paramount textile ltd

Southeast University Industrial Attachment

1

INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTParamount Textile Ltd

Southeast University


1





1





2

Department of textile engineering

Industrial Attachment

Supervising teacher

Prof. Syed Fakhrul Hassan Murad

Chairman

Department of textile engineering


Banani, Dhaka.

Submitted By:

Name Id. No. Contact Remarks

Anup Kumar Biswas 2009000400120 01923862487

[email protected]

MohimenurRhaman 2009000400032 01673909394

[email protected]

M. SadayatHossain 2009000400036 01675652545

[email protected]


3

Abstract

The aim of industrial practice is to make us familiar with any kind of industry, the whole

process going on the industry, its environment and also with the management system of the

industry. As a student Textile engineering department, the target of any student should be to

know the production process and the management system. It is because of the fact that to run

any industry not only production department is obvious but also the capability of managing

the whole system is an obvious matter. It is also a responsibility of an engineer is to develop

the ongoing process into a better system to cope with the present competition. Thus a

diversified challenge emerges in front of the manufacturer and other organizations. With a

view to overcome this consequence a new generation of engineering graduates with leadership

skills and management capabilities altogether are in demand.

We the students of Textile Engineering Department were sent to different industries and

assigned to different tasks. We were assigned to Paramount Textile Ltd. (Paramount group

Ltd.). This report is a presentation of our experience in the garments and also a details

presentation of our works in that industry.


3

Abstract
















3

Abstract
















4

AcknowledgementAll praises to Almighty Allah alone, the Most merciful and the most compassionate and His

Holy prophet “ Muhammad “ (Peace be Upon Him) the most perfect and exalted one among

and of ever born on the surface of earth, who is forever touch of guidance and knowledge for

the humanity.

The work presented in this manuscript was accomplished under the guidance generous

assistance, constructive criticism and enlightened supervision of Lecturer Md. Mahamudul

Islam. His efforts towards the inculcation of spirit of constant work and the maintenance of

professional integrity besides other invaluable words of advice will always serve as beacon of

light throughout the course. We take this humblest opportunity to our deepest sense of

gratitude and thankfulness to him.

This internship report is not the result of individual effort. It is a result of wonderful team-

work.

We are really thankful on HoripodoDev who is the General Manager of Admin & HR, of

Paramount Textile Ltd. who gave us the approval for making of that regard. We are also really

thankful on Mohammad ShahdathHossen who is the Deputy General Manager (Weaving) of

Paramount Textile Ltd. who helped us for getting information about our internship.

We are thankful to all those who supported us and provide us great help for completion of this

task. We have tried our level best to prepare this event with high level of accuracy but no one

claim to perfect other than Almighty Allah.

Executive summary


5

This report is the result of two months internship. During the internship it was required to

study the organization, department of the organization and critically relate the theoretical

aspects of the Textile to the practical situation.

Paramount Textile Ltd. operates throughout the world with over 2287employees as part of

PARAMOUNT team. Paramount collection has a wide selection of quality 100% cotton,

CVC, Cotton-polyester, competent professional staff, a team of talented merchandisers,

excellent supplies & support services, and state-of-the-art technology is the driving force

behind Paramount’s phenomenal growth in the past years. Paramount has expanded its

operations to include the Internet, and has taken advantage of the variety of international trade

facilitated by the Web. Now Paramountuses state-of-the-art client/server technology for its

market information processes to coordinate its network of global buyers and agents around the

world. Environmental Organizational and the individual challenges which are to face by the

department of “Paramount Textile Ltd.”. The motive of joining the Paramount is to have an

exposure of textile sector and potential to avail a sound and promising career. There are

noformal union in Paramount Group.

Methodology of internship


6

Every research program should follow some basic form of procedures. However mainly this

report is written on the basis of experience gathered during the period of Internship. We

carefully observed the various activities of different department, especially fabric section of

Paramount Textile Ltd. A qualitative research is used to conduct this study.

In order to make the report more meaningful and presentable two sources of data and

information have been used widely. Both primary and secondary data have been used to

prepare the report

Content


7

Topics Page no.

Introduction 9

Objectives of Internship 10

PARAMOUNT TEXTILE LIMITED AT A

GLANCE

11-12

PARAMOUNT TEXTILE LIMITED AT A

GLANCE

13

Head office (marketing)

CAD/Swatch

Fisibilitycheck

Preparation of dispo

Store

Soft winding

Yarn dyeing

Hard winding


8

Warping

Sizing

Draw-in

Weaving

Gray inspection

Singing

Washing

Stantaring

Sanforing

Quality assrunce

Conclusion

Reference


9

Initial Conversation

Industrial attachment is the first step to professional life of student, especially of technicalSide. It’s an indispensable part of study a practically running processing technology of anindustrial unit for a student .In our university , processing machines are not in continuousrunning condition, so it would only provide demonstration of mechanical features &processing technology of the material in accomplishment of the theory there of but not of thesituational variables to achieve practical knowledge. So two months industrial attachmentprogram in a dyeing mill was arranged for us.

Textile education can’t be completed without industrial training. Because this industrialattachment program minimizes the gap between theoretical and practical knowledge and makeme accustomed to industrial environment. I got an opportunity to complete two month longindustrial training in PARAMOUNT TEXTILE Ltd, which is a 100% export, orientedWeaving Industry. It has well planned & equipped fabric and Yarn dyeing-finishing units inaddition to facilitate weaving & woven fabric manufacturing.

The rationale behind the existing structure and future expansion of PARAMOUNTTEXTILE Ltd is to capture value-added at each stage of the textile manufacturing process.

Despite Bangladesh’s lack of indigenous cotton production capacity. PARAMOUNTTEXTILE Ltd has leveragedBangladesh’s labor cost advantage and export competitivenessto the Maximum.


10

Objectives of InternshipObjective:

The objective of the report is to learn about the overall activities of different departments in

Paramount Textile Ltd. A primary textile industry Academic knowledge is not perfect without

practical knowledge.

Specific Objectives:

This intern paper has been prepared for fulfilling the following specific objectives:

To enlarge the dimension of knowledge regarding fabric manufacturing as well as

others.

To define and evaluate the performance of fabric manufacturing Department as well as

others.

To observe the effectiveness of fabric manufacturing as well as others.

To get the additional knowledge in different sections of the organization.

To interchange opinions of the officials regarding their organization.

To know the economic condition of Bangladesh through Paramount Textile Ltd. of

Bangladesh.

To identify the difference between theory (what we have learned from the text) and

practice (what is really happened).

To compare the improvement of the present condition of the Paramount Textile Ltd.

with the previous years.

To mention the problems that the Paramount Textile Ltd. face in the process of

production and delivery of garments & give some suggestions.

To identify the strengths, weaknesses, opportunities and threats of the Paramount

Textile Ltd.


11

PARAMOUNT TEXTILE LIMITED AT A GLANCE

Name of the factory PARAMOUNT TEXTILE LTD.

Chair person Md. ShakhawatHossain

Head Office Chaklader House (Level-5&6),House # 22,Road #113/A,Gulshan-2,Dhaka-1212,Banladesh

Factory Village: GilarChala,P.O: 1 No C&B Bazar,Thana: Sreepur,Dist: Gazipur,Bangladesh.

Phone No. (+8802) +8809890618,9890467 (H) 880-682552555(F)

E-mail [email protected]

Website www.paramountgroupbd.com

Bank 1. National Credit and Commerce Bank Limited.Dilkusha Branch, Hossain Chamber,

43 Dilkusha C/A, Dhaka-1000.

2. ShahjalalIslami Bank Limited.Gulshan Branch, Dhaka.


12

Space 24 Bigas

Manpower 2287

Fabrics quantity 50,000 m /day

Dying capacity 60 ton / Day.

Fabrics a. In Tappet loom.

i. Plain.

ii. Twill.

iii. Sateen.

iv. Some combination weaveswhich are possible in tappet.

v. Oxford. (Warp rib and weftrib).

vi. Queen’s Oxford.

vii. Matt.

viii. Double cloth

b. In Dobby loom:i. Various types of weave.

ii. Diamond.

iii. Diaper.

iv. Herring bone.

v. Honey comb.

vi. The designs which are possible


13

in 16 healed frames.

Main Customers H&M, C&A, TEMA, NEXT, NORWEST, STUDIO TE,OLYMP, DAVID, CHERRY, MONDIAL, LEVIS,MAYARA, MARKS & SPENCER , CYAN FASHION, VF-ASIA, S-OLIVER


13




13




14

HISTORY OF PARAMOUNT TEXTILE LIMITED

Paramount Textile limited was incorporated under the companies Act (Act-8) of 1994 inJune

12, 2006 and went into commercial production in November 2008.

One of the leading manufacturers of fabric in Bangladesh. Having started the journey in 2006.

We commenced commercial production in 2008.Paramount textile produces high quality yarn

dyed woven fabric for fashion brands and retailers across the world. PARAMOUNT

TEXTILE is anOeko-Tex certified (Class#1) 100% export oriented woven fabric manufacturer

equipped with state of the art machineries sourced from LeadingEuropean and Asian

manufacturers, producing 15 million yards of fabric annually. The Factory is located in

Sreepur, Gazipur an hour drive from the Dhaka International Airport, Sprawled across 35 acre

of factory premise and 2287 numbers of skilled worker and employees. Paramount Textile

today is a name to be reckoned with both nationally and globally.

Factory area : Approx. 180acres. (Including ETP)

Type of the factory : Horizontally integrated

No. of employees : Approx. 2287.

Project cost : Approx. 350 Core taka


14


















14


















15

Organogram of PARAMOUNT TEXTILE Ltd,


16

Management system

Intercom telephone

Fax

E-mail

Written letters

Oral

Product name:

Woven yarn dyed, solid dyed, 100% Cotton & TC

Product Mix :

A. Gray fabric:

1. Solid dyed

2. Yarn dyed.

i. Stripe.

ii. Check.

