Inplant Training Report GSML
ReportOn
In-plant TrainingAt
GINI SILK MILLS LTD
During10/6/09 TO 4/7/09
By,
DHRUV RAKESH SHAHTYTC
ISO:08DSTXCH68ROLL: 52
D.K.T.E.’s Textile & Engineering Institute,Rajwada,
Ichalkaranji – 416115.
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Inplant Training Report GSML
CERTIFICATE
THIS IS TO CERTIFY THAT THE INPLANT
TRAINING REPORT PREPARED SATISFACTORALY
BY MR. DHRUV RAKESH SHAH OF THIRD YEAR
YEAR B.TEXT TC AND IS SUBMITTED TO THE
DKTE SOCIETYS TEXTILE AND ENGINEERING
INSTITUTE, ICHALKARANJI IN PARTIAL
FULFILMENT OF THE REQUIREMENT OF THE
TEXTILE CHEMISTRY COURSE OF SHIVAJI
UNIERSITY, KOLHAPUR.
TRG & PLACMENT OFFICER HOD TEXTILES
PRINCIPAL
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Inplant Training Report GSML
ACKNOWLEDGEMENT
This page of my In-plant Training Report is dedicated to thank all those who were helpful
to me while my Project Work and without whom, the preparation of this report would have been
very difficult.
.
Firstly I would like to mention the name of General Manager of GSML Mr. Dasgupta ji
who accepted the request from our Institute and allowed us to undergo training at GSML. Our
sincere thanks to our college’s training and placement officer Mr.S.S.Lavate
Also not to be forgotten are all the Departmental Heads of respective departments who
helped us in understanding what all we wanted to in a proper manner. And, last but not the least
all the employees of GSML who were very co-operative, helpful and friendly.
All in all it was a great experience at GSML.
DHRUV RAKESH SHAH
Mumbai
4 th JULY 2009
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Inplant Training Report GSML
PROGRAMS OF TRAINING
The training in the GSML started at 10th of June,2009
I was placed in Lab from 10th till 15 july,2009
In dyeing department from 16th till 22th july, 2009
In Finishing department from 23th to 29th july,2009
In Printing department from 30th to 4th july, 2009
In between while training in all the department I had taken oppurtinity to collect information
from other departments like Packing, folding, EDP, boiler ETP, ISO Information etc.
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INTRODUCTION OF GSML
Address of head office
413 jogani industrial estate,
opposite Kasturba Hospital,
J.R. Boricha Road,
Lower Parel,
Mumbai 400011
Tel 23020610/11/12
Plant address:
E-15,
MIDC-Tarapur,
Boisar
401506
Thane
Tel 02525271333
The Flagship Company of the group, GINI SILK MILLS LTD. The process house at Tarapur
is used for the dyeing and printing of fabrics. The annual capacity of the process house is 21.6
million meter.
GSML is involved the manufacturing and processing of the fabric from 1963. It has expertise in
the processing of the polyester cotton blend, polyester viscose blend, 100% cotton fabric, 100%
polyester fabric, Lycra blended fabric etc. It processes suiting, shirting, and curtain clothes.
GSML has its own brand as GINI fabrics itself and also takes work for the processing on job
work basis.
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Few of their esteemed buyers are
-Wills Lifestyle
-Westside,
-Peter England,
-Indigo Nation and
-Shopper stop
Total production per day in dyeing: 32800 mtrs.
Total production per day in singeing: 35-40000 mtrs.
Total production per day in finishing:60000mtrs
Water consumption/day: 1200000ltrs
Steam consumption/day: 96tons
Electricity consumption/day:.7000KW
Coal for steam/month:300000kg
Coal for Thermopac:170000kgs
Water/metre: 17ltrs
Steam coal/mtrs: 0.2kgs
Thermo coal/mtrs 0.15kgs
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INDEX
Sr.No. Departments Page No.1 LABORATORY 92 GERY DEPARTMENT 143 SINGEING 154 BLEACHING AND DYEING DEPARTMENT 175 FINISHING 276 PRINTING DEPARTMENT 337 BOILER DEPARTMENT 378 ETP 399 ELECTRICAL 4010 EDP DEPARTMENT 4111 STORES AND PURCHASE 42
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PLANT LAY-OUT
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ORGANIZATION STURCTURE
1) CHAIRMAN (Mr.V. HARLALKA)
2) MD (Mr.DEEPAK V. HARLALKA)
3) PROCSSING MANAGER (Mr. DASGUPTA)
I) DYEING INCHARG (Mr.DINESH YADAV)
II) FINISHING INCHARGE (Mr.PATIL)
III) PRINTING INCHARGE (Mr.JOSHI)
A) SENIOR SUPERVISOR
B) SUPERVISOR
C) JOBBER
D) OPERATOR
E) HELPER
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LABORATORY
MACHINES IN LABORATORY
NO. MACHINES NOS
1. Padding Mangle 1
2. IFB Front loading washing machine 1
3. Oven 1
4. Hot Plate 1
5. Infra colour HTHP Machine (24 Pot) 1
6. Rota dyeing Machine (18 Pot) 1
7. Water dye bath (6 Pot) 1
8. HTHP Glycerin Bath (1pot 300gm 2 pot 150 gm) 1
9. HTHP Glycerin Bath (12 Pot 20 grams) 1
10. Weighing balance Digital (250 grams max) 1
11. pH Indicator 1
12. Colour Matching Cabinet 1
13. Pilling Tester 1
14. Crock Meter 1
15. Pilling Tester 1
16. Crease Recovery Tester 1
17. Tearing strength Tester 1
18. Tensile strength tester 1
19. CCM (Premier colour scan)+PC+Printer 1
Gini Silk mills have a moderate sized testing laboratory, in which different work like testing
of chemicals, auxiliaries, dyes, water, coal etc are carried out with physical testing of fabric is
also carried out. Work of shade matching is also carried out in the laboratory.
