TEXTILE INTERNSHIP

REPORT

Vivin Tex

Ashwini Kumar (BFT/20/1585)

Tanisha Chaudhary (BFT/20/1015)

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 TEXTILE INTERNSHIP
REPORT

Vivin Tex

Ashwini Kumar (BFT/20/1585)

Tanisha Chaudhary (BFT/20/1015)
Department of Fashion Technology, 2020-24
National Institute of Fashion Technology, Kannur

13th June TO 25th June 2022

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 ACKNOWLEDGEMENT

We have got a great learning experience throughout this internship to see one of the
most well planned and advanced textile units. We wish to express our sincere gratitude
to Vivin Tex and to Mr. Sarvanan.D sir who gave us the opportunity to undergo
internship at Vivin Tex.

Expressing our heartfelt thanks to all those who have contributed

directly or indirectly in completing the internship.

We would like to thank NIFT Kannur for giving us this opportunity and facilitating
our internship. We also extend our gratitude to our mentor Chandramouli sir and all
staffs, lab assistants, technicians and other workers for their support and
encouragement during the period of our internship.

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 CERTIFICATE

This is to certify that this Report titled “Textile internship” is based on our, Ashwini
Kumar (BFT/20/1585) & Tanisha Chaudhary (BFT/20/1015), original research work,
carried out in partial fulfilment of the requirement for award of the Bachelor’s Degree in
Fashion Technology (Apparel Production), of the National Institute of Fashion Technology,
Kannur.

Signature of Course Coordinator Signature of mentor

Date

4
The main objectives of the project/internship were:

1. Understanding basic principles of production of textiles.

2. In depth study and understanding of all process involved in textile

production and the machinery and equipment used.

3. Knowledge about the company

4. Understanding the company’s process flow in production

5. Study the work environment and practices followed for textile production.

6. Study the faults and critical factors of production and determine the practices

adopted by the industry.

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6
7
 INDEX

Storage Room 13

Knitting 16

Dyeing 15

Printing 23

Finishing 28

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 DECLARATION

We Ashwini Kumar and Tanisha Chaudhary hereby declare that the internship
project report titled “Summer Textile Internship”, submitted towards the
fulfilment of two weeks internship is our original work and no part of the project
has been copied from any other reports or any other work carried by someone
else. Which has been submitted for any other degree or award. However, any
material taken from any other published source has been suitably referred and
acknowledged at various spaces.

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 PROJECT ABSTRACT

Project Type Textile Internship

Industry Vivin Tex
Address 1/999-B3 Lakshmi Ammal
Nagar,
Anna Nagar East, Poluvapatti,
Tiruppur - 641602,
Tamil Nadu, India.
Contact [email protected],
[email protected]
Mentor Mr.Sravanan

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 ABOUT COMPANY

▪ Vivin Tex was established in the year 2012 in Tirupur,

India with the vision ofmaking a great product with the
right expertise that will meet the market trend and demand.

▪ We are 108 people working across the supply chain as of now and
able to produce 70 thousand units per month and aiming to expand
to 150 thousand units per month in the near future.

▪ By Placing responsible and ethical business practices

in the center of what we do we promote progressive
and innovative mindset while consistently deliver
high- quality products and services to our customers.

▪ Our core product is a full range of circular knit from basics to

fashion and active wears for men, women and kids. We do
have strong expertise skill set on performance finishes such
as Antimicrobial, ultra-fresh, water repellent, cool skin
finishes in our product range.

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 List of Their Clients/ Buyers

 Disnep

 Lord Daniel - US

 Wrogn

 Roadster

 Chaos and order brand

 First Cry

 Aditya Birla

 JBC - Belgium

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Raw Material Store Room

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Objective
The Raw Materials Department is the department from where the work starts in the
plant. The main objectives of raw material department are storing, issuing, and
reconciliation of raw material intended for manufacturing.

