INTRODUCTION (VARDHMAN GROUP)

The industrial city Ludhiana, locate the fertile Malwa region of central Punjab is otherwise known as the Manchester of India. Within the precincts of this city located the corporate headquarters of the Vardhman Group, born in 1965, under the entrepreneurship of Late Lala Rattan Chand Oswal has today blosommed into one of the largest Textile Business house in India.

As its inception, Vardhman had an installed capacity of 14,000 spindles; today capacity has increased multifold to over 5.5 lacs spindles. In 1982 the group entered the sewing thread market in the country, which was a forward integration of the business. Today Vardhman threads are the second largest producer of sewing threads in India. In 1990, it undertook yet another diversification, this time into weaving business. The grey fabric weaving unit at Baddi (H.P.), commissioned in1990 with a capacity of 20,000 meters per day, has already made its mark as a quality producer of grey poplin/sheeting/shirting in the domestic as well as foreign market. This was followed by entry into fabric processing by setting up AURO Textiles at Baddi, which currently has a process capacity of 1lacs meters/day.

In the year 1999 the group has added yet another feather to its cap with the setting up of Vardhman Acrylics Ltd. Bharuch (Gujarat) which is joint venture Acrylic Fiber production undertaken with Marubeni and Exlan of Japan. The company also has strong presence in the market of Japan, Hong Kong, Korea, UK and EU in addition to the domestic market. Adherence to systems and dedication to quality has resulted in obtaining the coveted ISO 9002/ ISO 14000 quality award, which is the first in Textile industry in India.

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AURO DYEING

AURO DYEING is a unit of Vardhman Spinning and general Mills Ludhiana. It is located in a village Baddi, Tehsil-Nalagarh, District Solan. The AURO dyeing site occupies 45.000 square meters. Unit has a maximum production of 45 tons per day. The unit has two production sections: -

YARN DYEING FIBER DYEING

YARN DYEING

100% COTTON POLYESTER/COTTON BLEND 100% ACRYLIC ACRYLIC/COTTON BLEND COTTON/WOOL BLEND

AVERAGE PRODUCTION – 15 ton/day (max.)

FIBER DYEING

100% COTTON 100% POLYESTER ACRYLIC TOW 100% WOOL

AVERAGE PRODUCTION – 30 tons/day (max.)

AURO DYEING has collaboration with the Japanese concern and has the latest technology of dyeing. Most of the machinery has been imported from Japan.

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1. RESEARCH AND DEVELOPMENT

Research and Development department is an integral and necessary component of any industry. The success of any industry is not possible without R&D department and it depends on the efficient working of this department.

THE MAJOR FUNCTIONS OF THE R&D DEPARTMENT ARE

IT ACTS AS A NEXUS between the outside party and production department since the orders are taken from the outside party and after approval sent to the bulk section through this department.

QUALITY CONTROL of products and QUALITY CHECKS of input materials are done in this department.

MATCHING is another important function of this department. Shade is developed according to the reference recipe and the shade is to be matched with the standards under lowest number of trials.

THE DIFFERENT SECTIONS OF R&D DEPARTMENT ARE

1. QUALITY INPUT.2. QUALITY OUTPUT.3. PROCESS DEVELOPMENT CELL (PDC).4. OBBDM.5. SPDM.6. WEAVING SECTION (SHIRTING CELL)

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1.1 QUALITY INPUT In this section all the input materials like dyes, chemicals, different, fibres, grey yarn husk, water hardness etc. tested for there performance properties.

A) DYES TESTING

1) TESTING A NEW SAMPLE AS SUBTITUTE

Colour Value (Strength) Fastness (Dry Rubbing, Wet Rubbing,

Washing) Colour Fastness to Mercerization Solubility Migration Behavior

2) TESTING FOR RUNNING ITEM

Colour Value E Value (STD & PREVIOUS) Physical Appearance

FOLLOWING DYES ARE TESTED FOR THERE COLOUR VALUE:

REACTIVE DYES: Reactive Dyes are tested on OBBDM machine. ACRYLIC DYES: Acrylic Dyes are tested in Beaker Dyeing Machine.

VAT DYES: Vat Dyes are tested on AHIBA Machine.

DISPERSE DYES: Disperse Dyes are tested on HTHP Machine.

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A) In Dye the sub store person gives testing new dye and this dye is tested against the previous supply & standard. After testing E value and colour strength is also compared. Concerned person sends testing report to the colour substore and main storeafter sign.

B) Some dyes come for vendor analysis. After testing the record are maintained in the vendor development file.

C) Consistency of each dye is to be maintained in the corresponding file.

B) CHEMICAL TESTING:

In chemical testing the following chemical are tested for their percentage purity.

Salt Soda Acetic Acid Caustic Flakes

Caustic Lyes etc.

NaOCl is also tested for available Chlorine. Other auxiliaries are tested for solid content & different performance properties.

C) TEST FOR DIFFERENT AUXILIARIES:

1) WETTING AGENTS WETTING TEST SOLID CONTENT

2) DETERGENT/ WASHING OFF AGENTS CLEANING EFFICIENCY

3) RETARDER HALF DYEING TIME

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4) SOFTENER SOLID CONTENT APPLICATION TEST

D)HUSK TESTING :

Husk is tested for their moisture content. After testing report is send to main store and boiler section by the concerned person.

E) WATER HARDNESS :

Water hardness is tested four times in a day.

F) GREY YARN TESTING:

Grey yarn comes from different units tested in input section for their physical parameters and dye ability. Record of the grey yarn used for the production is maintained in the grey yarn-testing file. After testing the report is send to production Deptt. Commercial Deptt. , PPC Deptt. after signed by concerned person.

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1.2 QUALITY OUTPUT

INTRODUCTION

Performance of the product against the customer decides the quality of that product. Under the view of quality control the word QULITY means the best quality performance for the utmost satisfaction of the customer within a competitive price and CONTROL is the tool used by the management in securing this quality.

OBJECTIVE

The objective of QUALITY OUTPUT section is to control the quality of the product by testing and controlling all the related parameters. For this purpose the different tests, which are carried out here, are

1. COLOR FASTNESS TO WASHINGa) REACTIVE DYED YARNb) VAT DYED YARN

2. COLOR FASTNESS TO CROCKING. (Wet and Dry)

3. COLOR FASTNESS TO HYPOCHLORITE BLEACH/PEROXIDE BLEACH

4. RESISTANCE TO COLD WATER BLEEDINGa) REACTIVE DYED YARN AND VAT DYED YARNb) SPECIFIC SHADES OF VAT AND REACTIVE

5. COLOR FASTNESS TO MERCERIZING.

6. DETERMINATION OF WHITENESS INDEX OF TEXTILES.

7. COLOR MEASUREMENT OF TEXTILE INSTRUMENTS.

8. COLOR FASTNESS TO PERSPIRATION.

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9. PH OF WATER EXTRACT FROM BLEACHED TEXTILES.

10. COLOR FASTNESS TO LIGHT.

INSTRUMENTS USED IN THE QUALITY OUTPUT ARE

LAUNDROMETER To check the washing fastness.

CROCKMETER To check the wet and dry rubbing fastness.

RAPID OIL EXTRACTOR To check the % finish content. WRAP REEL

To make a lea of yarn.

LEA STRENGTH TESTERTo check the breaking strength of the lea.

CIRCULAR KNITING MACHINETo make knitted fabric from the yarn.

MOISTURE ANALYSERTo check the moisture content of the yarn.

