 4 This is the latest model USTER SINGLE YARN TESTER. This is
used for measuring the single yarn strength, R.K.M.(Resikilometer) & their variation. Testing speed:-100 to 400
Mt/min Test method:- ISO 2062, DIN 53834, ASTM D:-1578 JIS For 60 count yarn pretension wt 4.92 gramforce, Max Load 2KGF. USTER TESTER 5 This is the latest model of USTER EVENNESS TESTER. This
machine is used for measuring the mass variation in the sliver, roving & yarn also for hairiness index of yarn. Testing
speed is 25 to 800 Mt/ min. Test method:- ISO 53817 AUTOMATIC BOARD WINDER 100 45 -30 -45 A CB D
F G H I cms
15. 14 The yarn is wound on the black board with the help of winder machine. According to the count of the yarn the
wraps/inch is decided. The result are decided by the ASTM method. Cotton count Tex count Warp ASTM board
Pulley set INCH CMS 1 to 12 590 to 50 20 8 1 A 12 to 24 50 to 25 22 9 2 B 24 to 36 25 to 16 26 10 3 C 36 to
50 16 to 12 32 13 4 D 50 to 75 12 to 8 38 15 5 E 75 to 135 8 to 4 48 19 6 F ELECTRONIC TWIST TESTER By
the help of this electronic twister simply measured how much twist present in one inch of yarn . SINGLE YARN
STRENGTH TEST (STATEX TENSOSTATE - JUNIOR) Elongation% Time to break Tenacity. Rh
corrected tenacity Load Rh corrected load CSP SYSTEM
16. 15 By this system mainly different of yarn count strength product measured. Purpose:- To determine the count &
strength. Principle:- Works on the principle of constant rate of elongation. Lot size No of cones No of leas to prepare
Total no of leas Above 4000 kgs 15 152 30 Above 1000 kg to 4000kgs 10 103 30 100 kgs to 1000 kgs 5 53
15 Less than 100 kgs 2 23 6 General Information of machine:- Time: 4 hours, R.H:-652% , Temp:-272C, Air
pressure:- 4kg/m GSM: EPI*23.25 Warp = Warp count(Ne) PPI*23.25 Weft = Weft count(Ne) Therefore Fabric
GSM = Warp GSM + Weft GSM BY GSM CUTTER: Cutted fabric is weighted and multiplied by 100 FABRIC
TEAR STRENGTH TESTER: This instrument is used for testing the tear strength of the fabric in warp and weft way.
17. 16 Elmatear digital tear tester. Used for measuring fabric tear strength. Testing capacity 6400 gms
CONDITIONING SYSTEM: In the ALOK INDUSTRIES ther is LUWA conditioning system is used.In the LUWA
system there automatic adjusting the RH% = 65% & Temp = 22 deg.c CONDITIONING BOX: The conditioning
box is used for conditioning the material for testing.The conditioning is done at 65% RH & 27 deg.c temp
DEPARTMENT WISE QUALITY ASSURANCE ACTIVITIES WARPING: 1.Breakages Spinning breaks
Winding breaks Transporting breaks 2.Bottom %: Up to 1.5 3.Yarn tension 4.Beam heardness :60 -70 deg Shore
5.Pattern check for sectional warping 6. Shed checking
18. 17 Sizing: 1. Roller heardness 2. Dry cyl.Temp :140 deg.c & Pressure :3.5 bar 3. Saw box temp :90 deg.c 4.
Squzze roll pressure : 16 kn 5. Yarn tension in different zone 6. RH % 7. Viscosity 8. Size pick up % 9. Lappers in

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3000mt/1000 ends 10. Migration in 3000 mt/1000ends 11. Setting in the different zone LOOM: 1.Tpes of breaks
2.Fabric effect 3.Fabic width 4.Loom setting 5.Humidity 6.Temparature 7.Efficiency %
19. 18 PROCESS CONTROL STUDIES 1.WARPING: There are two types of warping Direct warping Sectional
warping The various studies performed in warping are End breakages study Performence of yarn General
observations like humidity, Machine parameters 2.SIZING: The various studies performed in Sizin are
Stertch,scosity & Size pick-up General observations fabrics likes Temparature,Lapper,Migratory Ends etc. Beam
heardness checking and its pressure on each ends 3.WEAVING: The various studies performed in weaving are
Snap round
20. 19 Loom stoppage study Quality round in order to check quality of fabric on running loom. Humidity verification
3.FOLDING: Two activities are being performed in folding depertment Mending of fabric Grading of fabic Grading
procedure of all fabrics is followed by 4 point American System. Grading of fabric is done depending upon the faults
present in fabric. PRODUCTION Planning & control In PPC or production Planning control section mainly planning
is done according to requirement in the market. The main purposes are: Follow up order and delivery on time.