System and Procedure

Work takes place in the following systematic order: -

The orders are placed in the Marketing Department, at the Head Office
stationed in Tirupur Tamil Nadu. The customer specifies its requirements in
the order.
A sales order is then prepared giving a systematic description of the
requirements by the Marketing Department, which is then sent to the factory.
The Sales order is received at the production planning and commitment department (PPC).
The PPC Department then makes the production planning chart
which includes allthe characteristics of the yarn required.
The Production Program is then sent to the Raw Materials Department.

Role of Raw Material Department

It receives the material, which is ordered by production department and issues the required
material to the department. In case of rejection, it stores the rejected material and returns it
to the seller end.

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Functions

• Development of collection for all the markets

• Domestic, International.

• Technical service (determining the technical details of count, TPI, twist direction,
etc.)

• To determine the following functionality of Designing Automation System.

• Business requirements.

• Linking of Design Department to Export/Product Department.

• Color Story Generation.

• Bulk/ New Shade Generation.

• Entry of New Cloth Card for Feeler and Sectional Sample.

• Yarn Order Story diversion for Samples.

• Yarn Consumption and Yarn Reservation.

• Creation of various master like brand, party etc.

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Chapter 1
Knitting

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Knitting

Knitting is a technique to turn thread or yarn into a piece of cloth. Knitted fabric
consists of horizontall parallel courses of yarn which is different from woven
cloth. The courses of threads or yarn are joined to each other by interlocking
loops in which a short loop of one course of yarn or thread is wrapped over the
another course.

Definition:
Knitting is a process of fabric forming by the intermeshing the loops of
yarns. When one loop is drawn through another, loops are formed in
horizontal or vertical direction

Weft knitting:

Weft Knitting is a method of forming a fabric in which the

loops are made inhorizontal way

Warp Knitting:

Warp Knitting is a method of forming a fabric in which the

loops are made in vertical way along the length of the fabric
from each warp yarns and intemeshing of loops take place in
a flat form of length wise basis.

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Knitting Structure:

Course:
The series of loops those are connected horizontally, continuously arc called as
coune. The horizontal row of loops that are made by adjacent needles in the
same knitting cycle.

Wales:
The series of loops that intermeshes vertically are known as Wales Vertical column of
loops that are made from same needle in successive knitting eyelet.

Knitted stitch:
The knitted stitch is the basic unit of intermeshing, It usually consists of three or more
intermeshed needle loops.

Stitch length:
The length of yarn required to product is known as stitch length or lop length a
complete knitted loop (Nelle loop and sinker loop)

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Knitting Variables:

Yarn Count
Yarn Twist
Spinning System
Yarn ply
Stitch length
Yarn tension
Take down tension
Machine gauge

Classification of Knitting Section:

In the knitting section of Vivin Tex (knitting Unit) all the machines are placed in to the same
floor only one section they had that is Circular knitting Section.
They have 10 knitting machines from Lakshmi (origin: Coimbatore local) and Pegasus Evo
(origin: German). Per day factory capacities is 2 tone.

Circular Knitting Section

Circular knitting machine is widely used throughout the knitting industry to produce
fabric. This machine can be built in almost any reasonable cameter and the small
diameter up to live. Which are used for wear. Machine for outerwear and under wear
may vary from 12 inch to 00 inch in liar meter according to manufactures requirement.
This machine can be used either us fabric or for making garments completely with
fancy stitch.

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Match needles are commonly employed in all modern circular machines because of
their simple action and also their ability to process more types of yarns Plain circular
machine uses only one sets of needles, circular b machine uses two sets of needles
i.e. Cylinder needle and Dial needle, the interlock circular knitting m/e also uses two
seis of needles by needles are long and strong As precatively for both dial and
evildoer. that is why multiple design and thick fabric can be produce with that
machine That machine is also called double Jersey machine.