B. Design.

1. In Tappet loom.

i. Plain.

ii. Twill.

iii. Sateen.

iv. Some combinations weave which are possible in tappet.

v. Oxford. (Warp rib and weft rib).

vi. Queen’s Oxford.

vii. Matt.


17

2. In Dobby loom:

i. Various types of weave.

ii. Diamond.

iii. Diaper.

iv. Herring bone.

v. Honey comb.

vi. The design which are possible in 16 heald frames.

Annual production capacity: 18millions per year.

Different DepartmentsA. Administration.

B. Human Resource and Development Dept.

C. Weaving Preparatory

D. Weaving.

E. R & D(Research & Development)

F. Woven finishing.

G. Yarn dyeing Dept.

H. Store.

I. Planning Dept.

J. Utility Dept.

K. Procurement & Purchasing


18

L. Marketing

M. QA Dept.

N. Inspection Dept.

O. Mechanical Dept.

P. Electrical Dept.

Job descriptionAS A SENIOR PRODUCTION OFFICER:

In a weaving factory a senior production officer plays a great role in production and man

power management who are production related. Here we enlist the duties of senior production

officer:

1) Follow up weaving production,

2) Regular observation of weaving floor,

3) Prepare weaving order status regularly,

4) Maintain the quality of the product,

5) To help the senior prod. Officer & co-operate with others for fulfilling the required

destination,

6) Utilization of manpower.


19

PRODUCTION OFFICER:

Production officer is the right hand of senior production officer and he is directly related with

production manpower and informs senior production officer time to time. Here are his listed

duties:-

1) Follow up overall weaving production,

2) Decide every m/c utilization during production,

3) Recruit new labor,

4) To inform the authority on the overall weaving prod. and make it financial

profitable,

5) Regular m/c maintenance,

6) Maintain sub-contract orders,

7) Help weaving manager& also guide the junior officers of the section, etc.

8) Daily production calculation.

9) Daily production report submitted to higher authority.

10) Sub ordinate worker facility.

11) Fabric fault analysis.

12) Maintain environment of the weaving floor.


20

Shift Change Schedule

There are three shifts per day in P.T.L. So each shift contain eight hour.

Shift Duration

A 06.00 AM – 02.00 PM

B 02.00 PM – 10.00 PM

C 10.00 PM – 06.00 AM

General shift 09.00 AM – 06.00 PM

General shift, which is applicable for some officers.

Man power in different section1. Weaving

a) Stuff & Officer-65

b) Worker-772

2. Dye House

a) ) Stuff & Officer -35

b) Worker -124

3. Yarn Dyeing

a) Stuff & Officer -78

b) Worker -589

4. Administration



21

5. Compliance


6. Utility

a) Stuff & Officer -16

b) Worker-48

7. Security-86

Total Manpower of the factory -2287

Some Buyer of Paramount Textile H&M

C&A

TEMA

NEXT

NORWEST

STUDIO TEX

OLYMP

DAVID

CHERRY

MONDIAL

LEVIS

MAYARAL

MARKS & SPENCER

CYAN FASHION

VF-ASIA

S-OLIVER


22

PVH

DAVID HAWERD

MARUBENI

VERTEX

Input & Output Sequence of the factoryYarn

↓

Store

↓

Soft Winding

↓

Yarn Dyeing

↓

Hard Winding

↓

Warping

↓

Sizing

↓

Drawing & Denting

↓

Weaving

↓

Finishing

↓

Inspection

↓

Delivery


23

Raw Materials


23

Raw Materials


23

Raw Materials


24

Some of the manufacturing companies from where Paramount procures there yarn are

1. Zaber Spinning Mill (Bangladesh)

2. GTM (India)

3. Nahar spinning mill (India)

4. Vardaman(India)

5. Jiangsu (China)

6. Winsome

7. Gulshan spinning mill (Bangladesh)

Some common type of yarns are tabulated below with local price

Count Type

10/1 Autocone

16/1 Autocone

16/1 Comb

20/1 Autocone

20/1 Comb

20/1 Card


25

20/1 Open end

30/1 Comb

40/1 Comb,Compact,Organic,BCI

50/1 Comb

60/1 Comb

40/2 Comb

80/2 Comb

100/2 Comb

24/1 Slub

30/1 Slub

16/1 Card

45 TC,PC,CVC

32/2

20/2


26

Winding

Section


26

Winding

Section


26

Winding

Section


27

Winding SectionIn fabric manufacturing (weaving) process this is the first stage where rewinding of supplied

yarn is done on to a desired package suitable for use in the next process.

Types of Winding:

1. Soft Winding.

2. Hard winding

Soft Winding SectionSoft Winding: where the grey yarn is wound on to a special dye spring or plastic bobbin and

the package (spool) is made softer and bulkier to make it suitable for dye penetration in the

(package) dyeing machine.

Dye Spring Plastic bobbin


27



Types of Winding:

1. Soft Winding.

2. Hard winding






27



Types of Winding:

1. Soft Winding.

2. Hard winding






28

Flow Chart of windingDISPO

↓

Store Requisition

↓

Receive the yarn

↓

Setting & Running

↓

Winding

↓

Checking (dia)

↓

Stop winding

↓

Quality assurance

↓

Root card making Delivery for dyeing

There are used two types of winding M/C

M/c Name CORAL TEXTILE

Manufacturer Shanghai Coral Textile machinery Co. Ltd

MFD 2008

R.P.M. of Motor 750

No. of Head 54

No. of Drum /head Grooved drum

Traversing system Individual


29

Stop motion Automatic

No. of m/c 01

Production per m/c 10,858 km /day [Assuming 80% efficiency]


Manufacturer Taizhrljingwi Textile, China

MFD Oct’2008

R.P.M. of Motor 750

No. of Head 54




No. of m/c 15

Production per m/c 1,62,876 km /day[Assuming 80%

efficiency]


29


No. of m/c 01




MFD Oct’2008

R.P.M. of Motor 750

No. of Head 54




No. of m/c 15


efficiency]


29


No. of m/c 01




MFD Oct’2008

R.P.M. of Motor 750

No. of Head 54




No. of m/c 15


efficiency]


30

Package density Calculation

We know package density ρ =mass (m)/volume (v) gm/cc

Volume= π (R2-r 2) h

R= outer radius of package

R= inner radius of package

h= height of package

Now we consider a sample of 40/1 cotton yarn whose

R=4.138

r= 1.59

h=15.24

Mass m=1000gm

So package density ρ=1000/π (4.1382-1.592)15.24 gm/cc

=1.433 gm/cc

Production calculation

We know production= speed (m/min) ×60×24 ×1.09/(840×40×2.2045)

Kg/day/head

When speed is 800m/min at 80% efficiency

Production=800×60×24×1.09/ (840×40×2.2045)kg/day/head

=10.5976kg/day/head

Total production=10.5976×54×12kg/day

=6867.2448kg/day


31

Dyeing


31

Dyeing


31

Dyeing


32

DyeingOBJECT:

To dye grey yarn for producingthe check and stripe fabric.

Flowchart of dyeing

Demineralization

↓

Bleaching

↓

Hot wash

↓

Dye run

↓

Neutralization

↓

Finishing

↓

Hydro extracting

↓

Drying


33

Dyeing Curve

400c

Dyeing recipe:

Process Recipes

Demineralization Ladiquest 0.5g/l

Acetic acid 0.1g/l

70°-15min

ChemicalsDosing

DyesDosing

SaltDosing

DosingSoda ash

Progressive

70%

Shadecheck

550

c


33

Dyeing Curve

400c

Dyeing recipe:

Process Recipes


Acetic acid 0.1g/l

70°-15min

ChemicalsDosing

DyesDosing

SaltDosing

DosingSoda ash

Progressive

70%

Shadecheck

550

c


33

Dyeing Curve

400c

Dyeing recipe:

Process Recipes


Acetic acid 0.1g/l

70°-15min

ChemicalsDosing

DyesDosing

SaltDosing

DosingSoda ash

Progressive

70%

Shadecheck

550

c


34

In dyeing section three types of dyeing M/c are used. Those are_

Yarn Dyeing (Fong’s)Model ALLWIN-85Serial No 36028258MFD(Manufacturing Date) 2011Country of Origin ChinaTemperature 140CSafety valve test 520 MPaDesign Pressure 520 MPaFunction DyeingManufacturing Company Fong’s national engineering Co.

Yarn Dyeing (Go Front)Model GRO-08Serial No 112MFD(Manufacturing Date) July’2011Country of Origin Chang ChengTemperature 160CSafety valve test 520 MPaDesign Pressure 520 MPa

Bleaching Caustic 1g/l

Per- oxide 4g/l

115°-20min

Dyeing Ladiquest 0.80g/l

Salt 40g/l

Suffix Yellow SPD 4%

Suffix Red SPD 0.2325%

Suffix Navy Blue 0.5663%

Soda ash 10g/l

Washing off Ladiphore RSK 0.4g/l

Finishing Permafix RDX 0.7%

Acetic acid 0.2g/l


35

Function DyeingManufacturing Company Go Front Holding Ltd.

Yarn Dyeing (Scdo Mat)Model 1800Serial No Y-802-4MFD(Manufacturing Date) Aug’08Country of Origin ChinaTemperature 140CSafety valve test 520 MPaDESIGN Pressure 520 MPaFunction DyeingManufacturing Company Xinlong Electricity Co. Ltd

Dryer M/c specification:

Dryer M/C 02Model SP-02170Serial No 90815MFD(Manufacturing Date) Sep’2009Country of Origin ChinaSpeed 17Function Dry the YarnManufacturing Company STALAM Dyeing & Printing Co Ltd.