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As the GSM is ISO 9001:2000 certified company, its every machine should be calibrated at a
particular interval. The time interval varies from machine to machine. Very sensitive electronic
machines requires frequent calibration such as CCM requires daily calibration where as the
thermostat in dyeing machines need an interval of 5-6 months while some simple mechanical
machine requires less calibration.
STANDARDS
The generalized standard for the fabric processed should be as follows
1) Skew = 2-3%
2) Shrinkage = 2.5-3%
3) Crock Fastness rating = Wet 3 and dry 4
4) Tear strength = >1000 for Warp and > 700 for weft
5) Pilling rating = 4
STAIN REMOVING
For removing stains on PV fabric the fabric is dipped in 1.5gpl KMnO4 and 3%H2SO4
solution for 10-15 minutes at room temperature
To neutralize chemicals, water at 30-400C is taken and 2-3gpl Oxalic acid is added with 0.5-
1gpl H2O2. Then add fabric. The colour of KMnO4 ie purple colour gets immediately
decolourised immediately. Keep it for 5-10 minutes in it and give one hot and one cold wash and
dry.
FOR DEFINISHING
For definishing of any sample which come from the finishing department because of some
fault like less water absorbency, is finish is not as per desired standard or some tonal change is
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there in the fabric which is to be redyed, is treated with 2-3gpl soap, 10-20gpl enzyme for half
hour at 60-700C
POLYESTER DYEING IN LAB
In polyester fabric there are two types. Firstly piece dyed and secondly top dyed.
Piece dyed fabric are fully white, while top dyed fabric are partially dyed in yarn form and then
fabric is formed.
In piece dyeing dyeing of fabric higher temperature is used for dyeing i.e. 1300C while in top
dyed fabric, the temperature of dyeing is in range of 90-1100C max and if more temperature is
kep than, the dye of already dyed dibre will bleed and it will stain undyed part and the depth of
top dyed part will also decrease, resulting in improper dyeing.
The generalized procedure in GSM for polyester dyeing is 1.50C/minute rise of temperature
till reaching the desired temperature for top or piece dyed material and a holding time of 45
minutes. Than cooling is done till 900C and the bath is drained.
The dyeing bath contains of 1gpl CH3COOH, 0.5gpl leveling agent (Either of the following
PDM which is having 2x power than DFT)
MLR of 1:10 is maintained
The Reduction clearing (RC) treatment is given only for dark shades with following
chemicals, Hydro 2gpl, soda 2gpl for 5 minutes at 600C after that soaping treatment is given with
2gpl soap and 2gpl soda for 5 minutes at 600C after that single cold wash is given to it.
PREPARATION OF TINTING SOLUTION
4R (2 LITRES) 4B(2 LITRES)
60 RED VIOLET IFBL 39.6 gms CL Blue 2RX
30 gms Dispersing Agent 28.4gms Red violet IFBL
10 ml Acetic Acid 30 gms Dispersing agent
10 ml Acetic acid
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Tinting solution is prepared in laboratory for the dyeing department 5 times a day so that the dye
does not get precipitated and is used in the tinting of the white shades so as to give more
whiteness in the cloth.
AUXILLARY TESTING
All the auxillarys which purchased by the GSM are tested for its solid content in terms of %.
The procedure of it is as follows.
1) First weigh the empty petry dish or bowl and note its weight.
2) Add around approx 2gms of auxillary and again weigh the weight of dish and sample in
it.
3) Now keep it in oven for 3 and half hour ant 105-1100C
4) After that remove it and take the wt of crucible having auxillary in it. It will always be
less than the earlier weight. So by this was the difference in the weight is calculated and
the % solid content present is found out.
CHEMICAL TESTING
Most of the chemicals which are used for textile processing are tested in the laboratory by
titration. There are standardized procedures for it to test the samples. Every staff who does the
testing are suppose to test the samples in the stipulated way only.
DYES TESTING
Dyes testing is done by application it on the fabric only. For each and every class of dyes such
as Direct dyes, reactive dyes, Sulphur Dyes, Disperse Dyes, Cationic dyes etc there are standard
procedures which are to be followed and the dyeing of the new dye and the standard dye called
the pill box sample is tested and are then checked on the CCM spectrophotometer meter for the
strength and the tone of the new sample. If the tone and strength of the sample does not match
than the sample is rejected.
