Textile Internship Report

at
Wintry Engineering &
Chemicals Pvt. Ltd.
Anju Shukla (BFT/22/422)
Dhrub Mishra (BFT/22/117)
Diksha Mandal (BFT/22/141)
Urmi Sharma (BFT/22/881)
 Introduction
Our 14-day internship at Wintry Engineering & Chemical Limited provided
invaluable practical insights into textile processing, complementing our B.F.Tech
studies at NIFT. We explored advanced techniques in wet processing, dyeing,
printing, and finishing, gaining hands-on experience with state-of-the-art
machinery. This experience enhanced our understanding of the industry's best
practices, quality control measures, and the complexities of fabric
transformation, bridging the gap between classroom learning and real-world
application.

Objectives:
Understand fabric processing stages.
Learn about machinery and workflows.
Recognize the importance of fabric quality.
Explore quality control and process optimization.
Company Overview
Established in 2003, Wintry Engineering Private Limited is a leading
textile processing company located in Dombivli East. It processes
raw materials for suppliers and buyers into high-quality fabrics. The
factory is equipped with modern machinery and a state-of-the-art
Effluent Treatment Plant (ETP) to ensure minimal environmental
impact. With around 250 employees, the company processes and
exports fabrics to countries like Sri Lanka and Bangladesh, boasting
an annual turnover of approximately ₹200 crores.
 PROCESS FLOW
1 RAW-MATERIAL 6 FINISHING

2 GREY DEPARTMENT 7 QUALITY INSPECTION

3 PRE-TREATMENT 8 FOLDING AND PACKING

4 DYEING

PRINTING
5
Grey fabric department
PURCHASE ORDER - When the buyer places an order. The grey department
analyzed the buyer’s requirement, they make a detailed order card with all the
information of the order mentioned such as;
Fabric specifications, Supplier’s details, Date of order, Quantity, Pricing.
FABRIC ISSUANCE - After the creation and approval of the PO, the next step
involves the issuance of grey fabric from the company’s stock.

INSPECTION - After the fabric is received, samples of the fabric is sent to the
specialized laboratories to perform different tests as per the specifications like;
GSM, Tensile strength, Tear strength etc.

BATCHING -
Company name- PARAS
RPM- 190/meter
5000 meter in single run.
Whatever the fabric requirement of the customer, company
always gives 18% extra fabric due to defects and srinkage.
 Singeing

3 Important Parameters for Singeing:

Intensity (depends on fabric count
& construction, more intensity in
compact fabric)
Speed
Position

Singeing is a crucial pre-treatment process in textile manufacturing, typically performed immediately after weaving or
knitting. This process involves passing the fabric in an open-width form over a gas flame or hot plate, carefully
calibrated to burn off protruding fibers without damaging the main structure of the fabric. The primary goal of singeing
is to produce a smooth, clean surface on the fabric, which enhances its luster and reduces the tendency for pilling.
Desizing Process Overview:

Desizing is the first step in fabric pretreatment, crucial for removing

sizing agents like starches and PVA used during weaving to
strengthen warp threads. These agents must be removed to ensure
proper dyeing and finishing. At Wintry, desizing involves enzymatic
hydrolysis, breaking down starch into water-soluble molecules. The
process occurs in a stainless steel desizing tank, equipped with
multiple rollers for thorough immersion and preparation of the fabric
for bleaching.
 Bleaching
Company name- MINZEL
Length of machine- 280
meter
Average speed- 70meter/
min

The bleaching process at Wintry removes impurities to achieve high whiteness, preparing fabric for dyeing or printing.
It uses hydrogen peroxide (10 g/L) with sodium hydroxide (30 g/L) to enhance penetration and remove fats. A
sequestering agent (2 g/L) neutralizes metal ions, while a wetting agent and stabilizer ensure even distribution and
controlled bleaching. The fabric is steamed at 98°C and hot-washed at 95°C to remove residuals. Finally, acetic acid (8
g/L) neutralizes alkaline residues, restoring the fabric's pH for further processing.
Bleaching Recipe
Mercerization

Mercerization is a vital finishing process in the textile industry, primarily used

for cellulose fabrics like cotton and flax. This treatment significantly enhances
the quality of the fabric, improving dye uptake, tear strength, and reducing
fabric shrinkage, while imparting a silk-like luster.

