Internship Report (Ginni Filaments)
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Transcript of Internship Report (Ginni Filaments)
Abhishek Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Introduction
The winter internship for semester 5 of Apparel Production required us to visit a textile industry
and study the following departments-
spinning
weaving
knitting
dyeing
printing
finishing
The industry selected by us was Ginni Filaments Limited, Kosi. Located in Tehsil Chatta,
District Mathura, Uttar Pradesh, GFL has constantly grown from one strength to another.
Installed capacity today stands at 64,560 spindles, with a capacity of thousand tonnes per
month.
Ginni Filaments have four of the above (spinning, knitting, dyeing and finishing)
The study was conducted from 27st December to 7th January.
The schedule for the study was as follows:
Unit Name Contact Person Duration
Spinning Unit
(Blow room to Finishing)
Mr. Ashwani Kamra
Mr. R.S. Maurya
Mr. O.P.S. Rathi
29 to 31.12.2010
R&D Department Mr. A.Ramkrishnan 01.01.2011
Knitting Department Mr. Sorabh Kohli 03.01.2011
Dyeing Department Mr. Anil Sharma 04.01.2011
Finishing Department Mr. Tapan Biswal 05.01.2011
Lab & Inspection
Department
Mr. Arvind Singh 06.01.2011
PPC Department Mr. Pankaj Dalal 07.01.2011
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Objectives of the Internship
The internship helps us to understand the structural and functional constituents of the industry,
as during the internship we learn to adapt to real industrial situations which equips us for
decision making in a realistic environment. The internship also helps to strengthen the
relationship between the industry and students. The textile internship was carried out to
develop a clear understanding about the following:
Flow process sequence and Technical details on machine particulars of weaving,
dyeing, printing, finishing, laboratory etc.
Particulars of raw material, intermediate products and final product, process details,
product quality parameters.
Particulars of the manufacturing environment.
Human resource management.
Productivity analysis for various processes.
a) To observe the various departments in the organization
b) To understand the various processes in the department
c) To understand their interrelation within the organization
d) To observe the various models and makes of the machines being used
e) To study the working environment of the industry
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Company Profile
In 1990, Ginni Filaments Ltd. (GFL) was commissioned with 26208 spindles to produce
ultrafine combed cotton yarn. A 100% export oriented unit, it was designed to produce a
quality that was genuinely world class. Sophisticated plant & machinery from the world
renowned machinery manufacturers viz. RIETER, Schlafhorst, Volkmann etc. with top of
the line support systems for quality monitoring were installed.
Located in Tehsil Chatta, Distt. Mathura, Uttar Pradesh, GFL has consistently grown from
one strength to another. Installed capacity today stands at 64560 spindles with a capacity
of 1000 tonnes per month.
The product range includes 100% combed cotton yarns from Ne16 to Ne50, both in
single and double ply construction.
In January 1998, GFL embarked upon an ambitious expansion project by entering the
arena for Open End Yarn. GFL has 1680 rotors with a capacity to produce 600 tonnes
per month of open end yarn in the count range of Ne 6 to 20. Products have been well
accepted by buyers around the world.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
The company also manufactures TFO doubled, compact spun, elitwist and gassed yarns.
The company has also graduated into knitted fabrics and installed 26 knitting machines
from M/sTerrot and Mayer to produce Single Jersey, Interlock, Rib Terry and Lycra
fabrics. Since April 2005, GFL has expanded into processed knitted fabrics. The
complete machinery has been imported from Thies &Santex. Ginni has started working
with some leading European brands and other global brands like Benetton, C & A, Allen
Solly, Van Heusen, J C Penny etc. The success story at GFL is the story of evolution of
single minded devotion to quality. The company obtained the ISO 9000 certification as
early as 1996 and also got the recognised as Trading house by the Govt. Of India.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
In order to get fully vertically integrated and be present from fibre to fashion, Ginni
Filaments Limited has entered garment business with its first unit in Noida in Sept. 2006,
with a capacity of 2,50,000 pcs per month. The capacity would be increased to one
million pcs per month in a phased manner.
The plant for spun-lace non woven fabrics with an installed capacity of 12,000 MT/p.a.
which is the first of its kind in India commenced production in March, 2007 in Panoli
Industrial Estate, Gujarat.
Converted products made out of spun-lace non woven fabrics have been launched by
the company in the Indian Market.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Milestones
Year Milestone Capacity
1990 Capacity installed 26208 Spindles
1993 Installed capacity increased to 36288 Spindles
1995 Installed capacity increased to 54432 Spindles
1995 Forward integration into knitting 29 Knitting
Machines
2005 Set up a knit process house 250 tons/month
2006 Installed capacity increased to 64560 Spindles
2006 Installation of rotor 1680 rotors
2006 Venture into Nonwoven Consumer Products
2006 Venture into Knit Garmenting 2,50,000
pcs/month
2007 Venture into Spunlace Nonwoven 12,000 mtr/p.a.
2007 Venture into Consumer products made from
spunlace fabric
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1. Spinning
1.1 Ginni Spinning – Kosi
Yarn Capacity (100% Cotton)
o Ring Spun Yarn (16s to 40s) – 67000 Spindles
Monthly Capacity – 1250 Tones
o Open End Yarn (6s to 20s)
1680 Rotors
Monthly Capacity Open End Yarn
600 Tones
Types of yarn produced
Warp yarn, Hoseiry yarn,slub yarn
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1.2 Flow Chart Spinning
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Godown Storage of bales
Blowroom
Bale CleaningBale OpeningMixing/Blending
CardingFiber to Fiber SeperationWaste (vegetable, seed fragments) RemovalEnd Product - Sliver
Comber Preparation Straightening, Uniformity, Evenness
Breaker Draw Frame First level of drawing to increase parallelization and uniformity of sliver.
Comber several slivers / ribbons are combined
Finisher Draw Frame Second level of drawing to get finer yarn.
Speed Frame drafting, twisting and winding takes place.
Spinning Open end spinning and ring spinning
To remove objectionable faults & to Convert ring bobbin into large package
To make the yarn suitable for packaging
Packing For the disposal of the final yarn
Textile Internship - Ginni Filaments Pvt. Ltd.
1.3 Storage: (Cotton Godown)
The mill consists of 5 godowns which are used for the storage of ginned cotton. The cotton is
purchased from domestic as well as international market. Main vendors of the raw material are
from Punjab, Haryana, Gujarat, Madhya Pradesh and United States of America. The main
motto of the company is to look after the quality of the ginned cotton and fiber maturity which
determines the market price of the raw cotton.
Proper protection from moisture is given to the godowns as it affects the fiber properties and
can alter the functional as well as aesthetic properties of the fiber. In addition there is a limited
no. of lights of low intensity or any electrical products in order to avoid fire in the godowns,
since ginned cotton is highly flammable.
Procurement of the purchased cotton is done by the commercial department.
Each godown has a capacity of 10,000 bales. Domestic bales comprise of 160-165 kgs of
cotton on average and international bales have 200-300 kgs of cotton per bale.
Random checking of the bales purchased is done manually
and is stored in an ordered manner.
Cotton varieties used for spinning here are Cotton J34, Mech1 & Mcu-5.
There is a separate storage room for organic cotton. Organic cotton is cultivated without
the usage of any harmful chemicals like pesticides and insecticides.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Information given on each stack of bales
Vendor GJ-0087
Vendor lot no. 34A6
Mill lot no. BL-006
Cotton Type MCU-5
No. of Bales 17
Date of receival: 13/12/2010
1.4 Blowroom
• Opening
• Cleaning
• Blending
The cotton arrives at the mill in large bales. The compressed mass of raw fiber must be
removed from the bales, blended, opened and cleaned. Blending is necessary so as to
obtain uniformity of fiber quality; opening is necessary in order to loosen the hard lumps of
fiber and disentangle them; Cleaning is required to remove trash – such as dirt, leaves,
burrs, and any remaining seeds – in order to prepare the fiber for spinning into yarn. These
functions are accomplished through a continuous series of stages.
Bale is opened manually by workers. They open the ropes which hold the bale together.
They do a little bit of cleaning while opening.
Then the bales are kept in columns according to their count. Like four columns of bales
having 16 bales in each columns, thus 64 bales in total. NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
The machine used for Bale opening and blending is RIETER Unifloc A10 .
RIETER UNIfloc A10
Efficient bale opening must prepare the material properly for the subsequent cleaning stages,
as well as making operation easy and ensuring that personnel are largely relieved of the need
to intervene unnecessarily. The UNIfloc A 10 fulfils these requirements.
Small tufts are essential for efficient cleaning. Small tufts offer a large surface area. Trash, dirt
and dust are exposed and can be removed gently.
