Vardhman Textiles
Vardhman Textiles
Vardhman Textiles
Yarn
25.39 Garment
Fibre
Power Plant
51.02
10.05 Steel
Sewing thread
8.98 Fabric
Production
Wide range of cotton
Synthetics and blended yarn
Grey and Dyed yarns
Hand Knitting Yarns (market leader in India)
Sheers Cotton/Nylon
They are:
Auro Spinning Mills
Auro Weaving Mills
Auro Dyeing Mills
Mahavir Spinning Mills
Auro Textiles
Auro Spinning Auro Weaving Auro Textiles
Auro Dyeing
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Auro Spinning Mills
Introduction
Yarn is the largest strategic business unit of the Vardhman
Group
2 Sampling Unit
Conditioning Packing
Processes
A. Sorting
Sorting is the process of removing contamination from the fibers.
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Machine Parts
1. Feeder
2. Licker-in Cylinder
3. Drum
4. Flats
5. Doffer
6. Drawing Unit
7. Coiler
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Working of the Carding
Machine
The fibres are separated and then brought together into a
loose strand (sliver).
The machine splits up the locks and tangled clumps of fibre and
then lines up each fibre so that all the fibres are almost parallel
with each other.
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Working
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E. Lap Former
Sliver from card which is passed through the breaker draw
frame is not suitable for feeding in the comber because the
feed material rqd. for the comber is a lap sheet
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Working
Slivers are fed to form a lap of 20 inches wide condensed with a
slight draft and weighing as per set length.
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Machine Specifications
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Working
The lap formed in the lap former is passed as an input.
http://www.cottonyarnmarket.net/OASMTP/COMBING%20PROCESS.pdf
G. Finisher Draw Frame
Finisher is the last machine where the irregularities in the strand can
be modified and no fault will pass onto the yarn.
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H. Speed Frame(Roving)
The main action of roving section is to reduce the linear density
of the draw frame sliver since the sliver is thicker and is not
suitable to feed into the ring frame directly to produce yarn.
The speed frame converts the thick drawn sliver into thin sliver
with low twist and produces fine roving.
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Working
Drafting: Attenuation of thick draw frame sliver into fine roving. The twisting
and stretching of sliver following the reduction in its diameter is called
drafting. The drafting frame used in Hall 5 is 3 over 3. It consist of 3 rollers
1. Front Roller
2. Middle Roller
3. Back Roller
Winding: It is the winding of the twisted roving on bobbin which is fed onto
the ring frame. The twisted yarn is wound around a bobbin. There is a flyer
over the bobbin which rotates at a different speed than bobbin.
Working
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Working
An overhead blower machines keeps removing the dirt and
dust particles from the roving frame.
It sucks impurities from the top and blows air at the bottom.
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Working
The feed material comes from speed frame i.e. roving bobbin is
placed on the creel.
Then feed material is passed under the guide rollers and into
the drafting zone where some draft is inserted in to the roving.
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t.in/2012/02/ring-frame-
material-passage-diagram-
of.html
J. Winding
It is primarily the last step in spinning process.
http://www.textilinvest.cz/media/technologie/Schlafhorst-338-RM-winding-
machine_TI.pdf
Machine Specifications
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machinery-technology/
Yarn Conditioning
When yarn is made, textile fibers are subjected to various
physical operations like opening, carding, drawing and
spinning.
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Working
With the vacuum principle and indirect steam, the yarn is
treated very gently in an absolutely saturated steam
atmosphere.
The vacuum first removes the air pockets from the yarn
package to ensure accelerated steam penetration and also
removes the atmospheric oxygen in order to prevent oxidation.
The packages are then dried and kept in such a condition that
moisture content remains 8% in the finished yarns.
Packaging
After the yarn packages are conditioned they are sent for
packaging. The yarn cones are packed for domestic
market/exports.
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Auro Dyeing Mills
Introduction
Yarn and fiber dyeing is done in the unit
Commercial Production
P&IR Department
Department Department
Rapid Dryer/R.F
Hydroextractor Post Winding
Dryer
Godown for
Conditioning Packing
Storage
A. Raw Material from
Storage
Customer Places
Order to
Marketing Division
Marketing Divison
co-ordinates and
provides yarn
Yarn Stored
before processing
A. Raw Material from
Storage
The capacity of the godown is 40 tonnes and its area is 45 X 18
metres.
If the yarn has to be outsourced, ASM checks for quality of the yarn
before sending it to ADM to assure quality for processing.
Reaction of the
Dyes are dissolved in Exhaustion of dye on
chemicals to form a
soln. fiber surface
covalent bond
The carrier of the HTHP machine is then loaded with the soft packages
on spindles or warp beams and then the carrier is loaded in the machine
for processing.
Post Treatment
Around 5-7 gms of yarn is wound around fingers and then the
shade is compared manually against the sample/shade card.
