Final Mill Tariniggng Report

7/27/2019 Final Mill Tariniggng Report

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CONTENTS

Particulars Page No.

Acknowledgement 2

Plant Layout 3

Singeing & Desizeing 8

Continuous Bleaching Range (CBR) 11

Mercerizer 13

Dyeing Department 15

Printing 28

Finishing 41

Folding 44

Lab Deptt. 46

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ACKNOWLEDGEMENT

This report marks the completion of the six week industrial training programme

undertaken as a part of B.Tech textile chemistry under M.D.U.

I am highly thankful to Mr. Pradeep Pathak, C.E.O.,Sarla Fabric Pvt. Ltd. firstly for

permitting us to undertake this training at such a modern processing house and overall

for the facilities that were made available for us in all the possible ways during this

period. We are also thankful to Mr.Saif ( Senior Manager, HR Dept.),&Ms Priya(HR

Dept.) for guiding us during the training period.

I am also indebted to all the staff members and the workers of the Sarla Fabric Pvt.

Ltd.

I express my heartiest thanks to Dr. Rishi P. Jamdagni(Director),

Dr.S.K.Dhamija (Training Officer) Prof. A.K. Patra (H.O.D.,T.C.) & all the faculty

members,T.I.T.S. Bhiwani for arranging my training at Sarla Fabric Pvt. Ltd.

Prepared By:

Atul Grover

Aniket Sharma

Vikas Goyal

T.I.T&S BHIWANI.

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Types of qualities processed in the company

Poplin

Cambrick

Cotton voil

Twill

Sateen

Dobby

Embroidery

Yarn dyed

Sheeting (reed=pick)

Lycra

Textured dobby

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Preparatory wet processing

1. Singeing and desizeing

Specifications:

Name of machine osthoff singe

Machine make Wuppertal ,germany

Model 42327 wuppertal

No. 6579

Objective of m/c :-

Singeing :- the short protruding fibres are removed burning, to get a smooth, even and

clean looking surface, which is essential for subsequent dyeing and printing purposes.

To avoid uneven dyeing, specks, haziness, pilling and to get smooth appearance. Desizing :- the sinzed fabric is given the enzymatic or oxidative desizing for the removal

of size material from the fabric (where the size material is mainly starch)

Thread length 45 mts.

Speed :-

1. For light weight (


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Singeing position :-

1. Tangential singeing

Used for lighter weight fabrics

2. Onto water cooled rollers

Used for slightly heavier quality

3. Onto free guided rollers

Used for very heavy qualities

Man power required 4

No. Of shift /day 3

Fuel used LPG Gas :air mixture 1:4

Roller width 2m

Working width 1.8m

Efficiency of singeing m/c 80%

Production of singeing m/c

. For light weight 90,000-1,00,000/- 24hrs

For medium and 80,000-50,000 /24hrs

For bottom weight 60,000/24hrs

Liquor capacity 740 liters

Two sensors are used to control feed liquor.

Brief description of the machine :-

Brush rollers a :- rotates in opposite direction to the fabricmovement and removes loose fibres from fabric surface and raises the

protruding fibres to carry out effective singeing.

Singeing zone :- here the protruding fibres aer singed by means of

two burners, which work on opposite faces of fabric.

Brush zone :- these rollers also rotates in opposite direction to the

fabric movements and removes loose fibres that are singed from fabric.

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Suction pump :- it is attached to brush roller b which sucks out

the singed fibres from the brush rollers and collect them in the separate

position. Desizing chamber :- here the fabric is given the oxidative desizing

treatment.

Pressing roller :- this roller presses the fabric on take up beam andgives frictional drive to the take up batch.

Damping roller :- water is passed through the damping rollers and

is used for fast dispersal of heat from fabric. Take up batch :- fabric that is singed and desized is taken up on

this roller after a complete batch is prepared. It is covered with polythene sheet

and kept for 16 hrs. Rotation afterenzymatic desized, and 24 hrs. Rotation

afteroxidative desizing.

Recipe for desizing :-

1. Enzymatic Desize :-

GLM Speed

m/min

Flame

Position

Trough

Temp.

Dwell

Time

Batching Pr.

(Bar)

Batching

Time(Hrs)

400 70 3 70 21 1.5-2 10-12

2. Oxidative Desize

GLM Speed

m/min

Flame

Position

Trough

Temp.

Dwell

Time

Batching Pr.

(Bar)

Batching

Time(Hrs)


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* machine make Benninger,Switzerland

* model Benninger, Agch 9290

* machine length 172 feet

* average operational speed 80 mts. / min.

* threading length 500 mts.

* fabric capacity of steamer 1300 mts.

* total capacity in running condition 2000 mts.

* number of operators 2 operator

* efficiency of machine 85%

* average daily production 1lakh meters / 24 hours

* roller width 2mts.

* working width 1.5mts

.

Objective of machine:

To remove out the solubilised form {dextrin soluble} of starch from the fabric.

To carry out the process of bleaching of desized / singed fabric.

To carry out the process of scouring along with the process of bleaching in the same

bath.

GLM 70-130 140-200 200&above For White

Chemical

H2O2 15 22 35 35

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Securone 1.5 1.5 1.5 1.5

WBL 5 5 5 5

ZMIN 6 7 7 7

NaOH 16 22 22 15

The fabric that has been desized contains a coating of the solubilised size, enzyme, wettingagents and other chemicals.Surface and removes the solubilised size and other chemicals from

the fabric.

1. Extracta: - Extracta are washing chambers. In this model of the CBR there are a total of

seven wash chambers, two before the impacta, to remove any size present on the fabric,rest after the steamer (3 for the hot wash and the last is divided into two halves one for

chambers have a temp of 80-90 C excepting the last which is maintained at a temp of

60 C(temperature of acid dosing chamber is 50 C) no chemicals are used during hotwater wash.

2. Impacta: - In this chamber chemical (bleaching or scouring) dosing takes place. It is

fitted with chemical pipelines to which valves are connected which maintain

The chemical proportion in the impacta at the right level

Automatically. Temperature of this chamber is recommended to be 40-50 C.