A whole series of functions support you to ensure simple, efficient bale opening. In particular,
optional scanning of the contours of the bale makes laborious alignment of the bale lay-down
unnecessary. Alignment is performed automatically during several takeoff cycles. The bales
are opened parallel, down to the last tuft. The intelligent control system ensures uniform bale
reduction.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1. Control cabinet – The functioning of the machine can be controlled using this
display.
2. Bale lay-down – The rows of bales put together to be taken up by the machine.
3. Take-off unit – This unit is responsible for sucking up the fibers from the bales.
4. Swivelling take-off tower with chassis – This is where the opening and blending
takes place.
5. Channel for material materiel transport
RIETER UNIflex B 60
This machine is used for Bale Cleaning. The fiber from UNIfloc A 10 goes to UNIflex B 60
via pipes. There is suction mechanism which transports the fiber through various processes.
This way the fiber is not exposed to the external environment while being transported.
The UNIflex B 60 is a fine-cleaner for natural fibers. Its maximum production capacity is 600
kg/hour. It can be used without any additional components as a feed machine for cards.
The single-cylinder concept permits a wide operating range with no damage to the fibers or
excessive loss of good fibers. Technological superiority is only one of the advantages offered
by the B 60. High running efficiency is a further important aspect.
State-of-the-art design
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Easy maintenance and trouble-free operation are high on the list of priorities. The design is
simple. A single cleaning cylinder minimizes the negative side effects familiar from multi-
cylinder cleaners – i.e. higher NEP counts and loss of good fibers.
The tufts are fed evenly into the lamellar chute by the integrated feeding fan and the divider
element. The material is guided downwards through the chute and a perforated drum.
Unidirectional feeding is performed by a feed roller and a feed trough. The nipping/combing
point distance is adjusted according to the staple length.
The modular grid with the carding element and the cleaning cylinder work together to open the
tufts further and separate the remaining trash from the fibers. A spiked or saw-tooth roller is
used, depending on the raw material.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1.5 CARDING
Before the raw stock can be made into yarn, the remaining impurities must be removed, the
fibres must be entangled, and they must be straightened. The straightening process puts
the fiber into a somewhat parallel lengthwise alignment. This is necessary for all staple
fibers; otherwise it would be impossible to produce fine yarns from what is originally a
tangled mass.
The cotton comes off of the Blowroom, and is then taken to carding machines. The carders line
up the fibers to make the spinning easier.
The lap is passed through a beater section and drawn on a rapidly revolving cylinder covered
with very fine hooks or wire brushes. The carding machine consists mainly of one big roller
with smaller ones surrounding it. All of the rollers are covered in small teeth, and as the cotton
progresses further on the teeth get finer (i.e. closer together).
The machine used for carding is RIETER C 50,C 60,C 4,C 4a.
No of carding machines – 27.
RIETER CARD C 50
With its unique geometry in the carding zone, the C 50 high-performance card provides one of
the main building blocks for achieving financial success. With a working width of 1500 mm,
output by the C 50 card is up to 50% higher than on conventional models – and is combined
with superior sliver quality. The ratio of output to energy and space requirements is
revolutionized by the C 50. It is available with coiler (CBA), integrated draw frame without
leveling (SB module) and in the auto-leveling version (RSB module) for use in the OE direct
process.
The machine has a capacity of up to 220 kg/hour. The consistently high carding quality is
achieved amongst other things by using the IGS Integrated Grinding System. This ensures
constant sharpness of the cylinder and flat clothing and long clothing lifetimes. These
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
guarantee a consistent sliver quality. With its modular construction the C 50 is very
maintenance friendly, and can be changed over very quickly to new production requirements.
The cotton enters the carding machine in web form(fine feed),and leaves the carding machine
in the form of sliver/ ribbon large rope/ sheet of fibers.
The cleaning efficiency of carding machine is 98%.
Machine specifications
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Model no. RIETER C50
Card no. 31
Count 20’s
Sliver Tex 5.60 ktex
Production rate 35-50 kg/hr
CAN ID White + pink tip
Target production 280-400 kg/shift
Delivery speed 104-149 m/min
Textile Internship - Ginni Filaments Pvt. Ltd.
1.6 COMBING PREPARATION
Before the carded yarn is sent for combing, it has to undergo through certain machines so as
to make the yarn into straight, uniform and parallel strands. Several slivers are combined
together which results in relatively narrow lap of compactly placed staple fibers. The
compactness of these fibers permits this cotton stock to be attenuated, or drawn out, to a sliver
of smaller diameter without falling apart.
The machine used for this purpose is RIETER SB2 & RIETER UNILAP E-30.
RIETER SB2
The SB drawframe module is impressive with its low space requirements and a delivery speed
of up to 800 m/min. The 3-over-3 drafting system is positioned inclined and permits up to a 5-
fold draft. The best parallelity of the fibers and thus an optimal sliver quality are guaranteed.
The drafting system geometry is based on the successful SB/RSB-D 40 drawframes. A
shortening of the process by one drawframe passage is possible depending on the yarn count,
raw material
and spinning process.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
RIETER UNILAP E-30
E 30 UNIlap combing preparation combines mill-proven engineering and soundly based
technology in a compact design – the ideal basis for superior productivity and economy. The 3-
over-3 drafting system ensures high fleece quality through optimum finishing drafting and
parallelization of the fibers. High-quality laps are produced by means of two lapping rollers and
a variable production speed. Laps produced on the UNIlap display outstanding unwinding
behavior on the comber.
UNIlap E 30 encompasses the latest knowhow based on technical and technological
experience with proven components from the previous successful model:
2-zone drafting for ideal fiber drawing
4 calendar rollers and automatic regulation of the lap loading
for perfect lap build-up
High production rates and quality levels by means of
VARIO speed
Improved running conditions – better reliability
Functional design for greater ease of operation
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
2-ZONE DRAFTING SYSTEM
The 2-zone drafting system enables the correct application of splitting pre- and main drafting in
both zones. Only optimal drafting distribution can ensure the best drafting conditions and the
resulting fiber parallelization. In particular, with longer fiber 2-zone drafting shows significant
quality advantages when predrafting is reduced and the main draft is increased.
4 calendar rollers and large lap rollers Regulated automatic lap loading
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
4-CALENDER ROLLERS – LARGE LAP ROLLERS
4 calendar rollers and large lap rollers allow for faultless batt structure and ensure secure and
optimal lap construction.
VARIOspeed
VARIOspeed permits permanent adjustment of the lap speed to the lap diameter during the
entire lap build-up cycle. Together with consistently better lap quality it also ensures higher
production rates.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
RIBBON LAP (LH10)
Ribbon lapping is also done to make fibers more uniform and even accompanied by lap
to lap doubling.
There are four automatic ribbon lapping machines.
Each ribbon lap weighs around 20 kgs.
Automatic doffing of the creels takes place and new cylindrical cones are loaded.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1.7 DRAW FRAME
The draw frame contributes less than 5% to the production costs of the yarn. However, its
influence on quality, especially evenness, is all the greater for this. If the Drawer frame is
not properly adjusted, there will also be effects on yarn strength & elongation.
Equalizing
One of the main tasks of the draw frame is improving evenness over short, medium &
especially long terms. Card slivers fed to the draw frame have a degree of unevenness that
cannot be tolerated in practice.
Parallelizing
To obtain an optimal value for strength in the yarn characteristics, the fibers must be
arranged parallel in the fiber strand. The draw frame has the task of creating this parallel
arrangement. It fulfills this task by way of the draft, since every drafting step leads to
straightening of the fibers.
The value of the draft must be adapted to the material that is to several fiber parameters:
The staple length
The mass of the fibers
The volume of the strand
The degree of order (parallel disposition)
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Dust Removal
Dust is steadily becoming a greater problem both in processing and for personnel involved.
It is therefore significant to remove dust in every possible step in the process.
1.7.1 BREAKER DRAW FRAME
Machine: LMW LDO/6
This machine is used for breaker draw frame.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Salient Features
High delivery speed of upto 500 mts/min
Production upto 360 kg/h
High efficiency
Flexibility
The pneumatically loaded 3-cylinder pressure bar drafting arrangement makes the
processing of noils as well as fibres of a staple length upto 75 mm possible
Controlled positive sliver feed table for can size of 600 x 1100 mm (24''x42'')
Sliver Compression
Sliver compression before coiling increases can content
Automatic can changer
Increases the efficiency of the machine
Cleanliness
Dust extraction improves the working condition
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1.7.2 FINISHER DRAW FRAME
This process is used for both open end as well as ring spun yarns.
In case of ring spun yarns, it is done after the combing process.