In case of non mercerized cotton, the dye consumption of light colors are 10-
15% and for dark colours its 25-30%
Mercerization
Flow Process
Softflow
Softflow dyeing technology is used at Wintry Engineering &
Chemicals Pvt. Ltd. for delicate fabrics that need gentle handling
and precise control. This method is ideal for textiles like
doublecloth, crepe, seersucker, polyester, and nylon. Polyester
needs isolated environment for dyeing to retain the temperature.
 Dyeing
PROCESS FLOW

Buyer’s Sample Dye Sample Sample Approval

Finishing Dye Preparation Dye Department

Testing Lab
Dyeing Machines

B D
A JIGGER
U-JETT SOFT FLOW
DYEING C DYEING E
DYEING
COLD PAD WINCH
BATCH DYEING
DYEING
U-JETT DYEING

NO. OF MACHINES: 5
FABRIC CAPACITY: In 400 kg machine, 350-370 kg can be dyed.
WATER CAPACITIY: 1000 litres.
TEMPERATURE: 130° C
Used for dyeing polyester fabric with dispersed dyes.

Both the fabric and the liquor are made to move.

The liquid is forced through a narrow jet which pulls the fabric
along and transports it through the jet.
The fabric is dyed in rope form.
Fabric with low dimensional stability should be avoided dyeing in
jet dyeing machine.
SOFT FLOW DYEING
NO. OF MACHINES: 10
BRAND: Dynemica, Kappa, TexFab
FABRIC CAPACITY: 450-880kg.
MACHINE CAPACITY: 550-1000kg.
Used for dyeing polyester fabrics with disperse dyes.
Polyester MLR= 1:5, Cotton= 1:6
Speed=250m/min
Knits and Woven fabrics can be dyed in the machine.
Fabric is dyed in the rope form and also bleached.
Bleaching can also be done.
Fabrics can be dyed in Softflow are Polyester Viscose, Nylon,
Polyester etc.
 COLD PAD BATCH

It is an open-width machine that can be used for

continuous open-width or batch-wise treatment of fabric.
Consists of a small trough to contain the padding liquor
and a pair of rollers to squeeze the liquor from the fabric.
The dye liquor is filled in the tank which is connected to
the trough to take the amount of liquor needed.
In CPB the fabric is impregnated into the dye liquor in the
NO. OF MACHINES: 4
trough and the excess liquor is squeezed out.
BRAND: Calico, Menzel
FABRIC CAPACITY: 30,000m. Here the fabric is made to move through the liquor.
CAPACITY: 60 litres. After dyeing, the light shade lot is kept in rotation for 8-10
Used for dyeing cotton and cotton blend fabric with
reactive dyes. hours and dark shade for 16 hours.
JIGGER DYEING
NO. OF MACHINES: 5
FABRIC CAPACITY: 2200m.
Company name- Bhatt Bros
No polyester dyeing.
A V-shapes stainless steel vessel containing dye liquor.
It has a pair of upper guide roll, an immersion and two draw rolls to
pull the fabric through the dye liquor.
The liquor is heated with the steam pipe at the bottom of the jigger.
The fabric is drawn from one roller to another for several cycles
until sufficient dyeing takes place.
After dyeing is over the dye liquor is run out from the vessel and
filled with cold water for rinsing.
The fabric is dyed in open width form.
 WINCH DYEING
NO. OF MACHINES: 4
Capacity: 800 kg
Used for washing delicate printed fabrics.
Winch consists of a vessel that has a curved back.
Over the top of the vessel it has a elliptical winch rotated
individually by electric motor.
The steam and chemical inlets are located in this chamber .
Fabric is being washed in this machine.
Mainly delicate fabrics are processed in winch as the fabric is
rotated with minimum tension.
The winch is prime mover of the fabric which is piled inside the
liquor for adequate time.
 PRINTING
Design Department

Sampling Department

Roller/Screens Development Department

Colour Lab and Chemical Department

Printing Department
TYPES OF PRINTING STYLES

Pigment
Pigment Discharge
Reactive
Vat Discharge (rarely used at Wintry)
Disperse
Brasso Print (rubber effect)
Digital
DYE PASTE
The ingredients found in the paste recipe include: Defoaming Agents: Emulsified pine oil (vat paste)
dyes or pigments, binders, thickeners, dispersing or
suspending agents Thickeners: Starches and gums, Sodium Alginate.

