MILL REPORT

Submitted By :

NAME AHMER ADNAN BALOCHDANISH HUSNAINZAIN UL WAHAB

Preface

In line with recent trends toward high-quality production and

diversification in the textile processing, much efforts is being exerted to

improve the performance of mixed fabrics of natural and synthetic fibres

and to introduce the new product with new values.

The report includes information presents a detailed description of

the standard latest working procedure in wet processing on

Polyester/Cellulosic blends, CVC, PC and Knitted fabrics.

As continuous wet processing for polyester/cellulosic blends,

CVC,PC and Knitted fabrics involves a large variety of fibre substrates,

processing methods for pretreatment and dyeing and finishing.

We proudly present our report which is based on wet processing. For this report we are extremely thankful to the talented people that worked and helped us in sorting out our circulated questionnaires and confusion

throughout the internship especially we would like to thanks Mr. Shoaib.A.Rehman the G.M of Wet processing department, Dipt.M Ghazal Abdi and many other skillful personalities and worker whose co-operating was very beneficial & studious for us.

We are also very thankful to,

Pretreatment.M Azhar Ali Raza.

Dyeing.M Ali Mehdi.

Finishing.M Abdul Mateen.

Printing.M Shakeel Hanif.

Special thanks to respected Mr.Muhammad Arif and

Mr.Mansoor Technical.Dep guided us each and every step during our

internship program.

Lucky Textile Mills

Lucky Textile Mills is a high profile set-up in the textile export industry of Pakistan. The company has 3 weaving mills consisting of 750 Sulzer Shuttle-less looms and 1 unit for wet processing .Latest modern technology continuous machines for dyeing and finishing processes.

lucky textiles mills started their operation in early 80s and by the grace of almighty Allah today the lucky textile mills has earned untarnishable image through the team of highly qualified, self motivated, sincere and professional people who take their customers as assets of the company. Lucky textile mills are ISO 9002 and iqnet certified.

Company Profile Company Name: lucky textile 4Country: PakistanAddress: L-8 , Block-21, Federal 'B'   Karachi

 

Products:

Lucky Textile Mills has its own products include:

Bed linen, Curtains, Bath Shower Curtains, Kitchen Curtains, Table Covers, Men's Uniform, Work Wear Shirts,  Five Pocket Pants, Six Pocket Cargo Pants, Blended Fabric, Cotton Fabric, Dyed Fabric, Grey Fabric, Printed Fabric, Bleach Fabric, Mercerized fabric, Finished fabric.

FLOW CHART FOR WET PROCESSING

Grey Fabric Inspection↓

Sewing or Stitching↓

Singeing↓

Desizing↓

Scouring↓

Bleaching↓

Mercerizing↓

Dyeing↓

Printing↓

Finishing↓

Final Inspection↓

Delivery

Planning:Planning is the most important step of every stage of the process

each and every person involve in the process must know flow of the material process and parameters .

Job Cards:Basically there are three types of Job cards.

1. Master card.2. Travel card.3. Colored card.

Master card:Master card is directly given to the department on which Job cards

are stapled.

Travel card:Travel card travel with the fabric on each and every stage of the

process from starting till finish it guide the operator that what si the process flow of the material.

Colored cards:There are 4 different colored cards used for the following

processes,

White Bleaching. Green Dyeing. Yellow Sample. Pink Printing.

GREIG DEPARTMENT

This is the first department of the wet processing industry. In Greig department inspection of fabric is done with the help of 100% inspection the fabric fault are counted and grading of fabric is done.

GREY DEPARTMENT DEALS:

To inspect, mend & grade the fabric. Making lots. To keep the record of store fabric. The rejected fabric is sent back to the respected Mill. Make bath and transfer it to the next department.

I-Inspection / Grading: -

The main purpose of the inspection is to check the Greige fabric for identify the faults.

Weaving Faults: -

Double Ends, Loose Ends, Broken Ends, Wrong Dent/Draw, Loose

Selvedge, Double Pick, Miss Pick, Design Cut, Knots, Hanging Threads,

Float,

Mechanical Faults: -

Starting Marks, Rapping Marks, Mending Marks, Hole /Cuts, Oil Stain

Yarn Faults: - Cockled Yarn, Weft Slub, Slubby Weft, CEP, Count Variation,

Hair, Jute, P Proplyene, Black Ends.

Others: - Oily Weft, Sizing Stain, Hard Size.

Minor Faults: -

The faults can be removed easily in further processing such as in Scouring, Bleaching and Mercerizing etc.

Major Faults: -Those faults that can not be removed in further processing are

major faults such as starting mark, rapping mark, whole etc.

Tacoma(Spain) Batch Making:Tacoma is brushing and batch making machine in greig

department. Batcher machine is used to made batch of the fabric.