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WORK FLOW AND RECORD MANAGEMENT
1) Fabric is manufactured and a design no. is given to it by the weaving section
2) Fabric come to processing mill and are kept in grey department where they are given a lot
no. by the grey department.
3) As per the requirement from Gini’s customer or Gini itself for its own brand inform the
laboratory to produce a particular range of colour shade e.g light shades, heavy shades
etc, or the party gives particular shade for colour matching.
4) After that, the required group of colour is produced on the required fabric which is called
as lab dip
5) After that the cuttings of the dyeing made are systematically pasted in a record book with
its recipe and they are given lab numbers to it.
6) After that, the shades which have been prepared, are forwarded to Gini’s head office for
selection of the few best shades by means of consensus.
7) Once its passed in the office or by their customers, its informed to the dyeing department
to dye the lot.
8) So not the dyeing department after getting the lab no lot no from the office or their
customers tells the grey department to bring the fabric to dyeing department and at the
same time inform the lab staff to provide the recipe of that lab no. shade
9) Now the lab staff searches for the lab no record they have preserved in their records and
the recipe for it is forwaded to dyeing department so that they can carry out the dyeing.
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GREY DEPARTMENT
The grey fabric comes in roll form or bale form. There are various parties who provide grey
fabric for the processing, including Gini’s own produced cloth which comes from the weaving
department situated in Daman and Karad.Which include plain fabrics & top dyed fabrics.
Initially when the fabric come in tempo or truck its entry is done at the security department.
When the fabric bales of Takas are unloaded the number of rolls or bales are counted by the
security persons and kept as the record and also tallied against the partys challan.
The next step in the grey room dept. is giving piece no., lot no., to the fabric and challan
entry is done in the register. After that the fabric’s inspection is done for faults like oil dagi, fold
mark, Weaving oil grease, missing weft, hoose pick, hole etc are checked along with the length
of the fabric. The length of the fabric is generally recorded half a meter less than the given.
After that it is informed to the party and if the party is satisfied with the length of the cloth and
the faults it have in it than the job card is made. Job card is very important thing. It is a card
which have all the information of the fabric its party its length and the colour or process to be
given to it. It also have information regarding which pieces are to be joined together for
processing etc.
After that the fabric is kept at the empty position in the grey room. The grey room have
marking for identification of the fabric. After the fabric are placed the place number and all other
detail are fed to the computer for easy retrieval later on when the fabric is to be processed.
For giving lot no, piece no GSM make use of readymade ink called ‘Century’s texmarker’.
This is yellow in color & remains on the fabric even after any of the stringent chemical
processing. Weight of each and every roll or bale is taken and that is also noted.
The total numbers of the workers in the grey department were 10 men and 5 women’s and
staff included 4 persons.
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SINGEING
In singeing machine initially the fabric is brushed to remove loose threads and then singed.
After it is passed in quenching chamber filled with water. Before that there is also steam injector
on both side of the fabric to extinguish any sparks etc. After that it is passed to plating in which it
lays the fabric evenly in the container.
GEARING
The drive to the brush rollers is given separately by the motor, while there is other motor
which gives drive to the singeing rollers, Speed-o-meter, plating rollers, other guide roller near
steam quenching and guide roller before quenching.
There is gas connection given to the burners. Where the gas is supplied by external LPG gas
cylinders. Minimum 2Kg/cm2 pressure is required which is achieved by attaching 8 commercial
cylinder simultaneously to a single line. Cylinders are kept in water, when gas is near emptying,
steam is injected in it so water gets hot and all the remaining gas in the cylinder comes under
pressure and full utilization of gas is done.
The steam is given in machine by the steam from burner. There is a separate motor for
exhaust of hot gases and a separate motor for blowing air required for burning of gases.
For blend dyeing the fabric is first dyed by both dyes and then singing is done, where as for
only polyester the singeing is done so as to reduce the pilling tendency.
PARAMETERS TO BE CHECKED
1) There should be no creases in fabric. It should be perfectly flat
2) Speed varies with the quality generally 60-90mpm and shirting 50-60mpm is kept
3) The flame direction is to be checked whether it is perfect or not
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4) Flame intensity should be checked. For heavy quality of fabric the flame intensity is kept
more.
COST
The cost for singeing of one meter of the cloth is charged at Rupee 0.5
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BLEACHING AND DYEING DEPARTMENT
GSM does not have a separate bleaching department. It included in the dyeing department
itself. The generalized process sequence of the fabric of various types are shown below. The
different types of fabric which GSM processes at its processing unit are as follows P/V shirting,
P/C shirting, 100%Cotton shirting in generally Top dyed and few in Piece dyed quality. In
suiting it processes Piece as well as top dyed suiting of Ginis own brand as well as job work. It
also processes Acrylic suiting and shirting goods in its unit. Other than suiting and shirting it has
capacity to process furnishing cloth of cotton or P/C blend for curtains.
