TEXTILE DYEING INDUSTRIES IN INDIA

Textile dyeing industries need huge quantity of water for textile dyeing, which they normally
pump out repeatedly from the ground or natural water sources resulting in depletion of ground
water level.

In the dyeing process textile industries generate huge quantity of toxic effluent containing colors,
sodium sulphate, sodium chloride, sodium hydroxide and traces of other salts. These are
generated after dyeing and after washing of garments / fabrics. After dyeing the waste water
produced is called Dye Bath water and after washing the waste water generated is called wash
water. Dye Bath contains higher solids in the range 4-5% whereas wash water contains only 0.5-
1% solids.

Based on the above mentioned fact SSP has developed a technology which can process such
harmful toxic effluent water and transform it into reusable water. Thus the textile industries will
have the advantage of using the same water in the dying process repeatedly; also the salt used for
dyeing can be reused or sold in the market.

The technology offered by SSP can overcome all problems pertaining to environmental pollution
in respect to textile dying industries.

The basic thrust of the technology is to convert entire quantity of effluent to zero level by
separating water and salt using evaporation and separation technology.

The concept and the treatment are based on the removal of the entire COD/BOD and the
condensate coming out to meet the fresh water quality requirement in the process.
TEXTILE BLEACHING, DYEING, PRINTING AND FINISHING, TEXTILE
AUXILIARIES

Textile processing is one of the important industries related with textile manufacturing
operations.

Textile processing is a general term that covers right from singeing (protruding fiber removal) to
finishing and printing of fabric. The various steps a fabric goes into are singeing, desizing,
bleaching, dyeing, and finishing.Bleaching is a process to make the fabric or yarn look brighter
and whiter. Dyeing is a process of applying coloring matter directly on fiber without any
additives.Finishing is the final process to impart the required end use finishes to the fabric and
lastly the printing process on fabric which is a science as well as an art.Textile auxiliaries such as
chemicals are used for all stages of the textile manufacturing process that is from pre-treatment
to dyeing and printing and finishing.

The textile industry occupies a leading position in the hierarchy of the Indian manufacturing
industry. It has witnessed several new directions in the era of liberalization. While textile exports
are increasing and India has become the largest exporter in world trade in cotton yarn and is an
important player of readymade garments, countrys international textile trade constitutes a mere
3% of the total world textile trade. Several mills have opted for modernization and expansion
and are going in for export-oriented units (EOUs) focused on production of cotton yarn. It has
passed through cyclical oscillations and at present, it is witnessing a recovery after a downturn.

Of the entire industry volume of about 5 million tonnes, polyester and polyester filament yarn
account for about 1.7 million tonnes, and acrylic, nylon, and viscose taken together for 300,000
tonnes. The balance is represented by cotton textiles. A majority - some three fourths - of the
textile mills are in the private sector. A few of the units are in the co-operative sector with the
public sector (Central and State) accounting for about 15% of the total.

The textile industry is classified into (i) textile mills comprising composite and spinning mills in
the organized segment, (ii) small powerloom and handloom units in the decentralized segment,
(iii) khadi-based units, (iv)manmade and synthetic fibre and spinning units, v) knitting units, and
(vi) made-ups (garments). Besides, the industry has a large number of small units scattered all
over the country which are engaged in processing, dyeing and printing of yarn, fabrics and for
conversion. The processing units include sizing, desizing, kiering, bleaching, mercerizing,
dyeing, printing and finishing.

The countrys per capita consumption of woven cotton fabrics is estimated at around 16.5 meters.
This has remained almost constant for quite some time with the increased production absorbed
by the expansion in population. Yarn is produced by the mills in the organized segment but is
consumed by powerloom and handloom segments as well. The production of cotton yarn is
divided into three categories, namely, coarse counts below 20s, medium counts between 20s and
40s, and fine counts above 40s. The average count spun has increased from about 25 in early
1960s to about 34 in 1990s. This indicates a change in product-mix in favour of finer textiles and
high value items.
The pattern of production of cloth in the textile industry is amazingly wide with regard to types
of fabrics produced with different mono and mixed materials.

In the conventional ring spinning system, increasing spindle speed beyond a level was
technologically difficult and economically non-feasible. The search for an alternative method of
yarn manufacture led to the development of three new technologies, namely, rotor open-end,
friction and air jet spinning. The spinning limits of the four technologies are 6-12, upto 30, 6-18,
and 20-80, respectively.

A major improvement in weaving efficiency has been brought about by developments in

spinning technology which has enabled production of yarn of higher quality. A major share of the
looms installed in composite mills is now of automatic looms. However, autolooms installed in
the decentralized and powerloom segments are small in number. Shuttleless technology, direct
wrapping, use of splicing technology, automatic doffing and knotting systems, help to increase
mill productivity. Speed of the auto looms or shuttleless looms is 60% higher than that of non-
autolooms.

