1

INTRODUCTION (VARDHMAN GROUP)

The industrial city Ludhiana, locate the fertile Malwa

region of central Punjab is otherwise known as the Manchester
of India. Within the precincts of this city located the corporate
headquarters of the Vardhman Group, born in 1965, under the
entrepreneurship of Late Lala Rattan Chand Oswal has today
blosommed into one of the largest Textile Business house in
India.

As its inception, Vardhman had an installed capacity of 14,000

spindles; today capacity has increased multifold to over 5.5
lacs spindles. In 1982 the group entered the sewing thread
market in the country, which was a forward integration of the
business. Today Vardhman threads are the second largest
producer of sewing threads in India. In 1990, it undertook yet
another diversification, this time into weaving business. The
grey fabric weaving unit at Baddi (H.P.), commissioned in1990
with a capacity of 20,000 meters per day, has already made its
mark as a quality producer of grey poplin/sheeting/shirting in
the domestic as well as foreign market. This was followed by
entry into fabric processing by setting up AURO Textiles at
Baddi, which currently has a process capacity of 1lacs
meters/day.

In the year 1999 the group has added yet another feather to its
cap with the setting up of Vardhman Acrylics Ltd. Bharuch
(Gujarat) which is joint venture Acrylic Fiber production
undertaken with Marubeni and Exlan of Japan. The company
also has strong presence in the market of Japan, Hong Kong,
Korea, UK and EU in addition to the domestic market.
Adherence to systems and dedication to quality has resulted in
obtaining the coveted ISO 9002/ ISO 14000 quality award,
which is the first in Textile industry in India.
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AURO DYEING

AURO DYEING is a unit of Vardhman Spinning and general Mills

Ludhiana. It is located in a village Baddi, Tehsil-Nalagarh,
District Solan. The AURO dyeing site occupies 45.000 square
meters. Unit has a maximum production of 45 tons per day.
The unit has two production sections: -

 YARN DYEING
 FIBER DYEING

YARN DYEING

 100% COTTON
 POLYESTER/COTTON BLEND
 100% ACRYLIC
 ACRYLIC/COTTON BLEND
 COTTON/WOOL BLEND

AVERAGE PRODUCTION – 15 ton/day (max.)

FIBER DYEING

 100% COTTON
 100% POLYESTER
 ACRYLIC TOW
 100% WOOL

AVERAGE PRODUCTION – 30 tons/day (max.)

AURO DYEING has collaboration with the Japanese concern

and has the latest technology of dyeing. Most of the
machinery has been imported from Japan.
 3

1. RESEARCH AND DEVELOPMENT

Research and Development department is an integral and

necessary component of any industry. The success of any
industry is not possible without R&D department and it
depends on the efficient working of this department.

THE MAJOR FUNCTIONS OF THE R&D

DEPARTMENT ARE

 IT ACTS AS A NEXUS between the outside party and

production department since the orders are taken from
the outside party and after approval sent to the bulk
section through this department.

 QUALITY CONTROL of products and QUALITY CHECKS of

input materials are done in this department.

 MATCHING is another important function of this

department. Shade is developed according to the
reference recipe and the shade is to be matched with the
standards under lowest number of trials.

THE DIFFERENT SECTIONS OF R&D DEPARTMENT

ARE

1. QUALITY INPUT.
2. QUALITY OUTPUT.
3. PROCESS DEVELOPMENT CELL (PDC).
4. OBBDM.
5. SPDM.
6. WEAVING SECTION (SHIRTING CELL)
 4

1.1 QUALITY INPUT

In this section all the input materials like dyes, chemicals,

different, fibres, grey yarn husk, water hardness etc. tested for
there performance properties.

A) DYES TESTING

1) TESTING A NEW SAMPLE AS SUBTITUTE

• Colour Value (Strength)

• Fastness (Dry Rubbing, Wet Rubbing,
Washing)
• Colour Fastness to Mercerization
• Solubility
• Migration Behavior

2) TESTING FOR RUNNING ITEM

• Colour Value ∆ E Value (STD & PREVIOUS)

• Physical Appearance

FOLLOWING DYES ARE TESTED FOR THERE COLOUR

VALUE:

REACTIVE DYES: Reactive Dyes are tested on OBBDM

machine.

ACRYLIC DYES: Acrylic Dyes are tested in Beaker Dyeing

Machine.

VAT DYES: Vat Dyes are tested on AHIBA Machine.

DISPERSE DYES: Disperse Dyes are tested on HTHP Machine.

 5

In Dye the sub store person gives testing new dye and this dye
is tested against the previous supply & standard. After
testing ∆ E value and colour strength is also compared.
Concerned person sends testing report to the colour
substore and main storeafter sign.

B) Some dyes come for vendor analysis. After testing the

record are maintained in the vendor development file.

Consistency of each dye is to be maintained in the

corresponding file.

B) CHEMICAL TESTING:

In chemical testing the following chemical are

tested for their percentage purity.
Salt
Soda
Acetic Acid
Caustic Flakes
Caustic Lyes etc.

NaOCl is also tested for available Chlorine.

Other auxiliaries are tested for solid content & different
performance properties.

C) TEST FOR DIFFERENT AUXILIARIES:

1) WETTING AGENTS
• WETTING TEST
• SOLID CONTENT

2) DETERGENT/ WASHING OFF AGENTS

• CLEANING EFFICIENCY

3) RETARDER
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• HALF DYEING TIME

4) SOFTENER
• SOLID CONTENT
• APPLICATION TEST

D) HUSK TESTING:

Husk is tested for their moisture content. After

testing report is send to main store and boiler section by the
concerned person.

E) WATER HARDNESS:

Water hardness is tested four times in a day.

F) GREY YARN TESTING:

Grey yarn comes from different units tested in input

section for their physical parameters and dye ability.
Record of the grey yarn used for the production is
maintained in the grey yarn-testing file. After testing the
report is send to production Deptt. Commercial Deptt. ,
PPC Deptt. after signed by concerned person.
 7

1.2 QUALITY OUTPUT

INTRODUCTION

Performance of the product against the customer decides the

quality of that product. Under the view of quality control the
word QULITY means the best quality performance for the
utmost satisfaction of the customer within a competitive price
and CONTROL is the tool used by the management in securing
this quality.

OBJECTIVE

The objective of QUALITY OUTPUT section is to control the

quality of the product by testing and controlling all the related
parameters. For this purpose the different tests, which are
carried out here, are

1. COLOR FASTNESS TO WASHING

a) REACTIVE DYED YARN
b) VAT DYED YARN

2. COLOR FASTNESS TO CROCKING. (Wet and Dry)

3. COLOR FASTNESS TO HYPOCHLORITE BLEACH/PEROXIDE

BLEACH

4. RESISTANCE TO COLD WATER BLEEDING

a) REACTIVE DYED YARN AND VAT DYED YARN
b) SPECIFIC SHADES OF VAT AND REACTIVE

5. COLOR FASTNESS TO MERCERIZING.

6. DETERMINATION OF WHITENESS INDEX OF TEXTILES.

7. COLOR MEASUREMENT OF TEXTILE INSTRUMENTS.

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8. COLOR FASTNESS TO PERSPIRATION.

9. PH OF WATER EXTRACT FROM BLEACHED TEXTILES.

10. COLOR FASTNESS TO LIGHT.

INSTRUMENTS USED IN THE QUALITY OUTPUT

ARE

 LAUNDROMETER
To check the washing fastness.

 CROCKMETER
To check the wet and dry rubbing fastness.

 RAPID OIL EXTRACTOR

To check the % finish content.

 WRAP REEL
To make a lea of yarn.

 LEA STRENGTH TESTER

To check the breaking strength of the lea.

 CIRCULAR KNITING MACHINE

To make knitted fabric from the yarn.