TOTAL MACHINES IN DYEING DEPARTMENT
1 Jet (U-Tube) 7
2 Baby Jet (U-Tube) 1
3 Horizontal Jet 2
4 Winch 2
5 VDR 1
6 Singeing machine 1
7 Jigger Dyeing Machine 14
8 Jumbo Jigger Dyeing Machine 5
9 Slit Machine 1
10 Float Dryer 1
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Below is the generalized sequence for some of the common sorts in GSMLP/V SHIRTING P/C SHIRTING 100% COTTON
SHIRTING (Top Dyed)GERY GREYStitching Stitching StitchingSingeing Singeing SingieingScouring in Jigger Scouring in Jigger Desize/ScouringHand Spotting (only in light shades) or with very heavy spots
Hand spotting (only in light shades) or with very heavy spots
Washing(for RMG materials only for removal of stains and spots in the fabric)
Jet Machine: first Stain removing is done than Dyeing is carried in fresh bath.
Mercerization Dyring on vertical drying range machine.
Dyeing on Jigger Jet Machine first Stain removing is done than Dyeing is carried in fresh bath.
Stenter for application of finish on the fabric
Slit machine for Checking of any faults in the fabric also for very high level of squeezing.
Dyeing on Jigger Dry finishing
Wet Finishing Slit machine for Checking of any faults in the fabric also for very high level of squeezing.
Below things as per requirement.
Below things as per requirement.
Wet finishing Sanforizing (zero-zero)
Sanforizing (zero-zero) Below things as per requirement
Calander/Shriner Calander
Calander/Shriner Calander Sanforizing (zero-zero) Deca finishDeca finish Calander/Shriner Calander FoldingFolding Deca finish CheckingChecking Folding PackingPacking Checking DeliveryDelivery Packing
Delivery
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Piece Dyed Suiting Top dyed Suiting
Grey Grey
Stitching Stitching
Singeing Singeing
Scouring Washing
Drying on VDR Drying on VDR
Heat setting on stenter Finishing on Stenter
Polyester dyeing on Jet Below things as per requirement.
Reduction clearing (For Dark Shades) Sanforizing (zero-zero)
Drying on VDR Deca finish
Cotton Dyeing on Jigger Folding
Drying on VDR Checking
Finishing on Stenter Packing
Below things as per requirement. Delivery
Sanforizing (zero-zero)
Deca finish
Folding
Checking
Packing
Delivery
HAND SPOTTING DEPARTMENT
The hand spotting department is a department whose work is to remove the stains from the
cloth. There are many stains on the fabric which gets on it while its manufacturing on the loom,
while transporting while storing in grey room etc. These stains need to be cleaned off, other wise
the processed goods will loose its value in terms of money and company may even lose it
potential customers. Hence hand spotting department is very crucial in any processing
department.
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In this department there were 8 workers who use to pull the fabric on a slant table lit with
good light and they pull the cloth towards them and check each and every meter of the cloth
which have spots on them. Generally all light colored clothes are hand spotted.
There are various chemicals used to remove the stains the most used solution was containing in it
2 kg FG
2 Kg EO 100 ( Stain removal)
2 Kg Oxalic Acid
In 25-30 liters of water.
There are also ready made solutions and solvents available for removal of grease, oil etc.
JIGGER DYEING
GSML have in all 19 jigger dyeing machines all them made by the manufacturer
Shakti Textile Engineering PVT LTD
Mumbai-400069
All the machines were equipped with Stop – Reverse – Forward Buttons on it. Additionally to
atomize the machine sensors were put so that if one end is complete the machine automatically
stops and again starts in the anti direction, hence less number of workers are needed in all.
In jigger machine the loading time varies as per the length of the fabric and its condition
varies between 10-45 minutes. All the jigger machines are run approximately at the speed of 65-
75 meters per minute.
The small jigger machines are having capacity for 150kg where as the jumbo jiggers are
having capacity of around 250-300kg of clothes.
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For soaping, washing etc the fabric is not rolled very perfectly or very evenly as no problem of
unevenness is there like in dyeing but in dying in jigger the fabric is rolled or wrapped on the
roller in a very evenly manner and very perfectly, evenly and very tightly.
Below are the few recipes on jigger dyeing machine for Stain removing, scouring, Dyeing .
