Industrial Training Report

On

Submitted to: Submitted by:

Mr. A. K. Khare Geetika Varshneya

Course Co-ordinator Jyoti Pal

Manoj Kumar Paras

Neha Kaushik 

Department of Fashion Technology (Apparel Production)

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

BANGALORE.

CERTIFICATE

This is to certify that the training report of “ Kailash Ribbon Factory Limited” is bonafide work of Geetika Varshneya , Jyoti Pal , Manoj Kumar Paras & Neha Kaushik towards the partial fulfillment of requirement for the Post graduate program in Apparel Production, 2007-09 at the National Institute of Fashion Technology, Bangalore.

Certified By:

Mr.A.K.Khare

Course Coordinator

Department of Apparel Production

NIFT, Bangalore

ACKNOWLEDGEMENT

We take this opportunity to express our sense of indebted gratitude to all those who helped us in completing this training. We are highly thankful to respected Mr.A.K.Khare ( H.O.D Apparel production NIFT, Bangalore) who is always keen to give his co-operation, motivation, encouragement and valuable guidance to us.

We want to express our deep thanks to Mr. S.K.Chaudhary, Managing Director Kailash Ribbons Factory Limited and Mr. Sushil Khanna, Technical Director Kailash Ribbons Factory Limited who helped us a lot in our training and gave their full cooperation, guidance and support.

GEETIKA VARSHNEYA

JYOTI PAL

MANOJ KUMAR PARAS

NEHA KAUSHIK

DECLARATION

We, Geetika Varshneya, Jyoti Pal, Manoj Kumar Paras & Neha Kaushik , hereby declair that the work done by us in the project titled “TRAINING REPORT AT “KAILASH RIBBON FACTORY LIMITED” is bonafide work. It has been carried and submitted in partial fulfillment of curriculum requirements of post graduation programme in apparel production at National Fashion Technology,Bangalore.

1.

2.

3.

4.

M.Ftech(AP)

NIFT,Bangalore

PREFACE

Being a student of National Institute of Fashion Technology, we are very pleased to disclose the report on our industrial training at Kailash Ribbon Factory Ltd., New Delhi dated from 17-12-07 to 29-12-07.

In bid to becoming a successful Manager. Industrial training fills the gap of theory what we learn in the college and the practice what we scrutinize in the company. Hence, industrial training is the only way out for the students of PG to learn all these aspects of the ideal thoughts of Production and its application in the industry.

The contents of the report include production, personnel and marketing details of the company.

Students,

Geetika Varshneya

Jyoti Pal

Manoj Kumar Paras

Neha Kaushik

N.I.F.T. , BANGALORE

CONTENTS

Company Profile…………………………1 Poly Bag………………………………….5 Hanger…………………………….……..10 Button……………………….……..…….12 Labels……………………………………17 Laser Cut Fabric Appliqué………………21 Printed Labels……………………………22 Transfer Print Label……………………..25 Hang Tags……………………………….27 Rubber , Badge/Patch……………………27 Barcode Label…………………………...28 Twill Tape………………………………29 Address of Units………………………...30

COMPANY PROFILE

Kailash Ribbons started in 1962, it was the smallest label manufacturing company in India. At present it has 50 computerised woven label machines and total staff strength is over 800.

With a production capacity of 4 million labels per day, Kailash is scaling new heights in a label-conscious world as well as in hang tags, barcodes, stickers, spun polyester sewing thread and different types of hangers just to name a few.

It is an ISO 9001:2000 certified company and the No. 1 manufacturer of labels on the Indian subcontinent.

 IO 91:2000 Certified Com

PRODUCTS:

The company is manufacturing

Woven labels Heat transfer labels

Hang tags

Barcodes

Plastic Hangers

Printed polybags

Metal and Polyester buttons

Sewing thread

Embroidered patches

Packaging materials.

To add to its interesting product profile Kailash is trading items like

Crochet laces Wooden hangers

Draw cords

Heat transfer appliqués

Labels

Decorative flowers and beads

Zippers

MARKET SHARE:35%

OFFICES : Dubai, UK,New York,Germeny,Colombo

TURNOVER:Rs.50 crore per annum.

