PROCESSING DEPARTMENT

TABLE OF CONTENTS

1. Department Overview
2. Department objectives
3. Key Performance Indicators of the
Department
4. Organization chart
5. Work flow and process
6. Process wise machinery
7. Key stakeholders
8. HIRA
9. Current Challenges and Opportunities
10.SOPs
11.Learnings
 DEPARTMENT OVERVIEW

Processing is the final stage in a composite textile industry. Processing makes the
griege fabric saleable after scouring to remove impurities, finishing to give softness &
bounce and mechanically processed to give smoothness, lustre and feel. In
processing, fabric is processed to match the standard finish & shade reference given
by the customer.
Production capacity of department. is 60k/day.
ROLE OF THE DEPARTMENT (FIBER-DYED & YARN-DYED
FABRICS)

In textile units that use fiber-dyed or yarn-dyed materials, the processing department handles
the post-weaving treatments of the fabric. It’s role is to:

 Enhance the fabric's quality (look, feel, durability).

 Perform finishing processes that prepare the fabric for final use for garments.

 Ensure that colors remain stable and fabric properties are maintained during finishing.
 R E S P ON S IB IL IT IE S OF T H E P R OC E S S IN G D E PART M E N T

A. Fabric Preparation B. Finishing

 Inspect fabric made from dyed Apply mechanical and chemical finishes to
yarn/fiber. improve fabric performance:
 Remove impurities or weaving oils  Softening for comfort.
through scouring.  Anti-pilling, wrinkle-free, or shrinkage
 Equalize fabric tension and remove control.
impurities before finishing.  Stiffening or water-repellent finishes,
if required.

C. Heat Setting (especially for synthetic yarn fabrics)

 Stabilize fabric shape and dimensions.

 Prevent shrinkage during further processing.
R E S P ON S IB IL IT IE S OF T H E P R OC E S S IN G
D E PART M E N T

D. Quality Assurance E. Machine Operation and Maintenance

Check for:  Operate processing machines (Scouring,
 Color consistency and fastness (colors stenter, calendars, etc.) efficiently.
shouldn’t bleed or fade).  Maintain machine settings to match
 Fabric appearance (no streaks, patches, or customer specifications.
distortions).
 Fabric dimensions (width, GSM, shrinkage
control).

F. Production Coordination G. Environmental and Chemical Safety

 Work closely in coordination with weaving,  Safely use and dispose of chemicals.
PPC, QA, fibre dyeing and folding  Minimize water and energy usage.
departments.  Follow pollution control norms (e.g., for
 Ensure smooth batch flow and proper finishing chemicals, wastewater).
record-keeping.
 AC C OU N TAB IL IT Y OF T H E P R OC E S S IN G D E PART M E N T

Area What They're Accountable For

Quality Final fabric quality, feel, and performance.

Ensuring fiber/yarn-dyed colors are not damaged during
Colour Integrity
processing.

Completing processing on schedule to meet delivery

Timeliness
deadlines. Processing cycle time – 7 days

Cost Control Efficient use of chemicals, water, and energy.

Following safety and environmental laws (e.g., STeP,
Compliance
ZDHC, GOTS, IMS, EnMS).
Ensuring the fabric meets customer needs for color,
Customer Satisfaction
softness, and finish.
 OR GAN IZAT ION S T R U C T U R E

Harkesh Kumar
(HOD)

Harish Bhatt
Harminder Nagi
(In charge – B&R)
(In charge – OTC)

Akhlesh Vacant Vijay Prakash Ashish Singh

(In charge–Grey Section) (In charge–Wet Section) (In charge–Stenter Section) (In charge–Mech. Section)

(Wet Section Officers) (Stenter Section Officers) (Mech. Section Officers)

(In charge – NPD)
Ramakant, Robin, Baleshwar, Amin, Ram Shivkumar Tanwar, Mahesh,
Sumit Kumar
Vacant Prakash, Sharat, Ravindra
Arjun Sharma, Vacant

(In charge – MIS)

Mandeep
 P R OC E S S IN G W OR K E R S ( C ON T. + R E GU L AR )