The textile industry has managed to modernise the spinning sector but there is a long way to go
on the weaving front. India's power loom sector has over 10,000 shuttleless looms as compared
to 150,000 in China. It may be recalled that India today is the third largest producer of cotton,
second largest producer of cotton yarn and the largest exporter of cotton yarn in the world. The
government has, under its new textile policy set an ambitious export target of $50 billion to be
achieved by 2010.

While the Indian textile industry is a premier industry in India with a large domestic market and
sizable exports (considering India's export earnings), it is still a small player in the global textile
market. The global market is expanding (estimated to grow from $ 309 billion to $ 856 billion
by 2014). India has several positive competitive strengths and can benefit from the global
expansion. However, India will have to catch up with modernization by restructuring and
upgrading its operations. It is an imperative and urgent need for the industry to focus on value
added products. With the end of the Multi-fibre Agreement at the end of 2004, the potential is
unlimited, if only the industry gets fully geared up to adopt global standards.
INTRODUCTION

SCOPE OF POLYMERS IN TEXTILE INDUSTRY

Fibers and Polymers, the journal of the Korean Fiber Society, provides you with state-of-the-art
research in fiber and polymer science and technology related to developments in the textile
industry.
Bridging the gap between fiber science and polymer science, the journal's topics include fiber
structure and property, dyeing and finishing, textile processing, and apparel science.

Ranks 9 out of 19 in the ISI category Materials Science, Textiles with an Impact Factor of 0.531.

Aims:
The international bimonthly journal Fibers and Polymers publishes original research results in
the fields of fiber and polymer science & engineering. Founded in the beginning of a new
millennium, Fibers and Polymers starts with international readership and authorship, combining
into one journal such closely related themes as fiber and polymer technologies.
Fibers and Polymers is unique because it covers interdisciplinary areas related to fibers,
polymers, textiles, apparels, colorants, fiber composites, and polymer processing.

Scope:

Chemistry of Fiber Materials, Polymer Reactions and Synthesis

Physical Properties of Fibers, Polymer Blends and Composites

Fiber Spinning and Textile Processing, Polymer Physics, Morphology

Colorants and Dyeing, Polymer Analysis and Characterization

Chemical Aftertreatment of Textiles, Polymer Processing and Rheology

Textile and Apparel Science, Functional Polymers

Polymers in Textiles

In todays world, one cannot think without polymers at each aspect of life. After
agriculture sector, the Textile has taken its own position as 2nd largest Industries for the
obvious reason of human need. Today Textile does not mean only appeal or just simply
dhoti/ sarees , but it has penetrated at each field i.e. in Industrial usages , High ways &
road constructions, buildings , railway trucks, decorative fabrics, medical Textile ,
Technical textiles and what not.

For every factor, polymers are required and at some areas it has become essential.
Today it is gradually by passing natural fibres like cotton, jute etc because of their
limitations in growing and are unable to fulfil such huge requirements in the world of
Textile.

The polymers in Textile in not a new thing. Since the inception of Nylon in the year
1930, it captured a large portion of Industrial yarn and fabrics such as wall ropes, belts ,
tyre cords and then in house hold use such as sarees, swimming costumes etc. Gradually
polyester arrived in 1970 and conquered the world of Textile for its own several positive
properties.

Polymers Natural

Life of finished product More Less

Fabric strength Higher Not that higher

Outlook better comparatively less

Scopes in Elaborate More such as micro, Semi- In natural fibres, all such
Styles /designs dull, full dull, bright, super varieties are yet to capture.
bright, bicomponents, easy
dye, Cataonic dyes.

Fabric manufacturing Less high because of wdg, warping,

cost Sizing

Operational Easier Needs humidification, better

advantages (wvg) preparation if goes for High
 reed/pick and high speed.

Wet process Easier Higher exp. because of de-

sizing, scouring &bleaching.

Daily maintenance of Easier Requires more washing,

dress ironing, etc.

Col. Fastness Better Comparatively less

The Advantages and Disadvantages of Polyester vs. Natural Fibres

Polymer Processing- Spinning Process of Polymers

According to Concorde, polymer processing are the "operations carried out on polymeric
materials or systems to increase their utility." Therefore, polymer processing is done to increase
the value of a polymer in order to obtain the desired shape, properties, and performance for a
polymer article. As far as textile industry is concerned, polymer processing can be explained as
the spinning process for manufacturing polymer fibers that are commonly known as synthetic
fibers.