 MOISTURE ANALYSER
To check the moisture content of the yarn.
 9

QUALITY ASSURANCE STANDARDS FOR

DYED PRODUCTS

S.N PARAMETER COTTON ACRYLIC PET

o FIBRE FIBRE FIBRE
1 MOISTURE 6.5-8% 1-2% 1-2%
CONTENT
2 FINISH 0.55- 0.2- 0.16
CONTENT 0.65% 0.3% -0.22%
3 WASHING 4 - 4/5 4 - 4/5 4 - 4/5
FASTNESS
4 RUBBING 3/4 3/4 3/4
FASTNESS
(DRY)
5 RUBBING 3 - 3/4 3 - 3/4 3 - 3/4
FASTNESS
(WET)
6 SHADE SHOULD MATCH WITH
STANDARD
7 LEVELNESS SHOULD BE UNIFORM
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MATERIAL FLOW IN OUTPUT SECTION

DYEING SECTION
↓
QUALITY
ASSURANCE
↓
YARN
TESTING
↓
RUBBING FASTNESS
TESTING
(WET AND DRY)
↓
WASHING FASTNESS
TESTING
↓
SAMPLING
↓
COUNT
TESTING
↓
C.S.P.
TESTING
↓
COLD WATER BLEEDING
TESTING
↓
REPORT IS SENT TO PRODUCTION
DEPARTMENT
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1.3 OBBDM SECTION

(OPEN BATH BEAKER DYEING MACHINE)

OBJECTIVE
Objective of OBBDM SECTION is to prepare the recipe for a
given shade for the bulk production as well as to prepare the
lab dips for the market orders. Generally the recipe of the
orders below 250 Kg is developed in this section. For this
purpose open bath beaker dyeing machine and HTHP machines
are used.

TYPES OF MATERIALS DYED IN THIS SECTION ARE

 100% COTTON (yarn and fibre)

 POLYESTER/COTTON blend (yarn)
 100% ACRYLIC (fibre)
 100% POLYESTER (yarn and fibre)
 100% WOOL

DIFFERENT DYES USED IN THIS SECTION ARE

 REACTIVE DYES and VAT DYES for cotton

 DISPERSE DYES for polyester
 BASIC DYES for acrylic
 ACID DYES for wool
 DISP/REACT AND FOROSOL DYES FOR P/C blend

MACHINE SPESIFICATIONS

NAME OF MACHINE NO OF MACHINES NO OF BEAKERS IN

MACHINE
OBBDM 4 1 having 6 beakers
3 having 14
beakers
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HTHP 1 12

OBBDM MACHINE
DYEING PROCEDURE (FOR REACTIVE VS DYES)

a) Start dyeing at 400 c and run the m/c for 15 min.

b) Add salt according to concentration of shade in 3
installments at an interval of 5 min.
c) Run for 15 min.
d) Add soda according to shade depth in 3 installments at
an interval of 5 min.
e) Now run the m/c for 50 min. At 600c.
f) Drain the beaker and wash the sample properly with
fresh water and give after treatment.

DYEING PROCEDURE (FOR REACTIVE HE DYES)

From step (a) to (d) same as for VS dyes.
(e) Run the m/c for 50 win at 800c
(f) Same as for VS dyes.

SALT-SODA CONCENTRATION (DEPTH WISE)

Conc .Of Salt Conc. Of Soda

Depth Of Shade
(NaCl) (Na2co3)
Up To 0.75% 20gpl 10 Gpl

0.75 - 2.0% 40Gpl 12 Gpl

2.0 - 4.0% 50Gpl 15 Gpl

4.0 - 6.5% 60Gpl 18 Gpl

Above 6.5% 70gpl 20 Gpl

Above 6.5% Soda - 5 Gpl
(Only For Red, Navy & 70 Gpl Caustic - 1.3
Black) Gpl
 13

AFTER TREATMENT (FOR VS & HE DYES)

a) Neutral with Acetic Acid - 5.0 g/l
Temp. - 600c
Time -5’
M:L R -1:15

b) Cold wash with fresh water for 5 min.

c) Soaping with Wetter 28 - 1.5 g/l

Temp. -900c
Time -5’
M:L R -1:15

d) Hot wash for 5 min.

DRYING

a) Hydro the sample.

b) Keep it in oven till dry.

SAMPLE CHECKING
Now check the sample (dyed) for shade & levelness in
mentioned light source.

HTHP MACHINE
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DYEING PROCEDURE (DISPERSE DYES)

After pippetting of colour load the lea in beaker and add water
to make the final volume (including chemical) 90 ml (i.e. 1:18
M:L R).
Chemicals to be added –
Solopol PES – 1.0 gpl
Ammonium Sulphate – 0.5 gpl
Acetic Acid – 0.5 gpl

a) Start dyeing at 500c and raise temp to 900c in full steam.

b) Run the m/c for 30 win.
c) Cool the m/c up to 800c with full cooling gradient.
d) Drain the beaker and wash the sample properly.
e) Hydro the sample and keep it in oven for drying.

DYEING PROCEDURE (FOROSOL DYES)

0 After pippetting dye solution add chemicals.

Lycol RDNI – 0.5 gpl
Ammonium Sulphate – 0.5 gpl
Acetic acid – 1.0 gpl
Salt – 4.0 gpl
Solopol PES – 0.5 gpl

Now add water to make final volume 90 ml (1:18 M:L R)

1 Run the m/c at 500c for 15 min.
2 Raise the temperature up to 1350c with heating gradient
20c/min.
3 Run the m/c for 30 win.
4 Cool the m/c up to 800c with full cooling gradient.
5 Run for next 20 min.
6 Drain the beaker and wash properly with fresh water.
7 Hydro the sample and keep it in oven for drying.
 15

SAMPLE CHECKING
Carbonize the sample & check shade.

Carbonizing Procedure
Make 100 ml solution with 70% H2SO4 & 20% water.
• Let the solution be cool up to 400c.
• Dip the sample for 5 min.
• Take out the sample carefully from solution and wash
with cold water.
• Neutralize the sample
• Now check the shade of polyester part.

1.4 SPDM SECTION

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OBJECTIVE

The objective of the SPDM (single package dyeing machine)

section is to dye the single package for the purpose of bulk
production as well as to produce the development shade. The
desired shade of the order above 250 kg is produced in this
section on a single package. For this purpose single package
dyeing machines are used. The procedure, which is followed in
SPDM, is followed in bulk, which helps in minimizing the
problems of the bulk production.

MACHINE SPESIFICATIONS

MAKE OF MACHINE NO OF MACHINES

HISAKA 7

FONG’S 2

DALAL 2

TOTAL NO OF MACHINES 11

DIFFERENT PARTS OF SPDM AND THEIR WORKING

 DYEING TANK

This is the main part of the machine situated at the center of

the machine. It is cylindrical in shape having the liquor capacity
of 12 ltrs. (HISAKA). It contains a spindle at the center where
package is placed. Dye solution circulates in-out through the
package. It contains the heating coils at the bottom. Steam is
passed through the coils for heating the liquor.
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 ADDITION TANK

An addition tank is situated near the main dye tank. All the
dyes and chemicals can be fed to the main dye tank through
this tank with the help of the feeding system.

 SUCTION PUMP

Suction pump is situated at the center bottom of the machine.

It
Sucks and delivers the liquor through the cheese.

 WATER INLET VALVE

One water inlet valve is attached at the bottom of the machine.

It performs the function of coldwater inlet in the tank.

 WATER OUTLET VALVE

This is called the drain valve. With the help of drain valve all
the liquor is drained after use.

 STEAM INLET AND OUTLET VALVE

Steam comes from the boiler for the purpose of heating the
liquor. It comes through the steam inlet valve and goes out
from outlet valve. A cold water pipe is connected to this steam
valve for the purpose of cooling.

 AIR PRESSURE VALVE

After closing the main tank air pressure valve generates the
required pressure for the dyeing. The maximum air pressure in
the HISAKA machines is 6kg/sq.cm.
1.5 PROCESS DEVELOPMENT CELL
(PDC)
 18

This is the section where all the new developments related to

process and materials are done and all the old processes are
controlled if any problem occurs.

