About Raymond

Raymond UCO Denim is a Joint Venture between Raymond Ltd, India's largest textile
and apparel major and UCO NV of Belgium. They produce and market specialty ring color and
stretch denim. With a combined capacity of 47 million and manufacturing facilities across 2
continents Europe and Asia, Raymond UCO will be in a best position to develop an optimal
and flexible service to meet global requirements of large international brands. Raymond UCO
Denim has state of the art manufacturing facilities in Yavatmal (India). All our facilities produce
differentiated ring spun denim, specialty denim and other niche products for the global fashion
market.
Raymond UCO Denim, Yavatmal, Maharashtra, India
Capacity: 40 million meters
Turnover: 400 Crore
Plant Details:

State of Art
To ensure the manufacture of products of international quality, this unit uses state-of-the-art
equipment, systems and practices. These include:

Tensorapid equipment to measure Tensile and tear strengths.

Uster testing to control the evenness of all yarns.
Each & every bale of yarn is tested and passed through a double passage draw for
effective quality blending.
Marzoli ring spinning frames and open-end spinning are equipped with auto doffing and
auto bobbin transfer systems. Together with Caipo and Amsler devices, these systems
produce creative denim yarns.
Indigo and sulphur dyeing is achieved through two-slasher dye ranges.
Suker Muller & Masters slasher dye ranges support Picanol & Vamatex high speed looms
to produce 20 million meters per annum.
The Denim Fabrics & Apparels is finished on the Cibitex range with micro processing to
stabilize shrinkage & skew. The stenter finish stabilizes shrinkage & width of stretch
products.
Routine Testing and checking at every stage of the manufacturing process.
Shade standards and consistency are maintained via a system of wash blankets tested
from every roll of Fabrics & Apparels.
The onsite laundry facility enables experimentation with creative finishing demonstrating
the full potential of each individual denim Fabrics & Apparels.

Processing of cotton
Cotton is the world's most important natural fibre. In the year 2007, the global yield was 25
million tons from 35 million hectares cultivated in more than 50 countries.
There are six main stages

Cultivating and Harvesting

Preparatory Processes

Spinning

Weaving or Knitting

Finishing

Marketing

Cultivating, harvesting and ginning

The Yavatmal is the District Head Quarter of Yavatmal District. Yavatmal is one of the
major cotton growing districts of Maharashrtra. About half of the gross cropped areas in the
district are under cotton cultivators. It is the important cash crop of the district the Progressive
cultivators use improved variety of cotton. Maharashtra is one of the major cotton producing
states in India about one-third area under cotton cultivation is in Maharashtra.
Cotton is grown anywhere with long, hot dry summers with plenty of sunshine and low
humidity. Indian cotton, gossypium arboreum, is finer but the staple is only suitable for hand
processing. Planting is from September to mid-November and the crop is harvested between
March and June. The cotton bolls are harvested by stripper harvesters and spindle pickers that
remove the entire boll from the plant. The cotton boll is the seed pod of the cotton plant, attached
to each of the thousands of seeds is fibers about 2.5 cm long.
The seed cotton goes in to a Cotton gin. The cotton gin separates seeds and removes the
"trash" (dirt, stems and leaves) from the fiber. In a saw gin, circular saws grab the fibre and pull
it through a grating that is too narrow for the seeds to pass. A roller gin is used with longer staple
cotton. Here a leather roller captures the cotton. A knife blade, set close to the roller, detaches the
seeds by drawing them through teeth in circular saws and revolving brushes which clean them
away.
The ginned cotton fiber, known as lint, is then compressed into bales which are about 1.5
m tall and weigh almost 220 kg. Only 33% of the crop is usable lint. Commercial cotton is priced
by quality, and that broadly relates to the average length of the staple, and the variety of the

plant. The cotton seed is pressed into a cooking oil. The husks and meal are processed into
animal feed, and the stems into paper.

Blow Room:
The section where the supplied compressed bale is turnt into a uniform lap of particular length by
opening, cleaning, blending or mixing is called blow room section. It is the first steps of
spinning.