Spinning of polymers

The polymers of synthetic fibers are almost always derived from by-products of petroleum and
natural gas which include nylon, polyethylene terephthalate, as well as other compounds like
acrylics, polyurethanes and polypropylene. Synthetic fibers, which are produced from these
polymers, are used for making various consumer and industrial textile products ranging from
clothing, home furnishings to conveyor belts. Most of the cellulosic yarns manufactured from
synthetic fibers are produced by extrusion of a thick, viscous liquid through the tiny holes of
equipment called spinneret which forms continuous filaments of semi-solid polymer.

The polymer is at first converted into a fluid state. If it is a thermoplastic polymer then it is just
melted otherwise it has to be dissolved in a solvent or has to be chemically treated in order to
form soluble or thermoplastic derivatives. The fluid polymer is then forced through the spinneret.
The polymer here cools to a rubbery state, and then finally solidifies. For making specialty yarn,
certain polymers have been technologically developed that do not melt, dissolve, or form
appropriate derivatives. In such cases, the small fluid molecules are mixed and reacted to form
the otherwise intractable polymers during the process of extrusion. There are typically four types
of spinning for polymers-wet spinning, dry spinning, melt spinning, and gel spinning. However,
before proceeding to know the actual processes of all these four types of spinning, one must
know about the basic process of extrusion and the spinneret used for it.
Types of Polymer Spinning Processes
As stated earlier, There are four types of spinning for polymers- wet spinning, dry spinning, melt
spinning, and gel spinning.

Wet Spinning: Of all the four processes, wet spinning is the oldest process. It is used for
polymers that need to be dissolved in a solvent to be spun. The spinneret remains submerged in a
chemical bath that leads the fiber to precipitate, and then solidify, as it emerges out of the
spinneret holes. The name of the process i.e. wet spinning has got its name from this "wet" bath
only. Acrylic fiber, rayon fiber, aramid fiber, modacrylic fiber, and spandex fibers, all are
manufactured through wet spinning.

Dry Spinning: It is also used for polymers that have to bedissolved in a solvent. However,
solidification results from evaporation of the solvent. After dissolving the polymer in a volatile
solvent, the solution is pumped through a spinneret. As the fibers emerge from the spinneret, air
or inert gas is used to evaporate the solvent which results in solidification of the fibers that can
be collected on a take-up wheel. The fibers are stretched which provides for orientation of the
polymer chains along the fiber axis. This technique is used only for polymers which cannot be
melt spun because of the safety and environmental concerns concerned with solvent handling.
Dry spinning may be used for manufacturing acetate fiber, triacetate fiber, acrylic fiber,
modacrylic fiber, PBI, spandex fiber, and vinyon.

Melt Spinning: is used for the polymeric fibers or the polymers that can be melted. The polymer
is melted and then pumped through a spinneret. The cooled and solidified molten fibers get
collected on a take-up wheel. The fibers, when stretched in both, the molten and solid states,
facilitate orientation of the polymer chains along the fiber axis. Melt spun fibers can be forced
through the spinneret in different cross-sectional shapes such as round, trilobal, pentagonal,
octagonal among others. Trilobal-shaped fibers are capable of reflecting more light which give a
sparkle to the fabrics. Pentagonal-shaped and hollow fibers are soil and dirt resistant and as such
are used for making carpets and rugs. Octagonal-shaped fibers offer glitter-free effects whereas
hollow fibers trap air, creating insulation. Polymers like polyethylene terephthalate and nylon 6,6
are melt spun in high volumes. Nylon fiber, olefin fiber, polyester fiber, saran fiber, etc. are also
manufactured through melt spinning.
Gel spinning: It is also known as dry-wet spinning because the filaments first pass through air
and then are cooled further in a liquid bath. Gel spinning is used to make very strong and other
fibers having special characteristics. The polymer here is partially liquid or in a "gel" state,
which keeps the polymer chains somewhat bound together at various points in liquid crystal
form.

This bond further results into strong inter-chain forces in the fiber increasing its tensile strength.
The polymer chains within the fibers also have a large degree of orientation, which increases its
strength. The filaments come out with an unusual high degree of orientation relative to each
other, further enhancing strength. The high strength polyethylene fiber and aramid fibers are
manufactured through this process.

Whatever spinning process is applied, the fibers are finally drawn to increase strength and
orientation. This may be done while the polymer is still in the process of solidifying or after it
has completely cooled down. Drawing pulls the molecular chains together and orients them
along the fiber axis, resulting in a considerably stronger yarn.
OVERVIEW OF THE COMPANY

CONCORDE TEX POLYMERS PVT. LTD is a private limited company. This report is being
submitted in practical completion of my degree I have under taken this project report. To gain
exposure on practical knowledge in to the work and working of the organization. I have chosen
CONCORDE TEX POLYMERS PVT. LTD. Not just because it has such an impressive field
record but also because of its pleasing service to the society.