For Stain removing before scouring
Sulpharmer- 1kg
Oelamine- 1kg
Tec C- 1Kg
At 800C for 2 ends
Bleaching of Cotton in P/C blend
H2O2- 1.5kg
Soda- 500gm
Soap- 200gm
Sodium Silicate- 500gm
For 6 ends at 850C then drain
Then
2 Ends for Hot wash then drain
Then
2 end for Cold wash then drain
Then
2 ends in Acetic acid then drain
ONE STEP SCOURING BLEACHING IN P/C BLEND
H2O2 1.5kg
Soda 500gms
Soap 200gms
Silicate 500gms
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Caustic 50gms
Helix 65gms
Then 1 Hot wash for 2 ends then drain
Then 1 Cold wash for 2 ends then drain
Then 2 ends in Acetic acid then drain
BLEACHING FOR READY MADE GARMENT FABRIC (RMG)
Caustic 1.5kg
Corex 0.3kg
Sulfarmer 0.3kg
Olemine 0.3kg
Soap 0.2kg
H2O2 1.5kg
Silicate 0.5kg
Soda 0.5kg
Give the treatment at 60-700C for 6 ends.And drop the bath
Then for neutralization
Bleaching powder 1.5kg
Soda 0.5kg
At room temperature for 6 ends and then drop the bath
Peroxide
H2O2 1.5kg
Silicate 0.5kg
Soda 0.5kg
Soap 0.3kg
Give this treatment at 800C for 4 ends and then drop the bath.
Neutralization
Acetic acid 0.500
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Give this treatment for 2 ends and drop the bath.
REACTIVE DYEING
In GSML generally Reactive H class dyeing is performed on the cotton fabric. The
generalized procedure for it is as follows.
For 150 kg of cloth in jigger the recipe for reactive H class dyeing is as follows.
Dye As per the % shade
Urea 200gms
Salt 10kg or as per the % shade
Insert the cloth in this bath at 800C and give 6-10 ends depending on the shade.
Than in the standing bath itself add Sodium carbonate
Na2CO3 4kg
Give 6 ends
Than in that bath itself add Caustic soda
NaOH 750gms
Give 6 ends and then drop the bath.
Give washing in the fresh bath at 85-900C for 4 ends
Then add acetic acid 1kg and give 2 ends for making the pH neutral
Then add cationic dye fixing agent Sandofix WEI 1kg in the same bath and give 6 ends for
assuring proper fastness at pH 4.5-5.5 and temperature at 25-35C
Then drain the bath.
Soaping
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Then give soaping for removing unfixed dyes.
Soap Poly EO 500gms
Temperature of 45-50C and give it for 6 ends and finally Drain the bath.
ACRYLIC DYEING
For the Cationic goods or acrylic goods the generalized procedure for the scouring and
Reduction clearing are as below
SCOURING
Hydros Cold 0.4kg
Give 4 end and drop the liquor
Give treatment with below solution
Liquor Ammonia 1.5kg
EO 100 0.2kg
Give 6 ends at 80-90C
After that give neutralization treatment
Poly acid/Acetic acid 98% 0.3-0.5kg
For 2 ends and drop the bath.
REDUCTION CLEARING TREATMENT FOR CATIONIC GOOD ON JIGGER
H2O2 1.5kg
Soda 0.5kg
Soap 0.2kg
Silicate 0.5kg
Give 6 ends at 70C and then give neutralization in fresh bath.
Neutralization
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Acetic acid 0.5kg
Finally drop the bath.
JET DYEING
There were total of 8 U tube jet and 2 horizontal Jet dyeing machine with one Baby jet U tube
dyeing machine which was used for the sampling purpose.
The U tube jet machine were built by Bhagyarekha-Devrekha (Surat)
Their maximum working pressure was 4kg/cm2 and working pressure is 2.5kg/cm2
7 jet were having capacity of around 150kg where as one other was having capacity of 250kg
and was generally used for suiting. Where as the baby jet had capacity of 25kg.
Where as the Horizontal jet dyeing machine belonged to Sanjay Engineering PVT LTD.
Dombivali. Their Maximum working pressure was 6kg/cm2 and working pressure was 2.5kg/cm2
This jet dyeing machine had capacity of 175kg.
RECIPES
The generalized recipe for jet scouring of Top dyed RMG garments on U tube are as follows
Corex 0.5kg
Sulfarmer 0.5kg
Olemine 0.5kg
EO-100 0.2kg
Emulsay 0.5kg
H2O2 1.0kg
Silicate 0.33kg
Give the above treatment for 40minutes at 60C.
After that drain the bath and give hot wash
Poly acid 0.25kg
White UDI 0.07%
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4B 0.035%
4R 0.007%
ED 0.5kg
Give the above treatment for 20 minutes at 65C
After that for whitening of cotton part give below treatment
White UBR 0.35gms
Salt 2gms
Acetic acid 0.25gms
Give above treatment for 15 minutes at 45C.
For Optical brightening of T/D RMG on jet the following recipe is used
White UDI 0.07%
4B 0.035%
4R 0.007%
Ranipal 2B 0.1%
Halio BS 0.01%
JET DYEING MACHINE WASHING
After the processing of dark shades on jet dyeing machine when ever light shade processing is
to be done then at that time washing of the machine with the following chemicals is necessary to
remove any stains or dye particles which could affect the colour of the light shade.
HCl 4kg
Caustic 3kg
Hydro 3kg
DFT 1kg
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FINISHING
GSML has a finishing department in which chemical and mechanical finishing to the fabric is
given. The finishing department have the following machinery as follows.