Commitment of delivery date Maintaining forward load Micro-Planning i.e. daily planning with weaving
preparatory and loom shed. PROCESS FLOW CHART Receiving work order from market Verification of work
order Preparation of Production Programme Approval of G.M (wvg.) Sample required Verification for R.M& loom
availbility Intimation to mkt NO YES Sample Development Verification YES
21. 20 As shown above flow chart of PPC, after receiving enquiry from market- the commitment of delivery date is
given based upon raw material availability, loom availability, complexity, reed availability, warping and sizing. If party
is supplying raw material then order is executed within 25 days. And if raw material is not available by party then
additional 15 days are required for preparatory. PRODUCTION PROGRAMME Production programme for
particular sort is made as follows: PP.no: 103110071568 PP date: 4/6/2010 Sort no.: AW0064348XG SONO:
3026051922/000010 Party: TURTLELIMITED STOP: 5100075252 Construction Reed/pick: 40/1cc
COTTON*40/1ccPC 65/35
22. 21 Weave : Dobby MCNO:AIRJET_PIC74.86CLRDOBY Picks/inch:80 Shade: Reed space: 66inch Insetion:
1 Reed: 68/4 Grey width:64 Meters: 888 SIZ. MTRS: 1003 Delivery Date: 23/06/2010 Desk loom no.:
MATERIAL TYPE KGS/100MTR K 40s/1 CTN COMB BLACK WARP 15.218 135.13 40s/1 CTN COMB
DaRKBLUE WEFT 07.797 069.23 In PPC dept. PP is made. PP is the production programme in which all details of
parameters of fabrics required by party is written depend this the INDENT is made where the necessary materials or
amount of materials required for production SORT MASTERING In sort mastering each new design is given new
sort number for quick identification. Sort no Type of fabrics 10001-19999 100% cotton 20001-29999 Viscose
30001-39999 Pet 40001-49999 Organic cotton 50001-59999 Dyed yarn 60001-69999 Slik fabrics
23. 22 WARPINGWARPINGWARPINGWARPING The main object of this department is to collect a no. of warp
ends from creel & to wind them in to a sheet on doubled flanged beam in such a manner that the threads are parallel to
each other. PROCESS FLOW CHART RAW MATERIAL OPENING OF CURTONS CREELING DENTING
LOADING EMPTY BEAM SETTING OF INFORMATIONNIN PANNEL
24. 23 TYING UP OF ENDS ON THE BEAM STARTING OF THE MACHINE MACHINE IS STOPPED
AFTER COMPLETION OF REQ.LENGTH ON THE BEAM ENDS ARE CUT UNLOADING THE FULL
BEAM AFTER COMPLETION BEAMS CREEL ENDS ARE CUT AT THE CREEL & CHANGE
SECTIONAL WARPING In sectional warping mainly the warping is done sectional where the warp thread before
winding in the beam it wind in a cylinder. So here winding does not happen directly. TECHNICAL
INFORMATION:- BEN-TRONIC Machine designation: BEN-TRONIC sectional warping machine.
PRASHANT GAMATEX sectional warping machine. Model: movable. Creel capacity: Ben-Tronic-960 cones ,
Prashant Gamatex: 3 m/c:672cones & 2 m/c 720 cones. Useful widths: 2200, 2600, 3000,3400,3800,4200 mm.
25. 24 Machine weight: approx 1100 to max 1400 kg.(depending up on useful width) Temp. : 10c-max 40c.
MACHINE DATA:- Warping speed: max 800m/min. Warping winding tension: 600N. Beaming speed:
400m/min. Beaming winding tension: 1500N (min 100N) VERSOMAT:- Make: BENNINGER Creel capacity:
480 cones. Tensioner: Disc type tensioner. Sensor: electrical sensor. Max speed: 800mt/min. Drum width:
2200mm. CALCULATION:- Total no of ends=7068 EPIPPI=108100 pattern No.of ends total A 120 3540

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B 30 900 C 30 888 D 30 870 E 30 870 no of section: total no of ends/total pattern ends=7068/240=29.5

26. 25 Total no of section=29 1 section0f 108 ends Section width=total pattern end/E.P.I=240/108=2.22 MAN
POWER IN SECTIONAL WARPING:- 1 operator/machine/shift. 1 jobber boy/machine/shift 3 creel boy/2
machine/shift DIRECT WARPING MACHINEDIRECT WARPING MACHINEDIRECT WARPING
MACHINEDIRECT WARPING MACHINE::::---- In direct warping the warp thread directly wind in a beam from
the creel. Here no need of any other cylinder before winding. GENERAL INFORMATION:- Machine name:
BENNINGER BEN-DIRECT beaming machine. KARLMAYER DIRECT beaming machine. Type of creel:- Vtype creel. Total no of machine:- 8(BENNINGER)+2(KARLMAYER) Capacity of creel:- 720-1088
Tensioner:- pre tensioning rod (The tension is given by adjusting the distance between the 2 rods. The distance setting
is 8mm.) Labour per m/c: 1
27. 26 TECHNICAL INFORMATION:- Machine designation:- BENNINGER BEN-DIRECT beaming machine.
Model:-stationary. Useful width:- ZS 1800, 1600, 2200, 2400mm. ZS 1400, 1800 , 2200, 2400, 2600,
2800mm. Machine weight:3500kg Air pressure: min 5bar- max. 8bars. Air consumption: approx 3m3/h at min. 5
bars Permissible ambient temp: min 10 c-max 40 c Ceiling height: Min 3000 mm. Distance from m/c to creel :
Min 4000mm MACHINE DATA:- Operating speed : 300-1200m/min Crawl speed: max 200 m/min Overall
yarn tension: max 450 N Beam weight : 1250 kg Maximum beam dia.: ZS 800:813mm,ZS1000:1016mm
Braking moment: Max 16000 Nm Clamping device:9000N Pressure device: 200-600 daN GENERAL
OBSERVATION:- M/C no NAME SPEED PRESSURE CREEL ENDS COUNT WIDHT 1 BEN- DIRECT
6oom/min 300 dan 1088 1028 60s 220cm
28. 27 2 BEN- DIRECT 250m/min 330dan 1088 936 60s 220cm 3 BEN- DIRECT 600m/min 250dan 1088 1074
60s 220cm 4 BEN- DIRECT 800m/min 200dan 1088 976 40s 220cm 5 BEN- DIRECT 800m/min 200dan 1088
1076 60s 220cm 6 BEN- DIRECT 300m/min 250 dan 1088 1018 60s 187cm 7 BEN- DIRECT 650m/min 200dan
1088 966 80s 220cm 8 BEN- DIRECT 900m/min 550dan 720 558 20s 187cm 9 KARL MAYER 700m/min
300dan 680 595 40s 187cm 10 KARL MAYER 800m/min 6oodan 720 648 20s 187cm CALCULATION:- No of
ends=Reed space reed count Total length L=A+13%+50mt Where, A=length in sizing 13%=this is considered
shrinkage 50mt=this is considered as sizing waste Waste planning:- 13%extra=30 count
29. 28 15%extra=20count 20%extra=below 20count TYPE OF FAULTS:- Slubs. Foreign matter. Thin places.
