TEXTILE INTERNSHIP REPORT

SHINGORA TEXTILES LIMITED LUDHIANA

SUBMITTED BY:

ANTAREKSH KUMAR PREM CHAURASIYA SANJEET KR. SUDARSHAN

SHINGORA TEXTILES LIMITEDSHINGORA TEXTILES LIMITED Shingora Textiles Limited is leading shawls manufacturers in India.Shingora Textiles Limited is leading shawls manufacturers in India.

It Offers a sophisticated range of products in Scarves, Woolen Shawls, It Offers a sophisticated range of products in Scarves, Woolen Shawls, stoles and variety of fabrics including jacquards & Woven in a delicate stoles and variety of fabrics including jacquards & Woven in a delicate blend of cotton, silk and wool.blend of cotton, silk and wool.

The manufacturing facilities equipped with state-of-the-art machinery The manufacturing facilities equipped with state-of-the-art machinery

for weaving, Dyeing and Printing is unmatched in the industry. for weaving, Dyeing and Printing is unmatched in the industry.

The unit is fully equipped to undertake in house production power The unit is fully equipped to undertake in house production power looms, jacquards, dobby looms. looms, jacquards, dobby looms.

They have an in-house Dyeing, printing and Packing sections to ensure They have an in-house Dyeing, printing and Packing sections to ensure timely delivery of all shipments.timely delivery of all shipments.

Shingora Textile Limited is one of the largest manufactures & exporters Shingora Textile Limited is one of the largest manufactures & exporters of Indian shawls, jacquard shawls, silk stoles, scarves, textiles, and of Indian shawls, jacquard shawls, silk stoles, scarves, textiles, and mufflers.mufflers.

PRODUCTION PLANNING AND CONTROL

EXPORT OFFICE

DYEING UNIT WEAVING UNIT

PRINTING UNIT

ORGANISATIONAL CHART

EXPORT OFFICE

CHECKINGPACKING AND DISPATCHING

FINANCESAMPLING

EXPORT OFFICEEXPORT OFFICE

DYEING UNIT

CHEKING AND SAMPLING DEPT.

PREPARATORY DEPT.

DYEING DEPT. DRYING DEPT.

PACKING AND DISPATCHING

YARN AND FABRIC CHECKING

DYE SAMPLING

QUALITY TEST

DYEING UNITDYEING UNIT

WEAVING UNIT

CHEKING AND SAMPLING

GOODS RECEIVING AND SENDING

PREPARATORYDEPARTMENT

POWER LOOM

HAND LOOM

PRINTING UNIT

SCREEN FORMATION

SCREEN PRINTING

SAMPLING AND TESTING

FINISHING

WEAVING AND PRINTING UNITSWEAVING AND PRINTING UNITS

EXPORT OFFICEEXPORT OFFICE::The export house is the main governing body of Shingora Textiles Limited. It The export house is the main governing body of Shingora Textiles Limited. It

consists of :consists of :

Production planning and control departmentProduction planning and control department Sampling departmentSampling department Finance departmentFinance department Checking departmentChecking department Packaging and dispatching departmentPackaging and dispatching department

Woven goods from the weaving unit after dyeing or printing (as required) are sentWoven goods from the weaving unit after dyeing or printing (as required) are sentto the export house. Following operations take place at the export office.to the export house. Following operations take place at the export office.

• Grey checkingGrey checking• Washing Washing • Hand pressing Hand pressing • Final checkingFinal checking• PackingPacking• DispatchingDispatching

Ground Floor

First Floor

WEAVING UNITWEAVING UNIT The weaving unit has both handlooms and power looms.The weaving unit has both handlooms and power looms. There are 45 handlooms and 50 power looms.There are 45 handlooms and 50 power looms. It has the capacity to produce 5750 meters per day. It has the capacity to produce 5750 meters per day. Production mainly and specifically depends on the demand by the buyer.Production mainly and specifically depends on the demand by the buyer. The raw materials for weaving are either provided by the buyer or The raw materials for weaving are either provided by the buyer or

according to buyer need by the production managers. according to buyer need by the production managers. Season also contributes to variation in production. Season also contributes to variation in production.

