ALOK INDUSTRIES (VAPI)

OBJECTIVES OF INDUSTRIAL VISIT

The objective of industrial visit include the coverage of the following departments

Pre treatment processes of grey fabric (woven) Dyeing process Quality control and testing

ALOK INDUSTRIES COMPANY PROFILE

Alok Industries or Alok Industries Ltd. is an India-based textile manufacturing company and was established in 1986. Alok Industries is a private textile manufacturing company and has manufacturing bases spread over 6 locations in Navi Mumbai in Vapi and Silvassa, situated in Maharashtr

ALOK INDUSTRIES PRODUCT WHEEL

HISTORY AND EVOLUTION

Alok was established in 1986 as a private limited company, with their first polyester

texturising plant being set up in 1989. They became a public limited company in 1993. Over

the years, they have expanded into weaving, knitting, processing, home textiles and garments.

And to ensure quality and cost efficiencies they have integrated backward into cotton

spinning and manufacturing partially oriented yarn through the continuous polymerisation

route. They also provide embroidered products through Grabal Alok Impex Ltd., their

associate company.

- That is how Alok Industries has evolved into a diversified manufacturer of world-class

home textiles, garments, apparel fabrics and polyester yarns, selling directly to

manufacturers, exporters, importers, retailers and to some of the world’s top brands.

- Alok has recently entered the domestic retail segment through a wholly owned subsidiary,

Alok Retail India Limited, with a chain of stores named ‘H&A’ that offer garments and home

textiles at attractive price points.

VISION AND MISSION OF THE COMPANY

VISION

To be the world's best integrated textile solutions enterprise with leadership position across

products and markets, exceeding customer & stakeholder expectation.

MISSION

Offer innovative, customized and value added services to our customers

Actively explore potential markets & products

Optimize use of all resources

Maximize people development initiatives

Become a process driven organization

Be a knowledge leader and an innovator in our businesses

Exceed compliances and global quality standards

Be an ethical, transparent and responsible global organization

MILESTONES

Yea

r

Milestone

1986 Incorporation of the Company

1993 Becomes a public limited company with a Rs. 4.5 crore IPO

1995 Sets up financial and technical collaboration with Grabal, Albert Grabher

GmbH & Co of Austria to make embroidered products through a joint venture

company, Grabal Alok Impex Ltd.

2003 Export Trading House status granted

2004 Turnover surpasses Rs. 1,000 crore

2006 Texprocil silver trophy awarded for second highest export in manufacturer

exporter – made ups category

2007 ISO 9001:2000 certification obtained

60 per cent stake in Mileta a.s. – a Czech Republic-based textile

company acquired

Controlling stake in U.K based retail store chain, ‘qs’ (now Store

Twenty one) acquired

Organic cotton contract farming commenced

Gold Trophy for best export performance to ‘Focus LAC’ countries

awarded by Synthetic & Rayon Textile Export Promotion Council

Awarded Silver trophy for highest fabric exports and Bronze trophy for

highest made ups export

2008 Turnover crosses Rs. 2,000 crore

Exports crosses Rs. 1,000 crore

Joint venture with National Textile Corporation (NTC) to develop,

revive New City Mills, Mumbai and Aurangabad Textile Mills,

Aurangabad formed

Awards from TEXPROCIL for 2007-2008

Gold Trophy for highest exports of bleached/yarn dyed/ printed

fabrics

Silver Trophy for highest export of made ups

Bronze Trophy for highest global exports

Special achievement award for exports in fabrics

Awarded Outstanding Exporter of the Year – Textiles  at the

International Trade Awards 2007-08; presented by DHL CNBC TV 18

and powered by ICRA

PROCESS FLOW

SHIPMENT

FINAL Q.A

FOLDING AND INSPECTION

PROCESSING

PROCESSING ORDER

MATERIAL PROCUREMENT

PRODUCTION PLANNING

SALE ORDER

PURCHASE ORDER

BUYERS APPROVAL

PRE PRODUCTION SAMPLING

BUYERS COMMENT

PROD. DEVELOPMENT AND LAB DIP.

BUYERS REQUIREMENT

PROCESS FLOW FOR WOVEN PROCESSING

GREY SECTION

• The fabrics are available in A, B, C, D which are already graded when received.

• 2000 steel racks has been provided for storage for upto 29 lakhs fabric rolls.

• Rolls are opened and sent for further processing of singeing and desizing.

FABRIC PROCESS FLOW :

The fabric are sourced from silvasa plant where 95% of the supply is received and the other 5% is from external source.

The product mix available and proceed:

Fabric By Weight : Light, Medium, HeavyFabric By Blend : Polycotton, Cottonviscose, Cottonlycra, CottonspandexFabric By Weave : Twill, Plain, Sateen, Satin, Dobby, Jacquard

Grey Singeing & Desizing Bleaching Mercirization

DyeingFinishingFolding

Grey Cloth Opening A frame batch Continuous singeing and desizing range

SINGEING AND DESIZING

• The fabrics run perpendicular to the direction of the gas.

