Professional Documents
Culture Documents
Training Report
Contents
1. Acknowledgement
2. Process Flow of material
3. Preparatory Section
3.1) Godown
3.2)Warping
3.3) Sizing
3.4) Drawing In
3.5) Rewinding
3.6) Cleaning
4. Loom-Shed
4.1) Unit- 1
4.2) Unit- 2
4.3) Unit- 3
4.4) unit- 3A
5. Folding
5.1) Objective
5.2) 4 point Grading
5.3) Folding Machine
5.4) Packing
ACKNOWLEDGEMENT
PROCESS FLOW
FROM SPINNING DEPTT.
CONE/ CHEESE
WARPING PROCESS
WARPER’S BEAM
SIZING PROCESS
WEAVER’S BEAM
AUTO DRAWING IN
LOOM SHED
GREY FABRIC
PACKAGING
DISPATCHING
YARN GODOWN
Warp Godown
A-2010 F-2015
B-2011
C-2012
D-2013 No. of Ply in yarn
Hall No. of E-2014
spg unit F-2015
G-2016 Count of yarn in Ne
H-2017
L 4 F C 1 4 0 0 4 4
A- Auro spg
K-Carded
B- Vardman spg Mills Serial No specific for type of yarn
C- Combed/Compact
E- Vardhman Merubeni
O-Open End
Textiles (VMT)
L- Arist spg Mills S-Slud
General mills
Y- Vardman Yarns
C-Vardhman fabrics
WARPING MACHINE
What is warping
The objective of warping is to convert a predetermined
number of single end packages, such as cones, cheese,
into a sheet of yarn of specifies length and width.
BEN-DIRECT 1000
MAKE Benninger
MODEL NAME BEN-1000
MAXIMUM SPEED 1200 mpm
TYPE OF CREEL ‘V’type
CREEL CAPACITY 640
BRAKE SYSTEM 5
BRAKES Hydraulic system
(pressure=5.8bar)
WARP STOP MOTION Photo-electric type
BEN-DIRECT 800
MAKE Benninger
MODEL NAME BEN-800
MAXIMUM SPEED 1200 mpm
TYPE OF CREEL ‘V’
CREEL CAPACITY 576
BRAKE SYSTEM 5
BRAKES Hydraulic system
(pressure=5.8 bar)
MACHINE NO:1
Make: BENNINGER Installation: 2000-01
Model: BEN-1000 Creel Capacity: 640
MACHINE NO:2
Make: BENNINGER Installation: 1997-98
Model: BEN-800 Creel Capacity: 576
MACHINE NO:3
Make: BENNINGER Installation: 2003-04
Model: BEN-1000 Creel Capacity: 640
WARPERS BEAM
SIZE KITCHEN
SIZE INGREDIENTS:-
Texoplast 86: - It is sulpho esterified starch. It is
better adhesive than maize starch. It is alkaline in
nature.
Sonycryl:S - It is a binder and chemically is an
ammonium salt based acrylic product. It has low
viscosity and high binding property.
Ketanol:SZ(PVA) - It is a binder. Its small sized
particles easily penetrate into the yarn and strongly
bind it from inside as sell as medium/bigger sized
particles protect its outer surface. It has similar
properties to that of PVA.
Soft sizer :- It is used as softenr.
Water :- It is a good solvent.
SIZING MACHINE
What is sizing
MACHINE NO:1
MACHINE NO:2
Make: Sucker Muller Hacoba
Model: WE 10 PC
Installatiopn: 2003-04
Creel Capacity:20Beams
Saw Box: 1Dip & 2Nip
Drying cylinder: 14
Max. Speed:-120mpm
In machine 1 & 2
OBSERVED ( 60- 70 m/min) depending on the count
of the yarn.