A dye paste can be stored for 10-14 days

Pigment Paste
Binder 35%
Fixer 3%
Liquid Ammonia 1%
Pigment Thickener 4%
Water Balance As requirement
Urea 5%
Total 200kg
 Pigment Discharge
Binder 20%
Fixer 3%
Liquid Ammonia 1%
Disperse Paste (recipe for 100%)
Pigment Thickener 4%
T.E.A. 1% U.G.V. 6%

D.E.G 1% Citric Acid 3%

N.R.T. (Discharge Chemical) 20% Loop Accelerator 1%

Urea 5%

VAT Paste
U.V.B. Gum 6% Color comes in 100%, 200%, 400%. So the final % of
Safolite 25% the paste recipe can differ depending on the colour
concentration for disperse paste.
Pine Oil ½%
Glycerin ½%
Khadi 15%
Soda Ash 6%
 Machines
Available in
Printing
Department
Screen Printing Screen Development
The nylon screen is also
Hand-Screen Printing called stencil with the size of
Gum is applied to the table and the workers 36x7 inches.
properly align the fabric manually. A coating of Reapa
The screen is brought and carefully placed on top Sensitinzer (Ammonium) &
of the fabric. Ezycoat 999plus
The Squeegee is used to spread the printing paste is applied to the clean
on the screen. screen and left to dry.
On both ends of the screen, there is one worker, Photochemical method is used for the preparation of the screen.
and they take turns spreading the paste.
Flat-screen Printing
The gum (adhesive) is continuously applied to the belt which
keeps the fabric static during printing.
Different screens are installed on top of the blanket in a long
continuous belt according to the colours.
The base colour is printed first, and the rest of the minor colour
comes later.
Sampling Department At each screen, one worker is assigned to observe for any errors
Hand-screen printing or defects.
Wintry has 2 flat-screen printing machines.
Max. production in 1 day can be 7000-8000 mt fabric.
 Rollers come in 3 sizes:
64 repeat
Roller Development
Digital laser engraving machine
Rotary Printing
15,000 mt fabric can be printed in 1 day.
82 repeat Jetstar Inkjet 30-35 metres per min speed is standard
92 repeat Rollers are made of nickel. and highest is 40-45 metres per min.
followed by a drying chamber with 180-190 C
6 Rotary Machines
5000 metres per hours
Designs with up to 14 colours present can be
printed in roller printing machine.

The print paste is supplied

from reservoirs to rotating
rollers.
Each roller imprints one
repeat of the design.
The price of one roller is about 5000 INR. As the roller spins, a doctor
It takes about 4 hours to make 1 complete roller ready blade in continuous mode
scrapes the excess paste
for use.
back to the colour trough
Ager Machine is used to steam the woven clothes after
printing which fixes the color. At 102° C with 26m/min to Process
40m/min speed.
Curing is done to fix the pigment color at 160° C for 8 mins. Stormac RD IV Machine
Digital Printing
Process
The design, printing speed, and other
parameters are set through the
computerised system.
The colour cans are installed inside the
machine.
The base of the fabric is pre-coating
because digital printing technology
cannot handle the additional viscosity of
a colour formula within the ink (Reactive,
Acid, Disperse). Ink is sourced from
Türkiye.
This pre-coating prevents the wicking and
enables a sharp print mark.
In 24 hours, Reggiani digital
Designs that were difficult to
printer prints about 6000
create in screen/roller printing
metres of fabric.
are easily produced in digital
printing.
 FINISHING DEPARTMENT
STENTER: CALENDERING:
1. Heat Setting 1. 3 machines dedicated to the calendering process.
2. Width & Shrinkage Control 2. Calendering involves passing fabric between rollers at
3. Chemical Treatments high temperatures and pressures to achieve a smooth,
4. Padding & Coating lustrous finish.
5. Bowing & Skew Control 3. Purpose: Flatten yarns, close fabric interlacements,
6. 150-180°C for cotton , lycra, velvet and more than 180°C and enhance the fabric's smoothness and sheen.
for polyester. 4. Variations: Beetling, watered, embossing, and
7. Company name- EHWHA(Korea) and MORTEX(Italy) Schreiner.
ZERO/SANFORZING: PEACH FINISHING:
1. They were having 4 machines from RAMSONS, primarily 1. They were having 1 peach finishing machine from the
used for sanforizing rayon fabric. company CARU, processing 6,000 meters in 12 hours.
2. Sanforizing is a mechanical finishing process that prevents 2. Peach Effect: Peaching gently sands fabrics to create a
shrinkage in woven fabrics, particularly cotton, by soft, protruded surface, giving them a "peach-like" feel.
stretching, fixing, and stabilizing fibers. 3. Process: This finish is achieved through
3. Controlled Compressive Shrinkage: The process is based on microsandpaper or carbon wire brushing, especially
passing the fabric through a movable elastic felt blanket effective on twill fabrics.
and metal rollers, leading to controlled compressive 4. Alternative Methods: Peaching can also be done with
shrinkage. specific chemicals or laundry abrasion to achieve
4. Enhanced Fabric Quality. similar effects.
5. 40-50 meter/minute.
Airo finish:
AIRO Machine: The AIRO finishing machine uses air transportation and mechanical action for textile
processing.
Fabric Transport: It drives fabric through processing tubes using an air-only system, minimizing tension.
Impact Grid: Fabric is ejected against a stainless steel impact grid, enhancing body, volume, and
stability.
Machine Name: The specific machine used is named AIRO 24 from company BIAN CALANI.
Cost: The cost of processing fabric with this machine is 10 Rs per meter.
 TEXTILE TESTING LAB
Washing Fastness Testing: Tensile Strength Testing:
Test Method: Fabric's color resistance is tested with Tensile Strength: Measures the maximum force a fabric
water, OBA detergent, and steel balls. can endure before breaking, with results recorded in
Rating: Post-wash, color change is rated from 1 (poor) to Newtons.
5 (excellent) using a grey scale. Titan 25 Machine: A universal tester by James Heal for
various tests, including tensile strength, with results in