Apart from Oekotex and Ecotex Certifications, kailash Ribbon's environment consciousness is also evident in its new development of bio-dehydrated polybags, which are soluble in fluids.

MANAGEMENT:

Mr. S.K.Chaudhary Ms. Shweta ChaudharyManaging Director Director

Mr. Sushil Khanna Ms. Suruchi ChaudharyTechnical Director Director

Mr. Ashish ChaudharyDirector

BUYERS:

Target Billblass

Design and source

Philips van huesen

Tommy hilfiger

C&A

CAG

Disney

Wal-mart

Supreme

Red cat

Otto AGN

Splash

Mango

Li-fung

AMC

Monsoon

Karstadt

Quelle

Colby

Carrefour

Tanzara

Zara

Kellwood

MANUFACTURING UNITS :

GURGAON

403, Udyog Vihar, Phase-III,

Gurgaon, Haryana

NEW DELHI

C-111, Mayapuri Industrial Area

Phase-II,

New Delhi -64

NEW DELHI

B-92, Mayapuri Industrial Area

Phase-I,

New Delhi -64

TIRUPUR

6,Bridgeway colony,

Extension ,Tirpur-07

TECHNOLOGY & QUALITY CONTROL

The real strength of Kailash Ribbons lies in its products technology and quality control.

A total of 50 state-of-the-art machines from MEI, Muller, Vauple and 26 CAD/ CAM System from Sophis (Belgium), Muller (Switzerland), Viable (USA), ensure technical excellence in an industry known for rapid change.

The Advanced Designing System, Ultrasonic Slitting Systems, Lazer Die-Cut, Embossed, Transfer Printing Machines and Ultra Modern in-house Dyeing Plant, help in producing samples in the shortest time.

Quality - With our continuous efforts to achieve International Standards we have been awarded ISO 9001-2000 and “OKO-TEX STANDARD 100 CLASS –I” Certificate which certifies that our products are Eco-Friendly & Azo-Free.

 

 

POLYBAG UNIT

RAW MATERIAL: Low density polymer, or linear low density polythene or a combination of both in which more ratio is of former than later.

SEQUENCE OF OPERATION:

POLYMER

TUBING MACHINE

CIRCULAR TUBE OF POLYBAG

PRINTING ON PLASTIC FORMED

SIDE SEALING

FOLDING OF POLYBAG

POLYBAG FORMED

DETAILS OF VARIOUS OPERATIONS:

1. FORMATION OF TUBE OF POLYBAG

TUBING MACHINE: KOISITE KABRA EXTRUSION TECHNIQUE

PURPOSE: To form a tube of polymer by melting the polymer with the help of air suction in upward direction.

METHOD :1. Feed the polymer chips in to the machine.2. melting the polymer.3. formation of tube by air suction 4. wrapping of tube in a roller

POLYMER MELT TEMPERATURE: 85 to 180°C

SIZE OF POLYMER TUBE(WIDTH): 4” to 28”

THICKNESS : Depends Upon Gauge.

PRODUCTION/ DAY: 600 kg

2. PRINTING OF POLYBAG:

FLEXO GRAVURE PRINTING MACHINE

PURPOSE: Printing logo or symbols of various industries

PARAMETERS :

Cylinder size or screen size: 9”-50” in circumferenceMaximum colors used: 2-10 generally 4Material of screen : nylonDaily wastage: 10-15 kgWeight of printed polymer tube: 50-60 kg

3. SIDE SEALING :

PURPOSE: To seal the sides to form a polybag.

PRODUCTION/DAY : 40,000 pieces

METHOD :

1. In this process, first one side of the polybag is cut by the blade.2. There is a laser, by which we sets the width of the polybag.3. Two sides of polybag is sealed by this machine.