VDR 1
Stenter 2
Deca 2
Shriner Calander 1
Calandering machine 1
Sanforizing machine 1
CHECK POINT BEFORE AND AFTER FINISHING
1) Before finishing CheckWhether shade is ok or not
CheckGoods are stain free
Check Width and pH
2) Check Mangle Pressure and temperature
Check Finishing solution it should be clear and uniform
Check pH it should be slightly acidic
3) While FinishingCompare finishing with standard sample
Check speed, finishing width
Finishing width will be 1-2 cm higher then required width
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VDR
Vertical drying machine is used to dry the fabric so that they can be finished on the stenter or
else wet fabric will not pick up the finishing solution and there will not be proper finish on the
fabric.
VDR consists of total 8 Teflon coated rollers which are steam heated from internally.
First the fabric from the trolley passes over the guide rollers and then passes through the
trough containing water and it is squeezed by padding mangle whose nip pressure is kept
3.5kg/cm2 and then it passes over the heated Teflon coated rollers. The rollers are heated to a
tune of 125 to 130C and then again collected in the trolley.
In some case where the fabric have to be given wet finish are not dried particularly polyester
blend, where as 100% cotton are generally dried fully or almost dried and then given finish.
The speed is adjustable, for higher weight fabric like suiting sets are dried at very slow speed,
where as thin shirting are dried at higher speed.
STENTER
Stenter is a machine used for drying, curing and heat setting of fabric. There were 2 five
chamber stenters in GSML. Both the machines are automated and are based on the inverter
system which consumes 40% less electricity on motors etc.
The name of manufacturer is
SM energy teknik and Electronic Ltd, Situated in Vadodara and having office in Thane.
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It was of the year 95
The model no was ECON 2100 Pin stenter
Each stenter requires 5-6 workers in all for each machine
The speed and temperature of the stenter is kept around 40m/min and 150-170C for shirting
and 25m/min and 180-190C for suiting.
1) In the stenter the fabric is first dip into the trough having finishing solution then it passes
through the three padding roller having pressure of 4kg/cm2 then the fabric move upward
where the stenter situated for saving place and reducing the temperature at the working
place.
2) Above it passes from many guide rollers and reaches bowing rollers
3) The bowing rollers are adjusted to minimize the bowing and skewing effect of weft yarns
on the fabric
4) Then it passes through the tension rollers which reduses or increases the tension on the
fabric.
5) It then passes through the uncurl roller which uncurls the fabric if it is curled.
6) Then it passes over the over feed rollers which over feeds the cloth as per the requirement.
7) Then the fabric fits on the pin properly because of the sensors and enters the chambers and
comes out of the other side and is piled on the trolley.
FINISHING RECIPES
Recipes for finishing depends on the feel which is needed to achieve. The customers
provide samples of the fabric they need and the similar finish is to be achieved on the fabrics.
Hence combination of different finishes are to be formulated and fabric is finished.
Stenter machine is basically used for 3 purposes
1) Heat setting of synthetic fabric
2) Curing which is done when the finish applied on the fabric needs to be cross linked or
fixed on fabric for giving desired effect
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Inplant Training Report GSML
3) Drying
RECIPES
Few of the generalized recipes for finishing in GSML are as below.
For Softeneing
Isotex 2.5kg
Softex 1.5kg
Polyacid 0.5kg
Make total volume to 100litres.
It will work for 1200-1300 meters for shirting of 36” width and 750meters for fabric of 58”
width for wet finishging
For dry finish 100 litres will work for 450-500mtrs of suiting of 36”
CALANDERING MACHINE
In calancdering machine the fabric gets little shine and good drape to the fabric is given.
Width of the fabric reduces in the process by 1” For export quality of goods two time
calandering is done to get effect on both sides of fabric
The machine is equipped with a 37KW motor and is a 7 bowl calander machine Fabric is
many times not passed through all the rollers as the width reduces very much beyond
requirement.
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Inplant Training Report GSML
In this machine the fabric is taken thought the tension rollers and passes through the guide
roller and then passes through the metallic rollers and Cellulosic polyamide coated rollers. No
two metal rollers are in contact with each other. And then after passing through the guide roller
the piler piles the fabric in the trolley.
SCHINER MACHINE
Schiner machine is a type of calendar which give shine to the fabric and hence increases the
lusture of it to a very high extent.
Schiner machine consist of two rollers only one metal roller which is eternally heated by coils
and another big roller over it of cellulose.
Temperature is maintained between 115-140C and the nip pressure is 12-30 ton or 40kg/cm2
– 80kg/cm2
COMPRESSIVE SHRINKAGE MACHINE (ZERO-ZERO OR SANFORISING
MACHINE)
Sanforising machine is used to compress the material and prevent the fabric form getting
shrinkage later on while in use.
The machine was manufactured by Dhall Ltd, situated in Ahemadabad
In this machine the fabric passes through many guides and then reaches the nip of the steam
heated roller and rubber blanket. The cylinder is heated to 105-115C when the rubber belt is wet
and when the roller presses the fabric over rubber belt the water forms high pressure steam the
forces the warp yarns to come closer and hence achieve shrinkage.
