TRAINING REPORT

LAKSHMI COTSYN LIMITED

FATEHPUR (U.P.) INDIA

SUBMITTED TO SUBMITTED BY
ALKA ALI VISHVAKARMA YADAV

UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE,

KANPUR
ACKNOWLEDGEMENT
 It gives me immense pleasure to thank all of those people, who have played
a pivotal role the course of the project and without whom, successful
completion of the project would not have taken place…..!
 We would like to thank LAKSHMI COTSYN LTD. (PROCESSING UNIT)
for providing me such opportunity to carry out his project. I would like to
express my sincere gratitude to processing department for their full support and
resource provided throughout the project (Uttar Pradesh Textile Technology
Institute) for giving us the opportunity of doing our Industrial training and
project in LAKSHMI COTSYN industries. 
 We would like to express our gratitude towards Mr. ASHOK PANDEY
(A.G.M HR)for his co-operation. I am especially indebted to Mr. SANJEEV
RANA (H.O.D OF DYEING) for his valuable role as a project supervisor, for
his help and guidance throughout the project report. I am especially indebted to
TEXTILE CHEMISTRY DEPARTMENT for academic guide of the college
for giving us the opportunity to accomplish of the project work……!
 We are thankful to ‘FRONT LEAD MANAGERS’ without their assistance,
training and project is not possible.
 CONTENT
 FLOW CHART
 USE PRODUCT
 NAME OF CHEMICAL AND DYES
 NAME OF MACHINES
 PROCESSING DEFECTS
 TECHNICAL PARAMETRE SOFT $ JET DYEING MACHINES
 RFD
 DYEING
 PROCESS OF RFD & DYEING FOR SOFT,JIGGER,JET DYEING MACHINES
 ROPE OPENER
 FINISHING
 QUALITY ASSURANCE
 M/C INSTRUMENT IN Q.A DEPARTMENT
 FINISH FOLDING
 DISCRIPTION OF LAB INSTRUMENT
 PROCESSING FLOW CHART

Grey fabric QA Folding

Pre shipment
RFD Finishing
sample

Dyeing Rope opener Delivery

 PRODUCTS
 Terry Towel
 Bed sheet
 100% Cotton Dyeing

DYES USED

 REACTIVE DYES ON COTTON

 CHEMICALS USED

 Wetting agent
 Dispersing agent
 Levelling agent
 Antifoaming agent
 Carrier
 Dye fixing agent
 Sequestering agent
 Scouring agent
 Lubricating agent
 Neutralising agent
 Soaping
 FINISHING DONE
 SOFT FINISH
 STIFF FINISH

PROCEDURE OF PROCESS HOUSE

 RFD
 DYEING
 FINISHING
 COATING
MACHINES FOR PROCESSING
 SINGEING MACHINE
 JIGGER DYEING MACHINE
 SOFT FLOW DYEING MACHINE
 STENTER
 WASHING MACHINE
 YARN DYEING MACHINE
 HYDRO MACHINE
 STEAM DRYER
 R.F. DRYER
 GAS SINGEING MACHINE
SINGEING
 
OBJECTS:
Singeing is the process of burning off protruding fibers from the surface of
 
fabric to improve clean surface. Singeing prevent pilling. Singeing makes
the material suitable for Dyeing and Printing.
GAS SINGEING MACHINE
 
MACHINE MAIN PARTS:
 Guide roller : They guide the fabric during running and & tension roller gives tension and

removes crease from fabric.

 Gas burner : They are used for burning the loose threads and fibers. Flame is exist from
those burners.
Brushing roller : They remove loose fibers and threads which are singed & loose fiber are
collected in dust bag.
Exhaust fan : It sucks the singed fibers & threads and dust inside the machine and releases
them out.
Cooling roller : The fabric is very hot after singeing so it is Cooled by water cold rollers.
isobutene, n-butane, pentane, etc. When the cloth is drawn over the flame at high speed, the
flame impinges on its.
WORKING: A gas singeing machine consists essentially one or more burners
to produce continuous, uniform flame. It is a mixture of air & natural gas, LPG,
propane, isobutene, n-butane, pentane, etc. When the cloth is drawn over the
flame at high speed, the flame impinges on its.

SINGEING MACHINE

DATA GAYATRI YAMUNA

FABRIC SPEED 80 MTR./MIN. 80-100 MTR./MIN.