Thick places. Bad piecing Bunch. Slough off- packing fault. MAN POWER DIRECT WARPING:- 1
supervisor/shift 1 operator/machine/shift 16creel boy/shift 1 fitter/shift 6helpers for beam carrier WARPING:- 100
HOUR: Cleaning Monthly:- Greasing, oiling. 3 Weekly:- Cleaning, checking attain major problem. Cleaning is done
by blow air of different parts as follows Complete machine
30. 29 Wind air Guide roll Pressure roll Terapezoidal threaded assembly Limit switch assembly Checking:- Oil level
of hydrolic Screw connections Drive belts Beam position Cylinder pressing device Comb traverse Device Oiling &
greasing of all moving parts. Sizing department The main object of sizing to improve the weavability of the fabric by
increasing the strength of the yarn using size paste. The strength of the yarn is increased up to 25%. The other purpose
is to reduce the hairiness of the yarn and make the warp as a warp sheet. PROCESS FLOW CHART Warpers beam
Loading creel beams Leasing Denting
31. 30 Loading empty weavers beam Setting of information in panel Tying up of Ends on the beam Starting of the
machine Machine is stopped after completion of req. length Ends are cut Unloading the full beam General information
Make: Benninger zell Model: Bensizetec, synchro 4 Maximum Creel capacity: 24 No of Machines: 9(normal
width=3, wider width=4, sectional=2) Country : Germany Type of creel: magazine creel Creel breaks: breaks
stripes with pistons Beam break: hydrolic Double size box: for more than 55 warp cover factor it uses to better
size. Mechanical information No. of sow boxes: 2 Size roll: 2+2
32. 31 Type of sow box: 2 dip 2 nip Moisture control: PLEAVA RIB Microprocessor: SIEMENS TOUCH
No of drying cylinders: 8 per drying cylinders, 4 main drying cylinders. Teflon coating is on drying cylinders to avoid
sticking of ends. Drying cylinder pressure:3.5 bar Wax box: to improve the softness & reduce hairiness of the yarn.
Leasing zones: diameter of bigger lease rod=60mm & small lease rod = 35 mm Pneumatic beam pressing system.
Beam pressing roll: length=340 cm, Diameter=8 cm Sizing level = 140mm Motor & Power Consumption
Exhaust fan : 2.2 kw Compressor: 4 kw Head stock down in device: 7.2 kw Cylinder drive motor:7.2 kw

Squeezing roller(2): 6.3kw Draw in device: 0.75 kw Beam doffing device:0.18 kw Warp taping device: 0.11 kw
Comb: 0.12kw Waxing device: 0.18 kw Immersion roller: 0.25 kw
33. 33. 32 Fan motor: 0.26kw Brake and clutch: 3.5kw Tension in different zones Creel: 703kn Saw box1-2:
329kn Saw box- dry cyl=112kn Leasing : 3598kn Beam pressing= 4790 kn Mixing recipe is done in Cold
mixer Cooker Storage Cooking time:1hr Sow box: 14 inches No. of cold mixer:3(no.1=1000lt, 2,3=2000lt)
No. of storage tank:8 Preparation of size paste The ingredients to be used in the sort are taken to the mixing room
and they are weighed The required water level is taken in the size mixer.
34. 34. 33 First starch and PVA are taken and it is mixed with water and cold stirring is done for 10-15 min. This
paste of water and starch is passed to cooker where the steam is injected to this paste and hot cooking is done for 13
min. After 30min the temp. is kept around 100 -110 . Then this mixture is passed into storage tank where softener
is added and then continuous cooking is done as per the req. If there is a blend or synthetic material is there then add
antistatic agents. Example of ratio of ingradiant: Count Nippa soft Super size Elavanol water 20Ne 150kg 22.5kg
4kg 22kg 60 Ne 100kg 12kg 15kg 17kg Maintenance of the sizing 1. Monthly maintenance: greasing & oiling
Cleaning: Complete machine Waxing trough Arbor screw Pneumatic control Checking: Safety equipment V-belt
condition Nipping impression Leveling of saw box Oiling & greasing:
35. 35. 34 Arbor screw shaft All points of drying cylinder Chain of positive drive Tensioner of positive drive Screw shaft
of immersion roller All bearing 2. Weekly maintenance: Cleaning: Complete machine by blowing air Saw box by hot
water Pneumatic control cabinets Electrical control cabinets Checking: Pressure gauge of steam line Working of all
steam traps cylinder Spiral cable of handy Leakage of air from all pneumatic line
36. 36. 35 Man power of the sizing 1sizer, 1 back sizer/machine/shift (for normal width) 1sizer, 2 back
sizer/machine/shift (for wider width) 1 supervisor/shift 1 shift in charge 2 data operator/shift 2 set ladder 1
mixing supervisor 1mixing man/ shift 3 helpers/shift Auto Drawing in Technical information Made : Stabuli
Model : Delta 110 No of machine: 5 Performance: Drawing in capacity: upto 3-4 warps in 8 hr Drawing speed:
100/140 ends/min Over all performance depend upon: M/C specification, count, no. of yarn ends/ warp, etc. Max
warp width: 230 cm Flange dia: max 1200 mm No of warp beam:1
37. 37. 36 Heald width :2.2/2.5/5.5 mm Heald length: 260-382 Heald thickness: 0.23-0.38 mm Heald type :
simplex and complex No. of frames: max 20 Beam knottingBeam knottingBeam knottingBeam knotting If on the
loom there is same quality is running then the new beam is knotted with the running beam. Made: Staubli Model:
topmatic Speed :500 ends/ min Time required: upto 1 hr No. of workers: 2 Beam gaitingBeam gaitingBeam
gaitingBeam gaiting Tying frame trolley is used to tear beam drawing in dept. to loom shed. Manufacturer: to do
company
38. 38. 37 No of workers for gaiting: 4 Time required: 1- 1.30 hr
39. 39. 38 WEAVING DEPARTMENT The objective of weaving is to produce fabric by the interlacement of warp and
weft. The other object is to produce defect free fabric by using the suitable mechanisms. There are mainly 9 units in
weaving dept. The loom distributes in that dept. are as follows: UNIT WIDTH NO. OF LOOM TYPE OF LOOM
M/C MANUFACTURER 1 Wider 80 Airjet Picanol 2 wider 80 Airjet Picanol 3 Wider & normal 52 Airjet Toyota
12 Jacquard Optimax 16 Jacquard Sulzer Sample Normal 4 Rapier Optimax 8 Sulzer 4 Normal 32 Airjet Picanol 40
Rapier Gamamax 30 Rapier Sulzer 5 Wider 144 Airjet Picanol 6 Normal 76 Airjet Toyota 228 Airjet Picanol 7
Wider 152 Airjet Picanol 38 Totota 8 Normal 12 Airjet Toyota 76 Rapier Vamatex 9A Wider 12 Airjet Toyota 16
Airjet Tsudakoma 104 Airjet Picanol 9B Normal 84 Airjet Toyota
40. 40. 39 9C Normal 80 Airjet Toyota 9D Normal 110 Rapier Optimax The looms that find in this dept. is mainly two
type according to shedding: AIRJET LOOM: Here weft is inserted by air that comes from the nozzle. RAPIER
LOOM: Here weft is mainly inserted bythe rapier assembly. Here mainly tip to tip transformation is occurred. Process
flow chart Weavers beam Drawing in Creeling weavers beam Beam knotting/gaiting Loading the empty cloth roll
Setting of information in panel Tying up of ends on the cloth roll Starting of the machine Machine is stopped after
competition of req. length wound
t : 400.ooo Date: 31.06.2010 Packed by: PP_VIINODS Grey yarn receiving from Alok spinning: ...