• The operations is performed by 3 machines (Osthoff seinge,Germany) and desizing is attached after singeing.

• Processing speed =>Light fabrics –120mts/min

Heavy fabrics – 60 mts/min

• Chemical used in desizing :-

• Wetting agent :- It increases in absorbancy.

• Enzymes – It removes size applied to the fabrics.

• Chelating agent – It restricts the reaction of any metal ion with any added chemicals.

• The machines process upto 30000 mts/shift.

BLEACHING

• The fabric is passed through the washing chambers is passed on to the Injecta chamber.

• Peroxide bleaching is used instead of hypochlorite because it provides permanent whiteness.

• It has 7 washing zones

• Initially three washers 90°C, 90°C, and 60°C and last four washers at 90 °C, 90 °C, 90 °C, and 60 °C respectively.

• Last chamber is meant for neutralization with acetic acid.

• 16 calendar rolls for drying with pressure of steam as 2 kg

• Running speed of fabric 80 m/min.

MERCIRIZATION

• It is the treatment for cotton yarns and fabrics.

It improves

Lustre

Wettability

Dimensional stability

Better dye uptake

• Chain mercirization is done in 2 machines and 1 chainless machine used for heavy/weight fabrics.

• Processing speed => 60-70 mts/min

• Chemicals used NaoH, Organic Acid, Caustic Soda.

• The final section comprises a highly- efficiency washing and neutralizing zone consisting of EXTRACTA compartments.

• Temp is maintained 90-95◦C and pH 5-6 for organic acid for neutralization.

DYEING

Pre-treatment fabric (cotton)

Pad Dry Pad Steam Continuous Dyeing

Pad Steaming (curing)

Washing

Dyed fabric

CPB DYEING

• It is only used for only reactive dyes.

• There are 3 CPB machines from BENNINGER.

• Dyeing process takes 16 hrs for dyeing at room temperature and operates at 50-60 mts/ min.

• Chemicals used –

• Fixer chemicals (sodium silicate)

• Reactive dyes.

• Soda and Caustic.

• Production/ Shift – 20000- 22000mts

THERMOSOL DYEING

• It is only used for only disperse, modified vat dye and reactive dyes.

• It has IR dryer chamber and used for dyeing the polyester part of the fabric.

• There are 3 IR dryer chamber which increases upto 450◦c.

• Dyeing process takes 16 hrs for dyeing at room temperature and operates at 50-60 mts/ min.

• Chemicals used –

Binders

Softner

Glauber’s Salt

Acetic Acid.

PAD DRY PAD STEAM

• It is used for –

• Colour development

• Reduction clearing in case of blended fabric double bath dyeing.

• There are 3 BENNINGER pad steam.

• Dyes which are processed in the pad steam machine are –

• Reactive dyes

• Vat dyes.

• Chemicals used for reactive pad steam process are – Salt, soda ash and caustic.

• Chemicals used for vat dye pad steam process – caustic hydro.

FINISHING

• 7 chambers in stenter.

• Bowing and heading rollers at the feed end to remove creases.

• Both pin and clip arrangements are used.

• Overfeed – 5%

• Fabric speed – 50m/min

CHAMBER NO

LIGHT SHADE MEDIUM SHADE DARK SHADE

1 110 0C 110 0C 110 0C

2 120 0C 120 0C 120 0C

3 130 0C 130 0C 130 0C

4 140 0C 140 0C 140 0C

5 140 0C 140 0C 150 0C

6 140 0C 140 0C 150 0C

7 140 0C 140 0C 150 0C

SANFORISING

• It is pre shrinking finishing.

• Rubber belt shrinks the fabric along with it

• Shrinkage > 5 %

• Speed 50 m/min

• Steam heated roller over belt at 110 0C

• 50 m fabric from in to out

• After shrinking zone, there is a setting zone to set the shrinkage in fabric.

CALENDERING

• Fabric speed of 70 m/min

• Expander rollers are used at feed end

• 3 roll system with 2 cotton rolls and one steel roll

• Temperature of calendars roller is 70 0C

• Pressure 70 N/mm

• Strength reduces after calendaring

• It improves the feel and surface appearance of fabric

PHYSICAL TESTING

• Yarn count ( warp reel & beesley balance)

• Original width

• Usable width

• Tpi , epi, ppi

• Tear strength tester

• Absorbency test

• Tensile strength(weft and warp)

• Pilling

• Shrinkage

COLOR FASTNESS TESTS

• The following tests are conducted and measured on the grey scale

▫ RUBBING FASTNESS( WET AND DRY)(AATCC)

▫ WASHING FASTNESS( TOP LOAD (ISO) AND FRONT LOAD

( AATCC) )

▫ COLOR FASTNESS TO WATER (AATCC)

• Color Fastness to light is also conducted using the ISO Standard test procedures

• The machines were mostly of the company James H. Heal.

• The key features of the lab were the softwares

▫ Datacolor that predicted recipes for the different dyeing and other processes using CMC Spectrophotometer and

▫ Auto color dispenser for solution making and dispensing