Professional Documents
Culture Documents
INTERNSHIP REPORT
BY
STUDENTS OF
MEHRAN UET JAMSHORO.
B.E (Textile Engineering) 4TH Year
(11 BATCH)
MOHAMMAD YOUSIF
11TE72
SADAM HUSSAIN
11TE75
MUJAHID MEHDI
11TE83
TANVEER HUSSAIN
11TE84
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We
proudly present our report which is based on Wet-processing. For this report we
are extremely thankful tothe talented people that worked and helped us in
sortingout our circulated questionnaires and confusionthroughout the
internship especially we would like tothanks the skillfulpersonalities and
workers whos co-operating was verybeneficial & studious for us.
Gray Manager
Pretreatment Manager
Mr. Kashif
Dyeing incharge
Dyeing department
Mr. Sarfraz
Printing department
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WET PROCESSING:
It is sequence of processes where fabric is treated in wet condition.
There are mainly six departments in wet processing.
1.
2.
3.
4.
5.
6.
Gray or Grayish
Pretreatment
Dyeing
Printing
Finishing
lab
GRAY
Gray department is the first and foremost department of any wet processing
industry. In Gray department inspection of fabric and grading of fabric is done. In
popular mill 10% fabric is inspect and checked if fabric comes from other mill. And 100%
fabric is inspected, if fabric comes from its own company (popular mill).
GREY DEPARTMENT DEALS:
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Total meter
Current meter
Width
Hanging thread
Oil stain
Cut pick
Miss pick
Double pick
Crack
Slubs
As it is
Scrap
Sorting
Reprocess
Concession
other
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PRETREATMENT
It is set of processes where fabric is made ready for dyeing or printing process. The following
processes are carried out in pretreatment department:
SINGEING:
Singeing is the first pretreatment process in which protruding fibers are burn out through
burning.
DESIZING:
Desizing is the second process of pretreatment, in which the size material is removed from the
fabric. It is very necessary to remove size material from fabric so as to make the fabric
hydrophilic because the size material (starch) which is appliedmakes the fabric hydrophobic in
nature due to its insolubility. Extremely enzymatic desizing and acid desizing are carried out in
production level but enzymatic desizing is more common and eco-friendly than the acidic
desizing.
Enzymatic desizing:
It is vast used method and slow method than acid desizing, but very cheap and reliable.After
application of enzymes, 8 to 12 hour rotation time is given for completionof process.
Polyethylene begs are wound on fabric for maintain the temperature of fabric at rotation time.
Acid desizing:
This is very rapid but risky type of desizing. In acid desizing, there is no need of temperature
which is given in bath. This method is done mainly for demineralizationof fabric which helps in
bleaching process as it chalet out the metal/ iron ions (which cause pin hole problems).
SCOURING:
In this process oils, waxes, dust, and dirt are removed from the fabric. This is done in three
steps:
I.
II.
III.
Saponification
Emulsification
Detergency
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BLEACHING:
It is process of pretreatment in which we remove the natural color pigments, chlorophyll and
xanthophyll.
Bleaching is done by two ways, simple bleaching and solomatic bleaching. Simple bleaching is
a process in which scouring and bleaching are done separately but in solomatic bleaching
scouring and bleaching takes place in same bath.
MERCERIZATION:
It is process of pretreatment used to increase the dye uptake of fabric by swelling. In
mercerization actually kidney shape crossection of cotton fiber is coverted into round or oval
shape and due to removal of caugulations dye uptakes is increased.
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OSTHOF-SENGE:
In Popular Fabrics there are two Osthof-senge machines are installed
I.
II.
OSTHOF-SENGEPK93
OSTHOF-SENGEFRG56
OSTHOF-SENGE PK93:
Specification:
Machine speed:
Total threading length: 40m
Fabric width process: 39-68
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OSTHOF-SENGE FRG56:
Specification:
Machine speed:
Total threading length: 40m
Fabric width process: 39-68
GOLLER BLEACH:
In this machine scouring and bleaching is carried out. In this machine one steamer that why
only one process can be carried out either scouring or bleaching or solomatic bleaching.