Different parts of circular knitting machine:

Creel: Creel is a part of a knitting machine. Hear yarn package are store and
ready to feed in the machine

VDQ pulley: It is a very important part of the machine. It controls the quality of
the product. Altering the position of the tension pulley changes the G.S M of the
fabric. If pulley moves towards the positive directive then the G.S.M, is decrease.
And in the reverse direction G S Mwill increase

Pulley belt: It controls the rotation of the

Brush: Its clean the pulley belt

Tension disk: It confront the tension of the supply Yarn.

Inlet and outlet stop motion: It is an important part of the machine, it stops the machine
instantly when a vim is break instantly.

Yarn guide: Its help the yarn to feed in the feeder

MPF Wheel: Its control the speed of the MPF. Pulley belt gives motion to the wheel.

Needle: It is a principal element of the knitting machine. Its help the yarns to
create a loop. And by this way fabric are produce. Prior to yarn feeding in needle
is raised to clear the old loop from the hook, and received the new loop above it
on needle stem, The new loop is thenenclosed in the needle hook as the needle
starts to descend

Feeder: Feeder is help yarn to feed in to the machine.

Feeder ring: It is a ring, where all feeders are pleased together.

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Needle track: Where all needle is placed together in a decent design

Sinker: It is most important element of the machine It helps to loop forming,

knocking over and holding down the loop.

Sinker ring: Sinker ring is a ring, where all sinkers are pleased
together.

Cambox: Where the cam arc set horizontally

Cam: Cam is devices which converts the rotary machine drive in to a suitable
reciprocatingaction for the needles and other elements.

Lyra Attachment: Lycra is placed hear. And feeding to the machine.

Lycra stop motion: It is one kind of stop motion to stop the machine when the lycra is
break.

Cylinder: Needle track are situated hear.

Cylinder Balancer: It helps the cylinder to set in a proper alignment.

Screen: It is a digital screen which show the all machine information and we can give command
according to our need to the machine.

Automatic oiler: It gives the machine oil all the time properly and automatically.

Power Switch: To give the power to the machine.

ON/OFF Switch: Helps the machine to start and stop.
Manual drive: To drive the machine manually.
Machine Motherboard: All the electronic parts are placed.

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Process Circular Knitting Section in Vivin Tex

Sample Fabric
Design
Analysis

Machine Setting for the Required Design

Knitting of the Fabric

Conform Required Quality

Types of yarn uses in Vivin Tex

Colleen

Viscose

Polyester/cotton

Polyester/viscose

Slub yarn

Types of knitted fabric Produced by Circular knitting m/c:

1. Rib
2. Interlock
3. Fleece
4. Terry
5. Mash

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Causes:

Yarn tension variation during production buckling of the needle latch.

Low G.S.M fabric production.

Remedies:

Contain some yarn tension during production

Use good conditioned needles.

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CHAPTER 2
DYEING

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Dyeing

Dyeing in Vivin Tex

Two type of dyeing process were there one is yarn dyeing and another one is piece dyeing.

1. Yarn Dyeing
2. Piece Dyeing

1. Yarn Dyeing:

The process of applying desired color to the spun yarn is termed as yarn
dyeing.

Feed: Undyed yarn

Delivery: Dyed yarn

Yarn Dyeing can be categorized into two forms

• Package Dyeing
• Hank Dyeing

2. Piece Dyeing:

The process of applying desired colour after weaving or knitting is termed as

Piece dyeing.

Feed: RFD (Ready For Dyeing) Fabric

Delivery: Dyed Fabric

• Pad-Batch Dyeing (Exhaust Dyeing)

• Semi-Continuous Dyeing
• Continuous Dyeing

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1. Yarn Dyeing

Significance of Yarn Dyeing

• To give specific colors to the yarns
• To create interesting checks, stripes and plaids
• To help dyestuff to penetrate to the fibers in the core of yarn
• Yarn dyed fabrics are usually deeper and richer in color

Dyes used in the Industry

• Reactive Dyes
• Vat Dyes

Lab Activity
• Shade Development
• In -Process shade matching
• Quality Testing (fastness)

There are two forms of yarn dyeing done in the industry

• Package Dyeing
• Hank Dyeing

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Package Dyeing

HTHP Package Dyeing

Dyeing method with High temperature and High Pressure in the form of packages
of any textile substrate in a pressure vessel is called as HTHP Package Dyeing.
Packages comes in two kind, either cylindrical or conical.

