DEPARTMENT OF BUSINESS ADMINISTRATION

(University of Karachi)

Submitted by,

ACKNOWLEDGEMENT

WE ARE FROM THE UNIVERSITY OF KARACHI , THANK THE ALMIGHTY ALLAH FOR THE SHOWING HIS BLESSING ON US AND ENABLING US TO GO WELL THROUGH THE TRAINING IN THE QUALITY DEPARTMENTOF THE AFROZE TEXTILE INDUSTRIES UNDER THE GUIDENCE OF Mr. ARMAN SHAH(QC MANAGER) AND HIS ALL STAFF. WE ARE ALSO THANKFUL TO OUR CHAIRMAN Dr. FASIHALLAH WHO GAVE US THE OPPORTUNITY.

TABLE OF CONTENTS
S.NO 1 2 CONTENTS INSPECTION & MENDING PRETREATMENT (INSPECTION,SINGEING,DESIZING.SCOURING, BLEACHING,MERCERIZATION) DYEING CONTINUOUS DYEING THERMOSOLE PAD STEAM PRINTING PANEL PRINTING ROTARY PRINTING FINISHING STENTER CALENDERING RAISING UTILITIES (BOILER,EFFLUENT WATER TREATMENT,R.O)

The Pakistan Textile Industry - An Overview:

The textile industry is one of the most important sectors of Pakistan. It contributes significantly to the country's GDP, exports as well as employment. It is, in fact, the backbone of the Pakistani economy. Established capacity: The textile industry of Pakistan has a total established spinning capacity of 1550 million kgs of yarn, weaving capacity of 4368 million square metres of fabric and finishing capacity of 4000 million square metres. The industry has a production capacity of 670 million units of garments, 400 million units of knitwear and 53 million kgs of towels. The industry has a total of 1221 units engaged in ginning and 442 units engaged in spinning. There are around 124 large units that undertake weaving and 425 small units. There are around 20600 power looms in operation in the industry. The industry also houses around 10 large finishing units and 625 small units. Pakistan's textile industry has about 50 large and 2500 small garment manufacturing units. Moreover, it also houses around 600 knitwear-producing units and 400 towel-producing units. Contribution to exports: According to recent figures, the Pakistan textile industry contributes more than 60% to the country's total exports, which amounts to around 5.2 billion US dollars. The industry contributes around 46% to the total output produced in the country. In Asia, Pakistan is the 8th largest exporter of textile products. Contribution to GDP and employment: The contribution of this industry to the total GDP is 8.5%. It provides employment to 38% of the work force in the country, which amounts to a figure of 15 million. However, the proportion of skilled labor is very less as compared to that of unskilled labor. Organizations in the industry: All Pakistan Textile Mills Association is the chief organization that determines the rules and regulations in the Pakistan textile industry.

PROCESSES OF TEXTILE MANUFACTURING

Textile manufacturing begins with the production or harvesting of raw fiber. Fiber used in textiles can be harvested from natural sources (e.g. wool, cotton) or manufactured from regenerative cellulose materials (e.g. rayon, acetate), or it can be entirely synthetic (e.g. polyester, nylon). After the raw natural or manufactured fibers are shipped from the farm or the chemical plant, they pass through four main stages of processing: Yarn production Fabric production Wet process Garment Manufacturing

In addition to garment as final product of these process stages, stock yarn (final customer product) and carpets are also manufactured within these stages but in different ways.

YARN FABRICATION
Yarn fabrication is the process, which converts raw fiber into yarn or thread. The fibers are prepared and then drawn out and twisted to form the yarn, which is then wound onto a bobbin or cone. The yarn fabrication is entirely dry, although some yarns maybe dyed and finished as a final customer product.

FABRIC PRODUCTION
Fabric production, the second step, involves weaving, knitting, tufting and non-woven. Tufting and non-woven are used in the fabric manufacturing but not as widely as weaving and knitting.