(In charge – NPD) (Mech. Section Officers) (Wet Section Officers) (Stenter Section Officers)
Sumit Kumar Shivkumar Tanwar, Mahesh, Ramakant, Robin, Vacant Baleshwar, Amin, Ram Prakash,
Ravindra Sharat, Arjun Sharma, Vacant

Regular Workers Contract Workers – 35 Contract Workers – 38 Contract Workers – 3

-3 Regular Workers - 37 Regular Workers - 49 Regular Workers - 48

Total Contract Workers – 76

Total Regular Workers - 137
  Pre-treatment (Scouring)
 Heat set
 Singeing
 Scouring on
 Relax (Continuous Scouring)
Jet (Rope Scouring)
Jigger (Open width Scouring)
Dolly (Rope scouring for Poly Wool)
 Drying (VDR or Stenter)
P R OC E S S FLOW
 Chemical finish
Softner finish
Wrinkle free
Teflon finish
 Mechanical finish
Calendaring
Shrinking range
Superfinish
KD
Multi Decatizing
 Quality Checking (Lab)
 Folding (For inspection)
 GREIGE SECTION

WET SECTION

PROCESSING HAS 4
SECTIONS
STENTER SECTION

MECHANICAL SECTION
 GREY SECTION

Fabric after inspection and measuring in weaving department first taken for grey mending to remove
neps, cut knots & loose threads and then stored in grey section.
Grey Issue capacity : 65k/day

- Store Fabric according to Quality, shade, order and loom wise

- Issues material to SPH according to planning received from PPC

FUNCTIONS OF
GREY SECTION - Makes continuous length of fabric for processing by stitching ends

- Maintain records of continuity cards and grey stocks

- Issue material as per requirement of SPH for Export & Domestic

 WET SECTION

In Wet Section, as per final finish/handle requirement and SOP’s for that particular
quality, fabric is Scoured/Denier reduction on different machines. The main functions of
each machine are different.
 MACHINE NAME NO. OF MACHINES
Gas Singeing 1

• Open width Scouring (Relax) 2

• Weight reduction 2

• Jet Dyeing 2
WET SECTION
• U-Jet 2

• Jigger 2

• Jumbo Jigger 1

• Dolly Winch 1

• Vertical Drying Range 1

• Rope Opener 1

• Checking & Spotting 2

Gas Singeing Relax Scouring

It is done to remove protruding fibers It is open width continuous scouring. Fabric is

from fabric by burning. scoured to remove grey impurities like oils, wax
etc. The machine helps release fabric tensions.

Jet (long jet/ U-jet) Vertical Drying Range (VDR)

It is used for drying the fabric by passing through steam
Jet machine is used for scouring, denier heated cylinders.
reduction and dyeing the fabric.

Jigger Scouring/Dyeing Weight Reduction Machine

It is used for denier reduction of fabric by using caustic
Jigger is open width scouring machine. It is
soda flakes.
used for bleaching also. Viscose/ cotton
dyeing is also done on jigger machines.
Dolly Scouring Machine
It is used for scouring of Polywool and polywool blends.
Singeing Machine

Open Width Relax Machine

Long Jet Dyeing U Jet Dyeing
Machine Machine
 VDR Machine WR Machine

Jigger Dyeing Machine Dolly Scouring Machine

 STENTER
SECTION

Stenter machine is one of the most important machine used in finishing process. It’s main
purpose is to control the width/GSM/shrinkage, dry the fabric and apply finishes.

Number of Stenter – 4
6 Chamber – 3 & 8 Chamber – 1
 FUNCTIONS OF STENTER MACHINE

Heat setting to stabilize the fabric dimensions and prevents shrinkage after washing and ironing.

Drying the fabric after washing/ scouring, dyeing using hot air.

To control width by keeping the fabric at desired width using adjustable pin chains.