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QUALITY ASSURANCE STANDARDS FOR DYED PRODUCTS

S.No

PARAMETER COTTON FIBRE

ACRYLIC FIBRE

PET FIBRE

1 MOISTURE CONTENT

6.5-8% 1-2% 1-2%

2 FINISH CONTENT

0.55-0.65%

0.2-0.3%

0.16 -0.22%

3 WASHING FASTNESS

4 - 4/5 4 - 4/5 4 - 4/5

4 RUBBINGFASTNESS (DRY)

3/4 3/4 3/4

5 RUBBINGFASTNESS (WET)

3 - 3/4 3 - 3/4 3 - 3/4

6 SHADE SHOULD MATCH WITH STANDARD

7 LEVELNESS SHOULD BE UNIFORM

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MATERIAL FLOW IN OUTPUT SECTION

DYEING SECTION

QUALITY ASSURANCE

YARN

TESTING

RUBBING FASTNESS TESTING

(WET AND DRY)

WASHING FASTNESS TESTING

SAMPLING

COUNT

TESTING

C.S.P. TESTING

COLD WATER BLEEDING

TESTING

REPORT IS SENT TO PRODUCTION DEPARTMENT

1.3 OBBDM SECTION

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(OPEN BATH BEAKER DYEING MACHINE)

OBJECTIVE

Objective of OBBDM SECTION is to prepare the recipe for a given shade for the bulk production as well as to prepare the lab dips for the market orders. Generally the recipe of the orders below 250 Kg is developed in this section. For this purpose open bath beaker dyeing machine and HTHP machines are used.

TYPES OF MATERIALS DYED IN THIS SECTION ARE

100% COTTON (yarn and fibre) POLYESTER/COTTON blend (yarn) 100% ACRYLIC (fibre) 100% POLYESTER (yarn and fibre) 100% WOOL

DIFFERENT DYES USED IN THIS SECTION ARE

REACTIVE DYES and VAT DYES for cotton DISPERSE DYES for polyester BASIC DYES for acrylic ACID DYES for wool DISP/REACT AND FOROSOL DYES FOR P/C blend

MACHINE SPESIFICATIONS NAME OF MACHINE NO OF MACHINES NO OF BEAKERS IN

MACHINE OBBDM 4 1 having 6 beakers

3 having 14 beakers

HTHP 1 12

OBBDM MACHINE

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DYEING PROCEDURE (FOR REACTIVE VS DYES)

a) Start dyeing at 400 c and run the m/c for 15 min.b) Add salt according to concentration of shade in 3

installments at an interval of 5 min.c) Run for 15 min.d) Add soda according to shade depth in 3 installments at

an interval of 5 min.e) Now run the m/c for 50 min. At 600c.f) Drain the beaker and wash the sample properly with

fresh water and give after treatment.

DYEING PROCEDURE (FOR REACTIVE HE DYES) From step (a) to (d) same as for VS dyes.(e) Run the m/c for 50 win at 800c(f) Same as for VS dyes.

SALT-SODA CONCENTRATION (DEPTH WISE)

Depth Of ShadeConc .Of Salt

(NaCl)Conc. Of Soda

(Na2co3)

Up To 0.75% 20gpl 10 Gpl

0.75 - 2.0% 40Gpl 12 Gpl

2.0 - 4.0% 50Gpl 15 Gpl

4.0 - 6.5% 60Gpl 18 Gpl

Above 6.5% 70gpl 20 Gpl

Above 6.5%(Only For Red, Navy &

Black)70 Gpl

Soda - 5 GplCaustic - 1.3

Gpl

AFTER TREATMENT (FOR VS & HE DYES)

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a) Neutral with Acetic Acid - 5.0 g/lTemp. - 600cTime -5’M:L R -1:15

b) Cold wash with fresh water for 5 min.

c) Soaping with Wetter 28 - 1.5 g/lTemp. -900cTime -5’M:L R -1:15

d) Hot wash for 5 min.

DRYING

a) Hydro the sample.b) Keep it in oven till dry.

SAMPLE CHECKING

Now check the sample (dyed) for shade & levelness in mentioned light source.

HTHP MACHINE

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DYEING PROCEDURE (DISPERSE DYES)

After pippetting of colour load the lea in beaker and add water to make the final volume (including chemical) 90 ml (i.e. 1:18 M:L R).Chemicals to be added –

Solopol PES – 1.0 gpl Ammonium Sulphate – 0.5 gpl

Acetic Acid – 0.5 gpl

a) Start dyeing at 500c and raise temp to 900c in full steam.b) Run the m/c for 30 win.c) Cool the m/c up to 800c with full cooling gradient.d) Drain the beaker and wash the sample properly.e) Hydro the sample and keep it in oven for drying.

DYEING PROCEDURE (FOROSOL DYES )

After pippetting dye solution add chemicals.Lycol RDNI – 0.5 gpl

Ammonium Sulphate – 0.5 gpl Acetic acid – 1.0 gpl

Salt – 4.0 gplSolopol PES – 0.5 gpl

Now add water to make final volume 90 ml (1:18 M:L R) Run the m/c at 500c for 15 min.Raise the temperature up to 1350c with heating gradient 20c/min.Run the m/c for 30 win.Cool the m/c up to 800c with full cooling gradient.Run for next 20 min.Drain the beaker and wash properly with fresh water.Hydro the sample and keep it in oven for drying.

SAMPLE CHECKING

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Carbonize the sample & check shade.

Carbonizing ProcedureMake 100 ml solution with 70% H2SO4 & 20% water.

Let the solution be cool up to 400c. Dip the sample for 5 min. Take out the sample carefully from solution and wash

with cold water. Neutralize the sample Now check the shade of polyester part.

1.4 SPDM SECTION

OBJECTIVE

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The objective of the SPDM (single package dyeing machine) section is to dye the single package for the purpose of bulk production as well as to produce the development shade. The desired shade of the order above 250 kg is produced in this section on a single package. For this purpose single package dyeing machines are used. The procedure, which is followed in SPDM, is followed in bulk, which helps in minimizing the problems of the bulk production.

MACHINE SPESIFICATIONS

MAKE OF MACHINE NO OF MACHINES

HISAKA 7

FONG’S 2

DALAL 2

TOTAL NO OF MACHINES 11

DIFFERENT PARTS OF SPDM AND THEIR WORKING

DYEING TANK

This is the main part of the machine situated at the center of the machine. It is cylindrical in shape having the liquor capacity of 12 ltrs. (HISAKA). It contains a spindle at the center where package is placed. Dye solution circulates in-out through the package. It contains the heating coils at the bottom. Steam is passed through the coils for heating the liquor.

ADDITION TANK

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An addition tank is situated near the main dye tank. All the dyes and chemicals can be fed to the main dye tank through this tank with the help of the feeding system.

SUCTION PUMP

Suction pump is situated at the center bottom of the machine. ItSucks and delivers the liquor through the cheese.

WATER INLET VALVE

One water inlet valve is attached at the bottom of the machine. It performs the function of coldwater inlet in the tank.

WATER OUTLET VALVE

This is called the drain valve. With the help of drain valve all the liquor is drained after use.

STEAM INLET AND OUTLET VALVE

Steam comes from the boiler for the purpose of heating the liquor. It comes through the steam inlet valve and goes out from outlet valve. A cold water pipe is connected to this steam valve for the purpose of cooling.

AIR PRESSURE VALVE After closing the main tank air pressure valve generates the required pressure for the dyeing. The maximum air pressure in the HISAKA machines is 6kg/sq.cm. 1.5 PROCESS DEVELOPMENT CELL

(PDC)

This is the section where all the new developments related to process and materials are done and all the old processes are controlled if any problem occurs.

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THE MAIN OBJECTIVE S OF THE PDC SECTION IS

TO DEAL WITH PROBLEMS IN DYIENG

If any problem in the bulk or lab occurs related to dyeing then it is deled by the PDC cell and controlled by this section by controlling and studying all the related parameters of dyeing. For example to get the shade right first time (RFT) all the parameters related to the process are studied and controlled.