WET PROCESSING
The fabric produced from the weaving or knitting is in rough condition and is often termed 'grey' fabric. The material is rough to the touch and contains impurities, which are either natural in the fibers or added to facilitate the process of fabric manufacture. Fabric processing (wet processing) is done to improve the appearance and serviceability of the fabric in many ways. The main operations carried out in this step include pre-treatment, dyeing, printing and finishing

GARMENT MANUFACTURING
The finished cloths are fabricated into a variety of apparel and household industrial products. The simpler of these products, such as bags, sheets, towels, blanket, and draperies often produced by the textile mills themselves, but apparel or more complex house-wares are usually fabricated by cutting trades.

YARN FABRICATION
Yarn dyeing and finishing are different from woven fabric finishing because there is no sizing and desizing operation. They are different from knit fabric finishing because of their mercerising operation and water use. The main processes involved are cleaning, scouring, bleaching, mercerizing, dyeing and special finishing. Sewing thread, textile and carpet yarn are typical product in this category. Several techniques are available for processing raw yarn into the finished product. The most common process is probably package dyeing, but other processes, such as space dyeing, are widely used. In package dyeing, yarn wound on perforated tubes is placed in a large vessel, which is sealed. The dye solution, at an appropriate temperature, is circulated through the yarn. The dyed yarn is washed, rinsed and dried.

Finally, the yarn is unraveled and then wound on cons for the subsequent use by other mills.

CARPET FABRICATION
Carpet mills use mostly manmade fibers (synthetic fibers: nylon, acrylic and polyester), but some wool and cotton is also processed. This category is characterized by any or all of the following operational units: bleaching, scouring, carbonizing, dyeing, printing resin treatment, water proofing, flam proofing, soil repellency, backing with foamed and unfoamed latex or jute. Carpet backing without other carpet manufacturing operation may be included in the dry processing mill category. Some carpet is backed with latex in a separate plant, other carpet mills do latexing in the same plant with the finishing.

OPERATIONS IN WETTING PROCESS

THE BASIC OPERATIONS We can consider the wet processing sector to have three distinct types of process included within it. These are represented along with their aims. 1- PREPARATION PROCESS: Exists to ensure that the textile has the right physical and chemical properties to enable it to be coloured or finished. EXAMPLE:Desizing, Singeing, Scouring, Bleaching etc. 2- COLOURATION PROCESSES: Exists to provide the textile with colour either for aesthetic reasons or for some functional purpose determined by the end-use of the product. EXAMPLE: Dyeing, Printing. 3- FINISHING PROCESSES: Exists to provide the textile with the properties that the end-use demands and which have not already been provided by any earlier processes. EXAMPLE:Water Repellency, Flame Repellency, Anti- soiling finish etc

STEP:1

INSPECTION and MENDING

The first step in textile wet processing is the inspection and mending of the griegh fabric. The greigh fabric which is obtained after weaving or knitting has some weaving or knitting faults. These faults decrease the quality of a finished fabric if they are not removed and badly affects the sales as well. These faults must be inspected and mended before further processing in order to result a good quality fabric. These faults are observed and corrected if they are up to a certain limit. If they are beyond limit then the fabric must be rejected. The method of observing these faults is called INSPECTION the correction of these faults is called MENDING. These faults are: Fault up to 2inch Mispick Double pick Broken pick Holes Slubs/knots Light stains Permanent stains Carbon black line Loose hanging threads Reed mark Color fly Wrong weft Oils stains Bad selvedge

STEP:2

PRE TREATMENT:
The main purpose of this department is to produce fabric which is ready for dyeing (RFD) and printing (RFP). Pretreatment includes: Singeing Desizing Scouring Bleaching Mercerization

SINGEING:
Singeing is the process in we remove the hairs of fibers on the surface Of fabric with the help of burner. There are two types of singing. Face back singeing: face and back both sides hairs are removed. Face only: face side hairs removed only. The fabric comes from batcher and then it passes from the pre brushing chamber where the fabric is brushed with the help of brushes. These brushes raise the fabrics hairs from the surface of the fabric. After brushing some unwanted particles or hairs are sucked by an exhaust which is fitted on the exit of the brushing roller .These particles are thrown in a large bin through exhaust and discarded. After brushing the fabric goes to the burner section where it is passes very quickly through the burners at high speed in such a manner that the fabric is not burnt. High flame intensity is applied such as 12mbar. In post brushing, the burnt hairs of fibers are raised by brushes and are sucked by exhaust and dissolved in water section and flows out.