Chemical finishing like softening, water repellent, wrinkle free etc. are done.
Stenter Machine
 MECHANICAL SECTION

In mechanical Section, according to final finish/handle requirement and SOP’s for

that particular quality, fabric is processed on different machines to improve its sale
value. The main functions of each machine are different.
 MECHANICAL SECTION

Machine Name No. of

Machine
• Calendar 1

• Shrinking Range (Zero/Zero) 2

• Super Finish 1

• Multi Decatising (MD) 1

• Kier Decatising (KD/TMT) 3

Calendar
The Calendar machine imparts sheen and smooth
touch to the fabric by improving the fabric’s opacity and
compressing it to make it lighter. To make the fabric
more aesthetically appealing, Calendaring is a must
process

Shrinking Range (Zero/Zero)

The main function of this machine is to controls shrinkage
in fabric. It gives breaking to the fabric. It improves
softness, suppleness, fullness, attractiveness in the fabric.
Super Finish
It is for pre-pressing before KD/TMT or final
pressing to impart smoothness and good
luster to final fabric.

Multi Decatising (MD)

It is for continuous open decatising, where
dullness (less sheen) is required in the final
fabric.

Kier Decatising (TMT/KD)

KD is also known as Permanent Shrunk
Process.
It is to impart permanent luster in fabric
and dimensional stability.
Zero Zero Machine Calendar Machine
 Super Finish Machine

KD Machine Multidecatizing Machine

 Production Data as per PPC Plan

Avg. Avg. Avg. Avg. Avg. Q1 Q2 Q3 Q4 Avg.

Description
(2019-20) (2020-21) (2021-22) (2022-23) (2023-24) (2024-25) (2024-25) (2024-25) (2024-25) (2024-25)

Prod./Day Avg.(Mts) 51597 44681 53302 55800 61464 53927

45561 33600 44089 57217
Target PPC Avg. (Mts) 51644 45966 53263 54779 55075 52270

Production

70000
61464
57217 55800 54779 55075
60000 53302 53927 52270
51597 53263
51644

50000 45561 44089 44681 45966

40000 33600

30000

20000

10000

0
Avg. Avg. Avg. Avg. Avg. Q1 Q2 Q3 Q4 YTD
(2019-20) (2020-21) (2021-22) (2022-23) (2023-24) (2024-25) (2024-25) (2024-25) (2024-25) (2024-25)

Prod./Day Avg.(Mts) Target PPC Avg. (Mts)

 C&D % age

Avg. Avg. Avg. Avg. Avg. Q1 Q2 Q3 Q4

Description Target
(2019-20) (2020-21) (2021-22) (2022-23) (2023-24) (2024-25) (2024-25) (2024-25) (2024-25) (2024-25)

Total C&D %age

3.18 2.60 2.71 2.63 1.75 1.17 0.56 0.40 0.31 0.36 0.41
Target

C&D %age
Total C&D %age Target

3.50
3.18
3.00
2.71 2.63
2.60
2.50

2.00
1.75

1.50
1.17
1.00

0.56
0.50 0.40 0.36 0.41
0.31

0.00
Avg. Avg. Avg. Avg. Target Avg. Q1 Q2 Q3 Q4 UTD
(2019-20) (2020-21) (2021-22) (2022-23) (2023-24) (2024-25) (2024-25) (2024-25) (2024-25) (2024-25)
 Expenses v/s Revenue (Rs/mt)
Avg. Avg. Avg. Avg. Avg. Q1 Q2 Q3 Q4
Description Budget
(2019-20) (2020-21) (2021-22) (2022-23) (2023-24) (2024-25) (2024-25) (2024-25) (2024-25) (2024-25)

Expenses (Rs/mt) 21.22 29.43 25.88 23.72 24.77 25.65 28.08 24.66 23.92 22.42 23.58

Revenue (Rs/mt) 19.92 18.57 20.62 22.41 22.66 23.26 23.14 23.29 23.87 23.94 22.90

Expenses v/s Revenue

35
29.43

30 28.08
25.88 24.77 25.65
23.72 24.66 23.92
23.87 23.94
23.26 23.14 23.29 23.58 22.90
25 22.66 22.42
21.22 22.41
19.92 20.62
20 18.57

15

10

0
Avg. Avg. Avg. Budget Avg. Avg. Q1 Q2 Q3 Q4 UTD
(2019-20) (2020-21) (2021-22) (2022-23) (2023-24) (2024-25) (2024-25) (2024-25) (2024-25) (2024-25)