Laser on a sealing machine

Sealing section of a sealing machine

Sealing of the side of a polybag for hanger cut by hot wire

QUALITY PARAMETER FOR POLYBAG: Stretch ability

RATE /POLYBAG: Rs.1 to 4

POLYMER SUPPLYING INDUSTRIES: Reliance, Gail

MAXIMUM WASTE PRODUCING MACHINE: Printing machine

DIFFERENT TYPES POLYBAG FOLDING:

GUSSET TYPE

OPEN FLAP

HANGER CUT

HANGER UNIT

MATERIAL USED: Polypropylene or high impact polystyrene.

SEQUENCE OF OPERATION:

POLYMER MELT

HANGER FORMING MACHINE

HANGER FORMED

METHOD OF FORMATION:

Polymer is melted at temperature of 10 HP -15 HP. Transferred to hanger forming machine in which there is a die in the shape of

hanger and a metal hook is placed. When polymer reaches the machine it is pressed and takes the shape of die and

hanger is formed as the shape of die. Taken out after some seconds after cooling. A die contains two hanger shape, and these two hangers are separated by hand. Extra polymer is cut out and finishing is done.

Hanger making machine

Dies for Hangers

PRODUCTION/SHIFT: 1800-2000 pcs.

NO.OF MACHINES: 5

PRODUCTION: 2 Hangers/machine at time

WASTAGE: 1-2%

DIE WEIGHT: 40-50 KG

MATERIAL OF DIE: WOOD

Spray is used to remove the plastic from machine.

BUTTON UNIT

RAW MATERIAL:

The common material for buttons is polyester, which is a special kind of plastic with properties that make it suitable for buttons. A variety of chemical dyes are added to the polyester to make different colors. To make buttons with the pearlescent sheen of shell buttons, red carbonate is added to the polyester. Black buttons are made with the addition of carbon black, and white buttons are made with titanium. The button making process also requires a chemical catalyst that hardens the polyester, and wax. Other materials that can be used for making buttons are pearl, glass. wood, and different types of metals.

SEQUENCE OF OPERATION:

Mixing the polyester

Pouring into the cylinder

Hardening the sheet

Cutting the sheet

Cutting the blanks

Cooling the blanks

Styling the blanks

Finishing the buttons

DETAILS OF VARIOUS PROCESSES:

MIXING THE POLYMER

Polyester arrives at a button factory in liquid form. At the start of the manufacturing process, polyester is drained from its storage tank and measured into a stainless steel kettle. Then dye is added, if the buttons are to be any color other than the natural translucence of the polyester. After the dye is mixed in, the liquid polyester is poured into a 3-gallon (11 l) metal beaker. The catalyst and liquid wax are added.

POURING INTO THE CYLINDER

The mixture of polyester, catalyst, and wax is then poured into a large rotating metal cylinder. The cylinders are made of steel and lined with chrome, and are typically 2 feet (61 cm) long and 4 feet (122 cm) in diameter. The cylinders lie on their sides on rollers which rotate the drums at 250 rpm. The polyester solution is slowly poured into the rotating interior of the cylinder, and the centrifugal force of the rotation causes the solution to spread, lining the drum with an even sheet. A greater amount of polyester is used for thicker buttons, and less for thinner ones. A 2-inch (5 cm) lip around the ends of the cylinder prevents the polyester from leaking out.

HARDENING THE SHEET

As the polyester rotates in the cylinder, it begins to interact with the chemical catalyst and harden. The wax rises to the top of the sheet, and also sinks to the bottom, so that the hardening polyester is eventually held between two layers of wax. This process is completed after 20 minutes of rotation. The resulting polyester

sheet has changed from its liquid state to a crumbly solid likened to the consistency of stale cheese.

CUTTING THE SHEET

When the sheet has reached the proper hardness, the drum is stopped and the sheet is cut. Then it is rolled out of the cylinder onto a wooden tube. The wax makes it easy to remove from the drum, but the material is still very delicate. The top layer of wax is then peeled off, and the sheet is transferred to a blanking machine.