41. 41. 40 Cut the fabric & unload the cloth roll General information PICANOLPICANOLPICANOLPICANOL
AIRJETAIRJETAIRJETAIRJET Name: Picanol Air jet Model: Omni plus Width: 190 cms (Normal), 340
cms(wider) Speed:850 rpm Cam & Dobby: Staubli Heald shaft capacity: 6 Delivary : single Air pressure

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requirement: Oil free: 0.05-0.01ppm. Dew point at maximum 2 . Air pressure in supply line most is at least 7 bar.
Pre winder: Name : Picanol Omni 2231 plus Model no.: IRO 2231 P19.3. Total pressure capacity: 2 Heald wire
details: 331mm-j type Eye size: 8*2.5mm Drop pin detail:
42. 41 Dimension: 165mm*11mm*0.5mm Weight: 0.5 grms per drop pin Production: 680m/day/loom (appx)
Model: False Selvage Cutter: B161126 Main nozzle: Picanol BE300623 Filling detector: BE 154883 Filling detector
sensor: BE157859 Various mechanism: Let off.: Positive let off. Motor is used. A gear provide motion from one side
to another. Shedding : open shed. Shed left angle: 24 Shed height: depends on quality, mainly counts. Cams are used
for shedding. Staubli co. positive shedding max 86 heald shafts with leaving cam. Picking: Airjet Profile reed and relay
nozzles are used. Main nozzles auxiliary nozzle, relay nozzles are used. Main nozzle: 2 Auxiliary nozzle: 2 Relay nozzle:
14 groups (28 relay nozzle, 26 relay valve) Filling detector: 2 Nozzle: Main nozzle: Picanol BE 300623=2 Auxiliary
nozzle: 2 Relay nozzle: 14 groups
43. 42 Stretch nozzle: 1 Distance between main and auxiliary nozzle: 100 mm Pressure: Main nozzle: 7 bar Auxiliary
nozzle: 5-8 bar Relay nozzle left: 9 bar Relay nozzle right: 9 bar Timing of nozzle: Main nozzle: 85 -20 Auxiliary
nozzle: 85 -20 Stretch nozzle: 245 -31 Loom shed: Department RH%: 84+/- 2 Air pressure: 7 bar Shed crossing:
299 +/-3 ELSY crossing: 1 LH=300 +/-3 2LH299 +/-3 By ELSY leno is formed Observation: Sr no. Warp cont
Weft count Warp blend Weft blend Reed Reed space Total no. of ends Picking Grey width Size pick up% rpm
13641 SZB 60S CTN 60S CTN 100% CTN 100% CTN 116/3 129 22416 110 126 9.2 525
44. 43 TOYOTA AIRJETTOYOTA AIRJETTOYOTA AIRJETTOYOTA AIRJET Name: Toyota Air jet
Model: Jat710, Jat610 Width: 180 cms (Normal), 340 cms(wider) Speed:700 rpm(avg) Type: profile reed &
relay nozzle. Technical specification: Staubli cam& Dobby, Electronic shedding. Various mechanism: Let off.:
Positive let off with motor Shedding : open shed. Shed left angle: 32 Shed height: depends on quality, mainly counts.
Cams are used for shedding. Picking: profile reed & relay nozzle Take up: positive take up with motor. Capacity of
cam : 16 heald frame Capacity of E shedding: 16 heald frame Maximum haeld shaft: 16 Selvage: leno+false
selvedge. Leno: 2 polyester+ textured yarn at both Nozzle: Main nozzle: 2 15795 A 80 COMB CTN 80 COMB
CTN 100% CTN 100% CTN 80/5 107 21200 93 104 13.7 500
45. 44 Tandom nozzle: 2,to pass yarn from weft accumulater Relay nozzle:30, Relay nozzle: First 26 nozzle have
distance of 26, last four are 40mm. Every 4 nozzle connect with one valve where as last one have 2 nozzles. Motor
used : Main motor Let off motor Take up motor Leno assembly E shedding motor For LH cutter motor Pre winder
motor Observation: Sr no. Warp cont Weft count Warp blend Weft blend Reed Reed space Total no. of ends
Picking Grey width Size pick up% rpm 62676 40S CTN 40S CTN 100% CTN 100% CTN 108/2 66 8510 80 66
5.3 452 10813 60 COMB CTN 60 COMB CTN 100% CTN 100% CTN 86/2 66 5868 88 64 18.3 500
46. 45 SULZER RAPIER JAQUARDSULZER RAPIER JAQUARDSULZER RAPIER JAQUARDSULZER
RAPIER JAQUARD Name: Sulzer Rapier Jacquard Model: G6300 Speed : 280 rpm Weft accumulater: iro
luna Temples : Fire ring temples Selvedge : plain Shedding: Jacquard STABULI Time of knotting: 3hr
Downtime: 6 hr Type of rapier: Flexible rapier Special feature: Double beam Beat up: 0 Shade crossing: 320
Shade angle: 32 Central lubrication: oil Observation: Sr no. Warp cont Weft count Warp blend Weft blend Reed
Reed space Total no. of ends Picking Grey width Size pick up% rpm JQ680 SZB 60S CTN 60S CTN 100% CTN
100% CTN 84/4 126.6 10640 50 122 27.8 278 JQ6797 60 COMB CTN 80 COMB CTN 100% CTN 100%
CTN 68/5 125 10600 104 122 18.3 270
47. 46 PICANOL RAPIER JAQUARDPICANOL RAPIER JAQUARDPICANOL RAPIER
JAQUARDPICANOL RAPIER JAQUARD Name: Picanol Jacquard Model: Optimax Speed : 280 rpm Weft
accumulater: LGl progress vector Working principle: Electro magnetic Type of reed: plain 84/4 Temples : Fire