FLAME TEMP. 700-800 OC 700-800 OC

GAS PRESSURE 8-10 MBAR 8-10 MBAR

FLAME HEIGHT 6-13 CM 6-13CM

GAS USED PROPANE + AIR PROPANE + AIR

WORK LOAD DISTRIBUTION 4 4

PRODUCTION 3600 MTR./HOUR 4800 MTR./HOUR

BURNER 2 2

SCRAY ROLLER 2 NO
SOFT FLOW DYEING MACHINE
 Fabric is dyeing in rope form.
 Temperature-130°C
 Pressure-3kg/cm²
 MLR- 1:4.5

BRAZZOLI- ITALY
  
 MAIN PUMP SPEED: 1000-1300RPM
 REEL SPEED: 250-350
 PLATER: ACC. TO REEL SPEED
 WATER CAPCITY: 3000 LT.
 MAXI. TEMP: 130-135’C (PRESSUER AT 130’C TEMP. 2-2.5KG)
 NOZZLE SIZE:180MM (SET ACC. TO FABRIC)
KEMPL:
 MAIN PUMP SPEED:1000-1400RPM
 REEL SPEED:150-250RPM
 NOZZLE SIZE:10 KG M/C- 220MM 100, 300, 1000 KG M/C-300MM
 WATER CAPACITY:300KG- 1500LT. 1000KG - 4000LT.
 MAXI. TEMP.: 130-135’C (PRESSER 2-2.5KG)
JET DYEING MACHINE
 Fabric is dyeing in rope form.
 Temperature-130°C
 Pressure-2.5kg/cm²
 MLR-1:8
 CIRCULAR HISAKA JET
 

MAIN PUMP SPEED: 50- 60%

REEL SPEED:200-300RPM
WATER CAPACITY:JET-1- 300LT, JET-2-
2600LT
NOZZLE SIZE:JET-1- 110MM, JET-2-
90MM
SPEARE NOZZLE SIZE FOR JET-2 110MM
 MAXI. TAMP. : 130-135’C (PRESSUER 2-
2.5KG)
 SAMILL JET M/C

 MAIN PUMP SPEED:900-1000 RPM

 REEL SPEED:600-750 RPM
 WATER CAPACITY:JET-3- 3000 LT, JET-4- 1250 LT
 NOZZLE SIZE: JET-3- 105MM, JET-4- 90 MM
 SPEARE NOZZLE SIZE FOR JET-3: 90/105/120MM
 MAXI. TAMP. :130-135’C (PRESSUER 2-2.5KG
 JIGGER DYEING MACHINE

 This machine is used for cotton dyeing.

 Temperature - 60ºC
 Dyeing is done in full width.
 Handling of process done by manually
 SANFORISING MACHINE
It is used to convert hard finish to soft finish. In this machine fabric
passes between steam heated cylinder and rubber belt. The combine
effect of heat and pressure help to achieve object of zero-zero
machine for this process rubber blanket is used in 0-0 machine. The
rubber blanket good stability and good resistance to ageing and
temperature. As a result of which in longer periods between grinding
and a limited risk of cracking in addition rubber blanket has a high
degree of flexibility and a smooth and level surface free from marks
and creases, to avoid damages to the material being finish felting
doesn’t form any ripples or cracks when it presses the material
against the heated cylinder. Rubber belt is continuously cooled by
spraying water. It is also known as compressive shrinking range.
 TECHNICAL DATA
1. Name of manufacturers: Ronson
2. No. of machines: 1
3. Speed: 15-20 meters/min.
(Depending upon the shrinkage required)
4. Life of belts: 18-24 months
5. Thickness of belt: 58 mm to 34 mm
6. Hardness of belt : 38 -40 degree shore
7. Steam consumption : 9600 kg/day
8. Power consumption: 480 units/day
 CALENDERING M/C
This machine is the most sensitive machine. In the processing section it is
done with 100% perfection because a fault once made in calendar cannot be
rectified.

OBJECT:-
 
 
To give shining and pressing look of the fabric. The machine is provided
with metal detecting device which detect any traces of metal present in the
cloth. If a metal is detected the m/c. is stopped immediately.
 The machine consist of three heating and pressing roller. The heating
roller is made of stainless steel. The top and bottom rollers are made of
polyamide and cotton respectively.
 
 TECHNICAL DATA:
 
 
1.Name of manufacturer: Ramisch Kleinewfers
2.No. of machine: 1
3.Speed: 20-25 meters/min.
4.Temperature: 120ºc
5.Production:35000 to 40000 meters/day
6.Steam consumption: 2400 kg/day
7.Power consumption: 480 units/day
 STENTER
It is HEART of any process house. It is versatile m/c. which is
used for various purposes. All types of fabrics are pass one or
more times through the machine. The capacity of any process
house is determined on the basis of no. of stenters

OBJECT OF STENTER
 Heat setting
 Drying and stretching
 Chemical finishing
 HEAT SETTING: Heat setting impart permanent dimension to fabric by
the action of heat, with or without steam. In this process new linkages are
formed which stabilize the shape dictated which will remain unchanged until
the material is subjected to a temperature higher than that of heat setting.
Heat setting of fiber dyed fabric is done at 175-180ºc in under feed mode
because above this temp sublimation of disperse dye may take place. Heat
setting of piece dyed fabric is done at 200-210ºc.
 
