MILL PRACTICE REPORT

Name of Organization: GHCL LIMITED (HOME TEXTILE DIVISION)

Duration: From 7th June to 18th July 2018

Submitted in Partial Fulfilment of the Requirement

For the Degree of Bachelor of Technology in Textile Technology

(M.D.U University, Rohtak)

Submitted by

Aniket Maheshwari – 15TT008

Rahul Raniwal—15TT059

Ujjwal Kumar – 15TT051

Department of Textile Technology

The Technological Institute of Textile and Sciences, Bhiwani-127021
December, 2018
 ACKNOWLEDGEMENT

We would like to express our sincerest gratitude towards GHCL Ltd., BHILAD for providing us the best
facility and working environment during our training period, at their esteemed organization. We are grateful
towards each and every employee of the GHCL Ltd., BHILAD for providing us their most valuable time and
experience. It is indeed a great pleasure for us to express our profound and sincere thanks to Mr.Saurabh
Kumar (Assistant Manager-HR) for his cooperation. We would like to thank Mr. Jitendra Kadam (D.G.M-
Weaving), Mr. L.H.Saiyed and Mr. Bhavesh Kumar, for giving their valuable time and attention during our
training. Their instructions proved to be quite beneficial during the training period.

Our association with the GHCL Ltd., BHILAD over the past 40 days has been immensely fruitful and we
sincerely hope that this association will continue.

Thank you GHCL.

OBJECT OF MILL TRAINING:-
 To know about the working atmosphere of the industry.

 To gather knowledge about the machine, their working principle & about their running condition and
also their maintenance.

 To acquire information about mill production, export & import policy

 To know administrative set-up & labor’s attitude in the industry.

Training in business organization infuses among students a sense of critical analysis of real managerial
situation to which they are exposed. Our institution has given us opportunity through training to be aware of
and cope with fast rate changing technology, management policies, and quality and productivity etc. This is
a bold attempt to bridge the gap between the “world of work” and studies imparted the institution.

We have worked in the concern for 40 days and prepared our Industrial
training report. Under the guidance of training officer, we analyzed various aspect of production. This has
helped us in boosting up our confidence and determination, which will help us to face any situation in the
years to come.
INDEX

S.NO CONTENT PAGE

NO.

1. GHCL LIMITED PROFILE

1.1. Group overview

1.
1.2. Management of GHCL ltd.

1.3. Dalmia group of industries

1.4. History of GHCL ltd.

1.5. Businesses

1.6. GHCL today

2. 2 WARPING

2.1 Direct Warping

2.2. Machine data

2.3. Technical Description

2.4. Work Load

2.5. Maintenance

2.6. Instructions

3 RE- WINDING SECTION

3. 3.1 Basic Description

3.3Technical Description

3.4 Workload
4. 4 SIZING

4.1 Effect Of Sizing On Yarn Properties

4.2 Sizing Machines

4.3 Procedure / Process Description

4.4 Recipe Of Sizing Paste As Per The Count Of Yarn

5 DRAWING-IN SECTION

5.1 Basic Description

5.
5.2 Manual Drawing-In section

5.3 Knotting and gaiting

6 WEAVING SECTION

6.1 Basic Description

6. 6.2 Machine Description

6.3 Workload

7 GREY INSPECTION

7.1 Basic Description

7. 7.2 Equipment

7.3 Machine set up:

7.4 Method:

7.5 Types of Faults

 8. 8 LOOM PRODUCTION

9 9 DIFFERENT CASE STUDIES DONE ON AIRJET WEAVING

MACHINE

8.1 Study Of Fringe Length

LISTS OF FIGURES-

1. Figures related to warping

2. Figures related to re-winding
3. Figures related to sizing
4. Figures related to drawing-in
5. Figures related to weaving

LISTS OF TABLES-
1. Tables technical description of machine running in weaving department
2. Tables of running status of various machine in different department
3. Tables of workload in each department
 HEIRARCHY OF GHCL

LEADERSHIP TEAM-
MR. SANJAY DALMIA (Chairman)

MR. ANURAG DALMIA (Director)

MR. NEELABH DALMIA (Director)

DR. B.C.JAIN (Independent Director)

MRS. VIJAYLAXMI JOSHI (Independent Director)

MR. MAHESH KUMAR KHERIA (Independent Director)

MR. G.C. SRIVASTAVA (Independent Director)

MR. K.C. JANI (Independent Director)

MR. LAVANYA RASTOGI (Independent Director)

MR. R.S. JALAN (Managing Director)

MR. RAMAN CHOPRA (CFO & Executive Director)

KEY MANAGEMENT TEAM-

MR. R.S. JALAN (MANAGING Director)

MR. RAMAN CHOPRA (CFO & Executive Director – Finance)

MR. SUNIL BHATNAGAR (President - Marketing, Soda Ash)

MR. N.N.RADIA (Chief Operating Officer, Soda Ash)

MR. MANU KAPUR (President & CEO – Home Textiles)

MR. M. SIVABALSUBRAMANIAN (Senior Vice President, Spinning)

MR. V.CHANDRAMOULI (Senior Vice President – Finance)

MR. RAJESH TRIPATHI (Vice President - Human Resources)

MR. SACHIN KULKARNI (Chief Operating Officer, Home Textiles)

MR. JAYESH P.SHAH (Vice President - Industrial Relations)

MR. GOPAKUMAR MENON (Vice President, Consumer Products)

MR. PANKAJ KUMAR (Vice President - Commercial, Soda Ash)

MR. P.N.RAO (Senior General Manager - Commercial (Raw Materials), Soda Ash)

MR. LOVISH AHUJA (Senior General Manager – Sustainability)

MR. BHUWNESHWAR MISHRA (General Manager - Company Secretary)

MR. NEERAJ JALAN (Business Head of HT Division)

MR. CHETAN RANA (Processing Head)

MR. KAMLESH MEHTA (HR &IR Department Head)

MR. JITENDRA KADAM (Weaving Department Head)

MR. HASMUKH GONDLIA (Head of Utility Department)

 1. COMPANY PROFILE-
GHCL Limited was incorporated on 14th of October 1983. The company has established itself as a well-
diversified group with an ascertained footprint in Chemicals, Textiles and Consumer Products segment.
In Chemicals, the company mainly manufactures Soda Ash (Anhydrous Sodium Carbonate) that is a major
raw material for Detergents & Glass industries and Sodium Bicarbonate (baking soda).

Its Textiles operations is an integrated vertical set up which commences right from spinning of fibre (yarn),
weaving, dyeing, printing till the finished products, like sheets & duvets, take shape which are primarily
exported worldwide.

Consumer Products operation is another business for GHCL where it is a leader in manufacturing and selling
Edible salt, Industrial grade salt and Honey in the country.

TEXTILES-
The Textiles division at GHCL is a vertically integrated manufacturing facility with spinning, wide-width
weaving, continuous fabric processing, and cut & sew facilities for manufacturing premium quality bed
linen.

GHCL’s spinning unit is located near Madurai in Tamil Nadu, India. We manufacture multiple varieties of
yarn ranging from 16s to 32s in open end, 30s to 120s in ring spun compact counts in 100% cotton and 24s
to 70s counts in blended yarns.

GHCL’s Home Textiles manufacturing is located near Vapi in Gujarat, India. Here yarn is woven into
fabric, which is then dyed, printed and finished into final products, like bed sheets, which is then exported
worldwide.

Both these plants have state-of-the-art facilities and machineries and ensure that every single aspect of its
textile production process is backed by a fabulous world class infrastructure.