PRODUCTION DETAILS:PRODUCTION DETAILS:

HANDLOOMHANDLOOM 45 Handlooms – installed capacity of (approx) 250 meters per day.45 Handlooms – installed capacity of (approx) 250 meters per day.

POWER LOOMPOWER LOOM 20 Shuttle Less Rapier Looms (SULZER; DORNIER) with Electronic 20 Shuttle Less Rapier Looms (SULZER; DORNIER) with Electronic

Jacquards (BONAS; upto 6144 hooks) – installed capacity of (approx) Jacquards (BONAS; upto 6144 hooks) – installed capacity of (approx) 2500 meters per day.2500 meters per day.

Continued…Continued…

12 Shuttle Less Rapier Looms with Electronic Dobbies (SULZER; 12 Shuttle Less Rapier Looms with Electronic Dobbies (SULZER; upto 20 shafts) – installed capacity of (approx) 2000 meters per upto 20 shafts) – installed capacity of (approx) 2000 meters per dayday

   18 Mechanical Shuttle Looms with Mechanical Dobbies (upto 24 18 Mechanical Shuttle Looms with Mechanical Dobbies (upto 24

shafts) – installed capacity of (approx) 1000 metersshafts) – installed capacity of (approx) 1000 meters

LAYOUT (WEAVING UNIT)LAYOUT (WEAVING UNIT)

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WEAVING PROCESSWEAVING PROCESS

SPEC SHEET RECEIVED

WEAVING PATTERN MADE PREPARED

SAMPLE GENERATED

SENT TO EXPORT OFFICE FOR APPROVAL

PREPARATORY PROCESS

LOOM SETTINGS

WEAVING

PACKED AND SENT TO EXPORT OFFICE

NEW SAMPLE PREPARED

IF MATCHED

IF NOT ACCEPTED

HAND LOOM

JACQUARD LOOM OVER PICK LOOM

JACQUARD WEAVE

WEAVING DEFECTSWEAVING DEFECTS FLOAT (JALA)FLOAT (JALA) A float or Jala is formed when there is no proper interlacement of the A float or Jala is formed when there is no proper interlacement of the

warp and weft yarns over a certain area.warp and weft yarns over a certain area. WEFT CRACK (JERKI) WEFT CRACK (JERKI) A strip in the fabric where the pick density is lower than normal is called A strip in the fabric where the pick density is lower than normal is called

a weft crack or jerkia weft crack or jerki

CRAMMED PICK (PATTI)CRAMMED PICK (PATTI) A strip in the fabric where the pick density is more than normal is called A strip in the fabric where the pick density is more than normal is called

a patti. The defect is caused by improper setting of the anti crack a patti. The defect is caused by improper setting of the anti crack motion.motion.

SHUTTLE SMASHSHUTTLE SMASH The defect is caused when many ends break consequent to a shuttle The defect is caused when many ends break consequent to a shuttle

trap. The main causes of shuttle trap is wrong timing of shedding .trap. The main causes of shuttle trap is wrong timing of shedding .

STAINS (DAGHI)STAINS (DAGHI) Stains are caused by lubricants and rust. Most of the stains can be Stains are caused by lubricants and rust. Most of the stains can be

traced back to poor maintenance and material handling.traced back to poor maintenance and material handling.

BOWINGBOWINGUsually caused by finishing. Woven filling yarns lie in an arc across fabric Usually caused by finishing. Woven filling yarns lie in an arc across fabric width: in knits the course lines lie in an arc across width of goods. Critical width: in knits the course lines lie in an arc across width of goods. Critical on stripes or patterns and not as critical on solid color fabrics. on stripes or patterns and not as critical on solid color fabrics.

BROKEN COLOR PATTERNBROKEN COLOR PATTERNUsually caused by colored yarn out of place on frame. Usually caused by colored yarn out of place on frame.

HOLEHOLE Caused by multiple yarn breakage. Caused by multiple yarn breakage.