Pre . Bru sh

Bur ner s

Post Brus h

DESIZING:
To remove the size material which is applied during weaving stage. The sizing material hinders the absorption of water or dye-liquor so its removal is essential which is known as desizing process. There are four types of desizing : Acidic desizing Basic desizing Oxidative desizing Enzymatic desizing

From the above types only enzymatic desizing is done in mostly industries because enzymes have low activation energy and they are activate in low temperature. After singeing the fabric goes to desizing bath and padded with the following chemicals: Desizing agent: to remove size material Wetting agent: for increasing absorbency or wet ability Acidic acid: for maintain ph of the fabric

Then the fabric is rolled on the batcher and it is rotated about 8-12 hrs to get dry then the fabric is washed with hot water. After desizing we check the fabric PH with help of PH solution and tegewa solution is used to check absorbency.

SCOURING:
Scouring is a process to remove fats, oils and waxes from the fabric and increase absorbency. Cotton goods as yarns and woven and knit fabrics

contains about 8-10% of natural impurities. Natural impurities require treatment with strong alkalis like caustic soda. Due to hydrogen peroxide bleaching the process of scouring has been eliminated. The ultimate aim of scouring is to make the material uniformly and highly absorbent in a cost effective manner so that there are no difficulties in process of dyeing, printing and finishing. Caustic and wetting agent are the chemicals used in this process. In the presence of caustic the cellulose structure is swelled and impurities come out from the fabric and removed.

BLEACHING:
Bleaching is a process of removal of all natural colors and stains. Bleaching can be done in the yarn stage or in the constructed fabric. Bleaching is necessary for producing white goods. Bleaching is normally carried out by hypochlorite, hydrogen peroxide or sodium chlorite. In Afroze textile industry, solomatic bleaching is carried out in which both scouring and bleaching perform together on textile fabric. The chemicals used in this process are: H2O2 NaOH Stabilizer Sequestering agent Wetting agent J- Scray Bianko Roller PreWashing Impacta

Batcher

Drying cylinder

Neutralization Chamber

Post Washing

Steamer

Exit scray

Winder

Batcher

Fabric for bleaching comes in batcher form, passes from J-Scray. Fabric then passes from roll called Bianko roller, which removes creases on the fabric and comes in to washing chambers for pre-washing. Pre-washing contains three chambers which are arranged in an inclined manner.This inclined arrangement of chambers help in draining out of dirty water. In prewashing, the fabric passes from vacuum here fluff on fabric is removed by water pressure. Then fabric goes to 2nd and 3rd chambers of pre-washing. Then fabric enters in impacta which contains bleaching chemicals. In impacta, there is a padder. Chemicals uniformly pickup by fabric with the help of this padder. Excess chemical will squeeze out by squeezer and fall back in trough. Fabric then goes to the steamer, where fixation of chemicals takes place. The temperature at the bottom portion of the steamer is 95 oC while the top portion of steamer is at 102oC. Then fabric again passes through post washing chambers followed by neutralization chamber. Neutralization chamber is divided into two parts, first part contain acid and other contain water for rinsing. In this chamber, fabric becomes neutral using acetic acid. Fabric then come in to drying section consists of 10 hot and 10 cold cylinders alternatively. At output there is winding arrangement which winds the fabric on the batcher.

MERCERIZATION
Mercerization is a very important operation in the wet processing industry. In mercerization process caustic is used which converts 35% crystalline region of cotton in to amorphous region and due to this conversion the reflectance increases which automatically increases the luster. The main objectives of mercerization are: To To To To increase absorbency /wet ability increase luster increase dye uptake. provide dimension stability

There are of two types of mercerization Cold mercerization Hot mercerization

In cold mercerization, the chilled caustic at 30oC is used. The speed of machine is kept at 30 m/min but production is low. In hot mercerization, the caustic at 60oC is used. The speed of machine is 60-65m/min and the production is high.