USES-

Bed sheet, duvet sheets, and comforter sheets

GHCL CORE VALUE-

We believe – Respect, Trust, Ownership and Integrated Team Work lead to Business
Success.
DALMIA GROUP OF COMPANIES-
PROFILE-
The Dalmia Group of Companies is one of the India’s oldest and most distinguished business houses with is
motto “Enterprise without Frontiers” intersically engraved in all its activities. The House of Dalmias was
founded by Late Sri. Ramkrishna Dalmia in the early part of 20 th Century. The legacy which was passed on
to Mr. Vishnu Hari Dalmia is now further strengthened and expanded by his son’s

Mr. Sanjay Dalmia (Chairman) and Mr. Anurag Dalmia (Vice Chairman)

Today it has evolved into a dynamic and globally progressive corporate entity. The core area of the group
are

1. TEXTILES-

Spinning - GHCL ltd., Paravai and Manaparai, Tamil Nadu, India

Weaving, Fabric processing, Cut & Sew, Finishing & Packaging

-GHCL ltd. Vapi, Gujarat, India
Product design, Development, Global sourcing & Supply to various International markets

2. SODA ASH-

GHCL ltd, India

SC GHCL UPSOM ROMANIA, SA

3. HEALTH CARE-

Alternative Healthcare Solutions - Dalmia Healthcare Ltd. (DHL)

Diluted Nitroglycerine - Bharat Pharma Ltd.

4. ITES-

KPO, B 2 B Experience, Channel Management - Colwell & Salmon

Business Process Outsourcing - Caretel InfoTech Ltd.

5. TOBACCO-

GTL, India

The Dalmia Group intends to be a significant contributor and integral part of the new wave of
entrepreneurship that will place India as the Global leader of the 21st century. Thus for the group, it is not
necessary to be present everywhere but in select segments where noteworthy value can be built for the
stakeholders and the environment at large. The group’s deep sense of Social Responsibility is reflected in
their ongoing works for the environment, people and philanthropic services.

HISTORY-

Year Event-

1983 – The Company was incorporated on 14th October, & obtained the Certificate of Commencement of
business on 5th December. It was promoted in the joint sector by the Gujarat Industrial Investment
Corporation, Ltd. (GIIC), GTC Industries Ltd. (formerly known as Golden Tobacco Co. Ltd.), Dalmia Dairy
Industries Ltd., their wholly owned subsidiaries and other investment Companies, Indian & NRI Associate
The company undertook to setup a plant for the manufacture of 1,200 tonnes per day of soda ash both light
and dense varieties.

1984 - On 9th January, the company entered into technical collaboration agreement with a consortium of
Akzo Zout Chemie Netherland and Klockner Industries Anlagen, GmbH, W. Germany for supply of
technical knowhow, basic engineering package and supervision of erection and commissioning of the
project.

-The Company retained the services of Humphreys & Glasgow Consultants Pvt. Ltd., as the Indian
Consultants to render consultancy services for detailed engineering, procurement, erection, supervision and
assistance in commissioning.

1986 - 15 shares subscribed for by the signatories to the Memorandum of Association. 7,19,99,985 shares
were then issued at par of which the following shares were reserved and allotted on a firm basis:

(i)1,87,49,991shares to GIIC;
(ii) 129,99,994 shares to GTC Industries, Ltd. and Dalmia Dairy Industries, Ltd. (Co-promoters) and
(iii) 50,00,000 shares to non-resident Indians on repatriation basis. Out of the remaining 3, 52, 50,000
shares,

the following shares were reserved for preferential allotment:

(i) 1,38,80,000 shares to non-resident Indians on repatriation basis (only 59,22,600 shares taken up);
(ii) 36,00,000 shares to employees (including Indian working directors)/workers of the Company and
promoters/co-promoter companies; (only 1,68,400 shares taken up);
(iii) 18,70,000 shares to shareholders of co-promoter companies and associate company (none were taken
up) and 15,00,000 shares to farmers, agriculturists and co-operative societies and rural investors (only
11,18,900 shares taken up).
The balance 1, 44, 00,000 shares along with the unsubscribed portion of 1, 36, 40,100 shares out of the
preferential quota, were offered for public subscription during August 1987.

1988 - The soda ash was marketed under the brand name "GHCL Soda Ash".

1989 - Lime Kiln was installed in order to overcome the low activity of lime produced in the lime kiln.

2002-Appoints Mr. J P Mehrotra as the company secretary.

-Allots new shares pursuant to the amalgamation of Sree Meenakshi Mills Ltd.
-Board approves the amalgamation of Icon Data Management Ltd with the company.
-Appoints Mr. D Rajgopalan as the Director on the Board, Mr. Mahesh Kheria is re-appointed as Alternate
Director for Mr. S H Ruparell.

2003-Changes in the Management Structure: Mr. S K Mukherjee steps down as MD from the company. Mr.
P Sampath and Mr. R S Jalan, Executive Directors are redesignated as the Sr. Executive Director Mr
Shyamsundar Vishwanath gives resgination as the director from the Board.
Appoints Mr Chaman Kumar as the Director of the company.
-Members approve the authorisation of delisting of equity shares from Calcutta and Delhi Stock Exchanges.
- Gujarat Heavy Chemicals Ltd has informed that with effect from November 21, 2003, the name of the
Company has been changed from 'Gujarat Heavy Chemicals Limited' to 'GHCL Limited'.

2004-Gujarat Heavy Chemicals Ltd has informed that pursuant to the application made by the company for
voluntary delisting of shares from the Delhi Stock Exchange Association Ltd (DSE), the DSE has confirmed
that the equity shares of the company have been delisted w.e.f. December 29, 2003.

2006-GHCL picks up UK`s Rosebys for Rs 180 cr

2007 - GHCl Limited has appointed Mr. Bhuwneshwar Mishra, as Company Secretary of the Company with
immediate effect.

2008- GHCL to takeover soda ash cos in US, China.

- GHCL - FCCB - Secod Reset Price.

2009- GHCL - Repurchase of FCCBs.

2010- GHCL - Appointment of Additional Director.

- GHCL - Change in Directorship.

2011- GHCL - Repurchase / buyback of Foreign Currency Convertible.

- GHCL Ltd - Change in Director(s).

2012- GHCL - Change in Directorate.

- Promoted in joint sector by Dalmia’s and Gujarat Government In India .

2013- Company has submitted to BSE a copy of the details regarding Employees Stock Option Scheme
(ESOS) of the Company in the prescribed format vide SEBI Circular dated January 17, 2013 read with
Clause 35C of the Listing Agreement.
- The Creditors Committee of SC GHCL Upsom SA, Romania, (GHCL Upsom) in their meeting held on
March 18, 2013 has decided to accept the highest bid of Euros 6.00mn made by Aloref SRL in association
with Ascom International SRL.
- GHCL Employee Stock Option Trust has sold 5,00,000 (Five Lac) equity shares of the Company on April
26, 2013 in open market.
- GHCL Employees Stock Option Trust has further sold 52,151 equity shares of the Company in the open
market in trenches between December 09, 2013 to December 20, 2013.
- GHCL Employees Stock Option Trust has further sold 13,312 equity shares of the Company in the open
market In trenches between December 23, 2013 to December 27, 2013.

2014- GHCL Employees Stock Option Trust has further sold 14,339 equity shares of the Company in the
open market In trenches between December 30, 2013 to January 03, 2014.
- GHCL Employees Stock Option Trust has further sold 17,735 equity shares of the Company in the open
market in trenches between January 06, 2014 to January 13, 2014
- The Company has successfully won the case filed against the order dated August 06, 2013 passed by
Adjudicating Officer of SEBI which the company went into an appeal before Hon’ble Securities Appellate
Tribunal (SAT).
- GHCL Employees Stock Option Trust has further sold 14,339 equity shares of the Company in the open
market in trenches between December 30, 2013 to January 03, 2014.

2015 -GHCL Ltd. Indian England NV, a wholly owned subsidiary company in Netherlands

BUSINESSES
Chemicals
The manufacturing facility of our Soda Ash plant is located at Sutrapada, in the state of Gujarat, India. The
region is famously known as the Saurashtra coastal belt and is ideal for the manufacturing of Soda Ash in
India

GHCL Limited, being one of the leading manufacturers of Soda Ash in India, has an annual production
capacity of 9, 50,000 metric tons, which contributes to almost 29% of the annual domestic requirement.

GHCL’s Soda Ash product line consists of Light grade, dense grade and Sodium Bicarbonate (Baking
Soda). Our Soda Ash is available across the Indian market under the brand name ‘LION’.

