Alok Industries_ Internship Ppt
Short Description
Download Alok Industries_ Internship Ppt...
Description
? ? ?
? ?
? ?
The textile internship has been completed in Alok Industries Pvt. Ltd, Vapi, Gujarat.
The duration of the internship was of two weeks where we had covered six different sections of textile processing.
Familiarized us with the various aspects of a Textile Processing Unit starting from its Organizational hierarchy to the functionality of the various departments.
Introduced us to the various brands of machineries available for carrying out the different textile processes to meet global standards.
? 6 The textile internship was carried out to develop a clear understanding about the following: Flow process sequence and Technical details on machine particulars of weaving, dyeing, printing, finishing, laboratory etc. Particulars of raw material, intermediate products and final product, process details, product quality parameters. Particulars of the manufacturing environment. Human resource management. Productivity analysis for various processes.
6 The internship helps us to To understand the structural and functional constituents of the industry. To adapt to real industrial situations which equips us for decision making in a realistic environment. To strengthen the relationship between the industry and students.
6 ulok Textiles td. 1986 - established as a private limited company 1989 ± Its irst polyester texturising plant being set up 1993 - a public limited company
6 ulok¶s ision To be the orld's best-integrated textile solutions enterprise ith leadership position across products and markets, exceeding customer & stakeholder expectation 6 O uIZuTIOu IE u
Vertically Integrated Textile Company on Cotton as well as Polyester stream
Sales of Rs. 2,976.93 crores and PAT of Rs.188.37 crores in FY 2009 (Audited)
xport of Rs. 1,054.50 crores in FY 2009 (Audited)
State of the art manufacturing facilities with Integrated Management System Certification
Two decades of providing wide range of quality textile products
6 Vxpanded into weaving, knitting, processing, home textiles garments integrated backward into cotton spinning and manufacturing POY through the continuous polymerization route. 6 Vntered the domestic retail segment through a wholly owned subsidiary, Alok Retail India Limited. 6 A chain of stores named µH A¶ that offer garments and home textiles at attractive price points. 6 Alok¶s vision 2012 To generate consolidated revenues of Rs. 75,00 crore. Consolidated PAT of Rs. 750 crores Among top 50 Best company in the country.
?
Timely expansions resulting in first mover advantage
Vxports increased from Rs. 100 crores in 2004 to about 1,050 crores in 2009 at a CAGR of 60%
Preferred Vendor status from leading retailers
Critical supplier for the Buyer due to Quality, Cost
Delivery (QCD)
Vconomies of scale coupled with low interest cost giving competitive advantage
Sustained margins due to forward and backward Integration
Wide range of products offered across different market segments
Product development and designing strength
State of the art infrastructure with modern machines
?
÷ ÷ ÷ ÷ ÷
÷÷ ÷
Only the weaving of terry towels is done in the Vapi plant of Alok Industries Ltd.
Different departments in this unit are: Design Studio Preparatory department V Warping V V Creel V H Creel V Sizing
Weaving Grey Processing Finishing ÷ ÷ ÷ ÷ ÷
÷÷ ÷
!"# 6
6
÷ ÷ ÷ ÷ ÷
÷÷ ÷
$""# %$
V Creel warping Creel installed in a 400 V shape Production capacity is 5.5 tonnes per day
H Creel warping Installed parallel to each other Production capacity is 3 tonnes per day Sectional warping is done
Sizing The machine has a capacity of 12 beams Production capacity is 10 tonnes per day A raising zone is provided for separating individual yarns after being sized
÷ ÷ ÷ ÷ ÷
÷÷ ÷
÷ ÷ ÷ ÷ ÷
÷÷ ÷
"&'()
Two types of looms Dobby Jacquard
Air-jet type looms i.e. use air pressure for weft insertion
Dobby - floor loom that controls warp threads using a device known as dobby.
Jacquard loom - mechanical loom that simplifies the process of manufacturing textiles with complex patterns such as brocade
Loom controlled by punch cards with punched holes, each row of which corresponds to one row of the design.
Double beams are used: Top beam Bottom Beam
Meant for complicated designs and can weave up to 6 colors. ÷ ÷ ÷ ÷ ÷
÷÷ ÷
% #' (
From weaving, towels are sent to grey section where they are inspected for defects before processing
Functions of grey section Inspection of rolls for defects Counting number of picks Rejection checking
÷ ÷ ÷ ÷ ÷
÷÷ ÷
? ?
Reactive dyes used for the dyeing of cotton fabric.
Grey section prepares rolls of fabric according to dyeing machines¶ capacity.
Auto chemical mixing for all machines.
2 machines having 90kg capacity used for preparing samples.
Dyeing machines - 90 kg, 350 kg, 700 kg, 1050 kg and 1400 kg.
The software used for dyeing is named ³Orgatex Batch Scheduler´.