Expenses (Rs/mt) Revenue (Rs/mt)

 Capacity/mc/
S. No. Name of M/C Make
shift (Mts)
1 Yamuna Relax Scouring Yamuna 15000
2 New Relax Scouring Harish 11000
3 Vertical Drying Range Texfab 7040
4 Singeing Osthoff Senge 29000
5 Hydraulic Jigger No.1 Harish 600
6 Hydraulic Jigger No.2 Harish 600
7 Jumbo Jigger Harish 2000
8 Dolly Winch J.K textile engg. 1000
9 Jet Dyeing No.1 Tex fab 1200
10 Jet Dyeing No.2 Pinak 1200
11 Sample Jet Dyeing Tex fab 10
MACHINE 12 U-Jet 1 Heatex 1800
13 U-Jet 2 Heatex 1800
CAPACITY AND 14 Weight Reduction No. 1 TexFab 1800
MAKE 15 Weight Reduction No. 2 TexFab 1200
16 Stenter No.1 Harish 13200
17 Stenter No.2 Harish 13200
18 Stenter No.3 Harish 11000
19 Stenter No.4 Harish 15400
20 TMT KD Machine TMT italy 9000
21 Biella K.D Biella shrunk italy 12000
22 Calendar machine Jiangyin Guoguang 11000
23 Multi Decatise Speretto Rimer 11000
24 Old Zero Zero Ronson 11000
25 New Zero Zero Ronson 11000
26 Super Finish M/c M-Tec germany 11000
27 Brushing H.K.Machines 2520
INTERNAL CUSTOMER

Customer Complaints
1. Incomplete delivery of beams.

2. Wrong beam numbers on pieces.

Processing department’s direct customer is
folding department. 3. Pieces without piece numbers received.

4. Mixing of beams of same quality.

5. Reprocessed goods not received beam wise.

6. Wrong tag on finished goods trolleys.

Internal Customer Complaints Managing Complaints

1. Pieces without piece numbers and wrong 1. Regular counselling with grey issue workers. Also
beam numbers received. instructed processing staff to re-write the number if any
sample cut from the piece.
2. Incomplete delivery of beams.
2. Proper planning and execution.
3. Mixing of beams of same quality.
3. Counselling with machine workmen to unload fabric beam
4. Reprocessed goods not received beam wise. wise after process.

5. Wrong tag on finished goods trolleys. 4. Regular counselling with workmen and shift staff.

6. Improper finish of fabric. 5. Counselling with machine operators to tag the trolley
properly.

6. Regular counselling with shift staff to check fabric before

delivering to folding
 HIRA – HAZARDOUS IDENTIFICATION AND RISK
ASSESSMENT

 HIRA is a systematic process used to identify potential hazards in a work place or process.

 Evaluate the risk associated with those hazards.

 Controls or eliminates the risk to ensure the safety of people machine and the environment.
GBTL Ltd. LIST OF HAZARDS WITH RISK ASSESSMENT Format

Doc. No: OHSMS-F-3.1.1 Issue No. : 9 Effective Date: 25.10.2023

Approved By: HOD (Process House ) Issued By: MR Page 1 of 2

Leg A B C Total = Intolerable /

S No. Activity Hazard Reason of Hazard Risk
al (0.1-4) (0.1-10) (0.1-4) (A+B) x C Tolerable

Sewer water overflow in wet Hot water with chemical on Foot and Multiple body
H24.1
section (NR) floor
No Slippery Floor
parts injury
1 1 2 4 Tolerable

Pouring of chemicals in relax Not wearing proper safety

H24.2 scouring m/c (R) Chemical Spillage No equipments, carelessness Hands and eyes injury 1 5 1 6 Tolerable
Keeping face just near to lid,
Opening of lids of relax scouring High temperature Steam and Hands and face
H24.3
m/c while running (NR) water
No carelessness, improper use
injury
1 1 4 8 Tolerable
of PPE’s
Wearing of loose cloth while m/c Multiple body parts
H24.4
operation (NR)
Rotating Parts No loose clothing, carelessness
injury
1 3 2 8 Tolerable