TO DEAL WITH COMPLAINTS If there is any complaint by the customer then that complaint is deled by the PDC cell. This section studies various parameters and reasons related to that problem. Mostly the complaint arises related to the quality of the substrate and necessary steps are taken to solve that problem for the complete satisfaction of the customer.

TO INTRODUCE NEW DYES AND CHEMICALS

If new dye or the chemical is to be introduced in the process then testing of that sample is done in this section. The testing is done through OBBDM section or if necessary through SPDM section. If the results are satisfactory then that dye or chemical is introduced in to the process.

TO INTRODUCE NEW DEVELOPMENTS

New development related to process, shade or the materials are done in this department. For example the latest developments are the development of the dyeing process of different blends like wool/cotton, acrylic/wool/nylon, wool/nylon, polyester/nylon and acrylic /cotton etc.

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TO DEVELOP VARIOUS METHODS OF COST AND TIME SAVINGS

Various methods of cost and time savings are introduced by this department by studying thoroughly the related process, which helps in higher productivity and lower dyeing cost.

TO INTRODUCE THE NEW WORK PRACTICES

The PDC section introduces the new method of doing the work so that it could be feasible and comparatively easier for the worker to do that work.

1.6 WEAVING SECTION-SHIRTING CELL

OBJECTIVE

The objective of the weaving section is to produce the dyed yarn of required shade and dye class.

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WORK PRACTICES

The different work practices carried out in the weaving section are -:

1.DESK-LOOM REQUEST FROM AURO WEAVING

Weaving section in the very first step, get the desk-loom request from the AURO WEAVING, which contains: -

Standards of the fabric. Shade numbers against each shade. Required dye class. Light source. Primary and secondary. Party. Count and construction

2. SHADE DEVELOPMENT

Development of each shade in 50 Gms on AHIBA TURBOMAT machine as per requirement.

Sent to AURO WEAVING after matching with standards.

3. MAKING OF DESK-LOOM AT AURO WEAVING

Produce desk-loom as per required design and construction.

Sent to AURO TEXTILE for processing.

4. PROCESSING

Processing is done as per dye class and count and then matching with standards is done. After matching the decision is taken to remake the desk-loom or to send to the party.

5. SEND TO PARTY FOR APPROVAL

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After approval of the desk-loom it is sent to the party. Then party gives the order for the production in bulk if approved by the party. Sometimes the party demands for the yardage (15 meters to 100 meters) to check the feel and finish of the quality of the fabric and bulk order is given after the approval of yardage.

6. ISSUING OF ORDER

The bulk order is issued from the AURO WEAVING to the AURO DYEING required by the party.

7. CONFIRMATION OF RECIPE

Recipe is confirmed by producing the shade on the SPDM by producing the 1 kg lot on SPDM.

After recipe confirmation it is sent to shop floor for the bulk production.

8. QUALITY CHECKING

After bulk production quality of the yarn is checked.

9. SEND TO A/W FOR FABRIC PRODUCTION

After Q. checking yarn is sent to A/W for fabric production.

2. PRODUCTION PLANNING AND CONTROL

The main objective of this department is to execute the orders

placed to the organization by effective scheduling. They also

keep a control over the orders by daily monitoring at each

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stage of SPDM, dyeing and dispatch. This department has to

decide the date for the dyeing of the particular lot in the bulk

The main functions of this department are:

1. Schedule Making

2. Monitoring

3. Dispo Making

Schedule Making: In this a schedule is made for

the orders placed by the branch offices in Delhi, Mumbai,

Tirupur, Ludhiana etc. and each office has been assigned

a maximum limit i.e. the amount of order /day to be

processed. Based on this allocation a schedule is made.

The particular order of a buyer is completed depending

upon the availability of the grey yarn, dyes and also upon

the urgency of the order placed. Thus based on these

parameters a plan for the procurement of the required

grey material is also prepared.

Monitoring: The PPC cell also has to keep a check

on the status of the orders being processed and also the

stage at which they are. It also monitors whether the

order or the lab dip for shade confirmation has been

dispatched on time and if not the reasons for the same.

Dispo Making: This includes the preparation and

execution of the disposition sheet. The planning done is

mainly of two types micro planning and macro planning.

Macro planning is done once a week and deals mainly with

the lots to be processed in the coming week. Micro

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planning in done every day for the next three days and

gives much more accurate details of the machine

allocation. It is much easier to make changes in the micro

planning than macro. This sheet also keeps a record of the

pending quantity of the order and at what stage.

3. PROCESS FLOW IN YARN DYEING

YARN IN CHEESE FORM

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PRE WINDING

DYEING

DRYING

QUALITY CHECKING

POST WINDING

CODITIONING↓

PACKING↓

DISPATCH

4. PRE WINDING

OBJECTIVE

The objective of the Pre Winding section is to convert the cone into soft package form for the purpose of dyeing.

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The grey yarn is supplied to AURO Dyeing from the following units:-

100% Cotton yarn

AURO Spinning Mills Vardhman Polytex Ltd. → V.S.G.M.(100% EOU) → V.S.G.M.

→ OSWAL Cotton spinning Mills → Arisht spinning Mills → Arihant Spinning Mills

Polyester/Cotton blend

→ V.S.G.M. → Arisht spinning Mills → AURO Spinning Mills

Acrylic/Cotton blend

→ V.S.G.M. → Arihant Spinning Mills

→ Vardhman Polytex Ltd.

MACHINE DETAILS

NAME KAMITSU PSM SSM

DRUMS 60 120 45

S SPEED (m/min)

440 480 1100

WINDING RANDOM RANDOM PRECISION

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DIA. OF DRUM 185 mm 198 mm

PACKAGE DENSITY

0.329 0.329 0.364 – 0.405

POWER (kw) 3.8 4.5

MAKE JAPAN GUJRAT ZURICH (SZD)

NO OF M/C’S 2 4 9

These machines are used to convert the cones into soft packages by winding the yarn on polypropylene cheeses. These polypropylene cheeses contain the perforations from which the dye liquor circulates through the yarn with an inside to outside flow.

CHEESE SPESIFICATIONS

WEIGHT – 130-135 gms LENGTH – 156 mm EX. DIA. – 79 mm INT.DIA. – 70 mm

Sr.No Pkg. Wt. (Gm)

Count Net Wt. Range (Gm)

Dia -Range (mm)

Traverse (mm)

Density(Gm/Cc)

1 1500 20 CBD 1475-1525 195-201 150 0.364-0.405

2 1400 20 CBD 1375-1425 191-197 150 ,,

3 1300 20 CBD 1275-1325 182-188 150 ,,

4 1200 20 CBD 1175-1225 176-182 150 ,,

5 1500 24 CBD 1475-1525 195-201 150 ,,

6 1400 24 CBD 1375-1425 191-197 150 ,,

7 1300 24 CBD 1275-1325 182-188 150 ,,

8 1200 24 CBD 1175-1225 176-182 150 ,,

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9 1500 30 CBD 1475-1525 195-201 150 ,,

10 1400 30 CBD 1375-1425 191-197 150 ,,

11 1300 30 CBD 1275-1325 182-188 150 ,,

12 1200 30 CBD 1175-1225 176-182 150 ,,

13 1500 40 CBD 1475-1525 195-201 150 ,,

14 1400 40 CBD 1375-1425 191-197 150 ,,

15 1300 40 CBD 1275-1325 182-188 150 ,,

16 1200 40 CBD 1175-1225 176-182 150 ,,

17 1500 50 CBD 1475-1525 195-201 150 ,,

18 1400 50 CBD 1375-1425 191-197 150 ,,

19 1300 50 CBD 1275-1325 182-188 150 ,,

20 1200 50 CBD 1175-1225 176-182 150 ,,

21 1500 60 CBD 1475-1525 195-201 150 ,,

22 1400 60 CBD 1375-1425 191-197 150 ,,

23 1300 60 CBD 1275-1325 182-188 150 ,,

24 1200 60 CBD 1175-1225 176-182 150 ,,

STANDARD PARAMETER FOR SSM(For Cotton, Package Wt. 1200 Gm –1500 Gm)