In the chapter a head, I would like to give the readers a report with an idea and analysis of the
organization and management of CONCORDE TEX POLYMERS

This company form organization is fully managed and controlled by the Proprietor Mr. Bala.
ABOUT THE COMPANY

CONCORDE TEX POLYMERS PVT. LTD belongs to Mr. BALA (proprietor). Company
Chairman, Mr. BALA continuously steers his companies toward success. Established more than
5 years ago, the company has emerged as a successful and vibrant enterprise. Employing 50
people, CONCORDE TEX POLYMERS has a sales turnover of Rs. 10 crores, as on 31st March,
2011.

It is almost a year since we drew up our vision, mission and values for the company. A recent
random survey indicated that most of us have imbibed these values to perform better at the work
place. Speed of response will enhance our individual performance and give the company a
winning outlook. It must be our endeavor to always seek ways and means to do better by the day.

CONCORDE TEX POLYMERS business plans and budgets have been finalized and their short
and long term actions plans are taking shape. All of them have an immense variety of strengths
and zeal at various levels. They have seen these emerge through their various teams that
overcame challenges and accomplished the impossible.

COMPANY MISSION

CONCORDE TEX POLYMERS mission is to achieve leadership in growth rate. They will
leverage their effective R & D, registration, manufacturing and marketing competencies through
their committed and proficient team.

They will strive to make their customers successful by providing high quality products, services
and solutions in domestic and global markets.

To expedite growth, we will user collaborations, acquisitions and manufacturing proximity to the
market in the segment of crop care, specialty and performance chemicals.
COMPANY VALUES

Customer Success - Believing that success lies in the success of existing and potential customers.
On this foundation, doing all possible to understand, fulful and exceed that customers stated and
unstated needs, thus enabling them to succeed on a continual basis.

Knowledge - Continuously ungrade skills and knowledge about technology, markets, products,
customers, regulations and business process. Encourage new ideas and their implementation
accross the company for commercial benefit.

Prosperity - Winning done better than other through exploiting new opportunities and enhaucing
the interests of every employee, share holder and stake holder. To be recognized and perceived
amoungst the leaders in the segment of operations.

Teamwork - Employees and channel partners thinking and working together across functions,
business and geographies, leveraging the available resources to achieve common goals.

Velocity - Responding to internal and external customers with a sense of urgency by consistent,
focussed and accelerated growth of the organisation with timely and optimal utilisation of all
resources.

COMPANY PRODUCTS

CONCORDE TEX POLYMERS range of products is known for excellence in product quality.
Our team always working for betterment of farmers, operating in Indian Market for more than 4
decades. The range of specialty chemicals that they have is used for different set of textile
industr. Some of the products include
 COMPANY
Company Name CONCORDE TEX POLYMERS PVT. LTD PROFILE

Address A 51, PALLADAM HI-TECH PARK,

SUKKAMPALAYAM VILLAGE,
K.N.PURAM POST, Palladam - 641664,
Tamil Nadu, India
Founded
2002
Phone No 91-4255-252678
Contact Person
Mr. BALA (proprietor)
Mobile +919626622333
Nature of Job Distributer of polymers
Products Polymer Chemicals
Departments Purchase, Dyeing, Marketing, Stores,
Accounts, Personal Departments.
Workers 150
Industry
Large Scale Industry
 ORGANISATION CHART

CHAIRMAN

MANAGING DIRECTOR

GENERAL MANAGER

ACCOUNTS DEPARTMENT MARKETING DEPARTMENTPERSONAL DEPARTMENT DIEING DEPARTMENT

STORES DEPARTMENT PURCHASE DEPARTMENT

ACCOUNTS MANAGER
STORES KEEPER MANAGER MANAGER SPECIAL OFFICERS MANAGER

CASHIER ASSISTANT WORKERS MARKETING EXECUTIVES ASSISTANT

OFFICE BOYS SALES BOYS

DEPARTMENTS

Purchase Department

The first function of textile mills is purchasing the raw materials. Raw materials include
purchasing of cotton. Before purchasing the samples of cottons are received after checking it the
purchasing order is sent. The purchase is done through the brokers, commission agents or
through the direct dealing of the polymer chemical industries. While receiving the polymers the
manager has to check for the quality. Then after receiving the polymers the density of the agents
are checked. They are purchasing verities of Polymer Chemicals. They are

Thickening Agents
Dye fixing agents
Dyeing chemicals
Printing chemicals

Mode of payment

Cash purchase

Cash purchase means purchasing raw materials for ready cash. The payments are made during
the purchase because while purchasing large quantity there will be a cash discount. The direct
payments are made through cashes and cheques.