Process Flow Of Package Dyeing Process Of Yarn

1. Grey Receipt
2. Loading into Carriers
3. Dyeing of HTHP
4. Unloading from carriers
5. Hydro Extraction
6. Radio Frequency Drying
7. Packaging of Dyed Yarns

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Machines employed for Package Dyeing

Dalals Dyeing Machine

Fong's Dyeing Machine

Hydro Extraction Machine

Radio Frequency Drier

SOP of Fong’s Dyeing Machine

Total no of machines: 7

Capacities: 60kg/300kg

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SOP Hydro Extraction Machine
Manufacturer: Centrifuge Berta
RPM: 1470cycles
Capacity: 160kg
Power: 16 kw

1. Machine is used for removing excess water by centrifugal extraction.

2. About 65% of water is removed by this process.

3. The machine is life around basket made of steel.
4. There are many holes at the base of the machine.
5. It is moveable that moves and the water is removed by centrifugal attraction.
6. Extracted water is drained through the holes.

SOP of Radio Frequency Drier

RF Drying helps in the drying of the wet yarns that are dyed. RF dryer is the
machine used tocarry out the process.
No of Machines: 3

Consists of the following components:

• Conveyor belt
• Control panel
• Back side conveyor belt

The remaining water in the cones is removed by passing it through the chamber
of RF Drier. The cones are kept on a moving belt in the chamber. The time is
adjusted by increasing decreasing the speed of the moving belt in the chamber.
A wet product submitted to a Radio Frequency (RF) field absorbs the electromagnetic
energy so that its internal temperature increases. If a sufficient amount of energy is
supplied, the water is converted into steam.

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Advantages

1. Uniform drying at low temperature where only the humid parts are heated.
2. Energy Saving (1.2 kg water per kw/hr high frequency power).
3. Improved fiber quality and fastness.
4. Residual humidity controlled within 1%.
5. Constant and repeatable drying level.
6. Space saving and time saving.
7. Instant controls and adjustments.

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Piece Dyeing

Dyes used in the Industry

Reactive Dyes: In a reactive dye a chromophore contains a substituent that is
activated and allowed to directly react to the surface of the substrate. Reactive dyes
have good fastness properties owing to the bonding that occurs during dyeing.
Reactive dyes are most commonly used in dyeing of cellulose like cotton or flax.

Forms of dyeing process done in the industry

Pad-Batch Dyeing (Exhaust Dyeing)
Semi-Continuous Dyeing
Continuous Dyeing (not Practiced in the industry)

Pad-Batch Dyeing (Exhaust Dyeing)

Batch dyeing is the most popular and common method used for dyeing of textile materials. It
is often referred to as Exhaust Dyeing.

Machines employed for Pad-Batch Dyeing

• Jig Dyeing Machine

• Jet Dyeing Machine

Jig Dyeing

SOP of Jig Dyeing Machine

Water Capacity: 500kg

Max Temperature: 98

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Process of jig dyeing

1. Cleaning of bath roll

2. Leading cloth is joined to the feeding roller.

3. Manually parts to the feeding roller.

4. Warm wash. (2 times)

5. Color wash. (2 times).

6. Salt wash. (2 times).

7. Solid wash at 60c.

8. Piece cut.

9. Acid wash 60c.

10. Cold wash (6 rounds)

11. Soaping wash (2 times)

12. Hot wash (2 times)

13. Cold wash (2 times)

14. Neutralization (by CH3COOH)

15. Fabric is unloaded to the batch roller

16. Wrapped with plastic sheet

Jumbo Jigger

It is the old form jigger machine also known as Open Jigger

where the quantity of water/steam/ speed control is done manually
by the operator.
Total no. of machine: 2

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Semi-Continuous Dyeing (Exhaust Dyeing)
Semi Continuous Dyeing is also known as pad batch dyeing. Such form of dyeing
is able to dye fabric length of 1000-2000m at economic cost.
In the process of semi-continuous dyeing that consists of pad-batch, pad roll where
the fabric is first impregnated with the dye liquor in, which is called a padding
chamber. In the pad-rollthis treatment is done at low temperature by employing
cooling chamber. This helps in fixation of dyes on the fiber.