Sr.No Count Sign Colour Side (Pkg)1 20 CBD H Double circle BLUE SINGLE2 20 BRD H Double circle YELLOW SINGLE3 24 CBD H Single circle PINK BOTH4 25 DRD Single circle YELLOW SINGLE5 30 CBD H Single circle YELLOW BOTH6 40 BRD Single circle VIOLET BOTH7 20 P/C Single circle BLUE BOTH8 30 P/C Double circle VIOLET SINGLE9 40 P/C Double circle PINK SINGLE10 34 BRD Single circle BLUE SINGLE11 30 BRD Single circle PINK SINGLE12 20 WARP Single circle VIOLET SINGLE

COUNTWISE MARK

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STANDARD PARAMETERS FOR KAMITSU & PSM

SR. NO.

COUNTPKG .WT

.(gm)DIA.

( m/m )TRAVERSE

(m/m)DENSITY

(gm/cc)# TENSION WT. (3 gm)

1 20 CBD 1200 GM 195-200 150-153 0.30-0.32 1-2

2 24 CBD 1200 GM 195-200 ,, ,, 1

3 30 CBD 1200 GM 195-200 ,, ,, 2

4 60 CBD 1050 GM 195-200 150 –151 0.34-0.35 NIL

5 40 CBD 1200 GM 195-200 150-153 0.30-0.32 NIL

6 20 P/C 1200 GM 188-193 ,, 0.34-0.35 1

7 30 P/C 1200 GM 188-193 ,, ,, NIL

8 40 P/C 1200 GM 188-193 ,, ,, NIL

9 20 wp 1200 GM 195-200 ,, 0.30-0.32 1

10 30 wp 1200 GM 195-200 ,, 0.30-0.32 NIL

5. YARN DYEING SECTION

OBJECTIVE

The objective of the yarn dyeing is to dye the grey yarn in package form. For this purpose HTHP package dyeing machines are used. The packages are loaded into the carrier situated into the machine where into-out flow is used to dye the package.

MACHINE SPECIFICATIONS

MAKE OF MACHINE No OF MACHINES

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HISAKA 7

FONG’S 6

POZZI 5

HARA 1

DALAL 2

TOTAL NO OF MACHINES

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DIFFERENT PARTS AND WORKING OF YARN DYEING MACHINE

MAIN DYE VESSEL

Yarn dyeing machine contains the main dye vessel in which the spindles are loaded. The cheeses are loaded on to the spindles and dyeing is carried out using into-out flow of the dye liquor. The dye tank contains heating coils lying at the bottom of the machine. Steam is used to heat he liquor in the tank.

ADDITION TANK

With the main dyeing tank addition tank is situated. All the additions of the chemicals are done through this tank. It contains a mixer to dissolve the chemicals and three electromagnetic sensors to sense the water level in the tank.

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DESSOLVING TANK

A Dissolving tank is also situated near the main dyeing vessel to dissolve the dye. Addition of the dye liquor is done through this tank to the main dye vessel. Similar to the addition tank it also contains the mixer and three electromagnetic coils.

MAIN CIRCULATING PUMP

The main circulating pump performs the function of circulating the dye liquor with into-out flow from the package.

DOZING PUMP

Dozing pump dozes the dye or chemical at a fixed rate to the main dyeing tank.

OVER FLOW VALVE

The function of the overflow valve is to overflow the liquor in the main dyeing tank whenever required.

THROTTLE VALVE

Throttle valve controls the flow of the dye liquor by changing the position of the valve and helps in the constant flow rate of the dye liquor through the package.

FOUR -WAY COCK

It performs the function to change the liquor flow from inside-out to outside-in and vice-versa.

WATER INLET VALVE

The hot and cold water is filled in the main dyeing tank and in the addition and dissolving tank with the help of water inlet valve.

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HEAT EXCHANGER

Heat exchangers are situated at the bottom of the tank to heat the liquor. Steam is passed through the heat exchangers for the heating. It is situated with a cooling pipe also for the cooling purpose.

STEAM INLET

The supply of the steam to the heat exchangers is done through the steam inlet system. The pressure of the inlet steam is kept to be 6 kg/sq.cm.

STEAM TRAP

It performs the function of separating the condensate from the steam.

SAFETY VALVE

Maximum pressure in the machine is kept to be 4 kg/sq cm. If the pressure inside the vessel exceeds this value then excess pressure is released by the safety valve.

AIR PRESSURE VALVE

Air pressure valve increases the pressure after lid is closed and decreases the pressure before opening of the lid.

PRESSURE GAUGE

It contains four operating systems: -1. PUMP DELIVERY generates pressure during

delivery of liquor by the pump.2. PUMP SUCTION generates pressure during

suction of liquor by the pump.3. IN DYE PRESSURE pressure of liquor after

passing from throttle valve.

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4. DYEING TANK PRESSURE pressure inside dyeing tank after lid is closed.

LEVEL GAUGE

It consists of a glass tube with a scale alongside it. The level inside the tube indicates the level of water inside the vessel.

HISAKA MACHINES

MACHINE PARAMETERS:

M/C No. /PARAMETER

YD--1 YD--2 YD--3 YD--6 YD--7 YD-8

MODEL LLC400/180 LLC-200/114 LLC-200/114 LLC-100/90 LLC-444-150 LLC-444/150

PROGRAMMER FUJI/PVH FUJI/R/H FUJI/PVH FUJI/PVH FUJI/PVHFUJI/PVH

PLC MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI

PUMP POWER 55 KW 37 KW 37 KW 18.5 KW 75 KW 75 KW

NO.OF PUMPS 3 3 3 3 3 3

PUMP DISCHARGE

(m3/min)20 10 10 5 24 24

NO. OF .PKG 450 200 200 100 444 444

LOT SIZE ON 1.5 kg /PKG

(kg)675 300 300 150 666 666

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WATER FILLING TIME

2’2` 45”

2’2` 45”

2’2` 40”

2’2`15”

2’3`15”

2’4`

LOW TEMP. DRAIN

2`3`30”

2`3`30”

2`3`45”

2`2.50”

2`3`30”

2`3`30”

HIGH TEMP DRAIN

6`8`

6`8`

6`9`

6`4.30”

6`9`

6`8`

HOT WATER TEMP (C)

5047.45

5046.25

5046.25

5047.70

5046.45

5047

MAX. HEATING RATE (C/min)

3.02.33

3.02.75

3.02.56

3.02.57

3.02.61

3.02.79

INJECTION FROM D/T

3`8`

3`2`30”

3`2`30”

3`3.30”

3`3`

3`3`30”

INJECTION FROM A/T

3`7`

3`3`30”

3`3`30”

3`3.30”

3`2`40”

3`3`30”

VOL. ( lts) 4200 2100 2100 1050 4662 4662

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PROGRAMMER

a) In programmer we feed the progm. and PTN no. with the help of deft keys on the temp. Panel of the programmer according to the given ptn.

b) There are diff. PTNS for diff. shades, substrate, type of dyes etc.

c) For running the progm. Enter the progm PTN no. And the operation starts according to progm. PTN.

d) The programmer of the m/c senses the PLC (programmable logic control) and PLC operator and control the value acc. to information / command given by the programmer.

e) The PTN can be changed only while the programmer operation is reset.