Credit purchase

Credit purchases means buying the yarns on the credit basis. When the credit purchase is made
the rate of the raw materials will be high and there will be no discount on the purchase of the raw
materials. Credit purchases are made due to the in sufficient of cash. There will a specific time
for payment of cash from the purchased day.
Thickening Agent

Acryprint series is a synthetic thickener designed especially for providing viscosity in pigment
printing system of textile printing. It is easy to handle and relatively low usage levels yield high
viscosity upon neutralization.

It forms smooth swelling as well as homogenous blend of all additives in the textile printing. It
makes stock paste preparation simple with excellent cost reduction. It is compatible with most
pigment concentrate, neutralizers, binders and printing system and hence provides excellent
color value.

Some advantages of ACRYPRINT K100 are mentioned below:

Excellent uniformity & reproducibility

Eco-friendly and users friendly
Sharp printing & smooth appearance
No clogging or chocking of screen
Simplicity in stock paste preparation
High color value with uniform leveling
Good salt resistance
Low quantity gives higher viscosity
High speed printing
Compatible with all additives
Easy to wash equipments
Excellent reduction in production cost
No back penetration
Good stock paste storage
Reduce effluent emissions
This product improves the wet fastness of reactive dyeing and prints. It also improves the storage
stability of reactive dyeing, which under humid conditions tend to undergo hydrolysis, adversely
affecting the wet fastness properties.

This product acts by combining with the reactive dye hydrolysates that have not been washed off
and would have otherwise reduced the fastness of the dyeing. The extent of improvement in the
fastness properties depends on the specific dyes present.

This product does not significantly affect the shade of reactive dyeings nor does treatment with
this product affect the fabric handle. The rub fastness is not impaired as long as the dyeings are
well soaped and rinsed.
Wetting Agents

They are providing the most powerful wetting agent which is best suited for the most efficient
wetting processes of grey yarns and fabrics of all types of fibers either in the cold or hot
Residual. Their wetting agents on the material impart a very high degree of absorbency to the
textile material.

General Characteristics:

Physical Appearance : Colorless to pale yellow liquid

Ionic Nature : Anionic

pH of 1% solution : 6.5 - 7.5

Miscible with hot water and also soluble in most of the polar
Miscibility :
solvents.

Stability to hard water : Very good

Applications:

Being a powerful wetting agent, it has many applications. Grey yarn may be made absorbent by
wetting with wetting agent solution prior to dyeing.

Excellent for wool particularly in top dyeing and fabric dyeing

Toweling material may be treated with wetting agent solution to improve its water absorbency.

Application on cotton fabrics prior to subjecting them to compressive shrinkage process.

In addition, it has excellent deareation properties. Because of deareation action, the bubble
formations are prevented resulting into a high degree of absorbency to the textile material.

Depending on the requirements 0.5 - 1 gpl of it may be used for different purposes.
Dyeing Chemicals

Textile dyeing chemicals are known for their excellent foam suppressing and wetting properties,
and are suitable for various stages of textile processing. These textile dyeing chemicals are
procured from the reliable manufacturers of the industry to ensure superior quality and
accurately composed formulations to the clients.

Antimussol D-AIR liq : Silicon Based De Aerating agent with excellent Foam Suppressing &
wetting properties, suitable for various stages of textile processing , especially suitable for
machine like Package, Soft Flow & Beam Dyeing machine

Antimussol FKI liq : Silicone based antifoaming agent stable to JET dyeing application.

Antimussol HT2S liq : Stable, silicone-free antifoaming agent especially for the wet treatment of
PES and PES in blends with other types of fibre.

Antimussol SDF liq : Silicone based antifoaming agent stable to JET dyeing application.

Dilatin ENI.IN liq : Low foaming diffusion accelerant with levelling action for dyeing of
polyester & its blends.

Dilatin POE liq : Diresul Antioxidant PRS liq : An Antioxidant for better dyebath stability during
Sulphur Dyeing

Diresul Oxidant BRI.IN liq : Stabilized Oxidizing agent for Sulphur Dyeings

Diresul Oxidant PRB liq : Drimagen ALK.IN liq : Alkaline pH buffering agent for dyeing of
cellulosic fibres with reactives.
Printing Chemicals

These cotton printing chemicals are suitable for

printing with pigment emulsions on all
types of cellulosics and their blends with
polyester. These cotton printing
chemicals are accurately formulated
using the best quality raw materials.

Printing chemicals are safe to use and

eco-friendly.

Arostit BLNDP.IN p: Discharging agent

for Cellulosic material and its blends.