3. Ben dip: - this is provided prior to the entry of the fabric into the steamer this is mainly

useful for heavier fabrics like bottoms which may not wet to proper extent. So the

heavier fabrics coming out of the impacta are given one more dip in their dip beforethey enter the steamer it is to be noted that dry steam may cause patches to appear in

undesirable.

4. Steamer :- earlier all steamers used were of two types, where the fabric was either passedin stretched or else in platted manner for particular duration for reaction to be carried

out.

This machine has a comb steamer, where the same fabric is passed in stretched

manner and then in relaxed form providing a dwell time of 15 min. For steaming priorto saturation, so that steaming is carried out by wet steam and no problem relating to dry

steam, as mentioned earlier appears.

5. Drying cylinders: - in total there are thirty cylinders in set of ten. The first two cylinders

where fabric first comes in contact with the cylinders are teflon coated. The first 20cylinders are meant for drying and are steam heated and the last 10 cylinders are

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maintained at room temperature when the fabric is to be taken for mercerising then

drying is not required and fabric is passed below these cylinders.

6. Exhaust fans: - there are three exhaust fan fitted at the top of cylinders sets, they driveaway the steam (coming out from the drying of the wet fabric) and avoid any chances of

steam condensation on the fabric.

3. Mercerizer

Specifications:

o Machine make Benninger (Germany)

o Model agch 9240 uzwill

o M/c type padless, chainless m/c for hot mercerization

o Threading length 370 mts

o Speed 60 mts./ min

o Efficiency of the m/c 90%

o Average production 70,000 mts./24 hrs

o No. of operators 2 operators + 1 helper

o Outlet caustic conc. 7-8be

o Dwell time 46-50sec

o Roller width 2mts.

o Working width 1.8mts.

Objective of the machine

Mercerization causes the de-convolution inside the cotton fabric, leading

to increase in absorbency. Mercerization also increases the tensile and tearing strength of cotton

fabric

It also increases the cover of the fabric The machine is used for carry out hot mercerization, which has the

following

Dimensional stability

Advantage

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1. Uniform penetration of alkali at higher temp.

2. No ring dyeing effects is observed.

3. Impregnation time is also reduced, leading to increase in speed and greaterproduction capacity.

Disadvantage

Hot mercerization does not improve the fabric lustre as alkali treatment higher temp,

makes the fabric surface rough/uneven so the light scattering from the surface becomesdiffused, leading to poor fabric lustre.

Various zones of the machine

Wetting zone :-Conc. of alkali (weak lye) 6-8 be

Impregnation zone

Impregnation conc.

Quality Concentration of alkali(in be)

Cotton (poplin) 18

Twill 29

Cotton voil 26

Cotton flax 18

Impregnation temp. 60 c

Dwelling time 45 sec.

Stabilisation zone Conc. Of alkali(weak lye) 6-8 be.

Temp. 85 c

Washing zone There is a counter flow from

GLM Caustic Soda Speed m/min Temp Change Over Time

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400 270-280 30-40 60-70 4-5

4.Dyeing department

Conventional dyeing range

Jet dyeing machine

In this machine, both fabric and water moves. Here we give movement to the water and fabric

moves through the impact of jet of water. Both fabric and water moves in same direction.

Jet dyeing machine is mainly used for polyester dyeing but it can be used for other quality also.

Machine name Jet dyeing machine(u-shape)

Manufacture Devrekha

No. Of machine 4 Capacity 350kg

Nozzle pressure 3kg/cm2

Dye used disperse, vat, reactive Fabric used cellulosic, synthetic

Total liquor 600lt.

Speed of fabric 400mt/min

In case of polyester:

MLR 1:3 Temperature 1300C

pH 4-4.5

Soft flow machine:- In this machine we use a roller called soft roller which help inreducing tension in fabric.

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Machine name soft flow

Manufacture texfab india

No. Of machine 1 No. Of worker 2

Capacity 400kg

Quality light to medium fabric Dye used disperse, vat, reactive

Temperature 1300C for PET, 60-700C forcotton

Nozzle pressure 0.5-1.0 bar Total liquor 3600-4000lt

Fabric speed 200-300mt/min

Winch dyeing machine

For light weight quality fabric, this winch dyeing machine is used.

Machine name winch dyeing Manufacture Shakti No. Of machine 8

Capacity 100kg

Used for washing of printed fabric

Form of material rope form

Dye liquor 150-200lt

Heating system direct

Heating medium steam Time taken 12-14hr.

Jigger :-

This machine is used for dyeing the cotton fabric. Fabric is used in open

width form in this machine. In this, cloth moves from one roller (let-off roller) to

another roller (take-up roller) through trough or liquor. After one complete turn,the movement of fabric get reversed i.e. Let-off becomes take-up and take-up

becomes let-off roller automatically thus the required number of turns are given

to the fabric. Thus in this machine, liquor is stationary and fabric moves.

Machine name Jigger(old) Manufacture Shakti

No. Of jigger 6(2 for sample)

No. Of worker 1 for 1 machine

Capacity 4-250kg Heating system indirect to direct

Speed of fabric 40-45mt/min

MLR 1:2,1:4

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Diameter of roller 250mm

Width of roller 2000mm

Time for 1 batch 10-12hr(reactive) Production 2000m/day per machine

Hydraulic jigger :-

It is almost same as old jigger, but only change is that it is fullyautomatic, microprocessor control and its capacity is high.