35






35






36

Observing Hydro Extracting Cycle & production calculation

Hydro extracting cycle is with time required

Lowering (30sec)

↓

Circulation (12 sec)

↓

Operation (5min, 40sec)

↓

Lifting (21sec)

Hydro M/C 03Model RZT 60Serial No 217MFD(Manufacturing Date) Sep’2011Country of Origin ChinaPower Supply 16 KW,50 HZ+2%,32 ANet Wt. 2500 KgMax Rotation (Drum) 1530Function DehydrationManufacturing Company STALAM Dyeing & Printing Co Ltd.


36



Lowering (30sec)

↓


↓


↓

Lifting (21sec)



36



Lowering (30sec)

↓


↓


↓

Lifting (21sec)



37

Water removing Efficiency:

Weight of cone after dyeing: 2.38kg

Weight of cone after drying: 1.11kg

Water removing Efficiency= (2.38-1.11)/2.38%

= 53.36%

Production calculation of RF Dryer

Length of RF Dryer=13m

At 28rpm it takes 21 min 9 sec to pass this length

Along this length it can accommodate 416 package 416kgs

So at 21 min9sec or 1269sec it can dry 416kgs

So in 1hr or 3600sec it can dry=416×3600/1269 kg/hr

=1180.14 kg/hr

So Production per day=1180.14×24kg

=22658.688 kg

=22.66 tons


38

Hard Winding


38

Hard Winding


38

Hard Winding


39

Hard Winding

Where the grey yarn dyeing machine is converted from spool to paper cone, to make the yarn

easily be fed to the sectional warping machine.

Flow Chart of hard windingRoot card

↓

Checking

↓

Receiving

↓

Prepare batch card

↓

Start Hard Winding

↓

Measuring weight

Finding out package density

We know package density ρ =mass (m)/volume(v) gm. /cc

Volume= π( R2-r2)h

R= outer dia. of package

r = inner dia. of package

h= height of package

Now we consider a sample of 40/1 cotton yarn whose

R=3.99cm

r= 1.60cm


40

h=15.24cm

Mass m=1000gm

So package density ρ=1000/π (3.992-1.602)15.24 gm. /cc

=1.563 gm. /cc

Production calculation

We know production= speed (m/min) ×60×24 ×1.09/(840×40×2.2045)

Kg/day/head

When speed is 800m/min at80% efficiency

Production=800×60×24×1.09/(840×40×2.2045)kg/day/head

=10.5976kg/day/head

Total production=10.5976×54×12kg/day

=6862.32kg/day

Faults in winding sectionFaults Causes

1. Excessive Hard package Excess tension

2. Excessive Loose package Less tension

3. Ring Faulty drum

4. Stitching Vibration of Package

5. Ribbon Ribbon breaker problem.

6. Bulging Improper alignment of Package

7. Entanglement Jerking package

8. Bunch Improper store and handling

9. Cut cone Package drop

10. Reverse winding Low pressure


41

Types of Maintenance:

1. Schedule maintenance.

2. Break down maintenance.

Spare item types:

1. Readymade / purchase

2. Fabrication tool in work shop / other side

3. Import item

Quality Control in winding Section:

The following quality is maintained in preparatory stage.

Shade matching:

The dyed yarn compared with lab drip sample or swatch card.

Level Checking:

During package dyeing dyes chemical enter in to package by pressure. So there is a possibility

to differ level in inner and outer side. It is checked and allow up to (5 -6) %.

Fastness:

Water and color fastness is checked.

Strength:

CSP, tenacity, CV% of tenacity, elongation are tested.

Package hardness:

Soft wound package is checked by hand if it is hard improper dyeing will occur, the hard

wound package also checked if it is less hard or too hard it will create problem in subsequent

process.


42

Material Handling Equipment for Winding Section:

1. Creel.

2. Trolley.

1. Creel: 2. Trolley


43

Warping


43

Warping


43

Warping


44

WarpingIn general terms, Warping is transpiring many yarns from a creel of single ends packages

forming a parallel sheet of yarn wound onto a beam a section a beam. Today’s warping m/c

can process many kinds of materials including course and fine filament & staple yarns, mono

filament, texture yarn & smooth yarns, silks & other synthetics yarn. Usually a static

eliminator device isrecommended for yarns that can generate static electricity.

The warp beam that is installed on a weaving m/c is called a weaver’s beam. A weaver’s beam

can contain several thousand ends & different reasons it is rarely produce in on operation.

Warping is aimed at preparing the weaver’s beam to be set up on the weaving m/c. Warping

carries out following operation:

Creation, out of a limited number of warp threads (Creel load), of a warp composed of

any number of threads with desire length;

Arrangement of above-mentioned threads according to the desire sequence;

Manufacturing of a warp beam with said characteristics;

If the creel capacity is equal or higher number of warp threads, the warping would

simply entail the direct winding on the warp beam of the threads coming from the

creel. Generally, this condition does not take place & even with creels of high capacity

the number of creel position never corresponds to the number of threads, which is

always by far higher than the number of bobbins, which is creel can contain.

This problem has been solved by dividing the warping operation into two phases:

o 1st phase: Unwinding the threads from the bobbins & their winding on

intermediate carriers, till attainment of the required total number of warp

threads;

o 2ndphase: Simultaneous rewinding of all these threads & subsequent winding

on weaver’s beam; the contemporaneity of these two operations is prerequisite

to produce a beam where all the treads show same tension & the length.


45

Types of warping:

Warping

Sectional (Conical drum or dresser) Direct (Preparatory beam)

Flow Chart of warping:

Cree ling

Knotting (Optional)

Drawing

Denting

Reed

Measurement Roller

Evener roller

Drum

Beaming


46

Layout plan of preparatory section


47

Operation Procedure Direct Warping:

1. As per production program given by assistant manager, preparation through the yarn

warp record register, the supervising officer collects griege yarn from store as per

required count, lot number and quantity.

2. The machine operates and helpers open / break the yarn cartoon and place the cones in

the creel head as per program and draw the head end of the cone through pretension

rods, feeler guides, yarn guides and then through expanded comb of beaming unit.

3. The basic creel data setting and machine data setting are done according to the

requirement as per m/c manufacturer operating instruction.

4. An empty beam is set in between driving clutch and engaged by means of electric

switch.

5. All the ends from the creel is wrapped around the beam manually one round.

6. The press roller is moved towards the beam by means of electric switch.

7. The m/c is then run slowly and checked for yarn alignment with beam flange on both

sides. To ensure alignment the expanded comb may be moved either to the right or left

as required by switch.

8. Thus the m/c is ready and the operational switch is to be turned on.

9. As the present length is achieved the m/c will stop automatically. The beam is doffed

by switch and another beam is mounted.

10. In this way a set of beams are made to feed the subsequent sizing process.


48

The m/c feature of sectional warping:

There are four sectional & one direct warping m/c using in PARAMOUNT Textile. Between

the machines two are UK IL & another two are Rabatex.

Warping M/C (UK IL) 02Model UI-501 SISerial No 5-359MFD(Manufacturing Date) Aug’08Country of Origin KoreanCreel Capacity 720M/C Motor RPM 400-500Function Sectional warpingManufacturing Company UK IL m/c Co. Ltd

Warping M/C (Rabatex) 02Model VM 108Serial No 46/6MFD(Manufacturing Date) Feb’10Country of Origin IndiaCreel Capacity 800M/C Motor RPM 450-550Function Sectional WarpingManufacturing Company Rabatex Industries Co. Ltd

Warping M/C (TSUDAKOMA) 01Model TWS-ESerial No 999MFD(Manufacturing Date) Apr’08Country of Origin JapanCreel Capacity 644M/C Motor RPM 600-700Function Direct WarpingManufacturing Company Tsudakoma Corporation

.


49

Causes of yarn breakage in warping:

1. Weak yarn.

2. Sloughing off.

3. Over lapping.

4. Knots/ bad splice.

5. Slubs.

6. Loose yarn.

7. Pig tail.

8. Cut yarn.

9. Bad tip cone.

10. Short cone.

Observing the end breakage

Serial no Position of breakage Time consumed

1 Between reed& drum 12sec

2 Near package 1min 4sec

3 Far package 1min 44sec

4 Between reed& drum 13sec

5 Missing end on Drum 2min 21sec

6 Between reed& drum 25 sec

7 Breakage from pkg 1min 33 sec

8 Missing end on Drum 2 min 33 sec

9 Missing end on Drum 2min 25 sec

10 Missing end on Drum 2 min


50

Monitor Display Sectional warping:

Drum Diameter: 3.35

Tension Device: Electromagnetic type (Auto controller)

If Stripe is, big shape or size then not necessary to cross lease, shape is small then used to

cross lease.

Reed Movement:

Sectional warping motor type:

3 phase induction motor

Rotation by Encoder

RPM : 350-400 (Drum)

AMB : 40C

Rating : Count Wise

Serve Factor : 100%

Patrol wash is used to cleaning the guide bar.

Jog –To maintain the yarn tension for loose yarn after creel.

TPM 500 Section 15

Speed 350 Width 70”

P-Roll 1.5 Total ends 5100

Count 20 Revolution 37.9

Type Cotton S-Width 118.63

Density 28.68 Feed 1.4276


51

Sizing


51

Sizing


51

Sizing


52

Sizing

Although thequality and the characteristics of the warp yarns coming out of the winding and

warping processes are quite good, they are still not good enough for the weaving process for

most of the yarns. The weaving process requires the warp yarn to be strong, smooth and

elastic or extensible to a certain degree. To achieve these properties of the warp yarns, a

protective coating of a polymeric film-forming agent(size) is applied to the warp yarns prior to

weaving; this process is called sizing or slashing. Sizing is not a value added process inwoven

fabric manufacturing. This is because, after the fabric is woven, the size materials will be

removed from the fabric during the finishing operation, which is called desiring.

Purposes of sizing

To increase the strength of the yarn.

To reduce the yarn hairiness that would cause problems in weaving process.

To increase the abrasion resistance of the yarns against other yarns and various

weaving machine elements.

To reduce fluff and fly during the waving process for the high speed weaving

machine.

To increase the weave ability of the warp yarn, this is the main goal of sizing.