Blow room section

Operations in the Blowroom

Opening
Cleaning
Dust Removal
Blending
Even feed of material to the card

Opening

The first operation required in the blowroom line is opening, carried out to the stage of tufts in
contrast to the cards, where it is performed to the stage of individual fibers. Tuft weight can be
reduced to about 0,1 mg in the blowroom. The small improvements by each of the subsequent
machines are obtained only by considerable additional effort, stressing of the material and
unnecessary fiber loss and a striking increase in nippiness. If necessary the card is able to assume
rather more of the overall task.

Cleaning
It has to be kept in mind that impurities can only be eliminated from surfaces of tufts. Within a
progressive line of machines it is therefore necessary to create new surfaces continuously by
opening the material. And even then the best blowroom line is not able to eliminate all, or even
almost all, of the foreign matter in the raw material. A blowroom installation removes
approximately 40 - 70% of the impurities. The result is dependent on the raw material, the
machines and the environmental conditions.
It is clear from this diagram that the cleaning effect cannot and should not be the same for all
impurity levels, since it is easier to remove a high percentage of dirt from a highly contaminated
material than from a less contaminated one. Looking at the machine, the cleaning effect is a
matter of adjustment. Increasing the degree of cleaning also increases the negative effect on
cotton when trying to improve cleaning by intensifying the operation, and this occurs mostly
exponentially. Therefore each machine in the line has an optimum range of treatment. It is
essential to know this range and to operate within it.
In an investigation saw that the quantity of waste eliminated on a cleaning machine by modifying
settings and speeds was raised from 0.6% to 1.2%: while the quantity of foreign matter
eliminated increased by only 41%, the quantity of fibers eliminated increased by 240%.
Normally, fibers represent about 40 - 60% of blowroom waste. Thus, in order to clean, it is
necessary to eliminate about as much fibers as foreign material. Since the proportion of fibers in
waste differs from one machine to another, and can be strongly influenced, the fiber loss at each
machine should be known. It can be expressed as a percentage of good fiber loss in relation to
total material eliminated, i.e. in cleaning efficiency (CE):
AT = total waste (%); AF = good fibers eliminated (%).
For example, if AT = 2.1% and AF = 0.65%:

Dust Removal
Almost all manufacturers of blowroom machinery now offer dust-removing machines or
equipment in addition to opening and cleaning machines. However, dust removal is not an easy
operation, since the dust particles are completely enclosed within the flocks and hence are held
back during suction (because the surrounding fibers act as a filter). Since, as shown it is mainly

the suction units that remove dust (in this example 64%), dust removal will be more intensive the
smaller the tufts. It follows that dust elimination takes place at all stages of the spinning process.

Blending
Blending of fiber material is an essential preliminary in the production of a yarn. Fibers can be
blended at various stages of the process. These possibilities should always be fully exploited, for
example by Transverse doubling transverse doubling. However, the start of the process is one of
the most important stages for blending, since the individual components are still separately
available and therefore can be metered exactly and without dependence upon random effects. A
well-assembled bale layout and even (and as far as possible simultaneous) extraction of fibers
from all bales is therefore of the utmost importance. Simultaneous extraction from all bales,
which used to be normal in conventional blending batteries, is now no longer possible (automatic
bale openers). Accordingly, intensive blending in a suitable blending machine must be carried
out after separate tuft extraction from individual bales of the layout. This blending operation
must collect the bunches of fibers arriving sequentially from individual bales and mix them
thorough.

Even Feed of Material to the Card

Finally, the blowroom must ensure that raw material is evenly delivered to the cards. Previously,
this was carried out by means of precisely weighed laps from the scutcher, but automatic tuft
feeding installations are used nowadays. While in the introductory phase such installations were
subject to problems regarding evenness of tuft delivery, today they generally operate well.

Carding
Carding is a mechanical process that disentangles, cleans and intermixes fibers to produce a
continuous web or sliver suitable for subsequent processing. This is achieved by passing the
fibers between differentially moving surfaces covered with card clothing. It breaks up locks and
unorganized clumps of fiber and then aligns the individual fibers to be parallel with each other.
In preparing wool fiber for spinning, carding is the step that comes after teasing. The proverbs of
the experts The Card is the heart of the Spinning Mill and Well Carded is half spun
demonstrate the immense significance of carding for final result of the spinning operation.