Textiles

Spinning facilities of our company is located near Madurai in the state of Tamil Nadu, India. Here we
produce 100% cotton compact yarn, cotton blend yarn, 100% polyester yarn, viscose blends yarn and other
fancy yarn.

Yarn from our facilities is known for its premium quality and is largely used for our internal consumption at
our home textiles facility. Some quantity of yarn is also sold in the domestic market as well as exported to
international markets. Currently the total production in the facilities is around 24,000 metric tonns annually.

GHCL’s Home Textiles facility is located in Vapi in the state of Gujarat, India. This facility oversees the
production process right from weaving to finished processed fabric, which is then converted into products
like duvet sets, sheet sets, comforter sets to name a few.

As one of the leading manufacturers of Home Textiles in India, the plant boasts of an annual production
capacity of 36 million metres of finished fabric per annum.
GHCL today is the “perennial innovators & fully integrated manufacturers of quality bed
linen”. Some of our recent innovations in the category of ‘sheets’ include: the PERFECT FIT,
EASYSHEET, microTWILL, CELLIANT, EXL Wrinkle Free Sheets, VERSATILE–Reversible Sheets,
Soft Wash Percale and Sustainable Fibre dyed sheets.

GHCL’s Home Textiles products are predominantly exported worldwide to countries like United Kingdom,
United States of America, Australia, Canada, Germany and other European Union countries as well.

Consumers Products
GHCL in 1999 diversified its line of business into edible salt trading and production. Our Consumer
Products Division has its salt works at Vedaranyam and the refinery at Chennai for its edible salt
manufacturing.

Spread over a vast expanse of 3500 acres of salt field, our Consumer Products Division is the largest
manufacturer of raw salt. Salt production at Veda salt works during a normal season is about 150,000
MTPA. The refinery at Chennai produces approximately 100,000 MTPA of salt that caters for our edible
and industrial grade salts and for institutional sales.

Consumer Products Division is a major supplier of raw salt for the caustic soda industry. The division
forayed into manufacturing and marketing of branded salt under the brand ‘SAPAN’ in the year 2000. ‘i-
FLO’ (www.iflo.co.in) is another brand from the Consumer Product Division of GHCL with a product
portfolio of edible salt, honey, whole spices and sprinklers that was launched in the year 2010. ‘i-FLO’
brand is positioned in the “Health and Wellness” platform.

GHCL TODAY-

 GHCL has come off age as one of the most reputed organizations and throughout its voyage
of three long decades and continuing, it has achieved historical landmarks which further add
to its agility and continuous growth model.
 GHCL contributes more than 25% of soda ash production of India2
 GHCL Consumer Products Division is the largest manufacturer of raw salt.

TYPES OF PRODUCT:
The manufacturing facility at Bhilad deals in sheets set which include a combination of bed sheets,
comforter and Duvet.

NUMBER OF DEPARTMENT WITH FUNCTION OF EACH:

 PPC: Product Planning and Control department is one of the important department for Textile
Company.
 The job of this department includes preparation of time and action calendar from each order from
order receiving to shipment.
A worksheet is prepared which contain:-
 Material resource planning
 Loading production
 Process selection and planning
 Facility location
 Estimating quantity and cost of production
 Capacity planning

 COMMERCIAL DEPARTMENT:-
In GHCL, commercial department deals with the
 Fabric sourcing
 Yarn sourcing
 Spare parts
 Chemical, dye and all type of raw materials.

 WEAVING DEPARTMENT:-
Weaving department of GHCL, BHILAD composed of 2 rewinding machine, 2 warping machine,
1sizing machine and 190 Airjet looms. (162 tsudakoma + 28 picanol)

 PROCESSING HOUSE:-
Composed of five sections
 Bleaching
 Dyeing
 Printing
 Finishing
 Process lab

 TESTING LAB:-
Instrument in textile lab
1. Tensile tester (Rosary labtech)
2. Martindale abrasion tester (Rossary labtech)
3. Crockmeter (Rossary labtech)
4. Elmendorf tearing tester (Rossary labtech)
5. Pilling tester
6. Presto (lea maker)
7. Good brand oven
8. Absorbency tester of bleached fabric
  MADE UPS:-
Made-ups: Made-ups include cutting and stitching where we have automatic cutting machine,
stitching machines.

 HR/IR DEPARTMENT:-
A typical human resource department carries out the following functions
 Man power planning
 Analysis and job description
 Determine wages and salaries
 Recruitment and selection
 Performance appraisal
 Training and development
 Labor management relations

 UTILITY DEPARTMENT:-

1) Water Requirement= 3200 kL/Day

2) Compressors:

Type Quantity Capacity

1.Centrifugal 3 3260 Cfm
2.Screw type 2 1000 Cfm

3) Generator:
Type = Man Bnw
Capacity = 3.6 Mega Watt
4) Electrical units per day - 85 – 90 K Unit

 LIGHTNING SYSTEM

5 tube lights are used per loom out of which 3 are above and 2 are below the loom.

TYPES OF MACHINE

 Rewinding
 Warping
 Sizing
 AirJet
 Knotting
HUMIDIFICATION:-

FOR TSUDAKOMA-

1. Make: LUWA
2. Air quantity handle: 2 lakh meter cube/hr.-per plant
There are total 3 plants of LUWA of same capacity.
3. Type of auto monitoring: sensor

FOR PICANOL-

1. Make- Batliboi
2. Air quantity handle:
3. Type of auto monitoring: sensor

In weaving shed, some display are present which shows the actual temperature and humidity present
in shed so according to requirement, sensor sense the change in temperature and send that data to
computer which control the humidification plant.
 2. WARPING

Warping is a process in which number of the yarns end from the yarn packages or cones are wound on the
warping beams.

Warping is transferring many yarns from a creel of the single end package forming a parallel sheet of the
yarn wound on to a beam.

The object of warp preparation is to transfer yarn from the spinner's package to a weaver's beam that can be
placed behind a loom ready for weaving. A weaver's beam usually contains several thousand ends and for a
variety of reasons, it can seldom be made in one operation.

There are two main objective of the warping-

-Collection of the number of the yarns end required in the fabrics

-winding a specific type of the package as required by subsequent process i.e. warper’s beam or ball etc.

2.1 Direct Warping

In this system single end of the yarn from the cones or packages are directly wounded on the warping
beams. This is the winding of total number of warp ends in full width in a single operation from creeled
bobbin.

This process or system is used for the mass production. This is used to make smaller intermediate beams
called warper’s beams. These smaller beams are combined later at the sizing stage to produce the weaver’s
beam. This process is called beaming

2.1.1. Machine Components Of Direct Warping 

A) Package:-

1) Type-Cone

2) Amount of the yarn length – Depends upon the yarn count

 3) Weight of cone – 2.5 kg

B) Tensioner:-

Figure 1. Typical type of Tensioner

1) Type-Capstan

 In Capstan type tensioner, yarn is first pre-wound to about 4-5 coils over it . Yarn is thereby
withdrawn by beam rotation, initiating a circular rotational motion to tensioner which is thus
negatively rotated by pulling action.
Function – prevents tension variation in the yarn

-Maintain proper level of tension

 It also possess, a brake system. Whenever tensioner rotation is to be stopped a rubber brake placed
just adjacent to it applies braking force causing tensioner to
Stop by means of spring placed underneath it which gets stretched, thus contact of brake with
tensioner occurs. (Brake applied whenever a warp end breaks )
 Every package has its own tensioner.
Hence no. of tensioner on creel stand = no. of package capacity
1. Benninger-1088
2. Karl Mayer- 1224
c) Ceramic guide & stop motion

Function: - Guides the yarn in a straight condition & prevents any entanglement

D) Denting in Comb

Fig No. 3- Typical Denting Reed

1) Design & feature-

 Zigzag form which can either be stretched or compressed as per require no. of dents
 If stretched length increases, no. of ends onto the beam are less and spacing between warp yarn is
more
 If compressed, no. of ends onto the beam are more ,and spacing between warp yarns is less.

