prince textile mills
TRANSCRIPT
TEXTILE INTERNSHIP REPORT
SHINGORA TEXTILES LIMITED LUDHIANA
SUBMITTED BY:
ANTAREKSH KUMAR PREM CHAURASIYA SANJEET KR. SUDARSHAN
SHINGORA TEXTILES LIMITEDSHINGORA TEXTILES LIMITED Shingora Textiles Limited is leading shawls manufacturers in India.Shingora Textiles Limited is leading shawls manufacturers in India.
It Offers a sophisticated range of products in Scarves, Woolen Shawls, It Offers a sophisticated range of products in Scarves, Woolen Shawls, stoles and variety of fabrics including jacquards & Woven in a delicate stoles and variety of fabrics including jacquards & Woven in a delicate blend of cotton, silk and wool.blend of cotton, silk and wool.
The manufacturing facilities equipped with state-of-the-art machinery The manufacturing facilities equipped with state-of-the-art machinery
for weaving, Dyeing and Printing is unmatched in the industry. for weaving, Dyeing and Printing is unmatched in the industry.
The unit is fully equipped to undertake in house production power The unit is fully equipped to undertake in house production power looms, jacquards, dobby looms. looms, jacquards, dobby looms.
They have an in-house Dyeing, printing and Packing sections to ensure They have an in-house Dyeing, printing and Packing sections to ensure timely delivery of all shipments.timely delivery of all shipments.
Shingora Textile Limited is one of the largest manufactures & exporters Shingora Textile Limited is one of the largest manufactures & exporters of Indian shawls, jacquard shawls, silk stoles, scarves, textiles, and of Indian shawls, jacquard shawls, silk stoles, scarves, textiles, and mufflers.mufflers.
PRODUCTION PLANNING AND CONTROL
EXPORT OFFICE
DYEING UNIT WEAVING UNIT
PRINTING UNIT
ORGANISATIONAL CHART
EXPORT OFFICE
CHECKINGPACKING AND DISPATCHING
FINANCESAMPLING
EXPORT OFFICEEXPORT OFFICE
DYEING UNIT
CHEKING AND SAMPLING DEPT.
PREPARATORY DEPT.
DYEING DEPT. DRYING DEPT.
PACKING AND DISPATCHING
YARN AND FABRIC CHECKING
DYE SAMPLING
QUALITY TEST
DYEING UNITDYEING UNIT
WEAVING UNIT
CHEKING AND SAMPLING
GOODS RECEIVING AND SENDING
PREPARATORYDEPARTMENT
POWER LOOM
HAND LOOM
PRINTING UNIT
SCREEN FORMATION
SCREEN PRINTING
SAMPLING AND TESTING
FINISHING
WEAVING AND PRINTING UNITSWEAVING AND PRINTING UNITS
EXPORT OFFICEEXPORT OFFICE::The export house is the main governing body of Shingora Textiles Limited. It The export house is the main governing body of Shingora Textiles Limited. It
consists of :consists of :
Production planning and control departmentProduction planning and control department Sampling departmentSampling department Finance departmentFinance department Checking departmentChecking department Packaging and dispatching departmentPackaging and dispatching department
Woven goods from the weaving unit after dyeing or printing (as required) are sentWoven goods from the weaving unit after dyeing or printing (as required) are sentto the export house. Following operations take place at the export office.to the export house. Following operations take place at the export office.
• Grey checkingGrey checking• Washing Washing • Hand pressing Hand pressing • Final checkingFinal checking• PackingPacking• DispatchingDispatching
Ground Floor
First Floor
WEAVING UNITWEAVING UNIT The weaving unit has both handlooms and power looms.The weaving unit has both handlooms and power looms. There are 45 handlooms and 50 power looms.There are 45 handlooms and 50 power looms. It has the capacity to produce 5750 meters per day. It has the capacity to produce 5750 meters per day. Production mainly and specifically depends on the demand by the buyer.Production mainly and specifically depends on the demand by the buyer. The raw materials for weaving are either provided by the buyer or The raw materials for weaving are either provided by the buyer or
according to buyer need by the production managers. according to buyer need by the production managers. Season also contributes to variation in production. Season also contributes to variation in production.
