OVERVIEW OF TEXTILE INDUSTRY

Modernization Is A Continuous Process And There Should Be Concerted

Efforts To Modernize Both Machinery And Manufacturing Processes
Regularly. It Is General Experience That Units Which Maintained The Process
Of Modernization Systematically Could Manage To Sustain Their Growth In
The Long Run.

Modernization In Fact Is Needed To Increase Production, Reduce The Cost Of

Production, Rationalize Labour, Reduce Maintenance And Power Cost Per Unit
Of Production Etc. Due To A Number Of Factors, The Vast Majority Of The
Textile Units In India Never Tried To Regularly Modernize Their Units. As A
Result The Indian Textile Industry Had Been Suffering From Technological
Obsolescence Since The Beginning Of The 20th Century.

Textile Industry Is One Of The Leading Textile Industries In The World.

Though Was Predominantly Unorganized Industry Even A Few Years Back,
But The Scenario Started Changing After The Economic Liberalization Of
Indian Economy In 1991. The Opening Up Of Economy Gave Much Needed
Thrust To Textile Industry, Which Has Now Successfully Become One Of The
Largest In The World.

Indian Textile Industry Largely Depends Upon The Textile Manufacturing And
Export. Its Play A Major Role In The Economy of The Country. Indian Textile
Industry Is Also The Largest In The Country In Terms Of Employment
Generation.

Indian Textile Industry can be divided in to several segments, some of which

can be listed as below:

 Cotton textile
 Silk textile
 Woollen textile
 Readymade garments
 Hand-crafted textile
 Jute and coir

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 Indian Textile Industry:

India’s Textile industry is the one of the leading textile industry in the world.
Thought it was predominantly unorganized industry even a few years back, but
the scenario started changing after the economic liberalization of Indian
economic in 1991. The opening up of economy gave the much –needed thrust to
the Indian textile industries, which has now successfully become one of the
largest in the world.

Indian textile largely depends upon the textile manufacturing and export. It also
plays on major role in the economy of the country. India earns about 27% of its
total foreign exchange through textile export. Further, the textile industry of
India also contributes nearly 14% of total Industrial production of the company.
It also contributes around 4% to the GDP of the country. Indian textile industry
is also the largest in the country in the term of employment generation. It not
only generates job in its own industry, but also opens up scopes for the other
ancillary sectors. Indian textile Industry currently generates employment to
more than 35 million people. It is also estimated that industry will generate 12
million new jobs by the year 2010.

Indian Textile Industry can be divided in to several segments, some of which

can be listed as below:

Cotton textile
Silk textile
Woollen textile
Readymade garments
Hand-crafted textile
Jute and coir

Contribution to Global Figures

 Largest exporter of cotton yarn and 2nd largest producer of cotton
producing ~36 million
 bales /annum
 2nd largest textile exporter after China; constitutes 5.2% of the total
global exports worth USD 772 billion

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  2nd largest exporter of jute goods, contributing ~USD 0.33 billion to
the total export
 2nd largest fiber producer, producing 13% of the total world’s textile
fiber
 2nd largest producer of silk, contributing 18% to the total world raw
silk production Indian Textile Industry
 2nd largest textile manufacturing capacity globally
 59% of the world’s loom capacity - highest market share
 24% of the world’s spindle capacity

About Textile Industry in Gujarat:

Surat, an emerging city in the state of Gujarat, is known as textile city of Gujarat. And, the
epithet is perfectly suited to the city. The textile industry is one of the oldest and the most
widespread industries in surat. A major part of the city’s population is associated with the
textile industry.

The textile industry is mainly engaged in the activity of yarn production, weaving, processing
as well as embroidery. Nearly 30 million meters of raw fabric and 25 million meters of
processed fabric are produced in surat daily. The city has several textile markets exist since
time immemorial, zampa bazaar, Bombay market and JJ textile market are among them.
Katargam, magdalla and udhana are the areas of surat where manufacture is mainly
concentrated. In the course of time, people from various other places like rajasthan and
Kolkata settled in surat in order to carry out their textile business.

 The famous brands of Garden and Vimal textiles evolved from surat of few other
brands like parag and prafful from surat did become famous for a short time, but fail
to create a lasting impression in the market.

 The main market for surat textile product are India and other Asian countries around
90% of polyester used in India comes from surat. However, international demand for
its product is not very significant. Middle East is the major export market for surat
textile products. According exports, more improvisation in the quality is required to
cater to the demands of the international market.

 The Surat textile industry has grown considerably over time; as per recent figures,
textile production in surat has grown by 10% in the last 5 years, while the market for
embroidery has grown almost negligible amount to around RS.30000 million over the
same period.