Machine name Hydraulic jigger

Manufacture Shakti

No. Of machine 1 Capacity 350kg

Trough capacity 2000lt Max. Temp. 100c Dyeing temp. 60-70c

Heating system direct or indirect

Steps of dyeing in jigger

S.no. Step temp.(0c) turns

1. Loading 50 -

2. Add resist salt 50 2

3. Dyeing 50 2

4. Salt addition10% 60 2

5. Dyeing 60 2


7. Dyeing 60 2


9. Fixation(soda ash) 70-80 4

10. Overflow wash R.T. 4

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11. Soaping 80 4

12. Hot wash 50 2

13. Cold wash R.T 2

Continuous dyeing range:-

Two m/cs constitutes the whole continuous dyeing range.

A. pad dry

B. pad steam

Pad dry:-

o M/c make Benninger (Germany)

o Mangle make Kusters

o Thread length 140 mts.

o Man power required 1 operator+1helper

o Speed 60 mts./ min

Brief description of the machine

Operation of the machine can divided into following sections

1. Feeding

o Fabric is fed from batch

o Fabric is guided through rollers, tensioners and scray to the padding zone.

o Presence of scray helps to feed the fabric uninterruptedly during the

change of the batch.

2. Padding

Fabric is padded with dye liquor in the kusters mangle present in this

machine

Capacity of the trough 60 liters Pneumatic and oil pressure is applied in the squeeze roller to get the

uniform expression through out the width of the fabric

Padding pressure is

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Left Middle Right

1.6 1.8 1.6

Temperature of the liquor room temperature

Expression or pick up depends on the type of fabric.

3. Airing

o Airing zone is there before the entry of fabric into IR drying unit to ensure

proper migration of dye particles inside the fibre matrix.

4. Infra red drying

o Air and propane gas are injected at very low pressure and these mixtures are

heat generated from this ignition heats up the ceramic plate, which becomes

red hot and generates IR wave.

o There are two IR drying columns, each consist of a set of three ceramic

plates in between which the fabric is passed.o

IR drying plates the migration of dye on fabric it dry up the fabric uniformly30-40% of moisture is removed by infrared drying

5. Hot flue drying

o It is divided into two chambers

o Fabric is passed over a no. Of rollers arranged at two different heights andis dried by hot air circulated by four blower fans (2 at the bottom & 2 at the

top), extra air is exhausted from the top.o Air is heated by passing over oils containing hot oil (therminol 55, coming

from the thermo pack)

o Temp. of the first chamber - 110 C, Second chamber - 120 C

Fan speed First chamber Second chamber

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Hot air fan 20% 30%

Exhaust fan 35% 25%

Exhaust air 85% 85%

6. Cooling cylinders

After drying the fabric it is cooled by passing it over two cooling cylinders(cooled by passing chilled water). This cooling is done to minimize the selvedge

to selvedge variation.

Recipe for vat dyeing

Ingredients Purpose Conc. (in gpl)

Vat dye Dye X

Setamol ws Dispersing agent 1Primasol amk Antimigrating agent 5-10

Invadine lun Deaerator 1

Albatex ffc Levelling agent 0.1

Recipe for reactive dyeing

Ingredients Purpose Conc. (in gpl)

Reactive dye Dye X

Ciba flow pad Deaerator 2

Primasol amk Antimigrating agent 5-10

Resist salt Mild oxiding agent 2

Setamol ws Dispersing agent 1 (only above 40 gpl)

Albatex ffc Levelling agent 0.1

Defects during pad dry system

o Dropping mainly in hot flue dryer thus check suction system properly.

o Crease marks takes place in hot flue dryer and in ir dryer.

o Tailing effecto Dark to light shade

o Colour spots

o Colour spurs

o Power failure

pad steam

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M/c make Benninger (Germany)

Thread length 360 mts

Man power required two operators and one helper

Average operational speed 50-60 mts/min.

Purpose of the machine

o In this machine color (reactive or vat) color is developed on the fabric after it isbeing pigmented in the pad-dry machine.

o This machine can also be used as washing machine, when the chemical input in

the machine is cut off and steamer is also kept out of operation.

Brief description about the machine

Feed zone

Feed material is the output of the pad-dry machine in case of development

of the dyed fabric.

Fabric is guided from the guide rollers, tensioners and scray to the paddingsection.

Presence of scray at the feed helps in uninterrupted feeding of material at

the feed section.

Fabric tension during is controlled automatically.

Padding zone

Name :- booster padding mangle

In this zone fabric is padded with developing chemicals Expression of the mangle :- 90-100% Capacityof the trough :- 60 lts.

Padding chemical temp :-. Room temp

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.Developing zone:-

Chemical feed for the reactive development

Ingredient Purpose Conc. (in gpl)

Glauber salt Exhausting agent 250

Soda ash Fixation agent 20

NaOH (48 be) Solubilising agent 9

Sitamol ws Dispersing agent 1 (only for torquoise shade)

Chemical feed for the vat development

Speed 50-60m/min


Hydro sulphite Reducing agent 31


Glauber salt Exhausting agent 15-20

Sodium nitrite Mild oxidising agent 5 (for blue dyes)

Albatex or Levelling agent 2

Mother dye liquor 70-20

Chemical feed for the vat development(for dark shade)

Speed 50-60m/min



NaOH (48 Be) Solubilising agent 50

Glauber salt Exhausting agent 10-15

Sodium nitrite Mild oxidising agent 5 (for blue dyes)

Albatex or Levelling agent 0

Mother dye liquor 70-20

Chemical feed for the reactive stripping

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Speed 20-30m/min




Sequestering Sequestering agent 2

Dispersing Dispersing agent 1

Steaming zone

o In this zone reaction of the developing chemical with the dye takes place.

o Thread length (in the steamer) 50mts.

o Steam supply (dry steam) 112 C

o Steam mix temp. (saturated) 90 Co Steamer inside temp. 99 C

o Roof heating 112 C

Washing zone

For reactive dyes

Removal of the unfixed, partially deposited and hydrolyseddyes.

For vat dyes

Removal of the unfixed, partially deposited and hydrolysed dyes.

Soaping causes the aggregation of dye molecules inside thefibres after which final shade is achieved.

