SRI BHAVANI TEXTILE PROCESSING:

The plant performs the following operations of wet processing

1. Singeing(Fabric)-Gas Singeing

2. Desizing3. Mercerisation(Fabric)4. Scouring and Bleaching5. Dyeing

-Kier boiler-Jigger-Jet dyeing-Beam dyeing

6. Dyeing(yarn)-Cheese dyeing

7. Finishing-Stenter-Zero-Zero-Calendering

8. Printing-Flat bed printing

9. Dot coating

DESIZING:

Mts=1095

Volume=650

Indent type=non organic

Temp=80

Weight=378

Time: 1: 15 min

Wash time:15 min

ITEM NAME G/L PERCENTAGE QUANTITYBeisol AFG 0 0.5 1.89Kleenox BAS 0 0.1 0.378Caustic SLYE 0 4 15.12KLENOX BAS 0 0.5 1.89Zycol TSA 0 0.3 1.1340Hydrogen peroxide 0 1.5 5.6700Contavan BRT 0 0.25 0.94500KLEENOX BAS 0 0 0.945Acetic acid 99% 1.5 0 0.975Caustic soda LYE 0 2 7.56KLEENOX BAS 0 0.25 0.945ZYCOL TAS 0 0.15 0.567

BLEACHING:

Mts=442

Weight=206.4

Volume=450l

Type=non organic

Temperature=80

ITEM G/L PERCENTAGE QUANTITYBleaching liquor 2 0 0.9Soda ash 0 0.05 0.10Hydrogen peroxide 0 1.5 3.09Sodium silicate 0 0.5 1.03270Sarometa 0 0.1 0.206Sapoleneconc 0.5 0 0.295Acetic acid 99% 2 0 0.90

MACHINE AND CAPACITY DETAILS

S.NO M/C CAPACITY(kg) VOLUME(litre) WIDTH(inch)1 Kier make up

tank735

2 Kier capacity 1500 3 Beam dying m/c 100 800 634 Jet dyeing m/c 100 9005 Jumbo jigger

1-3300 350 74

6 Jumbo jigger 300 350 747 PACIFIC jigger 1000 6008 Jigger 1 to 2 150 450 849 Jigger 3 to 4 125 375 72

10 Kier boiling 1500 3000

KIER BOILER

It has capacity of 15000 to 17000 Fabric from grey mercerization undergoes cold wash. Fabric from desizing undergoes hot and cold wash Then the material from both undergoes caustic boil in kier boiler Inside kier hot wash and cold wash is done Then treated with Hcl for scouring twice. Then cold wash is done after that soda is added Then the fabric is treated with chlorine for two times.

Then cold wash along with tinting is done.Then treated in hydrogen peroxide boiling for 4 hours in open boil.

DHOTHY BLEACHING

Grey Mercerization (or) Desizing

↓

Cold Wash

↓

Chlorine – 2 times

↓

2 Times Cold Wash& wash in Kier

↓

Hydrogen Peroxide – Bleaching with given Time & Temperature

↓

Cold Wash – 2 Times

↓

Acetic Acid

↓

Cold Wash& Tinting & Opening

JUMBO JIGGER for dyeing

Desizing / Singeing

↓

Caustic Soda

↓ Hot Wash & Cold Wash

Chlorine

↓

Hydro chloric Acid

↓ 3 times Cold Wash

Dyeing

Desizing

↓ Hot Wash

Soda Boil

↓

Hot Wash & Cold Wash

↓

Hydrogen Peroxide Boil

↓

Cold Wash – 2 Times

Hot Wash - 3 Times

↓

Acetic Acid

↓ Cold wash

Dyeing

For white

Singing

↓

Caustic Soda

↓

Hot Wash

↓

Cold Wash

↓

Chlorine

↓

Cold Wash

↓

Peroxide Boil & (2B)- which gives half white

↓

4 Times Washing

After 4 Times washing 2B is added with less steam

↓

Hot Wash

↓

Cold Wash

↓

Acetic Acid

↓

Cold Wash

↓

Drying

BEAM DYEING

In this process the solution only rotates. Beam width is 180 cm Holes to holes 150 cm

BEAM DYEING PROCESS

making of beam batching as per the width of fabric and overlap should be 3.5 cm over the beam end piece should be placed to reduce the end variation in fabric fabric should winded with proper tension in beam dying m/c water capacity is 800 ml reverse I s 3 minutes glycerein should be placed in rubber washer above the end piece a fabric should be place to reduse the shade variation after placing fabric water is added. After accetic acid and saromata and then steam make it 60deg temperature then check pH when pH is 4 to 5 sarcomata carrier TCI is pump into it maintain to 60 deg and added leveling agent (cidogen DETC is pump into it) when pH is not B/W 4 to 5 acetic acid also added then dye is added then temp is added to 90 deg by 10 minute I.e for every 1 minute 3deg is increased afer attaining 90deg. Every 1 min 2deg is added attain 130 deg within 20 minutes At 130 is maintain to 10 to 15 minutes Simple is checked Temperature is redused to 90 deg m/c is ruin off when shade is not match again repeated after comes to 90 deg due to high temperature and pressure after complete rein off

Speed is 20 to 120 m/min and width of fabric from 60 to 160 cm

Temperature varies, depends on fabric

DRYING / PADDING

Dyes : silicate = 4:1

To Remove excess colour

→ hydros caustic for 6 end

PRINTING:

Flat screen Printing machine -1 No.