CUTTING THE BLANKS

The blanking machine moves the polyester sheet along on a conveyor belt. As the sheet passes along the belt, circular steel cutting dies descend and punch out button-sized circles, called blanks. Buttons come in standard sizes, and different diameter dies can be loaded into the blanking machine, depending on the size needed. After the blanks are cut, they fall into a chute, and the punched out sheet of polyester rolls beneath the chute. Cutting the blanks from the sheet takes from two to four minutes, depending on the size of the buttons being made.

COOLING THE BLANKS

The blanks at this stage are hot, because the polyester is still reacting with the catalyst, releasing heat. So at this point the blanks are removed from the chute and poured into a nylon bag. The bag is then lowered into a tank of salt water, which is heated to 230°F (110°C). The blanks float in the salt water for 15 minutes. The water slowly cools, and the polyester blanks harden. Next, the nylon bag is transferred to a cold water tank, and the blanks reach their final state of hardness. After the hot and cold baths, the blanks are dried in a centrifugal drying machine, which spins them in a wire mesh basket.

STYLING THE BLANKS

The blanks are now ready to be cut into their finished button shape. The exact design of the button can be specified by a clothing manufacturer, and the button maker must make a steel cutting tool according to the design he is given. A different cutting tool is needed, for example, to make a beveled edge or a flat one, or to make a slightly concave button. When the appropriate cutting tool is in place, the buttons are poured into a hopper at the top of the cutting machine. The blanks fall into a holder where they are clamped tightly and moved toward the cutting tool. The spinning blade advances and cuts the button, then retracts. Next, the button moves beneath a set of drills, which create the holes. Like the cutting tool, the drills must be designed to conform to the clothing manufacturer's specifications. The design specifies not only two holes or four holes, but the diameter of the holes and the distance between them as well. After the buttons pass beneath the drill, they are sucked by vacuum out of the holder and into a box beneath the machine. Hundreds of buttons a minute can be made this way, though the number varies according to the size of the button and the complexity of the design.

FINISHING THE BUTTONS

After the buttons are cut and drilled, they have rough or sharp edges, scratches, and tool marks. They are placed into hexagonal tumbling drums, which contain water, an abrasive material, and a foaming agent. The drums spin for up to 24 hours. The buttons bounce around in the drum until they are smooth and shiny.

After tumbling, the buttons are washed and dried.

SELL : CO2 LASER ENGRAVING MACHINE (FOR BUTTONS)

CO2 series Laser Engraving Machine, one kind of the far infrared ray laser, is specially suitable for marking, cutting and engraving on the nonmetal materials. It is widely used for industry such as PMMA, Organic Glass, Bamboo and Wood articles, Resin, Plastics, Rubber, Paper, Clothing, Leather goods, Home appliance an IC.

QUALITY CHECKING OF BUTTON:

After the buttons are completely finished, they are placed on a conveyor belt and visually inspected for defects. The inspector must check each button for flaws and remove any cracked or mis-cut ones. The buttons are now ready for packaging and sale.

LABEL UNIT

OBJECT OF LABELING A PRODUCT:

To reflect the brand image /brand name

To convey care instruction

To let the consumer know the contents of the product.

To carry the information about the place of origin of the product

To carry the size(fitting criteria) of that particular product.

To carry miscellaneous information like product code,fire warning,eco-concerned message etc.

DIFFERENT TEMINOLOGIES

Brand label

Content label

Place of origin label

Wash care instruction label

Size label

BRAND LABEL

A piece of woven or printed, single or multicolored tape with written information and/or picture drawn onto it. Thus reflects the manufacturer’s image in the product.

The position of this label should be such that the customers first look should fall onto it.

CONTENT LABEL

A piece of woven or printed tape with written information on it about the content of the product.

CARE LABEL

The prime objective of this is to instruct the consumer, how to take care of the product in terms of washing, bleaching, drying, ironing, drycleaning etc.

There are five basic operations involved in the caring of textile and garments.