Unwinding

Strong lye

Load cell & Pin wheel

Washing & Neutralization

Weak lye

Winder & Batcher

Drying section

First fabric get unwind from the batcher and enters into the strong lye section and gets swell by passing through the caustic of 28 Baume concentration. Then fabric is now entered in the load cell region where shrinkage recovers which was caused by the caustic in strong lye and then fabric goes to the pin wheel section where width of the shrinked fabric recovers. And then weak lye section comes, here fabric is passed through the engraving and hollow rollers then a set of squeezer and padder there to remove the excess amount of liquor from the fabric. Primary washing is also done in this section . Then fabric enters into the washing range for the complete washing to remove all of the caustic. Then fabric goes to the neutralization chamber here the pH is maintained up to 5-7. After the washing chamber drying section starts. Total 12 drying cylinders are there and they are arranged in a vertical pattern. And then fabric after passing through scray wounds on the batcher for further processing.

STEP:3

DYEING
Dyeing is the process of imparting colors to a textile material in loose fiber, yarn, cloth or garment form by treatment with a dye. On industrial basis, there are of two types of dyeing which are: Continuous dyeing Exhaust dyeing Types of Dyeing Continuous Dyeing Batch Dyeing Methods of Dyeing a/c to their type Thermosol Machine, Pad-steam Winch, Jigger, Jet

In this report, we will only discuss continuous methods of dyeing which are:

THERMOSOL:
Thermosol dyeing is a continuous dyeing method which is applied mainly for the polyester/cotton blended materials. After padding and intermediate drying, thermosol fixation is carried out by dry heating for 60-120 sec. at 180- 210C depending on the form of the material and type of disperse dyes.

Entry batcher

Cold cylinders

Dyeing bath

Squeezing rollers Airing zone

Curing

Thermex

IR region

Cold cylinders

Exit Scray

Exit Batcher

The fabric comes on dyeing machine after setting from the stenter thats why its temperature is bit high so fabric first comes on the chilled rollers which cool down the temperature of fabric up to room temperature. The fabric now enters in dyeing trough which contains all chemicals and dye. When the dye is applied from here extra dye must remove by squeezing roll which is placed above trough section. By passing through the squeezing rollers the fabric further move towards airing section where temperature rise by contact of fabric with hot air. Temperature rise is given, due to avoidance of shocking impact in I.R zone. After airing zone IR zone is started which reduces moisture of the fabric up to 30% . Then the fabric move towards three chambers in which two are known as thermex and one is known as curing. Thermex is used to drying of fabric and absorb moisture this is done by giving the temperature to fabric. In thermex 1st chamber has temperature of about 125-130C and in the 2nd chamber the temperature is raised up to 150-180C for optimum drying. Curing chamber is for fixation of chemical auxiliaries having temperature 180-220oC. Then fabric moves on the cold cylinder for normalizing the temperature and finally on batcher.

PAD STEAM:
The pad steam process is spread all over the world as the most common continuous dyeing procedure with a wide range of different dyeing methods. Pad steam is used for dyeing lighter shades. Following processes can be performed on pad steam: Wet-on-wet (pad steam) Washing Vat development Pad-dry-chemical pad (Two bath dyeing) Reduction clearance (RC)

Entry Batcher

Chemical trough

Steamer

Water lock

Steep master
Neutralizati on chamber

Washing range Drying section

Vacuum section Exit Batcher

First fabric get unwind and passes through the trough .70% pick up is achieved here in the trough. Then fabric enters into the steamer for the fixation of chemical auxiliaries, then a water lock system is installed to minimize the steam losses. Temperature of water lock is 40C. Now fabric passes through the vacuum section where the fluff gets removed from the surface of fabric. Then fabric entered into the washing range of 5 chambers. Steep master is installed after washing chambers where fabric is allowed to stay for a time period of 2-10 minutes for the improvement of washing fastness. Detergent is also added into this chamber. Then fabric goes to the last tank which is neutralization chamber. This chamber is divided into two parts, one part contains acid in it that is acetic acid and normal water in the second part. PH is also maintained in this chamber from 5-7. After the washing chamber drying section is there. And then fabric after passing through scray wounds on the batcher for further processing.