Machines Used
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E. R.F.Dryer
Radio Frequency Dryer
The moisture content in the soft package after dyeing is roughly
150% than its weight.
The required moisture is 6-6.5% in cotton.
So, to dry the package to have a suitable moisture content it is
first subjected to hydro extractor to remove excess water and
then dried in an R.F Dryer.
There are 4 RF Dryers in ADM
Company: Monga Strayfield
Working of RF Dryer
In RF Dryer alternating electric field between two electrodes is created.
The dyed yarn packages are put across between the electrodes, where
the alternating energy causes polar molecules in the water to continuously
re-orient them to face opposite poles.
This movement causes friction due to which water in the material rapidly
evaporates throughout the material.
The radio waves vibrate the contained water molecules million times per
second.
Ventilator fans are used to remove damp air from the drying chamber.
Hydro
Drying Sample Check
Extraction/Unloading
Packing Despatch
A. Stomping
According to shade specified, the carrier is cleaned and put in
position.
The operator then starts the feed lattice.
Material is opened and fed on the lattice and water valve is
opened.
The head is put on the carrier and is pressed.
Pressing height depends on the weight of the lot.
Dimmi carrier is then lifted through the pressing unit and the carrier
is covered with a cap and latch.
Then with the help of the panel and crane, carrier is lifted and put
over dyeing machine.
B. Dyeing
The dyeing machine consists of the following parts:
Main Tank
Side Tank
Main Panel
The loading carrier is put in the main tank of the dyeing machine.
With the help of the side tank, the dose is injected according to
the recipe.
Fibres matched
2-3 gms of dyed Dried over sample Carded using against the
fibres taken dryer sample carder standard given by
buyer.
Fibres are loaded onto the feed lattice. There are 3 bowls in the
feed lattice
E. Washing
• Temperature is 45OC
• Addition of chemicals
Bowl 1 • Pressure given by squeeze rollers
• Temperature is 600 C
• Use of hot water
Bowl 2
• Finish is opened
• Temperature is 45o C
Bowl 4
E. Washing
Hopper2 and hydro machines are started.
Marketing
Recipe
QA of dyed deparment
Prouction generated by
material places order to
R&D
PPC
Winding Packaging
Testing
In Auro Dyeing Unit, the R&D department is responsible for
testing of the input as well as the output materials.
If Report OK
Chemicals
Sent to input Chemical Report chemicals
from suppliers
section testing generated issued to
to main store
production
Testing
Following tests are conducted for checking the quality of
incoming chemicals and auxiliaries.
Material Tested For
Chemicals Percentage Purity
Moisture Content
Solubility
Chlorine Content
Hardness
Applicability
pH
Colourfastness to Rubbing
Colourfastness to Hypochlorite
bleach/Peroxide bleach
Colourfastness to mercerizing
Colourfastness to perspiration
Colourfastness to light
Testing Of Packing Material
Following packing materials are tested:
Cartons
Paper Cones
Nylon Strips
Wax
Testing Of Packing Material
Cartons:
Checked for brushing strength and the instrument used is Brushing
Strength Tester.
Paper Cones:
Instrument used is Colaspe Strength (CP) Tester or Core Strength (CS)
Tester
Nylon Strips:
They are tested by determining no. of grains/inch
Wax:
It is checked for its composition and oil%.
Auro Weaving Mills
Introduction
Weaving unit of Vardhman Group
Marketing Production
PPC Department
Department Department
Folding and
Preparatory Loom Shed
Inspection
Section Section
Section
Quality
Assurance Packaging
Section
Production
Preparatory
Production Loomshed
Department
Inspection
Preparatory Section
Warp related preparation of the yarn
Auto
Warping Sizing
Drawing
Processes
A. Warping
Process of winding the yarn from cones onto a beam, to
create a warp beam.
Warper’s name
Sort no.
Beam no.
Length
No. of ends
Count
Shade no.
Blend
B.Sizing
Process of applying a protective coating on the yarn
surface mainly to impart strength for further processing.
Creel Zone
Size Box-1
Pre Dryer
Size Box – 2
Pre Dryer
Final Dryer
Steam Hood
Drying Zone
Head Stock
Control Panel
Control Panel Dryer
Control Panel Headstock
Sizing Chemical
The following four main chemicals are used to
make the starch paste:
Basic weaves like 1/1, 2/1, 3/1, 4/1, Oxford fabric, etc.
are produced.
Weaver's
Back Rest Dropper
Beam
Auxiliary
nozzle + Weft
Main Nozzle Relay Nozzle
Break
System
Weft sensor
Folding and Inspection
Section
Activities such as measuring, examining, gauging,
testing, one or more characteristics of a product or
source and comparing these with specific
requirements to determine conformity is called
“Inspection”.