 Drying and stretching: The piece dyed fabric after polyester dyeing is dried
and stretched on stenter to control width and length of fabric as required.
 
 Chemical finishing: Chemical finish give desired feel and properties to the
fabric. In this process 1st fabric is padded with the finishing chemicals then is
pass through the chamber having temperature gradually falling from 180ºc
to150ºc.
 
 FOLLOWING TYPE OF FINISHES ARE GIVEN TO THE FABRIC,
1) Softening purpose
2) Anti pilling finish
3) Soil release finish
4) Waterproof finish
5) Anti-creasing
 
FEEDING OF FABRIC
6) Over feeding : in this the speed of feed roller is greater than the speed of chain so
more fabric is come on the chain due to over feeding shrinkage takes places.
7) Under feeding :in this the speed of roller is less than the speed of chain so fabric
is come in tension condition and get required length and width.
 WORKING:
The fabric is for chemical finish passes through padding mangle
Otherwise direct from guide rollers. In the chambers hot air dries the fabric. Temp
is very high inside the chamber. Burn oil is separated& cool air is exhausted.
Blower blows the hot air. When fabric comes out cooler cools the fabric as its temp
is very high.
 TECHNICAL DATA :
1) Manufactures – Harish
2) Chambers – 6
3) No. of machine – 2
4) Fabric speed - depends on quality of fabric
5) Spindles – 12
6) Blowers – 12
7) Mangle pressure – top 3 kg & bottom 2.5 kg
8) Spindle rpm – 1380
9) Blower rpm – 2600
10)Work load distribution –5
11)Power consumption – 1000 unit/day.
 PROCESS OF RFD

SINGEING
DESIZING
SCOURING
BLEACHING
MERCERIZATION
 COTTON RFD
WETTING AGENT
SCOURING AGENT
EMULSIFIER
STABILIZER
WETTING AGENT
EMULSIFIER
PHMAINTAINNER
BLEACHING AGENT
NEUTRALIZING AGENT
CORE ALKALI REMOVER
 
Full form of RFD is Ready for Dyeing. RFD fabric is stage of
fabric where fabric is prepared for dyeing or printing but not yet
done.
Prior to dyeing and printing process of cotton fabric (Greige
fabric) washing is done to remove wax, fiber impurities, seed
coats, dirt and
oils spot from fabric to improved dyeing uptake and evenness.
Garment manufacturer can source cotton fabric in Greige or RFD
form.
 COTTON DYEING
 SOAPING AGENT
 BUFFER
 DYES FOR COTTON (REACTIVE &
DIRECT)
 EXHAUTING AGENT (NACl)
 FIXER (SODA ASH)
 NEAUTRALISEING AGENT
 SOAPING AGENT
 FIXING AGENT
Select RFD fabric  
↓ 
Recipe making 
↓ 
Select dyes  (Reactive dye)
↓ 
Dyeing 
↓ 
Hot wash 
↓ 
Neutralization 
↓ 
Soaping 
↓ 
Cold wash 
↓ 
Drying 
 POLYESTER RFD
FOR POLYESTER RFD ON JET (READY FOR DYEING) 
 SOAP (1.5gpl)
 STAIN REMOVER (2gpl)
 LUBRICENT (1.5gpl)

For RFD: 
 RT 10 min RT 20 min 110’C cool
110’c 20 min hold Drain
Hot wash:
 80’C 10 min Drain
 Hold