THE DIFFERENT OPERATIONS CARRIED OUT DURING DYEING ARE :-

Loading:

The yarn dyeing process is performed in cheese form. Cheeses are loaded on to carrier. Here the entire carriers are bottom type cheese carrier. The spindles are arranged on lower manifold. On each spindle 5 – 12 cheese can be loaded.

a) Before loading of material on carrier, check colour staining on carrier.

b) Check quality of pkg. by checking pkg. wt., dia., traverse, density ribbon on pkgs and deposition of fly.

c) Check pkgs for uniform winding.Extremely soft and hard cheese will cause difference in flow rate of liquor, which results in cheese-to-cheese shade variationd) Coning should be done is case of PSM and Kamitsu

pkgs.e) Place spacer between two pkgs in case of non-

interfixing cheese and in full bleach.

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f) Use proper & cleaned lock and lock plate depending upon the shades.

In case addition the lots size the amount of lot has to be adjusted in this at the time cheese loading use blind bobbin (the pipe of the same size as the bobbin) instead of cheese and use the blend pipe (the pipe is set on the whole of the spindle) in case whole spindle (one or more) has not to be loaded.

g) Before loading the dyg tank with carrier check the colour staining in case of full bleach lots, light shade and med. shades.

h) Lift the carrier by hoist and load it in dyg tank.i) Descend slowly the carrier and place the carrier on

the carrier receiving taper.j) Disengage the hanging fixer and set the carrier at

carrier receiving taper.k) Disengage the hanging fixer and set the carrier at

carrier receiver .

Dyeing:

a) Check PTN which is to be run.b) Close the dyg. tank with lid and lock the tank in

following sequence:

Close the lighting valve, release valve, and air inlet valve.Close the cover and turn the cover opening–closing handle till the complete engagement between vice. and the right and left vices are in become in perfect engagement.

Open the pkgs lighting valve. After closing the lid make sure that dyg tank lid is completely closed and turn the select switch of the safety device on the control panel in closed position.

c) Make sure that the cooling water to the pump and run the ptn.

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When m/c is to run turn the switch on the control panel on normal side from auto side

In case out-in flow direction the liquid level should be at the upper end of the carrier, so that water can be sucked from the upper end of the carrier.

Salt and Alkali Preparation:

Take the recipe from shift office and crosscheck it again.a) Before weighing colour, check all electronic balances on

daily basis against std. wt.b) Colour weigh should be done accurately in front of m/c

man.c) Colour for light shade i.e. about 50 ml should be

weighed on a balance of 300 gms.d) Colour above 2 kg should be weighed on 5 kg balance.e) Colour above 2 kg should be weight on 60 kg balance.f) Reactive dyes should dissolve at 45 C for 15-20 min at

60 Cg) Vat dyes should dissolve at 45 C for 15-20 min.h) Sulphur black dye should be dissolved at 88 C for 15-

20 min.i) Channeling should be checked before feeding colour.j) Alkali should be checked before feeding colour.k) Alkali should be predessolved for 10–15 min. Alkali

dosing should be done according to specified dosing ptn. mentioned on the ptn. sheet.

The dyestuff and other agents having dissolving temp. more than 40C should be dissolved in dissolving tank for level dyg.

Dosing PTN:

Feed dyes and other agents only after dissolving completely in the required tank (Dissolving / Additional)

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Check suction pressure and delivery pressure in dyg. Tank and find out the total head. Total head = delivery pressure – suction pressure

Now from the head & discharge (pump) graph i.e pump performance out the pump discharge.

Now calculate flow rate of the liquid (lt/kg/min)

Flow rate = pump discharge * 1000 ( lt/kg/min) Wt. of material More or less flow rate may cause even dyg. or air

on the lots. Generally dyg. should be carried out in the inside

to out side direction but in case uneven dyg is expected in cheese with the in- out direction only, the flow should be changed from in-out to out-in in little intervals.

In case of acrylic material wool or softly wound yarn, the shade collapse may occur, caused by the out side to in side flow, so the flow direction must be limited to the inside to out side in such case.* It is dangerous to heat up the empty tank & under any condition pump should not be operated without water.

Opening the cover:

Make sure that the liquid temp. in the dyg. tank is less than 80C.Open air bent valve and make sure that the tank internal pressure has reached 0( zero) on pressure gauge.

a) Make sure that the pump is stopped completely.b) Close the packing this tightening value.c) Open the release value.d) Turn the handle to open the vice and to disengage the

dune.e) Open the cover.

Water washing :When the liquor temp becomes below 80 C, open the air purge valve and remove the press.

37

a) Open the over flow valve and water feed valve and start the operation then the fresh water is supplied and dirty water is over flowed .

6. DRYING

After dyeing of the yarn in cheese form the wet packages are brought to the drying section for the purpose of drying. Drying of the packages is done in two ways: -

RAPID DRYER

RF DRYER

6.1 RAPID DRYER

Passing the hot air through the packages dries the wet packages on the rapid dryer and then conditioning is done by passing the cool air to keep a constant moisture content of the yarn.

MACHINE SPECIFICATIONS

NAME RAPID DRYER 1 RAPID DRYER 2

MAKE HISAKA HISAKA

MAX.CAPACITY 800 Kg 800 Kg

MOTOR POWER 120 kw 120 kw

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MAIN PARTS OF RAPID DRYER AND WORKING

MAIN VESSEL

The packages loaded onto the spindles are placed in the main vessel. In the main vessel hot air is circulated through the package with into out flow. Main vessel has a lid at the top of it. Pressure is generated in the vessel after closing the lid.

HEATER

The function of the heater is to heat the dry air at the required temperature, sent by the blower. Heater is connected to the outlet of the blower.

BLOWER

The function of the blower is to suck the dry air separated from the mist separator and blow towards the heater. It is connected to the outlet of the mist separator.

COOLER

Cooler performs the function of to decrease the temperature of the moist air coming out of the vessel.

MIST SEPERATOR

Mist separator separates the moisture and dust from the moist air with the help of filtration.

LIP SEALING RING

The function of the lip-sealing ring is to close the vessel with the help of air pressure.

39

MACHINE OPERATION

The different operations of the machine are: -

1. PRESSURE RISING The pressure of the machine rises after closing of the lid and when the blower starts operating.

2. DEHYDRATION

When hot air is passed through the package with out to in direction the water gets extracted from the package.

3. DRYING

When hot air is sent through the package with in to out flow the moisture present in the yarn gets vaporized and drying takes place.

4. WET ADJUSTMENT

Cool air is sent through the package with out to in direction to distribute the moisture evenly through the package.

5. PRESSURE REDUCTION

Pressure is reduced into the machine after the operation is over and then lid is opened.

40

6.2 R/F Dryer

It uses the direct heating method of the capacitor type.

Operation mechanism:-

Radio frequency rays are generated at 10000- 11000 dc volts and frequency 27.12+ 0.6 Mg Hz these establish a field between the top and bottom electrodes, all the polar molecules inside this field are affected. Since water molecules act as dipoles, the keep changing their orientation due to the high frequency of the applied voltage—this generates heat and eventually raises the temp. To boil at which moisture is converted to steam, which is sucked out with the aid of hot air blowing from the bottom.

Machine settings: -

a) Conveyer belt speed can be varied from 3m/hr. to 30 m/hr.

b) Electrode distance – can be varied between 260mm to 460mm.

Main machine parts: -a) Oscillator and R/F generation regionb) Electrodes c) Conveyer d) Water cooling unite) Exhaust fansf) Filterg) Heater unit.

Function of filters: -

Two filters are situated on the machine. They suck the clean air (1100cfm) heat it up by the heaters. This hot air aids in the removal of steam from the packages.