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  The main reason behind the growth of Indian textile industry is the city’s ability to
adapt to changes and the latest trends. The city is quick to respond to any changes in
the preference of people. The industrialists here have strong entrepreneurial skills.

In every day nearly 30million meters of raw fabric and 25 million of meters of processed
fabric produced in surat daily. In this city there are so many textile market are there which are
exist since times immemorial. The names of some Zampa Bazzar, Bombay Market, JJ Textile
and Jash Market are among them. Katargam, Magdalla and Udhana are the main Areas of
surat where you can find a lot of manufacturing is mainly concentrated. In the source of time,
the people found various other places like Rajasthan and Kolkata was stayed in surat in order
to make textile business in this city. In surat textile is the biggest employer where nearly 6
lakh power-looms and as many textile workers, mainly from Orissa, Bihar and UP, produce
some 3 Corer meters of cloth every day.

OVERVIEW OF THE COMPANY

Varun Dyeing And Printing Mills Pvt Ltd is a Private incorporated on 16
September 1994.

Directors of Varun Dyeing And Printing Mills Pvt Ltd are Yogesh Goyal,
Rakesh Goyal.

Factory manager is Mr. Ghanshyam Singh

It is classified as Non-govt Company and is registered at Registrar of

Companies, Ahmedabad.

Its authorized share capital is Rs. 15,000,000 and its paid up capital is Rs.
10,404,700. It is inolved in Spinning, weaving and finishing of textiles

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Registered address is 243/3 GIDC ESTATE SACHIN SURAT GJ 394230.

Varun Dyeing And Printing Mills Pvt Ltd's Annual General Meeting (AGM)
was last held on 14 June 2018 and as per records from Ministry of Corporate
Affairs (MCA).

Product manufactured by Varun Dyeing and Printing Mills Pvt Ltd.

Dyed

 Dani
 Shifon
 Marbal
 60 gram
 Roto

Print

 Weightless
 70/72
 Reniyal
 Jorjet

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 PRODUCTION PROCESS OF INDUSTRY

INTRODUCTION:-

Products are the goods and services produced and processes are the facilities,
skills, and technologies used to produce them. Production function or operation
function is the primary function of an industrial enterprise. It is also known as
conversion process or transformation process which transforms some of the
inputs (raw material and components) into outputs which are useful for the
consumers.

The production process is concerned with transforming a range of inputs into

those outputs that are required by the market.

This involves two main sets of resources - the transforming resources, and the
transformed resources.

 The transforming resources include the buildings, machinery, computers,

and people that carry out the transforming processes.
 The transformed resources are the raw materials and components that are
transformed into end products.

There are three main types of process: job, batch and flow
production.
Job production:- Job production is unique in the fact that the project is
considered to be a single operation, which requires the complete attention of the
operative before he or she passes on to the next job. Examples from the service
industries include cutting hair, and processing a customers' order in a store like
Argos.

Batch production:- Batches are continually processed through each

machine before moving on to the next operation. This method is sometimes
referred to as 'intermittent' production as different job types are held as work-in-
progress between the various stages of production.

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Flow production:- Batch production is described as 'intermittent' production
and is characterised by irregularity. If the rest period in batch production
disappeared it would then become flow production. Flow production is
therefore a continuous process of parts and sub-assemblies passing on from one
stage to another until completion.

CONVERSION
INPUTS OUTPUTS
PROCESS

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MANUFACTURING PROCESS AT VARUN DYEING AND
PRINTING MILLS PVT LTD.

RAW COTTON

FIBER PREPARATION

SPINNING

WEAVING

DYEING

PRINTING

FINISHING

CUTTING

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FIBER PREPARATION:-
Raw Cotton Contains Cotton Fiber Along With Small Plant Parts And Field
Trash That Are Not Removed By The Ginning Process. At This Stage, The
Cotton Fiber Has A Coating Of Oils And Waxes That Make It Hydrophobic.
Raw Fiber Is Suitable For Making Nonwovens To Be Used In Industrial
Products In Which Absorbency And Aesthetics Are Not Important. In Some
Cases, Nonwoven Fabrics Made With Raw Fiber Can Be Wet Processed In the
Same Manner As Woven And Knitted Fabrics

SPINNING:-
Most Spinning Is Done Using Break Or Open-End Spinning; This Is A
Technique Where The Staples Are Blown By Air Into A Rotating Drum, Where
They Attach Themselves To The Tail Of Formed Yarn That Is Continually
Being Drawn Out Of The Chamber. Other Methods of Break Spinning Use
Needles and Electrostatic Forces. This Method Has Replaced The Older
Methods Of Ring And Mule Spinning. It Is Also Easily Adapted For Artificial
Fibers.