Cool wash:
 Room temp. 10min drain SEND to Stenter
 POLYESTER DYEING

 LEVELING AGENT
 LUBRICANTING AGENT
 ACID BUFFER
 ANTIFOAMING AGENT
 PH MAINTAINER
 DISPERSING AGENT
 ANTIREDUCING AGENT
 DYES FOR POLY/ POLY-CATIONC FABRIC
 REDUCTION CLEARING AGENT
 Fabric Load 
↓ 
Water Level – As Required 
↓
Raise temp to 60 Degree C 
↓
Raise temp.to 90 Degree C & run time 10 min 
↓
Drain 
↓
Water Level – As Required 
↓
Raise temp. to 45 Degree C 
↓
Add Neutracid RBT (Non volatile Acid) & run time 10 min 
↓
Drain 
↓
Water Level – As Required 
↓
Raise temp. to 45 Degree C 
↓
Dye dosing for 10 min 
↓
 Raise temp. to 130 Degree C & run for 45 min 
↓
Drain 
↓
Water 
↓
Cooling at 70 Degree C & sample cheek if shade ok then bath drop 
↓
Hydrose+ Caustic at 80 DegreecC for 20 min 
↓
Hot wash 
↓
Acetic wash at cold temp. for 10 min 
↓
Acetic Acid + Softener is added at 45 Degree C & run for 10 min 
↓
Cold Wash 
 PH AT DIFFERENT STAGES FOR DYEING OF
COTTON:

 INITIAL BATH PH: 6.5-7

 BEFORE SCOURING AND BLEACHING, PH : 5.5-5.8
 SCOURING AND BLEACHING, BATH PH: 10-10.5
 AFTER SCOURING AND BLEACHING, PH: 8.5-9.0
 BEFORE AND AFTER LEVELLING CHEMICALS, PH: 6.7-7.0
 AFTER ADDING DYE, PH: 6.2-6.35
 AFTER ADDITION OF SALT, PH: 7.5-8.0
 AFTER ADDITION OF SODA, PH: 10.5-11.0
 BEFORE HOT WASH PH: 6.8-7.2
 HOT WASH, PH: 8.5-8.7
 TEMP. WITH GRADIENT AT DIFFERENT
STAGES

FOR COTTON:
 BEFORE SCOURING AND BLEACHING, TEMP.: 60* C
 DURING SCOURING AND BLEACHING, TEMP.: 100* C
 AFTER SCOURING AND BLEACHING TEMP.: 80* C
 DURING NEUTRALISATION, TEMP.: 50* C
 DURING ADDITION OF COLORS, TEMP.: 40* C
 DURING EXHAUSTION, TEMP.: 90* C-80* C
 DURING FIXATION, TEMP.: 70* C
 DURING SOAPING, TEMP.: 100* C
 DURING HOT WASH AND NEUTRALISATION, TEMP.: 80* C
 DURING FIXING AND SOFTENING, TEMP.: 45*C
 FOR POLYESTER

 INITIAL BATH PH: 6.5-7.0

 SCOURING BATH PH: 10.0-11.5
 BEFORE ADDITION OF LEVELLING CHEMICALS, PH: 6.0-6.5
 AFTER ADDITION OF LEVELLING CHEMICALS, PH: 4.5-4.7
 AFTER ADDITION OF COLORS, PH: 4.2-4.5
 BEFORE SOFTENER, BATH PH: 6.3-6.8
 AFTER SOFTENER ADDITION, BATH PH: 5.8-6.2
TEMPERATURE FOR POLYESTER

 PRE-TREATMENT TEMP.: 60*C-80*C

 COLOR MIXING TEMP.: 70*C
 COLOR DOSING TEMP.: 60*C
 DYEING TEMP.: 135* C
 SOAPING TEMP.: 100* C
 FIXING AND SOFTENING TEMP.: 45* C
 ROPE OPNER
This machine enables the material coming from the hydro extractor to be
open into proper form so as to make further process easier. It unwinds and
stretches the fabric in rope form.
Rope opener machine is used for tubular knit fabric to make it in open form.
In open form fabric finishing line, rope opener machine is used after 
hydro-extractor, de-watering and drying machine. 
Rope opening is a process that is applied for the  fabric through the
intended break Wales line on lengthwise direction prior to stenter processing.
During slitting, it is required to be aware about the cutting line otherwise, 
fabric faults can be occurred there. 

FUNCTION OF THE SLITTING MACHINE:

 Used to remove excess water after pretreatment and dyeing.
 To slit the tube fabric by the knife for opening of the fabric and ready for
stentering.
 Delivered fabric in crease free state.
 Before squeezing balloon is formed with the help of compressed air
passing by a nozzle or air sprayer.
 It can control the diameter of fabric and GSM and shrinkage by over
feeding mechanism.
 FINISHING:
These are the parameters which are checked on finished fabric…
 WIDTH
 G.S.M.
 EPI
 PPI
 WARP SHRINKAGE%
 WEFT SHRINKAGE%
 WARP TEAR STRENGTH
 WEFT TEAR STRENGTH
 WARP TENSILE STRENGTH
 WEFT TENSILE STRENGTH
 PILLING TEST
 RUBBING FASTNESS (DRY)
 RUBBING FASTNESS (WET)
 WASHING FASTNESS C.C.
 WASHING FASTNESS S.C.
 QUALITY ASSURANCE
OBJECT OF Q.A
FUNCTION OF Q.A. DEPARTMENT
 YARN TESTING
 FABRIC TESTING AFTER WEAVING
 FINISHED FABRIC TESTING
 DYES TESTING
 CHEMICAL TESTING
 TESTING ON CHEMICALS