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Inplant Training Report GSML
After that the fabric passes through the Felt roller which give more fuller feel to the fabric.
The rubber belt is 12 feet long and the thickness is of 2.5” The length is constant on all
machine of all make but the width varies from machine to machine
DECATISING MACHINE (DECA)
Decatising machine is a machine used to increase the bulkiness of the fabric and full ness of
the fabric by means of steam and pressure
There are two deca machine made by Dalal engineering and marketed by kumar Enterprises
Gujarat.
The machine was manufactured in year 2006 and other in 1996.
1) In decatising machine the fabric is rolled in-between the wrappers with a definite
pressure of around 1.5-2kg/cm2 for piece dyed and 5-6kg/cm2 for top dyed goods
2) Once the whole fabric is rolled up and loaded in the machine the fabric is steamed. The
steam from the rollers comes out from the layers of wrappers and fabric and gives a
fabric a soft and fuller feel
3) Steam is given for a time of 2-10minutes depending on the fabric.
4) After that the unloading of the fabric is done at one end and at the same time fabric is
load4d from other side.
5) Both rollers works simultaneously but the fabric which is rolled and unrolled are
independent of each other.
Total of 4 workers are required per machine.
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Inplant Training Report GSML
PRINTING DEPARTMENT
GSML has a printing department on the 2nd floor of the mill with a automatic flat bed printing
machine. The machine has 8 screen hence 8 colour printing is possible.
The department. Printing of Brasso, vat discharge, disperse, pigment etc printing is done here.
SCREEN MAKING
Design for the printing is made by the GSML’s artist or is provided by the customer.
After the making of design and finalizing of the design the design is passed to the tracing and
screen making department.
The tracer traces the screen on a tracing paper and then from a small tracing the same design
repeat is made on a special exposing film called Technova and repeats depending on the size of
the screen are exposed on the film and then that is dipped in ammonia solution where the
exposed part black and remaining remains transparent. Now that film is used to expose the
printing screen.
Printing screen is made with various quality of mesh size depending design to be printed. If
the design is sharp higher mesh no. is selected and if design is a blotch then lower mesh no. is
selected. The mesh are make of Generally nylon or Polyester.
The mesh if stretched on the stretching table and sticked on the frame with a adhesive on the
sides of the frame and then after dyring photo emulsion in a dark room is applied on it.
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Inplant Training Report GSML
The photo emulsion is prepared by
Photoemulsion 100gm
Ammonium dichromate 6-7gms
PVA 900gms
Poster colour 1-2gms
After even application of photoemulsion it is allowed to dry in the dark for half hour and after
that it is taken of the exposing by the Technova film.
The exposing is done on the screen for 6-8 times to cover the whole are of the screen. It is
exposed in UV light for 30-50seconds and after exposing is complete it is kept in the water tank
where the unexposed part gets loose and is washed off after 1 hour and the exposed part gets
hard
After drying a coating of lykar is applied on the whole screen, so its life increases.
ACTUAL PRINTING
GSML has a automatic Flat bed screen printing machine in its department with 8 colour
capacity.
The production in 12 hours is around 3500mtrs
The manufacturer of the machine is Tex Print Engineers LTD (Ahemadabad)
Once the screen preparation is over then the screen is put and fit on the machine and
depending on the number of colour that many screens are put one after the other. After putting
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Inplant Training Report GSML
the screens the fabric is layed on the rubber belt coated with adhesive so that the fabric does not
move while the printing is going on.
Afte that the paste is poured in between the two squeeges and printed on the fabric. All colour
are printed and then proper final setting of screen is done so that print comes at the exactly same
place where it is indented for. Or else there will defective printing and the cloth will not look
proper.
Below are the few generalized recipes of the printing at GSML
The gum for the different type of paste is earlier prepared and as per the requirement of the paste
in department the gum is mixed with the other components.
Disperse Paste
Gum L.V 8%
Ctiric Acid (pH) 1%
Pine oil (Anti foaming ) 1%
Loop accelerator 2%
Resist salt 1%
Water Remaining
Total 100kg
Brasso paste
Brasso 50%
Gum L.V 8%
Urea 2%
Glycerine 2%
Perminal KB 1%
Water Remaining
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Inplant Training Report GSML
Total 100kg
Pigment paste
Binder SLN 15%
EO 100 1.5%
Fixer CCL 3%
DAP (Depth enhancer) 1%
Kerosene 80%
Total 100Kg
After the application of the print paste to the fabric the fabric move ahead and again get
stationary for another part to get print.
After the printing the fabric move to the cuing chamber which is kept at 140-190C for
different type of the fabric.
For the brasso quality of print washing is necessary. The generalized recipe for the brasso
wash is as follows.
NaOH 1.5kg
H2O2 3kg
Soap 0.5kg
Meta silicate 0.5kg
Polyacid 1kg
The wash is given at 70C for 45 minutes. In that time the carbonized cotton is removed and net
effect at printed area can be seen clearly.