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CHAPTER 3
PRINTING

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Printing

Process Flow
1. order
2. design development
3. sampling (by screen printing)
4. sampling in printing machine
5. Paste preparation
6. final printing
7. curing
8. washing
9. zero - zero finish
10. packaging

Styles of printing

 In printing, style mikans the manner in which a printed effect is produced.

 It is distinct from the method of printing which involves the means by which the
pattern is produced.
 The Style of printing involves certain mechanical operation and chemical reactions.

Styles of printing they do

1. Direct style
2. Discharge style

Direct style

1. In this style, the color is applied directly to the fabric in the form of paste.

2. After printing and drying, the color is fixed by steaming or curing or thermo-
fixing or treatment with chemicals

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 3. Most classes of dyestuffs are printed by direct style

4. A direct print can be identified if the background is white, or has large portions of
white and the printed design is a lighter shade on the back of the fabric than on the
face.

5. This may not be evident on lightweight fabrics because of the strike-through of the
printing paste.

Discharge style

1. Discharge prints are produced through a two-step process.

2. In the first step, the fabric is dyed using a solid color.
3. In the second step, the fabric design is printed onto the fabric,
4. The print paste for the second step contains a powerful bleaching agent that
destroys the colorof the background dye.
5. A color discharge can be produced when the bleach agent and a dye (usually
vat) that does notreact with the bleach, are mixed in the same printing paste.
6. A discharge print can be identified if the background color is the same shade
on the face and back of the fabric.
7. The print design area is white or a different color or shade than the background.

Printing methods

1. Hand screen printing (Table printing)

2. Digital printing
3. Rotary screen printing

Printing Process

1. Rotary screen-printing machine is a further improvement of automatic flat

bed screen Phung machine.

2. erforated circular (or Cylindrical) metal screens are used for printing
instead of the flat s sreens.

3. The important part of this machine is the hollow, perforated thin shell of
nickel without a repeat joint.

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4. The squeegee lies inside the circular screen.

5. It is rod type or flexible blade type, activated by an electromagnet.

6. The machine is usually built for 6,9,12,15 or 18 colors for printing a

maximum width of 160, 180, 240, 320 cm.

7. If is suitable for printing any type of fabric of any construction, including knitted
fabrics.

8. Each screen is individually driven.

9. Printing paste is fed by special pumps individually to the different screens.

10. The print paste level inside the rotary screen is automatically and constantly
controlled.
11. The transfer of printing paste through the perforations of the screen on to the cloth
is governed byspecially designed squeegee blades.

12. Possible to fit the screen automatically whenever the machine stops, so that no
stop marks areproduced.
13. All screens fit in perfectly, independent of the movement of the fabric or the
blankets, so thata perfect fitting of the design is obtained consistently. Speed
of the machine can be adjusted from 10 to 100 m/min.
14. Printing is effected on a conveyor blanket, significantly shorter than the one
used for flat-bedprinting.
15. Printing machine is provided with a feed arrangement, a selvage
alignment unit and acontinuous gluing unit for gumming down the
fabric

16. Nowadays, vacuum principle is used for holding the fabric tightly, without any
movement andcreases.

17. For cleaning, each rotary screen can be dismantled and washed.

18. A change of pattern can be achieved in about 3 minutes per screen.

19. A high efficiency washing and drying unit is provided below the printing table.

20. Washing unit consists of circular brushes with constant water feed.

21. In vacuum principle-based machines, no washing unit is required.

22. The drying unit used hot air, the temperature of which is thermostatically controlled.

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Process

1. Order
2. Design development
3. Screen development
4. Sampling (by table screen printing)
5. Paste preparation
6. Sampling in printing machine
7. Final printing
8. Curing
9. Washing
10. Zero-Zero finish

Advantages Disadvantages

Highest production among all Not economical for short runs of the fabric
methods ofprinting. dueto the hitch dost of engraving of that of
a hand screen
Up to 24 colors can be printed and 8 to he sizes of repeal on the design is
10 colors can be printed easily. limited to about 85 cm. which is loss
than
Joint marks, which are perceptible in
other methods, are totally absent.