PRODUCTION DETAILS:PRODUCTION DETAILS:
HANDLOOMHANDLOOM 45 Handlooms – installed capacity of (approx) 250 meters per day.45 Handlooms – installed capacity of (approx) 250 meters per day.
POWER LOOMPOWER LOOM 20 Shuttle Less Rapier Looms (SULZER; DORNIER) with Electronic 20 Shuttle Less Rapier Looms (SULZER; DORNIER) with Electronic
Jacquards (BONAS; upto 6144 hooks) – installed capacity of (approx) Jacquards (BONAS; upto 6144 hooks) – installed capacity of (approx) 2500 meters per day.2500 meters per day.
Continued…Continued…
12 Shuttle Less Rapier Looms with Electronic Dobbies (SULZER; 12 Shuttle Less Rapier Looms with Electronic Dobbies (SULZER; upto 20 shafts) – installed capacity of (approx) 2000 meters per upto 20 shafts) – installed capacity of (approx) 2000 meters per dayday
18 Mechanical Shuttle Looms with Mechanical Dobbies (upto 24 18 Mechanical Shuttle Looms with Mechanical Dobbies (upto 24
shafts) – installed capacity of (approx) 1000 metersshafts) – installed capacity of (approx) 1000 meters
LAYOUT (WEAVING UNIT)LAYOUT (WEAVING UNIT)
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WEAVING PROCESSWEAVING PROCESS
SPEC SHEET RECEIVED
WEAVING PATTERN MADE PREPARED
SAMPLE GENERATED
SENT TO EXPORT OFFICE FOR APPROVAL
PREPARATORY PROCESS
LOOM SETTINGS
WEAVING
PACKED AND SENT TO EXPORT OFFICE
NEW SAMPLE PREPARED
IF MATCHED
IF NOT ACCEPTED
HAND LOOM
JACQUARD LOOM OVER PICK LOOM
JACQUARD WEAVE
WEAVING DEFECTSWEAVING DEFECTS FLOAT (JALA)FLOAT (JALA) A float or Jala is formed when there is no proper interlacement of the A float or Jala is formed when there is no proper interlacement of the
warp and weft yarns over a certain area.warp and weft yarns over a certain area. WEFT CRACK (JERKI) WEFT CRACK (JERKI) A strip in the fabric where the pick density is lower than normal is called A strip in the fabric where the pick density is lower than normal is called
a weft crack or jerkia weft crack or jerki
CRAMMED PICK (PATTI)CRAMMED PICK (PATTI) A strip in the fabric where the pick density is more than normal is called A strip in the fabric where the pick density is more than normal is called
a patti. The defect is caused by improper setting of the anti crack a patti. The defect is caused by improper setting of the anti crack motion.motion.
SHUTTLE SMASHSHUTTLE SMASH The defect is caused when many ends break consequent to a shuttle The defect is caused when many ends break consequent to a shuttle
trap. The main causes of shuttle trap is wrong timing of shedding .trap. The main causes of shuttle trap is wrong timing of shedding .
STAINS (DAGHI)STAINS (DAGHI) Stains are caused by lubricants and rust. Most of the stains can be Stains are caused by lubricants and rust. Most of the stains can be
traced back to poor maintenance and material handling.traced back to poor maintenance and material handling.
BOWINGBOWINGUsually caused by finishing. Woven filling yarns lie in an arc across fabric Usually caused by finishing. Woven filling yarns lie in an arc across fabric width: in knits the course lines lie in an arc across width of goods. Critical width: in knits the course lines lie in an arc across width of goods. Critical on stripes or patterns and not as critical on solid color fabrics. on stripes or patterns and not as critical on solid color fabrics.
BROKEN COLOR PATTERNBROKEN COLOR PATTERNUsually caused by colored yarn out of place on frame. Usually caused by colored yarn out of place on frame.
HOLEHOLE Caused by multiple yarn breakage. Caused by multiple yarn breakage.