Machine specification:
Machine name:
Model no. :
Machine speed:
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Machine specification:
Machine name: Benninger machine
Model no. : CH-9240 uzwil 1999
Machine speed: 50-100 m/min
Fabric width process: 120-128 max
Steamer: 01
Washing tanks: 06
GOLLER MERCERIZATION
In Popular Fabrics there is one Goller mercerization machine.
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DYEING
Adding color to textile product such as yarns, fibers, and fabrics is known as dyeing. There are
four main types of the dyes are usually used in Popular Fabrics:
1. Reactive dye:
2. Disperse dye:
3. Pigment dye:
4. Vat dye:
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x g/l
5 g/l
5 g/l
15 g/l
250 g/l
20 g/l
5 g/l
8 ml/l
2 g/l
x g/l
12 g/l
0.5 g/l
20 g/l
100 g/l
1 g/l
x g/l
1 g/l
1 g/l
0.5 g/l
1 g/l
x g/l
40 g/l
0.5 g/l
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4. For vat:
Pad dry:
Vat dye
Vat develop(reduction):
Sodium hydrosulfite
Caustic soda
Oxidation:
H2O2
Acetic acid
5. R.C (reduction cleaning):
Sodium hydrosulfite
Caustic soda
x g/l
40 g/l
40 ml/l
5 g/l
2 g/l
40 g/l
40 g/l
MACHINES
There are sevenmachines are used in Popular Fabrics Mill:
1.
2.
3.
4.
5.
6.
7.
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Machine parts:
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
Machine parts:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
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Machine Specification:
Recipe:
Machine parts:
I.
II.
III.
IV.
V.
VI.
Jigger Machine:
Jigger machine is old machine and categorized in exhaust dyeing machine. In
Popular Fabrics Mill, there are three Jigger machines and following process can be achieved:
Washing
Reduction cleaning
Desizing
Scouring
Bleaching
Dyeing
Vat dyeing develop
Washing
Principle of Jigger machine is very easy. The two rollers, one is unwound fabric roller and other
is winding roller in which processed fabric is wound. In between these rollers a bath in which
chemical is filled according to process.
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Recipe:
For Vat reduction:
Sodium hydrosulfite
Caustic soda
Temperature
For vat oxidation:
H2O2
Acetic acid
Temperature
30-40 g/l
30-40 g/l
70-75 oC
10 g/l
10 g/l
30-40 oC
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Drying machine:
It is used to dry fabrics. In Popular Fabric Mills, there are two drying machines. It works on basic drying
principle.
Main Parts:
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PRINTING
Coloration of fabrics on a pre-determined area of the fabric OR Technical dyeing on the pre
decided area of the fabrics is called printing.
TYPES OF PRINTING:
1. Pigment dye (paste form)
2. Reactive dye (powder form)
ENGRAVING DEPARTMENT
This department makes the sheets for printing known as screens.
There are two types of engraving
1. Rotary engraving
2. Flat engraving
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ROTARY ENGRAVING:
Engraving means exposing of design on the screen. These screens are made of nickel. Following
are parameters concern with screen:
Screen size (length):
Screen size
1280 mm
1620 mm
1850 mm
2650 mm
3050 mm
3500 mm
Screen repeat (diameter):
64 mm
82 mm
91.4 mm
101 mm
Screen mashes:
20 /cm
40 /cm
60 /cm
80 /cm
125 /cm
135 /cm
135 /cm
155 /cm
165 /cm
195 /cm
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Manual machine
Ink-jet machine
Manual machine now a days, not used.
Inkjet machine:
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Color preparation:
For printing color is prepared in paste form. In popular Fabrics Mill, there are two types of paste used:
Pigment paste
Reactive paste
Recipe:
1000 kg of pigment paste:
Urea
Liquor ammonia
Thickener
Binder
1000 kg of reactive paste:
Urea
Soda bicarbonate
Resist salt / RG
Thickener
4%
1.4 %
4 % (further depends on design and screen)
3%
15 %
4%
1.5 %
4 % (further depends on design and screen)
Note: IPS machine is used for color paste preparation. In Popular Fabric Mills, this
machine is out of order now days.