ring temples Selvedge : plain Shedding: Jacquard STABULI Time of knotting: 3hr Downtime: 6 hr No. of
Hooks: 2488 Type of rapier: Flexible rapier Sr no. Warp cont Weft count Warp blend Weft blend Reed Reed
space Total no. of ends Picking Grey width Size pick up% rpm JQ785 60S CTN 80S CTN 100% CTN 100% CTN
68/5 125 21200 104 122 20% 278 JQ807 60 COMB CTN 60 COMB CTN 100% CTN 100% CTN 68/5 125
21200 114 122 25% 280
48. 47 MAINTAINANCEMAINTAINANCEMAINTAINANCEMAINTAINANCE FOR RAPIERJACQUARD LOOM CLEANING: All types of belt by opening cover. Leno assembly Heald frame/heald wires &

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harness for Jacquard. Drop pin & contact bars Reed & Sley RH & LH gripper Tample & ITS ring CHEAKING:
OIL LEVEL CHEAKING ON THE GIVEN POINTS Main tank Take-Up & Let-off Dobby & Jacquard gear box
Leno & weft selsctor Lubrication pad of ribbon GREASING: At Sley Back Rest Beam BKT Heald frame
connecting liver brush
49. 48 Load cell Dobby leaver gear OILING: Dobby leaver bearing Cloth roll Weft cutter FOR AIRJET LOOM
CLENING: Leno Assembly Heald fream/Heald wire Drop pin & contact bar Reed/Sley Pre-winder Main cutteer &
selvedge cutter Temples Dobby liver & Under motion liver CHEAKING: o OIL LEVEL CHEAKING AT THE
FOLLOWING POINTS Main Tank Central lubrication Dobby o Cloth roll drive & ITS chain o All types of air &
pipes o All relay valve & main valve
50. 49 GREASING: GREASING AT THE FOLLOWING POINTS Whip roll-4 Whip roll BKT-2 Cloth roll-2
Sley-2 Dobby Under motion-2 Let-off gear-1 Liver-16 OILING: Oiling on Under motion liver Oiling on heald
frame connecting rods NOZZLE CHECKING PROCESS: Solution of water & EG liquid Switch on the machine
Set time by press meter Adjust and set the temp. Press heat button When time up it automatically stop Now clean the
nozzle with dry cloth Main nozzle Relay valve Relay nozzle Time 50min 50min 60min
51. 50 Temp. 40 40 50 Lubricant use: For airjet & rapier Position Oil no Amouny/year(lit) Main gear 150 2.5 Let
off & take off gear 460 2.5 Let off & take off bar 100 1 Cam box(610) 320 4-4.5 Cam box(710) 320 6-7 Auto
leveling 46 0.5 For jacquard Position Oil no Amouny/year(lit) Selector 150 1 Main tank 460 2.5 Jacquard gear box
100 20 Leno device 150 0.5 Jacquard greasing After 3 months Man power in weaving o 10 looms/weaver o 06
looms/weaver o Around 40 looms/ supervisor o 1 knotter/80 looms o 2dressers/80 looms o 1 maintaince/shift o 2
shift incharge
52. 51 ON LINE LOOM MONITORING STOP CODES: 11 Knotting 12 Gaiting 13 Repairing 14 Maintenance
15 Reed Change 16 Quality Setting 17 Chindi Checking 18 Design Approval 19 Sizing problem 20 No Beam 21 No
Weft 22 Electronic Fault 23 Wait For Gaiting 24 Wait For knotting 25 Patteren Correction 26 Redenting 27 Pressure
Down 28 Others
53. 52 Different light for indication: PICANOL White light on: electrical problem Red light on: breaking of warp
Red light on-off: beam was end, knoter have to knotting Yellow light on: breaking of weft Green light on: hand stop
Green light on-off: end of production of req. length Red+yellow on: warp & weft break Yellow+green on: creel is
end Red + green on: when leno or catch cord is broken Red + green+ yellow: bobbin brakage, feeling stop, warp
breakage. Toyota White light on: hand stop Red light on: breaking of warp Yellow light on: breaking or fault leno
wire. Green light on: weft yarn break white light on-off: end of production of req. length Red+green on: warp &
weft break, break of catch cord white+green on: creel is end Red+white + green on: bobbin is broken green+
yellow: leno breakage, feeling stop,
54. 53 Inspection & packing After weaving the fabric is inspected in this dept. to find out the fault in the fabric. After
inspection the fabric is gradified into 7 classes. Then it packs and export in market. In this dept. there are 18 machine
for normal width and 10 for wider width. The basic tasks are: Inspection Folding Packing Inspection Here mainly
Four Point American System is applied for inspection. The method of inspection is: Loom beam is fitted Fabric is
passed through guide roller Reach in checking zone First check width, EPI & PPI Then other problems are
checked There is a check meter to measure the length The report is record in report card where sort no, loom no,
count etc is written. The whole fabric is checked. Then fabric is gradified.
