Industrial Training Module for Textile Students

1. Importance of industrial training in textile branch

Textile department of SVITS is responsible for human resource

development for textile technology in India. Department of Textile
Technology is imparting education in crucial areas of textile
technology and its application.
Industrial exposure is very important part of student program, which
gives them an opportunity to get acquainted with the allied sector
of the Textile Industry. Being part of an organization gives them
invaluable insight in to the working and the dynamics of the
company. This internship also helps students to learn and improve
their interpersonal communication skills with colleagues, peer group
and workers.
To improve and enhance the practical knowledge about the
industries its working and culture.
Fields like Medicine, CA, Law are having 50 to 60 percentage of
practical exposure to improve their understanding similarly Textile
Technology is a branch which requires about 40 to 50 percentage of
industrial exposure.
Purpose of industrial training is to increase the number of visit so
that practical advancement in industries can be understood by the
students with ongoing theoretical curriculum.

2. Training schedule

3rd year students:

Extensive exposure for:

To observe and document different types of available machinery, their

features, specification, material process flow including the process
parameters available in the areas of:
o Spinning & winding section
o Weaving section
o Knitting section
o Dyeing, Printing and Finishing section
Quality parameters, waste percentage of raw material, intermediate
product, and final product of above mentioned different processes
should be noted. Defective samples may be collected from the
different sections like, spinning, weaving, knitting, dyeing, printing and
finishing and the causes of the defects and the processing faults may
be ascertained and their remedies may be suggested.

 To calculate the various productivity and the efficiency of intermediate

process.
If possible the costing/pricing may be ascertained fo0r the value
additions stage wise /section wise
Suitable yarn/fabric samples may be collected and documented in the
form of file giving the specifications and the processes followed.

Details about company

Company profile/Company details/Product profile with business
details
Organization Chart with job description of the core departments
Work process
Process flow and material flow in the company (documented as
flow process diagram)
Process flow diagram with time duration for each activity/process
Material flow diagram with value addition in each activity/process
Technologies involved
Machinery Infrastructure in the factory/organization
Documentation of technologies and equipments involved working
& specifications
Particularly in summer vacation for 3 weeks or 1 month. Study
particular industry problem and try to give solution either individually
or in group.

4th year students:

Major projectindividual or in small group for 15 days.

The students are supposed to study manufacturing process

thoroughly, observe and execute (with able guidance from department
in charge) different department functions and executes small projects
as per organizational need. They are expected to document the
different department functions & working procedures, analyze them
thoroughly and write down probable suggestions. They must gain
hands on experience on various manufacturing processes like cutting,
sewing, finishing, checking, data generation, reporting, and use of IT
tools in various stages of garment manufacturing. They also must
work on a mutually identified (with the organization) topic/area/brief
as projects.

3. Frequency of visit

Year
3rd year

4th year

Number of
visits
th
5 sem : 1 or2
visits
6th sem: 1 indus
training
7th sem : 1 or2
visits
8th sem : 1 indus
training with
project preparation

Duration
10 days
3 weeks or 1
months
10 days
2 weeks

4. Procedure

To get permission from the Industries either through letter, personal contacts,
or contacts from the students.
Provide transport facilities for the students and staff.
Refreshments for the students and staff.

Training module :Guidelines for Spinning

General information:
1. Name of the mill, address, and the year of establishment
2. No. Of spindles- warp weft, doubling and total
3. Yarn count spun -warp , weft , others
4. Average count of spinning department
5. Shift wise no. Of workers
6. No of preparation in spinning
7. Mill building, type, roof plan (layout)
8. Quantity of cotton consumed per month in kg
9. Quantity of yarn produced in kg per month
10. Plans of various departments showing the general layout of the department

Mixing and blow-room:

1. Layout plan, lighting scheme and fire prevention method.
2. Handling and transportation of bales.
3. Temperature and humidity.
4. Mixing( if possible) type and cotton used, assessment of staple length, trash
content.
5. Wastes (in detail) with resale realization rate and disposal.
6. Speeds and setting of various beaters.
7. Productive and ancillary workers- shift wise.
8. Lap wt, wt/yard, tolerance limit, lap rejection percentage etc.
9. Machinery maintenance program.
10. Quality control program.
11. Production per hour, operative hours and machine hours per 100kg.
12. No of bales consumed and the weight of cotton used.
13. Contamination detection system and sorting.
14. Air supply balancing between machines and lines.
15. No of beating points and description of beaters.
16. Type of blender/mixer.
17. Make model of machines.