Components of the machine:

1. Conveyor belt.2. Scray.3. Expanding rollers and guide rollers.4. Winder.5. Brush.

The fabric is placed on conveyor belt the pile is threaded through the tension rods and the guide rolls the fabric is than enter the scray than the fabric is passed through the expanding roll which expands the fabric to run in smooth through the machine. After it the fabric entered into the brushing section to brush the contaminants and fluff and fly because they may create problems in next process especially in dyeing and printing. The fabric is than rolled on a frame to make our required batch.

There are two Tacoma machines installed in Lucky textile 4.

Textile testing lab:Lucky textile mills is a large company in Karachi ciyt our 1000 of

sulzer looms running in this mills. There are four branch of lucky textile mills.1,2 3 and 4 units. Lucky textile 4 testing laboratory Is ISO 17025 accredited.the processing laboratory has latest testing equipments for testing fabric, yarn and also shade matching.the lab is divided into 4 portions.

Lab dip.

RND.

Physical.

Online Q.C.

Lab Dip:A lab dip is a swatch of fabric test dyed to hit a color standard.

Several lab dips may be submitted for feedback until the standard is achieved and the lab dip is approved. There is also now a machine used to read lab dips called a "spectrometer” which will give the same feedback. As not everyone sees color as well as the next (and you can be tested to see how well you see color) a machine can take out human error.

RND and Colour Matching:The main functions of RND department is to check all the running

chemicals used in the industry and also to find our troubleshooting and investigate the problem and solve it.They also check new chemicals available in market which pulfills the running chemical and it is cheaper than the running one.Importand tests conducted by RND portion,

Whitness.

CMC.

Formaldehyde test.

Water testing.

Raw material check.

Barium activity test.

Core pH.

Troubleshooting.

New product accesment.

Degree of desize.

Absorbency test.

Spectrophoto meter:

Spectrophotometry involves the use of a spectrophotometer. A spectrophotometer is a photometer (a device for measuring light intensity) that can measure intensity as a function of the color, or more specifically, the wavelength of light.We can take each and any type of test including shade matching, CIE whitness test, Burger whitness test and also this instrument give us the composition of shade.

Data Color D650 Dual Beam Spectrophoto meter.

Physical Testing:All the fhysical tests on a textile sample or material is conducted in

physical portion of the lab.the test conducted by the physical portion are,

Tensile strength.

Tear strength.

Seam.

Abration

Air permeability.

Pilling.

Appearance.

Rubbing fastness.

Washing fastness.

Colour fastness.

Water fastness.

Perspiration fastness.

Dry cleaning fastness.

Light fastness.skew and boa.

Physical testing machines:

Random Tumble Pilling TesterL:Random Tumble Pilling Tester RPT is using UPC controller, to

determine the pilling and fuzzing characteristics of textile fabrics. Stainless steel impellers rotate within  individually testing chambers constantly  tumbling test fabrics against cork liners. Compressed  air is also injected into the chamber to assist the tumbling action.

 Standards: ASTM D3512 , DIN 53867

Abrasion tester Martindle:

Used for testing abrasion resistance of wool or blend of wool's woven, knitted and non

woven fabric in specified pressure, also used for testing balling in light pressure for most fabrics,

especially for wool woven fabric. Controlled by microcomputer, displayed by LCD, printing

reports, simultaneity show accumulative used times of every standard abrasive and working state

of each test head.

Standards: GB/T4802.2,  FZ/T20020,  ISO5470,  IWS TM112/196, DIN53863/53865,

BS3424/5690, BS EN388/530, JIS L1096, ASTM D4966/4970, SN198.525.198.529, SFS4328

Orbiter Pilling:Orbiter Pilling and Snagging Tester can be used to test both woven

and knitted materials. Determination of fabric propensity to surface fuzzing and to pilling-

Standards:EN ISO 129-1

Whirlpool:Whirlpool Washing Machine is recommended by AATCC for AATCC test methods requiring repeated home laundering.

Standard:AATCC 135

Gyrowash:

This tester is an instrument for fabric, cotton, wool, linen, silk chemical fiber, knitting and woven fabric etc to test the fastness to washing, to milling and to dry clean. Also it can be applied to exam the fastness of the colorant. So it is necessary apparatus for textile quality monitor department.

Applicable standard:    ISO105-C05: 1989,GB/T3921.5, BS, JIS, DIN NF, AATCC, CIN/CGSB, AS, GB5711

Whirlpool Tumble Dryer Model : 

Front-loading dryer, recommended AATCC test methods requiring for repeated home drying

 STANDARDS: AATCC88B/C , AATCC124, AATCC130, AATCC135 AATCC159/172 , AATCC142/150 

Perspiration Fastness:Perspiration Kit is consisted of two parts, color-fastness-to-

perspiration device and dryer. This kit is used to determine color fastness to water and perspiration of textiles.

Standards: AATCC 15, 106, 107, 165 , ISO 105E01

Tensile strength tester:The tensile strength test is a modified grab test for determining the

breaking strength and elongation/stretch of fabrics.