52

Sizing









Purposes of sizing






machine.



52

Sizing









Purposes of sizing






machine.



53

Sizing quality:

Flowchart of sizingFlange Beam

Beam Stand

Feeding

Guide roller

Immersion Roller

Squeezing Roller

Paddler Roller

SIZING

SIZING RECIPE

SIZING PICK-UP

OPERATOR

HANDLING

SIZING MACHINE DESIGNADJUSTMENT

YARNMATERIALTYPE QUALITY


54

Saw Box

Cavity box

Dryer

Water tank

Cooking tank

Reservoir tank

Mahalu

Lease Rod

Reed

Dropper

Pressure Roller

Guide Roller

Sized Yarn

Sizing agent

True starch

Modified starch

Carboxyl methylcellulose (CMC)

Polyvinyl alcohol (PVA)

Polyacrelate


55

Polytex-460

Polytex BI

Wax

In PARAMOUNT textile, Polytex-460 &Polytex-BI are used as the sizing comical. Polytex-

460 &polytex BI is the combination of all others sizing agent except Wax.

Sizing Calculation:

Total required chemical = (total length* total ends*30%)/(1.6933*count*1000)+200L

Sizing M/C: There are two types of sizing M/C

Sizing M/C (TSUDAKOMA) 01Model HS-40Serial No 254MFD(Manufacturing Date) Apr’2008Country of Origin JapanBeam Capacity 16M/C Motor RPM 80 m/min (Max)Function SizingManufacturing Company ITOCHU Textile M/C Ltd.

Sizing M/C (Jupiter) 01Model MP0000.2195Serial No 03MFD(Manufacturing Date) Apr’2008Country of Origin IndiaBeam Capacity 1M/C Motor RPM 80 m/min (Max)Function SizingManufacturing Company Jupiter Industries


55

Polytex-460

Polytex BI

Wax



Sizing Calculation:






55

Polytex-460

Polytex BI

Wax



Sizing Calculation:






56

Units of the m/c:

1. Back Beam unit

2. Sizing Unit

3. Drying Unit

4.Leasing Unit

5.Beaming or Take up unit

Controlling Points:

1.Speed of the Yarn Passing

2.Drying Unit-Cylinder temperature must not exceed 150˚C to maintain R.H. less than 6%

which is a requisite for cotton yarn.

3. Squeezing Pressure: A typical roller pressure for wide variety of cotton yarn is given below.

First Squeeze: 0.12MPa

Secondsqueeze:0.2MPa

Immersion roller:0.1MPa

4.Separation Unit: Distances between the lease rods are to be carefully set up for solid dyed &

yarn dyed fabrics

5. Headstock: All the settings are done from here.

Size Box:

There are two size boxes and one hot wash box

Main parts of size box are

301= TENSION DETECTION ROLL

302= IMMERSION ROLL

303= FIRST SIZING ROLL

304= FIRST SQUEEZE ROLL

306= SECOND SIZING ROLL


56

Units of the m/c:

1. Back Beam unit

2. Sizing Unit

3. Drying Unit

4.Leasing Unit


Controlling Points:









yarn dyed fabrics


Size Box:




302= IMMERSION ROLL





56

Units of the m/c:

1. Back Beam unit

2. Sizing Unit

3. Drying Unit

4.Leasing Unit


Controlling Points:









yarn dyed fabrics


Size Box:




302= IMMERSION ROLL





57

308= SIZE BOX

307= SECOND SQUEEZE ROLL

310= LEVEL ADJUSTER

311= STEAM PIPE

312= COVER

Some typical size recipes used in PARAMOUNT given below with their function-

Construction: 30x30/120x70

Total ends: 6876

Recipes:

Recipes: Yarn count 30/1

Total ends:6876

Yarn count 30/1

Total ends:6876

Water 600 Lt 600 Lt

Sure Bond 60 kg 60 kg

CMC 20 kg 18kg

Size CA 15 kg 18 kg

Wax 2 kg 3 kg

Polytex. 460 20 kg 20 kg

Function:

1. Sure Bond: It work’s as adhesive to increase solidity percentage in the size recipes.

2. Starch: It also works as adhesive. As its price is of low it is mainly used to reduce the

size cost when yarn count is coarser

3. CMC: It is a synthetic adhesive used mainly to help in penetrating other chemicals

into yarn.

4. PVC:This adhesive is only used on finer count yarn.

5. Size CA:Its mainfunction is to bind protruding fibers with yarn.

6. Wax: It acts as a lubricating agent.


58

Costing of Size Ingredients

Ingredients Cost taka/kg

Sure bond 43-53

Starch 29

CMC 139

PVA 267

Size CA 70

Wax 255

Measuring of size take up% of a particular sample

Yarn count 40/1

Total ends 7420.

Recipes:

Water: 600 Lt

Sure bond: 60kg

Starch: 20kg

CMC: 20kg

Size CA: 15kg

Wax: 2kg

Wt. of 1m of total yarn before sizing = 0.12kg

Wt. of 1m of total yarn before sizing=0.1340kg

So, Size take up %=(0.134-0.12)/0.12%

=11.67%


59

Drawing, Denting


59

Drawing, Denting


59

Drawing, Denting


60

Drawing, Denting Section

Process definition:

After a sized beam or weaver’s beam is made, it is time to mount this beam over the loom.

There are two methods used to prepare this beam for mounting on a loom.

1. Warp tying or knotting (Quick style) change process.

2. Reaching – in /Drawing – in and beam gaiting.

Warp tying:

This method is limited to use where and exactly same article or quality of fabric is to be made

that is already running in the loom. The following points are considered-

1. The total number of warp ends should be the same as that of running.

2. The count of yarn and weave design should be same.

Before tying a new beam with an older one, the new beam is to undergo a process called

leasing, whereby the adjacent yarns are kept separated by placing a yarn in between them.

This is very essential in case of tying a yarn dyed beam; otherwise the warp pattern scheme

will be disturbed and lost.For monocular beam (solid dyed beam), tying is performed without

leasing.

Drawing – in:

The method of mounting weaver’s beam on to the loom, which is adopted for the same style

of working of adjacent warp yarns or yarn interlacement, compared to that of running in

looms.In this method warp yarns are separated individually as per count or color pattern from

the adjacent yarn and hooked to the access of drawer’s hook called reaching – in.

The yarn as it comes to “reach” or drawer’s hook is then drawn through dropper (or drop wire)

and then passed through the split of the reed dent called denting.


61

Operation procedure:

Warp tying:

1. According to that plan, knotting – in – charge & Drawing – in – charge jointly arrange

leasing of beams, the respective beams being identified from the sizing data sticker.

2. As leasing is completed the beam is transported to a specific loom and mounted on

loom beam bracket. The tying frame is set on proper position.

3. The ends of old beam and the ends of the new beam are accurately brushed and

gripped by the frame sothat older and newer ends make and upper & lower set of yarn

placed in proper tension.

4. The warp tying head is mounted over the tying frame. In case of STAUBLI machine,

number of knots per repeat of color pattern is entered in to machine.

5. Then the machine is started. After the programmed number of knots per color is

reached, knotting will stop. Operator will check the correctness of the knot and start

again by switch.

6. Thus knotting will be completed up to the end of set, tying up per set of older yarn

with lower set of new warp.

7. As knotting is completed, the knotting operator make a quality card mentioning

customer name, work number, beam number beam length, knotting operator’s name

and date and time of knotting.


62

8. The sizing date sticker is set over the quality (of doffing) card and the card is set over

the loom.

9. The knotting operator also makes a work record in his register book.

10. As knotting is completed, tying head and frame are removed, the old piece odd knotted

yarn is pulled through the machine, i.e. through heald wire and reeds and thus new

warp set is allowed to pass and made ready to run.

Drawing – in and reaching – in1. The customers fabric swatch is sent to the weaving section, generally after warping is

done, either by enclosed to the order sheet to form or separately. Assistant manager

(weaving) then analyzes the swatch for reproduction. In this stage the determines –

a. The design of sample i.e. whether dobby or tappet or combination of two.

b. The drawing – in, denting and lifting or tappet/ cam setting plan.

c. The required number of healed frame and reed count, draw width etc.

2. Then whenever the sized beam is ready, the worked out drawing – in plan, reed count

etc. against an order number is given to the drawing – in – charge for production.

Drawing – in – charge for production. Drawing – in – charge makes a work program

considering the following:

a. The availability of the run out loom for beam.

b. The availability or required number of reed count.

3. Drawing – in – charge and senior drawer find out the desired sized beam number from

the sizing production record, check against the specific work order number and from

transport these to the drawing – in – section by trolley and start working there.

4. According to the work order number each design/ drawing – in plan is recorded in the

register book, the produced sample being attached thereafter.


63

5. After drawing – in/ denting is completed each beam is set with a quality/ doffing card,

the sizing data sticker is being attached on the card.

6. During deciding the loom number the drawing – in – charge takes into consideration

designing scope and color insertion scope of the respective loom.

7. Finally beam gaiters carry this beam along with dropper, healds and reed with trolley

onto the specified loom and mount.

8. They will pull the new yarn from the beam and set in the loom with dropper, healds

and reed properly positioned and tie the new yarn with the old piece of cloth wrapped

around the surface roller with a number of small knots.

Knotting M/c:

Knotting (STAUBLI) 02Model TPM-201-PCSerial No GI 514344MFD(Manufacturing Date) 2008Country of Origin SwitzerlandVolt. 48 VAmp. 2.5 AFunction KnottingManufacturing Company TOPMATIC M/C Co Ltd.

Equipment used in Drawing denting and pinning Section:

Denting plate (Patti):


64

Drawing Hook:

Drop Wire:


64

Drawing Hook:

Drop Wire:


64

Drawing Hook:

Drop Wire:


65

R&D


65

R&D


65

R&D


66

R&DDesign Cell is one of the most important departments of PARAMOUNT TEXTILELTD.(weaving). When an order comes to the marketing or merchandizing officer he/she sendthe fabric to the design cell that is it possible or not possible in PARAMOUNT. They send aArticle request paper. Design cell analyze the fabric design and test the feasibility ofproduction and create an Article code and send this article code the marketing ormerchandizing officer and input data to the Data tax which is a software used inPARAMOUNT for all types of information by networking.