Carding
1. Layout plan, lighting scheme and fire prevention method.
2. Material handling.
3. Temperature and humidity.
4. Speeds of various pats like cylinder, licker in, doffer, flats, doffer comb,
stripping roller, grinding roller Machine make and model.
5. Hank of lap feed and hank of card sliver.
6. Draft constant and production constant of card.
7. Setting of card, size of the card.
8. Waste extraction and disposal of waste.

9. Frequency of stripping, grinding, recloting, etc.

10. Productive and ancillary workers - shift wise.
11. Production per hour, operative hours and machine hours per 100kg.
12. Maintenance schedule
13. Quality control program.
14. Can size and special features (f any) fitted on card.
15. Web weight.
16. Nep study.

Draw frame
1. Layout plan, lighting scheme and fire prevention method.
2. Material handling.
3. Temperature and humidity.
4. No. Of draw-frames, no of passages.
5. Drafting system for a draw-frame.
6. Sliver hank and wt. Tolerance limits, can size.
7. Hank of sliver fed and hank delivered.
8. Production per hour, operative hours and machine hour per 100kg.
9. Productive and ancillary workers - shift-wise.
10. Maintenance schedule.
11. Quality control program.
12. Special features.
13. Study of autoleveller.

Speed frame
1.Layout plan, lighting scheme and fire prevention method.
2.Material handling.
3.Temperature and humidity.

4.No of roving frame, spindles.

5.Spindle speed.
6.Twist multiple and TPI used for each preparation.
7.Draft, hank fed and hank delivered.
8.Production in Kg/spindle/shift.
9.Drafting system, can size, roving bobbin size.
10.Maintenance schedule, roller setting and gauge used for different cottons.
11.Productive and ancillary workers - shift wise.
12.Production per hour, operative hours and machine hours per 100kg.
13.Quality control program.
14.Breakage rate, waste details, doffing time and n. Of persons for doffing.
15.Threading method used for back and front row bobbins.
16.Various settings when count, hank, twist, etc are changed.

Comber
1. Layout plan, lighting scheme and fire prevention method.
2. Material handling.
3. Temperature and humidity
4. No. Of sliver lap, ribbon lap, comber - type and make.
5. Machine particulars and processing particulars i.e. Hank of sliver, draft, no of
doublings.
6. Production of sliver lap, ribbon lap (lap size and weight)
7. Comber setting for different preparations.
8. Speed of sliver lap, ribbon lap and comber.
9. Maintenance schedule.
10. Waste percent for different level of combing.
11. Quality control program.
12. Productive and ancillary workers- shift wise.
13. Special features

Ring frame

1. Layout plan, lighting scheme and fire prevention method.

2. Material handling.
3. Temperature and humidity
4. No. Of warps and weft ring frames with spindle/frame.
5. Spindle speed, front roller speed, twist constant, draft constant, drafting
arrangement.
6. TPI, draft(back and front zone ), twist factor used, traveler used.
7. Hank of sliver fed and count spun.
8. Production per frame per 8 hours, operative hours and machines per hour.
9. Yarn breakage rate, detailed study of yarn break.
10. Productive and ancillary workers - shift wise.
11. Quality control program
12. Maintenance schedule.
13. Study of ring data.
14. Details of spacers and traveler for different counts.
15. Compact spinning system and its working.
16. Spinning cycle and geometry.
17. Changes in machine setting when count change.

Training module: Knitting department

1. Material handling.
2. Temperature and humidity.
3. Yarn content of cone or cheese in kg.
4. Types of knots,
5. Maintenance schedule.
6. Quality control program.
7. Productive and ancillary workers - shift wise.
8. Knotters and splicers.
9. Setting at control panel.

10.Information available at control panel.

11.Cone angle, package density, winding angle.
12.Various machine settings.
13.Types of machine-dai, gauze, model ,SL etc.
14.Productive and ancillary workers - shift wise.
15.Name of the fabric.
16.Grey stage dimension - length and width.
17.Finished stage dimensions - length & width.
18.Count of yarn.
19.Machine speed in rpm.
20.Expected efficiency.
21.Production in m or yard/shift.
22.Sorts work and their particulars in the above manner.
23.Number of machine to jobber.
24.Breakage rate study.
25.Layout and lighting system, humidification etc.
26.Quality control program.
27.Different types of waste.
28.Jobber and their work load duties.