Carding process
The opened and blended fibers then undergo carding process. The functions of the carding
process are:

Individualization of fiber tufts to almost single fiber

Mixing of fibers to average out variations in fiber characteristics

Forming a homogenous web of uniform weight per unit area

THE COMBING PROCESS:

The combing process is normally used to produce smoother, finer, stronger and more uniform
yarns. Therefore, combing is commonly confined to high grade, long staple natural fibers. In
recent years, combing has been utilized for upgrading the quality of medium staple fibers. In
addition, a yarn made of combed cotton needs less twist than a carded yarn. However, these
quality improvements are obtained at the cost of additional expenditure on machines, floor-space
and personnel, together with a loss of raw material. Yarn production coast is increased by
something under 1 US$/Kg of yarn (depending on the intensity of combing).

To improve the yarn quality, the comber must perform the following operations:
Elimination of precisely pre-determined quantity of short fibers;
Elimination of the remaining impurities;
Elimination of a large proportion (not all) of the neps in the fiber material;
Formation of a sliver having maximum possible evenness;
Producing of more straight and parallel fibers.

Elimination of short fibers produces an improvement mainly in staple length, but also affects the
fineness of the raw material. The micronaire value of combed sliver is slightly higher than that of
feedstock (elimination of dead fibers). Also the degree of parallelization might reduce the interfiber adhesion in the sliver to such an extent that fibers slide apart while being pulled out of the
can i.e. sliver breaks or false drafts might be caused.
Types of Comber:

The major types of combers include:Rectilinear comber (with stationary or oscillating nippers),
Circular combers (English worsted process),
Rotary comber (production of Schappe spun yarns) and
Hackling machines (bast fibers).

The Combing Machine:-

The basic elements of the combing machine are shown in figure. These are the feeding element,
the nipper plate, the combing system and the detaching rollers. The feeding element consists of a
feed plate and feed roll. The main function of the feeding element is to feed the comber lap in a
series of short lengths. The nipper plate grips the fibers as a means of holding long fibers while
the short fibers, neps, and trash are being removed. The combing system consists of two combs.
The first one is a rotating bottom circular comb that performs the main combing action. The
second one is a linear top comb that completes the function of the bottom comb through vertical
combing movement.
Basic elements of the combing machine
The detaching rolls are two pairs of gripping rolls that rotate forward and backward in
intermittent fashion to hold and move the combed web for a net forward travel.
The objectives of combing mentioned earlier are accomplished by a precise sequence and
synchronized series of actions performed by the combing elements. The following text will
review this sequence of actions, or the combing cycle, in a very simplified manner to
demonstrate the function of each comber component.

Draw Frame

Draw frame is a machine for combining and drawing slivers of a textile fiber (as of hemp for
rope manufacture or cotton for spinning). Drawing is the operation by which slivers are blended,
doubled and leveled. In short staple spinning the term is only applied to the process at a draw
frame. In drawing slivers are elongated when passing through a group of pair rollers, each pair is
moving faster than previous one.
Actions Involved in Draw Frame
Drafting: It is the process of increasing length per unit weight of sliver. It is mainly due to
peripheral speed of the rollers.
Doubling: The process of combing two or more carded sliver into a single form is called
doubling. In draw frame m/c generally six slivers are fed to convert into one i.e. six doubling.
Drawing: In the cotton industry the term is applied exclusively to processing on the draw frame,
where the operation is one of doubling and drafting. Drawing= Drafting + Doubling.

Tasks of Draw frame

Equalizing: One of the main tasks of draw frame is improving evenness over short, medium and
especially long terms. Carded slivers are fed to the draw frame have degree on unevenness that
cannot be tolerated in practice and slivers from the comber contain the infamous piecing.
Parallelizing: To obtain an optional value for strength in the yarn characteristics, the fibers must
be arranged parallel in the fiber strand. The draw frame has the tasks of creating this parallel
arrangement.
Blending: In addition to the equalizing effect, doubling also provides a degree of compensation
of raw material variation by blending. Their results are exploited in particular way in the
production of blended yarns comprising cotton or synthetic blends. At the draw frame metering
of the individual components can be carried out very simply be selection of the number of slivers
entering the machines.
Dust Removal: Dust removal can only be carried out to a significant when there are high levels
of fiber. Since a large function the smallest particles adhere relatively strong to the fibers. High
performance draw frame is equipped with appropriate suction removal systems; more than 80%
of the incoming dust is extracted.