Half tone elects and vertical lines can be

produced very successfully by this method.

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Printing screen making technique:

Process

Design is created in design department. Then that design is first printed in digital
printing machine. After that design is forwarded to screen sampling department
forthe purpose to develop design on hand screen printing for creating sample.
Alter that des/an is passed to screen making department

There Nylon bolting cloth is taken. Synthetic photo solution is applied on it Then
it exposed in exposing machine for 2 minutes with tracing of design. Then it is
washed in water for development of design after that screen.

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CHAPTER 4
FINISHING

40
Finishing

Manufacturing Linen Textiles in Vivin Tex, finishing refers to the process that convert the
woven cloth into a usable material and more specifically to any process performed after
dyeingthe fabric to improve the loo, performance, or “hand” (feel) of the finished textile.

Process Flow Chart Of

Slit open

Dyed Fabric Bleached Fabric

Finishing on Stenter Machine

Calendering No Calendering

Sanforizing

Folding and Testing

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Stenter Machine

Stenter is a finishing machine which dries up the cloth and removes the
dimensional instability that occurs during the processing. The final finishing of
fabric is always done on a Stenter. The Stenters are normally provided with a
padder, a bow and a weft straightener device. The cloth to be finished passes
through the padder, where finishing chemicals are added and goes through how and
weft correction device before entering the drying chamber. It can be either pad or
dip tenter. The pair chains hold the cloth horizontally. The process is pad-dry and
drying is achieved by blowing hot air in the stenter chamber. The stenter is the most
important machine inthe finishing for stretching or stentering fabrics. The purpose
of the stenter machine is to bringing the length and width to pre-determine
dimensions and also for heat setting and it is used for applying finishing chemicals
and also shade variation is adjusted. The main function of the stenter is to stretch
the fabric width-wise and to recover the uniform width. Sometimes wetting agent
for example, a mixture of surface-active compound are used as chemical for the
heat setting and stretching process.

SOP of Stenter Machine

No. of Radiators:4
In each chamber maximum temperature: 180c
Standard temperature: 160-170c
Blower Fam speed: 100 rpm
Mangle: 2
DIP & 2 NIP Maximum NIP pressure: 6kg/cm2
Workable NIP pressure: 4kg/cm2
Workable width: 180 cm
Threading Length: 150m
Trough Capacity: 150L
Capacity: 150L
Standard Overfeed: 4%

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Components of Machine

1. Trough - Chemical is loaded on the trough.

2. Padding mangle - Squeezes out extra amount of chemical, leaving only

the required amount ofchemical inside the fabric. No dwell Time required.
(std mangle pressure-2.5kg)

3. Bianco - For head setting i.e, keep the warps vertically straight in one direction.

4. Overfeed roll - Shrinkage setting

5. Pinning table - To keep the width uniform

6. Camera - Moves left and right according to the image of selvedge on it.

7. Uncurler - Removes the curling of selvedge of fabric

8. Heat chamber - To dry the fabric. There are 6 heat chambers each with the
standard temperature of 150 c.

9. Detector and alarm - To detect any abnormalities in tension, load or

presence of dirt and ring alarm to inform the operator for immediate
action.