Labours - 6

FLAT SCREEN PRINTING

-Reactive

-Discharge

-Pigment

Note:

PVA is applied to the blanket to hold the fabric tightly whose intensity varies according to fabric thickness & repeat of the print.

REACTIVE:

Printing the fabric using reactive dyes.

After printing is done, fabric is passed through silicate padding for curing for a minimum of 16 hrs to a max of 24 hrs.

Drying Calendaring Finishing

The fabric to be passed through silicate padding is passed with the print downside.

Pressure of the padding mangle = 3.5 kg

DISCHARGE:

Fabric is passed through the ager for curing after printing.

The color of the fabric/print looks grey i.e. in the dull dust color after printing.

The required color of the print is attained only after ageing.

PIGMENT:

Pigment is used as the printing paste.

The print is dried in steam after printing, which sets the print & gives the original color.

RECIPE FOR PREPERING PRINTING PASTE:

1. Alsinate -45 kgs2. Cisalsin -8 kgs3. Kerosene Emulsion – 7kgs4. Water - 40 kgs

First mix cisalsin& kerosene Emulsion with water, then add Alsinate.Incase of Reactive paste, after mixing the paste with dye, purify the mixture.

ALSINATE:

1. Alsinate powder -3.5 kgs2. Printing gum -1 kg3. V.M Powder -0.5 kgs4. Hot water(40-45◦C) -95 Kgs

Add in mixer & prepare the paste.

CISALSIN:

1. Cisalsin powder -10 Kgs2. Emulsifier -1 Kg3. M.T.O -20 Kgs4. Hot Water(40-45◦C) -70 Kgs

First add cisalsin powder & mix in hot water & then add M.T.O & Emulsifier.

KEROSENE EMULSION:

1. M.T.O -90 Kgs2. Emulsifier -1 kg3. Water -10 Kgs

First mix M.T.O & Emulsifier and then mix it with water slowly

PIGMENT PASTE:

1. Binder -10 Kgs2. Lubrindal M.C.L -1.5 Kgs3. Lutex H.E.F -2 Kgs4. Urea -1.5 Kgs5. Water -70 Kgs

First mix binder and urea with water and then add lubrindal M.C.L & then mix lutex H.E.F.

BOILERS:

1. STEAM BOILERMake :Thermax, PuneModel :CPF60A/W54/5Capacity :6000Kgs/hrYear :2002Reg.No :T 6908Fuel : Groundnut Shell

2. THERMOPACMake :Thermax, PuneModel :VTA 15/121Capacity :15 lakhs/Kcal/hrYear :2003Fuel :Fire wood

YARN DYEING:

Capacity:

M/C Capacity Quantity Totalkgs Water Consumed/Mc

300 2 600 3000 Lts600 1 600 6500 Lts

150 1 150 1500 Lts125 1 125 1250 Lts75 1 75 750 Lts50 1 50 500 Lts30 1 30 300 Lts10 1 10 100 Lts5 1 5 50 Lts

TOTAL 1545 15950 Lts

DYEING PROCEDURE:

S.NO PROCESS TEMP (◦C) TIME (mins)1 Scouring/Boiling 95 452 Hot Wash 80 103 Acetic Acid/EAT 50 154 Light & Medium shade

dyeing60(1◦C/min) 60-75

5 Black Shade dyeing 60(1◦C/min) 906 Dark Shade dyeing 60(1◦C/min) 907 Addition 60(1◦C/min) 308 Washing 50 15 9 Washing(Acetic) 50 15

10 Soap(ADW &Sapoline conic)

95 15

11 Washing(Acetic acid/ZAB) 60 3012 Soap(Zycol AB) 98 2013 Cold Wash 27 1014 White Boil 100 9015 White Finishing 50 1516 Fixing(Hi fix) 50 1517 Fixing(For Pmf(erl)) 40(1◦C/min) 3018 Finishing 50(1◦C/min) 1519 Boil Soap & Soda(For

P/model,viscose,P/Viscose)95 20

20 Polyester dyeing 135(1.5◦C/min) 30

HYDRO EXTRACTOR:

Make: Lakshmi

Max: 24 cheeses

Time: 2 mins

Production: 600 Kgs/Shift

RF DRYER:

Make: Lakshmi

Model: INSTA 40/11

Year: 2004

Supply Voltage: 415 V ± 5 %

3Ǿ, 50 Hz

Input Power Requirement: 86 KVA

RF: 27.12 MHz ± 0.6 %

CONCLUSION

Thus this report provides the general features and composition of SRI BHAVANI TEXTILE PROCESSING equipped with latest machineries, skilled and qualified labours in the wet processing sector of both yarn and woven fabrics. This would prove to be an example of a well-managed industry in terms of technology as well as man power with sufficient resources and its effective utilization.