Combing Machine and Draw frame

Ring frame

Ring spinning is a method of spinning fibers, such as cotton, flax or wool, to make a yarn Ring
spinning is a continuous process, unlike mule spinning which uses an intermittent action. In ring
spinning, the roving is first attenuated by using drawing rollers, then spun and wound around a
rotating spindle which in its turn is contained within an independently rotating ring flyer.
Traditionally ring frames could only be used for the coarser counts, but they could be attended by
semi-skilled labor.
Operations involved in ring frame:

Creeling
Drafting
Twisting
Winding
Building
Doffing

Passage Diagram:

Main Parts Ring Frame:

1. Creel 2.Guide roller 3.Trumpet 4.Drafting rollers 5.Yarn guide 6.Lappet
7.Balloon controlling ring 8.Traveler 9. Ring 10. Spindle

Description:

The feed material come from speed frame i.e. roving bobbin is placed on the creel. The creel
which is attached to the machine is umbrella type. Then feed material is passed under the guide
rollers and through the trumpet in to the drafting zone. Here some draft is inserted in to the
roving. The draft system is 3 over 3 drafting system with apron. The delivery material that is
delivered from the front roller is reached to the traveler over pneumatic waste collector, lappet
and through balloon controlling ring. Lappet is used to control the material path and balloon
controlling ring is used to control the balloon formation and spinning tension. Here roving is
twisted by the movement of the traveler around the ring. The yarn is then wound on the ring cop.
Roving Bobbin Transport System
Roving Bobbin is one of the most delicate intermediate products to handle; Trascar-Utit offers an
automatic transport system from roving frame to spinning area in order to preserve the quality of
your product.
Roving bobbins are transported by a transport system moving along the aisles between the
Spinning Frames and interfaces to Roving Frames which feed the circuit with full roving
bobbins. The automation level of transport systems for this application can be customized
following the customers need: Manual Semi-automatic Automatic.
Technical Specification
Marzoli Integrated Transport System is equipped with a stainless steel rail. Its tapered
design ensures that the trolleys are always aligned with one another while its V-shape prevents
dirt accumulation inside the rail. These features ensure smooth trolleys movement which requires
only 1 to 4% force of the weight being lifted in order to operate. The assembly of the rail is easy
and fast: the rail components are held together with bracket and joint screws that work by friction
against the rail components: no holes, drilling or reworking of the rail components are required
during installation. Thanks to a removable window the rail is easy to access. Complete trolleys or
single rollers can be changed or added easily.
The Block Creeling Transport (MTT).The full roving bobbins are brought to the reserve
row of the spinning frame or directly inside the creel of the spinning frame by trolley trains (one
train per creel row). The first solution requires the operator to change the roving bobbins and to
piece them (as the random transport solution); the second one makes bobbin change no longer
necessary. Both solutions are ideal for spinning mills with highly flexible production programs.

Advantage of Ring Spinning System:

Any type of material (Fibre) can be spun

Wide range of count can be processed
It delivers a yarn with optimum characteristics.
Idealized twisting system
It is uncomplicated and easy to operate
Higher yarn strength can be achieved

Disadvantages of Ring Spinning System:

Low production
Machine generates more heat

Winding:
Winding is one of the most important operation, which is mainly occurred in spinning section.
Besides, it is also important in fabric manufacturing. In fabric manufacturing, directly winding is
not so much important, but rewinding is so important. The creation of large yarn packages that
can be easily unwound, is called winding. This makes using the yarn on subsequent machines
both easier and more economical.

After warping, some packages contain just a few grams of yarn which is unsuitable for the
efficiency of further processing, such as warping, twisting, and quelling. This necessitates the
preparation of a dense and uniform yarn package of sufficiently large size from unsuitable
packages which can unwind in the subsequent operations without interruptions, is called
rewinding. The yarn unwound from the package passes through yarn tensioned and control
systems, and with the help of a grooved cylinder, is wound evenly around the package; the yarn
enters the recess in the cylinder, thus the rotary movement of the cylinder corresponds to the
translation of the yarn. Winding machines currently have independent heads with individually
adjustable motors. A modern winding machine can process yarns ranging from a count of Ne 2 to
finer ones, at a winding speed of 400 to 2000 m/min.
Winding is more than just transferring yarn from one package to another. Further functions of
winding are to check the yarn and to eliminate any faults found.