Machine: RSB D35 RIETER
Rectangular CUBIcans contain up to 75% more material in comparison to round cans. This
reduces the operating expenses, results in quality benefits and increases the efficiency of
downstream processing. The active guidance of the can bottom permits CUBIcans to be
operated without springs and increases flexibility. CUBIcans protect the sliver better and are
more robust than a conventional rectangular can with a lateral slit.
Economy
Delivery speeds of up to 1 000 m/min
Up to 75% higher filling capacity in comparison to round cans for reduced operator
expense
Higher spinning machine efficiency
Quality
Precise levelling
Proven 4-over-3 drafting system
Effective suction system
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Flexibility
Automatic filter cleaning
Central lubrication
Central drafting system adjustment
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1.8 COMBING
When the fiber is intended for fine yarns, the sliver is put through an additional straightening
called combing. In this operation, fine toothed combs continue straightening the fibers until
they are arranged with such a high degree of parallelism that the short fibers called noils are
combed out and completely separated from the longer fibers.
In combing, several slivers / ribbons are combined.
Each sliver will have thin and thick spots, and by combining several slivers together a
more consistent size can be reached.
Since combining several slivers produces a very thick rope of cotton fibers, directly after
being combined the slivers are separated into rovings.
These rovings are then what are used in the spinning process.
The combing process forms a comb sliver made of the longest fibers, which, in turn, produces
a smoother & more even yarn. This operation eliminates as much as 25% of the original card
sliver; thus almost one-fourth of the raw cotton becomes waste. The combining process,
therefore, is identified with consumer’s goods or better quality. Since long staple yarns produce
stronger, smoother & more serviceable fabrics, quality cotton goods carry labels indicating that
they are made of combed yarns or combed cottons.
Machine Specifications
Model no. RIETER E60
Card no. 42
Count 20’s
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Sliver Tex 5.80 ktex
CAN ID White + steel strip
Target production 58 km/shift
RIETER E60
70 kg/h on the new, fully automated E 60 comber or 72 kg/h on the E 66 comber – these
are the effective production figures of the new combers. The increase in output has been
achieved by means of C•A•P•D 500 (Computer Aided Process Development). With
500 nips/min., up to 80 g/m batt weight, superior fiber selection and very good machine
running behavior, the combers produce top quality with maximum economy. The ROBOlap
fully automated lap changing and piecing system on the E 76 comber remains a unique
feature.
Economy
Effective output of the automated machines is up to 74 kg/h. This corresponds to
1.7 tonnes of combed sliver per day – a new record.
The E 66 / E 76 combers produce at up to 500 nips/min. in mill operations.
With equivalent quality, RIETER combers extract up to 2% fewer noils, i.e. achieve up to
2% raw material savings, compared to other systems.
Quality
High and uniform quality with reduced noil extraction is achieved uncompromisingly by
virtue of excellent fiber selection on the RIETER combers.
High yarn quality at high nip rates and highest possible batt weight. This applies to
imperfections and tenacity/elongation as well as infrequent weak places in the yarn.
Gentle fiber treatment by optimal coordination of comb movements and technology
elements - developed by RIETER.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Flexibility
The grade of raw material utilization and quality can be selectively controlled on the
basis of maximum output.
The 3-over-3 cylinder drafting system with pressure bar and variable break and main
draft distance enhances precise fiber guidance for all staple lengths.
The fully automated lap changing and piecing system on the E 76 ROBOlap comber is
unique worldwide.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1.9 ROVING / SPEED FRAME
At the speed frame, drafting, twisting and winding takes place. It is the last stage of the
preparatory unit before actual spinning takes place.
In speed frame, rove is formed from sliver as well as twist is provided using pliers.
Diameter of the fiber is reduced and the length is increased.
Here the slivers are fed and the wound bobbin is obtained.
These bobbins are placed on the roving frame, where further drawing out and twisting
takes place until the cotton stock is about the diameter of a pencil lead.
It is a preparatory stage for the final insertion of twist.
It gives no tensile strength & will break apart easily with nay slight pull
It is not done for open end spun yarns: only for ring spinning.
The machines used for this are LMW LF 1400-A and LMW LF 1465
LMW LF 1400-A
Salient Features
Flyer speed up to 1400rpm
Delivery speed up to 40 mts/min
Flexibility in drafting system
Top and Bottom clearer device with suction
Number of spindles up to 144
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Pneumo stop and Creel stop
High Production
Flyer Speed up to 1400 rpm (mechanical)
Delivery speed up to 30 mts/min. for cotton and 40mts/min. for synthetics
Package size 12" x 6.5"
User Friendliness
Positive Top and Bottom clearer system
Effective suction system for both top and bottom clearer waste
Dual compartment filter box
Electromagnetic device for reliable trough reversal
Simplified 3 rollers and 4 roller spring loaded Drafting system
Creel up to 7 rows for easy accessibility
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
LMW LF 1465
Salient Features:
Spindleage upto 200
Spindle speed upto 1500rpm (Mechanical)
Auto doffer with Provision for bobbin transport system
4 Segment servo drive : Bobbin , Flyer , Drafting and Bobbin trough
Drafting system- Double apron drafting system with 3 roller or 4 roller drafting
Unique Individual bobbin tilting for easy doffing incase of Manual doffing
Detachable flyer spindle for removing bobbins midway
Automatic roving tension controller
TDCL suction system for effective suction across the machine
4 row aluminum hexagonal roller creel
Ergonomic human machine interface
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1.10 SPINNING
Fiber is converted to yarns.
Spinning is the final formation of yarns from raw yarns which includes drafting, twisting
and winding.
The final drafting of the yarn is done at this stage.
Spinning of the yarn decides main two parameters: yarn twist and yarn count.
Yarn Twist: the amount of twist is an important factor in finished consumers’ goods. It
determines the appearance as well as the durability and serviceability of the fabric. Fine
yarns require more twist than coarse yarns.
Yarn Count: In the spinning process, there is always a fixed relation between the
weight of the original quantity of fiber and the length of the yarn produced from that
amount of raw material. This relation indicates the thickness of the yarn. It is determined
by the extent of the drawing process and is designated by numbers, which are called
the yarn count. This yarn count may be expressed according to the traditional method or
by the newer Tex system, which is based entirely upon the metric system of
measurement.
In Ginni filament Ltd., yarn count is measured in English count system(Ne) [No. of 840
yards strands per 1 English pound of pass.
The Tpi for knitting yarn is 3.6 to 3.7 depending on the requirement.
The roving, on bobbins, is placed in the spinning frame, where it passes through several
sets of rollers running at successively higher rates of speed and is finally drawn out to
the yarn of the size desired.
Spinning done here is of two types: Open end spinning & ring spinning.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1.10.1 Open End Spinning
It is a technology for creating yarn without using a spindle.
Also known as break spinning or rotor spinning.
Sliver from the card goes into the rotor, is spun into yarn and comes out, wrapped up on
a bobbin, all ready to go to the next step
There is no roving stage or re-packaging on an auto-coner.
The machines used here RIETER R1 (4 nos. having 960 rotors in total) &
SCHLAFHORST Autocoro S360 (2 nos. having 720 rotors in total).
In Open-end, 20 Tons yarn per day are being produced in the count range of Ne 6s to
Ne 20s.
Machine: RIETER R1
The fully automated R 1 rotor spinning machine offers enormous productivity potential with up
to 500 spinning positions and with up to 4 high-speed robots. Leadership in uniform yarn
quality is achieved through state-of-the-art spinning technology and AEROpiecing® for yarn-
like piecings. Energy-saving drives and a fully developed operating concept reduce running
costs to a minimum, creating the ideal preconditions for long-term, successful operation.
Economy
Up to 500 rotors per machine and 2, 3 or 4 robots with overlapping operating zones.
Inverters and optimized bearing technology reduce energy consumption.
Robots with extremely short cycle times for piecing and package change (< 25 s).
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Quality
Superior yarn quality due to the high spinning stability of the SC-R spinning box.
Constant high yarn quality due to SPEEDpass, BYpass and the fixed fiber beard
support.
Unique AEROpiecing® technology for yarn-like piecings.
Flexibility
Fast lot change on the machine display due to modern frequency-controlled drives.
Easy robot setting with the eXpert Piecing System (XPS).
Fancy yarn device from experts available as option including multicount / multitwist.
The machine in this mill produces cotton of count 7’s with a rotor speed of 75000 rpm. The
opening roll speed is 77000 rpm. Overall length of the yarn is 45km per shift, i.e.,
approximately 1186 kgs.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Machine: SCHLAFHORST Autocoro S360
The Autocoro S 360 combines proven Autocoro factors of success with an innovative piecing
technology: DigiPiecing. The result is: a particularly smart Autocoro. The new piecing process
and the digital piecing check ensure piecing with highest perfection even without automation.