Washing of fabric dyed with reactive dye

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Chamber & sub-chamber no Purpose Chemicals Temp.

(in c)

15 Cold wash - 40

16 Cold wash - 40

17.1 Neutralisation Acetic acid 60

17.2 Hot wash - 95

18 Soaping Cibacel ds 1gpl

Cibacron rsk 0.5gpl

95

19.1 Soaping 95

19.2 Soaping 95

20 Hot wash - 95

21.1 Neutralisation Acetic acid 6021.2 Washing - 60

Washing of fabric dyed with vat dye

Chamber & sub-chamber no. Purpose Chemicals Temp.

(in c)

15 Cold wash - 4016 Cold wash - 40

17.1 Oxidation Resist salt 60

17.2 Oxidation Resist salt 60

18 Soaping Cibacel ds 1gpl

Cibacron rski o.5gpl

95

19.1 Soaping 95

19.2 Soaping 95

20 Hot wash - 95

21.1 Neutralisation Acetic acid 60

21.2 Hot wash - 60

Cooling zone

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o No. of cooling cylinders two

o Temp. of cooling water room temp

Drying zone

Type of drying vertical cylinder drying range No. Of drying cylinders 10+10

Dimensions of cylinders 32 * 72

Pressure of steam in the cylinder 50 lbs/insq Steam consumption 60 kg/hr/cylinder

Checking points :

Level of the chemical liquor inside the kuster

mangle is regularly checked. Conc. of NaOH (during development of reactive

dyes) is checked.

Conc. of hydrosulphite (during development of vatdyes) is checked.

Procedure

Take 10 ml of hydros solution to be tested. To it add 10 ml of formaldehyde

solution. Make it to 250 ml. In the volumetric flask with distilled water. Take 25ml> of the above prepared solution end point of titration is brick red color

Hydros (gpl) = reading of burette * 4.35

Cold pad batch dyeing range

Specifications:

Machine make Benninger

Threading length 18 mts Average operational speed 60 mts/min.

Production 60,000 mts./24 hrs.

Name of padding machine Kusters mangle

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Brief description of m/c

Feed zone

Form of feeding batch

Pre cooling-there is a cooling cylinder within which chilled water from chilling

plant cools the surface of the cylinder and hence the fabric. Since the process

should be carried out in cold condition, a precooling arrangement of the fabric

gives uniform results

Padding zone

1. Name of the padding mangle kusters mangle

2. Temp. of liquor 20-25 c

3. Flow ratio of color and silicate 4 :14. Liquor capacity of trough 22 litres

Recipe

Reactive dye liquor

Dye x gpl

Urea 100 gpl

Albatex ffc 0.1 gpl

Sirriy sai 0.3 gpl

Alkali solution

NaOH (38 Be)

Sodium silicate 20 ml/lt

Padding pressure (in bars)

Left Middle Right

1.4 1.5 1.4

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Special features in the mangle

1. A jacket surrounds the trough of the mangle, which contains cold water to cool

the liquor in the trough.2. To get uniform pressure throughout the width of the mangle, there is a oil and

pneumatic pressure arrangement.3. The trough can be moved down automatically during washing4. A liquor level sensor is present.

5. A liquor temperature sensor is also present.

Delivery zone

1. Form of delivery batch2. Drive batch is positively driven by motor, pressing roller is driven in contact

with that.3. Intermittent pressing of the pressing roller.

4. Incorporation of PEsheet with in layers to get rid off stitch marks.5. The batch fabric is kept in rotating conditions for16 hrs and then go to the

soaper.

Soaper

It is used for washing the fabric with soap and hot water, after dyeing and after printing, toremove superficial dyes from fabric.

After cold pad batch , hold for 16 hrs and then use soaper.

In soaper, counter current water flows for washing the fabric.

o Manufacturer Beninger

o No. of machine 1

o Working width 1.8m

o Threading length 240m

o Washing system counter current flowo Mangle pressure 2bar

o No. Of worker 3

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Machine must always be washed and cleaned immediately after completion of one shade

Compartment Temperature 0C Function

W12 60 Cold wash

W13 95 Hot wash

W14 95 Soap

W15 95 Hot wash

W16 60 Cold wash + acetic acid(neutralisation)

W17 50 Cold wash

Then the fabric go to the vertical drying cylinders fordrying in which there is 22 cylinders out

of which there are 20 hot cylinders and 2 chilled cylinders

5.Printing

Printing department can be divided into following sections

1. Printing studio.

2. Print color kitchen.

3.

Printing section.4. Curing and steaming section.

5. Washing zone.

Printing studio:-

Objective:- the main objective of the print studio is to transfer the design obtained from the

buyer on to a perforated screen, so that the design become print able. Tracers in this department

adjusts the repeat size of the design to a factor of 64.2 cms (the circumference of the print roller)

this enables a perfect repetition of the design during printing. The tracers also make anyalteration in the design as may be demanded by the party. The screen rollers once prepared are

preserved for future use.

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4. Washing:- the roller is then washed by water in a water bath for 10 mins. Here unreacted

soft part of photo emulsion is washed off by a piece of sponge. now the design portion which

was turned to black on bld paper,becomes opaque on the screen roller, then the roller is dried.

5. Checking:- the roller is then thoroughly checked. The pores of the design portion are

properly opened by water. Undesirable pores are also covered by colour.

6. Curing:- chemicals on the screen roller are cured in the curing m/c by hot air at 180c

for 2 hrs.7. Rechecking:- rechecking & reqd. Manipulation of the screen roller is done.

8. Preparation of rfp roll:- finally two aluminium rings are attached at both edges of the

roller with araldite. The roller is now ready for printing.

Some special data related to screen roller formation.

No. of holes per inch can can be 60,70,80,100 & 125 for different variety screen withhigher no. Of holes per inch is used for finer quality design & screen with lower no. Of

holes per inch is used for blotch (wider and broad type ) design.