Srandards:

ISO 5034,1393

ASTM 5035

Elmatear Digital Tear Tester:Digital Tear Tester Elmatear: simplifies and accelerates routine

tear testing. Simply select the unit of measurement and the number of plies and you are ready to test. The test results are displayed digitally. No calculations are required.

Air Permeability Tester:Air Permeability Tester for textiles consists of an arrangement for

holding the test specimens between two flat faces so as to expose a known area to the flow of air through it, a vacuum system to draw air through the exposed area of the test specimens.

Wascator:

Wascator is suitable for checking dimensional stability during washing and for checking the effect of washing detergent and the chemical products on textile.

Standard:ISO 5077/6330

GSM Cutter:This instrument is a circular fabric sample cutter with which a

uniform circular fabric is cut without measuring. The specimen which is cut with the help of the Fabric GSM Cutter is 100 cm2 areas. This instrument is complete with a piece of cutting board and 12 spare blades.

Light box:

light box is used to check the fabric in following conditions;

day-light

incandescent

back-light

U-V light

     

Singe Desize Machine (Binninger Osthoff):

In lucky textile 4 processing there are two singe desize machines installed. The production of the machine is 1.5 lacks. Osthoff has a advantage than the finer fabric can run in double which increase in production we can say that we can double our production.

Singeing is the removal of protruding fiber from the surface of the fabric in order to improve their surface appearance and sharp surface for printing and dyeing. If not done, this will disturb the appearance of dyed and printed fabric.

Parameters for singeing:

• Singeing position

• Flame intensity

• Fabric speed

• Distance between fabric and burner

Machine Components: Guide rollers Pre dryng Pre rushing Singeing chamber(4 burners). Cooling drums Post brushing Desizing unit Winder.

2

3

1. Tension rod: The purpose of tension rods is to give tension to the fabric and to stay away from crease formation.

2. Guide Roll :

Fabric is passed above the guide rollers for feeding the fabric in to the brush rollers.

3. Pre and Post Brush Rollers:

Before singeing the fabrics is brushed to losen and protruding fibers and moved rapidly normally about 110m/min a suction system is installed to suck the fluff and ashe.

4. Singeing box :

After brush roller the fabric is moved over projectile of gas burner to burn protruding fibres.4 burners are installed on this machine. The flame is composed of 70% of air and 30% of gas. To avoid fabric yellowish shade that’s why we use blue flame.

5. Chemical Bath :

later than the achievement of singeing the fabric immediately feed in to the chemical tank to remove the size of fabric.The desizer is used in Lucky Textile 4 is (Ecozyme HB 400).the temperature of chemical tank is 60 °C.

Desizer EcozymeWetting agent Recogen WBLSequestering agnt Secron 530

6. Winder :The winder roll the fabric over the batcher and than it is left for 4

to 6 hours.

7. Cooling Drums :In singeing section the fabric passed over the cooling drums to

down the temperature of the fabric after burners. The water circulates inside the drums.

8. Donier rolls :The donier rolls move in to and fro motion evenly distribute the

fabric.The time,temperature and pH must be maintained because the enzyme will be active when the conditions are provided.

SCOURING & BLEACHING

SCOURING;

The process of scouring is to make material highly and uniformly absorbent. (i-e the removal of natural impurities like wax, fats, oils). When oils and fats are heated with a solution of sodium or potassium hydroxide, they hydrolyzed into glycerol and the alkali salts of fatty acid, these salts of fatty acid are soaps therefore his particular hydrolysis is referred to as saponification,

BLEACHING; Scouring removes almost all the impurities except natural coloring

matters which are ultimately broken down with bleaching agents. Bleaching is necessary for producing white goods either as finished products or for dyeing pastel shades.

In Lucky textile 4continuous Binninger machine is used for scour and bleach.the average production of the machine is 1.5 lacks and another positive feature of the machine is that the finner fabric can run in double.

Binninger Continuous Scour Bleach:

CONTINUOS SCOURING &BLEACHING is carried out for following purpose,

· For a High Degree of Whiteness· Complete Degrading of Seeds & Removal of All Impurities· Outstanding &Even Absorbency· Low Fiber Damage· Improved Hand of the Fabric· Reproducibility of Finishing Result· High Efficiency· Short Amortization Time

In the application of Benninger technology the complete pretreatment with a steamer stage always consists of the following series of processes:

■ INJECTA for desizing

■ EXTRACTA for washing

■ IMPACTA for impregnating

■ REACTA a combination steamer with tight strand fabric guidance and roller bed plaiting

■ FORTRACTA for pre-washing

■ EXTRACTA/TRIKOFLEX for washing

INJECTA (Desizing):The fabric is treated with steam and water in a narrow casings.