10. Platter area - Output zone

11. Air blower for cleaning.

Working process

The fabric is collected from the batcher to the scary and then it is passed through the
padders where the finishes are applied and sometimes shade and variation is corrected.
The fabric is entered into the mahlo (weft straightener) the function of the mahlo is to set
the bow and also weave of the fabric is griped by the clips and pins are also provided but
the pins has a disadvantage that the pins make holes at the selvedge but the stretching of
the pins are greater than the clips. these clips and pins are joined to endless chain there
are 8 to 10 chambers provided on the machine each chamber contains a burner and filter
are provided to separate dust from air the circulating fans blow air from the base to the
upper side and exhaust fan sucks all the hot air within the chambers. Attraction rollers are
provided to stretch the warp yarn.
After stentering we can increase the width of the fabric up to 1.5 - 2 inch. The
speed of the machine is about 7 - 150 m/minute. 3 m fabric can run in each.

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Operating Process

1. Delivery of wet fabric rolls covered with plastic sheets and ticketed as for
finish from bleaching and dyeing department.

2. Supervisor gives the chemical recipe according to the roll number in the programmed
book.
3. Buckets and chemical tanks are cleaned and then chemicals are prepared as
per the given recipe. Checkpoint - weighing of chemicals checked by the
supervisor randomly.

4. Operator re open the plastic sheets

and input the rolls offabric.

5. Chemical shifting from chemical tank to Truff.

6. Parameter setting ( e.g. temperature, pressure, width etc.) by the operator

7. Machine will run.

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Check points:
1. Automatic limit (left, right) According to the width of fabric.

2. Heat chamber net cleaned regularly for even heating/dyeing.

3. Brushers changed twice a day based on the deposition of yarn on them.

4. If fabric has loose thread on the surface uncurler is switched on.

5. Machine stopped immediately on the ringing of alarm which may be due to roll
change, filling of chemical in truff etc.

6. plater man checks the fabric on output side.

7. In case of any defect or non-conformance to quality it should be immediately

informed to thesupervisor (not followed).

8. Output rolls again covered with plastic sheet and tickets for calender or for zero.

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Calendaring

It is the process used to impact chemical finish to fabric using frictional force between
calendar rolls. There isone 3 bowl calendar machine. The main objective of calendaring is:
To upgrade the fabric hand and to impact a smooth silky touch to the fabric, improve the
opacity of the fabric, compress the fabric and reduce its thickness, impart different degree of
luster to the fabric, reduce yarn slippage.

SOP of calendaring machine

working width: 150m

threading length: 10m
standard speed: 500m/min
temperature :100c
Max pressure: 150c

components of machines

Metal detector detect the presence of metal on the surface of fabric and rings alarm
seem detector: Detect presence of stitch in the fabric in same roll and ring alarm. Pressure
then drop to 0 tillthe stitched part is rolled on the output roller and then resumes with 200
N.

Calendar rolls:

 Bottom roller made of cotton: for soft finish the fabric is passed through cotton
bowl. This roller is made up of cotton.

 Mid roller made of fiber: To avoid selvedge overlapping on batcher.


 Top roller made of steel through which stream is applied to fabric: to give a
smoothness and luster


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

 The temperature is provided to steel roller about 32 - 200 c with help of electric
heater as we increasethe temperature shining will increases only used for cotton
CVC and a percale and PC.

 Cooling drum: cool down the fabric water circulates inside the cooling drum


 Amperemeter: Shows the current consumption of machine. (not working)

guide rollers guide the fabric through the machine 4000 to 5000 m fabric
input at a time 8-9 ampere current utilized.

Operating process

 Delivery of fabric rolls wrapped in plastic sheet and ticketed as for

calendar from China stenter Machine plastic sheet and un wrapped
and input roll loaded manually.

 Checkpoint rolls are loaded such that face side of fabric is in contact with calendar
rollers for softer hand and more luster.