OPEN REED OPEN REED Results from a bent reed wire causing warp ends to be held apart, Results from a bent reed wire causing warp ends to be held apart, exposing the filling yarn.exposing the filling yarn.
SLUBSLUB (WOVEN FABRIC)(WOVEN FABRIC)
Usually caused by an extra piece of yarn that is woven into fabric. It can Usually caused by an extra piece of yarn that is woven into fabric. It can also be caused by thick places in the yarn. Often is caused by fly waste also be caused by thick places in the yarn. Often is caused by fly waste being spun in yarn in the spinning process. being spun in yarn in the spinning process.
DYEINGDYEING The dyeing unit of Shingora Textiles undertakes mainly dyeing of The dyeing unit of Shingora Textiles undertakes mainly dyeing of
wool,cotton,silk,nylon and linen . wool,cotton,silk,nylon and linen .
Both yarn dyeing and fabric dyeing is done. Both yarn dyeing and fabric dyeing is done.
Yarn dyeing is done in cheese form, in high temperature high pressure Yarn dyeing is done in cheese form, in high temperature high pressure machine. Weight of each cheese is 1 kg to 1.2 kg. Machine capacity machine. Weight of each cheese is 1 kg to 1.2 kg. Machine capacity upto 250 kg.upto 250 kg.
The temperature for HTHP yarn dyeing is 140 ˚C and pressure is The temperature for HTHP yarn dyeing is 140 ˚C and pressure is maintained at 60 pounds .maintained at 60 pounds .
fabric dyeing is done in open winch dyeing machines. fabric dyeing is done in open winch dyeing machines.
Continued…Continued…
The length of the fabric can range from 80 m – 600 m, and the The length of the fabric can range from 80 m – 600 m, and the width can range from 15” – 50” . Dyeing process requires 6 – 8 width can range from 15” – 50” . Dyeing process requires 6 – 8 hours , depending on shade and yarn/fabric.hours , depending on shade and yarn/fabric.
After receiving the samples the dyeing experts try to generate the After receiving the samples the dyeing experts try to generate the same color as required, by mixing the basic dyes. same color as required, by mixing the basic dyes.
The newly formed dye is applied on a sample and then sent for The newly formed dye is applied on a sample and then sent for color approval. color approval.
After color approval different fastness tests are carried on the After color approval different fastness tests are carried on the sample and points are given accordingly. sample and points are given accordingly.
If the fastness is not acceptable the dyeing parameters and If the fastness is not acceptable the dyeing parameters and method is revised and modifications are done to achieve best method is revised and modifications are done to achieve best fastness quality. fastness quality.
LAYOUT (DYEING UNIT)LAYOUT (DYEING UNIT)
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DYEING PROCESSDYEING PROCESS
DYE SAMPLE PREPARED
DYE FABRIC SAMPLE PREPARED
COLOR MATCHING
FASTNESS TESTS
REPORT SENT TO PPC
PRERARATORY PROCESS
DYEING
DRYING
PACKED AND SENT TO EXPORT OFFICE
NEW SAMPLE PREPARED
IF MATCHED
IF NOT MATCHED
IF ACCEPTED
IF NOT ACCEPTED
DYEING DEFECTSDYEING DEFECTS Common Causes of Dyeing Defects:Common Causes of Dyeing Defects:
1.1. The material is not well prepared for dyeing and printing:The material is not well prepared for dyeing and printing:
a. Material having dead fibres or other defective fibresa. Material having dead fibres or other defective fibresb. Left over of Chemicals after bleaching etc.b. Left over of Chemicals after bleaching etc.c. Material not properly desizedc. Material not properly desizedd. Absorbancy of the fabric not properd. Absorbancy of the fabric not propere. Sticking of insoluble material on the fibrese. Sticking of insoluble material on the fibresg. Impurities are not removed properlyg. Impurities are not removed properly
2.2. Water Quality not Proper:Water Quality not Proper:
a. More Hardness of watera. More Hardness of waterb. Water has metal ions such as iron.b. Water has metal ions such as iron.c. pH of water not properc. pH of water not properd. Water having more chlorined. Water having more chlorine
Continued…Continued…
3.3. Due to Shortcomings in making Dyeing Solution: Due to Shortcomings in making Dyeing Solution:
a. Improper weight ratio of colors, material and chemicals.a. Improper weight ratio of colors, material and chemicals.b. Improper material to water ratiob. Improper material to water ratioc. Improper filtering of concentrated colors.c. Improper filtering of concentrated colors.