Here, there is high turbulence and temperatures of over 100°C. The INJECTA needs only a fraction of the space needed by conventional desizing machines.

IMPECTA ( Impregnating):

In the IMPACTA the fabric is impregnated with chemicals for subsequent trouble free steaming process. The clever design ensures that a high liquor exchange is achieved. The chemicals are distributed immediately at the right place in the fabric.

The cloth web is guided through two narrow casings and causes the impregnation liquor to circulate in the fabric running direction. The liquor enters the unit in the middle of the cloth web and is drawn off at the side. This creates a horizontal circulation. In the narrow casings the fabric run causes an additional current in the fabric running direction. Hence an additional vertical circulation through both casings results.

CHEMICALS:Hydrogen peroxide, WBL, Caustic, Stablizer OKR.

REACTA (Steamer):In the REACTA steamer the chemicals react with the fibres

themselves and the accompanying substances. The combination steamer with tight strand cloth run and plaiting on a roller bed permits reaction times of 1 to 60 minutes. An automatic steam conditioning and regulating. station guarantees constant conditions and an air free atmosphere.

FORTRACTA( Pre-washing):

In the FORTRACTA impurities sticking to the fabric surface are removed. Fast reduction of chemical and dirt concentration is also taking place.first twi chembers contains hot water and third one is a cold one.

Universal washing compartment TRIKOFLEX is used for elastic and bi-elastic woven fabrics

■ Optimum shrinkage results due to low tension fabric transport, short distances and large support surfaces

■ Up to 40% higher washing effect is achieved by dual liquor circulation in separate chambers

■ Double sided washing of dense fabrics

■ Variable drive techniques

■ Externally adjustable spray lines

EXTRACTA ( Washing):

In the EXTRACTA the accompanying sub stances, which have been made soluble by steaming, are washed out. The high washing effect of this machine is achieved through exact liquor segregation and counter-flow guidance. It has been designed for especially low power and water consumption. The TRIKOFLEX drum washing machine is utilized when fabrics exhibit high shrinkage potential.all the chembers containing hot water except the last one which contains cold water with formic acid for the neutralization of the fabric.

MERCERIZING

OBJECTIVES

To increase luster.

To increase the affinity for dyes.

To increase the tensile strength.

To give dimensional stability

Use of dye after mercerizing is less

Width control

After mercerizing increase cost of fabric Rs 2.70 per meter.

In this process cotton is dipped in a solution of NaOH so that NaOH penetrated in to the fibre and then NaOH is washed out completely by neutralizing by dilute acid like sulphuric acid. When mercerizing fibre are examined under microscope. It is seen that each fibres in twisted ribbon like form. After mercerizing fibres become cylindrical and free from twists.

To increase the luster cotton must be prevented from shrinkage.

This can be achieved by stretching the yarn or fabric. Shrinkage of the

fabric can also controlled by mercerization.

In Lucky Textile 4 Monforts 3.20 mtr wide capacity 30,000 mtrs/day with E Control for mercerizing 100% cotton & blends.

Componets of machine:

Gauide rollers

J-box scray

Be control valve

Reaction zone.

Stablizing zone.

Brine Pump

Brine control valve

Recovery pumps

Filter 2

Chain Wheel

Selvedge Guider

Shower Pumps 30

Suction Pumps 20

Washers

Dryers

Heat Exchange

Guide rollers:-

Fabric passes all these rollers so that fabric contains no crease.Fabric passes through 4 selved rollers so that stretch the fabric in order to remove selvedge crease.

J-Scray:-

It is also very important part of Enterence. It is used when there is

need to change batch of fabric. When fabric of J- Scray runs the tension

of cloth guider is increase because there is more chance of crease.

BE CONTROL VALVE: -

How much quantity of Be is required? It is taken in a TIP from

mixers by operating Be control valve. It is being operated from panel.

BRINE PUMP: -

The function of brine pump is circulation of water. Brine pump supply water to the heat exchanger.

BRINE CONTROL VALVE: -

Brine control valve control the quantity of water. The working of

Brine control valve is automatically. It is being operated from panel.

FILTER: - Filter, filter the dirty water. It drains the fluff and again supplies

water to the washers. There are two filters on the machine to filter caustic.

HEAT exchanger:-

The function of Heat Exchanger, exchange the heat of the NaOH.

Working Of Machine:-

Impregnation/reaction zone:

The fabric is repeatedly impregnated with caustic soda by additional spray pipes in the roll passages. Squeezing is effected by the weight of the rolls and the cloth tension.In strong lye Be of caustic is 29 and temperature is 60 c.5 tanks 2 for strong lie and 3 for squeezing.

Stabilization zone

lye extraction process is initiated by intensive spraying with weak lye. The caustic Be in weak lye 7.3 and temperature 95 c.