55. 54 M/C Diagram: Checking device beam Path of yarn Guide roller
56. 55 Inspection system In this dept. mainly Four Point American system is used. Sr.no Damage length Point count
1.0 weft wise 1.1 01 1.2 02 1.3 03 1.4 04 2.0 warp wise 2.1 04 3.0 Partial Defect 3.1 02 Note: All color foreign
matter should be removed All partial defect more than 5mm should be cut. II quality/ grading(for minimum 5mm
should be cut) Points per piece Points per shipment 15 points/1oo sq mtr 12 points/100sq mtr
57. 56 Gradation system There are mainly 7 grade for fabric. They are: Grade Pts/100sq mtr Pts/100lnr mtr(normal)
Pts/100lnr mtr (wider) Fabric length A 15 24 45 >=20 mtr(d) >=40 mtr(e) B 22 35 67 >=20 mtr C 31.25 50 95
>=20 mtr D No bar No bar (>1 mtr-<10 mtr No bar (>5 mtr->20 mtr) >=1 mtr-=<10 mtr E No bar No bar (>1
mtr-<10 mtr) No bar (>1 mtr->5 mtr) >=11 mtr- <20mtr F All continuous defect No bar All continuous defect >20
mtr G 47 75 Nil >20 mtr All remaining qualities less than for 1 mtr as follow Market length Packing Chindi 0-25 cm

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Kg Fents 25-99 cm kg Formula: total points*39.37*100*total mtr/width=points/100 sq mtrs.

58. 57 Name of faults that measure: COVER SPINNING FAULT WEAVING FAULT PARTIAL DEFECT
Bumping Reediness Neppines Unevenness Hazyness Streakiness Kitty level Coarsepick Chocked yarn Color
containing count Variation dirty end double weft high twist yarn, knots, neps moire effect, oily effect slub slubby effect
uneven weft three ply coarse end Ball formation, Black stain Broken end Broken pick Bump mark Broken pattern
Design change Design cut Double end Double pick Double weft Fine end Hanging thread Starting mark Thin place
Thickplace Knots Lasing in Leno cut Less width Missing end Nozzle mark Oily stain Pulled warp Reed cut Short pick
Sizing prob. Etc. Crack Hole Float Knotting Multiple breakage Rust stain Sizing/c stop Tear drop stitches
59. 58 Packing After inspection, packing is done the steps of packing are: Material stag on a moving plate Move
to wrapper plate & wrapped with plastic Blade cut excess plastic Punched to next plate where an air suction is
done to brief packing Next heat(150 is given to brief packing. Final packing is done Information written on delivery
package: Roll no= Piece no.= Meter Weight in kg= Grade= Delivery= Party name= Sort no=
Information written on the order slip: Sort no= Party no= Delivery order= Address of party= Deliver date=
Transport type=
60. 59 Packing is done in 3 color plastic: white for grade A,B, green for organic, Red for C,D,E,F KNITTING
Knitting is the production of fabric by forming loops with yarn, which are interlaced in a variety of ways to form the
fabric. Traditional hand knitting , using knitting needles or pins is thought to have existed as early as the 5th century,
although other simpler techniques of inter meshing and knotting of yarns existed much earlier. There are mainly two
types of knitting: weft knitting: the loop formed across the weft. warp knitting: the loop formed across the warp. Here
mainly weft knitting machine is shown. Process flow chart In knitting mainly a loop form. The other yarn passes
through that loop and knitting is occurred. A cam is there which provide the needle motion. In this needle the weft is
passed. The yarn path shown below: Package Passing through aluminum stick Then passes through coni. Then it fed
through feeder Then it come into needle & loop form The needle reciprocated according to design by the cam
61. 60 Fabric is produce General information No. of Machine: Single jourcy=87 Double jourcy=83 Jacquard=9
Flat bed= 17 Manufacturer : Pai lung, Mayer&cie, Kaeo Heng Production: 300 kg/machine/day Doffing: after
20000 revulution. Single jourcy m/c: Diameter: 30 Gauge : 24 Feeder use: 90 Rpm: 28 Coni rpm :25 Roll
weight: 25 kg Conter: 1000 GSM: 196 Inter lock, double jourcy m/c: Diameter: 30 Gauge: 24 Feeder: 96
Rpm: 36 Coni rpm : avg45 Roll wt. : 25 kg
62. 61 Conter :2065 GSM: 154 Rib, double jourcy m/c: Diameter: 30 Gauge: 18 Feeder: 72 Rpm: 34
Coni rpm : avg15 Roll wt. : 25 kg Conter :2329 GSM: 172 Jacquard knitting m/c: Diameter: 30( single jourcy)
,30(double jourcy) Gauge: 24(single jourcy), 20( double jourcy) Feeder: 92 Rpm: 30 Coni rpm :30 Roll wt. :
25 kg Conter :2450 GSM: 165 Jacquard: it is use for rapid repeat & a wide repeat. Flat knitting: Used for
make collers and cough of t-sirt Latch needle is used Maximum width produce: 48
63. 62 Quality assurance activities GSM testing Fabric testing Stitch lengths Feed yarn is 1st tested and then
dispatched for bulk Maintaince activity Cleaning and setting of m/c: for cotton800000rev, 1600000rev. At the time
of cleaning cam, needle, dial, gear, shaft everything is cleaned and clean with oil. Oil level is checking. There is
three fan to remove cotton fly from yarn. Inspection and checking After the fabric is produce the fabric go to
inspection dept. for final checking. The yarn fault is checked according to there wt. the measure fault that check in the
dept is: Holes Press off Needle line Oil line Thick and thin place line
64. 63 Lycra jump Pin hole Lycra line Oil drop Shade variation White spot Yarn cut Loop cut The
fabric is then graded in three class. Class A= 5 defect/25kg Class B= 10defect/25kg Rejected=more than10
defect/25 kg The fabric is then packed. In red pack for sample, white pack for A grade, and yellow for B grade
fabric.
65. 64 CP & POY department CP (Continuous polymerization) In this dept. mainly polymer chip is produced. Here
polymerization is mainly done. Polymerization mainly that process where mainly the monomer is converted into a
higher mol. Wt. polymer to pr. Wt. polymer to produce yarn. Procedure: The main raw materials for this process is
PTA(poly Teripthelic acid), and MEG(Mono ethylic glycol). The PTA is found in form of liquid or solid and MEG is
in liquid from. The PTA stores in a large tank call PTA day bin and MEG is in a small tank. Now this two are mixed at
a ratio of 2:1 and form a slurry which in a high temp. converted into a paste of this two ingredients. Now this paste

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makes a reaction. This reaction is an ESTERIFICATION reaction. Here the paste is esterified and as a product H2O
is produced. Then the esterifies paste react with SB2O3. Now it forms 25% low polymer. This Low polymer at last at
vacuum condition at a temp. of 290 it produce final polymer. Then filtration is done. Then this is converted directly into
the POY by melt spinning process or into small polymer chips.