STEP:4

PRINTING:
Textile printing is the process of applying colour to fabric in definite patterns or designs. Printing is done by means of two different machines: Rotary screen printing Flat (bed) screen printing or Panel printing

In Rotary printing , cylindrical shaped or rotary screens are used. Rotary is usually used to print small designs. The diameter of screens can be varied according to the design to be printed. The diameter of screens can be varied according to the design to be printed. The screen sizes may be of 64,71,81,91,101 repeats. The screens of rotary printing are made from Nickel.

WHILE

In flat bed printing, flat screens are used which are made up of Nylon. This type of printing is expensive as compare to rotary printing and it is employed to produce bigger designs. There are two types of printing which are: Reactive printing Pigment printing The chemicals used in Reactive printing are: Resist salt Urea Soda ash The chemicals used in Pigment printing are: Binder Urea Liquor ammonia Thickener

In case of reactive printing, fabric is washed after steaming while in case of pigment printing washing is not required. The drying temperature should be 110-120oC.

Entry Batcher

Suction section

Gluing section

Printing area

Trolley

Plaiter

Curing or Steaming

Drying section

Fabric gets unwind from batcher and passes through threading and goes in the vicinity of suction system where fluff is removed and by passing through the dancing rollers fabric gets stick to the blanket. Here a gluing section installed to apply glue onto the surface of blanket due to which the fabric sticks on the blanket and do not move while passing through screens. Now the printing area starts where screens are placed side by side and chemicals are dosed in to the screens by means of pumps. In this way, the fabric gets printed and passes through the drying section by means of conveyer belt. After that curing or steaming is carried out according to the type of printing employed. Then finally the fabric is piled by means of plaiter in the trolley. After printing process, there is a light inspection system to check that either the desired shade is achieved on the fabric or not. Different lights are used for this purpose according to the demand of customer that are: D65 CWF 3000 UV

STEP:5

FINISHING
Textile finishing is a term which includes many processes in order to produce a final finished fabric. Finishing is carried out to give the textile materials a certain properties like luster, drape, softness, dimension stability, crease recovery, water repellency and flame retardancy etc. The type of finishes and their methods of application depend upon the nature of the fibrous material and their arrangement in yarns or fabric. The three main finishing operations are carried out by following machines: Stenter Calendar Raising

STENTER
Stenter is a setting and finishing machine used to set the dimension of warp or weft i.e. to set the width of the fabric.It is also used to control cross and bowing problems. On stenter the fabric is either set or finished. The fabric is either set for dye, set for print or set for mercerize after bleaching operation. All types of chemical finishes can be applied by using stenter. Setting of fabric is done by two ways: HEAT SET: It is normally done for PC fabric. The maximum temperature given is 200 C to 210 C and the speed is 60 m/min 65 m/min. NORMAL SET: It is done for cotton fabric. The maximum temperature here is 160 C 180 C and the speed is 70 m/min 75 m/min.

Trolley

Guide roll Cutting/ Suction

Trough

Squeez er Heat section

Mahlo system

Cooling section Exit Batcher

Panel

Winder

The fabric from the trolley travels through guide rollers and comes in the trough where the desired finishing chemicals are applied on it and so the fabric gets wet. Moisture in the fabric is given to elongate it while stretching as dry fabric will tear on stretching. Then fabric goes in the squeezer which squeezes the extra chemicals from fabric. Then through tensioning rollers fabric enters into the Mahlo system where curved rollers are installed for removing bowing by moving the rollers downward in case of forward bowing and vice versa for backward bowing and straight rollers for eliminating cross by moving to and fro. The fabric then enters in the endless chain system where it is clipped or pinned and moves through the heating chambers to set its width by stretching and by the application of heat simultaneously. After that, the fabric is cooled in cooling chamber and then move towards winder through the guide rollers and then wound on batcher.

CALENDERING:
Calendaring is a mechanically produced finish achieved by passing fabric between a series of rollers. Calendaring primarily imparts luster and filling of fabric and is usually the final treatment for the fabrics in the finishing sequence. The name of the calendaring machine is Ramisch Guarneri Calendering machine.