Washing and neutralizingAt the end of the stabilizing operation the caustic soda

concentration has been so far reduced . Any residual alkali is now washed out in the washing machine. The amount of washing water is economical and objectively controlled by measuring the weak lye concentration. Exact neutralization of the fabric is ensured through automatic pH control.The temperature of the washing range is 95 c.

Bleaching Chamber:-

The machine is equiped with a bleaching section in between washing range where some times bleaching can be done as needed.

HEAT EXCHANGER: -

The function of Heat Exchanger, exchange the heat of the NaOH.

DRYERS: -

The function of dryer is dry the fabric.

Important factors:-

The ribbon like structure after mercerizing change in to round shape.

We use NaOH because it is cheaper than KOH. Temperature must be controlled. The fabric must be neutralized and not let in alkaline condition

otherwise the fabric may be degraded.

PAD THERMOSOL: Benninger

Pad thermosol is a high temperature dyeing.on pad thermosol we ca get dark shades we are not fixing the dyes on pad steam we can dye vat, disperse and disperse dyes.

PROCESS SEQUENCE IN PAD STEAM

Batcher

↓

Screy

↓

Cooling Drum

↓

Padding

↓

I.R (predrying)

↓

Chamber (drying and curing chambers)

↓

Cooling Drum

↓

Screy

↓

Batcher

CONFIGURATION OF MACHINE

Speed of the machine is 80 RPM.

There are 10 burners each chamber contain 2 burners.

There are 2 circulation fans.

Kuster padders use for padding.

The pressure of the padders are 1.5-2 bar.

There is an unwinder and 1 winder.

The chemical use for process are migrating agent,anti foaming agent,wetting agent.

Teflon on rollers use for unsticking of dyes and pad rollers help in sticking the chemicals.

Screy can contain 600-700 meter fabric.

In I.R 30% of moisture can remove

In I.R chambers there are some bricks in which air and natural gas burnt.

In this machine there are 5 chambers,3 chambers for drying and 2 chambers for curing.

Temperature of the chambers depends on the quality of the fabric.

We use dry air in chambers through burning of oil and gas.

Efficiency rate of this machine is 4800meters in 1 hour.

For reactive and vat dyes temperature is low inside the chamber and for disperse dyes we use high temperature inside the chambers for drying and curing.

In thermosol the temperature of polyester is higher then cotton fabrics.

The highest temperature for polyester is 210ºC and if we increase further then polyester burns.

Fastness properties depend upon the depth.

Thermosol use for pad dry cure, wet on wet and pad dry process.

Working of Machines:

The fabric is unwound and then pass through brushing section here the fluff is brushed and fabric is collected and stored in scra.fabric passes over cooling drums to cool down the temperature of fabric because when we are dyeing PC fabric then after RC fabric is hot enough.the fabric is then passed through Kuster padders,two types of pressure used in Kuster padders hydraulic and neumatic.the central pressure is hydraulic and sides pressure is neumatic.we can adjust the pressure of the padders .

Then there is given I.R system the temperature of I.R is about 60-50 c.there are two I.R installed the temperature of first I.R kept 850 c and second 800c.the function of I.R is to remove 30-35% moisture.the fabric is then passed through the thermos, 5 chambers are provided,

1-2 Drying.

3 Drying.

4-5 Fixation.

The fabric is then passed through cooling drums and finally fabric is collected on a batcher.

PAD STEAM DYEING MACHINE (Benninger)

Pad steam is used for dyeing light shades and the fastness propertiws of the pad steam is better than pad thermosol.on pad steam fixation of dyes also done.the max temperature of the machine is 100 cand speed 80 m/min.we can done RC,VAT develop,wet on wet and chemical pad. In pad steam there are three types of flows

1-Counter flow

2-Static flow

3-Over flow

In pad steam there are two I.R for high production. We can plant one I.R for normal production.In pad steam we use urea and steam for increasing the moisture but we use steam in the replacement of urea because is less costly then urea also the urea damage the environment. In pad steam there is an E control or economical control. E control provide good results but initially produce some variations.

CONFIGURATION OF MACHINE:

There is an inlet for the batcher.

After inlet we have screy.

After screy we have padders,kuster padders are use for padding which prevent the listing problem.

There is a steamer for curing, the temperature of base and the roof of the steamer is change to prevent the dropping effect.

After steamer the fabric enters into the washing range for removing the unfix dyes.

There are 10 chambers in washing range the first two chamber contain cold water while the 5 chambers are of hot water, after hot water chambers we have a neutralizing chamber in which we neutralize the fabric the pH in this chamber is 5 means acidic in nature and after the neutralizing chamber we have further 2 cold water chamber after the washing range we have a drying rollers on which the fabric gets dry , the temperature of the dryers 210ºC.After dryers we have screy and then winder and fabric is collected on batcher.