The Spinning Machine Takes The Roving, Thins It And Twists It, Creating
Yarn.

In Mule Spinning The Roving Is Pulled Off A Bobbin And Fed Through
Rollers, Which Are Feeding At Several Different Speeds. This Thins The
Roving At A Consistent Rate. If The Roving Was Not A Consistent Size, Then
This Step Could Cause A Break In The Yarn, Or Could Jam The Machine. The
Yarn Is Twisted Through The Spinning Of The Bobbin As The Carriage Moves
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Out, And Is Rolled Onto A Cop As The Carriage Returns. Mule Spinning
Produces A Finer Thread Than The Less Skilled Ring Spinning.

MULE SPINNING RING SPINNING

WEAVING:-

Weaving Is A Method Of Fabric Production In Which Two Distinct Sets Of

Yarns Or Threads Are Interlaced At Right Angles To Form A Fabric Or Cloth.
The Other Methods Are Knitting, Lace Making, Felting, And Braiding Or
Plaiting. The Longitudinal Threads Are Called The Warp And The Lateral
Threads Are The Weft Or Filling. (Weft or woof is an old English word
meaning "that which is woven) The
Method In Which These Threads
Are Inter Woven Affects The
Characteristics Of The Cloth.

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 Cloth Is Usually Woven On A Loom, A Device That Holds The Warp
Threads In Place While Filling Threads Are Woven Through Them. A Fabric
Band Which Meets This Definition Of Cloth (Warp Threads With A Weft
Thread Winding Between) Can Also Be Made Using Other Methods, Including
Tablet Weaving, Back-Strap, Or Other Techniques Without Looms.

DYEING:-
The Most Commonly
Used Processes For
Imparting Colour To
Cotton Are Piece Dyeing
And Yarn Dyeing. In Piece
Dyeing, Which Is Used
Primarily For Fabrics That
Are To Be A Solid Colour,
A Continuous Length Of
Dry Cloth Is Passed Full-
Width Through A Trough
Of Hot Dye Solution. The Cloth Then Goes Between Padded Rollers That
Squeeze In The Colour Evenly And Removes The Excess Liquid. In One
Variation Of This Basic Method, The Fabric, In A Rope-Like Coil, Is Processed
On A Reel That Passes In And Out Of A Dye Beck Or Vat.

Yarn Dyeing, Which Occurs Before The Cloth Is

Woven Or Knitted, Is Used To Produce
Gingham Checks, Plaids, Woven Stripes And
Other Special Effects. Blue Dyed Warp Yarns,
For Example, Are Combined With White Filling
Yarns In Denim Construction.

PRINTING:-
A Typical Printing Machine Has A Large
Padded Drum Or Cylinder, Which Is Surrounded
By A Series Of Copper Rollers, Each With Its
Own Dye Trough And Doctor Blade That
Scrapes Away Excess Dye. The Number Of Rollers Varies According To The
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Fabric Design, Since Each Colour In The Design Is Etched On A Separate
Roller. As The Cloth Moves Between The Rotating Drum And Rollers Under
Great Pressure, It Picks Up Colour From The Engraved Area Of Each Roller In
Sequence. The Printed Cloth Is Dried Immediately And Conveyed To An Oven
That Sets The Dye.

Automatic Screen-Printing
Is Another Principal Method
For Imparting Coloured
Designs To Cotton Fabrics.
Although Slower Than
Roller Printing, It Has The
Advantage Of Producing
Much Larger And More
Intricate Designs, Elaborate Shadings And Various Handcrafted Effects.

FINISHING:-
The Final Step In Fabric Production. Hundreds Of Finishes Can Be Applied To
Textiles, And The Methods Of Application Are As Varied As The Finishes.

Cotton Fabrics Are Probably Finished In More Different Ways Than Any Other
Type Of Fabrics. Some Finishes Change The Look And Feel Of The Cotton
Fabric, While Others Add Special Characteristics Such As Durable Press, Water
Repellence, Flame Resistance, Shrinkage Control And Others. Several Different
Finishes May Be Applied To A Single Fabric.

CUTTING:-
The Fabric Is Then Cut With The Help Of Cloth Cutting Machines Suitable
For The Type Of The Cloth. These Can Be Band Cutters Having Similar Work
Method Like That Of Band Saws; Cutters Having Rotary Blades; Machines
Having Reciprocal Blades Which Saw Up And Down; Die Clickers Similar To
Die Or Punch Press; Or Computerized Machines That Use Either Blades Or
Laser Beams To Cut The Fabric In Desired Shapes.