Only 37 points are allowed in 100 yards of fabric roll and only
4 major faults are allowed in the fabric per 100 yards.
Machines:
7 machines - only inspection
2 machines - inspection and folding.
Quality Assurance Section
Responsible for checking the fabric faults.
Central
Product P&IR Production
Development Department Department
Cell
Preparatory Drawing in
Sizing section
Section Section
Preparatory Drawing in
Section section
Sectional Manual
Direct Warping Auto drawing
Warping Drawing
Central Product
Development Cell
Related to the designing and development of the fabric
according to customer requirements.
Division of CPDC
Product
Development
Cell
Creative
Pilot plant
Design Cell
Central
Product
Developme
nt Cell
Creative Design Cell
Comprises of designers
For fashion forecasting
Making designs and collections in accordance with the world
trends.
Collections
To get new
According to
orders from
their customer
the
requirements
customers.
Creative Design Cell
Before designing, a thorough research work is done
To know the colour and style for the next season
To know the end use of fabric.
Bulk Order
Given
Product Development Cell
Completely customer based
Count Construction
Weave Blend
Product Development Cell
Order received
Bulk Order Article creation
after deskloom
Execution for bulk
approval
Product Development Cell
Deskloom:
Process flow
Sizing
Warping
Drawing
Weaving
Sizing
One of the most important operation to attain
maximum weaving efficiency .
Manual drawing
Auto drawing
No. of machines
Manual drawing 9
Auto drawing 1
Weaving
It is conducted in the loomshed section .
Airjet looms
Production/day : 60,000 m
Yarn Wastage: 7%
Process flow of weaving
from dyed yarn
Dyed Yarn
Sectional Warping
Drawing
Knotting
Gaiting
Fabric Production
Process flow of weaving from
greige yarn
Greige yarn
Direct Warping
Drawing
Knotting
Gaiting
Fabric Production
Processes
Warping
In Mahavir Spinning Mills both grey fabric and yarn dyed
fabric is produced .
Weaver's
Creel Drum
beam
Sectional warping
Benninger Bentronic Prashant Gamatex
4 machines 2 machines
Capacity: 684 cones Capacity: 784 cones
2. Flexible rapier
No. Of machines:
No. Of machines: 7
No. Of machines: 4
Penguin
Auro Textiles
Auro Textiles
Auro Textiles was set up in Baddi (H.P) in DECEMBER
2000.
Mercerizati
Scouring Bleaching Emerizing
on
Fabric
Dyeing Finishing Inspection
Testing
Rolling Dispatch
Processes
A. Grey Opening
Auro Textiles deals with RFD fabric(grey fabric).Grey fabric
is their basic raw material.
There are four in house made machines that are used for
roll opening. The speed of the machines is 60-70m/min
and the fabric after opening is checked for air tightness
and creases.
B. Stitching
This department deals with the stitching of fabric to
ensure the continuous length for further processes.
PTR(Perble)(D
esizing,
Scouring,
Bleaching
Mercerisation
Dyeing Sueding
Washing
Dyeing
Finishing
Singeing
Singeing is the first pretreatment process.
Exhaust
Brush Singeing Unit
Systems
NPS(To
Old
increase
perble-
the
whitenes Ostoff Chloride
bleachin
s of
g
fabric)
New
perble-
Peroxide
bleachin
g
PTR(Perble Range)
Desizing and
Guider Washing
Scouring
NaClO2
Bleach Washing H2O2 Bleach
(optional)
No. of machines:4
Prediction of
Customer Qulaity
recipe by Recipe selection
requirement check(feasibility)
spectrophotometer
Colour Developing
Padding(Pad
dispensing(Techno Drying CDR(Continuous
mangle)
rama) drying range)
Soaping Finishing
Chemical Substore
The pilot plant gives the recipe to the dyeing. Mostly
reactive or vat dyes are used for cotton and disperse dyes
are used for polyester.
Length of shades
Main Dyeing Process
Customer Lab Dip Order
Order Preparation Approval
I.R Zone
Hot flute
chamber
Cooling cylinder
Pad Dry Machine
In the I.R Zone drying of fabric takes place. Upto 70% of
fabric is dried.
Intensive
washing(9th
Washing Neutralisation
chamber
onwards)
Vertical drying
Check fastness Finishing
range(27 rollers)
Pad Steam Machine
Alkaline solution is prepared in the tank area.
Thermofix
Reduction
clearing(to
removeunfixed dye)
Thermofix Process
It utilizes the high rate of dyeing achieved at high
temperature (commonly in the region of 210oC).
Soil release
Airo Release
Calendar finish
Anti UV
Process Flow
Chemical
Tank Stenter
Recipe
Sanfor/Cure
Pad Dry /Calenderin
g
Stenter
Functions of stenter machine
Machine Specifications:
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