Termo Chem and Termo Print:

Termo Chem

In lucky Textile 4 Processing TERMO CHEM and TERMO DEPO Termoelettronica system is installed , for dosage and storage for chemical products. Used for prepare the bath for bleaching and washing lines .Termo CHEM has Automatic dosage system for auxiliary products and liquid chemicals . Big tank with agitator , including pump for transport the bath. - Perfect conditions . 1 Termo DEPO : System for control the quantity of each product.

Termo chem. Dept in Lucky textile 4 has another responsibility of storing chemicals used during process all type of chemicals are provided from termochem the chemicals can be transferd to the machine through pipes for bulk production otherwise the chemicals are given to the machine operators manually and they prepared the bath them selves.

Termo Print:

In lucky Textile 4 Processing TERMO PRINT system is installed both for sample making and as well as for bulk recipe paste, for sample matching 5-6 kg past is prepared and for bulk we can prepare 30-100 kg paste. Reactive dyes are used and pigments used for printing.

Advantages of Termo Print:1. Accuracy.2. Time saving.3. Automatic.

Components of the Machine: Head 1 Head 2 Mixer Filter Printer.

Head 1:Head 1 contain chemical tanks.

Head 2:Head 2 contains pigments or dyes.

Mixer:Mixer is used to mix the paste, two stirrers are present each work

at a time. If one is operational other one is washed before running.

Filter:To filter the past otherwise some contaminant will may combined

with the past and printed on to the fabric.

Printer:The recipe is printed on a paper than pasted on the past box.

Process flow:

Head 1 → Head 2 → Mixer → Filter

High stirrer:

High stirrer is used when the paste is prepared in bulk and also for urgent mixing of the paste.

Print Paste:

A print past mainly contains,

Liquor Ammonia. Binder. Urea. Thickner. Fixing Agent. Softning Agent.

Types of Pastes:

Paste is prepared a/c to the requirement of the process and the customer.

a. If we say 5% paste it means it contain 5% binder.b. If we say 50% past it means it contains 50% binder.

CAD CAM DEPARTMENT:-

The design given by the customer may be on a paper or directly they given a sample fabric to the cad cam department they scan the design in the computer.

Softwares used: RAM Set Photoshop Bitmap

After the aproval of the design by the customer design is sent to the engraving department.

Engraving department:

Screen making and striping,

First we make a screen with stainless steel sheet of about 320 cm max or through stripping pattern are removed by washing screen using water and chemicals on Aqua jet ,

Phenyl

Formic Acid

Formic Acid

Methylene

The number of mashes or a screen varies as 60, 80, 100, 125, 155, 180 per linear inch.

The diameter of screen is 640, 720, 820, 914, 1018mm Max screens length = 3500or 350 cm

The screens they are using made of Stainless steel.

Print Screen Sizees:

1280 mm 58 inches 148cm

1620mm 71inches 180 cm

1850mm 77inches 198cm

2650mm 101inches 260cm

2800mm 115inches 295cm

3200mm 131inches 333cm

Screen Coating:

Screen is coated with coated material SCR 64. Screen is coated upside down for 15-30 min at high temp over 180-200c and left for dry about 10-30 min.

Screen exposing:

Exposing section is connected to cad-cam section. Lucky textile 4 has two exposing machines.

1. Ink Jet CST.2. DLE exposing.

The exposing machine is called CST ink Jet and it works on almost the same way as an ink jet printer. The header is loaded with color pasted and it prints the pattern in the required paste.In DLE engraving The coated screen is directly exposed with UV light, without masking by wax, ink or film. No consumables are needed.

Screen Developing:

The screen is developed which means only that parts where patterns are printed on screen are removed from coating while other remains same.

Oven Heat (polymerization):The screen is again oven heated.

Hindering:

The screen is thoroughly washed normally to make sure the patterned area is open

i.e. Mashes are not closed by coating or another dust.

Dried and Heated:

Finally the screen is heated and dried and sent to the rotary machine

Sample Table: (Zimmer)

On the sample table the print paste is prepared a/c to the sample colors. The recipie of the print paste includes,

Water, Urea, L.Ammonia, thickner etc.

The machine works on magnetic systems.GTE and TE are the adisives to stick the fabric maximum 27 meter fabric can be print on the machine.the sample is taked about 2-7 meter.speed of the convayor belt is about 5-18 m/min.the colour is dosed iinto the screen and different dia rods are used for different shades for darker we use a heavy rod instead od a lighter one. Washing area at the end of the blanket for the washing of the convayor belt.

Rotary (Zimmer) Austria:

In Lucky textile Rotary Zimmer is used for Printing.Rotary Zimmer is a latest machine for printing with 3.20 mtr wide with 16 colors with all repeats open bearing.the production of the machine is 1-1.5 lacks m.the speed of the machine is 3-100 m/min .mainly three types of colours are used.