Particularly productive with 360 spinning positions, rotor speeds up to 130,000 rpm and
take-up speeds up
to 230 m/min
Premium Belcoro yarn quality and Autocoro package quality
Ideal for all applications and raw materials
DigiPiecing means: no more shaft drives. Instead: 100 % digital control and execution of
the piecing process by means of high-precision single drives.
In the Autocoro S 360, Corolab XQ, the most successful and most sophisticated clearer
technology in the world, not only ensures unequalled yarn quality but also 100 %
digitally controlled piecings.
The machine in this mill produces cotton of count 9’s with a rotor speed of 92000 rpm. Overall
length of the yarn is 53km per shift, i.e., approximately 1469 kgs.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1.10.2 RING SPINNING
The ring frame is a faster process, but produces a relatively coarser yarn.
Its hundred of spindles, whirling thousands of revolutions a minute, and its constant
spinning action provide a fast operation.
It completes the manufacturing of yarn by-
o Drawing out the roving
o Inserting the twist,&
o Winding the yarn on bobbins.
On each side of the frame are the spindles, above them are the draughting (drafting)
rollers and on top is the creel loaded with bobbins of roving.
The roving (unspun thread) passed downwards from the bobbins to the draughting
rollers.
Here the back roller steadied the incoming thread, while the front roller which was
moving much faster pulled thread out (attenuated) forcing the fibres to mesh together.
The rollers are individually adjustable, originally by mean of levers and weights.
The attenuated roving now passes through a thread guide that is adjusted to be
exactly above the spindle.
Thread guides are on a thread rail which allows them to be hinged out of the way for
doffing or piecing a broken thread.
The attenuated roving passes down to the spindle assembly, where it is threaded
though a small ring called the traveller.
The traveller rotates on the ring. It is this that gives the ring frame its name.
From here it is attached to the existing thread on the spindle.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
The machines used here are RIETER G35 & Jingwei F1520.
42 Tons of Single Ring Spun Combed yarn per day in the count range of
Ne 16 to Ne 50 is being produced.
Machine: RIETER G35
The G 35 ring spinning machine is a further milestone in RIETER ring spinning technology.
The functions of the mill-proven G 33 predecessor model have been augmented by new
options for producing fancy yarns and core-spun yarns. Customers benefit from a powerful,
high-quality machine with a wide range of spinning technology features.
Economy
Modular machine design with up to 1 632 spindles.
High economic efficiency – longer machines reduce the fixed proportion of production
costs per kilogram of yarn.
The reduction in energy consumption – a core component of manufacturing,
maintenance and operating costs – has been given top priority.
Quality
The mill-proven Ri-Q-Draft drafting system with pneumatically loaded guide arm and the
Ri-Q-Bridge for superior spinning conditions provide a sound basis for high yarn quality.
Intermediate drive – consistent quality on long machines with > 1 200 spindles.
SERVOgrip – the RIETER innovation for genuine doffing without unwinding – eliminates
underwound threads and considerably reduces fiber fly on ring spinning machines.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Flexibility
Designed for coarse and very fine yarns.
The MEMOset article module stores spinning parameters for up to 18 different yarns.
The data are available at any time and can be called up and processed on-screen.
Machine functions, spindle drive, FLEXIdraft, ROBOload and the travelling cleaner are
centrally controlled. This enables all functions to be operated via a central operator and
display unit. FLEXIstart machine function – spinning start-up in quarter or half-sides
(> 1 200 spindles).
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Machine: Jingwei F1520
This spinning frame is the latest development with high-speed, high-efficiency, high-quality and
high stability and reliability of the distinct characteristics.
Features:
Count-20’s
TPM-677
Spindle speed (max) – 16400
Spindle Speed (avg) - 15800
.
1.11 WINDING / AUTOCONER:
Objective - 1. To remove objectionable faults
2. To Convert ring bobbin into large package
Process
Here the winding of the cones takes place from the bobbins obtained from the
spinning department. It’s done by intertwining at the right twist.
Each cone weighs around 2.21 kg
There are 43 automatic coner machine and three semi automated coning
machine.
The machine has 72 heads. Each head has 8 cops fitted at a time.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
It has an external attachment for insertion of empty cones after one set of winding
is complete. It is known as ‘creel’.
Here the spindle feed system is also automatic.
As soon as the cop reaches for winding the pneumatic system works two separate
system takes thread from cone and cop for splicing. The movement of the two
system work simultaneously and as soon as splicing gets completed, winding
starts.
The conveyor belt mechanism in the saucer is provided with suction scissors that
enable cross winding by joining the cop and cone thread. It is also provided with a
sensor.
The sensor first detects a full cop and then gives a signal, after which thread for
top winding is inserted.
In case of yarn breakage, the machine automatically rethreads the cone and cop
thread. For this purpose there are suction arm and the gripper arm. The two arms
take thread from the cone and cop respectively and fuse them at the splicer with
the help of a compressor.
If winding of yarn in cop is not proper, then machine ejects the cop and it is being
exited from the machine using the same mechanism which was used for feeding.
The machine has stations which store cones both before and after winding.
The roller/cylinder on which cone rolls for winding has spiral opening shape for
giving twist.
The Machine used here is Autoconer Schlafhorst 338
Machine features:
High-performance basic equipment, machine concept with extension capability.
Safe and reliable winding process through monitoring by sensors.
FX-series for highest quality during winding and in downstream processing.
Flexible, modular splicing system for all textile applications.
Resource-conserving yarn winding.
Intelligent man-to-machine-communication.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Technical features:
Materials wound: Single and plied yarns of natural and manmade staple fibres
Yarn count range: 333 tex - 5,9 tex (Nm 3 - Nm 170, Ne 2 - Ne 100); others after
winding test
Yarn package formats: 3", 4", 5", 6"; cylindrical and tapered
Package diameter: Max. 320 mm
Winding speed: Infinitely adjustable from 300 to 2.000 m/min
Winding of bobbins: Autoconer 338, Type RM, D, V
Rewinding of packages: Autoconer 338, Type E, K
Rewinding of package residues: Autoconer 338, Type RC
1.12 YARN CONDITIONING
1. Machine : LUWA
Process:
This is a moisture regaining room.
Conditioning is done for humidifying cotton in order to increase its strength,
This is so because cellulose forms hydrogen bonds with water which further enhances
its strength.
Here, the cones obtained from the winding department are exposed in a container for
around 4 hour at 58-65 deg Celsius & 1% moisture.
The huge container has a capacity of about 620 cones at a time.NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Conditioning department also has a checking section where the cones are tested for
any stains or shade variation under ultra violet rays.
2. Yarn conditioning plant:
The cones obtained from the winding department are exposed in a room for about 1 hr
in two cycles.
Cycle-1:
Temperature for hosiery yarn is 57 degrees with a pressure of 190 Mbar with a dwell
time of 10 minutes, while temperature for warp yarns is 70 degree Celsius with a
pressure of 200 Mbar for a dwell time of 3 minutes.
Cycle-2:
Temperature for hosiery yarn is 62 degrees with a pressure of 190 Mbar for a dwell time
of 35 minutes, while temperature for warp yarns is 80 degree Celsius with a pressure of
220 Mbar for a dwell time of 20 minutes.
Wax is applied to all knit yarns whereas no application of wax in the warp yarns.
Application of wax on knits increases their weight by 2.5%.
3. Normal room conditioning:
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
It is done 15 minutes prior to packing.
It is done so as to avoid any sort of condensation on the polythene.
Cones are passed through ultraviolet rays room so as to check the yarn count
uniformity.
1.13 PACKING
The packing is done here in three different ways.
They are:-
Packing in Cartoon Boxes
Packing in Bags
Packing in Pallet packing
For regional and local markets cartoon box packing and bag packing is done whereas for
international exports pallet packing is preferred. Generally the weight of boxes is about 55 kgs.
Packing is done on the basis of:
Count
Blend
Lot No.
Case No.NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Shade No.
Cone Tip
No. of Cones
Net Wt.
Gross Wt.
60% of the total production of cotton yarn is consumed by the internal industries of Ginni
Filaments Ltd. and remaining 40% is exported to other parts of the country as well as abroad.