Hostapal EPP liq : Emulsifier for pigment printing

Minerprint Finish S liq : Additive for improving the softness and fastness of prints & paste
runnability

Minerprint Transparent Elastil FG pa : Ready-to-Print paste for lacquered and glossy elastic
effects

Minerprint White Elastil FG pa : Ready-to-Print paste for elastic effects MinerprintMatt Lacquer
NT liq : Paste for printing on dark grounds

Printofix Binder 1912 PLUS : Eco friendly binder for aqueous printing
Dyeing Department

Dyeing is the process of adding color to textile products like fibers, yarns, and fabrics. Dyeing is
normally done in a special solution containing dyes and particular chemical material. After
dyeing, dye molecules have uncut chemical bond with fiber molecules. The temperature and time
controlling are two key factors in dyeing. There are mainly two classes of dye, natural and man-
made.

Acrylic fibers are dyed with basic dyes; while nylon and protein fibers such as wool and silk are
dyed with acid dyes, and polyester yarn is dyed with disperse dyes. Cotton is dyed with a range
of dye types, including vat dyes, and modern synthetic reactive and direct dyes.

The common dyeing process of cotton yarn with reactive dyes at package form is as follows:

1. The raw yarn is wound on a spring tube to achieve a package suitable for dye penetration.

2. These softened packages are loaded on a dyeing carrier's spindle one on another.

3. The packages are pressed up to a desired height to achieve suitable density of packing.

4. The carrier is loaded on the dyeing machine and the yarn is dyed.

5. After dyeing, the packages are unloaded from the carrier into a trolly.

6. Now the trolly is taken to hydro extractor where water is removed.

7. The packages are hydro extracted to remove the maximum amount of water leaving the
desired color into raw yarn.

8. The packages are then dried to achieve the final dyed package.

After this process, the dyed yarn packages are packed and delivered.
Dyeing Methods

Direct Dyeing

When a dye is applied directly to the fabric without the aid of an affixing agent, it is called direct
dyeing. In this method the dyestuff is either fermented (for natural dye) or chemically reduced
(for synthetic vat and sulfur dyes) before being applied. The direct dyes, which are largely used
for dyeing cotton, are water soluble and can be applied directly to the fiber from an aqueous
solution. Most other classes of synthetic dye, other than vat and sulfur dyes, are also applied in
this way.

Yarn Dyeing

When dyeing is done after the fiber has been spun into yarn, it is called Yarn dyeing. There are
many forms of yarn dyeing- Skein (Hank) Dyeing, Package Dyeing, Warp-beam Dyeing, and
Space Dyeing.

Skein (Hank) Dyeing

The yarns are loosely arranged in skeins or hanks. These are then hung over a rung and
immersed in a dyebath in a large container. In this method, the colour penetration is the best and
the yarns retain a softer, loftier feel.

Package Dyeing

The yarns are wound on spools, cones or similar units and these packages of yarn are stacked on
perforated rods in a rack and then immersed in a tank. In the tank, the dye is forced outward from
the rods under pressure through the spools and then back to the packages towards the center to
penetrate the entire yarn as thoroughly as possible.

Warp-beam Dyeing

It is similar to package dyeing but more economical. Here, yarn is wound on to a perforated warp
beam, immersed in a tank and dyed under pressure.

Space Dyeing

In this method, the yarn is dyed at intervals along its length. For these two procedures- knit-
deknit method and OPI Space-Dye Applicator- are adopted. In the first method, the yarn is
knitted on either a circular or flat-bed knitting machine and the knitted cloth is then dyed and
subsequently it is deknitted. Since the dye does not readily penetrate the areas of the yarn where
it crosses itself, alternated dyed and undyed spaces appear. The OPI Space-Dye Applicator
technique produces multi coloured space- dyed yarns. The yarns are dyed intermittently as they
run at high speeds of upto 1000 yards (900 m) per minute through spaced dyebaths with
continuous subjection to shock waves produced by compressed air assuming supersonic
velocities.

Problems in Dyeing and remedies

The art of processing of textiles today is well known to all processors. In the past the organized
sector dominated the textile scene; whereas today the decentralized process houses are
predominant. There is a shift in emphasis from the requirements related to finished products to
environment related requirements. Requirements related to the finished product fastness & other
properties of dyestuffs & chemicals, processing etc. shift of emphasis environment related
requirements, cost reduction, security, energy & water saving, toxicology, hygiene legal
regulations, and competitiveness.

Reduction in costs and utilities are achieved by the trend to telescope processes. In order to be
competitive processors would have to give equal if not better quality then the existing material at
the same price. Considering the energy and labour costs, the only means of maintaining a
competitive edge is to lay emphasis on 'Quality'. Good quality does not necessarily mean
increased prices, but in fact would mean "Doing it right the first time" thereby reduce the costs.

Thus with this theme in mind of "Doing it right the first time" we would have to first understand
the problems in the process of dyeing. So, this paper mainly discusses "Problems in Dyeing & its
remedies".