1. Disperse 2. Reactive3. Pigments

Process flow:Entry → Printing → Dryer→ Exit

Components of machine: Entry Suction Flat rollers Trolley Printing zone Sensor Conveyor belt washing Dryer

The fabric is passes through guide screen rollers to the suction area here the sucker sucks the fabric fluff and dust particles.flats are provided when we use knit fabric.the fabric enter into the trolley where PVA is aapplied to stick he fabric with the blanket belt.the machine is provided with an I.R system and cambered plate to give temperature to the thermoplastic glue.then the fabric enters into the printing zone.the fabric is sandwiched b/w the rollers and the blanket,magnetic system of printing is used.

Colour is dozed into the sqeegee through pumps automatically.the first screen roller is to press the fabric and the secong gathers the remaining fluff.the printing starts from the third screen.each screen prints a single colour.the number of the screen depends on the type of design.the sensor is used to control the speed of the blanket.the fabric than entered into compact HC dryer 160-180 c.the dryer has 5 burners.the dryer has three passages air is blown into the chambers 2 time.finally the fabric is collected by a crank gear mechanism to a trolley.

Note: We mostly use Pigments because pigments are not too much costly and the process is also easy.

Cominox squeegee Washing machine:

COMINOX develops and manufactures machines and systems out of stainless steel for washing and drying of screens, color tubes and squeegees from rotary- and flat-print, color pails, buckets and batching

tanks. The squeegee is entered into the machine for about 75 seconds and 6-8 bar of water sprayed than air sprayed.

Screen washing Machine:

In screen washing machine the screen is washed the machine consistes of brushes and water spray nozzels to wash the screen.

AGER ZIMMER (ARIOLI):

The main purpose of steam ager is fixation of the print. Three processes can be done on the ager.300 meter fabric can run at a time.the machine consists of 4 circulating fans and 2 exhaust speed of machine is 80 m/min.

Pigments fixing Hot air from oil boiler. Reactive Dyes fixing. Steam (saturated) Disperse dyes fixing. High temperature from oil boiler.

Time and temperature can be set a/c to the process,

Disperse 8-10 min 170-180c. Reactive 10-12min 102c. Pigments 6min 110-165c.

PROCESS

Entry

↓

Curing

↓

Exit

The fabric entered into the curing chambers for about 80 min in loop form for the fixation. Suction system is provided the rollers present in the machine for loop formation moves with the help of chains.

Stenter machines (Monforts Montex):

The purpose of the stenter machine is to bringing the length and width to pre determine dimensions and also for heat setting and it is used for applying finishing chemicals and also shade variation is adjusted.

Components of Machine:

Paders Weft straightner (Mahlo) Burners 10 Heat recovery Attraction rollers Circulating fans 10,8 Exhaust fans 2 Winder 2 Clips Pins I.R Cooling drums 2

The fabric is collected from the batcher to the scray and then it is passed through the padders where the finishes are applied and some times shade variation is corrected.The fabric is entered into the mahlo (weft straigtner) the function of the mahlo is to set the bow and also weave of the fabric is griped by the clips and pins are also provided but the pins

has a disadvantage that they pins make holes at the selvedge but the stretchning of the pins are greater than the clips.these clips and pins are joined to endless chain.there are 8 to 10 chambers provided on the machine each chamber contains a burner and filters are provided to separate dust from air.the circulating fans blow air from the base to the upper side and exhaust fans sucks all the hot air within the chambers.Attraction rollers ar provided to stretch the warp yarn.

After stentering we can increase the width of the fabric up to 1.5-2 inch.The speed of the machine is about 7-150 m/min.3 meters fabric can run in each chamber.temperature is adjusted that a/c to the fabric as for,

PC 210 c Cotton 110-130 c

After dyeing 160-170c and after print 130-140c.

Differentiate b/w 10 F,8 F and knit stenter:

Stenter 10 F:

The word 10 F stands for 10 flames.in stenter 10 F clips are used to stretch the fabric and this is a disadvantage that holes appears on the selvedge of the fabric and also uneven dyeing is achieved.

Stenter 8 F:

Stenter 8 F has 8 flames and the main purpose of 8F stenter same as 10F stenter. The basic advantage of the machine is dyeing can also done on 8F machine and has I.R system. Finishing, dyeing can also done even we can dye pigment , heat setting and also we can control skew and bow problems and another advantage is using light shades no clip marks appears.

Knit Stenter:

The basic difference of the knit stenter machine is that it is used for knit fabric weft straightning,heat setting,dyeing, light shades and also for print and knit fiishing chemicals applicaions.Pins are also provided with the clips.flat rollers are present and a brush to hold the pin,the L-guide is also used for knit fabric and a selvedge cutter with suction privided.

Calendering Machine (Kuster):

Calendaring is an operation carried out on a fabric to improve its aesthetics. Purpose of calendaring is:

To upgrade the fabric hand and to impart a smooth silky touch to the fabric.

To improve the opacity of the fabric

To compress the fabric and reduce its thickness.

To impart different degree of luster to the fabric.