Drying cylinders =14 (4-4-6)
Drying cylinders Dia = 800mm
Drying cylinders length = 2000mm
Size boxes =2
Squeeze rolls = 2 in each size box
Size rolls = 2 in each size box
Feed rolls =2
Drying cylinder temperature
MACHINE NO:3
Make: Benninger Model: Benninger Zell
Installatiopn: 1997-98 Creel Capacity:20Beams
Saw Box: 1Dip & 1Nip Drying cylinder: 12
Max. Speed:-120mpm
In machine No.3
Drying cylinders =12 (4-4-4)
Drying cylinders Dia = 800mm
Drying cylinders length = 2000mm
Size boxes =2
Squeeze rolls = 1 in each size box
Size rolls = 1 in each size box
Feed rolls =2
Drying cylinder temperature
In zone 1 (drying) = 140 ̊C for cotton
In zone 2 (Pre- Drying) = 850C
Waxing temperature = 35-500C
Waxing roller rpm = 750
Moisture regain = 7.5% for cotton
4.5% forP/C blends
Shore hardness of immersion roller = 750
Shore hardness of Squeeze Roll = 750
Shore hardness of feed roller = 650
Shore hardness of size roll = 1000
AUTO DRAWING IN
Machine specifications
Make :- Staubli
Model :- Delta-110
Installation :- 2006-07
Capacity :- 20 frames
Maximum Speed :- 140 ends per minute
Average Speed :- 120 ends per minute
Heald wire used :- Simplex and Duplex
Drop wires used :- 0.2mm & 0.4mm
Length of heald wires :- 331mm
Passage of material
Weaver’s Beam
Drop Pins
Heald Wire
Reed
REWINDING M/C
What is rewinding.
Bottom cones are rewound to get full cones and can be
used in selvedge purpose of other.
Cleaning
LOOM SHED
Loom Shed-1
Loom Shed-2
Loom Shed-3
Loom Shed-3A
Loom Shed:-
Interlacement of two mutually perpendicular yarns
forms the fabric.
1. Main Nozzle
2. Pre-winder
3. WF Sensor
4. Stop Pin
5. Leno Selvedge
6. Take up roller
7. Weft Package
8. Air filter
9. Jetting (to inject air )
10. Guide for waste selvedge
11. Catch yarn guide
12. Catch cord Yarn
Unit 1
Unit 2
Unit 3
Unit 3A
All the Units have Air-jet looms.
There are in total 272 looms
The looms are of three different manufacturers viz.
TSUDAKOMA, PICANOL & TOYOTA.
65 64 63 34 33 32 31 2 1
66 62 61 36 35 30 29 4 3
67 60 59 38 37 28 27 6 5
68 58 57 40 39 26 25 8 7
69 56 55 42 41 24 23 10 9
70 54 53 44 43 22 21 12 11
71 52 51 46 45 20 19 14 13
72 50 49 48 47 18 17 16 15
TSUDAKOMA-ZAX
Distinguishable Features:-
o Positive shedding by STAUBLI cam.
o Temple ring is mounted above the fabric woven.
o Max. 6 frames can run at a time.
o Mechanical type cutter for dummy selvedge.
o Seven Wheel takeup Mechanism
TOYOTA JAT-710
Distinguishable Features:-
o Positive shedding by STAUBLI cam.
o Temple ring is mounted above the fabric woven.
o Max. 7 or 10 frames can run at a time.
o Mechanical type cutter for dummy selvedge.
o Seven Wheel takeup Mechanism
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Training Report 2017
73 75 77 79 81 83 85 87 89 91 93
74 76 78 80 82 84 86 88 90 92 94
115 113 111 109 107 105 103 101 99 97 95
116 1114 112 110 108 106 104 102 100 98 96
117 119 121 123 125 127 129 131 133 135 137
118 120 122 124 126 128 130 132 134 136 138
159 157 155 153 151 149 147 145 143 141 139
160 158 156 154 152 150 148 146 144 142 140
PICANOL DELTA-X
Distinguishable Features-
Shedding is positive cam shedding by STAUBLI
1610
Temple ring is mounted above the fabric woven.
Max. 6 frames can run at a time.
Seven Wheel takeup Mechanism
Equiped with Electronic Let-off.