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FINISHING
Finishing department is the last department of wet processing. Here we give
additional application to get more qualitative fabric like here we increase the softness;
shininess, luster, absorbency and lot of more properties of the fabric
The fabric treated here mainly two purposes
1. Equalizing
2. Finishing
1 Equalizing:
Equalizing is the process in which we parallelize the warp and weft yarn of the fabric.
This process is mainly done after bleaching and mercerization. In this process no recipe is
needed, just treated with water in trough and pass through machines parameters of finishing
department.
2 Finishing:
Finishing is the process in which we give additional properties on to the fabric this is
done after dyeing or printing of fabric. In this process we need proper recipe for making
finished fabric. Recipe is depend on endure quality and customer requirements. Mainly finished
goods contain more softness luster shines easy handling.
Types of Finishing
There are two types used to make finished fabric
1 Chemical
2 Mechanical
CHEMICAL METHOD:
Recipe:
For soft finishing:
Poly ethylene soft XL
Silicon soft CSE
Binder 77
Libra fix ML
Acetic acid
For hard finish:
UTM 50 (PVA)
Wet Optra
25 gm/l
15 gm/l
10 gm/l
5 gm/l
.25 gm/l
(crocking improves)
(washing improves)
(ph. control)
90 gm/l
0.5 gm/l
(wetting agent)
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(increase strength)
Bruckner stenter
Bruckner stenter
Bruckner stenter
Bruckner stenter
model 1995
model 1995
model 2001
model 2003
120
80
102
125
VI.
VII.
VIII.
IX.
Scary: Scary is used to store extra fabric length as to connect new batch
Composter: It maintains the fabric speed and gives proper tension
Trough: It is a box in which required chemical recipe is putted maximum 40-50 liter
Padding: This is used to squeeze the fabric and to make even chemical pickup%
throughout fabric.
Mahlo: Mahlo is a mechanism which parallelizes the weft yarn of fabric. Mahlo is
basically set of rollers. Three SQ rollers responsible for cross control and two bow rollers
responsible for curve control.
Chain: It is used to make fabric in open width form and clips are used to hold the fabric
width
Heating chamber: It is specially mechanism in which fabric is to dried at 120C-200C
temperature
Cooling roller: It is two heavy steel drum which is used to cool down the dry fabric
Batch: To wound in proper way
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MECHANICAL METHOD:
In Popular Fabrics Mill three machines are used for mechanical finishing. Mechanical method
isan especial setup in which finishing on fabric gets from machines moving parts and no
additional chemical require.
1. Peach machine
2. Calendar machine
3. Sanforizing machine
Peach machine:
This machine is used for softening on fabric. When one side peach paper is used then it is
known as emerzing finish and when both sides peach paper is used then it is known as Falaen
finish. Different peach papers are used, depends on fabric quality.
Machine specification:
Company
sucker muller hacoba
Model
2000
Type
SF-4C
Machine speed
30 m/min
Main parts of machine:
Trolley
Brushing device
Tensioning and guide rollers
Peach mechanism:
o 4 peach paper rollers
o 2 tape rollers
o 5 top steel rollers
Tension rollers
Wooden roller
Trolley
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Calander machine:
This machine is used for shininess purpose.
Machine specification:
Company
Ramisch Kleinewefers
Model
1996
Type
RKK
Main parts of machine:
Batcher
Tensioning and guide rollers
Curved type steel roller
Three large cylinders connected with each other:
o Chile cylinder/ taflon rubber cylinder: containing cold water which gives
moisture to the fabric.
o Steel cylinder: containing oil which gives shines to the fabric. Depends on
fabric quality hot oil or cold one used.
o Wooden cylinder
Tensioning rollers
Batcher
Sanforizing Machine:
This machine is used for shrinkage control (increase or decrease) and also softening provides.
Machine specification:
Company
Batcher
Scary
Tension rollers
Steel cylinder: pre moisture provider.
Sanfirize mechanism:
o Rubber belt which connects two roller (start and end)
o Steel cylinder: steam in side cylinder.
o Through/bath: water in the bath.