41

Conveyer belt speed calculations:-

At a power of 85Kw the machine evaporates 85 X 1.1 = 93.5 L of moisture per hour.

1 m length of belt accommodates N packages i.e 6 X ( 4.7 to 5) = 27 to 30

Let M be the amount of moisture required to remove from the package the speed of belt should be:- 93.5 m/hr. N X M

Production rates :-

N X conveyer speed - packages per hour

Or

Package weight X N X conveyer speed (kg per hour)Taking the value of conveyor speed as calculated above:-

Production = package weight X 93.5 Kg/hr. M

Now M is function of a) rpm at hydro.b) Time at hydro.c) Package weightd) Yarn counte) Material type(i.e combed or carded)f) Surrounding atmospheric conditions

42

To run different packages (differing in moisture content) at the same speed:-

93.5 should be constant;n X m or n X m - constant i.e. n1 X m1 = n2 X m2 = n3 X m3 = ……………………

n- can be controlled by varying the space between the packages (manually)m- can be varied by adjusting the hydro rpm & time.

Precautions and safety measures :-

There should not be any dust particles between the electrode region , since they might effect the capacitance of the system. It is recommended to clean the machine twice a week with air pressure.

The anode current should not exceed 12.5 amperes (when the conveyor is completely loaded), if it does adjust the electrode settings.

At the distribution board switch on the pump and fan required for cooling before switching on the R/F drier, and wait for another 5 mins. To start the R/F rays.

To halt the machine stop the R/F , wait for 5 mins. And then stop the pump and fan.

Do not clean the machine while it is in operation as it sucks in air at 220 cfm

Not to leave materials inside for a prolonged time interval

Do not feed in material without centrifuging. For bleached yarns allow 5mm more electrode

settings and run at greater speed to avoid over drying.

43

BERTA 24 T.E.

After emerging from the dyeing chamber the dyed yarns have moisture content of around 120% to 170% , to bring this value down to an acceptable limit (45% - 55% to be used on the R/F drier) hydro extractor is employed.

Principle and working:-

The hydro extractor works on the principle of centrifugal force and inertia.Yarn winded in the from of cheese are loaded in the centrifuge which provides the centrifugal force, and due to inertia factors the moisture/water particles separate from the cheese. The factors, which determine the quantity of moisture/water, removed from the cheese are i> angular velocity of the centrifuge & ii> the time interval at which the cheese are rotated.

Construction:-

a>4 carriers each having a capacity of 12 spools/cheese.b> 2 centrifuges having separate motors.c>centering unit.d>hydraulic system to lift the covers.(4 L capacity)

Centrifuge motor=7.5 Kw

Machine settings:-Rpm0 to 1500Time0 to 8 mins.

CONTROL PANEL :-

44

PROCEDURE TO START THE MACHINE:-

Set the main switch to position 1 Manually lift the covers. Mount the packages/cheese on the carriers. Manually put down the covers. Set the rpm & time values. Press the green colored start/stop cycle button & the

machine will operate in the auto mode. To halt the cycles again press the green button. To stop the machine in case of emergency press the

lower left red colored button.

45

VoltageIndicator

rpm1 & rpm2 selector GREEN RED ORANGE

Emergency Stop cycle start/stop manual manual Sideways up & down

|

|

|

TimeSET

Rpm display hours

7. POST WINDING

OBJECTIVE

The objective of the post winding section is to convert the dyed packages into the cone.

Number of PSM machines-10Number of AUTOCONER-2Number of MECHCONER-1

The same PSM machines are used in post winding as that in pre winding with some differences.

Spindles are used in place of cradle. Wax is applied by wax roller. Taper angle is provided to cones. Drum diameter is reduced. Speed of machine is increased to 500 m/min.

DIFFERTENCE BETWEEN PSM AND AUTOCONER

Spindle is provided in AUTOCONER not in SSM. AUTOCONER has greater speed as compared to SSM. Electronic measuring gauge is present in AUTOCONER.

8. CONDITIONING

Uniformity of moisture in yarn may suffer due to dyeing and drying treatments. To achieve this uniformity conditioning is done.

46

PRINCIPLE: - It is based on principle of condensation of steam. First of all vacuum is created which lowers the boiling point of water to 55*c resulting in generation of steam which condense on yarn. Secondary advantage of YCP is weight gain by yarn due to condensation of steam.

MACHINE: - SEIGER CONDITIONING PLANT MAKE: - AMOTO ENGG.PVT.LTD. CONTROLLER: -SIEMENS

PRESSURE -680 -680 -100 0 -500 -10

TEMPRATURE 55 60 55 60 0 0  S1 S2 S3 S4 S5 S6

CAPACITY: - 1.5 Ton

PROCESS TIME: - 75min

SPECIFICATIONS: -

Diameter of shell - 2000mm Height of shell - 2200mm Length of shell - 5100mm Weight gain - 1.8%

9. PACKAGING

47

After conditioning material is dispatched in cartons. Following parameters are mentioned on carton.

MILL: - SUBSTRATE: - COUNT: - SHADE N0. -

LOT N0: -N0.OF CONES: -DATE: - NET WT.: -

GROSS WT.: -

The size of the cartoon can be:

24”x24”x21” : 25-27 cones(max. capacity 45kg) 23”x23”x21” : 20 cones(max. capacity 25 kg) 16”x16”x14” : for minicones(max. capacity 10kg) 32”x26.5”x13.75” : 40 cones(max. capacity 40kg) for

export

10. PROCESS FLOW FOR FIBRE DYEING

STAMPING

PRESSING

48

DYEING

HYDOREXTRACTOR

CAKE UNLOADING

COTTON, PET, ACRYLIC FIBER ACRYLIC TOW WASHING RANGE ALEA DRYER

HYDROEXTRACTOR SEYDEL

DRYING RE BREAKER

BAILING MACHINE BALING

PARAGON, HARMONY, RANGOLI DAFFODIL RAINBOW RANGOLI ARIHANT VSGM HARMONY VSGM AURO Spng

11. STAMPING AND PRESSING

OBJECTIVE

Objective of the stamping is to load and stamp the fibre of required density, into the carrier for the purpose of dyeing.

49

WORKING

The material is fed into the feed lattice. From feed lattice the material goes to the swing feeder. Swing feeder place the material on the carrier with the uniform movement. Hot water feeding system attached in the swing material helps in wetting of the fiber and proper loading. Stamping road stamp the fibre in the carrier with its constant up and down movement. After stamping the dummy is placed on to the carrier and then taken for the pressing on the pressing machine. Pressing machine works on the principle of hydraulic pressure, which press the material at the effective height for the required density of the substrate.

MACHINE SPESIFICATIONS

NAME OF MACHINE MAKE OF MACHINE NO OF MACHINESSTAMPING OSCAR JAPAN 3PRESSING MAKK Engg. INDIA

& OSCAR JAPAN 2

TOTAL MACHINES 5

STANDARD DENSITY:

For cotton – 0.32 gm/cm2

For polyester -- 0.59 gm/ cm2

Pashupati tow -- 0.56gm/ cm2

Val tow -- 0.54 gm/ cm2

HEIGHT OF FIBRE IN CARRIER FOR REQUIRED DENSITY:

POLYESTER (P-0.59 gm/cm2) COTTON (P-0.32 gm/cm2)

LOT SIZE

EFFECTIVE HEIGHT

PRESSING WT (cm)

LOT SIZE

EFFECTIVE HEIGHT

PRESS HEIGHT (cm)

50

(kg)AS PER

SCALE ON PRESSING

(kg)AS PER SCALE ON PRESSING

M/C

650 128 138 350 128138

625122 138 325 117 127

600 118 132 300 108 118

575 113 128 275 99 109

550 108 123 250 90 100

525 103 118 225 81 91

500 98 113 200 72 82

47593 108 175 63 63

45088 103 ,, ,, ,,

425 83 98 ,, ,, ,,

40078 93 ,, ,, ,,

37573 88 ,, ,, ,,

30069 83 ,, ,, ,,

12. FIBRE DYEING

OBJECTIVE

The objective of the fiber dyeing is to dye the fiber loaded in the carrier at the stage of stamping and pressing. For this

51

purpose fibre dyeing HTHP machines are used. Principle of the fiber dyeing machines is same as that of yarn dyeing machines. In to out flow of the liquor is used to dye the fiber in the machine.