THE MAIN OBJECTIVE S OF THE PDC SECTION IS

 TO DEAL WITH PROBLEMS IN DYIENG

If any problem in the bulk or lab occurs related to dyeing then

it is deled by the PDC cell and controlled by this section by
controlling and studying all the related parameters of dyeing.
For example to get the shade right first time (RFT) all the
parameters related to the process are studied and controlled.

 TO DEAL WITH COMPLAINTS

If there is any complaint by the customer then that complaint is

deled by the PDC cell. This section studies various parameters
and reasons related to that problem. Mostly the complaint
arises related to the quality of the substrate and necessary
steps are taken to solve that problem for the complete
satisfaction of the customer.

 TO INTRODUCE NEW DYES AND CHEMICALS

If new dye or the chemical is to be introduced in the process

then testing of that sample is done in this section. The testing
is done through OBBDM section or if necessary through SPDM
section. If the results are satisfactory then that dye or chemical
is introduced in to the process.

 TO INTRODUCE NEW DEVELOPMENTS

New development related to process, shade or the materials

are done in this department. For example the latest
 19

developments are the development of the dyeing process of

different blends like wool/cotton, acrylic/wool/nylon,
wool/nylon, polyester/nylon and acrylic /cotton etc.

 TO DEVELOP VARIOUS METHODS OF COST AND TIME

SAVINGS

Various methods of cost and time savings are introduced by

this department by studying thoroughly the related process,
which helps in higher productivity and lower dyeing cost.

 TO INTRODUCE THE NEW WORK PRACTICES

The PDC section introduces the new method of doing the

work so that it could be feasible and comparatively easier for
the worker to do that work.

1.6 WEAVING SECTION-SHIRTING CELL

OBJECTIVE
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The objective of the weaving section is to produce the dyed

yarn of required shade and dye class.

WORK PRACTICES

The different work practices carried out in the weaving section

are -:

1.DESK-LOOM REQUEST FROM AURO WEAVING

Weaving section in the very first step, get the desk-loom

request from the AURO WEAVING, which contains: -

 Standards of the fabric.

 Shade numbers against each shade.
 Required dye class.
 Light source. Primary and secondary.
 Party.
 Count and construction

2. SHADE DEVELOPMENT

 Development of each shade in 50 Gms on AHIBA

TURBOMAT machine as per requirement.
 Sent to AURO WEAVING after matching with standards.

3. MAKING OF DESK-LOOM AT AURO

WEAVING

 Produce desk-loom as per required design and

construction.
 Sent to AURO TEXTILE for processing.

4. PROCESSING
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 Processing is done as per dye class and count and then

matching with standards is done. After matching the
decision is taken to remake the desk-loom or to send to
the party.

5. SEND TO PARTY FOR APPROVAL

 After approval of the desk-loom it is sent to the party.

Then party gives the order for the production in bulk if
approved by the party. Sometimes the party demands
for the yardage (15 meters to 100 meters) to check the
feel and finish of the quality of the fabric and bulk order
is given after the approval of yardage.

6. ISSUING OF ORDER

 The bulk order is issued from the AURO WEAVING to the

AURO DYEING required by the party.

7. CONFIRMATION OF RECIPE

 Recipe is confirmed by producing the shade on the

SPDM by producing the 1 kg lot on SPDM.
 After recipe confirmation it is sent to shop floor for the
bulk production.

8. QUALITY CHECKING

 After bulk production quality of the yarn is checked.

9. SEND TO A/W FOR FABRIC PRODUCTION

 After Q. checking yarn is sent to A/W for fabric

production.
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2. PRODUCTION PLANNING AND CONTROL

The main objective of this department is to execute the orders

placed to the organization by effective scheduling. They also
keep a control over the orders by daily monitoring at each
stage of SPDM, dyeing and dispatch. This department has to
decide the date for the dyeing of the particular lot in the bulk
The main functions of this department are:
1. Schedule Making
2. Monitoring
3. Dispo Making
 Schedule Making: In this a schedule is made for
the orders placed by the branch offices in Delhi, Mumbai,
Tirupur, Ludhiana etc. and each office has been assigned
a maximum limit i.e. the amount of order /day to be
processed. Based on this allocation a schedule is made.
The particular order of a buyer is completed depending
upon the availability of the grey yarn, dyes and also upon
the urgency of the order placed. Thus based on these
parameters a plan for the procurement of the required
grey material is also prepared.
 Monitoring: The PPC cell also has to keep a check
on the status of the orders being processed and also the
stage at which they are. It also monitors whether the
order or the lab dip for shade confirmation has been
dispatched on time and if not the reasons for the same.
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 Dispo Making: This includes the preparation and

execution of the disposition sheet. The planning done is
mainly of two types micro planning and macro planning.
Macro planning is done once a week and deals mainly with
the lots to be processed in the coming week. Micro
planning in done every day for the next three days and
gives much more accurate details of the machine
allocation. It is much easier to make changes in the micro
planning than macro. This sheet also keeps a record of the
pending quantity of the order and at what stage.
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3. PROCESS FLOW IN YARN DYEING

YARN IN CHEESE FORM

↓

PRE WINDING
↓

DYEING
↓

DRYING
↓

QUALITY CHECKING
↓

POST WINDING
↓

CODITIONING
↓

PACKING
↓

DISPATCH

4. PRE WINDING
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OBJECTIVE

The objective of the Pre Winding section is to convert the

cone into soft package form for the purpose of dyeing.

The grey yarn is supplied to AURO Dyeing from the following

units:-

 100% Cotton yarn

→ AURO Spinning Mills

→ Vardhman Polytex Ltd.
→ V.S.G.M.(100% EOU)
→ V.S.G.M.
→ OSWAL Cotton spinning Mills
→ Arisht spinning Mills
→ Arihant Spinning Mills

 Polyester/Cotton blend

→ V.S.G.M.
→ Arisht spinning Mills
→ AURO Spinning Mills

 Acrylic/Cotton blend

→ V.S.G.M.
→ Arihant Spinning Mills
→ Vardhman Polytex Ltd.

MACHINE DETAILS
 26

NAME KAMITSU PSM SSM

DRUMS 60 120 45

S SPEED 440 480 1100

(m/min)
WINDING RANDOM RANDOM PRECISION

DIA. OF DRUM 185 mm 198 mm

PACKAGE 0.329 0.329 0.364 –

DENSITY 0.405

POWER (kw) 3.8 4.5

MAKE JAPAN GUJRAT ZURICH

(SZD)
NO OF M/C’S 2 4 9

These machines are used to convert the cones into soft

packages by winding the yarn on polypropylene cheeses. These
polypropylene cheeses contain the perforations from which the
dye liquor circulates through the yarn with an inside to outside
flow.

CHEESE SPESIFICATIONS

 WEIGHT – 130-135 gms

 LENGTH – 156 mm
 EX. DIA. – 79 mm
 INT.DIA. – 70 mm
 27

STANDARD PARAMETER FOR SSM

(For Cotton, Package Wt. 1200 Gm –1500 Gm)

Sr.No Pkg. Wt. Count Net Wt. Dia Travers Density

(Gm) Range -Range e (mm) (Gm/Cc)
(Gm) (mm)
1 1500 20 CBD 1475-1525 195-201 150 0.364-0.405
2 1400 20 CBD 1375-1425 191-197 150 ,,
3 1300 20 CBD 1275-1325 182-188 150 ,,
4 1200 20 CBD 1175-1225 176-182 150 ,,
5 1500 24 CBD 1475-1525 195-201 150 ,,
6 1400 24 CBD 1375-1425 191-197 150 ,,
7 1300 24 CBD 1275-1325 182-188 150 ,,
8 1200 24 CBD 1175-1225 176-182 150 ,,
9 1500 30 CBD 1475-1525 195-201 150 ,,
10 1400 30 CBD 1375-1425 191-197 150 ,,
11 1300 30 CBD 1275-1325 182-188 150 ,,
12 1200 30 CBD 1175-1225 176-182 150 ,,
13 1500 40 CBD 1475-1525 195-201 150 ,,
14 1400 40 CBD 1375-1425 191-197 150 ,,
15 1300 40 CBD 1275-1325 182-188 150 ,,
16 1200 40 CBD 1175-1225 176-182 150 ,,
17 1500 50 CBD 1475-1525 195-201 150 ,,
18 1400 50 CBD 1375-1425 191-197 150 ,,
19 1300 50 CBD 1275-1325 182-188 150 ,,
20 1200 50 CBD 1175-1225 176-182 150 ,,
21 1500 60 CBD 1475-1525 195-201 150 ,,
22 1400 60 CBD 1375-1425 191-197 150 ,,
23 1300 60 CBD 1275-1325 182-188 150 ,,
24 1200 60 CBD 1175-1225 176-182 150 ,,
 28