1.14 Yarn Specifications
COUNT NE16/1C
H
NE20/1CH NE24/1CH NE30/1C
H
NE32/1CH NE40/1CH
Actual count 16 20 24 30 32 40
Count CV% 1.4 1.3 1.4 1.4 1.4 1.4
RKM 18.8 18.5 17.5 16.7 16.5 16
RKM CV% 8.0 8.0 8.0 8.0 8.0 < 8.5
Elongation 5.0 5.0 5.1 5.1 4.5 4.25
Elongation Cv% 8.0 8.0 8.0 8.0 8.0 < 8
USTER &
IMPERFECTION
Uster % 8.2 8.6 8.9 9.6 9.8 10.5
Thin Place/Km(-50%) 0 0 0 0 1 5
Thick Place/Km(+50%) 4 7 11 20 20 40
Neps/Km(+200%) 12 13 20 45 48 55
Total Imperfection 16 20 31 65 69 100
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Hairiness 8.8 8.5 8.0 7.2 7.2 6.5
CLASSIMAT
FAULT/100KM
A1B1C1D1 55 70 72 80 82 < 150
A3B3C2D2 1 0 2 2 2 < 2
EFG 0 1 0 0 0 0
H1,I1 1 1 1 1 1 10
H2,I2 0 0 0 0 0 5
1.15 Other Unique Features
BIAS
It is unique software to control inventory and issuing of cotton bales to have a
consistent day to day mixing. After receipt of approved cotton lots in the factory
premises, each bale of every consignment is tested and graded with BIAS (BALE
INVENTORY AND ANALYSYS SYSTEM), stacked in Warehouse
bales and its consumption for defined end product. Issue of Raw material is generated
with, BIAS system generating bale lay out for the Uniflock to avoid problems of barre
and inconsistency in Quality.
Contamination free yarn
Today, contamination is the single most major problem for any spinner throughout the
world. To detect unwanted contamination, we have modernised our plant with latest
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
equipment as given below :-
BARCO : To detect & eliminate Contamination in Blowroom we have installed this
system from M/s BARCO, Belgium in all Blowroom Lines.
Quantum Clearer: To detect & eliminate Contamination on Winding M/c, this is a
latest Optical based clearer QUANTUM CLEARER from M/s Zellweger Uster in
Autoconer. This has a capacity to detect visual contamination upto 5% visibility.
LOEPHE YARNMASTER 930 Plus : This yarn clearer is installed in Autoconer to
detect contamination in yarn along with other objectionable faults.
Elite Spinning
To produce a special yarn having low hairiness and higher strength, these M/cs were
installed to cater special requirement of customer, aspiring for niche market segments.
Length Measuring Device
Our Autoconers and Cheese Winding machines are equipped with electronic Length
Measuring Device so that we can guarantee fixed length material for improved warping
efficiency and lower wastage.
MESDAN Wet Splicer
Our doubled yarn is knotless one. Again thanks to the modern technology of Wet
Splicer from M/s MEASDAN, which we have installed on all our TFOs & Cheese
Winders.
XORELLA Conditioning
All yarn is XORELLA conditioned for Steam setting of twist present in the yarn resulting
in better performance in further processing.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
LUWA Air-conditioning system
A computerised Air conditioning system maintains Temperature and Humidity in the
department throughout the year
2. Knitting
LOCATION
o Kosi
CAPACITIES
o Knitting - 29 machines – 300 MT per
day
o Knits processing – 10 Tons of Processed Knitted Fabrics per day consisting of (5
tones of tubular and 5 tons of open-width)
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
PRODUCT TYPE ON OFFER
o Single Jersey, Single Jersey with Lycra , Rib, Rib with
Lycra,Interlock,Pique,Pique with Lycra,Gassed Single Jersey ,Viscose
Lycra ,Terry Fabric,Interlock Polyester Fabric,Polar Fleece Fabric, Cotton
Melange Single Jersey, Cotton Melange with Lycra
FIBRE SPECIFICATIONS
o 100% conventional cotton, organic cotton, viscose, modal, polyester, cotton
spandex, viscose spandex, and lycra
SPECIAL FINISHES
o Teflon
o Stain Resistant
o Water Repellant
o Fire Retardant
MACHINERY
o Knitting - Circular knitting machines from Mayer & Cie & Terrot
o Knits processing – ECOMASTER dyeing machines
o Finishing equipments from Santex
QUALITY CERTIFICATIONS
o OE 100: Organic Exchange certification
There are two types of Knitted FabricsNIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Single Jersey
Double Jersey
Factors affecting the structure of the knitted fabrics
Machine Diameter: the machine diameters used in Ginni are 30”, 32”, 34” and 36”
Gauge of the machine: the available gauges in Ginni are 18gg/20gg/24gg/28gg
Loop Length: a crucial factor as it determines the gram per square meter (GSM) of the fabric.
Knitting in Ginni
Before the yarn is put to any application it is checked for impurities such as dirt, vegetable
impurities (which prevents dyes from entering the fabric) , polypropylene or hair, fabric , plastic
etc. an effective solution to this employed by Ginni is the usage of premium cotton such as
Shankar 6 or Supeema Cotton (America).
After the order is confirmed by the buyer, his requirements are analyzed. Then the yarn is sent
for testing where factors such as fiber length, yarn strength etc are determined. Other specified
conditions are also catered to such as the addition of Spandex. The ratio of Spandex to the
yarn is given as per order (normally its is 5:90)
There are two knitting machines used in Ginni Filaments Ltd.
Flat Knitting Machine : Shima Seiki and Kauo Heng
Circular Knitting Machine: Mayer & Cie and Terrot
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Flat Knitting machines are used only for collars and cuffs. Rest all knitting is done on circular
machines. Spandex is attached to each thread or alternate according to the buyer’s demand.
Knitting is done yarn lot-wise so that the dye pick up doesn’t mismatch to avoid fabric defects
like barre etc.
A special software called STARFISH is used in Ginni which helps to optimize yarn processing
and select knitting machines to achieve the desired final product specifications.
Organic Knitting
Ginni caters to buyer’s eco-friendly fabric needs. Many buyers these days prefer their fabric to
be completely organic so as to cause minimum environment damage possible and also gain a
brand value. In organic fabrics no harmful chemicals are employed at any stage. In order to be
able to produce organic fabrics Ginni has acquired a license from Holland which certifies they
have all the necessary equipments and conditions that are needed for the same. The primary
conditions for a fabric to be organically approved are:-
1. No pesticides should be used on the farms for a minimum duration of five years where
the cotton is being grown.
2. The organic yarn and fabric should be kept aloof from other yarns and fabric to avoid
contamination of any kind.
3. No artificially processed chemicals should be used on the yarns/fabrics at any stage of
the manufacturing
4. It should be 100% eco-friendly
5. The machines should be effectively cleaned before using them for the organic raw
material
After Knitting is done the fabric is stacked according to counts in the godown with racks. All the
different types of fabrics are stacked in the same room. Ginni avoids electrical lights as there
would be a chance of fire otherwise.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
The organic fabric is stacked separately and its contact with the other fabrics is avoided. This
is done all in accordance with the buyer’s need. Even a slight detection of contamination would
lead to the rejection of fabric.
Fabric Inspection:
The Grey Inspection Department conducts the fabric examination using the Japanese ten-
point system. The inspection is carried out manually.
Japanese 10 Point System
This system assigns penalty points to each defect present depending upon its length. These
points per defect length vary for warp and filling yarns. In ten points system, a piece is graded
first. If the points do not exceed the total yardage of the piece, the piece is not allowed for
various widths being inspected.
Warp Defects Penalty Points
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
10-36” 10
5-10” 5
1-5” 3
Upto 1” 1
Filling Yarn Penalty Points
Full Width 10
5” to half the width of the goods 5
1-5” 3
Upto 1” 1
Knitting Defects
1. Skewing: Skewing effect is seen as a line or design running at a slight angle across the cloth
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
2. Bowing or Twisting: A line or a design may curve across the fabric. This
bowing is the distortion caused by faulty take-up mechanism on the knitting machine.
3. Needle Lines: Needle lines or vertical lines are due to a wale that is either tighter or looser than
the adjacent ones. This is caused by needle movement due to a tight fit in its slot or a defective sinker.
4. Barre: horizontal stripes in fabric; possibly due to lower tension in one of the feeders, loops formed
in the knitting cycle initiated by that particular feeder were slightly larger than the rest thus causing an
embossed appearance in the form of stripes.
5. Foreign fly between loops of constructed fabric:
Unclean environment or improper maintenance of machine can cause fly to end up in the knitting zone
where it becomes part of the fabric. Depending on the nature of the material that gets caught up fly can
be removed with ease or difficulty. It is usually a minor defect unless very frequent.
6. Thin Yarn: One of the feeder is receiving yarn from a spool that has finer yarn. This is a major
defect which will leave bands across the entire width of the fabric.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
7.Thick Yarn : One of the feeder is receiving yarn from a spool which has thicker yarn. This will also
lead to barre till the spool exhausts or is changed.