PARAMOUNT’s Design department is equipped with hand loom and sophisticated software“TEX-DESK DOBBY” From India & KOPPERMANN from GERMANY.

After getting Article code planning discuss with marketing officer about costing. Thenmarketing officer send mail or discuss directly to the buyer about pricing of the product.

If buyer agree with the price then marketing officer send mail to the central planning sectionwith Article code.

Planning take a print of dispo paper for the article code from the system data tex. Afterprinting dispo paper they send it to the design cell to check or verify. Design cell check andgive drawing and denting plan and send it to the planning section again.

Planning then send it to the various section where these information required and at a timerequisition all necessary raw materials or other materials.

Flowchart of R&D:

Head office (marketing)

CAD /Swatch

Feasibility Check

Create Dispo number

Create CAD (Koppermann&Textronic)

Color Analysis

Dispo Dispatching

Yarn Dyeing Lab/Lab Dip

Planning

CCI Warping


67

CCI Sizing

CCI Loom

Sample sends in Marketing Dept.

Buyer Approval

Bulk Order

Feasibility check

Possible Ends per inch by using Available Reed in Inventory in PARAMOUNT by denting 2,

3 and 4 in a dent for yarn dyed fabric.

Hand Loom Section:

In PARAMOUNT Textile Ltd there is a hand loom section. There are several hand loom

section with combined section, such as treadle, treadle pad dobby, treadle and jacquard. There

is also hank winding frame, sample high speed warping machine, sectional warping machine

also.

When PARAMOUNT gets a new order without any swatch, then a cad is prepared and sends

it to the Hand loom section. There a small size of sample is prepared. If the sample is prepared

successfully according to specification, then the planning department took necessary step for

bulk production.

After getting Article code planning discuss with marketing officer about costing. Then

marketing officer send mail or discuss directly to the buyer about pricing of the product.If

buyer agree with the price then marketing officer send mail to the central planning section

with Article code.Planning take a print of dispo paper for the article code from the system data

tex. After printing dispo paper they send it to the design cell to check or verify. Design cell

check and give drawing and denting plan and send it to the planning section again.Planning

then send it to the various section where these information required and at a time requisition

all necessary raw materials or other materials.

WhenOrder comes to the Marketing Section, then they contact with the Product development

(in case of new product) or Design cell (in case of available product) that, is it possible or not


68

possible in PARAMOUNT. They Send an Article Request paper. After reaching the Article

Request paper Design cell produce Article Code and send mail to the planning and marketing

section.

Dispo paper contains following types of information:

1. Fabric Specification.

2. Yarn composition

3. Finished type.

4. Finished fabric’s EPI x PPI

5. Finished fabric’s width.

6. Required length.

7. Reed count.

8. Grey EPI and PPI.

9. Grey width.

10. Reed width.

11. Reed EPI

12. Required greige length.

13. Required warp length.

14. Ground Ends.

15. Selvedge Ends.

16. Cover Factor.

17. Numerical Plan (Warp & Weft)

18. Drawing & Denting Plan.


69

P.O No:2012/902 Line No :

01

Count ( Warp x Weft) 40X40

Customer: C & A Yarn Composition (Warp x

Weft)

100 % Cotton

Finished

Fabric

Details

Dispo No:

F205896

Ref :

Swatch

Ends × Pick (Finished) 84×80

Fabric Type Check Finish fabric width (inch) 57/58”

Design Plain Required finished length

(meter)

6913

Finish Regular

Soft

Delivery Date (Finish) 10/12/2012

Grey

fabric

Details

Dispo No:

W205896

Request

No:

P25695

Ends × Pick (Grey) 78×80

Buyer Ref DH#

16634B

Grey Width (inch) 62.11

Color Navy/Mint

check

Require Grey(meter) 7514.13

Reed No 74.25/2 Required loom

Production(meter)

7667.48

Reed Width

(inch)

65.45 Required warp length

(meter)

8519.42

Delivery Date 08/12/2012 Ground inch 4860

R & D Selvedge inch


70

Comments

Color break

down

Color Breakdown:

Count Shade Color Code Quantity ( kg) Length (Mtr) Cones

Warp

40/1 Cream BE11760 308.72 77447.30 270

40/1 Navy NV45321 308.72 77447.30 270

Warp Total 617.44 Section : 9

Weft

40/1 Cream BE11760 308.52

40/1 Navy NV45321 308.52

Weft Total 617.04

Dyed Yarn Details

Dispo No: Y205896 Delivery Date: 18/11/2012

SL no Count Shade ALD No Grey yarn

(Kg)

Dyed yarn

(Kg)

Yarn Type

1 40/1 Cream BE11760 633.07 617.24 Combed

2 40/1 Navy NV45321 633.07 617.24 Combed

Total 1266.13 1234.48


71

Dispo paper goes to the following sections

1. Design cell.

2. Store.

3. Winding.

4. Yarn dyeing.

5. Warping.

6. Sizing.

7. Drawing and denting.

8. Loom.

9. Finishing


72

WEAVING


72

WEAVING


72

WEAVING


73

WEAVING SECTION

Process definition:

The act of inter lacing Warp yarn(of a beam) with the inserted weft yarn in a definite order to

form a fabric suitable for use as a dress material, domestic or industrial purpose is called

weaving. The machine used for this purpose is called loom.

Process equipment:

Air jet loom

Loom shed – 1:

Total no of loom - 178

Loom shed – 2:

Total no of loom - 40


74

Lay out plan of weaving

Shed 1:

Shed 2:


74


Shed 1:

Shed 2:


74


Shed 1:

Shed 2:


75

EQUIPMENTS OF LOOM SECTION

The machine used for the purpose of weaving can be categorized as follows:

Brand name of the

Loom

Shedding Device Weft Insertion RPM No. of Looms

Picanolomniplus 800 Tappet 06 600-700 10

Picanolomniplus Tappet

Dobby

04 450-550 52

Toyota JAT 710 Cam 06 700-950 15

Toyota JAT 710 Dobby 06 600-700 01

Toyota JA 600/610 Tappet

Dobby

2+4+6 525-650 34

Tsudakoma ZAX

9100

Cam 06 750-850 12

Tsudakoma ZAX Dobby Tappet 04 500-650 13

Tsudakoma ZAX

205,205i

Cam 02,06 450-600 81

Total 218


76

SPECIFICATIONS OF AIR JET LOOM:

GENERAL SPECIFICATION

Motor R.P.M : 1410

M/C speed : 625 PPM

Motor pulley dia. : 100mm

M/C pulley dia. : 225mm

Reed : Profiled reed

Shedding : Cam, Electric Dobby

Take up motion : Electronic

Let off motion : Electronic

Warp stop : Electrical

Weft stop : Electronic

HEALD SHAFT SPECIFICATION

Brand Name : New light

Manufacturer : Nankai industrial Co. Ltd.

Origin : Japan

PHOTO ELECTRIC SENSOR

Model : CY-21P-SK

Manufacturer : Sunx Ltd.

Origin : Taiwan

LENO BOBBIN WINDER

Brand Name : Precision spooler

Model : PS

Manufacturer : Sankin engineering Co. Ltd.


77

Origin : Japan

SIGNAL LAMP

Manufacturer : Hayashi feeler Co. Ltd.

Origin : Japan

CABLE

Manufacturer : Mitsubishi Cable Industries Ltd.

Origin : Japan

REED SPECIFICATION

Brand Name : (i) RTOS (ii) Setiakiji reed

Origin : Japan

Type : Profile reed

Reed Count : 129, 121, 116, 106, 99, 92, 88/2,

74/4, 72/4 etc.

Reed Width 172.50cm

WARP BEEM CARRIER

Brand Name : TODO

Model : S-1500

Maker : Marubeni Corp

Origin : Japan

OVER ALL CLEANER

Brand Name : LUWA

Type : Suction

LOOM MOTOR SPECIFICATION (3 Phase Inductor Motor)

R.P.M : 1410

Maker : Meidensha Corp

H.P : 3KW


78

SIGNAL LAMP:

COLOR INDICATION

Red : Warp breakage

Green : Weft breakage

White : Loom stop

Yellow : Selvedge leno bobbin breakage

LENO SETTING:

Right side : 10°

Left side : 280°

How to release or wind a weft:

This screen always appears when the machine Stops.Each drum number is displayed.

Releasing a weft:

Release Single, Turn switch. This switch releases a single turn of wefton the drum.


78

SIGNAL LAMP:

COLOR INDICATION

Red : Warp breakage


White : Loom stop


LENO SETTING:

Right side : 10°

Left side : 280°



Releasing a weft:



78

SIGNAL LAMP:

COLOR INDICATION

Red : Warp breakage


White : Loom stop


LENO SETTING:

Right side : 10°

Left side : 280°



Releasing a weft:



79

Release Turns

Release Turns switch. This switch releases turns of weft on thedrum.

Forward inching switch:

This switch should be pressed with INTER-LOCK switch a held down.Holding down

FORWARD inching switch runs the machine in the forward direction at allow speed;

releasing it stops the machineoperation.

Air jet weaving machines run at a speed several times higher than in the conventional ones.

Therefore, adjusting them requires instruments suitable for measurement of fast revolution

motions, such as pressure gauges, stroboscopes, tension meters, and others as listed below.


79

Release Turns










79

Release Turns










80

Production ProcedureOperation stuff:

Assistant Manager – section in charge

Production officer – shift in charge

Loom Technicians – shift wise running loom checking/ tuning/ setting & gauging

Senior loom operator – as a line jobber, for production & Q.C.