Length of the screen roller is 1.75 mts.

A screen roller can print up to 50000 mts.

One kg. Of photo emulsion in mixed with 50ml. Of centiliser which can be coated on 4

screen rollers.

Design Department

In this design department , sample designs are developed on the computer with

matching of design as well as their creativity. They have used designing software andprint out the design on paper. If the design is very fine and complicated then it is

prepared on paper by hand with help of experts.

o Machine name hp design jet 500

o Manufacture hp

o Used for paper print

o Paper used mtltifilm,

Transparent clear film

o Speed 6inch/min

o No. Of colour 4

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Screen exposing techniques

o Computerised screen exposing

o Manual screen exposing

Computerised screen exposing

In this technique, coated nickel screen is fixed on machine and program of the

design is entered. Automatically design is drawn on the screen or engraved onscreen as well as the exposing of the screen takes place by U.V.. Light.

No. Of machine 1

Machine name luscher engraving & exposing

Manufacture luscher

Ink used wax black ink

Length of machine 120inch

No. Of cycle of engraving 1

No. Of cycle of exposing 4

Total time taken 15 min

Manual screen exposing

Exposing time for 1 repeat 4-5min

Exposing time for full screen 40-50min

Screen length 50-60inch

Sample Printing machine

(Baby Printing machine)

o Machine name Digital printingmachineo No. Of machine 1

o Manufacture Nimaki textile jetTxz-1600

o Speed 10m/hr

o No. Of colour used 8

o Printing width 62inch

o Dyes taken pigment, reactive

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Print colour kitchen

As the name suggest this section of printing of printing department is concerned with print paste

preparation, which is made readily available for printing. Two different methods for print paste

preparation, one for pigment and other for discharge printing.

For discharge print (in general)

Chemical Quantity ( in %)

Safolite 20

Soda ash 7

Pine oil 2

Glycerine 2

Hindustan gum 6

Water 63

Total 100

For colour discharge, we use the same recipe but with the addition of colour (non-

dischargeable).

Preparation of Hindustan gum

50kg of Hindustan gum powder is mixed with 100kg of water & fast

stirring is done for 10-12 min. Then it is taken in a tumbler and slow stirring is done for 10-12hrs. From this paste 6% is added to the main stock paste.

Preparation of the printing paste

All the chemicals of stock paste are mixed thoroughly in the PVCcontainer by means of a motor driven stirrer for 1 to1.5 hrs again the vat colour as per the shade,

is dissolved in water, stirred well and mixed with the stock paste. This mixture is stirred for 10-15 min. This paste is ready to be used for printing.

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For pigment print

Recipe for stock paste

Chemical Quantity (in%)

Binder 4400 10-12

Thickener nca 3-3.5

Liquor ammonia 1

Fixer 2

Water Rest

Total 100

For reactive print

Recipe for stock paste

Chemical Quantity (in%)

Reactive dye X%

Urea 15-20%

Resist salt 2.5-3%Sodium bicarbonate 4%

Sodium alginate 4-5%

Water Rest

Total 100%

Preparation of printing paste of pigment

The ingredients are taken in a stirring tank of 800kg capacity and stirred for 35min. This mixture

is transferred to any of the over head chamber of 2400kg capacity. Required amount of pigmentis taken, as per shade requirement. In PVC container and is mixed with the stock paste in the

tank and stirred for 10min. This paste is ready to be used for printing.

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Printing section

Printing machine

Name of m/c Rotary screen printing m/c

Machine make Laxmi

No. of machine 2

Total no. of printing rollers 12

No. of chamber in drying zone 5 No. of dryer fans 10

No. of exhaust fans 3

No. of radiators 5

Temp. of drying chambers 1090C, 1220C, 1370C, 1500C, 1380C

Avg speed of m/c 20-40m/min

Min. Speed of m/c 10-12m/min

Max. Speed of m/c 40-50m/ min

Length of machine 25.84m

Width of machine 2.30m

Type of blanket rubber blanket

Length of blanket 16m Width of blanket 64inch

Thickness of blanket 1mm

Type of squeezee magnetic squeezee

Brief description of the m/c

Feed zone

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Fabric passes over batch roll through guide rollers, there are two brass rollers

followed two suction to remove the floating fibres and dust on fabric surface

Printing zone

Thereis an endless rotating rubber conveyer in this zone. At first fabric is pasted with

the rubber conveyer by the pressure roller with the help of PVA then the fabric comes under the

printing roller through which the print paste is applied the pressure of the printing roller can beadjusted by changing rod inside it. A single colour is applied by one printing roller generally

darker colour containing rollers are arranged gradually from back to front. Different coloured

print pastes are applied by different square shaped hollow and perforated rods (squeeze) byindividual pumps. The rubber conveyer is cleaned by water and doctor blade under the machine.

length of the fabric in this zone is 23 feets. fabric after printing zone enter drying zone.

Drying zone

There are five chambers in this zone containing five radiators. Hot oil is circulatedthrough the radiators and the blowers circulate the hot air. For pigment printing drying temp. is

around 160 deg and for discharge printing it is around 140deg.generally the temp. of first two

chambers is kept lower than the subsequent chambers. Fabric after drying goes to delivery zone.

Delivery zone

Fabric coming from drying zone passes through guide rollers and is lapper into the

trolley.

Factors to be checked at the time of printing :-

The design printed on the fabric coming out from the printing bed is checked carefully.

Distortion of the design occurs mainly due to chocking of the printing rollers or due to thefloating fibers attached with the printing rollers.

Sponge wetted with water to avoid chocking is used to wash printing rollers

Again a dummy roller is fitted at the beginning of the printing bed the surface of which is coated

by gum. When fabric passes through the surface of this roller it arrests the floating fibresattached to the fabric

For a broad design it is checked whether the fabric coming out from the delivery zone is properly

dried or not. Temperature of the drying chambers are increased if necessary.