The ultimate law of accuracy states, "when working towards a solution of a problem, it always
helps if you know the answer provided, of course you know there is problem".

Every manufacturing unit has a number of problems, however problem solving cannot be
considered to be astrology or palmistry, but it needs the fullest knowledge of basic facts.

The stages in the processing of textiles are:

GREY CLOTH

PRETREATMENT

DYEING

FINISHING
Remedies:

By ensuring proper pretreatment.

Proper dosing of dyes and chemicals.

 Heat should be same throughout the dye liquor.

Proper salt addition

 Problems of Dye in the Environment:
Dyes cause a lot of problems in the environment. The problems which are caused in
environment by dyes are given below:
1. Depending on exposure time and dye concentration, dyes can have acute and/or
chronic effects on exposed organisms.
2. The presence of very small quantities of dyes in water (less then 1 ppm) is highly
visible due to their brilliance.
3. The greatest environmental concern with dyes is their absorption and reflection of
sunlight entering the water. Light absorption diminishes photosynthetic activity of algae
and seriously influence on the food chain.
4. Dyes can remain in the environment for an extended period of time, because of high
thermal and photo stability. For instance, the half-life of hydrolysed Reactive Blue 19 is
about 46 years at pH 7 and 25 C.
5. Many dyes and their breakdown products are carcinogenic, mutagenicand/or toxic to
life. Dyes are mostly introduced into the environment through industrial effluents.
There is sample evidence of their harmful effects. Triple primary cancers involving
kidney, urinary bladder and liver of dye workers have been reported. Most of the dyes,
used in the textile industry are known only by their trade name, while their chemical
nature and biological hazards are not known. Mathur et. al. studied the mutagenicity of
textile dyes (known only by their trade name, used in Pali, identified as one of the most
polluted cities in India) and the effluents containing these dyes, and the influence on the
health of textile dyeing workers and the environment. The dyes were used in their crude
form and no following purification was attempted, because they wanted to test the
potential danger that dyes represent in actual use. The results clearly indicated that most
of the used dyes are highly mutagenic. Brow net. al, published an article, to show it is
possible to predict the toxicity of new azo dyes. The systematic backtracking of the flows
of wastewater from textile-finishing companies led to the identification of textile dyes as
a cause of strongly mutagenic effects. The textile dyes used in the textile-finishing
companies in the European Union were examined for mutagenicity. According to the
obtained results the dyes that proved to be mutagenic have been replaced with less
harmful substances.

The degradation product of dyes could be carcinogenic. The formation of Discoloration

of Textile Wastewaters 177 carcinogenic aromatic amine o-to lidine from the dye Direct
Blue 14 by skin bacteria has been established.
6. Textile dyes can cause allergies such as contact dermatitis and respiratory diseases,
allergic reaction in eyes, skin irritation, and irritation to mucous membrane and the upper
respiratory tract. Reactive dyes form covalent bonds with cellulose, woollen and PA
fibres. It is assumed that in the same way reactive dyes can bond with NH2 and SH
group of proteins in living organisms. A lot of investigations of respiratory diseases in
 workers dealing with reactive dyes have been made. Certain reactive dyes have caused
respiratory sensitisation of workers occupationally exposed to them.
Public perception of water quality is greatly influenced by the colour. So, the removal of
colour from wastewater is often more important than the removal of the soluble
colourless organic substances. Removal of the dyes from the textile wastewater is often
very costly, but a stringent environmental legislation has stimulated the textile sector in
developing wastewater treatment plants.
Accounts Department

Accounts department also plays a vital role in the businesses by monitoring the income and
expenditure, regulating receipts and payments the financial strength as otherwise of the unit at
any time. Accounts helps to know whether the businesses are in running progress or not. So
hence every business needs to maintain the accounts as per the rule of the government and want
to pay the tax according to the profit of business. Accounts help to know the current financial
position of businesses when ever needed. Further it will help him to know the level of the
investment in the fixed assets, working capital, fixed expenses etc. Concorde polymers maintain
all the account with the help of well experienced accountants. They maintain all the accounts like
journal, ledger, and trail balance etc, for every transaction the entries and the accounts are
entered. All the accounts related to the other departments are also handled and kept in control.
While purchasing and selling the yarn and the other items they will receive the bills they use to
file all the bills in the separate books of accounts. They have the separate beam stock book for
recording the stocks. By using separate book all the personal expenses are entered. Auditing is
easy because of maintaining the accounts properly. They are paying the tax regularly every year.
Before auditing all the accounts are checked by the auditor and then it is submitted. Hence the
accounts departments are maintained strictly and properly in order to maintain the stable high
profit.
Marketing Department

Marketing is the main function because without the market the goods cannot be sold out. But in
the field of textile the role of the marketing department is not much necessary, because the entire
produced good are not the finished goods and it should take away for the further process. In
Concorde Polymers they are marketing the two varieties of yarn as 40and 30 based on their
thickness. The 40 is used for making shirts and 60 are used for making pants. In Concorde
polymers the manager directly deals with the other nearby buyers. So the marketing department
is not done in full effort.