66. 65 Some important information about this process: This process is mainly 3 reaction: Esterification, UFPP,
Finshing TiO2 is used here as adhesive. Sb2O3 is used here as catalyst The whole process is done at a temp of 280290 The whole process is done under pressure The whole process is controlled by the 7 operating consoles with
automatic microprocessor controlled. The raw materials are received from this company: Paras alloys and Salts Indian
oxide and chemicals Hongcong hauchang antimony chmical Sachtleben holding A.S Agrofort holding A.S Saudi basic
industries Corp. Losa industries ltd Mitsui & co. ltd. Reliance industries ltd. Daily production of this CP= 540 tons.
67. 66 POY DEPARTMENTPOY DEPARTMENTPOY DEPARTMENTPOY DEPARTMENT POY (Partially
Oriented Yarn) is produced from polymer chips. Wet chip hopper:-3kg air pressure also to store the chips for
further process. It also has waste collector system containing microdust and impurities coming from continuous
polymer. Vibro feeder:- It is having functions of feeding the reserve chips kept in hopper. Crystallizer:-It drives the
chips and remove microdust particles. Chips column:- The temperature in the column is around 265 C and kept for
6 hours and hence it is maintained. Dry chip hopper:-From chip column the dry process is done in this hopper.
Extruder hopper:- Here chips are melt at 295C. It has 6 zones called as manifold. Separate motor is provided for
every zone. Polymer filter:-It removes dust and clean the polymer chips. Spinning floor:-Coolling filament through
perforated board. Oil pump:-To oil the yarn surface to reduce static change & microbal attack. PASSAGE:-Duct
coming from CP department having melted chips 350C- polymer cooler- cooling the melted chip-polymer boosterfor further process high pressure boosting pump is provided with higher capacity motor.
68. 67 In this POY department has two unit. IN UNIT 1 Total line:- 10 (Each lines consists of 24 heads) A single
line of TMT winder 6 heads each head having 12 feeder from where 12 package wound. 46=2412=288 Package
is being produced. Each package have weight of 10.2 kg. Remaining 9 line block having 8 heads each head having 10
feeder from where 10 package wound. 38=2410=2409=2160 Package is being produced. Each package have
weight of 15 kg. M/c Manufacturer-Beijing chonglee (China). Production calculation: Actual speed of spool Actual
denier no of position 60/(90001000)=_______kg/hr. Spindle Speed- 2500m/min LOY(Low Oriented Yarn)
2500-4000m/min POY(Partially Oriented Yarn) 4000-7500m/min FOY(Fully Oriented Yarn) Production per day of
POY department- 150 metric ton IN UNIT 2 Total no of lines:- 12 single line of having 6 heads each head having
10 feeder from where 10 package wound 46=2410=24012=2880 Package is being produced.
69. 68 Production-350 metric ton/day. M/c Manufacturer- Barmag(Germany) M/c Name- Wings Higher denier yarn
is being produced in this department. QUALITY ASSURANCE DEPARTMENT (POY) In this quality assurance
department mainly tested tensile strength, elongation%, draw force, evenness & cross section of Partially Oriented
Yarn. (1) TENSILE TESTING OF YARN Purpose:- Determination of elongation% & Tenacity of POY. Principle:Operating on the principle of constant rate of elongation. Appatratus:- STATIMAT ME & Yarn strength tester.
General Information of machine (a) Gauge length 250 mm (b) Test speed 1000mm/min (c) Pretension 0.5 CN/tex (d)
Drop of force 90% (e) Compressed air pressure- 5bar (f) Temperature of the lab 25C to 32C (2) DRAW
TENSION TESTING OF YARN Purpose:- Determination of draw tension of POY Principle:- Measuring of yarn
draw tension at constant extension & speed.
70. 69 Apparatus:- DTI 500 General Information of machine (a)Feed rate 170m/min (b) Test length 170m (c)Draw
ratio1.70 (d) Heating tube temperature 185C (e)Compressed air pressure= 6 bar (f) Temperature of lab 25C to
32C (3) EVENNESS TESTING OF YARN Purpose:- Testing of linear density(Unevenness) of POY. Principle:when a yarn sample passes through capacitance testing slot, quality change (variation in linear density) is transformed
to corresponding electric signal. Apparatus:- Keisokki KET80 Type C General Information of machine:- (a)Test
speed 200m/min (b) Range12.5% (c)Evaluation time =1 min (d) Compressed air pressure =4 bar (e)Temperature of
lab 25C to 32C Gradation Norms For POY As Per Weight Range Beijing Chonglee Winders Existing Proposed
Serial no Grade Wt. range in kg Wt. range in kg 1 1E 14.5kg to 15.2 kg 14.5kg to 15.2kg 2 1A 10kg to 14.449kg
10kg to 14.449kg 3 1M 3kg to 9.999kg 5kg to 9.999kg
71. 70 4 SS 500gm to 2.999kg 3 kg to 4.999kg 5 CLQ 200gm to 499gm 500 gm to 2.999kg TMT Winders

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Existing Proposed Serial no Grade Wt. range in kg Wt. range in kg 1 1E 10.5kg to 14.250kg 9.750kg to 10.5 kg 2
1A 5 kg to 10.449kg 7 kg to 9.749kg 3 1M 2kg to 4.999kg 5kg to 6.999kg 4 SS 500gm to 1.999kg 3kg to
4.999kg 5 CLQ 200gm to 499 gm 500gm to 2.999kg FINISHING MATERIAL (POY) FLOW DIAGRAM POY
1 POY 2 T/UP Denier Checking T/UP Textile lab Packing Scheduled Testing Packing Visual Inspection 100% Visual
Inspection 100% Grade wise/Denier wise Grade wise/Denier wise Pin trolly Fillings Pin trolly Fillings Weighment
Weighment Strapping Strapping
72. 71 Polymer GP Spinneret Condition Air Finish Guide PigTail Guide Intermingale line Guide 1 Guide 2 Winder
POY MACHINE DIAGRAPOY MACHINE DIAGRAPOY MACHINE DIAGRAPOY MACHINE
DIAGRAMMMM
73. 72 TEXTURISING Texturising is a process of providing an artificial crimp to man-made fibre to impart properties
somewhat similar to natural twist fibres, it can be provided by melt spinning in continuation by passing it from crimping
machines. It may be gear crimp or false twist texturising. It is a method of marking the PET yarn wearable. End
product of POY is POY yarn wound on spool the weight varies from 10.5kg-22kgs. The yarn is very lustrous and not
at all comfortable for wearing. It generates static charges and air permeability of those fabrics is very poor. Here in this
machines the output is made up from the bulk out of flat continuous POY yarn and termed as Draw Textured Yarn.