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The level of the color in the PVC container is checked. It is also checked whether colors are

coming out from the squeeze properly.

The cleaning system of the rubber conveyer under the printing bed and the PVC application to itis also checked.

Curing & steaming section

Continuous ager (steaming m/c.)

Name of the m/c continous ager m/c

Maker name gayatri m/c

Thread length 200 m

Speed 15 m/min (normal)

6-8 m/min (min.)

50 m/min (max.)

Drying system steaming

Steaming time 8-2 min.

Temperature of m/c 101 c for discharge

150-180 c for pigment

Pressure of steam at feed 18-20 kg./cm sq

Roof heating system by hot oil


The m/c contains 26 guide rollers each at the top & at the bottom, both feed

and delivery takes place from the front side of the m/c. Fabric simply passes through the

series of guide rollers during the process. Both direct & indirect system of heating are in

this m/c. Water is heated by hot oil pipes located below the m/c, to generate indirectsteam, another purpose of steam is to saturate the direct steam to be applied on the

fabric. The roof of the m/c is heated to about 130 - 140 c to avoid steam condensationof the steam & hence dropping on the fabric. Direct steam is also applied at the feed and

delivery to avoid droppings. Discharging agent present in the printing paste forms a

fume inside the m/c with the help of saturated steam, which actually develops the coloron the fabric surface.

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Special features :

o Both curing (for pigment) & steaming (for discharge) can be carried out in this

m/c for curing there are 2 radiators & 2 blowers.

o Pre steaming arrangement is here to avoid dropping in the fabric.

o Both feed & delivery are on same side of the m/c

Defects :

Tearing of the fabric inside the m/c.

Dropping of water droplets on the fabric. This occurs if roof temp.

Is inadequate or steam contains water molecules. Insufficient development. This occurs amount of safolite in the

print paste is low, level of water in tank is low or amount of steam is sufficient.

LOOP AGER

Name of the m/c loop ager Machine make Swastik textile

Engineers pvt. Ltd.

Machine speed 15 m/min(normal)

1-2 m/min (min.)

30 m/min (max.)

Steaming time 6-15 min.

Temp. with in the m/c 101 c for

discharge Roof heating system steam

No. of exhaust 2

No. of loops formed inside the m/c 30


In this m/c the feed and delivery is located on different sides of the m/c. Fabric loop is formed at

the feed by a loop former situated at the feed. The fabric inside the m/c is moved by means of

guide bars. Since the fabric is in loop from so the length of the fabric and hence steaming time ismore roof is steam heated to avoid droppings. Water tanks are there at the right hand side of the

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m/c water is heated by hot oil to produce steam. Discharging agent present in the print paste

forms a fume inside the m/c with help of saturated steam, which actually develops the color on

the fabric surface channels of exhaust system are located inside the m/c to avoid droplets looplength and speed of the m/c is adjusted according to the nature of the fabric and the nature of

design.

Special features of the m/c :

o As the fabric passes inside the m/c in loop form, more steaming time is available.

o Loop length inside the m/c can be varied so developing time can also be varied

according to the nature of the fabric and nature of design.

Defects :

o Tearing of the fabric inside the m/c.

o Dropping of water droplets on the fabric. This occurs if roof temp. Is not proper,

steam contains water particles.

o Insufficient developing. This occurs if amount of safolite in the printing paste is

low, level of water in tank is low or amount of steam is sufficient.

o Discharging of the base color at undesirable places. This occurs due to thefollowing causes :

1. Safolite causes fumes of sulphur dioxide, which mixed with the steam and forms fumes

of sulphurous and sulphuric acid. These fumes damage the base color and also the

cellulose.2. If two neighboring loops touch each other side and if discharging agent of one loop

discharges the base solor of neighboring loops at undesirable places, patchy marks

appear in the fabric causing damage.

Curing machine (Continous type)

Name of the m/c Curing m/c or Polymeriser

Machine make Gayatri m/c products

Thread length 140 mts.

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Speed of m/c 6-8 m/min (min)

20-50 m/min (max.)

Drying system hot air

Steaming system 6-10 min. Temp. with in the m/c 150-180 c

No. of blower 4 (2 at feed & 2 at delivery side)

No. of exhaust 3

No. of radiators 2 (1 at feed &1 at delivery side)

Brief description of the m/c :

The delivery and feed are located on opposed side of the m/c. Set of guide rollers arethere at the top as well as at the bottom of which top rollers are driven by chain and

gear. Fabric simply passes through these guide rollers, two radiators are there one at thefeed & the other at the delivery through which hot oil is circulated two blowers areprovided behind each radiator, which blows hot air to the fabric and curing is done by

this hot air exhaust systems open from time to maintain proper temperature inside the

m/c speed of the m/c is adjusted according to the nature of the fabric and the nature of

the print pattern.

Defects :

o The major defects of this m/c is tearing of the fabric inside the m/c

o Sometimes fabric is folded at the selvedges leading to improper curing.

Curing machine (loop type)

Name of the m/c curing m/c

Makers name Swastik Textile Engineers Pvt. Ltd.

Thread length 150 m

Speed of the m/c 15 m/min (normal)

30 m/min (high)

Drying system hot oil

Curing time 6-15 min.

Temp. In the m/c 150-180 c

No. Of exhaust 1

No. Of loops formed 30

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In this machine the feed and delivery is located on different sides of the machine fabric

loop is formed at the feed by a loop former situated at the feed. The fabric inside themachine is moved by means of guide bar. Since the fabric is in loop form so the length

of fabric and hence curing time is more loop length and speed of the machine is adjusted

according to the nature of the fabric and the nature of the design.

Special feature of the machine

As the fabric passed inside the machine in loop form, more curing time is available Loop inside the machine can be varied so curing time can also be varied according to the

nature of the fabric and the nature of the design.