Batcher

Guide roll Exit batcher

Metallic detector

Seam detecter Cotton roller

Screw roller
Steel and teflon rollers

Winder

The fabric after dyeing or printing comes to the calendaring machine for the improvement in its luster, softness and filling. The fabric from batcher travel through guide rollers and moves towards metal detector to avoid damaging of teflon roll because if there is any metallic particle present in the fabric it will damage the teflon roller which afterwards engrave the design periodically on the fabric. During the pressure being applied between steel and teflon rollers, so if metallic part detected, first machine is stopped automatically then pressure between the teflon and steel is released i.e. a wider space is given to by pass the fabric without affecting the teflon rolls. After metallic detector, seam detector comes which when senses any stitching releases the pressure i.e. move apart and provide greater space than the space for normal fabric without stopping the machine to avoid engraving of thread mark on teflon roll because of heavy pressure application from steel roller. Then fabric move towards screw roller which gives tension to the fabric and move it towards steel roller. The fabric is passed between steel and teflon roller which give filling to the fabric by pressing. The luster is also produced because of steel roller by means of heat which is produced by injecting oil in the hollow steel roller. Hot oil is coming from oil boiler which when comes to calendaring machine then inlet is manually opened so oil flows inside the steel roller and heat it. After steel roller fabric goes towards cotton roller which softens the fabric. Both steel and cotton roller are moving in same direction and teflon roller is in opposite direction. Then through guide rollers fabric move towards winder then to exit batcher which contains the finished fabric having desired properties.

RAISING
The purpose of raising is to lift a layer of fibers on the surface of fabric. It gives a soft handle to the fabric and makes the material more attractive. It also increases the comfort ability of the fabric. Raising can be carried out

on all types of natural and synthetic fibers. This operation is performed using card wires. Raising lowers the strength of the fabric. Raising machines are of two types: Single acting : Gives finish on one side Double acting: Produce finish on both sides

Batcher

Guide roll

Drum roll Exit batcher

Counter pile

Pile roller

Winder

The fabric from the batcher first comes to the guide rollers which balance the fabric and allow it to move forward. The steel roller is also adjusted which removes moisture present on the fabric. The fabric now comes to drum roll on which 36 brushing rollers are mounted containing iron pins. The brushing rollers are divided into 18 pairs of pile and counter pile rollers. Direction of pins are opposite in both of the pile and counter pile rollers. These rollers basically raise the fibers. The pins of pile rollers enter into the fabric and raise the fibers while counter pile take out pile roller from fabric The length of drum roll on which these counter pile and pile rollers are adjusted is124 inch. The speed of pile and counter pile is 100m/min. Direction of drum roll is opposite to that of brushing rollers in order to grip the fabric. An air blower is also adjusted to remove the fluff coming out from the fabric during raising. Then finally after passing through threading rollers, the fabric gets wind on the batcher.

STEP:6

UTILITIES
Utilities are very important in proceeding the basic process carried out in an industry. Without utilities, it is almost impossible to run the plant and these also help us to control the capital cost because cost controlling is the major factor while running any plant or industry. The basic utilities of a textile industry are: Boiler Effluent water treatment unit Reverse osmosis (R.O) unit

BOILER
Boiler is a directly fired tabular apparatus which primarily convert fuel energy into latent heat of vaporization. There are two general types of steam generating boilers: Fire Tube Boiler Water Tube Boiler

Fire Tube Boiler consists of a cylindrical vessel having tubes passing through it which are rolled into the heads at each end of the vessel. The tube bundle is generally horizontal, and the upper section of the vessel is not tubed. Combustion gases pass through the tubes and water level is carried in the vessel to immerse the tubes completely but allowing disengaging space between the water level and top portion of the vessel. Fire tube boiler seldom exceed 8ft in diameter and steam pressure is generally limited to 100 to 150 psig. They are used for low capacity services up to 15000 to 20,000 lb/hr of steam production. Fuels employed may be coal, oil or gas.

WHILE

Water Tube Boiler have water with in its tubes. Combustion of coke or coal, gas and oil provides radiation to the boiler tubes and further heat transfer is accomplished by the flow of hot gases over the tubes to provide convection heat transfer. There are three types of water tube boilers.