Two pressures used:
o Pressure for shrinkage control. This pressure moves cylinder up and down.
o Pressure for rankle control. This pressure contract and expand rubber belt
curve.
Dryer:
o Large cylinder
o Blanket around cylinder
o Steel cylinder
Batcher
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LABORATORY
Laboratory is the place where all the (gray fabric testing, dyes, pigments, finishes and other auxiliaries)
are inspected and tested. Actually all the decisions are made after the approval of lab.
Popular mills lab is categorized in three sections:
Physical testing
RND (chemical testing)
Lab dyeing or lab dip
Physical testing:
In physical test, many tests are carried out but in Popular Mill following tests are carried out:
Size content:
It is used to check the size content/material on fabric.
Tagwa solution is used. Just drop two or three drops of tagwa solution on fabric,
size content is known by this method,
Tagawa scale is used for measuring the size material. The impact of tagawa
solution is compare with tagawa scale and measure the actual size material.
Scale contains 1-9 readings and acceptable range is 4-5.
PH of fabric:
PH is power of hydrogen.
Universal PH solution is used.
The PH scale is 1-14 and 7 is neutral reading.
Blend ratio (PC):
Used to measure the ratio of PC blend.
Dry the PC sample.
Weigh the PC sample
PC sample is dipped on sulfuric acid of 70% concentrsted solution for about
10mins.
The cotton material is dissolvedin the solution because cotton is sensitive to acid
but this solution does not effect polyester.
Sample is dried and sample is weighed.
Ratio of polyester of pc blend is calculated by following formula :
(Weight of first sample weight of 2nd sample/weight of 1st sample)* 100
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Absorbency test:
Cut three sample large then 10cm. (left, center and right)
Mark the 10cm scale on sample through stamp.
Dip end of sample in tarquish solution for one min.
Through capillaryaction solution travels upward.
Hence absorbency is measured.
Whiteness test:
This is simply measure on data color spectrometer.
Three test are carried out (left, center and right)
70-80% whiteness is acceptable.
Pilling test:
This test is done on NC-Martindale (England).
Cut two pieces of fabric front and back for using pillar cutter.
Mostly 1000 rotations for good result and also set on customer demand.
After completing test, sample is compare with standard card .
GSM test:
Universal GSM cutter is used for cutting the sample.
Just weigh the sample, GSM is achieved.
Dyeing tests:
Rubbing fastness test:
Crock meter machine is used for rubbing test.
Take sample for test and fixe on machine.
Take two standard white samples, one is dry and another is 100% wet.
First fix dry sample in its position and start machine.
According to test method rotations are selected, here 10 rotations are
set.
After completing task, check the stains on white sample and compare
with gray scale for giving reading.
Now same way wet sample is fixed and checked.
Washing fastness test:
Cut the sample of 10*4 cm and attach with un-mercerized fabric of 10*4 cm.
Prepare solution according to test method and put onto the pot.
Now put the sample onto the pot and pot is then fixed on machine.
Temperature and time is giving according to test method.
After completing time, sample is dried.
Now match the staining on fabric with standard gray scale and give reading.
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Perspiration test:
Cut two pieces of sample and also take two pieces of un-mercerized
fabric.
Attach one sample and one un-mercerized piece.
One sample is dip on acidic solution while other dip on basic solution for
2-3mins.
These samples are then brought on per-spirometer.
Samples are placed on sheet/plate.
Seal the machine & apply the standard weight & fixed the position with
nuts.
Remove the weight & give time about 4hours.
Finally check the staining on un-mercerized fabric and give readings.
Shrinkage test:
Mark the fabric with standard area of 50 cm. Two areas are marked.
This fabric is put on to the washing machine:
o Standard washing machine
o Manual washing machine
After washing fabric is squeeze on spun machine.
Then after fabric is dried on drying machine.
Now finally check that how much shrinkage in the sample.
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Folding
This is the final department of processing department. Taking samples from each and
every roll and faults are detected and the grading is done. The rolls are separated in shade wise.
The defected fabric is separated. The grading is done a/c to the customer requirement.
There are two types of machines used in Popular Fabrics Mill namely,
Rolling machine.
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