Washing Bleaching

Drying

Ironing

Drycleaning

PACKAGE LABEL

Packaging often has labels attached to (or integral with) the package. These communicate pricing, bar codes, UPC identification, usage guidance, addresses, advertising, etc. They also may be used to help resist or indicate tampering or pilferage.

TYPES OF LABELS

WOVEN LABELS

Computerized Woven Label manufacturing machine

Taffeta

Attractive and delicate woven labels, the advantages of which include low price and a large choice of colours of the yarns used in their production. Taffeta woven label is the most commonly used quality looks great in high definition. It is made on jacquard looms.

Satin

Elegant woven labels ideal for smart clothing being equally its decorative element as well as an information label. The advantages of satin include background gloss, smooth surface and higher weave density. Satin woven ;label is a soft and silky label with a natural shine. It is made on jacquard looms.

High Density

Woven labels produced using very thin yarn with the highest weave density, which will fulfil the requirements of even the most demanding clients. This technology allows for a precise reproduction of a logo or any graphic design.

The raw materials and stabilization process used, guarantee the constancy of the woven labels' appearance despite multiple washings.

AVAILABLE WIDTHS

FINISHING STYLES :Double Thermal Stabilisation, Ultrasonic Edge Quality Refining, "Laser" For Emblem And Zipper Puller Cutting, Specialized Equipment For Footwear Labels Sticking And Pressing.

in ribbon longitudinal center fold in ribbon

straight cut

end fold asymmetrical end fold one-sided fold

longitudinal end fold center fold longitudinal center fold

[mm]   9 12 14 17 20 22 24 30 33 40 50 66 100 200

taffeta and high density

* * * * * * * * * * * * * *

Satin * * * * * * * * * *

manhattan fold mitre fold laser die cut

incised (zipper puller) with self-adhesive tape

and die cutwith thermal tape

ultrasonic cut(soft edges) double-sided

(front and back)

 

NEW FINISHING STYLES

New finishing styles of our woven labels: asymmetrical end fold, one-sided fold, longitudinal center fold, with thermal tape, longitudinal center fold in ribbon.

DOUBLE-SIDEDWoven ribbons for "Logo bands" (including High Definition)

MITRE FOLDit is a folding operation allowing for creating hang tags.

LASERBy using a laser beam, we cut and engrave custom shapes on ribbon, which can be initially hardened or softened according to client’s requirements.

ULTRASONIC CUTTINGA new technology of mechanical/thermal fabric cutting guaranteeing smooth edges. Used for cutting the fabric into ribbons and for finishing individual woven labels. Especially recommended for woven labels that are in direct contact with the skin.

LASER CUT FABRIC APLIQUE

Laser cutting machine

A fine, clean, accurate depth of cut is achieved by software controlled adjustment of both the cutting speed and the power output of the laser

cut.

PRINTED LABELS

METHOD OF PRINTING A LABEL :

1. A die of a design is paste over the rollers.

2. No. of rollers is equal to the no. of colors in the design.

3. Colors are feed through the rollers.

4. As the tape passes between the rollers, prints will transfer on the tape.

5. Pass it through the heating plate for drying.

6. If both side of the label has printing, first one side is printed and passes through the heat plate then opposite side is printed and dried.

7. After printing, the labels are cut and fold.

Roller printing

Heat setting

PREPRATION OF DIE FOR LABEL PRINTING:

1. Make the design in a designing software.2. Take the negative and cut the nylon sheets in the size of negative.

3. Transfer the design from negative to nylon sheet by placing both in a machine shown below and exposing both of them at the temp. of 65°c for 600 sec.

4. Nylon sheets are washed in a washing m/c with perchlorate solution, in which all rest part except design is melted and we get the die for the design.

5. Dry this for hardening.

Die for roller printing

Wasing of die

COLOR FASTNESS TESTING METHOD OF PRINTING LABELS:

Instrument used: GRETAGMACBETH SPECTRALIGHT III color matching box.