OPEN REED OPEN REED Results from a bent reed wire causing warp ends to be held apart, Results from a bent reed wire causing warp ends to be held apart, exposing the filling yarn.exposing the filling yarn.

SLUBSLUB (WOVEN FABRIC)(WOVEN FABRIC)

Usually caused by an extra piece of yarn that is woven into fabric. It can Usually caused by an extra piece of yarn that is woven into fabric. It can also be caused by thick places in the yarn. Often is caused by fly waste also be caused by thick places in the yarn. Often is caused by fly waste being spun in yarn in the spinning process. being spun in yarn in the spinning process.

DYEINGDYEING The dyeing unit of Shingora Textiles undertakes mainly dyeing of The dyeing unit of Shingora Textiles undertakes mainly dyeing of

wool,cotton,silk,nylon and linen . wool,cotton,silk,nylon and linen .

Both yarn dyeing and fabric dyeing is done. Both yarn dyeing and fabric dyeing is done.

Yarn dyeing is done in cheese form, in high temperature high pressure Yarn dyeing is done in cheese form, in high temperature high pressure machine. Weight of each cheese is 1 kg to 1.2 kg. Machine capacity machine. Weight of each cheese is 1 kg to 1.2 kg. Machine capacity upto 250 kg.upto 250 kg.

The temperature for HTHP yarn dyeing is 140 ˚C and pressure is The temperature for HTHP yarn dyeing is 140 ˚C and pressure is maintained at 60 pounds .maintained at 60 pounds .

fabric dyeing is done in open winch dyeing machines. fabric dyeing is done in open winch dyeing machines.

Continued…Continued…

The length of the fabric can range from 80 m – 600 m, and the The length of the fabric can range from 80 m – 600 m, and the width can range from 15” – 50” . Dyeing process requires 6 – 8 width can range from 15” – 50” . Dyeing process requires 6 – 8 hours , depending on shade and yarn/fabric.hours , depending on shade and yarn/fabric.

After receiving the samples the dyeing experts try to generate the After receiving the samples the dyeing experts try to generate the same color as required, by mixing the basic dyes. same color as required, by mixing the basic dyes.

The newly formed dye is applied on a sample and then sent for The newly formed dye is applied on a sample and then sent for color approval. color approval.

After color approval different fastness tests are carried on the After color approval different fastness tests are carried on the sample and points are given accordingly. sample and points are given accordingly.

If the fastness is not acceptable the dyeing parameters and If the fastness is not acceptable the dyeing parameters and method is revised and modifications are done to achieve best method is revised and modifications are done to achieve best fastness quality. fastness quality.

LAYOUT (DYEING UNIT)LAYOUT (DYEING UNIT)

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DYEING PROCESSDYEING PROCESS

DYE SAMPLE PREPARED

DYE FABRIC SAMPLE PREPARED

COLOR MATCHING

FASTNESS TESTS

REPORT SENT TO PPC

PRERARATORY PROCESS

DYEING

DRYING

PACKED AND SENT TO EXPORT OFFICE

NEW SAMPLE PREPARED

IF MATCHED

IF NOT MATCHED

IF ACCEPTED

IF NOT ACCEPTED

DYEING DEFECTSDYEING DEFECTS Common Causes of Dyeing Defects:Common Causes of Dyeing Defects:

1.1. The material is not well prepared for dyeing and printing:The material is not well prepared for dyeing and printing:

a. Material having dead fibres or other defective fibresa. Material having dead fibres or other defective fibresb. Left over of Chemicals after bleaching etc.b. Left over of Chemicals after bleaching etc.c. Material not properly desizedc. Material not properly desizedd. Absorbancy of the fabric not properd. Absorbancy of the fabric not propere. Sticking of insoluble material on the fibrese. Sticking of insoluble material on the fibresg. Impurities are not removed properlyg. Impurities are not removed properly

2.2. Water Quality not Proper:Water Quality not Proper:

a. More Hardness of watera. More Hardness of waterb. Water has metal ions such as iron.b. Water has metal ions such as iron.c. pH of water not properc. pH of water not properd. Water having more chlorined. Water having more chlorine

Continued…Continued…

3.3. Due to Shortcomings in making Dyeing Solution: Due to Shortcomings in making Dyeing Solution:

a. Improper weight ratio of colors, material and chemicals.a. Improper weight ratio of colors, material and chemicals.b. Improper material to water ratiob. Improper material to water ratioc. Improper filtering of concentrated colors.c. Improper filtering of concentrated colors.