COUNTWISE MARK
Sr.No Count Sign Colour Side (Pkg)
1 20 CBD H Double circle BLUE SINGLE
2 20 BRD H Double circle YELLOW SINGLE
3 24 CBD H Single circle PINK BOTH
4 25 DRD Single circle YELLOW SINGLE
5 30 CBD H Single circle YELLOW BOTH
6 40 BRD Single circle VIOLET BOTH
7 20 P/C Single circle BLUE BOTH
8 30 P/C Double circle VIOLET SINGLE
9 40 P/C Double circle PINK SINGLE
10 34 BRD Single circle BLUE SINGLE
11 30 BRD Single circle PINK SINGLE
12 20 WARP Single circle VIOLET SINGLE

STANDARD PARAMETERS FOR KAMITSU & PSM

SR. PKG .WT DIA. TRAVERSE DENSITY # TENSION WT.

COUNT
NO. .(gm) ( m/m ) (m/m) (gm/cc) (3 gm)

1 20 CBD 1200 GM 195-200 150-153 0.30-0.32 1-2

2 24 CBD 1200 GM 195-200 ,, ,, 1

3 30 CBD 1200 GM 195-200 ,, ,, 2

4 60 CBD 1050 GM 195-200 150 –151 0.34-0.35 NIL

5 40 CBD 1200 GM 195-200 150-153 0.30-0.32 NIL

6 20 P/C 1200 GM 188-193 ,, 0.34-0.35 1

7 30 P/C 1200 GM 188-193 ,, ,, NIL

8 40 P/C 1200 GM 188-193 ,, ,, NIL

9 20 wp 1200 GM 195-200 ,, 0.30-0.32 1

10 30 wp 1200 GM 195-200 ,, 0.30-0.32 NIL

5. YARN DYEING SECTION

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OBJECTIVE

The objective of the yarn dyeing is to dye the grey yarn in

package form. For this purpose HTHP package dyeing machines
are used. The packages are loaded into the carrier situated into
the machine where into-out flow is used to dye the package.

MACHINE SPECIFICATIONS

MAKE OF MACHINE No OF MACHINES

HISAKA 7

FONG’S 6

POZZI 5

HARA 1

DALAL 2

TOTAL NO OF 21
MACHINES

DIFFERENT PARTS AND WORKING OF YARN

DYEING MACHINE

 MAIN DYE VESSEL

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Yarn dyeing machine contains the main dye vessel in which the
spindles are loaded. The cheeses are loaded on to the spindles
and dyeing is carried out using into-out flow of the dye liquor.
The dye tank contains heating coils lying at the bottom of the
machine. Steam is used to heat he liquor in the tank.

 ADDITION TANK

With the main dyeing tank addition tank is situated. All the
additions of the chemicals are done through this tank. It
contains a mixer to dissolve the chemicals and three
electromagnetic sensors to sense the water level in the tank.

 DESSOLVING TANK

A Dissolving tank is also situated near the main dyeing vessel

to dissolve the dye. Addition of the dye liquor is done through
this tank to the main dye vessel. Similar to the addition tank it
also contains the mixer and three electromagnetic coils.

 MAIN CIRCULATING PUMP

The main circulating pump performs the function of circulating

the dye liquor with into-out flow from the package.

 DOZING PUMP

Dozing pump dozes the dye or chemical at a fixed rate to the

main dyeing tank.

 OVER FLOW VALVE

The function of the overflow valve is to overflow the liquor in

the main dyeing tank whenever required.

 THROTTLE VALVE
 31

Throttle valve controls the flow of the dye liquor by changing

the position of the valve and helps in the constant flow rate of
the dye liquor through the package.

 FOUR -WAY COCK

It performs the function to change the liquor flow from inside-

out to outside-in and vice-versa.

 WATER INLET VALVE

The hot and cold water is filled in the main dyeing tank and in
the addition and dissolving tank with the help of water inlet
valve.

 HEAT EXCHANGER

Heat exchangers are situated at the bottom of the tank to heat

the liquor. Steam is passed through the heat exchangers for
the heating. It is situated with a cooling pipe also for the
cooling purpose.

 STEAM INLET

The supply of the steam to the heat exchangers is done

through the steam inlet system. The pressure of the inlet
steam is kept to be 6 kg/sq.cm.

 STEAM TRAP

It performs the function of separating the condensate from the

steam.

 SAFETY VALVE

Maximum pressure in the machine is kept to be 4 kg/sq cm. If

the pressure inside the vessel exceeds this value then excess
pressure is released by the safety valve.
 32

 AIR PRESSURE VALVE

Air pressure valve increases the pressure after lid is closed and
decreases the pressure before opening of the lid.

 PRESSURE GAUGE

It contains four operating systems: -

1. PUMP DELIVERY generates pressure during
delivery of liquor by the pump.
2. PUMP SUCTION generates pressure during
suction of liquor by the pump.
3. IN DYE PRESSURE pressure of liquor after
passing from throttle valve.
4. DYEING TANK PRESSURE pressure inside
dyeing tank after lid is closed.

 LEVEL GAUGE

It consists of a glass tube with a scale alongside it. The level

inside the tube indicates the level of water inside the vessel.

HISAKA MACHINES
MACHINE PARAMETERS:
 33

M/C No. /
YD--1 YD--2 YD--3 YD--6 YD--7 YD-8
PARAMETER

MODEL LLC400/180 LLC-200/114 LLC-200/114 LLC-100/90 LLC-444-150 LLC-444/150

FUJI/PVH
PROGRAMMER FUJI/PVH FUJI/R/H FUJI/PVH FUJI/PVH FUJI/PVH

PLC MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI

PUMP POWER 55 KW 37 KW 37 KW 18.5 KW 75 KW 75 KW

NO.OF PUMPS 3 3 3 3 3 3

PUMP
DISCHARGE 20 10 10 5 24 24
(m3/min)

NO. OF .PKG 450 200 200 100 444 444

LOT SIZE ON
1.5 kg /PKG 675 300 300 150 666 666
(kg)
WATER 2’ 2’ 2’ 2’ 2’ 2’
FILLING TIME 2` 45” 2` 45” 2` 40” 2`15” 3`15” 4`

LOW TEMP. 2` 2` 2` 2` 2` 2`
DRAIN 3`30” 3`30” 3`45” 2.50” 3`30” 3`30”

HIGH TEMP 6` 6` 6` 6` 6` 6`
DRAIN 8` 8` 9` 4.30” 9` 8`

HOT WATER 50 50 50 50 50 50
TEMP (°C) 47.45 46.25 46.25 47.70 46.45 47

MAX. HEATING 3.0 3.0 3.0 3.0 3.0 3.0

RATE (°C/min) 2.33 2.75 2.56 2.57 2.61 2.79

INJECTION 3` 3` 3` 3` 3` 3`
FROM D/T 8` 2`30” 2`30” 3.30” 3` 3`30”

INJECTION 3` 3` 3` 3` 3` 3`
FROM A/T 7` 3`30” 3`30” 3.30” 2`40” 3`30”

VOL. ( lts) 4200 2100 2100 1050 4662 4662

PROGRAMMER

a) In programmer we feed the progm. and PTN no. with

the help of deft keys on the temp. Panel of the
programmer according to the given ptn.
b) There are diff. PTNS for diff. shades, substrate, type of
dyes etc.
 34

c) For running the progm. Enter the progm PTN no. And
the operation starts according to progm. PTN.
d) The programmer of the m/c senses the PLC
(programmable logic control) and PLC operator and
control the value acc. to information / command given
by the programmer.
e) The PTN can be changed only while the programmer
operation is reset.