8. Laddering: Continued knitting with a broken needle.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
9. Hole Fabric Fall off: One reason for a hole of this type can be the needle latch getting stuck in flat
bed machines.
4. Research and Development
A. Dye Lab
Data Color spectrophotometer Complete color solution machine
Ahibha Nuance Lab dyeing machine
Autolab Dispensing system
Veriwide Shade matching system
1. SPECTROPHOTOMETER
PROCESS: Recipe prediction and colour matching with spectrophotometer.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
APPARATUS USED: Data Color spectrophotometer
OBJECTIVE: To check/ Pass/ Fail the dyed sample against the approved buyer
standard.
PROCEDURE:
a) Clean the work place and the machine before the start of the work.
b) Ensure that the machine must be in working condition.
c) The operator of the spectrophotometer must be skilled.
d) Power on the machine.
e) Calibrate the spectrophotometer.
f) Calibration must be done in every four hours.
g) First measure the standard, take atleast four readings and sample should be fold
enough so that light cannot pass through it.
h) Measure the batch (trial). Take atleast four readings.
i) Check and print the report for buyer’s reference.
2. LAB DYEING MACHINE
PURPOSE: For experimenting with various dye solutions to get the desired color
shades.
APPARATUS: Datacolor Ahiba Nuance Top Speed II Infrared (IR) Lab Dyeing Machine
PROCESS: Its an Easy to operate multi-step controller with alpha-numeric program
names. It has advanced microprocessor technology controls the heating and cooling
system. The dyeing parameters are constantly monitored during every step of the
dyeing process and displayed on the large graphical display. The memory cards store
an unlimited number of processes. Increased power output ensures reproducible level
dyeing. Suitable for all types of substrates
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
3. DISPENSING SYSTEM
PURPOSE: ensure that dye solutions used in the lab and on the dispenser are
prepared accurately and consistently.
APPARATUS: AUTOLAB Dispensing System
PROCESS: it provides a range of gravimetric dispensers provide the best of both
worlds: speed, accuracy and maintenance-free performance. Datacolor AUTOLAB™ TF
systems are tube-free, eliminating the possibility of sedimentation and therefore any
need to clean the system. They use dedicated individual injectors to transfer solution
from each dye bottle, removing any possibility of cross contamination.
4. SHADE MATCHING SYSTEM
PURPOSE : To ensure proper shade matching according to the specified requirements
APPARATUS: Veriwide Shade Matching System
PROCESS: In today’s complex colour requirements, a shade cannot always be
assessed under one light source. Several may be needed so that the shade is viewed in
applicable conditions. This allows inconsistencies such as metamerism to be detected.
When two coloured materials have identical spectral reflection curves, they will match
visually under any illuminant.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
B. Testing and Quality Control Section
The quality assurance laboratory has the following test methods and devices to ensure a
standard quality of fabric produced.
Gyro wash To test fastness of various methods
(AATCC,ISO.).
Accudry Tumble-drying solution.
Perspirometer Fastness to acid and alkali perspiration.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Tensile Strength Tester To determine the tensile strength and
seam slippage of the fabric
Ph meter To check ph of the fabric.
Crock meter To check rubbing fastness in dry as well
as wet condition.
Washcator Washing m/c could handle various testing
standards.
Pilling & Snugging Tester To check the abrasion and pilling on fabric
Tensile Strength Tester To determine the tensile strength and
seam slippage of the fabric
Color Matching Test The matching of the fabric colour with the
standards followed in the industry
Beesley Balance To determine the count of the fabric
Rubbing Fastness Test To determine the colour fastness of the
fabric to rubbing
GSM Balance Determine the GSM and GLM of the fabric.
Tear Strength Tester To measure the force required to continue
a tear which has already been started in
the fabric.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
1. YARN TESTING
PURPOSE: To determine the count of the yarn.
APPARATUS USED: a) Warp Reel
b) Digital Weighing Balance
PROCEDURE:
a) Take atleast five samples (yarn cone) of each batch.
b) Set the warp reel meter at zero position.
c) Make the lee in the machine for 80 revolutions. It comes total to 120 yards of yarn
(one turn is equal to 1.5 yard)
d) Take out samples and weigh them in the weighing balance individually.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
CALCULATION:
a) Count = 64.8 / Weight of the lee. Take average count of five samples.
b) Count CV = S.D/ X! * 100 where S.D = √ ∑(x-x!)^ 2 / n
c) Tex = 590.5/ Count
2. TPI & TPM
PURPOSE: To determine the TPI and TPM of yarn.
APPARATUS USED: TPI tester
PROCEDURE: Take at least 5 samples.
CALCULATIONS:
a) TPI = Take the average of 5 samples
b) TPM = TPI/ √Count
3. COLOUR FASTNESS TEST
PURPOSE: To determine the colour fastness of coloured textile to crocking.
APPARATUS USED: Standard Crocking cloth of 5*5 cm.
Take 13*5 cm of test sample as test specimen.
Crock Meter
PROCEDURE:
DRY RUB
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
a) Place the test specimen flat on the crock meter on the long direction with the help of the
clamp.
b) Fix the standard Crock cloth in the finger of the Crock meter.
c) Lower the covered finger on the test specimen and rub against the specimen for 10
turns.
d) Then unclip the crock cloth and assess the colour staining of the crock with the help
of the grey scale.
WET RUB
a) Place the test specimen flat on the crock meter on the long direction with the help of
the clamps.
b) Wet the standard crock cloth by dipping it in distilled water taken in a clean beaker.
c) Fix the standard crock cloth I the finger of the crock meter.
d) Lower the covered finger on to the test specimen and rub against the specimen for
10 turns.
e) Then unclip the crock cloth and dry it at 60^ C and assess the colour staining in the
cloth with the help of grey scale.
4. COLOR MATCHING TEST
PROCESS: Colour matching
APPARATUS USED: Light Box
PANTONE COLOR PLANNER (TCX, TC)
PROCEDURE:
There are matching cabinets where the colour matching is done. The fabric is placed under
various light conditions and then compared with the standard and graded accordingly. The
standards used here are from the PANTONE COLOR PLANNER which has TCX and TC as
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
their two standard editions which are used in GINNI. The book is priced at Forty Five thousand
rupees only.
5. TENSILE STRENGTH TESTER
PURPOSE: To determine the tensile strength and seam slippage of the fabric
APPARATUS USED: TITAN TENSILE STRENGTH TESTER
PROCEDURE:
a) Two samples of fabric are taken
b) The sample was placed between the jaws of the machine
c) The lower jaw of the machine is fixed while the upper jaw is movable
d) The fabric samples are then stretched both longitudinally and widthwise for warp and
weft testing respectively
e) A force of around 3000 N is applied by the upper jaw while stretching the fabric.
f) The point of the maximum tolerance of the fabric is noted down.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
6. BEESLEY BALANCE
PURPOSE: To determine the count of the fabric
APPARATUS USED: BEESLEY BALANCE
PROCEDURE:
a) A thread sample from the fabric is taken
b) The thread is of predetermined length
c) The thread sample is then weighed in the balance
d) The count of the thread is determined by using the following definition
e) The count of the fabric is equal to No. of 840 yards in one pound of the yarn.
7. RUBBING FASTNESS TESTER
PURPOSE: To determine the colour fastness of the fabric to rubbing
APPARATUS USED: a) Crockmeter
b) Grey Scale
PROCEDURE:
a) A sample piece of the fabric of 10x5 is taken
b) Two white fabric samples are taken , one wet and the other dry.
c) The sample fabric is fixed and the dry white sample is attached to the nip of the Crockmeter.
d) The nip is then moved to and fro with a downward force of 9 N in 10 cycles
e) Step d is repeated with a wet sample of the white fabric
f) The sample fabric is then compared with the grey scale.
g) The fading of colour is hence determined.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
8. GSM BALANCE
PURPOSE: To determine the GSM and GLM of the fabric.
APPARATUS USED: GSM BALANCE
PROCEDURE:
a) The fabric sample is taken of predetermined dimensions.
b) The fabric sample is then weighed in the GSM balance
c) The GSM and GLM are then calculated using the following formula.