Training module : Textile chemistry department

1. Name of the mill/process house and address and date of establishment.
2. Total productivity per day for cellulosic.
3. Total productivity per day for synthetics and blends.
4. Bleaching production per day.
5. Dyeing production per day.
6. Printing production per day.
7. Finishing production per day.

8. Details of sort:
9. Total available area.
10. Area utilization.
11. Layout.
12. Water consumption/day.
13. Electricity consumption per day.
14. Steam consumption per day.
15. Total cost of water.
16. Cost of steam.
17. Bleaching cost per meter.
18. Dyeing cost per meter.
19. Printing cost per meter.
20. Finishing cost per meter.
21. Total processing cost per meter.

Grey room
1. Inspection of goods.
2. Classification of faults.
3. Grey room record.
4. Stitching of goods for preparing lots.
5. Particular of goods in grey room.
6. How are stains removed.
7. Other corrective procedure carried out in grey room.
8. Number of workers in grey room and their functions.
9. Assessment of goods for faults.
10. Preparation of ink.
11. Layout of gray room.
12. Number of stitching machines.

13. Manufacturers of stitching machine.

14. Particulars of thread used in stitching machine with reference to fiber
composition, count, etc.
15. Design of observation table.
16. Number of supervisor per shift.

Bleaching department
1. General sequence of processing various goods (name of sort, width, weight
gm/sq m, finished width)
2. Layout of bleaching department.
3. Name of machinery manufacturers.
4. Bleaching sequence for various sorts.
5. Design of various machinery.
6. Power consumption, water consumption, steam consumption, in each process
and each machine.
7. Formulation of each bleaching process i.e. recipe for ex de-sizing recipe
concentration, time, PH, temperature, express cone, in terms of g/l, owf%, as
per the process.
8. What is the total water, steam and electricity consumption of bleaching
department.
9. Number of workers on each machine with their designation.
10. Total number of workers i bleaching department/shift.
11. No of shift.
12. No of workers per day.
13. Chemical cost of bleaching/ meter.
14. Labor cost of bleaching / meter.
15. Depreciation.
16. Electricity cost, water cost, steam cost per meter.
17. Total cost of bleaching per meter.
18. Rates charge per meter.
19. Details of chemicals consumed in bleaching department per month.

20. Preparation of chemicals and auxiliaries in the mill.

21. Precaution to be taken in bleaching department for obtaining good quality.
22. Loss of width and weight of each sort in bleaching.
23. Production and efficiency of each department per shift.
24. Total bleaching production per day.

Mercerising
1. Layout of mecerising department.
2. Number of ends and their dimensions and storage capacity.
3. Number of mercerizing machine their type (pad chain, pad less, chinless)
manufacturers.
4. Design of mercerizing machine.
5. Concentration of caustic received through tankers (testing of caustic dye by
different methods)
6. Concentration of caustic for mercerisation.
7. Name of the wetting agent its concentration in mercerization.
8. Mercerisation time, temperature.
9. Essential steps for obtaining goods.
10. Faults and their remedies in mercerising.
11. Barium number for each sort.
12. Width of each sort after mercerization.
13. Number of workers and their designation.
14. Cost of chemical per meter.
15. Cost of labor per meter,
16. Cost of electricity/ steam per meter.
17. Total cost mercerisation.
18. Controls in mercerisation.
19. Production/ shift and efficiency.
20. Total production / day.

21. Caustic requirement wetting agents requirement/month.

22. Quality mercerized per month.
23. Percentage of caustic recovered.
24. Diagram & function of caustic.
25. Cost of recovery.
26. Electricity and steam consumption.