THE DIFFERENT OPERATIONS CARRIED OUT

DURING DYEING ARE :-

Loading:
The yarn dyeing process is performed in cheese form.
Cheeses are loaded on to carrier. Here the entire carriers are
bottom type cheese carrier. The spindles are arranged on
lower manifold. On each spindle 5 – 12 cheese can be
loaded.
a) Before loading of material on carrier, check colour
staining on carrier.
b) Check quality of pkg. by checking pkg. wt., dia.,
traverse, density ribbon on pkgs and deposition of
fly.
c) Check pkgs for uniform winding.
Extremely soft and hard cheese will cause difference
in flow rate of liquor, which results in cheese-to-
cheese shade variation
d) Coning should be done is case of PSM and Kamitsu
pkgs.
e) Place spacer between two pkgs in case of non-
interfixing cheese and in full bleach.
f) Use proper & cleaned lock and lock plate
depending upon the shades.
• In case addition the lots size the amount of lot has
to be adjusted in this at the time cheese loading
use blind bobbin (the pipe of the same size as the
bobbin) instead of cheese and use the blend pipe
 35

(the pipe is set on the whole of the spindle) in case

whole spindle (one or more) has not to be loaded.
g) Before loading the dyg tank with carrier check the
colour staining in case of full bleach lots, light
shade and med. shades.
h) Lift the carrier by hoist and load it in dyg tank.
i) Descend slowly the carrier and place the carrier on
the carrier receiving taper.
j) Disengage the hanging fixer and set the carrier at
carrier receiving taper.
k) Disengage the hanging fixer and set the carrier at
carrier receiver .

Dyeing:
a) Check PTN which is to be run.
b) Close the dyg. tank with lid and lock the tank in
following sequence:

Close the lighting valve, release valve, and air inlet

valve.
Close the cover and turn the cover opening–closing
handle till the complete engagement between vice.
and the right and left vices are in become in perfect
engagement.
Open the pkgs lighting valve.
After closing the lid make sure that dyg tank lid is
completely closed and turn the select switch of the safety
device on the control panel in closed position.

c) Make sure that the cooling water to the pump and run
the ptn.
•When m/c is to run turn the switch on the control
panel on normal side from auto side
• In case out-in flow direction the liquid level should
be at the upper end of the carrier, so that water
can be sucked from the upper end of the carrier.
 36

Salt and Alkali Preparation:

Take the recipe from shift office and crosscheck it again.

a) Before weighing colour, check all electronic balances on
daily basis against std. wt.
b) Colour weigh should be done accurately in front of m/c
man.
c) Colour for light shade i.e. about 50 ml should be
weighed on a balance of 300 gms.
d) Colour above 2 kg should be weighed on 5 kg balance.
e) Colour above 2 kg should be weight on 60 kg balance.
f) Reactive dyes should dissolve at 45 °C for 15-20 min at
60 °C
g) Vat dyes should dissolve at 45 °C for 15-20 min.
h) Sulphur black dye should be dissolved at 88 °C for 15-
20 min.
i) Channeling should be checked before feeding colour.
j) Alkali should be checked before feeding colour.
k) Alkali should be predessolved for 10–15 min. Alkali
dosing should be done according to specified dosing
ptn. mentioned on the ptn. sheet.
• The dyestuff and other agents having dissolving
temp. more than 40°C should be dissolved in
dissolving tank for level dyg.

Dosing PTN:

 Feed dyes and other agents only after dissolving

completely in the required tank (Dissolving /
Additional)
 Check suction pressure and delivery pressure in
dyg. Tank and find out the total head.
Total head = delivery pressure – suction pressure
 Now from the head & discharge (pump) graph i.e
pump performance out the pump discharge.
 Now calculate flow rate of the liquid (lt/kg/min)
 37

Flow rate = pump discharge * 1000 ( lt/kg/min)

Wt. of material
 More or less flow rate may cause even dyg. or air
on the lots.
 Generally dyg. should be carried out in the inside
to out side direction but in case uneven dyg is
expected in cheese with the in- out direction only,
the flow should be changed from in-out to out-in in
little intervals.
In case of acrylic material wool or softly wound yarn,
the shade collapse may occur, caused by the out side
to in side flow, so the flow direction must be limited
to the inside to out side in such case.
* It is dangerous to heat up the empty tank & under
any condition pump should not be operated without
water.

Opening the cover:

0 Make sure that the liquid temp. in the dyg. tank is

less than 80°C.
1 Open air bent valve and make sure that the tank
internal pressure has reached 0( zero) on pressure gauge.
a) Make sure that the pump is stopped completely.
b) Close the packing this tightening value.
c) Open the release value.
d) Turn the handle to open the vice and to disengage the
dune.
e) Open the cover.
Water washing :
When the liquor temp becomes below 80 °C, open the air
purge valve and remove the press.
a) Open the over flow valve and water feed valve and
start the operation then the fresh water is supplied and
dirty water is over flowed .

6. DRYING
 38

After dyeing of the yarn in cheese form the wet packages

are brought to the drying section for the purpose of drying.
Drying of the packages is done in two ways: -

 RAPID DRYER

 RF DRYER

6.1 RAPID DRYER

Passing the hot air through the packages dries the wet
packages on the rapid dryer and then conditioning is done
by passing the cool air to keep a constant moisture content
of the yarn.

MACHINE SPECIFICATIONS

NAME RAPID DRYER 1 RAPID DRYER 2

MAKE HISAKA HISAKA

MAX.CAPACITY 800 Kg 800 Kg

MOTOR POWER 120 kw 120 kw

MAIN PARTS OF RAPID DRYER AND WORKING

 MAIN VESSEL
 39

The packages loaded onto the spindles are placed in the

main vessel. In the main vessel hot air is circulated through
the package with into out flow. Main vessel has a lid at the
top of it. Pressure is generated in the vessel after closing the
lid.

 HEATER

The function of the heater is to heat the dry air at the

required temperature, sent by the blower. Heater is
connected to the outlet of the blower.

 BLOWER

The function of the blower is to suck the dry air separated

from the mist separator and blow towards the heater. It is
connected to the outlet of the mist separator.

 COOLER

Cooler performs the function of to decrease the temperature

of the moist air coming out of the vessel.

 MIST SEPERATOR

Mist separator separates the moisture and dust from the

moist air with the help of filtration.

 LIP SEALING RING

The function of the lip-sealing ring is to close the vessel with

the help of air pressure.

MACHINE OPERATION

The different operations of the machine are: -

 40

1. PRESSURE RISING
The pressure of the machine rises after closing of the lid and
when the blower starts operating.

2. DEHYDRATION

When hot air is passed through the package with out to in

direction the water gets extracted from the package.

3. DRYING

When hot air is sent through the package with in to out flow
the moisture present in the yarn gets vaporized and drying
takes place.

4. WET ADJUSTMENT

Cool air is sent through the package with out to in direction

to distribute the moisture evenly through the package.

5. PRESSURE REDUCTION

Pressure is reduced into the machine after the operation is

over and then lid is opened.

6.2 R/F Dryer

• It uses the direct heating method of the capacitor type.
 41

• Operation mechanism:-

Radio frequency rays are generated at 10000- 11000 dc

volts and frequency 27.12+ 0.6 Mg Hz these establish a
field between the top and bottom electrodes, all the polar
molecules inside this field are affected. Since water
molecules act as dipoles, the keep changing their
orientation due to the high frequency of the applied
voltage—this generates heat and eventually raises the
temp. To boil at which moisture is converted to steam,
which is sucked out with the aid of hot air blowing from
the bottom.

• Machine settings: -

a) Conveyer belt speed can be varied from 3m/hr. to 30

m/hr.
b) Electrode distance – can be varied between 260mm
to 460mm.

• Main machine parts: -

a) Oscillator and R/F generation region
b) Electrodes
c) Conveyer
d) Water cooling unit
e) Exhaust fans
f) Filter
g) Heater unit.