Loom Operator

Helpers & movers – for supplying yarn and yarn cartoons

Casual worker – For keeping the machine & section clean

Different parts of Air Jet loom:

1. EDP (Electronic Drum prewinder).

2. Tappet(Cam).

3. Lever and Puller.

4. Reed.

5. Dobby.

6. Easing roller.

7. Back rest.

8. Take up roller.

9. Cloth roller.

10. Weft Feeler.

11. Dummy selvedge stop.

12. Weft cutter.

13. Drop wire and bar.

14. Leno selvedge attachment.

15. Main nozzle.

16. Sub nozzle.


81

17. Tample.

18. Dummy selvedge system.

19. Monitor and Mother board

20. Pressure control Switch.

21. Grease tank.

Adjustment of setting:

Cutter to reed distance: 1mm

Temple to reed: 3mm

EDP pins to bend: 0.5mm.

Sub nozzle to sub nozzle: 88mm.

Two pick gear: 0.23m

Shed Size

→Plain:

Shed angle: 30°

Shed depth: 3 – 3.5cm

→Plain + Shateen:

Shed angle: 20°

Shed depth: 2.5cm

→Twill:

Shed angle: 25°

Shed depth: 3.5cm


82

FABRIC INSPECTIONPROCESS DEFINATION:

Fabric inspection is the process of identifying weaving faults in the fabric just after the grey

fabric production in the loom.

Equipment:

1. Inspection table

2. Fabric inspection machine(Nazer, L 90p, Pakistan)

Key Accessories:

Nipper, Pointer, Cutter, Comb etc.

Machine set-upM/C Set Value & Parameter

Check

: M/C Set Value & Functionality

Check

1. Guide roller speed : 40 meter/min

2. Light : Artificial day light

3.Length measuring meter : Attached with the fabric & the m/c

4. Automatic cutter(knife) : Functionality check

5. Slippage measuring roller : Functionality observe

6. Batcher : Check batcher setting with motor

Operation Procedure:

The steps involved in the Inspection Process are as follows:

1. Inspector connects the batcher with motor and feeds the fabric by the guide roller. The

fabric goes through a special table where there are arrangements for special lighting to

detect faults in the fabric visually.


83

2. Fabric is inspected as per inspection procedure of 4-point system. After the inspection,

the fabric is rolled or folded without any crease and is packed by polythene paper. The

inspector puts the Identification Sticker on the fabric roll with details of the fabric (i.e.

order no, customer, batch no, shade, roll no, usable width composition etc.).

Type of fabric : Maximum Roll size

(meter)

1. Poplin : 250

2. Yarn dyed : 250

3. T.C Fabric : 300

4. Twill : 150

3. The good as well as reject quantities are entered in the MASH module of Datatex

system with respective quality codes and then they are transferred to the finished goods

stores.


84

FINISHING


84

FINISHING


84

FINISHING


85

Finishing Section

Finishing Machineries

1. Singeing De-sizing 1 set

2. Washing machine 1 set

3. Stenter 1 set

4. Peach Finishing 1 set

5. Sanforizing 1 set

Singeing – DesizingSingeing is a process by which projecting or floating fibers stand out on the surface of the

fabric are burned off. Singeing is done to remove hairy fibers projecting from surface of cloth

and given a smoothen face. It is also done to increase luster in the finished fabric and to

prepare the fabric for next process.

De-sizing is the first wet processing textile finishing technology employed to remove the

sizing material from the fabric. It depends on the solubility of the film forming polymer, on

the effects of numerous subsequent wet processing steps, on the interactions with added

chemicals. It is done to remove starch from the fabric and to increase absorbency of the fabric.


85

Finishing Section




3. Stenter 1 set












85

Finishing Section




3. Stenter 1 set












86

Scouring and Bleaching

Scouring is the process by which all natural and adventitious impurities such as well as oil,

wax, fat etc. are removed to produced hydrophilic and clean textile material. It is vital process

of wet processing. It is done to make the fabric highly hydrophilic and to remove impurities

such as oils, waxes, gum, husks as completely as possible.

Bleaching of textile material is chemical or commercial process which can be defined as

destruction of natural coloring matters to impart a pure permanent and basic white effects

suitable for the production of white finishes, level dyeing and desired printed shade with the

minimum or on tendering or without diminishing the tensile strength. It is done to ensure a

pure and permanent basic white color fabric and to destruction of natural coloring matters

from the fabric.

Scouring & Bleaching M/C 01Model LMHO-022Serial No 200RMFD(Manufacturing Date) Aug’08Country of Origin ChinaM/C Temp. (60-90)CFunction Scouring & BleachingManufacturing Company Jiangsu Redflag Printing & Dyeing Co Ltd.


86











from the fabric.



86











from the fabric.



87

Stentatering

Stentering is done to soften and to control width of the fabric. It is done to give the required

finish to the fabric.

Stentering (VIROCK) M/C 01Model LV K4000-200×8Serial No 0807MFD(Manufacturing Date) 28thAug’2008Country of Origin ChinaPower Supply 30V ,<16AM/C rpm 60m/minFunction Soft & Width ControllingManufacturing Company WUXI Dakal Dyeing & Printing M/C Ltd.

Some finishes:

1. Soft/regular finish

2. ETI (Easy to Iron)/wrinkle free finish/resin finish

3. Easy care

4. Paper touch finish

5. Peach finish


87

Stentatering




Some finishes:



3. Easy care


5. Peach finish


87

Stentatering




Some finishes:



3. Easy care


5. Peach finish


88

Typical recipe:

Soft finish:


Tubingal 11/2: 8 gm/L

Jinssofter AS852: 20 gm/L

Terasil NNO: 10 gm/L

Acetic acid: 0.5 gm/L

Resin finish:


Fixapreat eco: 50 gm/L

CondensolFm: 10 gm/L (Catalyst)

Siligenpcp: 20 gm/L (Softening agent)

Aniston EPD: 20 gm/L (Softening agent)

Jinsofter AS822: 20 gm/L (Softening agent)


Karoline jet B: 1gm/L (Wetting agent)


88

Typical recipe:

Soft finish:






Resin finish:










88

Typical recipe:

Soft finish:






Resin finish:










89

4. Peach finish:

Peach finishing is done to give soft, hairy and smooth surface effect to the fabric. For this

emery rollers used.

Peach Finish M/C (Xetma) 01Model DE-08280-AueSerial No 160-008/NW 2200MFD(Manufacturing Date) 2008Country of Origin GermanyCompressed Air 6 barPower Supply B/PE/NAC-4000/+10%,50 Hz,200 AFunction FinishingManufacturing Company XetmaVollenweider GmbH Co Ltd.

SanforizingSanforizing is mainly done to control shrinkage of the fabric. It is also done to give a better

softening effect and controlling width of the fabric.

Step wise process:

Spraying Unit Steam Roller Rubber Belt Cylinder Steam Roller

Blanket Cylinder (Ironing for permanent shrinkage control)

Sunforising M/C 01Model LMH-442-200Serial No 804MFD(Manufacturing Date) 2008Country of Origin ChinaSteam 2.5 Kgf/cm2

Pressure 2.8KNFunction CalendaringManufacturing Company WUXI Dakal Dyeing & Printing M/C Ltd.


90

Finishing

To ensure safe and consumer friendly fabric PARAMOUNT has its own high- tech

laboratoryand computer data processing system. The laboratory is fully equipped with modern

testing equipments enabling them to check the fabrics in all the stages of required testing

criteria and performances. Testingequipments are sourced from renowned companies, such as-

JAMES H HEAL-UK

SDL ATLAS-UK

DATA COLOR SpectroPhotometer-USA


91

QA


91

QA


91

QA


92

Four Point Inspection System:

Generally any piece of fabric with less than 40 points fault per 100 square yard is allowed to

pass however for a roll; the average value should not exceed 28 points per 100 square yards.

More than 40 points fault per 100 square yards is recorded as reject. Normally fabric faults are

recorded using the 4-point system given below:

4-Point Grading System

Fault length Points to be assigned

(0 to 7.5) cm or less than 3” 1 points

(7.5 to 15) cm or (3” to 6”) 2 points

(15 to 22.5) cm or (6” to 9”) 3 points

More than 22.5 cm or 9” 4 points

Assessing Fabric Fault

Faults name Definition Faults area Points

Double pick In full width an extra pick 0 to 9 inch

over

4

Miss pick Missing of one or more picks 0 to 9 inch

over

4

Reverse pick After arriving reverse back and causes

double pick

0 to 3 inch

over

1

Broken or half pick Pick less than full length 0 to 9 inch

over

4

Crack More than three pick missing 0 to 9 inch

over

4

Snarling Bunch of weft yarn woven in one place 1 inch 2


93

Pressure loose Loop formed in the fabric Between 1

yards

4

Let-off mark Weft way mark for irregular pick dense 0 to 9 inch

over

4

Wrong pattern Design broken on warp way 0 to 9 inch

over

Starting mark Weft way mark while starting the loom Full width 4

Reed mark Reed having more gap than the normal

way.So warp way line visible

Reject

Temple mark Along the temple one or more pin mark

visible

Reject

Count mixing Mixing of various count Reject

Slubs Bunch fibers in yarn 0 to 1 inch 1

Double yarn One extra warp yarn woven along with

regular warp

Reject

Loose warp One or more warp yarn having more looser

than another warp

Mandible Reject

Tight warp One or more warp yarn having more tighter

than another warp

Mandible Reject

Stitch/warp float One or more warp yarn not properly

interlaced with weft for some distance

0 to 3 inch

over

1

Oil spot Oil drop in the fabric

Zala Bunch of warp yarn breakage 0 to 9 inch

over

4

Bad selvedge Narrow or higher width of selvedge Informed

weaving


94

Quality Assurance Dept

Finished Fabric Test Report Date:

Order No. : Test Std. : P.T .LCustomer : Construction :Shade : Fiber Comp. : 100% CottonRecipe No. : Finish Type :