FORMULA
GSM = Weight of the fabric (in grams)/ Area of the fabric
GLM = Width of the fabric x GSM/ 100
9. pH Meter
PURPOSE: To determine the colour fastness of the fabric to acidic perspiration
APPARATUS USED: PERSPIROMETER
PROCEDURE:
a) A fabric sample of known dimensions are taken
b) Another multifibre sample is taken of the same dimensions.
c) Both the fabric samples are taken and then stitched
d) The fabric samples are then soaked in water and then in ISO acid solution for 15 min.
e) It is also subjected to an alkaline solution according to the requirements.
f) The samples are then soaked in AATCC acidic solution
g) The samples are then taken finally to the Perspirometer to check the colour fading as
compared to the grey scale.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
10. SNUGGING & PILLING TESTER
PURPOSE: To check the abrasion and pilling on fabric
APPARATUS: ORBITOR pilling tester
PROCEDURE:
a) Two fabric samples of different diameters are taken.
b) One fabric sample is taken and placed on the plate of the machine.
c) The second sample is taken and fixed on the revolving plate of the tester.
d) The apparatus is then kept in position and samples are rubbed against each other
for 100 revolutions or as required.
e) The pilling card is then used to match against the original fabric.
f) The rating is done between 1-5
9) TEAR STRENGTH TESTER
PURPOSE: To measure the force required to continue a tear which has already been
started in the fabric.
APPARATUS USED: TEAR STRENGTH TESTER
PROCEDURE:
a) A rectangular sample of fabric is taken
b) A cut is made in a rectangular sample to form two "tongues"
c) The reference lines are marked to indicate the point the tear is to be continued to.
d) One tongue is then placed in the upper jaw of a tensile tester, the other tongue in the
lower jaw.
e) The two jaws opened to continue the tear to the reference line.
f) The average tear strength is then calculated
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
10. PERSPIROMETER
PURPOSE: determination of color fastness of fabric, cloth, to water, seawater and
perspiration.
APPARATUS: PARAMOUNT perspirometer
PROCEDURE: A compound specimen is used to soak in artificial perspiration resolution
(separately in acid and alkali) completely. Natural dry for 30 minutes, then use this
tester to apply a constant pressure. The specimen is then put in 37ºC drying oven for 4
hours. The specimen is removed, left to completely dry, then compared with a gray
scale to evaluate the perspiration-resistance level. (Suitable for all fiber).
11. SWATCH CUTTER
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
PURPOSE: Used to cut any kind of fabric in any shape and size instantly &
conveniently.
APPARATUS: PARAMOUNT Swatch Cutter
PROCEDURE: the swatch cutter has a bearing drive circular blade which is at right
angle rail for parallel swatch cutting. It also includes the feature of Laser alignment
cutting. Finally a Scale cutting mat for speedy measurement
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Dyeing
The cloth is issued by the grey godown department. It is then sent for singeing and desizing
and then for bleaching and scouring.
Greige Room
No. of machines - 9
Types of machines - Greige opening machine
Brand - Ranson’s
- Copiwala
This machine is used for the opening of the fabric in the greige form. The fabric is taken up
from the rolls and is opened in trolleys. Every roll has a bale slip consisting of – slot no.,
meters, gross weight, net weight, packed by, no. of pieces, sale no., MTRL, sort no. chk no. ,
sales order, purchase order and packing order in meters.
In the Greige room, each opening machine is provided with a Kosha overlock machine, used to
join the edges of the rolls of the fabric. The fabric rolls are joined to attain a length equivalent
to the required length which is usually 4000-5000 meters depending on the GSM of the fabric.
The fabric wound on the rolls is of 200-300 meters in length. The rolls are joined in order to
create batches for processing. After the processing is done they are again cut and packed into
rolls of desired lengths.
Singeing and Desizing
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
No. of machines - 5
1. Singeing Desizing machine (pad-steam) - Osthoff
2. Singeing Desizing machine (pad-steam) - Benninger
3. Singeing machine (pad-batch) - Osthoff
After being opened by the greige department, the fabric is sent for singeing and desizing. The
singeing desizing machine consists of two parts, one for singeing and the second part for
desizing. The fabric is fed to the gas singeing machine through guide rolls. The guide rolls are
provided to keep the fabric aligned in the centre. The fabric is passed through the gas burners
in such a way that both sides of the fabric come in contact with the flame. This flame burns the
protruding fibers from the fabric surface, thus giving a smooth surface to the fabric. Utmost
care is taken while singeing the fabric as it can get degraded by the flame of the gas burner. If
the fabric does not have the desired tension then there is a possibility of it getting burnt by the
flame.
The fabric, just after singeing, is passed through the trough containing desize liquor at a
temperature of 620C to 800C. The desize liquor is prepared in a tank containing enzymes (of
desired quantity as per the requirements of the buyer), wetting agent, sequestering agent,
stabilizer, hydrogen peroxide and caustic soda. All these chemicals are mixed in 1500 liters of
water and then this mixture is sent to the desize bath. Approximately 2000-3000 meters of
fabric can be desized from 1500 liters of the liquor. While desizing, the pick up of the fabric is
90%. The speed of the fabric is 110m/min. The production capacity of the machine is approx.
162,000 meters per day. After desizing, the fabric, in form of rolls, is kept for 8 hours and is
rotated continuously in order to give reaction time for the enzymes to react over the size matter
and disintegrate it; also the chemicals do not coagulate at one particular area, as it will
degrade the fabric.
Bleaching
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Bleaching is done to remove the natural grey color of the fabric so as to obtained white color
before dyeing which is very important to achieve the right color shade on the fabric on dyeing.
This process is carried out on a separate machine. This company uses Hydrogen peroxide for
the purpose of bleaching.
The main ingredients of the bleaching bath include H2O2 (8%-full bleach), wetting agent (1%),
NaOH (2-5%) and stabilizer for H2O2 (1%). The process is carried out at a temperature of 90-
100 degree Celsius for 2-3 hours.
Bleaching is of two types –
1) Half bleaching
2) Full bleaching
If the fabric is to be dyed in very dark colors, half-bleach is carried out by halving most of the
ingredients of bleaching. In the case of the fabric being dyed black, the process of bleaching is
totally avoided. Full bleaching is carried out for fabrics were pastel shades and bright shades
are intended to be achieved.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
The fabric is automatically unwounded and then reversed for uniform dyeing. The cloth is
reversed again after the dyeing procedure is completed.
Three types of fabric is dyed
1. Open width fabric
2. Tubular fabric with spandex
3. Tubular fabric without spandex
The tubular fabric with spandex is split open and then heat set as the presence of spandex
prevents the uniform penetration of dyes. Then the fabric is overlocked for the further dyeing
process.
Dyeing of tubular and open width is done using the same method as per cotton fabric dyeing
requirements.
High Temperature High Pressure (HTHP) Dyeing Machines
These machines are imported from Germany.
While atmospheric pressure dying machines are used for cotton, HTHP machines are used
specifically for polyester (but can also be used to dye cotton).
The temperature in this machine can go upto 140-160 degree Celsius along with increased
pressure.
While dyeing cotton, the time is greatly reduced with the expense being increased
.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
BATCH DYEING PROCESS:
Batch Dyeing Process is the most popular and common method used for dyeing of textile
materials. Batch dyeing is also sometimes referred to as Exhaust dyeing. This is because in
this process, the dye gets slowly transferred from a comparatively large volume dyebath to the
substrate or material that is to be dyed. The time taken is also longer. The dye is meant to
'exhaust' from dyebath to the substrate.
In batch processes, textile substrates can be easily dyed at any stage of their assembly into
the desired textile product. This includes fibre, yarn, fabric or garment. Some type of batch
dyeing machines can function at temperatures only up to 1000oC. For example cotton, rayon,
nylon, wool etc. can be dyed at 1000oC or lower temperatures.
Jet dyeing
Fabric is placed in a heated tube where jets of dye solution are forced through it at high
pressures. The fabric too moves along the tube. The solution moves faster than the cloth while
coloring it thoroughly.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
PROCEDURE FOR DYEING:
1. Fabric is sent to the color lab. A sample of 1 m from each batch is sent and a recipe is
created for the suitable dye and approved by the fabric dyeing department.
2. The ratio of quantities of the dye stuff is calculated according to the weight of the fabric
required for bulk production.
3. The dye solution (for bulk dyeing) is sent to the lab for matching.
4. Dyeing is carried out using VAT or Reactive dyeing method
PROCEDURE FOR VAT DYEING:
1. A dispersion of the vat dye is created.
2. This is padded on to the fabric and excess dye is squeezed out.
3. The fabric is then sent to the pad dry machine. It is then dried and stored.
4. Next, steaming of the fabric is done in the pad steam machine, which increases the rate
of reaction of dye uptake.
5. Reduction takes place which converts the insoluble vat into a soluble leuco compound.
6. Then oxidation takes place in the peroxide chamber which converts the leuco
compound back to its insoluble form.
7. Soaping removes the extra dye stuff, washes and cleans the fabric.
8. Finally, neutralization takes place and the fabric is rolled onto batches.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
PROCEDURE FOR REACTIVE DYEING:
1. Dyeing is done through CPB (cold pad batch).
2. Fabric is padded and taken out wet.
3. The fabric batch is then rotated for about 16 hours for the reaction to take place
between the dye and the fiber molecules.