÷ ÷ ÷ ÷ ÷
÷÷ ÷
GRVIGV - 9 RANSON¶s COPIWALA
SINGVING DVSI ING ± 5 OSTHOFF(PAD STVAM) BVNNINGVR(PAD STVAM) OSTHOFF(PAD BATCH)
PRV-TRVATMVNT ± 9 BVNNINGVR (PRVTRVATMVNT) - 4 BVNNINGVR(MVRCVRI ATIO N) ± 5 PRV WASHING (INJVCTA) IMPACTA (CHVMICAL TRVATMVNT) STVAMVR POST WASHING (IMPACTA) VVRTICAL DRYING RANGV
DYVING
KUSTVR¶s CPB - 4 BVNNINGVR CDR - 2 BVNNINGVR PAD STVAM - 3 MONFORTS THVRMOSOL ± 2
WASHING ARIOLI SOAPVR ± 1 V COLD PAD BATCH WASH V COLD WASH
FINISHING
MONFORTS STVNTVR ± 4 KKA CALVNDVR ± 1 KUSTVRS CALVNDVR ± 2 MONFORTS SANFORI VR ± 1
FOLDING
PACKAGING
COPIVALA TVSTING - 12 TVSTA PACKAGING ± 1 ÷ ÷ ÷ ÷ ÷
÷÷ ÷
? ? ~ ~ ~
Chemical Storage Tanks ± 40 Capacity - 500 liters (600 - 650 kilos) DLV Software - Liquid Product Automatic Volumetric Dozing Color Chemical containing tanks (Loading Junction) Loading Junction has two connectors ± delivery and feeding points. Pneumatic pumps are used for the transfer of the liquids. The feeding time of the liquids - 3 to 5 minutes DAP unit ± ³Powder Auxiliaries Dissolving Unit´ Separate tanks for Salt and Hydrous (Capacity ± 2000 -1000 kg) Units are connected to the ³load cell dissolving cycle´ Color Preparation ± 12 tanks Pressure - 6 bars ; Dissolving Temperature - 70ÔC. 45 TRS tanks. (TRS ± Automatic weighing for powder dye stuff.) 40 tanks - 45 kg ; 5 tanks - 90 kg each. SGQ (6 chambers) - 450 kg each SSC - 18 kg. JIT (Just in Time) ± 2 kg ÷ ÷ ÷ ÷ ÷
÷÷ ÷
?
GRVY OPVNING MACHINV
HSING CHVNG ± 4
MVRCVRI ING DOMIVR ± 1
SAMPLV DYVING
FINISHING
1 machine of 10kg capacity 1 machine of 5kg capacity
DYVING (SOFTFLOW)
750kg capacity ( 3 chambers) - 4 500kg capacity (2 chambers) - 5 1500kg capacity (6 chambers) - 1 1000kg capacity (4 chambers) - 2 110kg capacity (1 chamber) - 2 250kg capacity (1 chamber) - 2 50kg capacity - 2
÷ ÷ ÷ ÷ ÷
SANTA STRVTCH ± 1 FONGS RVLAX DRYVR ±1 SANTVX PLAITVR ± 1 OPVN WIDTH FINISHING STVNTVR : CORINO FOLDING Done on two floors, the ground floor has one inspection and one packaging machine both of Testa. The first floor has Hsing Cheng (Taiwan) checking machine (13 ) Inspection method is followed. The four point grading system
PACKAGING
Automatic packaging machine (Testa) : 8 different types of fabric packed at a time Unloading is spread across 4 trolleys in either side of the conveyor belt ÷÷ ÷
* ? ? +
Capacity range - 5 - 1070 kg.
Lot Card specifying the dyeing details of the yarn approved by QA lab.
There are two types of dyes used in the department. Vat Dye (caustic based) Reactive Dye (salt, soda based)
Boiling is carried out for 45 minutes In out function- from spindle to package (takes 3 mins.) Out in function- from package to spindle (takes 6 mins.) SPINNING UNIT (SILVASSA)
AFTVR TRVATMVNT
YARN DYVING (VAPI)
DYVING
WINDING ÷ ÷ ÷ ÷ ÷
LOADING MACHINV
PRV - TRVATMVNT
APPROVAL Q A
PACKING ÷÷ ÷
, ? ? ? Scouring Yarn is put through a caustic soda bath followed by hydrogen peroxide and acetic acid treatment. Process carried out at 100°C
Dyeing by Batch Process. Yarn cheeses placed in the spindles Placed in respective carriers to the dyeing, soaping and finishing of yarns Temperature V Light - 60°C - 70°C for 40 - 60 mins. V Medium - 80°C - 90°C for 60 ± 80 mins. V Dark - 80°C - 110°C for 80 ± 90 mins.
÷ ÷ ÷ ÷ ÷
? ? ? ? Chemicals - Hydrogen peroxide, Pervalin RS, Acetic acid and Perfil 210. This process is carried out at 95°C
* ? + Soft packages winding from dyed cheese to cones. Checking is done
* + In cartons - Less quantity of cones Bulk packing V Packing machine used V Wounds the cones with thin plastic sheet in a circular manner V Cones rotated automatically on a revolving platform for winding
÷÷ ÷
÷ ÷ ÷ ÷ ÷
÷÷ ÷
?