To reduce yarn slippage.

The mechanical finish is done for softness and shining of the fabric or stiffness according to the nature of the chemical, this process is done after the chemical finishing as per buyer requirement.Speed of the machine is 10-100 m/min.

Componets of machine:

Winder Metal detector Seam detectol Rollers (cotton,reclon and steel) Anti static rod Oscillating roll Batcher sensor cooling drum

Seam detector:

Function of seam detector is to byepass the seam.

Metal detector:

Metal detector to detect metal particals.

Anti static rod:

Anti static rod is used to remove static charges.

Small winder:

When we have to calender short width fabric and we can also run short width fabric with long width fabric.

Oscillating roll:

To avoid selvedge overlaping on batcher.

Cotton roll:

For soft finish the fabric is passed through cotton bowl. This roller is made up of cotton.

Steel roll:

To give smoothness and luster.the temperature is provided to steel roller about 32-200 c with help of electric heater as we increase the temperature shining will increases only used for cotton CVC and percale and PC.

Reclon roll:

When fabric passess through Reclon roll and steel roll giving smooth and luster effect is generated.when it runs with steel roll and reclon roll and cotton roll dull effect is generated.when it runs b/w steel and reclon gloss effect is generated.

Cooling drum:

Cool down the fabric water circulates inside the cooling drum.

SANFORISING MACHINE:

Monforts Sanforizer:

The processed fabrics are subjected to elongation during processing. The shrinkage is controlled in the merceriser and stenter to some extent and it is ultimately brought within the norms in the latest monforts sanforizer made in Germany. The width ranges from 40cms to 325cms. Sanforising is a mechanical of treating the textile fabrics to prevent the normal dimension alterations of warp weft, which occur in the finishing operation; especially those carried on in laundering &allied operations.

MECHANICAL COMPRESSIVE SHRINKAGE: -

The fabric is compressed by the contraction of the conveyor surfaces on which the fabric has been made to adhere. The conveyor takes the form of a rubber belt or sleeve. The outer end expands as it passes over a roller and at this point the fabric is applied. The surface contracts with it, expansion and contraction are controlled, precise and predetermined length can be obtained, hence the process is positive.

EVASET PRINCIPLE a specially made rubber sleeve is tensioned b/w roller 2 and 3. A driving roll on the outside of sleeve and deflects

the upper run of sleeve into a reverse curvature, the driving roller 1 is steam heated.

The outer surface of rubber sleeve is expanded as it moves round the tension roller. The driving roller nips the fabric into contact with the expanded surface contract on taking up the reverse curvature around the driving roller.

Folding :

Taking samples from each and every roll and faults are detected and the grading is done then shade is forwarded to the shading department.the rolls are seperated in shade wise.the defected fabric is seperated.the grading is done a/c to the customer requirement.

There are two machines in Lucky textile 4 namely,

Rolling machine. Flat folding machine.

The rolling machine is used for making the rolls of A and B grade

fabrics and other graded fabrics are separated and folded on flat folding machine.

LOOS Boiler:

In Lucky textile 4 processing loos boiler is equiped which is generating 16 ton/hour steam.Two boilers are working while other two are in standby.

LOOS boilers a hot water boilers and steam LOOS includes three-pass steam boilers in a performance range from 175 to 55,000 kg/h, hot water boilers for capacities up to 38 and heating boilers up to 19.2 MW. The various models of boiler are manufactured in all pressure stages and for all fuels and can be fitted if required with heat recovery systems to improve efficiency for all technical heating processes.Boiler house components based on modular technology for easy planning, quick assembly and fully automated, safe operation complete the range of the LOOS boiler manufacturer. The boiler manufacturer is individual plant parts and components for the steam plants are correctly dimensioned, matched to each other and assembled into a ready-to-connect module.Servicing support around the clock, every day of the year: As a boiler manufacturer, LOOS offers a competent, fast, efficient customer service. Trained customer service engineers on 24-hour standby

combined with a central spare parts service guarantee optimum availability of your steam plant.

CAT G3516 ENGINE - POWER GENERATOR:

Blocks, crankshafts, liners and connecting rods are common with higher loaded CAT diesel engines providing longer life at lower gas engine loads. Timing is automatically controlled to maintain continuous detonation protection.

Lucky textile using generators as follows,

1. CAT model # G3516 AMFG Rating 975 KW and 965 KW

2. JENBACHER model # JGS 3201064 KW , MFG Rating 965 KW

RO PLANT (LUCKY TEXTILE 4):

Pretreated water is pumped into the membrane housings along the membrane surface. Pure water is permitted to pass through the membrane while ionic, organic, colloidal and bacterial contaminants are swept away in a concentrated solution. Consequently, a reverse osmosis system always creates two continuous exit streams: pure water (permeate) and brine (concentrate). Normally 50 to 75 percent of the feed water can be recovered as permeate.