4. Washing of the fabric is done without steaming in the soaping process.
5. Neutralization takes place and the fabric is rolled onto batches.
The machines used for dyeing are State of the art Thies high temperature high pressure soft
flow dyeing machine model ECO-MASTER. Vessel Capacity varies from 40kgs to 1080kgs.
PADDER
In the padding stage the fabric is wet by the dyeing solution. Then as the fabric is passed
through the two rolls the excess liquid is squeezed out. Then the fabric is dried using one of
several processes.
RELEX DRYER
This is employed to completely dry the tubular fabric. It also stretches out and presses out the
dyed fabric. A large volume of air, circulated with the help of specially positioned well designed
jets, with removable nozzles, enables drying of fabrics in between Teflon – Glass Conveyors in
the shortest possible time and with an effect, almost similar to Tumbling effect.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
STENTER
1. Padding of finishing chemical
2. Bow-bias correction i.e. weft straightening
3. Fabric width controlling
4. Drying
This is basically a smoothing out of the cloth. Because after bleaching, or any wet process, the
cloth will get wrinkled or creased. Stentering (done by "stenterers") removes these bumps.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
COMPACTION
Compaction is similar to calendaring in wovens. The steps involved are:
a. A roller for centering unit
b. Weft straightener device for skew(2 rollers) or bowing(2 rollers) adjustments
c. Over feed rollers
d. Gumming by Poly vinyl alcohol (PVA)
e. IR heater to dry the gum (temp. maintained at 300C.)
f. Cutter to remove the curls at the ends
g. 2 woollen felts heated through cylinders(135C.) heated by steam to provide
backside and front side compaction
h. 2 Teflon shoes to give desired pressure in percentage as per the requirement
of the fabric quality.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
INSPECTION
DEFECTS PRESENT IN THE FABRIC
Abrasion mark
Barre
Bow
Coarse end/pick
Color fly (fly waste)
Coarse end/ pick
Dead cotton (trash)
Double end/pick
End out
Fine end
Hole
Jerk-in
Loose/tight course
Needle line
Pills
Alien (foreign) fiber
Bird’s eye
Color bleeding/ staining
Broken end/pick
Color smear
Crease mark
Doctor streak
Dropper stitch
Filing bar
Fuzzy
Weavy cloth.
Harness Misdraw (reed
Misdraw )
Knot
Mispick
Mis register ( out or
register )
Open read ( reed mark )
Sanforising mark
Set mark ( stop mark)
Skew
Slub
Snag
Stain
Temple mark
Tight end/pick
Uneven dyeing
Warp streak
Wrinkle
Scalloped selvage
Shuttle mark ( trapped
shuttle )
Slack end/pick
Slug
Soiled end/filling/yarn
Thick /thin place
Thin filing/end
Tight (slack/wavy) selvage
Uneven weaving
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
ACCEPTABILITY OF ROLL
Fabric shipments exceeding the following points totals are considered to be second
quality and are not acceptable
o Warp knits – avg. 15 points per 100 linear yard
o Blends weft knit yarns - avg. 15 points per 100 linear yard
o Synthetic Woven - avg. 15 points per 100 linear yard
o Twills, cotton, linens - avg. 20 points per 100 linear yard
o Body mapping - avg. 0 points per 100 linear yard
o Flat Knit Rib - avg. 0 points per 100 linear yard
o Engineering prints - avg. 0 points per 100 linear yard
Defect calculation = Total defects/Total linear yards x 100
No individual roll is considered of first quality if the point is greater than 20per 100 linear yard.
INSPECTION EQUIPMENT REQUIREMENTS
o Flat surface/viewing area
o Variable speed drive and yardage or meter counter
o Under carriage light
o Overhead light
o Clean inspection frame free of any sharp edges that would damage fabric
o Tension free positive driven machines for knitted fabrics
Inspection speed not to exceed 20 yards per min.
Inspection Lighting
o Examination and grading is performed with overhead direct light
o Overhead direct lighting mounted parallel to the viewing surface
o Inspection frame tilted to left fabric pass at an angle of 40-60 to the horizontal
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
o Overhead CWF lighting should be provided for an illumination level of a minimum
of 100 foot candels (1075 LUX) on the surface of fabric
o Backlight only should be used on an exception basis for specific fabric types and
faults.
o In no case fabric should be rejected for faults only visible with the backlight if
The fabric is not visible in garment form as would normally be worn
The fault will not cost the fabric or garment to fail in its use
550 tonnes of monthly inspection is projected
Around 18 tonnes of fabric is daily received out of which 17 tonnes are inspected and 13
tonnes are packed.
Up to date 418.3 tonnes of fabric has been packaged in the month
The major defects that occur are rope marks and patchy.
The inspection is also performed depending on the urgencies of the orders
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
PACKAGING
Packaging is carried out in the ground floor using an automatic packaging machine from Testa.
The steps involved in the packaging are as follows:
i) Loading of the roll
ii) Scanning of the label
iii) Wrapping with plastic and cutting
iv) Sealing of the package through heated coils
v) Roll is rotated and hot air is blown so that the plastic sticks together
vi) Label sticking
vii) Dispatching
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Eight different types of fabric can be packed at a time as the unloading is spread across 4
trolleys in either side of the conveyor belt.
Process Machine
Heat Setting
Interlocking Juki M8o-665 Flatlock
Dyeing ECO MASTER
HT/HP Dyeing Machine, Capacity
1080Kgs
ECO MASTER
HT/HP Dyeing Machine, Capacity 360Kgs
Padding Hiper - Stretch
Ballon Padding Machine
Drying (Tubular) Hiper - Shrink
Relax Dryer
Drying (Open Width) StenMech STENTER
Carriers SINTEX
Compaction FAB - CON
Shoe type Compacting Machine
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Learning Experience
Interning at the Textile manufacturing giant organization like GINNI FILAMENTS for two weeks is
good platform for any internee who is pursuing a career in the field of garment and textiles. It was
really a nice and informative learning experience.
As an internee, it was really a matter of surprise to acknowledge the well managed system of the
huge infrastructure of Ginni Filaments, which is responsible for handling human resource, machine
and the material in abundance and round the clock in a year to produce world class cotton fabrics.
It was the first time we had an opportunity to get exposed to such a vast Textile Industry where
the latest technology and the latest machines are being used. We also had a nice experience to
see and understand the concepts and working of automated spinning unit . We had an
opportunity to see the Ginni Filaments laboratory where world standard testing is done.
Indeed, it was an amazing learning experience which we will be cherishing forever including the
time spent at the canteen of the Ginni Filaments which served us with delicious food and will
never forget the freezing cold days spent there making it a learning aspect overall .
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Acknowledgement
As a student of Apparel Manufacturing and Information Technology, we had learnt different stages
involved in the manufacture of a fabric and then to garments in theoretical manner. Through this
textile internship we could co-relate the things and understood the practical implications of all the
processes involved in a textile industry.
This two weeks internship though was not our first visit to any textile industry but was very useful since
information of every process involved starting from cotton in bales form to the finished fabric in dyed
form were gathered in practical manner which has helped us to understand the processes more
clearly .
It was a great experience working as a group and interacting with different people and getting the
useful information on various departments and their functions & systems.
We are thankful to Mr.S.N.Sharma (General Manager[P&A]) , Mr. Aswani Kamra (AGM
Production) ,Mr. A.Ramakrishnan (DGM) , Mr. Sorabh Kohli , Mr. Anil Sharma , Mr. Tapan Biswal , Mr.
Arvind Singh , Mr. Pankaj Dalal , Mr. Puneet Arora and Mr. Nitin Saraswat (Welfare Officer) who guided
us every second towards the work and gave their support and knowledge from the grass root level of
the industry .
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
Bibliography
1. Textiles-Fiber to fabric
By- Bernard P.Corbman
2. Textiles Terms and Definitions
Compiled by: The Textile Institute Textile Terms and
Definitions Committee
3. Handbook of Textiles
By-P.V.Vidyasagar
4. Textile Warp Sizing
By-Dr.Paul V Seydal
5. Fabric Science
By- Arthur Price, Allen C Cohen, Ingrid Johnson
6. Encyclopedia of Textiles
By-P V Vidyasagar
7. Textile Weaving and Design
By- W S Murphy
8. Technology of Dyeing
By Dr. V.A.Shenai
9. Mechanism of Spinning Machines
By-R.S.RengasamyNIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar
Textile Internship - Ginni Filaments Pvt. Ltd.
II. Internet:
1. www.ginnifilaments.com
NIFT Bangalore / DFT 2008-12 /Abhishek , Nishant Kumar