Carelessness, Not wearing

H24.5 Pouring of caustic in W.R.m/c (R) Caustic spillage No
proper safety equipment
Burn Injury 1 3 2 8 Tolerable

Opening of lids in the running Carelessness, Not wearing

H24.6 W.R.m/c (R) Caustic water No proper safety equipment Hands, eyes injury 1 1 3 6 Tolerable

Carelessness, hot water

Opening of lid of jet dyeing m/c (R) High
pressure and Eyes and Multiple
H24.7
temperature of water
No spillage, Not wearing proper
body parts injury
1 1 3 6 Tolerable
PPE’s

Making vat colour and pouring Carelessness, hot water and Hands and other
H24.8 chemical in jigger trough (R) Chemical spillage No chemical spillage on body, body parts injury 1 3 2 8 Tolerable
Not wearing proper PPE’s

Fabric may burn while Fire, burn injury,

passing through flame, Multiple body parts
H24.9 Singeing m/c (R) Fire hazard No
carelessness, improper injury, property
1 10 4 44 Intolerable
flame, gas leakage damage

Fire, burn injury,

Leakage of LPG cylinder, Multiple body parts
H24.10 Storage of LPG cylinder (R) Fire hazard No
improper storage injury, property
1 10 4 44 Intolerable
damage
GBTL Ltd. LIST OF HAZARDS WITH RISK Format
ASSESSMENT
Doc. No: OHSMS-F-3.1.1 Issue No. : 9 Effective Date: 25.10.2023
Approved By: HOD (Process House ) Issued By: MR Page 1 of 2

S No. Activity Hazard Legal Risk A B C Total = Intolerable

Reason of Hazard (0.1-4) (0.1-10) (0.1-4) (A+B) x C / Tolerable

H25.1 Feeding of fabric in mangle on

stenter m/c (R) Rotating parts NO Carelessness, loose clothing Hands injury 1 3 2 8 Tolerable

H25.2 Feeding of fabric into running

chain on stenter m/c (R) Rotating parts NO Carelessness, loose clothing Multiple body parts
injury 1 3 2 8 Tolerable

Spillage of chemical, slippery Burn injury, Multiple

H25.3 Preparation
(R)
of finishing solution Finishing chemical
exposure NO floor, improper handling, body parts injury, eyes 1 3 2 8 Tolerable
improper use of PPE’s injury
Fire, Burn injury,
H25.4 Hot
(R)
air chamber on stenter m/c Fire hazard NO Improper cleaning, carelessness,
Fly and fluff deposition Multiple Body parts 1 5 4 24 Intolerable
injury

H25.5 Feeding of fabric to all running

and guide roll and guiders (R)
Rotating parts,
weight of roller NO Carelessness, loose clothing,
poor maintenance
Head, Hand and Foot
injury 1 3 2 8 Tolerable
Threading of fabric through nip
H26.1 of hard and soft roll in calendar Rotating parts NO Carelessness, loose clothing Hands injury 1 3 3 12 Intolerable
m/c (R)
Threading of fabric through Rotating parts, hot Hands injury, Burn
H26.2 heated cylinder and rubber belt surface NO Carelessness, loose clothing Injury 1 3 3 12 Intolerable
on Zero Zero m/c (R)
Threading of fabric through Rotating parts, hot Hands injury, Burn
H26.3 heated cylinder and silicon belt surface NO Carelessness, loose clothing Injury 1 3 3 12 Intolerable
on Super Finish m/c (R)

Carelessness, damaged floor, Multiple body parts

H27.1 Transportation of material (R) Trolley movement NO
slippery floor injury
1 3 2 8 Tolerable

Carelessness, improper
H27.2 Stitching work Stitching needles No operation, improper use of Finger & Eye injury 1 1 4 8 Tolerable
tools
 HEALTH AND S AFETY HAZARD EVALUATION CHART

Points Rating Scale

Complete
Complete Control but Control not
No Control- Partial Control Control with
Degree of Control A Procedure is Absent required
procedure

4 points 3 points 2 points 1 point 0.1 point

High Moderate Low Very Low Tolerable
Severity of Impact B
10 points 05 points 03 points 01 point 0.1 point