2) Function:-

 Maintains proper spacing between adjacent yarn ends being supplied from creel zone.
 Undergoes reciprocating motion to avoid any entanglement of yarn end onto beam package.

3) Range of dents - 300-700.

E) Measuring Roller

Fig No .4- Front View of Direct Warping Machine

1) Function

 Placed just after the comb, it functions in giving an idea as to how many rotations of it would yield
in wounding of 1m of yarn

On beam package. It rotates positively, its no. of rotations decides the length of yarn wound on
package.

 Polished to avoid any chances of yarn abrasion

G) Press Roller

1) Location - alongside beam

2) Type - Wooden cylindrical.

3) Function - To apply pressure against warper beam in order to prepare a firm & compact package .It is
negatively rotated by frictional contact with warper beam.

H) Warper Beam

Fig No.5 - Typical Direct Warper Beam

1) Function - Yarn ends finally wound over warp beam. Hence, it functions in pulling the yarn from
package (cone) .It is positively rotated by means of servo motor
2.2 Technical Data of Various Machine -
No. MANUFACTURER BENNINGER KARL MAYER

1 MODEL Bendirect Warp direct

2 MADE IN Switzerland Switzerland

3 YEAR 2010 2011
4 MAX SPEED 1200mpm 1200mpm
5 RUNNING SPEED 800mpm 800mpm
6 COUNT 30s-100s 30s-100s
7 CREEL CAPACITY 1088 1224
8 WASTE % 2.5% 2.5%
9 EFFICIENCY 65% 65%
11 BEAM DIA 800-1400 mm 800-1400mm
12 BEAM WIDTH 2.4mtrs 2.4mtrs

13 MAX POSSIBLE WARP 2400mm 2400mm

WIDTH
14 MIN. POSSIBLE WARP 1800mm 1800mm
WIDTH

15 MAX. FLANGE DIA 800mm 1000mm

16 NO. OF OPERATOR 1operator + 1 helper 1operator + 1 helper

17 INPUT SUPPLY 400V AC,60HZ 400V AC,60HZ

18 HYDRAULIC PRESSURE 40BAR (MIN) 40BAR (MIN)

(WARPING) 50 BAR (MAX) 50 BAR (MAX)

19 PRODUCTION PER SHIFT ~3,00,000 m ~3,00,000 m

 2.3 Table No. Workload and Duties

S.NO MACHINE DESIGNATION NO.OF SUCH DUTY

WORKERS

1. BENNINGER OPERATOR 1 Worker / machine -Operating the

machine
MODEL- Bendirect
-Knotting
-Manipulating the
settings on the
machine as required.

-Arranging cones on
CREEL BOY 1 Worker / machine creel stand
-Assistance in
knotting if multiple
breaks occur

-Maintenance of
machine
FITTER 3 Workers for 1 -General repairing
machines
 2. KARL MAYER OPERATOR 1 Worker / machine Operating the
machine
MODEL- Warp
direct -Knotting
-Manipulating the
settings on the
machine as required.

-Arranging cones on
CREEL BOY 1 Worker / machine creel stand
-Assistance in
knotting if multiple
breaks occur

-Maintenance of
machine
FITTER 3 Workers for 1 -General repairing
machines

2.4 MAINTAINANCE SCHEDULE (WARPING)

Daily Maintenance:

General Cleaning:

1) Cleaning and Care Of Acrylic Glass

2) Rolls

3) Trapezoidal Threaded Spindle and Limit Switch Assembly

4) Motors

5 Day Maintenance:

1) General cleaning

2) Checking the oil level

3) Checking screwed connections - Fitting pipes

4) Drive Belts: 1.Maintainance

2. Fitting

3. Deflection Tables

45 Days Maintenance:

1) General Cleaning

2) Inspection and maintenance work every 100 operating hour

3) Lubricating Quills

4) Cleaning/Lubricating trapezoidal threaded spindle

5) Checking the warp beams

6) Cleaning/Lubricating comb traversing chains

7) Greasing the presser device cylinder

8) Resetting maintenance interval

7 Month And 1.2 Year Maintenance:

1) General Cleaning

2) Inspection and maintenance work every 100 operating hours

3) Inspection and maintenance work every 1000 operating hours

4) Inspection and maintenance work every 5000 operating hours

5) Replacing presser roll bearings:

1. Removing the presser roll

2. Replacing the bearing

3. Fitting the presser roll

6) Replacing guide roll bearing:

1. Removing the guide roll

 2. Fitting the guide roll

7) Replacing the quill bearing

1. Quill bearing –Drive side

2. Dismounting the quills

8) Replacing the brake caliper seals – mounting the quills

9) Seals

10) Replacing the serrated cones

11) Resetting maintenance interval

2.5 INSTRUCTIONS:-

FOR DIRECT WARPER-

1. Reach 15 minutes before the shift starts and take charge from the previous shift operator.
2. Before starting a new program check the no. of cones in the creel, cone tip, Lot No. and yarn
supplier as mentioned in the set book for the program.
3. Enter data to the computer as per the job program .Details such as job no. , sort no. , total
ends , yarn count, no. of total beams, beam no.
4. Load the empty beam on the machine.
5. As per machine signal attend the breakage and start the machine. Keep the entry in the record
book of breakage, if there is any problem in the machine then inform the shift incharge.
6. Keep the waste in its proper place
7. Maintain the house keeping of the creel and the machine properly, look at oil leakage when
machine is empty if required then clean the area with the help of creel boy
8. Always wear mask during working hours.
 3. REWINDING-

3.1. Reshmi Industries Pvt. Ltd

A) No. of machines – 1

B) Type – Cross-winding machine

C) Manufacturing year: 2007

D) Model: ROWD

C) Function – Responsible for making large package (cone) from small packages.

D) Operation – Here one small package is responsible for making cone with doffing process manually
regulated. Here empty cone is manually transported through a conveyer belt.

E) Capacity of machine / No. of heads – 120

F) Type of tensioner: Disc type tensioner

G) Method of splicing: Hand splicing

H) Type of doffing - manual

I) Type of winding – Random winding Machine

J) Speed of machine will be kept constant at 550 m/min

3.2 WORKLOAD-

S.NO MACHINE NAME DESIGNATION NO.OF SUCH DUTY

WORKERS
1 Reshmi Industries OPERATOR 1 Worker - Doffing
Pvt. Ltd - Donning
- Regulating
 machine
operation

- General
repairing
- Machine
maintenance
FITTER 2 Worker

3.3MAINTAINANCE SCHEDULE (WINDING MACHINE)

Daily maintenance of Rashmi Winder Machine:

1) M/C cleaning daily in all shift

2) Cone peg alignment

3) Yarn stop motion sensor

4) Yarn tension disc position

5) Pre tensioner setting

6) Slub catcher position/setting

7) Anti patterning assembly

8) Drum surface

9) Drum bearing

10) Spindle adopter

11) All ceramic in yarn passage

Weekly Maintenance Of Rjk Automatics M/C:

1) Oil level in the tank

2) Oil circulation for all spindles

3) Empty cone conveyor belt

 4. SIZING

Sizing is process of application of starch on to the beam which imparts strength and increases the abrasion
resistant so that the breakage in the yarn threads will decrease during the further process.

Sizing agents are selected on the basis of type of fabric, environmental friendliness, ease of removal, cost
considerations, effluent treatment etc.

Effect of Sizing on Yarn Properties

 Yarn elasticity decreases.
 Yarn strength increase.
 Flexibility of yarn decrease.
 Smoothness of yarn increases.
 Irregularity of yarn decreases.
 Yarn diameter increase.
 Yarn weight increases.