Longitudinal drum Cross drum straight tube Cross drum bent tube

Material of construction (MOC) of boiler is Stainless steel and it is insulated with Glass wool. The design conditions for 8ton and 15ton boiler are as under : DESIGN CONDITIONS Boiler Type Design and Manufacturer Max.allowable temperature and pressure Hydraulic test pressure Design Standard Boiler Weight Model number Capacity 15 TON BOILER 8 TON BOILER

Smoke tube boiler Descon Engg Ltd. 12.5 Bar (G) & 193.3oC

Smoke tube boiler Descon Engg Ltd. 12 Bar (G) & 193.32oC

22.25 Bar (G) TRD 29 Tons DDOFSS-15-12.5 15 TPH : 193.3oC Saturated steam

21.50 Bar (G) TRD 22 Tons DDOFSS-8-12 : 8 TPH : 191.6oC Saturated steam

The production of a boiler may vary according to load. The routine production is: Bleaching : Pad steam : Mercerizing : Red flag : Winch : Jigger : Printing : Thermosol : Singeing : Stenter : 3ton/hr 2.5ton/hr 3ton/hr 2.5ton/hr 2.5ton/hr 3ton/hr 0.5ton/hr 0.8ton/hr 0.7ton/hr 0.5ton/hr(if dyeing)

The parameters required to control for achieving greater efficiency of boiler: Temperature Water Fuel

Water comes from over head tank which consist of high amount of TDS approx 250-300 which is removed by softener unit. This unit controls the amount of Ca and Mg by using an Ion Exchange Resin. If any TDS remain in the water then it will cause scaling in the boiler. From softener plant, the water now enters into the feed water tank where water heats up to 85C to remove oxygen which may cause corrosion in the boiler. Then the water move towards economizer where the temperature of water reaches up to 95C by means of the hot flue gases coming out from the boiler in to the economizer and flowing inside the coils of economizer. Economizer decreases the gas consumption up to 10%. Water now move towards boiler one draft system and one exhaust is placed at the front of boiler, three pass system is used in the boiler, chimney is also present to exhaust the gases . Expansion door is present at the back of boiler to control the pressure inside the boiler when pressure becomes high.70-72 cubic meter gas is used for the consumption of 1ton steam. Sodium chloride is used for the back washing of softener unit. The steam generated by the boiler finally to different machines according to the demand.

Water supply tank

Softener

Feed Water Tank

NaCl Dosing Economizer BOILER Bleaching Stenter Winch

STEAM DISTRIBUTION HEADER Dyeing

Steamer

Washing Mercerization

Singeing

EFFLUENT WATER TREATMENT UNIT

The waste water coming from production cannot be discharged directly as it contains a number of compounds which are harmful for the environment. So, before discarding the waste water, it is first treated in order to minimize its PH, TDS, TSS, BOD, COD and Turbidity so that it may not cause any hazards. The waste water treatment plant at AFROZE TEXTILES is designed by AQUA TECH. The values of the parameters before and after the treatment are as under: Parameters Waste Water Discharging Water PH TDS TSS BOD COD Turbidity 10-11; 7-12 1000-3000; 1400-1500 150-400 400-500 500-700 80; 150-300 7 1000 30-35 80 99-105 15; 70-75