Instructions:

1. First we have to identify the primary and secondary lights as per the recommendation of buyer.

2. It is compulsory to test the sample is tested in both lights.

3. For checking and evaluation after laundering D-65 light is used.

4. For checking and evaluation after crocking D-65 light is used.

5. In case the buyer has not specified the light it should be checked in D-65 light.

D-65 simulated daylight.

For example:

GAP/OLD NAVY: primary source: CWF and secondary source: A.

TRANSFER PRINT LABEL

HEAT TRANSFER PRINTING

Heat-transfer printing is the process used to transfer ink on a carrier paper to another surface. When heat and pressure is applied to the carrier paper, the ink is transferred. The types of heat transfer printing paper vary depending on the different receiving surfaces such as ceramic, cloth and heavy fabrics.

The process of transferring images to a large variety of products without messy inks by-products or screens is possible with Heat Transfer Technology. The process is fast, it lasts and it is profitable.

Heat transfer printing is clean and environmentally safe. There are no suspect liquid by-products. The only by product is paper. Heat Transfer printing is the primary element in apparel manufacturing operations utilizing the increasingly popular agile manufacturing. It is the perfect medium for the demands of today's marketplace - short run and sample production.

With the help of specially formulated dye-sublimation inks and advances in graphics and RIP software packages, operators now have greater control and flexibility which results in a better quality end product.

METHOD OF HEAT TRANSFER PRINTING:

Prepare the design on a computer by the designing software. Take the negative or positive printout of the design.

Transfer the design on Cumolint paper and make a screen.

Apply an ink on a carrier paper through this screen and dry the paper by passing it through the heating zone.

From a heat press transfer the design from a carrier paper to the product.

Screen formation

Application of ink on carrier paper

HEAT PRESS:

A Heat Press is the machine that presses a transfer onto an imprintable substrate. Using high temperatures and heavy pressures for a certain amount of time, the transfer is permanently embedded into the product.

CUSTOM HANG TAGS

Hang tags are not simply for brand information purposes. They add value to your clothes by strongly identifying your brand on display. Hang tags can be creatively produced with customized shapes and materials.

Custom die cut shapes

Paper, plastic, vinyl, corrugated, metal and leather materials

Varnish, aqueous, U.V., laminate, and custom coatings

Brass, nickel, aluminum, and steel eyelets

RUBBER/PVC/SILCONE PATCH/BADGES

Using rubber, PVC and silicone patches can enhance the look of your products. Jeans, jackets, bags, footware and accessories need more unique brand identification methods.

Rubber, PVC and silicone are excellent in expressing vivid colors with 3D effect.

METHOD OF MAKING RUBBER BADGES :

Before a badge can be produced Tooling and Die or Mold is required.

RUBBER–STAMP ANALOGY : For easy comprehension we always like to give the rubber-stamp analogy; a rubber stamp is a negative that will leave a positive print. If any changes are required to the print, whether reduction in size or any modification to the print, a new rubber-stamp is needed.

DIE : A die is usually a cylindrical block of steel that has the negative impression of a badge embedded on one flat end of the steel.

MOLD : A mold is made out of high quality rubber that can withstand high temperature and used with the centrifugal cast type of manufacturing process.

Polymer of rubber is fed to the machine and rubber badges come out according to the shape of die and it is cool down at room temp.

BARCODE

A barcode (also bar code) is a machine-readable representation of information (usually dark ink on a light background to create high and low reflectance which is converted to 1s and 0s). Originally, barcodes stored data in the widths and spacings of printed parallel lines, but today they also come in patterns of dots, concentric circles, and text codes hidden within images. Barcodes can be read by optical scanners called barcode readers or scanned from an image by special software. Barcodes are widely used to implement Auto ID Data Capture (AIDC) systems that improve the speed and accuracy of computer data entry.

It is printed by roller printing machine.

TWILL TAPE

Twill tape is a flat twill-woven ribbon of cotton, linen, polyester, or wool.

Twill tape is available in various widths, generally up to 1 inch (2.5 cm), and a wide range of colors.

Twill tape is used in sewing and tailoring to reinforce seams, make casings, bind edges, and make sturdy ties for closing garments.