Function of filters: -

Two filters are situated on the machine. They suck the

clean air (1100cfm) heat it up by the heaters. This hot
air aids in the removal of steam from the packages.
• Conveyer belt speed calculations:-

 At a power of 85Kw the machine evaporates 85 X 1.1 = 93.5 L of

moisture per hour.
 42

 1 m length of belt accommodates N packages i.e 6 X ( 4.7

to 5) = 27 to 30

Let M be the amount of moisture required to remove from

the package
 the speed of belt should be:-
93.5 m/hr.
N XM

• Production rates :-

N X conveyer speed - packages per hour

Or

Package weight X N X conveyer speed (kg per hour)

Taking the value of conveyor speed as calculated
above:-

Production = package weight X 93.5 Kg/hr.

M

Now M is function of
a) rpm at hydro.
b) Time at hydro.
c) Package weight
d) Yarn count
e) Material type(i.e combed or carded)
f) Surrounding atmospheric conditions

To run different packages (differing in moisture content) at

the same speed:-

93.5 should be constant;

 43

nXm
or nXm - constant
i.e. n1 X m1 = n2 X m2 = n3 X m3 =
……………………

n- can be controlled by varying the space between the

packages (manually)
m- can be varied by adjusting the hydro rpm & time.

Precautions and safety measures :-

 There should not be any dust particles between the

electrode region , since they might effect the
capacitance of the system. It is recommended to
clean the machine twice a week with air pressure.
 The anode current should not exceed 12.5 amperes
(when the conveyor is completely loaded), if it does
adjust the electrode settings.
 At the distribution board switch on the pump and fan
required for cooling before switching on the R/F drier,
and wait for another 5 mins. To start the R/F rays.
 To halt the machine stop the R/F , wait for 5 mins.
And then stop the pump and fan.
 Do not clean the machine while it is in operation as it
sucks in air at 220 cfm
 Not to leave materials inside for a prolonged time
interval
 Do not feed in material without centrifuging.
 For bleached yarns allow 5mm more electrode
settings and run at greater speed to avoid over
drying.
 44

BERTA 24 T.E.

After emerging from the dyeing chamber the dyed yarns

have moisture content of around 120% to 170% , to bring
this value down to an acceptable limit (45% - 55% to be
used on the R/F drier) hydro extractor is employed.

Principle and working:-

The hydro extractor works on the principle of centrifugal

force and inertia.Yarn winded in the from of cheese are
loaded in the centrifuge which provides the centrifugal force,
and due to inertia factors the moisture/water particles
separate from the cheese. The factors, which determine the
quantity of moisture/water, removed from the cheese are 
i> angular velocity of the centrifuge &
ii> the time interval at which the cheese are rotated.

Construction:-

a>4 carriers each having a capacity of 12 spools/cheese.

b> 2 centrifuges having separate motors.
c>centering unit.
d>hydraulic system to lift the covers.(4 L capacity)

Centrifuge motor=7.5 Kw

Machine settings:-
Rpm0 to 1500
Time0 to 8 mins.

Voltage CONTROL PANEL :-

Indicator

Tim Rpm display

rpm1 & rpm2 selector GREEN RED ORANGE
e hours
SET

Emergency
Stop cycle start/stop manual manual
Sideways up & down
| | |
 45

PROCEDURE TO START THE MACHINE:-

 Set the main switch to position 1

 Manually lift the covers.
 Mount the packages/cheese on the carriers.
 Manually put down the covers.
 Set the rpm & time values.
 Press the green colored start/stop cycle button & the
machine will operate in the auto mode.
 To halt the cycles again press the green button.
 To stop the machine in case of emergency press the
lower left red colored button.

7. POST WINDING
OBJECTIVE
 46

The objective of the post winding section is to convert the

dyed packages into the cone.

Number of PSM machines-10

Number of AUTOCONER-2
Number of MECHCONER-1

The same PSM machines are used in post winding as that in

pre winding with some differences.
 Spindles are used in place of cradle.
 Wax is applied by wax roller.
 Taper angle is provided to cones.
 Drum diameter is reduced.
 Speed of machine is increased to 500 m/min.

DIFFERTENCE BETWEEN PSM AND AUTOCONER

 Spindle is provided in AUTOCONER not in SSM.

 AUTOCONER has greater speed as compared to SSM.
 Electronic measuring gauge is present in AUTOCONER.

8. CONDITIONING
Uniformity of moisture in yarn may suffer due to
dyeing and drying treatments. To achieve this uniformity
conditioning is done.

PRINCIPLE: - It is based on principle of condensation of

steam. First of all vacuum is created which lowers the boiling
 47

point of water to 55*c resulting in generation of steam which

condense on yarn.
Secondary advantage of YCP is weight gain by
yarn due to condensation of steam.

MACHINE: -
SEIGER CONDITIONING PLANT
MAKE: - AMOTO ENGG.PVT.LTD.
CONTROLLER: -SIEMENS

PRESSURE -680 -680 -100 0 -500 -10

TEMPRATURE 55 60 55 60 0 0
S1 S2 S3 S4 S5 S6

CAPACITY: - 1.5 Ton

PROCESS TIME: - 75min

SPECIFICATIONS: -

Diameter of shell - 2000mm

Height of shell - 2200mm
Length of shell - 5100mm
Weight gain - 1.8%

9. PACKAGING
After conditioning material is
dispatched in cartons. Following parameters are mentioned
on carton.
 48

MILL: -
SUBSTRATE: -
COUNT: -
SHADE N0. -
LOT N0: -
N0.OF CONES: -
DATE: -
NET WT.: -
GROSS WT.: -

The size of the cartoon can be:

• 24”x24”x21” : 25-27 cones(max. capacity 45kg)

• 23”x23”x21” : 20 cones(max. capacity 25 kg)
• 16”x16”x14” : for minicones(max. capacity 10kg)
• 32”x26.5”x13.75” : 40 cones(max. capacity 40kg) for
export

10. PROCESS FLOW FOR FIBRE DYEING

STAMPING

PRESSING

DYEING
 49

HYDOREXTRACTOR

CAKE UNLOADING

COTTON, PET, ACRYLIC FIBER ACRYLIC

TOW

WASHING RANGE ALEA

DRYER

HYDROEXTRACTOR SEYDEL

DRYING RE
BREAKER

BAILING MACHINE BALING

PARAGON, HARMONY, RANGOLI DAFFODIL

RAINBOW RANGOLI ARIHANT VSGM

HARMONY VSGM

AURO Spng

11. STAMPING AND PRESSING

OBJECTIVE

Objective of the stamping is to load and stamp the fibre of

required density, into the carrier for the purpose of dyeing.

WORKING
 50

The material is fed into the feed lattice. From feed lattice the
material goes to the swing feeder. Swing feeder place the
material on the carrier with the uniform movement. Hot
water feeding system attached in the swing material helps in
wetting of the fiber and proper loading. Stamping road
stamp the fibre in the carrier with its constant up and down
movement. After stamping the dummy is placed on to the
carrier and then taken for the pressing on the pressing
machine. Pressing machine works on the principle of
hydraulic pressure, which press the material at the effective
height for the required density of the substrate.

MACHINE SPESIFICATIONS

NAME OF MACHINE MAKE OF MACHINE NO OF MACHINES

STAMPING OSCAR JAPAN 3
PRESSING MAKK Engg. INDIA 2
& OSCAR JAPAN
TOTAL MACHINES 5

STANDARD DENSITY:

For cotton – 0.32 gm/cm2

For polyester -- 0.59 gm/ cm2
Pashupati tow -- 0.56gm/ cm2
Val tow -- 0.54 gm/ cm2

HEIGHT OF FIBRE IN CARRIER FOR REQUIRED

DENSITY:

POLYESTER (P-0.59 gm/cm2) COTTON (P-0.32 gm/cm2)

PRESSING PRESS HEIGHT
LOT WT (cm) LOT (cm)
EFFECTIVE EFFECTIVE
SIZE AS PER SIZE AS PER SCALE
HEIGHT HEIGHT
(kg) SCALE ON (kg) ON PRESSING
PRESSING M/C
650 128 138 350 128 138
 51

625
122 138 325 117 127

600 118 132 300 108 118

575 113 128 275 99 109
550 108 123 250 90 100

525 103 118 225 81 91

500 98 113 200 72 82

475
93 108 175 63 63
450
88 103 ,, ,, ,,

425 83 98 ,, ,, ,,
400
78 93 ,, ,, ,,
375
73 88 ,, ,, ,,
300
69 83 ,, ,, ,,

12. FIBRE DYEING

OBJECTIVE

The objective of the fiber dyeing is to dye the fiber loaded in

the carrier at the stage of stamping and pressing. For this
purpose fibre dyeing HTHP machines are used. Principle of
the fiber dyeing machines is same as that of yarn dyeing
 52

machines. In to out flow of the liquor is used to dye the fiber

in the machine.