4.4. Due to Shortcomings in the dye machinery: Due to Shortcomings in the dye machinery:

a. Coming out of Dye liquor during dyeinga. Coming out of Dye liquor during dyeingb. Defective instruments controlling temperature, pressure speed . b. Defective instruments controlling temperature, pressure speed .

Testing lab Cheese winding

Winch dyeing Cheese dyeing

Cheese dyeing machine Hydro extractor

Dyed cheese for drying Open drying

PRINTINGPRINTING Only hand screen printing is done at Shingora Textiles.Only hand screen printing is done at Shingora Textiles.

It sends a sample of its printing requirements. The printing unit then It sends a sample of its printing requirements. The printing unit then generates its own sample of the print and fastness properties and generates its own sample of the print and fastness properties and sends this sample to Shingora Textiles for approval. sends this sample to Shingora Textiles for approval.

Once the sample is approved the final printing starts. Once the sample is approved the final printing starts.

The printed goods after receiving at Shingora Textiles are sent for The printed goods after receiving at Shingora Textiles are sent for checking and then for washing and pressing and finally are packed checking and then for washing and pressing and finally are packed and dispatched.and dispatched.

PRINTING PROCESS AT SHINGORA TEXTILESPRINTING PROCESS AT SHINGORA TEXTILES

PRINT PASTE DEVELOPMENT

SAMPLE GENERATED PREPARED

FASTNESS TEST

PRINT SCREEN DEVELOPMENT

PRINTED SAMPLE GENERATED

SENT FOR APPROVAL WITH

FASTNESS REPORTS

PRINTING

DRYING

PACKED AND SENT TO EXPORT OFFICE

NEW SAMPLE PREPARED

IF MATCHED

IF NOT MATCHED

IF ACCEPTED

IF NOT ACCEPTED

FUSING ( FOR PLASTIC BASED PRINTS )

BASED PAI

PRINT SCREENS

CALENDERINGCALENDERING

Calendering Calendering is essentially an ironing process that adds is essentially an ironing process that adds sheen to the fabric.sheen to the fabric.

The mode varies according to the type of finish desired.The mode varies according to the type of finish desired. Calenders are heavy material rollers made up of atleast Calenders are heavy material rollers made up of atleast

two rolls.two rolls. Wool fabrics are calendered or polished.Wool fabrics are calendered or polished. The process adds a soft luster.The process adds a soft luster.

Objective:Objective: It improves the bulkiness, bulging effect & better drape It improves the bulkiness, bulging effect & better drape

of the fabric by the application of steam & pressure.of the fabric by the application of steam & pressure.

FINISHING PROCESSESFINISHING PROCESSES Calendering, Embroidery ,Washing and Pressing are done in Calendering, Embroidery ,Washing and Pressing are done in

Shingora Textiles.Shingora Textiles.

Calendering and Embroidery are done as per garment requirements.Calendering and Embroidery are done as per garment requirements.

After receiving the goods from dyeing and printing unit, they are After receiving the goods from dyeing and printing unit, they are sent for calendering or embroidery, if required.sent for calendering or embroidery, if required.

Finally they sent for washing and pressing.Finally they sent for washing and pressing.

PPC Department of Shingora Textiles manage these outsourcing.PPC Department of Shingora Textiles manage these outsourcing.

After receiving goods from these outsource units, they are sent to After receiving goods from these outsource units, they are sent to the checking department.the checking department.

Once approved they are sent to the packing and dispatching Once approved they are sent to the packing and dispatching departmnent.departmnent.

THANK YOUTHANK YOU