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Inplant Training Report GSML
BOILER DEPARTMENT GSML have total of 2 boiler made by the Shakti Boilers Dombivali.
1) 4 ton/hr Horizontal fire tube boiler actual production 3 tons/hr
2) 1 ton/hr coil boiler actual production 600kg/hr
It also have one thermopac heater machine and one non working oil fire boiler.
The maximum operating pressure is of 10kg/cm2 but normally it is operated at 7kg/cm2
pressure.
1) Hand firing is used in steam boiler. Water is sparyed on coal initially so that the small
particles of coal stick to the big ones.
2) Two feed pumps of multistage having 6-7 propellers in each are used to feed water to
boiler
3) Mobery is connected at outside boiler having a float in it over boiler water which indicate
the feed pump to work or stay off as required.
4) Coal is used as the firing medium A grade goal generates 7kg of steam from 1 kg.
The small water boiler gets heating from the thermopac oil heated in thermopac. This is
installed to overcome the problem of low capacity and pressure drop.
The water for the boiler needs to be softened. It is treated in Anion resin tank which reduces
the ppm to 5-10 and ph 7-8.5 which is standard for feed water to boiler.
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Inplant Training Report GSML
The resin needs to be charged after 70000ltrs of tank water or 210000 ltrs of water of MIDC.
From the resin chamber the water gets into storage tank and from there to the boiler as required.
The condensed steam is also utilized which reduces the energy consumption to great extent.
THERMOPAC
1) There is a installed thermopac for the heating of the oil for heating the stenter chambers.
2) Thermopac is heated by coal and is fired by machines in the fire box and is grinded to
small particles for proper and maximum energy from coal.
3) The oil used her is of Servo named Thermia Plus.
4) The oil is heated to 245C and the return oil is of around 220C
5) This oil is also used to heat water in the small boiler.
Thermopac and boiler are weekly maintained and checked for the basic parts and once in a
year the full opening and checking of the each and every part is done.
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Inplant Training Report GSML
EFFELUENT TREATMENT PLANT
Effluent treatment plant is the most curcial part of a company as it reduces the pollution to the
environment.
GSML has its own ETP plant and can process all the effluent in its own in house plant.
The ETP plant is of primary type here.
The process is as follows
1) First the water from the plant passes through a screen where large parts are trapped.
2) Then it is passed to collection tank where the air is blown from inside of tank to areate it
and it helps in reducing the temperature and also COD.
3) After that depending on the pH of the water alum or Lime is added to neutralize the
water.
4) After that it goes to the calri flocculator where the sedimentation of the sludge takes place
5) The sludge collected at bottom is taken to dry.
6) Where as the water is passed from the sand filter and then through carbon filter to filter
the small particles in it and then the water is checked for COD and pH and the let out of
the company.
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Inplant Training Report GSML
ELECTRICAL GSML purchases the electricity from the electric company and also has in house DG
plant to run the full plant.
They have a 750KVA transformer which is generally run at 75% capacity.
The daily consumption is of around 7000 units and power factor is to be maintained at
0.99.
The electricity to the machine in following way
1) Metering Box which is sealed
2) High tension breaker for 11000V
3) Step Down transformer from 11000V to 433V
4) Low tension Breaker
5) Power house
6) Machines
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Inplant Training Report GSML
EDP DEPARTMENT EDP (electronic Data processing department) is the a small department with 5 computers.
The main function of the EDP department is to entry all the details of the processing of the
fabric by lot number and also to input the stage at where the fabric is currently.
It deals with all the data collection in the unit, like pay to workers, staff, dispatch details, grey
department details, processing details etc and to coordinate with the head office of the GSML
situated at Mumbai.
There is always online connection with the head office so that the staff in the HO can view
the complete position of the company.
They have a software to commutate with each other. All the computers in the company at
tarapur, karad, daman and the head office are connected to each other and can share data with
them
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STORES AND PURCHASE At GSML there is a stores department which looks for any requirement of the dyes chemicals,
electrical parts, stationary in the whole plant.
The requirement in the plant is to be written in a memo and to be given to the stores. So after
that the stores issues that thing to the person requiring it.
The memo is kept for record and are fed to the computer every day which helps check the
stock.
There is ERP system installed in the GSML in which all the information is updated. The ERP
is also connected to the Head office in Mumbai. After there is any stock which is falling short is
getting near over than the staff at stores tell the Head office staff who have the purchasing power.
They check the stock there and order for the quotation of the goods. Once the quotation are
received the staff of Head office order that thing and that thing gets delivered to the plant
directly.
The new things which come to the plant are first checked if they are as per the standards. If it
is Dyes, chemicals etc it is cheeked in the Laboratory and after the report of lab they accept the
item an feed that data in computer. If it is not ok then the items are rejected.
All the items in the stores are kept as their names so that it become very easy for the staff to
find them when ever it is required.
The installation of a stable ERP system is going after which all the departments of whole
plant and other weaving plant and head office will get connected to each other and the paper
work will reduce very much and will also result in proper and easy functioning of the mill and
also save space for saving the hard copies
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