Warping:
The warping consists of collecting predetermined number of ends from a set of wound package
and transferring them in a sheet form to a weavers beam. The parallel winding of warp ends
small package (bobbin) to a common package (warp beam) is called warping

Textile Warping Machine: EMERICK

Product Description:
Our EMERICK is a major provider of advanced Textile Warping Machine. Procured from
reputed brands these products are manufactured from good quality material. The use of modern
technology and sophisticated machinery delivers our products an exceptional quality. Flawless
design, high performance, energy efficiency, smooth operation and versatility are some
outstanding features of these customers. These can be availed by the customers at affordable
prices.

Features:

Noiseless operation
Easy handling
Sturdy construction

Details for Textile Warping Machines:

Benninger Bentronic /electronic sectional warping machine

Chain Maxi Diameter - 1000 mm*
Length and Height Of Cone (1600 210 mm)*
Cone Angle - 7.5o*
Yarn Maximum Tension - 600 N*
Motor - 11 kW at 1480 RPM*
Maximum Speed - 800 m/mm*
Beaming Motor - 22 kW at 1480 RPM*
With 1 creels 1995 (850 spindles, 200 mm)*

Weaving:
The process of producing a fabric by interlacing warp and weft threads is known as
weaving. The machine used for weaving is known as weaving machine or loom. Weaving is an
art that has been practiced for thousands of years. The earliest application of weaving dates back
to the Egyptian civilization. Over the years, both the process as well as the machine has
undergone phenomenal changes. As of today, there is a wide range of looms being used, right
from the simplest hand loom to the most sophisticated loom.

Rapier Loom:

Insertion of weft by rapier is a mechanically modern & refined version of the primitive method
of fabric production in which the weft was secured in a slot of a stick. At present version of the
gripper head which are attached to rapiers which are flexible tapes or rigid rods. Mr. John Gabler
can be regarded as the father of modern rapier technology he has built a rapier device on a cotton
weaving machine in 1922.

Scope of Rapier:

Single rapier loom can insert weft only on alternate rapier traverse.
In many cases this is modified to achieve a higher rapier velocity in the early and late
parts of the movement and thus over maximum velocity halfway through the movement.
Due to high rate of insertion the possibility of yarn breakages rate may increase.
Additionally, it is necessary to control the weft by passing it through an effective tension
arrangement so that the weaving tension will be more uniform, this can also occurred
weft break.

Features of Rapier Loom:

A useful feature of rigid rapiers is that they can be simultaneously inserted in two sheds
one above the other, for producing double plush and certain carpets.
Rapier loom may have various types according to the weft insertion mechanism &
number of pick such as insertion of double pick, insertion of single pick, two phase rapier
etc.
In all rapier looms to-and-fro-movement of the rapiers is derived initially either from a
linkage mechanism or from a cam. The use of linkage mechanism has the advantages of
simplicity reliability & is cheap, quite and consumers less energy than a cam mechanism
but it does not provide any dwell to the rapiers.
The only two phase rapier in commercial operation is the saurer of width 2 x 185 cm or 2
x 220 cm having weft insertion rate is about 1200 mpm.
The rigid rapier is driven from the centre and has a rapier head at each end.In one cycle
of 360 degree the rapier inserts one pick alternately in the right hand and the left hand
fabrics, the picks being inserted and beaten up in opposite phase .
In gabler system of weft insertion the rapier system is combined with air jet picking
system.
Gabler system rapier may be single sided or double sided. The machine include on gabler
system Draper DSL,Gusken etc.Those operating on dewas system include dornier,
picanol, Novo pignon SACM, Gunne, Smit, Sommet, Sulzer-Ruti etc.