4.1 Types of Sizing Machine-

 FIG. BENNINGER SIZING MACHINE

4.2 MACHINE SPECIFICATION-

 MACHINE NAME- BENNINGER

 TYPE- BEN SIZETECH
 CREEL CAPACITY- 28 (14 UP & 14 DOWN)
 SIZE BOX- 2 A &B
 IMMERSION TYPE- 2 dip-2 nip
 MAXIMUM SPEED- 60-80 M/Min (Max Up to 120 M/Min)

Special features:
 Moisture control
 Automatic size box temperature
 Automatic size box control
 Automatic size input in saw box
 4.3 FLOW OF MATERIAL-

CREEL SQUEEZE ROLLER PENDULUM

ROLLER

BEAM BOTTOM ROLLER

SIZED BEAM
GUIDE ROLLER MINI CYLINDER

LOAD SHELL DRYING CYLINDER

DANCING ROLLER WAXING DEVICE

IMMERSION LEASE RODS

ROLLER

SQUEEZE ROLLER COMB

BOTTOM ROLLER TAPE ROD

IMMERSION GUIDE ROLLER

ROLLER
 4.4 MACHINE SETTING-

S NO. DESCRIPTION STANDARD RUNNING

1. Creel tension 3.5-5.5(as per set) 500N
2. Saw box stretch -0.3 & 0.6 -0.3 & 0.6
3. Leasing tension 13.5 2790 N
4. Winding tension 16.5 2411 N
5. Beam press 15.0 3101 N
6. Squeeze pressure 5-10 ( 0-60 MPM speed ) 10
7. Mositure 6.5% (for cotton yarn only) 6.5% (for cotton yarn only)
8. Saw box temperature 88 (+-5) C 88 C
9. Size level 160mm 160mm
10. Flap level Full Full
11. Steam let –off 50 m before 50 m before

Machine speed-

 30s-40s-60s = 75 MPM
 80s-92s-100s = 50 MPM

Stretch control:

The stretch can be controlled at entry section and output section of saw box by controlling following
tensions we can Adjust Stretch in Warp Threads.

1) Feed roll tension

2) Wet splitting tension

3) Leasing zone tension

4) Creel tension

5) Winding tension

4.5 Paste recipes for different counts:

 30, 40 &60 Ne
Water: - 800 litre
Super Coat: - 125 kg
 PVA 25:- kg
Glysophyl: - 2 kg

 80 & 100 Ne
Water: - 600 litre
Size-C: - 100 kg
PVA: - 20 kg
Cel Size: - 10 kg
Cel Sof: - 1.5 kg

Size paste cooker:

The cooker is made up of stainless steel having capacity of 1200 litre. There is a hollow tube arranged i.e.
Spherical order placed inside the periphery of the cooker. The tube is having small holes around it to provide
The steam.

Method of preparation of size mix:

1) Clean the cooker.

2) Take required amount of water & start stirrer.

3) Take required amount of adhesives (Starch).

4) Take required amount of binder.

5) Cold stirring for 20 minutes.

6) Close the cap of cooker & start steam up to 120° C.

Cost of sizing: 15 Rs/Kg of yarn

Defects in sized beams: cut edge, sticky ends, back selvedge, crossing, size patch ,ball formation.

Size percentage estimation:

 13 -15 % For 30 – 40 Ne
 14 - 16 % For 60 Ne
 12 – 15 % For 80 – 100 Ne
Storage of weaving beams:

The prepared weaving beams can stored at left hand side passage of sizing M/C. There will be up to 50
beams can be stored.

Transportation of the beams:

The beams are handled by Prashant trolley, while the creeling of the warpers beam is done by rope.

Size process control norms:

Squeeze roll pressure: 5 – 13 N

Viscosity: 10 – 11 Sec

Saw box temperature: 90 ° C

M/C Speed: 60 – 80 M/Min

Stretch: 0.6 – 0.8 %

4.6 MAINTAINANCE SCHEDULE (SIZING)

Daily Maintenance:
1) Sizing M/C - Clean air intake to servomotor (Ac)
2) Cylinder dryer:
1. Clean the insulators & the sensors rollers for the moisture content instrument.
2. Check vacuum valves in the steam piping to the rotary joints for correct functioning and
absence of leaks & replacing immediately where necessary.

3 Day Maintenance:

1) Beam creels - Check rails (If fitted) for dirt and foreign bodies, cleaning where necessary.

Weekly Maintenance:

1) Sizing M/C - Check & maintain air line supply sets.

15 Days Maintenance:
 1) Sizing M/C:

1. Clean steam & size piping.

2. Check steam & size piping.
3. Check steam pressure, readjusting, and reducing valve if necessary.
4. Check air pressure, readjusting, and reducing valve if necessary.
5. Check compressed air piping for leaks.

2) Beam Creels: check brakes (visually & by ear), replacing if necessary (if fitted).

3) Sizing Centre:

1. Check for leaks.

2. Check the safety valves for good working order.

4) Cylinder Drier:

1. Check the Teflon coating on the drying cylinder & the steam heated guide roller & measuring
roller.
2. Check safety valves for good working order.
3. Check steam system for leaks.

5) Head Stocks:

1. Check comb functions.

2. Comb expansion.
3. Comb traversing.
4. Replace damaged comb segments.
5. Check limit switch at protective for correct working order.

45 Days Maintenance:
1) Sizing M/C:
1. Use compressed air to clean out pneumatic control cabinet, visual inspection.
2. Electrical control cabinet, visual inspection & cleaning if necessary.
3. Check fuse links for corrosion, cleaning if necessary.
2) Sizing Centre: Check the nip (Use carbon paper to make nip imprint)
3) Cylinder Drier:
1. Check vent pipes, removing fouling & blockages where necessary.
2. Check fans, removing fouling where necessary.
4) Headstock:
1. Electrical compartment at right hand side of the headstock, visual inspection & cleaning if
necessary.
2. Use compressed air to clean the pneumatic compartment at the right hand side of the headstock,
visual inspection.

Quarterly Maintenance:
1) Sizing M/C:
1. Clean away excess oil & grease from M/C internal compartments.
2. Check all drive chains for correct tensioning, retightening if necessary.
3. Clean valves & filters, replacing where necessary.
2) Sizing Centre: Remove oil from the cones in the precision variable speed gear boxes using
cleaning medium which does not contain grease.

Yearly Maintenance:
Ben-Sizetec – Automatize – S7
Preventive battery charge in the power supply of the computer unit in the main pannel, because
failure of the battery will to loss all data.
 5.Manual Drawing-In Section
5.1- Description- In this section, the ends on weaver beam are drawn-in through heald wires and drop pins
as per given specific order.

5.2 Workload In Drawing In Section

No: of machines = 7

S.No DESIGNATION NO: OF DUTY

SUCH
WORKERS

1. To bring heald wires, Drop pins from cleaning

section.
1. 6
DRAWER 2. Assistance in drawing-in through heald wires
as per design.
1. To bring beam from beam rack.
2. 4 2. To bring heald wires, drop pins from cleaning
section.
LEECHER
3. Assistance in drawing-in operation.
1. To pass warp ends through profiled reed
during drawing-in operation.
3. 4
REED MAN 2. To replace faulty reed with correct reed on
machine.

5.3 Knotting and gaiting

Knotting – When during the weaving if oneweaver beam is over and we have torun the next lot of almost
the same count and having the end equal or less then the previous beam then to save the timeknotting is done
in which knotting of new beam and previous beam warp is done and the warp is taken forward
Gaiting – When the ends are grater in the new beam or count difference is very large then gaiting is done in
which drawing in of warp from drop pin heald eye and finally to reed and all these parts are simultaneously
changes on to the loom.

For knotting a knotting trolley is provided along with the device which ties knots at about 450 knots per
minute by staubli. Gaiting is done by moving beam drop pins and reed by the trolley

Steps for knotting process

1) Old beam remove

2) Cleaning

3) Beam doffing

4) Leasing & Remove entanglement

5) Brushing

6) Combing

7) Old warp sheet= Combing + Leasing + Brushing

8) Knotting

9) Beam setting

10) Yarn is slowly pass in the drop wire & Heald frame

11) One pick is entered & the sample cut out

12) If sample is ok then loom is allowed to start and give the production
 6. LOOM SHED-

6.1 BASIC DESCRIPTION

Sized Beam is placed onto the loom, having drawn-in as per the given specific order through the
heald –eye & Drop pin, and fabric is thereby formed. This fabric then undergoes a preliminary
inspection & then stacked in roll form and sent for further processes.
6.1.1 LIST OF MACHINES –

1.TSUDOKAMA Airjet
weaving machine

Model – Zax – N(Navi)

Zax-9100

2.PICANOL Airjet weaving

macine

Model- Omniplus summum-2-

P

TOTAL NO OF MACHINES-
  PSUDOKAMA Airjet weaving machine-- 162

 PICANOL Airjet weaving machine—28 (Inaugurated feb.2018)

6.2. Machine Specification:-

1 TSUDOKOMA-

Fig No. 12 TSUDAKOMA ZAX 9100

TYPE - Air jet weaving machine with electronically controlled dobby.