MACHINE SPECIFICATIONS

MACHINE MAKE CapacityLeters

CapacityKgs

PumpPower kw

Dia of vessel mm

FD-1 HISAKA 2400 350 37 1200

FD-2 HISAKA 3000 650 45 1400

FD-3 HISAKA 3000 650 45 1400

FD-4 HISAKA 3000 650 45 1400

FD-5 HISAKA 3000 650 45 1400

FD-6 HISAKA 3000 650 45 1400

FD-7 HISAKA 3000 650 45 1400

FD-8 HISAKA 3000 650 45 1400

DIFFERENT PARTS AND WORKING OF FIBER DYEING MACHINE

MAIN DYE VESSEL

Yarn dyeing machine contains the main dye vessel in which the spindles are loaded. The cheeses are loaded on to the

52

spindles and dyeing is carried out using into-out flow of the dye liquor. The dye tank contains heating coils lying at the bottom of the machine. Steam is used to heat he liquor in the tank.

ADDITION TANK

With the main dyeing tank addition tank is situated. All the additions of the chemicals are done through this tank. It contains a mixer to dissolve the chemicals and three electromagnetic sensors to sense the water level in the tank.

DISSOLVING TANK

A Dissolving tank is also situated near the main dyeing vessel to dissolve the dye. Addition of the dye liquor is done through this tank to the main dye vessel. Similar to the addition tank it also contains the mixer and three electromagnetic coils.

MAIN CIRCULATING PUMP

The main circulating pump performs the function of circulating the dye liquor with into-out flow from the package.

DOZING PUMP

Dozing pump dozes the dye or chemical at a fixed rate to the main dyeing tank.

OVER FLOW VALVE

The function of the overflow valve is to overflow the liquor in the main dyeing tank whenever required.

THROTTLE VALVE

53

Throttle valve controls the flow of the dye liquor by changing the position of the valve and helps in the constant flow rate of the dye liquor through the package.

FOUR -WAY COCK

It performs the function to change the liquor flow from inside-out to outside-in and vice-versa.

WATER INLET VALVE

The hot and cold water is filled in the main dyeing tank and in the addition and dissolving tank with the help of water inlet valve.

HEAT EXCHANGER

Heat exchangers are situated at the bottom of the tank to heat the liquor. Steam is passed through the heat exchangers for the heating. It is situated with a cooling pipe also for the cooling purpose.

STEAM INLET

The supply of the steam to the heat exchangers is done through the steam inlet system. The pressure of the inlet steam is kept to be 6 kg/sq.cm.

STEAM TRAP

It performs the function of separating the condensate from the steam.

SAFETY VALVE

54

Maximum pressure in the machine is kept to be 4 kg/sq cm. If the pressure inside the vessel exceeds this value then excess pressure is released by the safety valve.

AIR PRESSURE VALVE

Air pressure valve increases the pressure after lid is closed and decreases the pressure before opening of the lid.

PRESSURE GAUGE

It contains four operating systems: -5. PUMP DELIVERY generates pressure during

delivery of liquor by the pump.6. PUMP SUCTION generates pressure during

suction of liquor by the pump.7. IN DYE PRESSURE is pressure of liquor after

passing from throttle valve.8. DYEING TANK PRESSURE is pressure inside

dyeing tank after lid is closed.

LEVEL GAUGE

It consists of a glass tube with a scale alongside it. The level inside the tube indicates the level of water inside the vessel.

13. HYDRO EXTRACTOR

OBJECTIVE

The objective of the hydro extractor is to remove the excess water from the dyed fiber in the carrier. Hydro extractor works on the principle of centrifugal force. Carrier is rotated

55

at a high speed in the machine and the excess water is removed from the carrier.

MOTOR RPM-1410MAKE-TOYU JAPANNO OF MACHINES- 1

PROCESS TIME

FOR COTTON- 3 min.FOR POLYESTER- 5 minFOR ACRYLIC- 6 min

14. CAKE UNLOADING

After hydro extractor the cake is unloaded from the carrier. It is taken on the unloading machine where the carrier is reversed on the wooden plate and the cake is unloaded on it.

15. WASHING RANGE

OBJECTIVE

After dyeing and unloading the cotton and acrylic fibers are brought into the washing section for the purpose of washing.

56

Where soaping and washing of the fibers are taken out in four bowl washing range.

THE DIFFERENT STAGES OF THE WASHING SECTION ARE

CAKE BREAKER

After unloading the cake is first taken to the cake breaker section where the cake is broken and opened into tufts form.

HOPPER LATTICE

A constant and limited delivery of the fibers is sent to the next section with the help of the hopper lattice.

WASHING BOWL 1

This is the stage where scouring and washing of the fibers is done. The washing liquor temperature for the reactive dye is 60 ˚c and for sulphur dye is 45 ˚c. In case of reactive dyes wetting agent and soaping agent is used and in case of sulphur dyes hydrogen peroxide and acetic acid are also used for the oxidation.

SQUEEZING

After scouring squeezing of the fibers is done with the help of squeeze rollers at a pressure of 3 kg per square cm.

WASHING BOWL 2

After squeezing the fibers are taken to the second washing bowl where the fibers are washed at a temperature of 60˚ c with water. Cationic Fixer is also applied if required.

WASHING BOWL 3

57

In the third bowl washing of the fibers is done with the cold water at a temperature of 30˚ c.

WASHING BOWL 4

In the fourth bowl the cationic softener is applied to the fibers at a temperature of 45˚ c.

HYDRO EXTRACTOR

After a constant feed from the hopper lattice the excess water from the fibers is removed in hydro extractor, which works on the principle of centrifugal force.

DRYING RANGE

After a constant feed from the hopper lattice the fibers for the complete drying are taken to the drying section where the fibers are dried at three different drying chambers. These three chambers consist of the 6 drum dryer range with a temperature of 120˚c, 120˚c and 110˚c respectively.

SOOT POINT

After drying the fibers are passed through the conveyor to the soot point and sent for packing.

16. ALEA DRYER

OBJECTIVE

The objective of the ALEA DRYER is to open the acrylic tow after dyeing, with air pressure and dry it with hot air circulation.

58

THE THREE MAIN SECTIONS OF THE ALEA DRYER ARE -:

1. ANTISTATIC APPLICATION

In this section the antistatic is applied to the acrylic tow to reduce the static charge on the fibers. The antistatic finish from Vaptex is applied on to the fibers with the help of the kiss roll system on both sides of the fibers. The speed of the fibers is generally 5 kg per minute.

2. OPENING SECTION

In this section the opening of the fibers is done with them help of air pressure. The fibers are passed through a vertical air chamber. In this chamber air is blown through the fibers at a pressure of 1.5 kg per square cm to 1.6 kg per square cm. Due to the air pressure the tow is changed into the open strand of fibers with a greater volume.

3. DRYING SECTION

In this section the drying of the opened tow is done with circulating the hot air through the fibers. The fibers are passed through two drying chambers on a lattice where the temperature of hot air is 100˚c and 95˚c. respectively.