Features of Rapier Loom:

Control panel: The loom is controlled by the control panel with a micro-computer, the lcd
display provides a very user-friendly human-machine interface, which shows the production
statistic data of each shift and provides the weft color programming function.
Weft color selection: The machine adopts electronic color selector up to 8 colors, and the color
selection pattern is programmed directly on the machine control panel.
Wefting: Wefting mechanism adopts 6-lever wefting structure and can ensure the adjustment of
the rapier entry and exit time and ensure stable wefting and insertion motion. This machine
adopts 4 levers, short connectors and short sley to complete the beating motion, the rock shaft
adopts 110mm(diameter) seamless tube to ensure the beating strength and can be suitable for
high-speed motion and weaving of heavy and high density fabrics. The rapier transmission box
adopts the advanced helix umbrella gears to ensure stable transmission. The tension device
adopts 3-rear-beam tension structure, which is specially designed for balancing the warp tension
of high-density weaving and can improve the quality of the weaving fabrics.
Pick finding mechanism:

The machine adopts electronic let-off mechanism with a high-accuracy step motor and
the optimized mechanical take-up system for stable and accurate pick finding motion.
The pick finding motion is very stable and proved to be very successful and reliable.
The adoption of two pressing rollers on the fabric winding roller enables the worker to
unload the fabric from the fabric roller without stop. The frequent adoption of bearings
for the major moving parts provides better performance and easier maintenance.

Advantages of Rapier Loom: Over Conventional Loom:

The rapier loom doesnt require dynamic forces or anything like the magnitude as those
involved in the conventional loom.
The weft insertion rate in a rapier loom is very much influenced by the method of weft
control.
Weft insertion rate is very high rather than any conventional loom
It can occur double pick at a time by double picking insertion system. Here is no need to
cut the weft selvedges and no weft wastage.
Weft insertion rate is very high rather than any conventional loom Rigid rapiers has a
useful features that they can be simultaneously inserted in two sheds one above the
other ,for producing double plush and certain carpets.
Looms that use rigid rapiers eliminate entirely the need to assist the rapier head through
the warp shed, this is a un doubted advantages.

Rapier Loom Machine: itema R9500

Key Features:

Single or twin Warp beams

Programmable motorized weft cutter
Power outlet on electrical panel (220V, 16A)
Selvedge
Motorized selvedge and leno device
Lateral and central pneumatic tuckers*
Lateral and central mechanic tuckers*
Selvedge thermo cut*

Singeing:
Singeing is the process of burning of the fiber hairs projecting through the fabric surface. It is
done to obtain a uniform & smooth fabric surface by removing hairiness. To ensure uniform
optical reflectance throughout the fabric surface in subsequent fabric wet process.
Objectives & Advantages of Singeing

Singeing of a fabric is done in order to obtain a clean fabric surface which allows the
structure of the fabric to be clearly seen.

Fabrics, which have been singed, soil less easily than un-singed fabrics.
The risk of pilling, especially with synthetics and their blends, is reduced in case of

singed fabrics.
Singed fabrics allow printing of fine intricate patterns with high clarity and detail.
The risk of skittery dyeings with singed articles dyed in dark shades is considerably
reduced, as randomly protruding fibres are removed in singeing which could cause
diffused reflection of light.

Necessity of Singeing in Textile

Singeing of textile materials is necessary for te following reasons:

Cotton materials are valued for their smooth appearance. After the formation of fabric it
has a fuzzy or hairy appearance due to projecting fibers, thus affecting the luster and

smoothness cotton is known for.

Unsigned fabrics are soiled easily
The protruding fibers obstruct the subsequent dyeing and printing process
Goods which are to be mercerized are signed to maximize the luster
In fabrics of polyester and cellulosic fiber blends singeing is the best method to control
pilling, sometimes double singeing is done to minimize the pilling.

Singeing Process
Singeing process is as follows:

To produce a smooth surface finish on fabrics made from staple fibers first the fabric

surfaces are brushed lightly to raise the unwanted fiber ends.

Then the fabric is singed with or passed over heated copper plates or open gas flames.

The fiber ends burn off.

The fabric is moved very rapidly, and only the fiber ends are destroyed.
As soon as the fabric leaves the singeing area, it enters a water bath or desizing bath. This
stops any singeing afterglow or sparks that might damage the cloth.

Mercerization

Mercerization is a finishing treatment of cotton with a strong caustic alkaline solution in order to
improve the luster, hard and other properties,. It has been seeing an increase in application
recently.
Effect of Mercerization:

Improve Luster.
Increase ability to absorb dye.
Improve reaction with a verity of chemicals.
Improve stability of form.
Improve strength/elongation.
Improve smoothness.
It has been shown that the increase in the luster occurs because of an effect.
The cotton fiber do convoluted.
The cross-sectional shape changes.