NO. OF MACHINES -162

Table No.Specifications of TSUDAKOMA ZAX 9100

ITEMS SPECIFICATIONS OPTIONS

Drive 1. Direct start of rush-start motor drive PSC Programmable speed

control
2. PSS programmable start
3. Push-button operation with both hands.
4. Slow inching with inverter (both forward and
backward)
Weft 1.Main and sub nozzle combined system Independent auxiliary main
insertion nozzle timing control
Auxiliary main nozzle
 Stretch nozzle WBS weft brake system
2. New solenoid valves with built in manifolds FIC Fuzzy insertion control
Independent sub-nozzle timing control by color Main nozzle clamper
Sub – nozzle boosting system.
AJC auto jet controller , First pick control

Shedding Crank play shedding – Shaft no. 4 ESS Electronic shedding

system
Positive cam shedding – Shaft no. up to 8
Auto leveling ( positive cam )
Positive dobby Shedding (electronic , floor mounted)
Positive cam shedding – shaft
Shaft no. up to 16
no. up to 10
Jacquard Shedding
Selvedge name jacquard

Let off Double roll electronic let-off (ELO) , WITH KICK BACK EURO BEAM
FUNCTION
With negative easing or positive easing TWIN BEAM

Take up ETU Electronic take up , with automatic density change

function ( 8 kind of densities)
Temple Top mounted type ( inclined cloth passage towards loom Low mounted type
front )

Beating Crank type beating , multiple sley sword beating:

- 4 links (reed space up
to 230 cm)
- 6 links ( reed space up
to 250 cm or more)
Offset rocking Shaft with intermediate supporter

Weft supply Floor mounted for 4 packages (2 colors), Floor mounted

stand for 8 packages ( 4 colors), Floor mounted for 10 packages
( 6 colors)
Selvedge Planetary gear motion ZTN needle-less tuck-in
formation device( left , right,
intermediate)
2/2 selvedge motion , center
leno, electric leno
 Waste weft Catch cord type (2 roll type) , Catch cord type ( gear type) Independent shedding motion
removal for catch cord

Cutter Mechanical cutter Electrical cutter

Lubrication Oil bath system for main driving parts , centralized Centralized lubrication
lubrication ( manual grease) ( automatic grease)

Stop motion Weft yarn – reflective type feeler

Warp yarn – Electric 6-row contact bar system
Others – Stop motion for selvedge and catch cord yarn
Stop cause indication – indication by message on Navi
board , 4 color multi- function indication lamps
Weave Navi board – automatic data setting , recommended
navigation setting indication optimum weaving condition information
system , automatic controlling, troubleshooting and self-diagnosis
function
Network application – Weaving advice, operation manual
TLM Tsudakoma Loom monitoring system

BEAM CARD:-

It represent all the details about the fabric running on the loom.

It contains various perspective-

o LOOM NO.
o SORT NO.
o WEAVE
o WARP COUNT
o WEFT COUNT
o REED
o PICK
o TOTAL ENDS
o REED SPACE
o GREY WIDTH
o BEAM NO. / JOB NO.
o LENGTH
o SIZER
o SIZING DATE
 o SHIFT
o K/G
o S/C

Fig. Sample of beam card

DIFFERENT SETTINGS ON TSUDOKAMA LOOMS- (RUNNING)

S.NO. SORT NO. OF WEAVE WARP WEFT EPI PPI AVERAGE AVERAGE AVERAGE
NO. LOOMS PATTERN COUNT COUN OF OF WARP
OF WEFT
T (Ne) RUNNING
(Ne) (Cmpx4)
(Cmpx4)
(%)

1 15030 22 Plain 1/30 1/30 72 68/1 88 4 7

2 15127 6 Plain 1/30 1/30 72 64/1 61 10 19
3 15134 4 Plain 1/30 1/30 72 60/1 88 2 3
4 17028 5 Plain 1/40 1/40 90 70/1 91 3 7
5 18146 4 Plain 1/40 1/40 100 75/1 87 7 11
6 20209 4 Plain 1/40 1/40 110 80/1 84 6 15
7 20257 3 Plain 1/40 1/40 110 80/1 80 6 24
8 20447 4 Plain 1/40 1/40 106 84/1 91 3 9
9 20661 1 Plain 1/40 1/40 110 80/1 89 11 42
10 21018 3 Satin 1/40 1/40 132 72/1 81 5 16
11 22133 1 Stripe 1/40 1/40 132 72/1 89 10 16
12 25241 1 Plain 1/50 1/50 148 90/1 87 5 9
13 25258 1 Plain 1/50 1/50 148 90/1 82 9 12
14 29008 1 Plain 1/30 1/106 72 52/4 83 7 10
15 30212 4 Satin 1/60 1/60 185 100/1 79 9 33
16 30653 1 Satin 1/60 1/60 175 115/1 82 7 21
17 33019 11 Satin 1/60 1/60 185 65/2 89 2 24
18 40554 4 Satin 1/100 1/100 195 65/3 79 12 26
19 40751 4 Satin 1/80 1/80 195 65/3 83 6 24
20 40755 2 Satin 1/80 1/80 195 98/2 69 19 37
21 40760 5 Satin 1/60 1/80 185 67/3 84 6 19
22 45066 7 Satin 1/100 1/80 220 73/3 83 10 27
23 50617 5 Satin 1/80 1/100 205 72/4 68 12 19
24 50752 4 Satin 1/60 1/177 148 86/4 90 4 12
25 50758 1 Satin 1/60 1/177 132 59/6 92 4 4
26 50762 4 Stripe 1/100 1/100 205 72/4 48 50 91
27 52022 13 Satin 1/60 1/177 148 61/6 83 6 17
28 60494 6 Satin 1/80 1/120 220 74/5 80 9 29
29 60526 2 Satin 1/80 1/100 195 66/6 74 6 54
30 60529 6 Satin 1/100 1/100 220 62/6 83 9 32
31 70178 3 Satin 1/60 3/265 132 60/3 85 6 17
32 80195 5 Satin 1/60 2/265 175 76/4 82 8 19
33 80238 5 Satin 1/80 2/100 220 71/4 78 8 13
34 80327 7 Satin 1/100 3/100 220 59/3 75 12 35
35 09046 4 Plain 1/20 1/10 45 41/1 86 4 18

BEAM CARD, SHIFT REPORT, CLOTH REPORT, AND INSERTION TIMING OF GIVEN
SAMPLES: - (ON LOOM)