MACHINE SPECIFICATIONS

MACHINE MAKE Capacit Capacit Pump Dia of

y y Power vessel
Leters Kgs kw mm

FD-1 HISAKA 2400 350 37 1200

FD-2 HISAKA 3000 650 45 1400

FD-3 HISAKA 3000 650 45 1400

FD-4 HISAKA 3000 650 45 1400

FD-5 HISAKA 3000 650 45 1400

FD-6 HISAKA 3000 650 45 1400

FD-7 HISAKA 3000 650 45 1400

FD-8 HISAKA 3000 650 45 1400

DIFFERENT PARTS AND WORKING OF FIBER

DYEING MACHINE

 MAIN DYE VESSEL

Yarn dyeing machine contains the main dye vessel in which

the spindles are loaded. The cheeses are loaded on to the
spindles and dyeing is carried out using into-out flow of the
dye liquor. The dye tank contains heating coils lying at the
 53

bottom of the machine. Steam is used to heat he liquor in

the tank.

 ADDITION TANK

With the main dyeing tank addition tank is situated. All the
additions of the chemicals are done through this tank. It
contains a mixer to dissolve the chemicals and three
electromagnetic sensors to sense the water level in the tank.

 DISSOLVING TANK

A Dissolving tank is also situated near the main dyeing

vessel to dissolve the dye. Addition of the dye liquor is done
through this tank to the main dye vessel. Similar to the
addition tank it also contains the mixer and three
electromagnetic coils.

 MAIN CIRCULATING PUMP

The main circulating pump performs the function of

circulating the dye liquor with into-out flow from the
package.

 DOZING PUMP

Dozing pump dozes the dye or chemical at a fixed rate to the

main dyeing tank.

 OVER FLOW VALVE

The function of the overflow valve is to overflow the liquor in

the main dyeing tank whenever required.

 THROTTLE VALVE
 54

Throttle valve controls the flow of the dye liquor by changing

the position of the valve and helps in the constant flow rate
of the dye liquor through the package.

 FOUR -WAY COCK

It performs the function to change the liquor flow from

inside-out to outside-in and vice-versa.

 WATER INLET VALVE

The hot and cold water is filled in the main dyeing tank and
in the addition and dissolving tank with the help of water
inlet valve.

 HEAT EXCHANGER

Heat exchangers are situated at the bottom of the tank to

heat the liquor. Steam is passed through the heat
exchangers for the heating. It is situated with a cooling pipe
also for the cooling purpose.

 STEAM INLET

The supply of the steam to the heat exchangers is done

through the steam inlet system. The pressure of the inlet
steam is kept to be 6 kg/sq.cm.

 STEAM TRAP

It performs the function of separating the condensate from

the steam.

 SAFETY VALVE
 55

Maximum pressure in the machine is kept to be 4 kg/sq cm.

If the pressure inside the vessel exceeds this value then
excess pressure is released by the safety valve.

 AIR PRESSURE VALVE

Air pressure valve increases the pressure after lid is closed

and decreases the pressure before opening of the lid.

 PRESSURE GAUGE

It contains four operating systems: -

5. PUMP DELIVERY generates pressure during
delivery of liquor by the pump.
6. PUMP SUCTION generates pressure during
suction of liquor by the pump.
7. IN DYE PRESSURE is pressure of liquor after
passing from throttle valve.
8. DYEING TANK PRESSURE is pressure inside
dyeing tank after lid is closed.

 LEVEL GAUGE

It consists of a glass tube with a scale alongside it. The level

inside the tube indicates the level of water inside the vessel.

13. HYDRO EXTRACTOR

OBJECTIVE

The objective of the hydro extractor is to remove the excess

water from the dyed fiber in the carrier. Hydro extractor
 56

works on the principle of centrifugal force. Carrier is rotated

at a high speed in the machine and the excess water is
removed from the carrier.

MOTOR RPM-1410
MAKE-TOYU JAPAN
NO OF MACHINES- 1

PROCESS TIME

FOR COTTON- 3 min.

FOR POLYESTER- 5 min
FOR ACRYLIC- 6 min

14. CAKE UNLOADING

After hydro extractor the cake is unloaded from the carrier. It
is taken on the unloading machine where the carrier is
reversed on the wooden plate and the cake is unloaded on it.

15. WASHING RANGE

OBJECTIVE

After dyeing and unloading the cotton and acrylic fibers are
brought into the washing section for the purpose of washing.
 57

Where soaping and washing of the fibers are taken out in

four bowl washing range.

THE DIFFERENT STAGES OF THE WASHING SECTION

ARE

 CAKE BREAKER

After unloading the cake is first taken to the cake breaker

section where the cake is broken and opened into tufts form.

 HOPPER LATTICE

A constant and limited delivery of the fibers is sent to the

next section with the help of the hopper lattice.

 WASHING BOWL 1

This is the stage where scouring and washing of the fibers is

done. The washing liquor temperature for the reactive dye is
60 ˚c and for sulphur dye is 45 ˚c. In case of reactive dyes
wetting agent and soaping agent is used and in case of
sulphur dyes hydrogen peroxide and acetic acid are also
used for the oxidation.

 SQUEEZING

After scouring squeezing of the fibers is done with the help

of squeeze rollers at a pressure of 3 kg per square cm.

 WASHING BOWL 2

After squeezing the fibers are taken to the second washing

bowl where the fibers are washed at a temperature of 60˚ c
with water. Cationic Fixer is also applied if required.

 WASHING BOWL 3
 58

In the third bowl washing of the fibers is done with the cold
water at a temperature of 30˚ c.

 WASHING BOWL 4

In the fourth bowl the cationic softener is applied to the

fibers at a temperature of 45˚ c.

 HYDRO EXTRACTOR

After a constant feed from the hopper lattice the excess

water from the fibers is removed in hydro extractor, which
works on the principle of centrifugal force.

 DRYING RANGE

After a constant feed from the hopper lattice the fibers for
the complete drying are taken to the drying section where
the fibers are dried at three different drying chambers.
These three chambers consist of the 6 drum dryer range
with a temperature of 120˚c, 120˚c and 110˚c respectively.

 SOOT POINT

After drying the fibers are passed through the conveyor to

the soot point and sent for packing.

16. ALEA DRYER

OBJECTIVE
 59

The objective of the ALEA DRYER is to open the acrylic tow

after dyeing, with air pressure and dry it with hot air
circulation.

THE THREE MAIN SECTIONS OF THE ALEA DRYER ARE

-:

1. ANTISTATIC APPLICATION

In this section the antistatic is applied to the acrylic tow to

reduce the static charge on the fibers. The antistatic finish
from Vaptex is applied on to the fibers with the help of the
kiss roll system on both sides of the fibers. The speed of the
fibers is generally 5 kg per minute.

2. OPENING SECTION

In this section the opening of the fibers is done with them

help of air pressure. The fibers are passed through a vertical
air chamber. In this chamber air is blown through the fibers
at a pressure of 1.5 kg per square cm to 1.6 kg per square
cm. Due to the air pressure the tow is changed into the open
strand of fibers with a greater volume.

3. DRYING SECTION

In this section the drying of the opened tow is done with

circulating the hot air through the fibers. The fibers are
passed through two drying chambers on a lattice where the
temperature of hot air is 100˚c and 95˚c. respectively.