Defects

Tearing of the fabric inside the machine

Immature curing of the fabric

Sometimes fabric is folded at the selvedges leading to improper curing in that portion of

the fabric.

Washing zone

Printed fabric is washed either in the continuous washing range or open widthprint washer. Georgette or moscrepe fabric are washed in the width in the winch machine

since the wet strength of these are very low.

Open width print washer

Name of m/c Open width print washer

Machine maker SM Energy Teknik & Electronic ltd.

Length of washing zone 45 ft

Length of drying zone 18 ft

No. Of washing chamber 6(chemical is applied at third chamber)

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No. Of drying cylinders 12

Speed of m/c 40-80 mts./min.


o Feed the fabric is feed into the machine through guide rollers from trolley or

palette.

o First chamber fabric is passed over a special type of perforated roller and cold

water jet is sprayed on the fabric.o Second chamber fabric is passed over a wire mesh in the form of an extended

pleated form. Water jet is applied on the fabric from top. This helps to

remove impurities from the fabric.

6. Finishing Department

This department takes fabric from printing and dyeing department. Stenter machine is commonly

used in this department, main use of this m/c is to develop the feel of fabric and to give the final

touch. In discharge printing this m/c is used to develop the printed portion.

Stenter:-

Specification:-

Machine name Stenter

Manufacturer Smecon

Speed :

For light weight fabric 69 m/min

heavy weight fabric 20m/min

Pressure 1.5 bar in side

1.6 bar in centre

Drying tome 30 sec

Blown fans 10

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Exhaust fans - 3

No. Of radiators 5

Length of chamber 3m

Process type - continuous

Form of feeding open width form

Temp.(in0

C) of chambers :

1st 2nd 3rd 4th 5th 6th

175 192 182 193 190 194

Sanforiser

The main work of this m/c is to control the shrinkage of fabric..

Specification:

Manufacturer Ramson

Process type continuous

Speed 50 m/min

Heating arrangement direct steam supply

Form of feeding open width form

Process

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Fabric is feeded to the m/c from feeding end and it passes through a rubber

blanket running in contact with hot shoe. Then it enters over a blanket running over a

metal drum. Various parameters of m/c setting are given below:

(a) main steam pressure 6kg/cm2

(b) drum rubber belt 2.5kg/cm2

(c) palmer 2kg/cm2

(d)speed of m/c 50m/min

Fabric is collected in trolley or batch after passing through m/c.

Non confirmity product

1. Shade is not matched

2. Shrinkage is not within limits3. Different types of stains in fabric

4. Skew, bowing is observed in fabric

5. Rubber mark, of crease is observed in fabric

6. Centre-selvedge variation is observed

Preventive remedies:

1. Shade is not matched.

If difference is less ,then it is carried out in stenter by pigment topping.

If difference is higher and also the quality of material is high then it is matched in dyeingdepartment

2. Shrinkage is not within limit

In weft direction if shrinkage is greater than 3% then it is re-stretched and set the width to

keep shrinkage within limit.

In warp direction if the shrinkage is greater than 3% then it is de-sanforised to keep theshrinkage within limits.

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In case if shrinkage is too small that is less than 1% than it is re-sanforised to increase the

shrinkage but within 3% limit

3. Different types of stains in fabric

After several experiment, the chemical or route is decided by the concerned person in thelab. The stain is removed from the fabric either in jig or by gunning.

If stain is not removed then fabric is converted in black shade.

4. Skew, bowing is observed in fabric

The fabric is re-stentered through bianco where skew-bowing is corrected.

. 5. Rubber mark, o-o crease is observed in fabric

During power failure in sanforiser rubber mark and o-o crease is occuered. This fabric isre-stentered.

7.Folding department

In this department, fabric is checked. If they find any big fault they send it in rejection

department. If the fault is not so big and it is covered in reprocessing they send it for re-process.

If the fabric is fresh they send this fabric in excise department for dispatch. They use 4 pointsystem for inspection.

Machines used in folding department

Fabric inspection table:-

No. of tables 7

No. of checkers 2 (one on each side)

Specifications:-

Dimensions 96*48

Fabric form folded form

Production 7000mts. / shift.(depend on workers)

Illumination 2 tube lights right above the table

8.1.2 Fabric inspection machine:-

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Make Trueshape

Number of machines 7

Number of operators 2 (1 checker + 1 helper)

Specifications:-

Speed variable (0 - 100 mts / min.)

Angle of table 60

Fabric width 71 (max)

Illuminations top and bottom lightening (6 tubes each)

Other accessories length metering scale (automatic)

Width measuring scale

Forward and reversing mechanism

Production 5000 mts. /8 hours

Differentiation of defects:-

Defects found in fabric is differentiated according to the colour of sticker-

Defect poi colour

1 to 3 inch 1 yellow sticker

3 to 6 inch 2 green sticker

6 to 9 inch 3 orange sticker

9 to 12 inch 4 pink sticker

Q1 - 40 points/100yard2 i.e. Accepted.

Q2 - 40-55 points/100yard2

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Q3 - short piece i.e. 3-10mt. Length fabric roll

Q4 - rejected.

8.Lab section

Instrument used in the lab

Dyeing lab

Instrument make Model Purpose

Paramount Digi light Digitally light fastness tester

Data color

International

Ahiba infra red dyeing m/c Exhaust dyeing

Mathis Padding m/c Padding (for PDPS)

Mathis Mathis infra red dryer Drying (for PDPS)

Mathis Chemical pad, steam, washing

range

Padding,steaming, washing (for

PDPS)

Mathis Curing & steaming m/c Curing & steaming

- Distilled water plant For distilled water

Mathis Printing m/c Sample printing

Paramount Paramount digi wash Exhaust dyeing, shrinking checking

Ifb Maxidry 4550 Tumble dryer

Ifb Supermol Washing m/c

Ifb Senator Washing m/c

Jindal scientificind.