Probability of High Moderate Low Very Low Tolerable

C
Occurrence 4 points 3 points 2 Points 1 Point 0.1 point

Significance rating (A + B) x C

*Any hazard getting 12 or more rating will be treated as significant or intolerable

*Any hazard getting less than 12 rating will be treated as insignificant or tolerable

* Any activity causing fatality, disablement or partial disablement will be treated as Intolerable.
* Any activity which is legal & if not complied with will be treated as Intolerable.
 CRITERIA FOR EVALUATION

EXISTING CONTROL SEVERITY OF IMPACT ON HUMAN & PROBABILITY OF

A OVER THE HAZARD B. PROPERTY C. OCCURRENCE
SCORE CRITERIA SCORE CRITERIA SCORE CRITERIA
Slight impact (first aid treatment not Once a month or less
4 No control 0.1 required, loss of property for less than 1 frequent
rs.500/-)

Partial control / not Low impact (first aid treatment

3 completely reliable 1 required, loss of property for less than 2 Once a week
rs.1000/-)

Complete control and Medium impact (causing absence from

2 standardized 3 duty for more than 12 hrs. but less 3 Once a day
procedures absent than 48 hrs, loss of property for
rs.1000 to rs.50, 000/-)

Complete control and High impact (causing absence from

1 standardized 5 duty for more than 48 hrs. loss of 4 Several times a day
procedures exist property for rs.50, 000 to rs.100000/-)

Fatal to human life (death or

10 permanent disability. loss of property Continuous
for over 1, 00,000/-)

TOTAL SCORE : ( A +B ) X C
 1. Poly/Viscose Fabric (Rigid. Weft Stretch & Bi Stretch)

2. Poly/Viscose/Wool Fabric (Rigid, Weft Stretch & Bi Stretch)

3. TR Fabric ( Rigid & Stretch)

4. TR Piece Dyed and PV Piece Dyed

5. Poly/Viscose/Wool Jacketing Fabric (Tweeds)

OUR
6. Poly/Viscose/Cotton Fabric (Rigid, Weft Stretch)
PRODUCTS
7. Poly/Viscose/Linen Fabric (Rigid, Weft Stretch)

8. Cobalt Black Fabric (Rigid, Weft Stretch & Bi Stretch)

9. Poly Viscose Zentra Fabric (Weft Stretch)

10.Poly/Viscose White Fabric (Rigid, Weft Stretch & Bi Stretch)

11.Poly/Viscose/Modal Fabric

12.Poly/Viscose/Nylon (Weft Stretch & Bi Stretch)

 1. To sustain Rejection and C&D due to crease, stains & holes

2. To improve OTIF (On Time In Full) Percentage.

3. Maintain consistency in Fabric quality.

OUR CHALLENGES 4. Cost consciousness and meet the budgeted target.

5. Utilization of machine and Human Resource efficiently.

6. Following standard SOPs.

7. Hardness of water increasing.

PROJECTS RUNNING

1. Increase in fresh packing percentage of RMG goods.

2. Increase in fresh packing percentage of Bi-stretch goods.

3. Reduction of RT and C&D due to process defect in OTC materials – Target

achieved but further micro planning to sustain and reduce.

4. Reduction in consumption of water in wet process - Target achieved but further

micro planning to sustain and reduce.

5. Reduction in utility cost.

6. Increase productivity by process optimization without affecting the quality.

P R OC E S S IN G S OP ’ S

SOP’s are attached as Hyperlink. Click on

SOP’s to open file.
 LEARNINGS FROM THE
PRESENTATION

 Grasp the end to end process : from greige fabric to finished product.

 Know the sequence and purpose of each processing stage.

 Basic knowledge of key machines (stenter, Relax, Jet, KD etc.)

 To produce quality fabric as per customer requirement.

 To ensure finished fabric meets colour standard and performance.

 Efficient use of water, chemicals and energy.

 Continual improvement to control C&D (Cuts and defects) and increase fresh %age.

 Timely delivery of fabric to folding with in processing cycle time of 7 days.

 To identify hazard risks, mitigate hazard and attain safety.

 Understand chemical safety : handling, storage and transportation etc.

THANK YOU