Tear Strength Testing: Newtons.

Tear Strength: Measures fabric resistance to tearing in

warp and weft directions.
Tester: Paramount Manual Tear Strength Tester, used
for cotton, costs ₹4,800.

Seam Slippage Testing

Seam Slippage: Measures fabric seam resistance to slipping
under tension, important for garment durability.
James Heal Machine: The test is performed using a James
Heal machine, with results expressed in kg, pounds, or
newtons.
Shrinkage Testing: Random Pilling Testing:
Shrinkage Testing: Evaluates fabric dimensional stability after Pilling: Formation of small, fuzzy balls on fabric surfaces
washing, using templates of 25 cm², 35 cm², or 50 cm². due to wear.
Process: Fabrics are washed (10-12 minutes to 1 hour) and Test Method: The Random Pilling test at Wintry uses a
dried (tumble for cotton, line-dried for rayon) according to James Heal machine that rotates the fabric sample for 30
ISO 8330 and AATCC 135 standards. minutes to simulate wear conditions.

Rubbing Fastness Testing:

Rubbing Fastness: Tests fabric color resistance to rubbing
in wet and dry conditions.
Test Method: Uses a Paramount machine with 10 strokes on
samples, and results are rated from 1 (worst) to 5 (best)
using a grey scale.
Martindale Abrasion-cum-Pilling Testing:
1. Abrasion Resistance & Pilling: Evaluates fabric durability
and pilling tendency.
2. Martindale Tester: Uses a Paramount Martindale tester to
rub the fabric against a standard abrasive surface under
specified pressure.

GSM TESTING:
1. GSM and Fabric Durability: Higher GSM indicates thicker,
more durable fabric, suitable for specific activities.
2. This machine is light weight and highly accurate in results.

COLOUR MATCHING BOX:

1. Ensures consistent color evaluation under controlled lighting.
2. Uses multiple light sources to detect color variations.
3. Key tool for identifying color flaws early in production.
4. Helps products meet industry color standards.
 Color
Sno. Light Source Type of light Watt
Temperature

MATCHING BOX:
Artificial 6500
1. D-65 18W
Day Light Degree K

COLOUR
4000
2. TL-84 Fluorescent Light- Pont of sale light 18W
Degree K

Tungsten 60W 2300-2800

3. Incandescent Light
Filament Bulb Degree K

Cool White Fluorescent Office Lightning 4100

4. CWF 18W
Degree K

Ultra Ultra
5. UV 18W
Violet light Violet Light
 Test Method Standards at Wintry
To ensure accuracy and consistency, Wintry adheres to the following test methods:

- Shrinkage: ISO 8330, AATCC 135

- Colour Fastness to Washing: ISO 105, C06, AATCC 612A
- Colour Fastness to Rubbing: ISO 10512, ATCC 8
- Colour Fastness to Water: ISO E01, AATCC 107
- Colour Fastness to Perspiration: ISO 105 E04, AATCC 115
- Tensile: ASTM D 5034
- Tear: ASTM D 1424
- Seam Slippage: ASTM D 1683
- Random Tumble Pilling: ASTM D 3512
- Martindale: ASTM E 4970
- Construction: ASTM D 3775
- Weight: ASTM D 3776
 FOLDING AND PACKAGING
Plating Machine: Manual Inspection and
Folding:
Folding Capacity: Wintry has two plating machines, each Skilled Team: The department has 20 workers for manual
capable of folding 500 meters of fabric. inspection and folding, divided into pairs at each
Purpose: These machines ensure consistent and accurate inspection table.
folding, reducing handling and potential damage. Inspection Method: Uses the 4-point system to assess
and classify fabric defects, ensuring quality before
folding and packaging.
Inspection with Roller Folding:

Roller Folding Machines: Combines machine

efficiency with inspection for consistent and
uniform folding.
High Standards: The department integrates
machinery and skilled personnel to maintain high-
quality fabric finishing.
 Quality Control Measures
AFTER STENTER:
Surface Smoothness: Ensures a uniform, smooth, and lustrous finish on
the fabric.
Thickness Control: Maintains consistent fabric thickness and density.
Dimensional Stability: Preserves the fabric's size and shape during the
process.

AFTER CALENDERING:
Uniform Surface: Checks for smoothness and consistent
finishes.
Physical Standards: Verifies density, luster, and stability.
Quality Boost: Enhances fabric aesthetics and
functionality.

AFTER SANFORIZING:
Shrinkage Testing: Ensures fabrics meet industry standards for residual
shrinkage.
Visual Inspection: Confirms uniform appearance, smoothness, and consistent
color.
Handling: Assesses fabric softness and drape to meet customer expectations.
Challenges
At Wintry, we observed there could be improvement in the following domains:

Unorganized departments: Often rolls were misplaced, not stored in the proper place and it took a while to find
them among other lot.

Improper maintenance of exhausts, water was always dripping in certain areas in the pre-treatment
department.

The bleaching department office is not maintained, and the walls have developed mold (dark brown/black
patches) due to improper ventilation and the stale air. This can cause health issues.

Lighting is not proper in most departments except the merchandising, and design departments.

Due to improper drainage and uneven surfaces, the formation of stagnant water during rain is a common
occurrence.

No Safety Measures: Lack of safety precautions.

Missing Fire Extinguishers: Not enough fire safety equipment.

Environmental Considerations
Caustic Recovery Unit: Specialized equipment to recover and purify caustic soda from
spent solutions.
A caustic recovery plant is crucial for improving efficiency, reducing costs, and minimizing
environmental impact in the textile processing industry. Minimizes chemical waste and reduces the
environmental impact by recycling caustic soda and lowering the volume of hazardous waste.
Filtration and Separation:
Filters: Remove impurities and solid particulates from the caustic solution.
Centrifuges: Separate solids from liquids to purify the caustic soda.
Recycling and Purification:
Neutralization Tanks: Treat residual chemicals to neutralize waste.
Reagent Addition: Add chemicals to adjust the pH and improve caustic soda quality.
Storage and Handling:
Storage Tanks: For recovered and purified caustic soda ready for reuse.
Pumps and Piping: Transport caustic solutions through the plant.
Applications:
Bleaching: Reclaims caustic soda used in the bleaching process.
Dyeing: Recovers caustic soda from dyeing processes to be reused in subsequent batches.
Textile Finishing: Purifies caustic soda used in various finishing treatments.
 OBSERVATIONS
COSTING AND SOME OTHER INFORMATION:
Basic costing of sample- 200 to 350 rs / meter(depends on the fabric processing and finishing).
Basic costing after fabric goes for bulk-
1.Printing – 45 rs/mtr
2.Dye- 30rs/mtr
3.RFD- 20rs/mtr
It takes atlest 10 days for the aaproval of mass production.
If bulk production for dyeing comes ,than it takes atlest 20 to 25 days to complete the production.
Before processing of any fabric , srinkage of fabric is always checked as it is the most important part.
They export to srilanka, Dubey, Bangladesh, zudio, reliance, jack n jones, Africa, dmart, shoppersstop,
teddy etc.
They have atlest 1000 workers, 12 to 15 workers in one machine.
Area of industry is 10 to 17 acres.(MAY BE ESTABLISH 12 YEARS BACK)
THANK YOU