Waste water from the production comes into storage tank after passing through different gauzes and nets to remove unwanted substances like polythene bags, fabric, wrappers etc. Water from storage tank is pumped into the pipes from which the water is showered due to perforations. This showering is done to lower the temperature of water up to 35 oC from 50oC. Water now comes in to four equalization tanks in which heavy suspended particles are settle down step by step in each tank. The capacity of each tank is 50,000 gallons. These all tanks are adjusted to perform sedimentation. Air dissolving tube (ADT) is just like a cylinder or we can say it is a cylinder in which dissolved air is present which is dosed in to the waste water before feeding into the DAF. This dissolved air allows the sludge to come up on the surface of clean water, so that it may easily removed. The water now moves into the DAF which has three portions (a) Reaction chamber (b) Product chamber (c) Sludge chamber. Before feeding into the DAF, the waste water is dosed with alum, polymer and dissolved air. After dosing , it is passed through zigzag piping and comes in to Reaction chamber of the DAF, where this waste water is given time to circulate till the sludge separates and comes at the top. The feed enters into DAF by Feed Header. When the sludge comes upward, then clean water goes in product chamber through internal pipes (usually three pipes are present). A scooper is adjusted in the carriage which throws the sludge into Sludge chamber. The carriage is the moving part of the DAF which completes one rotation in 4 minutes. The capacity of DAF is 10,000 gallons. The normal feed rate of DAF is 40-50 m3/hour. The product of DAF comes in to DSF tank by gravity through PVC piping arrangement. From this tank, the feed water is pumped into DSF by centrifugal pumps. The capacity of DSF tank is 30-35m3/hr. The suspended solids are completely removed in DSF. The capacity of DSF is 10,000 gallon. In the bottom of DSF, granules are present (small concrete stones) on to which a layer of 0.5 micron sand is present. This sand flows upward with water and comes back. Due to this process, the clean water falls in product chamber and sand again settles down at the bottom. Water is coming in to DSF at a pressure of 40 psi. Sand and water are moving upward by an air pressure of 140 psi. The product of DSF goes to UF section if further treatment is required other wise the concentrate is discharged directly from DSF. The sludge from rejection chamber of DAF comes in to the sludge tank by gravity through pipes. From sludge tank, the heavy sludge goes to decanter by gravity. In the decanter, the sludge is allowed to stay until its water is drawn off. After the removal of water the

moist sludge is taken into bins by a small pipe which is adjusted in the decanter and this sludge is then left to get dry. Finally this sludge is sold because it is used for road carpeting as a substitute of charcoal. In the decanter, de-watering polymer is dosed.

Waste Water Storage Air Dissolvi ng Tube (ADT)

Showering

Eq. Tank 1

Eq. Tank 2 Eq. Tank

Polymer

Alum

H2SO4

3 Eq. Tank 4

DAF

DSF feed tnk

Sludge Tank Decanter

DSF Concentrat e goes with discharged water UF feed tank

REVERSE OSMOSIS
Reverse Osmosis is the reversal of the natural flow of osmosis. The goal of this process is to separate the pure water from the salt and other contaminants. When the natural osmotic flow is reversed, water from the salt solution is forced through the membrane in the opposite direction by application of pressure - thus the term REVERSE OSMOSIS.

NaOCl dosing

Well or Bore

Storage tank

ACF#1

Chlorine contact tank

Cartridge filter (5-micron)

ACF#2

DMF

Antiscalan t dosing H2SO4 Dosing Cartridge filter (1-micron) R.O (1 stage)

st

NaHSO3 Dosing

R.O (2 stage)
n d

De-gasifier Rejection PRODUCTION

Water from well comes in a storage tank. The capacity of this tank is 50,000gallon. The sedimentation occurs in this tank and all suspended particles are settled down. After storage tank the water passes from ACF # 1, where activated carbon is used for the adsorption of impurities. The tank is filled with 60% of carbon. Carbon filtration is a physical treatment process. Involving adsorption and removal of undesirable contents from water. Water isnow entered in to chlorine contact tank where NaOCl is dosed to stop the bacterial growth. After that water flows in to the DMF tank where filtration occur through the sand, silica and anthracite. Due to this filtration, up to 10 micron size particles of suspended impurities are removed. From DMF, water goes to cartridge filter of 5 micron where particles up to 5 micron are removed and similarly in 1 micron cartridge filter, up to 1 micron particles are removed. Cartridge filter is made of polypropylene and one vessel contains 10 filters. The removal of dissolved impurities is carried out in R.O membranes which are divided in two stages, the waste of stage 1 enters into stage 2. The concentrate of second stage goes to the rejection while the permeate of both the stages goes to Degasifier where the dissolved gases are removed. In the de-gasifier, the water to be treated casecade down through highly efficient polypropylene packing media. The media allows the water to break into droplets and increase the surface area, giving a high active surface area. The blower pulls air up through the unit in a cross current direction for rapid and efficient gas removal.

REFERENCES
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Dispersing agent (2gm/lit) + wetting agent (2gm/lit) + dyes (3colours) + water (make volume up to 100ml)