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INDUSTRIAL SAFETY MEASURES IN TEXTILE INDUSTRY
Introduction:-
“Measures or techniques implemented to reduce the risk of injury, loss and
danger to persons, property or the environment, in any facility or place
involving the manufacturing, producing and processing of goods or
merchandise.”

There Are Numerous Health and Safety (H&S) Issues Associated with The
textile Industry. These Include: Chemical Exposure From The Processing and
Dyeing Of Materials; Exposure To Cotton And Other Organic Dusts, Which
Can Affect The Throat And Lungs; Musculoskeletal Stresses; Noise exposure,
Which Can Lead To Hearing Loss; Temperature And Ventilation, Which Can
Lead To Fatigue And Dehydration If Temperatures Are Too High; And
Working Hours And Breaks, Including Access To Food, Drinks And Bathroom
Facilities.

Objectives of Industrial Safety: -

The objectives of industrial safety are as follows:

1. Industrial safety is needed to check all the possible chances of accidents

for preventing loss of life and permanent disability of any industrial
employee, any damage to machine and material as it leads to the loss to
the whole establishment.
2. It is needed to eliminate accidents causing work stoppage and production
loss.
3. It is required to educate all members regarding the safety principles to
avoid accidents in industry.
4. It is needed to prevent accidents in industry by reducing any hazard to
minimum.

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 5. It is required to educate all members regarding the safety principles to
avoid accidents in industry

INDUSTRIAL SAFETY MEASURES IN VARUN DYEING &

PRINTING MILLS PVT LTD.

CHEMICAL SAFETY

 Hazardous Chemicals and their Symbols

 Material Safety Data Sheet
 Risk Assessment of Chemicals
 Health Effects of Dyes and Chemicals
 First Aid

LABORATORY SAFETY PROTOCOL

 Laboratory Safety Protocol

 Factory Floor Safety Protocol

RESPONSIBILITY

 Role of The Management

 Role of The Factory Staff

CHEMICAL SAFETY

HAZARDOUS CHEMICALS AND THEIR SYMBOLS

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Substances used directly in work activities (e.g. adhesives, solvents, cleaning
agents); Substances generated during work activities (e.g. fumes from soldering
and welding); naturally occurring substances (e.g. dust); and Biological agents
such as bacteria and other micro-organisms.

MATERIAL SAFETY DATA SHEETS

Material Safety Data Sheets (MSDS) Exist To Provide Workers With The
Proper Procedures For Handling Or Working With
Particular Substances And Should Therefore Be
Supplied For Each Individual Substance. MSDS
Includes Information As Physical Data (Melting Point,
Boiling Point And Flash Point), Toxicity, Health
Effects, Reactivity, Required Storage Conditions,
Disposal Methods, Protective Equipment, First Aid,
And Spill Or Leak Procedures.

RISK ASSESSMENT OF CHEMICALS

An inventory and risk assessment of all chemicals and dyes that are present at
the factory must be undertaken by the management. The MSDS simplify this
process by providing much of the information required in this risk assessment.
The risk assessment should consider how chemicals are stored and handled. The
information in the inventory and risk assessment must be made available to all
workers.

HEALTH EFFECTS OF DYES AND CHEMICALS

The most common hazard of reactive dyes is respiratory problems due to the
inhalation of dye particles. Sometimes they can affect a person’s immune
system and in extreme cases this can mean that when the person next inhales the
dye their body can react dramatically. This is called respiratory sensitization and
symptoms include itching, watery eyes, sneezing and symptoms of asthma such
as coughing and wheezing.

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RESPONSIBILITY
ROLE OF THE MANAGEMENT

PROVIDE BASIC NEEDS

Employees Should Be Given Access To Safe Drinking Water As Well As A

Clean Area For Meals. Meals Should Be Taken In A Separate Area Away From
The Factory Production. The Factory Staff Should Also Have Access To A
Sufficient Number Of Toilets Of Adequate Quality, This Is A Legal
Requirement And Contained In Most Codes Of Conduct Provided By Buyers.