17. SEYDEL SECTION

(SEYDEL-870 STRETCH BREAK CONVERTER)

OBJECTIVE

59

The objective of the Seydel section is to convert the acrylic tow into sliver form with the principle of stretching, breaking and drafting.

The material flow in the Seydel machine is in this way: -

FEEDING UNIT↓

PREBREAKING ZONE ↓

PREBREAKING ZONE ↓

BREAKING ZONE ↓

REBREAKING ZONE ↓

SLIVER COMPACTOR ↓

CRIMPER BOX REGULAR HIGH BULK CSR ADAPTOR UNIT COOLING CONVEYER BELT COOLING CONVEYER BELT CAN CAN

60

Draft is provided separately in each zone to stretch and break fibers by engaging different gears. After stretching crimp is provided to compensate the loss of crimp in previous process.

Two types of slivers are formed in this sectionN type slivers- these types of fibers are non shrinkable in nature.S type slivers- these types of fibers are shrinkage active.

MACHINE SPECIFICATIONS

MACHINE SEYDEL 870

DELIVERY SPEED 240 m/min

TOW WEIGHT 120-220 ktex

DRAW RATIO 2.2-22

SLIVER WEIGHT 30-60 ktex

SHRINKAGE 15-25 %

POWER 60 kw

18. REBREAKER

61

OBJECTIVE

The objective of the REBREAKER unit is to blend and draft the N type and S type slivers in the 50:50 ratio. For this purpose the slivers are passed through creel to the drafting rollers.

MAIN PARTS

FEED UNIT

o CREEL for the feeding of sliver.o CREEL ROLL to give smooth passage.o CREEL GUIDE to guide the sliver.

DRAFTING ROLLERS

To give the required draft to the slivers. It consists of three-roll system in which one is top roll and two are the bottom rolls.

SPECIFICATIONS

MAKE-NSC (FRANCE) DELIVERY SPEED (REBREAKING)-250 m/min. max DELIVRY SPEED (BLENDING)-350 m/min PRESSURE CYLINDER DIAMETER-130 mm

19. CHAIN GILL

It is assembled with REBREAKER. It performs the function of blending, drafting and Gilling with its combing unit and convert sliver into bump top.

62

19.1 BALE PRESS

After making of bump top 8 bump tops are fed into bale press machine for making a bale of 200 kg apx. Machine works on the principle of hydraulic pressure. Eight bales of the weight 25 kg are pressed and packed together in this machine.

MAKE OF MACHINE-MAK INDIANO OF MACHINES-1

20. BOILERS:

No. of Boilers : THREE

63

Make : Thermax, Chinchwad

Year of Manufacture : 1994 and 1998

Capacity of Boiler : (i) 8 ton/hr.

(steam generated) (ii) 12 ton/hr.

Type of Boiler : Fluid Pac (water in tube)

Water consumption : 500m3/day

Type of Fuel : Rice Husk/LPG

Fuel Consumption : 106 tonnes/day

Total Cost Of Fuel : Rs.1,70,000/day

Cost of Steam : 40 paise/kg.

Steam Pressure : 10kg/cm2

Temperature of steam : 1750C

Temperature of boiler : 5800C

Surface Area of tubes : (i) 314 mt2 (ii) 451 mt2

No. of Workers : 8 per day

The water used in the boiler is first dealkalanised using

hydrochloric acid (strength 33%).

The hardness of water should not be more than 5ppm

and the T.D.S. should be less then 300ppm.

The suspended particular matter in the flue gases

should not exceed 100mg/lit.

21. EFFLUENT TREATMENT PLANT

64

In this plant, effluent from all the departments of the unit is

collected to remove the hazardous elements from the

effluent so that it does not cause any pollution when it is

disposed off.

Process Sequence:

The raw water is received in the Bar Screen Chamber, which

separates the floating matter, coarse solids from the

effluent. The screened wastewater goes to Equalization

Tank. The effluent is pumped to Oil Removal Tank, which

separates the oil from the effluent. This oil is removed with

the help of slotted pipe mechanism. The effluent then enters

to the Solid Contact Clarifier where limewater, pickling acid

(waste hydrochloric acid) and polyelectrolyte is added. All

these chemicals are dosed into central draft tube. Solid

Contact Clarifier helps in reducing the color and the

suspended solids from the effluent. The overflow of Solid

Contact Clarifier enters to the pH correction tank (not in ETP-

1) where pH is maintained to 7.0-7.5. The overflow from here

enters into Aeration Tank where diffused aeration system is

used for aeration. The Aeration Tank also contains bacteria,

which shall maintain the B.O.D. level, and the fans attached

maintain the D.O. level. A regular feed of urea and D.A.P. has

to be given to this tank to maintain the amount of bacteria

(2500-3000 mg/lit). The effluent from Aeration Tank flows

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into the Secondary Clarifier where the biomass settles at the

bottom and clear effluent flows out. The settled biomass in

the Secondary Clarifier is returned partly to Aeration Tank to

maintain the Mixed Liquid Suspended Solids in Aeration

Tank. The excess sludge after removal of water in a

Decanter with the help of polyelectrolyte will be transferred

to the to the trolleys from where it is disposed off. The water

after treatment is either sent down the drain or used for

irrigation in the nearby fields.

Main components of ETP:

a)Equalization Tank: In this tank, input water from all

the various sections of the unit is collected so that pH,

BOD etc. of the water becomes constant.

b)Oil Removal Trap: In this tank all the grease and oil (if

any) is removed from the water by a pipe that has a slit

on the top from where oil layer is removed.

c) Flash Mixer: This tank is used for dozing of the

chemicals into the water.

d) Solid Contact Clarifier: Here the water with the

chemicals is given ample time for reaction to take

place.

e) pH Correction Tank: The pH of the output water

should be neutral not so the pH is corrected by the

addition of the required reagent.

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f) Aeration Tank: Air is injected inside the water for

maintaining the required levels of DO. This is done with

the help of fans or injecting compressed air in the

water.

g) Secondary Clarifier: this tank is used for removing

the bacteria from the water and clear water flows out

from here.

h) Sludge Slump: The sludge collected from the clarifiers

is stored in the sludge slump from where it is sent to

the decanter.

i) Decanter: The main function of this part is to separate

the water from the sludge.

Specifications:

No. of plants : Two

Capacity : 2500m3/day/plant

Make : E.T.P.-I Hindustan Doro Oliver

Limited.

E.T.P.-II Ion Exchange Limited.

Cost Of Treatment : Rs.3.3/litre (in case of pickling acid)

Rs. 5.5/litre (in case of ferric chloride)

AMOUNT OF CHEMICAL USED AND THEIR FUNCTION

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CHEMICAL AMOUNT USED FUNCTIONLime 800 kg/day Maintain the required

alkalinity

Pickling Acid 10,000-12,000ltr/day Coagulating agent

Polyelectroly

te

15 kg/day Flocculating agent

Urea and

D.A.P.

Depends on Amount of

Bacteria

Growth of Bacteria

WASTE WATER CHARACTERISTICS

PARAMETERS INLET OUTLETFlow Rate 2500m3/day ------

PH 10-10.5 7.0-7.5

B.O.D. (Biological Oxygen

Demand)

650ppm 32ppm

C.O.D. (Chemical Oxygen

Demand)

700-750ppm 250ppm

T.S.S. (Total Suspended

Solid)

300ppm <100ppm

D.O. (Dissolved Oxygen) 1ppm 2-4ppm

Temperature 40-500C Ambient

Color Colored Colorless

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Difference in E.T.P.I and E.T.P.II

E.T.P.I E.T.P.II

Flash mixer is used to dose

chemicals

Chemicals are added to

Primary Clarifier

No pH correction tank There is a pH correction tank

Aeration Tank has fans for

aeration.

Compressed air is passed in

the water.

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