Stenter Machine:
A machine or apparatus for stretching or stentering fabrics. The purpose of the stenter machine is
to bringing the length and width to pre determine dimensions and also for heat setting and it is
used for applying finishing chemicals and also shade variation is adjusted. The main function of
the stenter is to stretch the fabric widthwise and to recover the uniform width.
Functions of Stenter Machines:

Heat setting is done by the stenter for lycra fabric, synthetic and blended fabric.
Width of the fabric is controlled by the stenter.
Finishing chemical apply on fabric by the stenter.
.
Moisture of the fabric is controlled by the stenter.
Fabric is dried by the stentering process.
Shrinkage property of the fabric is controlled.

Working Procedure of Stenter Machine:

The fabric is collected from the batcher to the scray and then it is passed through the padders
where the finishes are applied and sometimes shade variation is corrected. The fabric is entered
into the mahlo (weft straigtner) the function of the mahlo is to set the bow and also weave of the

fabric is gripped by the clips and pins are also provided but the pins has a disadvantage that they
pins make holes at the selvedge but the stretching of the pins are greater than the clips. These
clips and pins are joined to endless chain. There are 8 to 10 chambers provided on the machine
each chamber contains a burner and filters are provided to separate dust from air. The
circulating fans blow air from the base to the upper side and exhaust fans sucks all the hot air
within the chambers. Attraction rollers are provided to stretch the warp yarn.

Sheet Dyeing:
Dyeing is a process of coloring textile materials for giving attractive look. In broadly we can
explain, dyeing is a process by which a yarn, fabric, garments and any other materials that come
to contact of dye by presence of auxiliaries that create the condition of dyeing environment.
Dyeing operation is done by different types of dyeing machine. The machine which is used to
dyeing or coloring of materials like yarn, fabric, garments or any other materials is called
dyeing machine. Dyeing machines come in all shapes and sizes to accommodate the various
forms and quantities of textile materials. Actually it is the device that is used by different
industries for imparting colors. Various types of dyeing machineries are used to dye the textile
materials.
Process Sequence in Indigo Slasher / Sheet Dyeing:

The passage of flow of yarns in slasher dyeing is shown below-

Pre-treatment:
Pre-treatment process in sheet dyeing consists of treatment of the cotton yarn sheet with caustic
and wetting agent. Pre-wetting is carried out in order to get proper dyeing of the sheet. Prewetting is carried out with a Wetting agent, at room temperature. In some cases, if well
penetration of the dye is required, the yarns are treated with strong caustic soda solution followed
by hot wash and cold wash treatment prior to dyeing. The pH of the bath is 11.8-12

Washing: Cold washing is carried out at room temperature.

Dyeing (Indigo blue dye): The dyeing is carried out in 4 to 8 dye boxes. The dyeing is carried
out with; Indigo powder, Sodium hydrosulphite, Caustic soda, Dispersing agent
Typical dipping time of sheet in each tank is 15secs and oxidation time is about 90secs.
Washing: The dyed yarn sheet is subsequently in order to remove the unfix dye from the yarn
surface. However the number of washing tank may vary. Typical wash type is: cold wash at
room temperature and hot wash at temperature of 70C.
Drying: The dyed yarn sheet is dried by passing it through drying hot cylinders.
Accumulator: The function of accumulator is to store the extra yarn sheet when the machine is
stopped or at the time of size beam doffing, so the dyeing cannot be stop.

Sizing: The yarns are sized in order to achieve the required strength.
Drying: The dyed sheet is dried by passing through drying cylinders.
INDIGO DYEING RANGE SUCKER MULLER
COMPRISING OF THE FOLLOWING:
8 Dyeing tanks in stainless steel with measurement and temperature control
Padder pressure up to 10 tn and rollers in stainless steel.
3 washing tanks in ss with the same features but several capacity.
8 dyeing tanks have a natural oxidation system.
Pre-drying by 8 drums with temperature control
drying by 10 drums with temperature control.
liquid waxing by a liquid wax system at dryer drums exit.
accumulation unit to allow non-stop 100 m capacity approx.
With opening bars and comb to regulate width and thread distribution in folder
With a maximum width of 2000 mm.