Average Speed:- 750rpm
Heald Frame Used:-Steel Heddle, Alu Power124
Picking is done by means of compressed air
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Training Report 2017
Cutters-
The weft cutter used is of electronic type
The selvedge cutter used is of mechanical
type
Mechanical take-up is there
Let-off is of electronic type.
Weave:- S twill , Matt
Catch Cord :- 12
Weft Range:- Spx , K spx , Compact
Picanol Omni
Positive cam shedding is there – By Staubli 1600
Picking is done by means of compressed air.
Two cutters are used and both the cutters are of
electronic type.
Temple ring is mounted above the cloth
Mechanical take-up is used
Electronic let-off is there
At max. 7 heald frames can be used
TOYOTA JAT-710(WIDER)
Distinguishable Features:-
o Positive cam shedding by STAUBLI 1781A.
o Temple ring is mounted below the fabric woven.
o Max. 7 or 10 frames can run at a time.
o Mechanical type cutter for dummy selvedge.
o Seven Wheel takeup Mechanism
o Equiped with Electronic Let-off.
o Easing Motion present in Whip Roll.
o Average Speed:-750 rpm
o Heald Frame Used :- Newlight
TSUDACOMA Zax
Distinguishable Features:-
o Positive shedding by STAUBLI cam.
o Temple ring is mounted above the fabric woven.
o Max. 6 frames can run at a time.
o Mechanical type cutter for dummy selvedge.
o Seven Wheel takeup Mechanism
o Equiped with Electronic Let-off.
o Easing Motion present in Whip Roll.
o Main motor data-
Power consumption 3.7kw
Three phase induction motor
RPM of Driving motor 1390
o Average Speed:-730 rpm
o Heald Frame Used :- Nankai , Newlight
o Weave:- Plain , Satin , S Satin
o Width:-190cm
o Catch Cord :- 8
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Training Report 2017
TSUDAKOMA (ZAX-e):
Distinguishable Features:-
o Positive cam shedding by STAUBLI 1661.
o Temple ring is mounted above the fabric woven.
o Max. 6 or 8 frames can run at a time.
o Mechanical type cutter for dummy selvedge.
o Seven Wheel takeup Mechanism
o Equiped with Electronic Let-off.
o Easing Motion present in Whip Roll.
o Main motor data-
Power consumption 3.7kw
Three phase induction motor
RPM of Driving motor 1390
o Average Speed:-750 rpm
o Heald Frame Used :- Nankai , Newlight
o Weave:- Plain , S Satin , Z twill , S twill
o Width:-190cm
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Training Report 2017
o Catch Cord :- 8
o Weft Range :- Com. , Lyc , PC , Slub
Folding section
4- Point Grading
Defects in both warp & weft Direction shall be assigned
points using the following criteria---
FABRIC GRADING:
In 100 mtrs fabric four major faults and minor faults so that
the total points should not exceed 38 points is known as
FRESH Fabric, (Also fabric having some more points but
passable (internally called as B grade). Final order to the
customers is made in the form of fresh only. So the passable
fabric is mended to get fresh fabric. The fabric which is not
mendable is rejected.)
MACHINES IN FOLDING
Inspection machines-
there are total 9 inspection machines for the fabric
inspection,
Manufacture is Almac and yash.
The speed of the inspection is kept 20-25 mpm.
Folding or flatting machines-
There are 2 folding machines used for forming the bale
of the fabric.
Bale pressing machine-
There are 1 bale pressing machine for pressing the bale.
Mending table-
There are mending 2 tables for reworking i.e. for
mending the damages if possible.
FOLDING:
ROLLING M/C
Two rolling M/c are there for finally rolling the inspected
fabric into Fabric Rolls for final transportation.
Speed- 100meters of fabric /min
SlubbyWeft
Oily Weft
Uneven Weft
Weft Distortion
Broken Pattern
MINOR:
Warp Slub
Stain
Contamination
Mending Impression
Weft Slub
PACKING
BLUE LDPE: For Lycra fabric
WHITE LDPE- For 100% cotton fabric
Two different color LDPE is used for the packing