1. FOR PLAIN FABRIC

BEAM CARD SHIFT REPORT

CLOTH REPORT INSERTION TIMINGS

1. FOR STRIPE FABRIC (20 mm STRIP)

BEAM CARD SHIFT REPORT

CLOTH REPORT INSERTION TIMINGS

1. FOR SATIN FABRIC

BEAM CARD SHIFT REPORT

 CLOTH REPORT INSERTION TIMINGS

2. PICANOL-

Figure. - PICANOL Airjet weaving machine

 MACHINE SPECIFICATION:-
BASIC MACHINE:-

MODEL OMNIPLUS SUMMUM- 2-P-340

FRAME with RHS width reduction
MONITORING Picanol blue box electronic platform with integrated microprocessor
DISPLAY With touchscreen and interactive colour display
REED MOTION Balanced sley, driven by conjugated cams
Reed holder for profile reed
WEFT INSERTION Pneumatic weft insertion by main and relay nozzle(eco one),
Timing of electromagnetic valves set and controlled by microprocessor,
With separate airtank per weaving channel and electronically controlled
pressure,
With integrated pressure sensor ,
Without bobbin change detection ,
With air master software and integrated air consumption meter.
FILLING DETECTION Double optical, for the use of continuous reed
COLOUR SELECTION 2 colours, pattern monitored by microprocessor
HARNESS DRIVE With suspension elements for 10 harness –DRC30
SHEDDDING MOTION Positive outside cam motion staubli type 1781
Frame up to 10 harness, equipped with 10 drive levers and 10 cams.
Single barrel
Weave pattern: pattern and weave repeat to be specified.
With levelling device.
PICKFINDING Automatic slow motion device.
Automatic pickfinder
BEAM BEARINGS Bearings for the use of beam flanges max. diam.1000mm,
With adaptors type DIN
LET –OFF MOTION Electronic let-off,
With collecting drum for waste.
BACK RETS Smooth hard-chromium plated feeler roller on ball bearings,
 Whip roll tube hard-chromium plated on ball bearings,
With easing motion,
With warp tension measuring device type TSF
WARP STOP MOTION Electrical divided, Grob type KFW5620-pitc 25mm,
With zone selection,
Max. possible capacity 6 electrodes,
With broken end finding handle,
With detection each contact roe
CLOTH TAKE-UP Take-up roll: fine metallised
Pressure roll: felt strip covered,
With second pressure roll,
Cloth roll wind up in the machine ,
With metallised cloth roll
With fixed grooved anti-creased rod
TAKE-UP MOTION Electronic take-up “ETU”
With programmable variable pick density system.
SELVEDGES Rotary split motion: e-leno,
With electronic driven independent selvedge device LHS and RHS
(ELSY)
With horizontal bobbin rack RHS for 12 bobbins,
Electrical waste cutter RHS
TEMPLES Temple with adjustable brackets,
One set of standard temple cylinders
LUBRICATION With continuous forced oil circulation system
MACHINE DRIVE By SUMO 9 voltage (380-460 )
Electronically controlled slow forward and backward motion,
Max. production speed: 700 rpm
Machine speed depending on:
-yarn and preparation quality,
-type of fabrics,
-shedding motion (number of harness ,cam type)
POWER SUPPLY Voltage and frequency to be specified
ADDITIONAL EQUIPMENT:-

HARNESS FRAMES 10 extra reinforced rideless harness frames GTP:XLF Xtra LIGHT 152

For heald length 11 inch,

Pitch 12 mm, quick attachment type DRC30, With center brace,

With integrated heddle dampers

WARP BEAM Single section ground beam

With flanges dia. 1000 mm class 1, barrel dia. 216 mm

Without buttonholes
WEFT SUPPLY 2 vertical bobbin racks for 12 bobbin diam. 290 mm,

With fixation stand for weft accumulator heads,

2 prewinder heads with separated windings (1131 ) and integrated

package break sensor
OPTIONAL EQIPMENT:-

LOOM APRON With loom apron

P.F.T. SYSTEM Programmable filling tensioners
SPEED CONTROL SYSTEM With multispeed
PACKAGE BREAK With 12 package break detector(s)
DECTEOR
DOUBLE INSERTION With double pick insertion
SIX PICK INSERTION With 6-pick insertion on 2 channel
RELAY NOZZLE VALVES With ARVD II plus system (adaptive relay valve drive).

DIFFERENT SETTINGS ON PICANOL LOOMS- (RUNNING):-

S.NO. SORT NO. OF WEAVE WARP WEFT EPI PPI AVERAGE AVERAGE AVERAGE
NO. LOOMS PATTERN COUNT COUN OF OF WARP
OF WEFT
T (Ne) RUNNING
(Ne) (Cmpx4)
(Cmpx4)
(%)

1 20631 28 Plain 1/40 1/40 110 80/1 93 2 3

BEAM CARD, SHIFT REPORT, CLOTH REPORT, AND INSERTION TIMING OF GIVEN
SAMPLES: - (ON LOOM)

1. FOR PLAIN FABRIC

BEAM CARD SHIFT REPORT

CLOTH REPORT INSERTION TIMINGS

6.3 Workload

No: of machines = 190 (162 tsudakoma + 28 picanol)

Table No. 18 Designations and Duties in Weaving Department

S.NO DESIGNATION NO: OF SUCH DUTY

WORKERS

1. To tackle weft break.

1. WEAVER For Tsudakoma 6
machines /worker 2. To join warp end break.
For picanol 6 machines/ 3. To tackle end breakage at catch cord.
worker
4. To replace empty weft package to full
weft package.

5. To replace empty selvedge yarn

package to full package.
 2. WEAVER RELIEVER Same function as weaver but performs at
the time when weaver goes for
lunch or other activities.

1. Cleaning all the waste from loom

3. UTILITY BOY 2
shed (carried in a large bag).
2. Oiling and greasing.
3. Cleaning of rack beam waste.

4. KNOTTING 6 Carry the beam from drawing-in

OPERATOR section (it would be carried by 2
( 2 operator for 1 beam operators). Then beam loading is
knotting) carried out, then knotting is carried
out by automatic machine named
STAUBLI.

1. To remove the defects

5. TROUBLE SHOOTER 5
Two types of defects:
(2 For Tsudakoma, 3 for (Filling, Warp damage)
picanol) 2. To increase the production by
increasing efficiency.

1. To set the new beam on the

6. BEAM GATTER 6
machine.

HUMIDIFICATION PLANTS:-

BATLIBOI –HUMIDIFICATION PLANT

SUMMARY-

DESCRIPTION LOOM ACTUAL ROOM ACTUAL

Dept. Rh% 79.2%Rh 74.9Rh%
Dept. Dry’c 23.6 30.2
Dept. Dry’f 74.4 86.4
Dept. Wet’c 21 26.5
Dept. Wet’f 69.8 79.7
 SETPOINTS

Set Rh% 80%Rh 65%Rh

Set T’c 26
Set T’f 78.8
POSITIONING

FAD 100%
RAD 0%
EAD 100%

6.4 MAINTAINANCE SCHEDULE (WEAVING SHED):-

 Daily Schedule – All Looms

 Weekly Schedule – 25 Looms/Day
 Monthly Schedule – 5 Looms/Day
 Quarterly Schedule - 2 Looms/Day
 Half yearly Schedule – 1 Loom/Day
 Yearly Schedule – 1 Loom/Alternate Day

Daily Maintenance:

1) Easing motion - Check for rust around the easing lever & grease nipple of the rod end.

2) Easing motion - check the yarn debris is not wound around them.

3) Motor pulley and V belt - Check the yarn debris is not wound around them.

4) Shedding timing pulley and belt - check the yarn debris is not wound around them.

5) Planetary slide shaft - check the yarn debris is not wound around them.

6) Centralized Lubrication - Check the grease leakage.

7) Centralized Lubrication - when the munal grease type is used. Check that handle operations are smooth.

8) Inside control box - check that the cable is not caught by the door.

9) Main motor - check that fan does not touch the door.
10) Main motor - check bolts for cover are not loose.

11) Whole Loom - check for abnormal smell & color change. Check covers do not touch a moving part.

Weekly Maintenance:

1) Timing belt tensions.

2) Joint section of hf attachment.

Monthly Maintenance:

1) Leno gear cleaning & greasing.

2) Clutch immature clearance check.

3) Encoder gear clean & grease.

4) Cloth roll chain greasing, emery roll & press roll cleaning & greasing.

3 Month Maintenance:

1) Check that the motor shaft does not have backlash.

2) Cam box oil level change.

3) Lh/Rh side wall oil level check.

4) Take up let off gear & greasing.

5) Air filter & oil filter clean.

6 Month Maintenance:

1) Leno motion clean.

2) Lh/Rh side wall oil level.

3) Belt tension check.

4) Sensor cleaning.

5) Let off take up drive gear box.

6) Air filter.

7) Reed clean.

8) Main nozzle clean.