17. SEYDEL SECTION

(SEYDEL-870 STRETCH BREAK CONVERTER)

 60

OBJECTIVE

The objective of the Seydel section is to convert the acrylic

tow into sliver form with the principle of stretching, breaking
and drafting.

The material flow in the Seydel machine is in this way: -

FEEDING UNIT
↓
PREBREAKING ZONE
↓
PREBREAKING ZONE
↓
BREAKING ZONE
↓
REBREAKING ZONE
↓
SLIVER COMPACTOR
↓
← CRIMPER BOX →
↓ ↓
REGULAR
HIGH BULK
↓
↓
CSR
ADAPTOR UNIT
↓
↓
COOLING CONVEYER BELT COOLING
CONVEYER BELT
↓
↓
CAN
CAN
 61

Draft is provided separately in each zone to stretch and

break fibers by engaging different gears. After stretching
crimp is provided to compensate the loss of crimp in
previous process.

Two types of slivers are formed in this section

0 N type slivers- these types of fibers are non shrinkable
in nature.
1 S type slivers- these types of fibers are shrinkage
active.

MACHINE SPECIFICATIONS

MACHINE SEYDEL 870

DELIVERY SPEED 240 m/min

TOW WEIGHT 120-220 ktex

DRAW RATIO 2.2-22

SLIVER WEIGHT 30-60 ktex

SHRINKAGE 15-25 %

POWER 60 kw
 62

18. REBREAKER

OBJECTIVE

The objective of the REBREAKER unit is to blend and draft

the N type and S type slivers in the 50:50 ratio. For this
purpose the slivers are passed through creel to the drafting
rollers.

MAIN PARTS

FEED UNIT

o CREEL for the feeding of sliver.

o CREEL ROLL to give smooth passage.
o CREEL GUIDE to guide the sliver.

DRAFTING ROLLERS

To give the required draft to the slivers. It consists of three-

roll system in which one is top roll and two are the bottom
rolls.

SPECIFICATIONS

 MAKE-NSC (FRANCE)
 DELIVERY SPEED (REBREAKING)-250 m/min. max
 DELIVRY SPEED (BLENDING)-350 m/min
 PRESSURE CYLINDER DIAMETER-130 mm
 63

19. CHAIN GILL

It is assembled with REBREAKER. It performs the function of
blending, drafting and Gilling with its combing unit and
convert sliver into bump top.

19.1 BALE PRESS

After making of bump top 8 bump tops are fed into bale
press machine for making a bale of 200 kg apx. Machine
works on the principle of hydraulic pressure. Eight bales of
the weight 25 kg are pressed and packed together in this
machine.

MAKE OF MACHINE-MAK INDIA

NO OF MACHINES-1
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20. BOILERS:

No. of Boilers : THREE

Make : Thermax, Chinchwad

Year of Manufacture : 1994 and 1998

Capacity of Boiler : (i) 8 ton/hr.
(steam generated) (ii) 12 ton/hr.
Type of Boiler : Fluid Pac (water in tube)
Water consumption : 500m3/day
Type of Fuel : Rice Husk/LPG
Fuel Consumption : 106 tonnes/day
Total Cost Of Fuel : Rs.1,70,000/day
Cost of Steam : 40 paise/kg.
Steam Pressure : 10kg/cm2
Temperature of steam : 1750C
Temperature of boiler : 5800C
Surface Area of tubes : (i) 314 mt2 (ii) 451 mt2
No. of Workers : 8 per day

 The water used in the boiler is first dealkalanised

using hydrochloric acid (strength 33%).
 The hardness of water should not be more than
5ppm and the T.D.S. should be less then 300ppm.
 The suspended particular matter in the flue gases
should not exceed 100mg/lit.
 65

21. EFFLUENT TREATMENT PLANT

In this plant, effluent from all the departments of the unit is

collected to remove the hazardous elements from the
effluent so that it does not cause any pollution when it is
disposed off.

Process Sequence:
The raw water is received in the Bar Screen Chamber, which
separates the floating matter, coarse solids from the
effluent. The screened wastewater goes to Equalization
Tank. The effluent is pumped to Oil Removal Tank, which
separates the oil from the effluent. This oil is removed with
the help of slotted pipe mechanism. The effluent then enters
to the Solid Contact Clarifier where limewater, pickling acid
(waste hydrochloric acid) and polyelectrolyte is added. All
these chemicals are dosed into central draft tube. Solid
Contact Clarifier helps in reducing the color and the
suspended solids from the effluent. The overflow of Solid
Contact Clarifier enters to the pH correction tank (not in ETP-
1) where pH is maintained to 7.0-7.5. The overflow from here
enters into Aeration Tank where diffused aeration system is
used for aeration. The Aeration Tank also contains bacteria,
which shall maintain the B.O.D. level, and the fans attached
 66

maintain the D.O. level. A regular feed of urea and D.A.P. has
to be given to this tank to maintain the amount of bacteria
(2500-3000 mg/lit). The effluent from Aeration Tank flows
into the Secondary Clarifier where the biomass settles at the
bottom and clear effluent flows out. The settled biomass in
the Secondary Clarifier is returned partly to Aeration Tank to
maintain the Mixed Liquid Suspended Solids in Aeration
Tank. The excess sludge after removal of water in a
Decanter with the help of polyelectrolyte will be transferred
to the to the trolleys from where it is disposed off. The water
after treatment is either sent down the drain or used for
irrigation in the nearby fields.

Main components of ETP:

a) Equalization Tank: In this tank, input water from all

the various sections of the unit is collected so that pH,
BOD etc. of the water becomes constant.

b) Oil Removal Trap: In this tank all the grease and oil (if
any) is removed from the water by a pipe that has a slit
on the top from where oil layer is removed.

c) Flash Mixer: This tank is used for dozing of the

chemicals into the water.
 67

d) Solid Contact Clarifier: Here the water with the

chemicals is given ample time for reaction to take
place.

e) pH Correction Tank: The pH of the output water

should be neutral not so the pH is corrected by the
addition of the required reagent.

f) Aeration Tank: Air is injected inside the water for

maintaining the required levels of DO. This is done with
the help of fans or injecting compressed air in the
water.

g) Secondary Clarifier: this tank is used for removing

the bacteria from the water and clear water flows out
from here.

h) Sludge Slump: The sludge collected from the clarifiers

is stored in the sludge slump from where it is sent to
the decanter.

i) Decanter: The main function of this part is to separate

the water from the sludge.

Specifications:
No. of plants : Two
Capacity : 2500m3/day/plant
Make : E.T.P.-I Hindustan Doro Oliver
Limited.
E.T.P.-II Ion Exchange Limited.
 68

Cost Of Treatment : Rs.3.3/litre (in case of pickling acid)

Rs. 5.5/litre (in case of ferric chloride)

AMOUNT OF CHEMICAL USED AND THEIR FUNCTION

CHEMICAL AMOUNT USED FUNCTION

Lime 800 kg/day Maintain the required
alkalinity
Pickling Acid 10,000-12,000ltr/day Coagulating agent
Polyelectroly 15 kg/day Flocculating agent
te
Urea and Depends on Amount of Growth of Bacteria
D.A.P. Bacteria

WASTE WATER CHARACTERISTICS

PARAMETERS INLET OUTLET

Flow Rate 2500m3/day ------
PH 10-10.5 7.0-7.5
B.O.D. (Biological Oxygen 650ppm 32ppm
Demand)
C.O.D. (Chemical Oxygen 700-750ppm 250ppm
Demand)
T.S.S. (Total Suspended 300ppm <100ppm
Solid)
D.O. (Dissolved Oxygen) 1ppm 2-4ppm
Temperature 40-500C Ambient
Color Colored Colorless
 69

Difference in E.T.P.I and E.T.P.II

E.T.P.I E.T.P.II
Flash mixer is used to dose Chemicals are added to
chemicals Primary Clarifier
No pH correction tank There is a pH correction tank
Aeration Tank has fans for Compressed air is passed in
aeration. the water.