In properly printed fabrics the color is bonded with the fiber, so as to resist washing and friction.
Whereas in dyeing proper the whole fabric is uniformly covered with one color, in printing one or more colors are applied to it in certain parts only, and in sharply defined patterns.
(,$'(#'() by far the most used technology today. Two types exist: rotary screen printing and flat (bed) screen printing A blade squeezes the printing paste through openings in the screen onto the fabric.
')'#" # .#' $'(#'() a process of printing on textiles and garments using specialized or modified inkjet technology. Inkjet printing on fabric is possible with an inkjet printer by using fabric sheets with a removable paper backing and is used for sample preparations. ÷ ÷ ÷ ÷ ÷
÷÷ ÷
The printing department carries out the following processes for printed products:
?
* ?? +
÷ ÷ ÷ ÷ ÷
? ?
?
/ *0 $')1 (# "(2 " #'& +
*0 &"#2% +
÷÷ ÷
?
The industry is mainly confined to rotary screen printing for the bulk production while flatbed screen printing is used for sample preparation.
Screens are prepared in the following steps for the printing to be done through it
?
?
?/ * +
The mesh of the screens are in the range of 40, 50, 60, 125, 145, 165 units per inch. ÷ ÷ ÷ ÷ ÷
÷÷ ÷
The machineries: Sample making machines V Laxmi V Mimaki Digital Printer 1 Laxmi rotary machine 3 Reggiani rotary screen printing machines V 2 to 14 colors of patterns can be printed on the fabric using the machines in the industry. V The capacity of the rotary machine is 20 to 100 meters/seconds depending upon factors like design and the number of colors in that design and the types of the fabric (coarser takes less time as compared to finer fabric). ÷ ÷ ÷ ÷ ÷
÷÷ ÷
!"#$ $
%$&$ ÷ ÷ ÷ ÷ ÷
÷÷ ÷
Arioli loop ager
Arioli polymerizer
The average daily production of each of the screen printers is 70,000 m with the rpm of each rotary screen as 150-200. ÷ ÷ ÷ ÷ ÷
÷÷ ÷
÷ ÷ ÷ ÷ ÷
÷÷ ÷
Functions of the Department To keep step by step quality maintenance of the order that is being processed in the unit. Laboratories check for the physical and fastness properties Chemical tests might be carried out to cater buyer¶s specifications Mini machines of each process to treat the samples and match them with the effective results.
÷ ÷ ÷ ÷ ÷
÷÷ ÷
Separate laboratories for 2 Woven Sections, Yarn Processing Section and Terry Towel unit.
Knits and printing section - quality tests done in the same lab used by the narrow width woven s section.
They follow international standards for the quality assessments which includes: ASTMD( mostly for physical tests) AATCC( mostly used for color fastness tests) ISO
÷ ÷ ÷ ÷ ÷
÷÷ ÷
!%' " ? #( 32
YARN COUNT ( WARP RVVL BVVSLVY BALANCV) ORIGINAL WIDTH USABLV WIDTH TPI , VPI, PPI TVAR STRVNGTH TVSTVR ABSORBVNCY TVST TVNSILV STRVNGTH(WVFT AND WARP) PILLING SHRINKAGV
÷ ÷ ÷ ÷ ÷
÷÷ ÷
"#( ? #
The following tests are conducted and measured on the grey scale RUBBING FASTNVSS( WVT AND DRY)(AATCC) WASHING FASTNVSS( TOP LOAD (ISO) AND FRONT LOAD ( AATCC) ) COLOR FASTNVSS TO WATVR (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
÷ ÷ ÷ ÷ ÷
÷÷ ÷
"$!' " 1$"' ( 0#! 2'00 (#2% '() 1" !'( $ 23 #' ( "$" '#%-
÷ ÷ ÷ ÷ ÷
÷÷ ÷
'( (%!)%%*$' #** $#& %( )) )+%#,($%$
÷ ÷ ÷ ÷ ÷
÷÷ ÷
÷ ÷ ÷ ÷ ÷
÷÷ ÷
÷ ÷ ÷ ÷ ÷
÷÷ ÷
Alok Industries is an organization par excellence in the field of garments and textiles.
Its huge infrastructure yet profound attention of the higher officials offered to us, as interns¶, bear evidence to the same fact.
The same meticulous attention given and ethics practiced in the daily production of Alok has made it reach the zenith where it stands successfully today.
The internship has been an enterprise of much interest to us as it has exposed us to a real working environment of a textile processing unit.
This internship has helped us learn how actually a production unit works and the amount of impromptu decisions that has to be taken daily to keep the production running without any hindrances.
Thus, it will lay the foundation in the array of practical knowledge gained before stepping out of college and into a career in the textile industry.
AN VFFORT BY: ARPIT SAXVNA PALLAVI SRIVASTAVA ROHAN DWIVVDI SURVNDRA MARANDI SURYA BAKSHI TANIYA DUTTA ÷ ÷ ÷ ÷ ÷
÷÷ ÷
View more...
Comments