And this bulk is formed by spindle running at 850-1000 rpm having 3 discs in zigzag manner. The flat polyester yarn
have covalent linkage with luster is removed by heater. THE MATERIAL FLOW CHART Creel (Spool) Guide Rod
Primary Heater(150 -250 ) Cooling PlateSpindle(disc), (850-1000rpm)V2 rod Air pressure inlet chamber for
punching(4.2bar) V4 shaft Internediator Secondary heater(150 -190 Package Drum bakelite package V3 shaft Oil
roller Guide Outlet roller
74. 73 GENRAL INFORMATION There are total 92 machines divide in 4 units in the company. Unit1- 36
machines Unit2- 16 machines Unit3 - 24machines Unit4- 24 machines (Auto Doffing) Machines are mainly
manufactured by these companies: HIMSON Bhogibhai HIMSon Devananadbhai Alidhra- Hansrajbhai
Alidhra- Babubhai Barmarg- China Murata- Japan Himson- Autodoffing TECHNICAL DATA Machine Setting
Throughout speed 750 mpm Draw Ratio 1.715L 1.715R D/y Ratio 1.52 Jet over feed 4.15% Stabilizing overfeed
6% Oil shaft speed 1.8mpm
75. 74 Travers speed 375 Temp Primary:200 Secondary:185 Machine data Machine no. D-Tex 15 D-Tex 7
Manufacturer HIMSON Alidhra POY denier 250/48 130/34 Spinner Alok Alok Merge no. 220681 108118 DTY
denier 150/48 75/34 Lot no 10555 10624 Doff time 6.2hr 13 hr Doff wt. 5.3kg 5.3kg Paper tube color Blue-black
strip Blue No. of spindle : 312-336 for manual Doffer, for auto doffer 216 PRODUCTION DATA Calculation
Production=(0.00016*m/c speed*denier* no.of spindle) Production Chart performance target Last month Best
achived Hall1A Hall1B Hall1A Hall1B Hall1A Hall1B production 1617.5 1816.8 1757.0 1816.8 Efficiency% 93.0
93.0 88.42 89.64 91.32 88.90 1st grade 96.5 96.5 95.65 95.76 97.7 97.64 Avg. package 4.3kg 4.3kg 3.98kg 4.06
kg 4.33kg 4.25 Ends down% 1.0 1.0 2.7 2.6 1.97 2.6 Idle% 1.0 1.0 2.64 1.97 1.49 1.3 Waste% 0.3 0.35 0.5 0.41
0.33 0.3
76. 75 Per day 400 tons produce in this dept. PACKING & INSPECTION There are mainly 3 types of products,
those produce in the dept. They are: NIM- No intermingling SIM- Sub intermingling HIM- High intermingling On
this basis the products are divided in three qualities: First quality Printing quality Claimless quality This division is
done on the basis of following chart: FIRST QUALITY Defects Knitting Weft G.F.T Micro normal Roto SIM Export
HIM B.F/Loops 5-6/kg 4-5/kg nil 5-6/kg 1-2/kg 3-4/kg nil Cross winding 2 2 nil nil 1 1 nil Oil stain 63 70 70 63 68
66 68 Hardness nil nil nil nil nil Nil nil Slippage nil nil nil nil nil Nil nil Tight spot nil 1-2/kg 2-4/kg nil nil Nil nil Bulk
variation nil Very less Very less nil nil Nil nil Weak yarn nil nil nil nil nil Nil nil Winding mistake nil nil nil nil nil Nil nil
77. 76 Nips variation N.A N.A N.A N.A 1/MT 1/MT nil High oil nil nil nil nil nil Nil nil PRINTING QUALITY
Defects Weft Roto SIM B.F/Loops 4-6/kg 3-5/kg 3-8/kg Cross winding oneside, 4-6 oneside, oneside, Oil stain
high high High Hardness normal normal normal Slippage nil nil nil Tight spot 4-6/kg nil nil Bulk variation Allow Allow
Allow Weak yarn Very less Very less Very less Winding mistake Allow Allow Allow Nips variation nil Allow Allow
High oil Abnomal Abnomal Abnomal CLAIMLESS QUALITY Defects Weft Roto SIM JOB LOT B.F/Loops
76/kg 76/kg 78/kg 78/kg Cross winding Both side, >6-10 Both side, > 6-10 Both side, > 6-10 Both side, >10 Oil
stain Max Max Max Max Hardness Abnomal Allow Allow Allow Slippage Allow Allow Allow Allow Tight spot

Allow Allow Allow Allow Bulk variation Allow Allow Allow Allow Weak yarn Allow Allow Allow Allow Winding
mistake N.A Allow Allow Allow Nips variation Allow Allow Allow Allow High oil Allow Allow Allow Allow
78. 78. 77 Mixdenial Max Max Max Allow For packing 3 color packs are used. Red for C.L quality, Green for Printing
quality, and white one for export quality. Q.A OF TEXTURISING WRAP REEL: here mainly denier is measured in
90 mtr length. STATIMATEME: for measuring elongation, tenacity in a length of 500 mm-4 package from a lot.
ITIMAT LAB: it measures punch put up into texture yarn TEXTUREMATME: to measure shrinkage and crimp
contraction TWISTER: Gauge length 50 mm is test for measure the TPM. TKD: Tube knitting dyeing, here mainly
sample of a lot is knitted and then dyed. Now by shade variation the irregularity is measured.

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