Test Parameters Test Method Requirement Results RemarkThreads Per Inch Ends

PicksYarn Count ISO 7211-5 Warp

WeftFabricWidth(Inch) Overall

UseableFabric Weight (gm/m2) EN ISO 12127 Max deviation 5%Dimensional StabilityTo Washing

EN ISO6330/4A:2000

Shirt/Dress Crepes. VoilesWarp +/-3.0% Max. 5%Weft +/-3.0% Max. 5%

Tensile Strength ISO 13934-2:1999 Warp 140 N 100 NWeft 140 N 100 N

Tear Strength ISO 13937-1:2000 Warp 7 N 6 NWeft 7N 6 N

Seam Slippage ISO 13936-1:2004(6 mm)

Warp 80 N 60 NWeft 80 N 60 N

Abrasion Resistance(Martindale)

EN ISO 12947-2:1998 Lt. Shade Dk. Shade4c @ 10’000revs 3c @ 10000 revs

Pilling Resistance ISO 12945-2:2000 ¾ @ 2’000 Revs.Color Fastness ToCrocking

ISO 105 x 10 Lt. Shade Dk. ShadeDry- 4s 3sWet- 3/4s 2s

Color Fastness To Wash ISO 105 C06, 60℃ Change- 4c Change- 3/4Staining- 3/4 Staining- 2/3

Color Fastness To Water ISO 105 E01 Change- 4c Change- 3/4Staining- 3/4s Staining- 2/3

Color Fastness ToPerspiration

ISO 105 E04 (Acid) Change- 4c Change- 3/4Staining- 3/4 Staining- 2/3

ISO 105 E04 (Alkali) Change- 4c Change- 3/4Staining- 3/4 Staining- 2/3

Color Fastness To Light ISO 105 B02 Change- 5c, White & Pastels- 4c

………………….. ……………………….Tasted by Approved by


95

PHYSICAL TESTSTest Name Equipments Manufacturer

Thread per inch Thread counter James. H. Heal &

Company, Halifax,

England

Gram per square meter G.S.M tester James. H. Heal &

Company, Halifax,

England

Width test Measuring tape N/A

Tensile strength Elmendorf tearing tester

1653

James. H. Heal &

Company, Halifax,

England

Seam slippage Alphatens James. H. Heal &

Company, Halifax,

England

Abrasion resistance Nu-Martindale

Abrasion & Pilling tester

James. H. Heal &

Company, Halifax,

England

Pilling resistance ICI pilling box James. H. Heal &

Company, Halifax,


96

England

Thermal stability Roaches Roaches engineering

limited

Crease resistance Shirley crease

recovery tester

James. H. Heal &

Company, Halifax,

England

CHEMICAL TESTTest Name Equipments Manufacturer

Wash Fastness Gyro wash James. H. Heal &

Company, Halifax,

England

Water Fastness Perspirometer&

Carbolite

James. H. Heal &

Company, Halifax,

England

Sweat Fastness Perspirometer&

Carbolite

James. H. Heal &

Company, Halifax,

England

Light Fastness Light fastness

Tester(Mercury vapor lamp)

James. H. Heal &

Company, Halifax,

England

Crocking Fastness Crocometer James. H. Heal &


97

Company, Halifax,

England

Washing stability Wascator James. H. Heal &

Company, Halifax,

England

ANALYSISTest Name Equipments Manufacturer

Fiber analysis Electronic microscope James swift U.K.

Fabric analysis Balance, Thread counter N/A

Design analysis N/A N/A


98

Utility


98

Utility


98

Utility


99

It is one of the important sectors of a textile factory.

Generator, Air compressor, Boiler, Chiller, Water

treatment plant (WTP), Effluent treatment plant (ETP),

Humidification plant, Dryer


99






99






100

ETP

The effluent generated from different sections of a textile mill must be treated before they aredischarged to environment. Various chemicals & physical means are introduced for thispurpose. The effluent treatment plant in PARAMOUNT TEXTILE LTD. is biochemicalcombination process developed by India.

Objects:

This process is provided for treating the effluents of dyeing, finishing, weaving & thus allowdischarging it s per norms given by World Bank dept of environment of Bangladesh. Thisprocess comprises of collecting, pumping, clarification, Characteristics of raw effluents:

Volume : 140 cubic meter / day

Peak flow : 148 cub met / hr

pH : 7.6-7.8

BOD : 250-800 PPM

COD : 500 PPM

TDS : 2000 PPM

TSS : 200 PPM

D.O :0.50- 0.60 PPM

Color : Reddish- Black


101

Requirement of discharge effluent as per World Bank:

pH : 7- 7.5

BOD : < 50

COD : < 198

TSS : < 100

TDS : 602

DO : 5-5.5

Color : No.

Chemicals used & their colors:

Chemicals used AppearanceFerrous sulphate Granular solid, greenish colorLime White granular solidPoly acrylate White granular solidSulphuric acid Clear liquid


102

Product Quality Check:

Following chemical tests are carried out to check the quality:

- BOD- COD- Total suspended solids- Total dissolved solids- Color- pH

Flow Chart of Effluent Treatment:

Raw effluent↓

Equalization↓

Collection Sump↓

Pump station↓

Clarifier↓

Aeration tank↓

Setting tank↓

Clear water, pH check↓

Drain


103

Sludge Separation:

Sludge of DAF↓

Sludge thickening plant↓

Sludge drying be


104

Typical Output of the Plant:

This information we collect from the regular ETP operation chart

Raw effluent treated 15000 LPHRaw effluent color Reddish BlackRaw effluent pH 7.8Raw effluent TDS 1998Raw effluent TSS 200Raw effluent DO 0.52Raw effluent BOD 250Raw effluent COD 500Treated effluent color NilTreated Effluent Temp 380CTreated Effluent PH 7.2Treated Effluent TDS 600Treated Effluent TSS 100Treated Effluent DO 5Treated Effluent BOD 45Treated Effluent COD 198


105

WTPWTP means water treatment plant. In normal water there are including many type of organiccompound such as Mg, Ca, Zn, K, Fe etc. To remove this compound WTP are used in textileindustries. Otherwise after dyeing some mark are found in woven fabric. Another manyproblems are found in a fabric such as shade matching problem, dyes problem. To minimizethis type of problems WTP are used. So it is very useful for textile industries. In paramounttextile there are 2 water treatment plants.

Objective

To make suitable water for Dyeing, Sizing, Finishing etc. To minimize various type of marks.

Effect

Various type of mark in fabric, dyeing problem etc.

Working process of WTP

There are 3 tanks in WTP, which are:

1. Multi Grad Filter2. Braine Solution Tank3. Softener Tank (Resin are include in Softener tank)

Flow diagram of WTP:

Ground water

Pump

Multi grad filter

Braine solution

Softener

Yarn dyeing section Sizing Finis


106


107

Aeration

In between the aeration tank, the Fe is removed mainly. Basically Fe is not removed in generalway. So it is very match tough to remove. By oxidation Fe is remove easily.

Multi Grad Filter

It is a7 layers tank where the bacteria remove. These 7 layers are made by sand which work asfilter.

Softener Tank

In softener tank, Mg, Ca, Zn, K is removed. Actually all these metal parts are formed in “ion”and reacts with resign and water made metal free.

Brine solution

When capacity of ionization power of resign is discriminately low then brine solution ishelped to recover the power.

Capacity

Three plants are working here.

A. 150 m3/hrB. 100 m3/hrC. 60 m3/hr

Different M/c which are used in Utility section:

Diesel Engine 01Model GSW 275Serial No 0237044/006MFD(Manufacturing Date) Jan’08Country of Origin UKWDG 311Frame Core UCD 274KRPM 500Power 50 Hz, 400 VFunction Power GenerateManufacturing Company PRAMAC Co. Ltd

Chiller 01Model YSX 437 (3)-174Serial No 011MFD(Manufacturing Date) Nov’11Country of Origin ChinaChilled water Temp 7C


108

Chilled water Flux 273 M3/HrCooling water Inlet 32CCooling water Flux 425 M3/HrFuel Gas Inlet Temp 195CFuel Gas Flux 16729 Kg/HrSteam Pressure 8 MPaSteam Consumption 1860 Kg/HrPower Supply 3 , 400V,50 HzElectric Power 72 KWWorking Wt. 24.1 TonEx Work No SXHL 1331Function To Cool the waterCompany Name Jiangsu Shungliang Air Conditioning

Equipment Co. Ltd

Pump 15Model Y 160 ML 2Serial No 080429079MFD(Manufacturing Date)Country of Origin ChinaCos 0.88Power 15 HpRPM 2930Power Supply 50 Hz, 380 V, 21.8 AFunction Water SupplyManufacturing Company

Generator 05Model JGS 320 GSNLSerial No 5849181MFD(Manufacturing Date) 2008Country of Origin AustriaRated Power 1415 KWRated Voltage 400/231 VCurrent 2042 AMass 15500 KgMax Temp 30 CFunction Current GenerateManufacturing Company GE Jenbacher GmbH & Co. Ltd

Boiler (Danlim Royal) 02Model ZL-ZSerial No 014AMFD(Manufacturing Date) Jun’08Country of Origin KoreaActual Evaporation 8000 Kg/Hr


109

Design Pressure 1 MpaHeat Efficiency 90 %Fuel Consumption 42 Nm3/HrHeating Surface 97 M2

Capacity 100 M3/MinPower 15 KWNormal Size 40 AManufacturing Company DanelimRoyel Boiler Co. Ltd

Boiler (Weihupt) 01Model G 70/2-ASerial No 0085Q 0723MFD(Manufacturing Date) 2010Country of Origin GermanyGas Type Natural (N)Rating (Min 800-Max 8500) KWSupply Pressure (Min 15-Max 500) mbarElectric Rating 2389 KWPower 400 V, 1-50 Hz, 10 AManufacturing Company Max WeishauptGmpHCo.Ltd

Air Compressor 06Model ZT 250 VSDSerial No APF 154024MFD(Manufacturing Date) 2010Country of Origin BelgiumWorking Pressure 8.6 BarInput Power 240 KWRotational Shaft speed 2370 r/minManufacturing Company Atlas Copco Air Power Co. Ltd

Air Dryer 06Model FD 1250 A FSSerial No 8573-1MFD(Manufacturing Date) 08Country of Origin BelgiumWorking Air 13 BarWeight 860 Kg,Power Supply 400 V, 50 Hz, 8.3 KWAmbient Max 45CManufacturing Company Atlas Copco Air Power Co. Ltd

Cooling Tower 08Model ZONZLG 760


110

Serial No 200-0-11-920MFD(Manufacturing Date) Nov’08Country of Origin ChinaPower 11 KWRPM 180Model Of Blower Fan JTLZ 58Output Temp 32CInput Temp 38CWater Pressure 44 KPaFrame Wt 3820 KgManufacturing Company SHUANGLIANG FRP COOLING

MACHINARY CO.