4.4. Due to Shortcomings in the dye machinery: Due to Shortcomings in the dye machinery:
a. Coming out of Dye liquor during dyeinga. Coming out of Dye liquor during dyeingb. Defective instruments controlling temperature, pressure speed . b. Defective instruments controlling temperature, pressure speed .
Testing lab Cheese winding
Winch dyeing Cheese dyeing
Cheese dyeing machine Hydro extractor
Dyed cheese for drying Open drying
PRINTINGPRINTING Only hand screen printing is done at Shingora Textiles.Only hand screen printing is done at Shingora Textiles.
It sends a sample of its printing requirements. The printing unit then It sends a sample of its printing requirements. The printing unit then generates its own sample of the print and fastness properties and generates its own sample of the print and fastness properties and sends this sample to Shingora Textiles for approval. sends this sample to Shingora Textiles for approval.
Once the sample is approved the final printing starts. Once the sample is approved the final printing starts.
The printed goods after receiving at Shingora Textiles are sent for The printed goods after receiving at Shingora Textiles are sent for checking and then for washing and pressing and finally are packed checking and then for washing and pressing and finally are packed and dispatched.and dispatched.
PRINTING PROCESS AT SHINGORA TEXTILESPRINTING PROCESS AT SHINGORA TEXTILES
PRINT PASTE DEVELOPMENT
SAMPLE GENERATED PREPARED
FASTNESS TEST
PRINT SCREEN DEVELOPMENT
PRINTED SAMPLE GENERATED
SENT FOR APPROVAL WITH
FASTNESS REPORTS
PRINTING
DRYING
PACKED AND SENT TO EXPORT OFFICE
NEW SAMPLE PREPARED
IF MATCHED
IF NOT MATCHED
IF ACCEPTED
IF NOT ACCEPTED
FUSING ( FOR PLASTIC BASED PRINTS )
BASED PAI
PRINT SCREENS
CALENDERINGCALENDERING
Calendering Calendering is essentially an ironing process that adds is essentially an ironing process that adds sheen to the fabric.sheen to the fabric.
The mode varies according to the type of finish desired.The mode varies according to the type of finish desired. Calenders are heavy material rollers made up of atleast Calenders are heavy material rollers made up of atleast
two rolls.two rolls. Wool fabrics are calendered or polished.Wool fabrics are calendered or polished. The process adds a soft luster.The process adds a soft luster.
Objective:Objective: It improves the bulkiness, bulging effect & better drape It improves the bulkiness, bulging effect & better drape
of the fabric by the application of steam & pressure.of the fabric by the application of steam & pressure.
FINISHING PROCESSESFINISHING PROCESSES Calendering, Embroidery ,Washing and Pressing are done in Calendering, Embroidery ,Washing and Pressing are done in
Shingora Textiles.Shingora Textiles.
Calendering and Embroidery are done as per garment requirements.Calendering and Embroidery are done as per garment requirements.
After receiving the goods from dyeing and printing unit, they are After receiving the goods from dyeing and printing unit, they are sent for calendering or embroidery, if required.sent for calendering or embroidery, if required.
Finally they sent for washing and pressing.Finally they sent for washing and pressing.
PPC Department of Shingora Textiles manage these outsourcing.PPC Department of Shingora Textiles manage these outsourcing.
After receiving goods from these outsource units, they are sent to After receiving goods from these outsource units, they are sent to the checking department.the checking department.
Once approved they are sent to the packing and dispatching Once approved they are sent to the packing and dispatching departmnent.departmnent.
THANK YOUTHANK YOU