 There Should Also Be Signs Saying “No Food And Drink” In Areas Such
As The Laboratory, Store Room And Factory Floor, And Any Other
Areas Where It Is Not Safe To Consume Food, For Example Because Of
The Risk Of Contamination By Chemicals.
 Hazardous Chemicals Should Be Clearly Marked In An Appropriate
Language And With Clear Symbols That People Have Been Trained To
Recognise And Understand.
 Heavy Objects Should Be Marked As Such To Avoid Musculoskeletal
Accidents. Substances Or Items That Present A Fire Hazard Should Be
Clearly Labelled With The Universally Recognized Symbol.
 Signs Should Be Placed Near Inflammable Substances Stating That It Is
Not Permitted To Smoke Or Have Open Fires. Showers And Eye
Washes Should Be Made Available And Clearly Marked.

ROLE OF THE FACTORY STAFF

Each Employee Should Have Sufficient Appropriate Training And Experience

So That They Can Perform All Their Required Job Activities. Where Relevant
Each Employee Should:

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• Be Aware Of the Contents of MSDS And Of Potential H&S Hazards.

• Follow All Protocol In The Safe Handling And Disposal Of Dyes And
Chemicals.

• Be Aware Of The Fire Protocol, Where Fire Extinguishers Are And Where
The Nearest Exit Is And Where Assembly Points Are.

• Be Aware Of Where The First Aid Kit Is.

• Wash Hands Before Meals, When Leaving The Work Area And At The End
Of The Shift. This Will Prevent Accidental Ingestion Of Chemicals Or Contact
With Eyes.

• Maintain Correct Posture When Lifting Or Carrying Heavy Objects.

• Report All Accidents And Sicknesses To The Manager As Soon As They

Occur.

• Report Any Defects Or Problems With The Machinery That Might Lead To
Potential Accidents.

FACILITY LAYOUT/PLANT LAYOUT

“Plant layout is such a systematic and efficient functional arrangement of
various departments, machines, tools, equipment and other supports services of
an industrial organization that will facilitate the smooth processing of the
proposed or undertaken product in the most effective, most efficient and most
economical manner in the minimum possible time”

Plant layout is the physical arrangement of industrial facilities. It involves the

allocation of space & the arrangement of equipment in such a manner that
overall operating costs are minimized.

In the words of Sansonneti and Malilick (Factory management Vol. 103) “It is
planning the right equipment, coupled with right place, to permit the processing
of a product unit in the most effective manner, through the shortest possible
distance and in the shortest possible time.”

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Need of Plant layout:
Many situations give rise to the problem of plant layout. Two plants having
similar operations may not have identical layout. This may be due to size of the
plant, nature of the process and management’s calibre. The necessity of plant
layout may be feel and the problem may arise when.

(i) There are design changes in the product.

(ii) There is an expansion of the enterprise.

(iii) There is proposed variation in the size of the departments.

(iv) Some new product is to be added to the existing line.

(v) Some new department is to be added to enterprise and there is reallocation

of the existing department.

(vi) A new plant is to be set up.

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FIXED POSITION FACILITIES:-
Fixed position facilities Comes the closest to meeting our goal of moving the
product as little as possible as it undergoes production processing. In these
facilities, the product occupies a constant fixed position in the centre of the
manufacturing area. Rather than physically moving the product through
different processing points, the workers and the equipment necessary for
manufacturing steps are brought to the product.

Process layouts:-
Process layouts are those in which equipment and workstations are arranged
according to the type of process they perform. Saws would be one part of the
manufacturing area; drill presses would be in another; welding stations would
be in a third; and paint booths would be in a fourth area. Process layouts are
used primarily in job shops, where the facility produces a variety of 9 different
products and each requires a different series of processing steps to be performed
in a different sequence.

Milling Grinder
Receiving Shipping

Inspection

Lath Drill
Storage Finish Goods
Assembly

Process layouts require the most movement of products from workstation to

workstation since the equipment is arranged without regard to the processing
needs of any one product. Job shops can attempt to reduce this unnecessary
handling.

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They can then determine the total number of product movements between
workstations for all of their products and arrange the different process areas to
reduce the total number of product movements. Process layouts do have the
advantage, however, of maximizing the efficiency of machinery usage. All
products requiring drilling, for example, are moved to the same drill press.
Therefore, the total number of drill presses required is kept to a minimum.

IMPORTANCE OF THE LAYOUT:-

 Economies in handling
 Effective use of available area
 Minimization of production delay
 Improved quality control
 Minimum equipment investment
 Better production control
 Better supervision
 Improved utilization of labour
 Improved employee morale
 Avoidance of unnecessary and costly charges

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BIBLIOGRAPHY
Singh, Rajender. Introduction To Basic Manufacturing Process & Workshop
Technology. New Age International, 2006.

Chand, Smriti. " Industrial Plant Layout: Meaning, Definition, Need and
Importance" The Next Generation Library .

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