Dyeing department
1.layout of dyeing department.
2.Machinery in dyeing department. Number of machines, manufacturers.
3.Electricity consumption, steam consumption, water consumption on each
machine.
4.Speed and capacity of each machine.
5.Name of the sorts dyed their particulars and their end uses.
6.Cellulosic dyeing percentage and synthetic dyeing percentage.
7.Dyeing production per day.
8.Number of shifts.
9.Total dyeing production/day.
10.Dyes uses & their percentage.
11.Various dye consumption (kgs/month, auxiliaries and chemicals consumption
kg per month with name of manufacturer)
12.Detailed dyeing recipe of every color ( which should include shade,
concentration of dye, auxiliaries, chemicals M:L ratio, time , temperature, no
of ends given)
13.Percentage of redyeing,
14.Defective cloth after dyeing.
15.Total dyeing cost.
A. Cost of dyeing
B. Cost of chemicals.
C. Cost of labor

D. Cost of power steam and power

16.Quantity of water required per day.

17.Normality of water used.
18.Number of workers, their designation for each individual machines.
19.Total number of workers.
20.Problems in dyeing and their remedies.
21.Rates charges for dyeing for individual sort.
22.Number of technicians and their designation.
23.Total steam, electricity, water consumption per day.
24.Matching of shades.
25.Correction of faulty shades.

Finishing department
1. Layout of finishing department.
2. Machinery, numbers and manufacturers.
3. Power consumption, steam consumption, of individual machinery.
4. Speed and efficiency of individual finishing machinery.
5. Production/shift.
6. Total production/day.
7. Total electricity consumption per day.
8. Total steam consumption per day.
9. Various finishing operations carried out for various sorts.
10. Details of each finishing process, formulation, recipe, temperature, time, etc,
of each finishing. Wash in wear, anti crease, water repellent, shirting, suiting,
etc (samples of both grey and finished fabric if possible).
11. Function of individual auxiliaries use in various finishing formulation,
manufacturers names.
12. Total finishing cost for individual various types of finishes/meter, chemical
cost , labor cost.
13. Rates charged per meter.

14. Number of workers on individual machine & their designation.

15. Total number of workers in finishing department.
16. Number of supervisors/day.
17. Problems and remedies in various finishing processes.
18. Grey width and finished width & their testing.
19. Desired properties of finished goods.
20. Construction, working, & problems of various machinery & corrective
measures.
21. Maintenance.

Testing and Quality control

How are the following tested in mill
1. Sodium hydroxide
2. Sodium carbonate
3. Hydrochloric acid.
4. Sulphuric acid
5. Acetic acid
6. Hypochlorite
7. Hydrogen peroxide
8. Sodium hydro sulphide
9. Soap
10. Detergent.
11. Water softener
12. Optical brightener
13. Wetting agent
14. Dispersing agent
15. Retarding agent
16. Surface active agent
17. Rangolite-c

18. Zinc sulphoxylate formaldehyde

19. Enzymes
20. Glauber salt, formic acid
21. Sodium sulphide
22. Deformars

Training module : Garment industry

General information
1. Name of industry, address, year of establishment.
2. Number of machines - spreading, cutting, sewing, pressing, etc
3. Types of garment produced.
4. Shift wise number of workers and number of workers in each section.
5. Name of countries where garments exported.
6. Plan of various departments showing general layout of the department
including building type, roof plan.
7. Safety measures provided.
8. Production per day.
9. Sample preparation method and approval.

Fabric inspection
1. Fabric purchasing order and method.
2. Details of fabric inspection machine.
3. Role of fabric inspector.
4. Different fabric defects.
5. Marking of fabric defects.

Marker planning and pattern making

1. Marker planning/ pattern making - manual, computerized, CAD.

2. Measurement taking, size chart, block preparation method.

Spreading, Cutting and Fusing

1. Spreading method and machinery details, ply tension for woven and knitted
fabric.
2. Cutting machinery, type of knife used, specification, methods, advantages and
disadvantages of different cutting machine & their applications.
3. Fusing machinery specification, method of fusing.
4. Maintenance of machines.

Sewing
1. Specification and features(types of stitch, speed, name of different parts,
application, etc) of different sewing machine.
2. Feed mechanism used, needles used, any extra attachment eg guide, folders,
etc. Used in machines, tension adjustment etc.
3. Working of embroidery machine.
4. Labels sewing.
5. Maintenance of machine.

Pressing and Finishing

1. Different types of pressing table.
2. Pressing equipment.
3. Working of thread sucker.

Quality checking of Garments

1. Checking of pattern, size, stitching defects, labels etc.
2. Problems of puckering causes and remedies.

Other information

1. Role of merchandiser.
2. Importance of industrial engineering in that industry.
3. Idea of garment dyeing.
4. Fabric washing before garment manufacturing.