111

Maintenance


111

Maintenance


111

Maintenance


112

MaintenanceMaintenance is one of the main concerning points for any production oriented organization.

PARAMOUNT having its own maintenance department is a strong section. It has a skilled

group of maintenance manpower.

Manpower:

Section Name of No of Description

Man

Required

Coverage for off

day, Total

Machine/Job Machine per Shift

leave &

absenteeism

In charge 0 0 1

Asst Engineer 0 0 1

Maintenance Mechanical 218 Forman 0 0 1

loom Senior Fitter 2 2 8

Fitter 2 2 8

Asst Fitter 2 3 9

Helper 3 3+General shift6 18

Total=46

In a weaving factory, Maintenance is done mainly on Sizing machine and on looms.


113

Maintenance of sizing machinePeriodical Inspection

Daily Inspection

Remove any lint on the suction filter for the cooling fan for the driving motors in each section.

Check any trouble and the following points:

→Abnormal noise,

→surface condition, vibration, rotation irregularity of each roll;

→Tension in each section;

→Steam, air size and oil leakage;

→Steam pressure:

a. Main supply pressure

b. Supply pressure to the drying cylinder

c. Supply pressure to the sizing section.

→Air pressure:

a. Main supply pressure,

b. Pressure during power failure-at the beam stand and the middle section,

c. pressure due to the cut mark device-standard 0.3MPa.

→Steam drain exhaust;

→Squeeze roll pressuring condition;

→Exhausting drain in the air filter equipment.


114

Weekly inspection

→Exhaust drain from the air compressor and the pressure reducing valve with the filter;

→Remove lint from the static electricity eliminator.

1. Roll chain tension

Adjust tension with tension wheel. If the chain has slack replace it.Some check points are-

a. Sizing section: Sizing roll driving

b.Drying Section: Pre-cylinder drying and main cylinder drying.

c.Take-up section:Warp beam and doffing driving,Taking-up roll driving.

2. V-Belt Tension

Slide the motor base and the V-belt tension. Checkingpoint’s are-

a.Size circulation pump

b.Winding motor

Every three month inspection

1. Steam strainer cleaning:

Clean the strainer two or three days after starting operation for the first time. Clean it every

three months after that.

2. Take up box frame and hydraulic unit:

Check the oil amount in the take up box frame and hydraulic unit. Supply if it is necessary.If

oil is dirty replaces it.

3. Pressuredrop after passing the air filter in the pneumatic piping

When the pressure difference between the primary and secondary side reaches 0.1MParepace

the element.


115

4. Cleaning of the steam trap: Clean the steam trap two or three days after starting operation

for the first time. Clean it every three months after that.

Every six month inspection

Polish the rubber rolls in the sizing section every six months.

Check the bearings.

Tools for assembly

1. 1-ton chain block: Four sets

2. 1-ton forklift: 1-2 sets

3. Transit and stepladder

Final Fabric Inspection M/c:

Final Fabric Inspection 04Model 820Serial No 090-095MFD(Manufacturing Date) Aug’2008Country of Origin ChinaNet Wt. 850 KgFunction Fabric InspectionManufacturing Company WUXI Golden Sun Textile Machinery

Fittings Ltd.

Man power

A staff of four to six required to unpack, install and wire the machine.

Lubrication

1. Lubrication position and required amount

Model Oil or grease Application Q’ty/unit

HS40 Oil Take-up gear box 6.5 litres


116

Sizing gear motor 6.0 litres

Heatproof Oil Centralized

lubrication oil

3.0 litres

Hydraulic actuation

oil

Oil tank 15.0 litres

Grease Sliding section,

bearing

1.0 liters

2. Recommended Oil

Manufacturer Oil Grease Hydraulic

actuation oil

Centralized

lubrication

Nippon oil

Corporation

FBK OIL

RO150

MULTINOC

GREASE 2

FAIRCOL A46

ESSO Teresso 150 Beacon EP2 Teresso32

MOBIL Mobil DTE

Extra heavy

Mobilux Grease

2

Mobil Rarus 425

Maintenance of loom

Periodical Inspection and Maintenance

Inspection Position Check points Maintenance

Brake Check for abnormally highly

temperature

Adjust

Selvedge Check for abnormal noise Adjust to 0.2mm

Feeler Head Check for dirt on the lens Clean the lens


117

Cutter Check the weft is well Replace damaged edges

Selvedge formation Check that the selvedge yarn is

threaded properly and in

uniform tension

Correctly threading and adjust

tension

Temple Check that the temple marks do

not appear

Adjust

Catch cord Check that the tuft is not

wound on the take up roll

Remove the tuft and clean

Inspection and Maintenance after weaving


Whole loom Check driving and lubrication

section

Remove lint and waste yarns

lubricate

Temple Check the temple ring rotates

easily and are not worn out

Remove lint and dirt,

whenneed replace

FDP Check that lint has not

adhered to the hook pin, main

drum or pin drum

Clean

Healed frame Check that the healed frame

height difference is 2mm or

less compared with specific

value

Adjust the healed frame

height

Air filter Check if the drain is filled up Drain

Let off Check that yarn has not

adhered to the easing shaft

Remove waste yarn

Lubrication Grease nipples, teeth of open

gears

Apply grease with brush

Every Six Month Inspection and Maintenance


118


Thread guide Check for dirt Clean

Hook pin assembly of FDP Check inside for dirt Clean

Sensors Check that they function

normally

Replace

Gear box of take-up and let-

off Section

Check for dirt of oil Replace

Air Filter Check that the filter element

is not clogged

Clean ,replace

Reed Check for adhesive monomer

and abrasions

Clean, replace

Main nozzle Check that the pipe is not

bent

Replace

Sub nozzle Check for bent on the tips Replace

Yearly Inspection and Maintenance


Warp beam Check that abrasion of

journal section is 0.3mm or

less

Shock absorber Check the function Replace

Cutter on the LH Check the edge for sharpness Grind or replace

Hook pin assembly Check that abrasion is 0.5mm

or less

Remove burr

Cloth roll metal bush Check that bush abrasion is

0.8mm or less

Replace

Every Three yearly Inspection and Maintenance


Cloth roll Check that the roll rotates

smoothly and cloth is wound

Replace the brake lining


119

Sub nozzle Check for dirt Clean

Every Seven year Inspection and Maintenance


Overhaul Loom, Bearings, Gear ,Cams,

Hook pins, Main motor

Shedding section, Let-off and

take-up section,FDP section

Lubrication Points

Position Period Lubricant type

Driving Section Gear box- 6 months

Main motor-3 months

Oil A

Grease C

Shedding Section Heald Frame Guide-1 week Grease A

Let off Section Gear box-6 months

Gears-After weaving

Oil B

Grease A

Take-up Section Gear box-6 months

Gears-6 months

Oil B

Oil A

Selvedge Section Slide Gear-After weaving

Bobbin Shaft-After weaving

Grease A

Cutter Section Cutter lever pin-After

weaving

Cutter cam-After weaving

Grease A

Automation Support Bracket-After

weaving

Grease A

Recommended Lubricants

Manufacturer Name

NIPPON OIL CORPORATION FBK Oil RO100

SHELL Tellus Oil C100

JOMO Ratus 100


120

MOBIL Mobil DTE Oil Heavy

EXXON Teresso 100

Tools and Their Functions

Name Functions

Pulley Puller

Adapter

For removing the motor pulley from the main motor shaft

G6 type puller For pulling out the loom pulley from the crank shaft

Turnbuckle For opening the split of the motor base

Tube Cutter When cutting the synthetic flexible tube

Torque wrench When mounting the reed on the reed holder

Adjusting

Bracket

When adjusting the vertical position of the tension metal supporter

G3 type puller For disassembling the FDP drum to remove the drum holder

Lifting rod bar Moving up the press roll in gaiting


121

ConclusionWe are enough fortunate that we have got an opportunity of having a training in this mill

during the training period. We‘ve received co-operation & association from the authority fully.

All the machines & materials found on appreciable working condition. All the stuffs &

officers were very much helpful to us. We apologize for our any behavior which may

disappoint the officers and personnel. Due to secrecy act, all the data on costing & marketing

activities has not been supplied & hence the data given regarding to this do not resemblance to

the actual data. The whole process is not possible to bind in such a small frame as this report,

hence our effort spent on summarizing, not describing them.


122

Reference1. Paramount Desk

2. Book of weaving_Dr. M. K. TALUKDAR, Prof. P. K.SRIRAMULU and Prof. D.B.AJGAONKAR.

3. Textile Terms and Definition by the Textile Institute (Tenth Edition), 1997.

4. Textile Industry under Globalization by M. Soundarapandin (First Edition), 2004.

5. Hand Book of Technical Textiles by A R Horrocks and S C Anand (First Edition),2000.

6. Textile Testing By P. Angappan (Fourth Edition), 1997.

7. http://www.BGMEA.com

8. http://www.ebookee.com.cn

9. http://www.EzineArticles.com

10. http://www. Google /history of weaving (visited : 30th December,2012)