3. Machine runs applying entrance breaking pressure of 20 Bar. 200 N calendar pressure
applied on fabric.

 A standard speed is maintained thereafter. Theoretical std speed 50 m/min.
Speed used 70m/min 

Checkpoints:

 In case machine stops due to presence of metal detected it must be

removed immediately. Dirt found on rollers during the process are remove
manually there and then. Rollers cleaned with water after completion of
rolls or according to the roll to be used next ( white dyed fabric).
2. In case of any defect of the output roll it must be immediately informed to the
supervisor (not followed). On completion of roll it is wrapped with plastic sheets and
ticketed as for zero zero.

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 Zero Zero

Used to impact pre-determined Shrinkage to fabric to reduce the progressive shrinkage

during itswear. There are 2 flexa compacta machines.
In sanforizing process shrinkage is achieved by passing the cotton fabric onto a
movable elastic felt blanket is released it assumes a shortened conditional. thus the
cotton fabric is forced to conform this compression. The shrinkage amount of fabric
is dependent on :

1. The nature of the fibers

2. The character of threads
3. The way of interlacing of thread in the fabric.
4. Crimp in yarn.
5. Cycle of washing number of

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Components of machine

1. Display board with information about machine and for setting parameters shrinkage,
temperature etc.

2. Comino-to remove bowing/skewing of fabric.

3. Porous metal roller wrapped with woolen felt. Steam forced to fabric through this roll.

4. Rubber roll

5. Sprayer to cool rubber.

6. Heated metal roller (130c) to set shrinkage

7. Cool metal roller for fabric to relax.

8. Detectors for uniformity in width failing which machine stops immediately. Safety
detector a wire which when pulled and stops the machine immediately.

9. Air pipe for cleaning.

Operating Process

Delivery of rolls wrapped in plastic sheet ticketed as “for zero zero” from calendar machine
or Stentor machine. Rubber blanket heated upto 130c.

Checkpoints

 steam and air pressure checked

 Hardness of rubber checked and grinded if required.
 The required shrinkage is set on display board according to fabric used by operators
based on their experience.
 Output fabric is observed where the shrinkage is modified required.
 Machine cleaned using a air pipe.

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Folding

It is the process used to convert the finished fabric rolls into open On completion of process,
rolls wrapped in plastic sheets . For folding or testing department.

There are 2 folding machines available

at Vivin tex.

Operating Process

1. Fabric is delivered wrapped in plastic sheet from zero zero machine.

2. Roll is unwrapped and fabric unwounded to certain length and the roll is kept to be rotating
slowly.

3. End of fabric fixed with clamps on machine bed.

4. 2 operators hold the fabric from both sides(widthwise).

5. Machine runs.

6. On completion of one type/color of fabric in one roll, machine is stopped and fabric is cut
from the stitch area.

7. Cut part separated on another trolley and machine started again.

8. On completion of roll. All folded fabrics are loaded individually on one trolley which are
the carried to testingdepartment.

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Components of Machine:

Machine bed: Folded fabric rests on the machine bed

Rods: to guide fabric on the machine bed.
CAM and Follower: rotate and move the clamps
Clamps: Carry the fabric from one end to other folding at both the ends.

Rotor mat

It is a machine used to impact different aesthetic effect in fabric like cotton, linen, wool and
their blends by virtue of mechanical process i.e. beating. Only yarn dyed fabric are subjected
to mechanical finish in rotor mat machine after washing
There are 4 rotor mat machines.

SOP of Rotor mat

Name: MAT De Bertoldi
Made in: Italy
Capacity: G rope x 1 00(600 min or max
Liquor: 200 lit
Maximum Temperature: 120°C

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 CONCLUSION

The internship helped to broaden our understanding of various subjects taught to us in

college. The time spent in the industry was very useful. It gave us immense practical and
technical knowledge. The interaction with the operators and other unit members helped us to
understand the various day to day operation, problems and their solutions that they come
across. This internship has been a great learning experience as it not only helped us to know
various textile processes in a better way, but also helped us relate to whatever we have been
learning, about textile processing till date in our classroom.
The industry insisted us to stay along the workers at the factory time and allowed us to
interact with them, which helped us to mould ourselves professionally. We conclude that
here, the best work culture is maintained with excellent HR manager.

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