9) Sub nozzle Clean.

10) FD pin Clean.

Yearly Maintenance:

1) Inside the control box - check than there is not any unused cable or uncovered cable terminal.

2) Inside the control box - check that the screws on the terminal blocks are not loose.

3) Friction roll - check for abrasion of the rubber stripe.

4) Press Roll = check that abrasion of journal section is 0.3 mm or less.

5) Rubber stripe belt - check that abrasion of journal section is 0.3 mm or less.

6) Warp beam - check that abrasion of journal section is 0.3 mm or less.

7) Warp beam metal bush - check bush for abrasion.

8) Shock Absorber - check for function.

9) Nylon bush - check for function.

10) Damper guide pin - check the edge of sharpness.

11) Cutter on LH - check the edge of sharpness.

12) Hook pin assembly - check the hook pin hole for abrasion. (Check that abrasion is 0.5 mm or less)

13) Cloth roll metal - check that bush abrasion is 0.8 mm or less.
TYPES OF LUBRICANT USED:

Gear oil- servo 100

Cam box (staubli) –servo 320

Cam box (dobby) - Syngear 320

Let off and take off – Syngear 680

Side wall- servo 100

7 GREY FABRIC INSPECTION SECTION-

7.1 Basic Description

Here there occurs a preliminary fabric inspection in order to scrutinize the origin of fabric faults pertaining
to various department till loom shed as in

1. Preparatory Section

2. Sizing Section

3. Spinning Section etc.

This inspection gives an idea as to different incorrect process parameter set on machine at various sections.
Correspondingly, a report is prepared and is sent to corresponding department.

The faults so registered are further scrutinized on the basis of whether they can be tackled or not i.e.
Mendable
Un-mendable

7.2 Equipment
1) Inspection table
2) Fabric inspection machine

7.3 Machine set up:

Machine set up Parameter range Set value
1) Roller speed 100-1500 rev/hour. 590-600 rev/hour.
2) Light - Artificial light
3) Length measuring meter (Attached with the machine).

7.4 Method:
1) As the fabric reaches its “set cut length” in the loom the cloth is cut and the cloth roll is
doffed off from the loom.
2) The cloth roll might also be cut and doffed off before the preset length as and when it is needed.
3) According to set rule the “cloth doffer” cuts and doffs off cloth roll and record the doff
length in the loom quality/doffing card and also sticks a doffing stickers over the cloth roll
for identification.
4) The roll is then unrolled over the inspection table where it is visually checked yard to yard
(100%) against light and repaired or mended for any smaller extent of faults like protruding
or projecting yarn, yarn naps, slubs, crack, floats, oil stains which can’t be repaired, the fault
area is identified by putting yarn tails or laces in the selvedge area.
5) The mended fabric is then inspected over the grey fabric inspection machine visually against
light in a pre-set speed (m/min).

7.5 Types of Faults

Table No. 20 Different Types of Faults

S. NO. DEFECT CODE DISCRIPTION

1 101 SUB
2 103 NEPS
3 104 SLUBY WARP/WEFT
4 105 THICK ENDS
5 106 FINE ENDS
6 107 YARN VARIATION
7 108 CONTAMINATION
8 109 KNOT
9 113 HIGH TWIST YARN
10 115 YARN HARINESS
11 116 LOW TWIST YARN
12 117 MULTIPLE BREAKAGE
13 201 DIRTY FIBRE
14 202 ABRASSION
15 203 MISSING ENDS
16 204 FLOAT
17 205 TEMPLE MARK
18 206 DOUBLE ENDS
19 207 PICK VARIATION
20 208 WRONG DRAWING
21 209 REED MARK
22 210 TIGHT ENDS
23 211 SNARL
24 212 WARP SLACK ENDS
25 213 DOUBLE PICK
26 214 SIZING STAIN
27 215 BEND PICK
28 217 BALL FORMATION
29 218 MENDING IMPRESSION
30 220 WRONG DENTING
31 221 THIN PLACE
32 222 TEMPLE CUT
33 223 BROKEN PICK
34 224 OIL STAIN
35 225 SINGLE PICK
36 226 MENDING HOLE
37 227 WARP CUT
38 228 BEAM VARIATION
39 229 SUPPORT MARK
40 230 FOLD MARK
41 232 WEFT CRACK
42 233 PICK FINDING
43 234 WRONG PICK INSERSION
44 235 DISTORATION
45 236 SHADE VARIATION
46 237 TOUCHING
47 238 MOON MARK
48 239 YARN IMPRESSION
49 240 THICK PLACE
50 241 LASHING
 51 301 STITCH
52 302 STOPPAGE MARK
53 303 PATCHES
54 304 STITCH IMPRESSION
55 305 HOLE
56 306 BLANKET IMPRESSION
57 307 FLUFF STAIN
58 308 CREASE MARK
59 309 WEFT PATTA
60 310 WIDTH VARIATION
61 311 COLOUR STAIN
62 312 DROPING
63 314 LAY MARK(STEAMER)
64 315 INSECT STAIN
65 319 WHITE STAIN
66 322 MISS PRINT
67 323 SMUDGING
68 324 BLACK STAIN
69 325 OIL STAIN
70 326 HANDLING STAIN
71 327 SELVEDGE CUT
72 328 OUT PRINT
73 331 STARTING MARK
74 332 BUMPING MARK
75 333 DOBBY LINE
76 334 RUST STAIN
77 335 WATER MARK
78 336 LOOSE PICK
79 337 LOOSE END
80 338 UN-EVEN WEFT
81 339 COURSE PICK

7.6 Workload of Different Worker at Inspection

Table No. Workload of Different Worker at Inspection

S.NO DESIGNATION NO.OF SUCH WORKERS DUTY

1 GREY CHECKER 1 Worker / machine -Detect fabric damage and
mark it, thereby mention
the report about type of
damage at that particular
position.
2 ROLL DOFFER 2-3 Workers in complete -To bring fabric roll for
section inspection
3 WARE HOUSE MAN -To take the fabric to the
storage section.

8.PRODUCTION

TOTAL PRODUCTION IN LOOM SHED - (per day)

Production In mtr./hr./day = PPM X No. of loom X time X efficiency / PPI X 39.37 X

100
(TSUDOKAMA)

= 600 X60 X 162 X 24 X 74.74 / 84 X 39.37 X 100

= 31632.6 m

Production In mtr./hr./day = PPM X No. of loom X time X efficiency / PPI X 39.37 X

100
(PICANOL)

= 800 X60X 28 X 24 X 93 / 80 X 39.37 X 100

 = 9524.4 m

Total production in loom shed in mtr./hr/day = (31632.6 + 9524.4 )m = 41157 m

9. CASE STUDIES DONE ON AIRJET WEAVING MACHINE

STUDY OF FRINGE LENGTH

FRINGE LENGTH – It is the length of the weft which is cut after the beat up by the right hand side cutter
which along with the auxiliary selvedge go in the waste. This length has to be kept optimum so as to be kept
optimum because if the length is more than the wastage of yarn is large and the cost will increase and if
length is less than the required then it will not be gripped by the auxiliary selvedge. So the length is kept in
such a way that weft gripped properly and the waste is not too large hence controlling the cost of the fabric

This length is found to be 50mm for cotton and 55 for polyester

The length is more in case of polyester because it tend to come back after beat up and secondly for gripping
and avoid recoiling stretch nozzle has to be used hence the length is high.

RESULTS: study was done on all the looms and the length was found out 190 loom of airjet only 117 were
having the length in given standard is 50mm and 55mm and other were running not as per standard. Also 64
loom of had fringe length above 50 mm for cotton and 9 loom running on polyester had fringe length above
then 55 mm.

REMEDIES: the Fringe length can be controlled only by rectifying the wrong setting on the accumulator by
the help of the gauges.

If we decrease the drum diameter of the accumulator then the pick length will decrease therefore the length
of fringe can be controlled
CONCLUSION:- We had completed “ In depth study of the functions of weaving department”.

As well as case study of FRINGE LENGTH along with the Result and Remedies.