 PHYSICAL APPEARANCE
 COLOUR
 MOISTURE CONTENT
 SOLID CONTENT
 PH
 SOLUBILITY
 SPECIFIC GRAVITY
 TESTING ON DYES

 COLOUR
 PHYSICAL APPEARANCE
 DELTA E
 RUBBING FASTNESS
 WASHING FASTNESS
 LIGHT FASTNESS
 MACHINES/INSTRUMENTS IN Q.A.
DEPARTMENT

ABRASION RESISTANCE (ASTM D-4966)

 Wt. used for abrasion test-12kpa
 No. of specimen-4
 No. of cycles-as per requirement
PILLING RESISTANCE (ASTM D-4970)
 Wt. used for pilling test-3kpa
 No. of specimen-4
 No. of cycles-2000
 SMART RUB CROCK METER (AATCCTM 8)

 COLOUR FASTNESS TO RUBBING IN DRY AND WET CONDITION ARE

CHECKED.
 SAMPLE SIZE-5X13 CM
 LOADING-9N
 CROCKING CLOTH SIZE-5X5CM²
 NO. OF STROKES-10STROKES/10SECOND

SUNTEST CPS+ (ISO 105B-02/AATCC 16)

 LIGHT FASTNESS TESTER
 LIGHT SOURCE-20 ARTIFICIAL FADING UNIT
 DWELL TIME-20HOURS
 UNISTRETCH 500
FUNCTION-
 TENSILE TESTER (ASTMD5034/D2261)
 TEAR TESTER (ASTM2261)
 PEEL BOND TEST (ASTMD2724)
 LEA STRENGTH TEST (ASTMD1578)
 SINGLE YARN STRENGTH
 RKM
SAMPLE SIZE-
 TEAR – 75X200 MM
 TENSILE -100X150 MM
 PEEL BOND – 150X75 MM
 LEA – 120 YARDS
 
 WASHING MACHINE (ISO6330

 USED FOR MEASURING SHRINKAGE% IN WARP AND WEFT DIRECTION.

 SAMPLE SIZE- 50X50CM²
 SHRINKAGE% IN WARP = TOTAL DEVIATION IN WARP/3%
 SHRINKAGE% IN WEFT = TOTAL DEVIATION IN WEFT/3%
PH METER
 USED FOR MEASURING PH OF CHEMICALS.
 PH < 7 ACIDIC
 PH >7 ALKALINE
 PH =7 NEUTRAL
 
 FINISH FOLDING
 Perch machine check: shade% centre to selvedge effect, Repeat Size
 Finished fabric are inspected and dispatched after giving point.
MACHINES:-
 STATING MACHINE FOR CUTTING FABRIC
 ALMAC INSPECTION MACHINE
 After Q.A. approval fabric is send to FINISH FOLDING department for inspection.
 There are 2 checking standard-
 POINT SYSTEM
 FLAG SYSTEM
 After inspection fabric cut as requirement and make packing list.
 Then pass this list to marketing department.
 Marketing department send this list to customer.
 If sample is passed by customer then finish folding rolled the fabric and dispatch it.
 These are some defects which is inspected by finish folding department…
 DISCRIPTION OF LAB
INSTRUMENT
COPOWER AUTOMATIC DISPENSING SYSTEM
 NO. OF BOTTLES FOR DYES AND CHEMICALS – 72
 NO. OF BOTTLES FOR AUXILIARIES – 5
SPECTROPHOTOMETER
 MODEL – COLOUR I7
 MAKE - MACBETH
 USED FOR COLOUR MATCHING, SHADE CORRECTION & RECIPE
FORMULATION.
 LIGHT SOURCE – D65-10, TL84-10, F02-10
STARLET INFRARED BEAKER DYEING MACHINE

 NO. OF MACHINES – 4
 HEATING – INFRA RED RADIATION
 NO. OF POTS – 24 POTS / MACHINE (IN 3 MACHINES)
 SAMPLE SIZE IN 3 MACHINES – 10 GM. MAX
 NO. OF POTS – 4 POTS / MACHINES (IN LAST MACHINE)
 SAMPLE SIZE IN LAST MACHINE – 50 GM. MAX
 SPEED – 45 RPM
 MLR – 1:10
THANK YOU