Jindal instruments Oven

- - Desiccators

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Countron 7100-02 pH indicator

Jindal Muffle furnace Drying

Physical lab

Instrument make Model Purpose

Paramount Astmd 1424 Tearing strength tester

Toshniwal - Digital thermometer

Paramount Crease recovery tester Crease recovery

Paramount Beesley balance Direct yarn count

Paramount Digital pilling tester Pilling

Paramount Digi tra epi & ppi

Paramount Cutter Cutting

Paramount Polarising projection microscope Yarn dia.Paramount Martindale abrasion tester Abrasion testing

Paramount Digi crock Rubbing testing

Grateg Macbeth Spectralight 111 Color matching cabinet

Paramount Digi strength Seam, lea and tensile tester

Paramount Drape meter Draping coefficient

Paramount Digital incubator Drying

Presto precision standard Sublimation tester Sublimation fastness

Paraount Twist tester Tpi

Paramount Digi wrap Reeling

Laboratory dyeing

A. Pad dry pad system

1. Vat dyeing

Padding

Mangle pressure:- 2 bar

Speed :- 1.8 mts./min.

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Color trough recipe

Drying

Infra red drying:-

Speed:- 2 mts/min.

Pad steam washer

Speed:- 2 mts/min.

Chemical trough recipe

Chemical Purpose Quantity(in gpl)

Hydrose Vatting agent 31

Naoh (48be) Solubilising agent 33

Common salt Exhausting agent 10

Sodium nitrite (for blue rsns) Oxidising agent 5

Albatex or (only for dark shade) Levelling agent 2

Mother liquor 70

Pick up 65%

Washing chamber Ingredients Tempreture

( c)

Pressure

(in bar)

First Cold water 30 2

Second Resist salt 90 2

Third Soap 95 2

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Fourth Hot water 95 2

Fifth Acetic acid 30 4

2. Reactive dyeing

Padding

Speed 2mts/min

Pressure 2 bar

Color trough recipe

Chemicals Purpose Quantity (in gpl)

Primasol amk Anti migrating agent 5/10/15

Ciba flow pad De aerating agent 2

Resist salt Mild oxidising agent 2

Pick up 60%

Drying

Infrared dryer

Speed:- 2 mts./min.

Pad steam washer

Speed :- 2 mts./min.

Chemical trough recipe

Chemical Purpose Quantity (in gpl)

NaOH (48be) Fixation agent 9

Soda ash Fixation agent 20

Common salt Exhausting agent 250

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Dekol fbsn Chelating agent 2

Mother liquor (only for bulk dyeing 70

Pick up 65%

Washing chamber Ingredient Temperature

(c)

Quantity

(in gpl)

First Acetic acid 30 2

Second Water 70 2

Third Soap 95 2

Fourth Water 95 2

Fifth Acetic acid 30 4

B. Cold pad batch dyeing

Reactive dye

Padding

Mangle pressure:- 2 bar

Speed:- 1.8 mts./min.

Color trough recipe

Color :- x gpl

Ciba flow pad:- 2 gpl

Urea:- 100 gpl

Chemical solution:- 1/5 of total volume

Chemical solution

Sodium silicate (grade 1):- 425 gpl

Caustic lye(38be) :- 20 ml/l

Storage time :- 16 hours

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It is followed by cold wash (30-40C) --- soaping at 90C hot wash (95C) rinse .

It is observed that whether the fabric inside the drying zone is moved properly without folding.

Measures to be taken before starting the machine

Speed of the machine is set according to the nature of the design. For a design of less number ofcolors the speed is set at higher side. But for a very fine design the speed is lowered.

Pressure of the pressure roller is adjusted according to the nature of the fabric and nature of

design.

Action of the brush rollers and the suction system is checked.

PVA roller is cleaned properly.

All the motors pumping the liquids (water, colors) are checked.

Temperature of the drying chambers are adjusted properly according to the requirement

Mathis printing machine

Purpose :- for testing the new printing colors

Speed :- 6-8 mts./min.

Magnetic intensity :- 0-10 flux

To run

1. Apply gum on the table surface2. Spread the fabric sample on the surface

3. Place designed frame on the surface

4. Switch on the main switch and magnet5. Set magnet intensity and speed

6. Bring the iron bar at the start position

7. Put the printing paste at the start position

8. Set the direction of movement of bar

9. Press turn button to start printing.

To stop

1. Switch off the magnet and transporter

2. Remove the frame and iron bar3. Remove the fabric sample gently

4. Switch off the main switch

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Testing carried out in the lab

Water testing

Following tests are performed on water.

o ppm (parts per million)

Procedure

1. Take 50ml. Of water (to be tested) in a beaker.2. Titrate it against solochrome black solution until color of water changes to blue.

3. Now add two three drops of ammonia buffer.

4. Then titrate it against EDTA solution until the color of solution turns white.

Test for core pH

Procedure

1. 250 ml of distilled water (of ph 6.5-6.6) is taken in a beaker.

2. It is boiled for 10 min.

3. Now add 10gm of fabric to be tested, cut in smaller pieces.4. Again boil for 10 min.

5. Cool down the solution to the room temp.

6. Check pH of water using electronic pH meter.

Calculation of count

1. Using the Bessley balance

Procedure:-

1. Cut the fabric piece in both warp and weft direction according to the size of

template.2. Put the rider on left side of the Bessley balance.

3. Remove the threads from the fabric and put in the right side of balance to balance the

weight of rider.4. No of threads required to balance the rider weight gives directly the count of yarn

used in the warp and weft direction.

2. Without using Bessley balance

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Procedure:-

1. Cut the fabric sample of any size.

2. Remove at least 10 threads from the sample (all of equal size)3. Measure the length of the thread after removing the crimp.

4. Weigh all the threads.5. Use the following formula:

Count = no. of threads*thread length *0.00535

Weight of all threads

Final Mill Tariniggng Report

Documents

Transcript of Final Mill Tariniggng Report