Duties & responsibilities of marketing officer:

Dealing with the buyer & convince the buyer is the main duty of marketing officer. A marketing
officer also has some other duties. The main duties & responsibilities of marketing officer are
given bellow-

1) To prepare cost sheet by dealing with the buyer.

2) To make different steps by discussing with the high officials & merchandiser.

3) To maintain a regular & good relationship between commercial officer & merchandiser.

4) To maintain a communication with the buyers and buying house.

5) Communicate with better criteria of the products.

Actually the responsibilities & duties of marketing officer begin from getting order of buyer &
end after receiving goods by buyer. So, he should be always smart, energetic & sincere.
Store Department

The purchased raw materials are stored in stores room for the production processes. In the
storage department they are having a large area of godown for storing their purchase of raw
material and they are keeping safe from destruction until they used for production process. The
main function of the storage is due to avoid un necessary accidents like fire, theft etc the stock
level can be identified by maintaining the proper ledger accounts. This department is under the
control store man
Personnel Department

The function of Personnel Department/ Human Resource Department in the Textile Industry
plays a crucial role in maintaining the utilization of machinery and labour productivity. It has
been noticed that in most of the Textile Mills, the Personnel/ HR department is managed by
graduates and post graduates without the legal back ground. At present, the availability of law
professionals in the HR Department is very limited. In other words, most of the persons working
in the Personnel Department/ Human Resource Department are lacking the legal knowledge in
the Textile Industry

1. Time office functions

2. Social Welfare Legislation: ESI, PF, Employees Compensation Act, Gratuity &
Bonus Act
3. Factories Act, Industrial Dispute Act & Standing Order Act
4. Team effort & Co-ordination
5. Domestic Enquiry and Disciplinary Action
6. Belongingness and Image building
7. Negotiation Skill
8. Women Employment System in Textile Mills
9. Recruitment, Selection and Induction
10. Handling of Employees
11. Liaison with Government departments, Public & Thirty Party
12. House Keeping and Kaizen
13. Statutory record maintenance & importance of personal file
14. Importance of Safety & Security System
15. Trade Union in Textile Industry, various Awards & Settlements
TEXTILE DYEING & PRINTING MILL

The bleaching of the textile is done to bring the whiteness finishing in the fabric where as dyeing
for various shades. The art lies in colouring the textiles in such a manner that the colour may be
fast or may not ordinarily be removed by such operations as washing, rubbing, sunlight etc.

The art of dyeing is a branch of applied chemistry in which a severe use of both physical and
chemical principle is made in order to bring about a permanent union between dyes and the
fibres. The local application of colour is carried out by some form of printing and the greater part
of textile printing concerns woven cotton piece goods, the process is some times called calico
printing, at the same time it must be released that very considerable quantities of rayons are
printed as well as small amount of silk and wools.

Cotton textile industry by large occupies a unique place in the industrial map of the country.
These are single large organized industries as well as a large number of auxiliary industries
depending upon the sector.

Textile dyeing and printing is the one of the main part of the industry which gets it done from the
out side by the small textile mills. Large mills have their own dyeing and printing sections. So
there is very good scope for new entrants.
COTTON YARN DYEING

In primitive era, the early man used to cover his body with easily available natural materials like
tree leaves, bark, raw fibres and skin of hunted animals to protect them self from extremities of
environment. In modern era every civilized person is to wear garments of its own preference
unlike their cast or creed but as per prevalent custom and fashion.

There are many forms of yarn dyeing. Common forms are at the package form and at the hank
form. Cotton yarns are mostly dyed at package form and acrylic or woollen yarns are dyed at
hank form. Textile dyeing industry is booming day by day with the increasing demand of dyed
clothes. So, there are good scope for new entrants.

Few Indian Major Players are as under:

Bahuma Polytex Ltd. Betex India Ltd.

Bhilwara Processors Ltd.
Delta Polysters Ltd.
Dhruv Globals Ltd.
Donear Industries Ltd.
Gangotri Textiles Ltd.
Gupta Exim (India) Pvt. Ltd.
Hotz Industries Ltd.
Imperial Dyeing Ltd.
Nahar Spinning Mills Ltd.
Nobletex Industries Ltd.
Pact Industries Ltd.
Pratibha Syntex Ltd.
Rupa Dyeing & Prtg. Pvt. Ltd.
S L M-Maneklal Inds. Ltd.
S P L Industries (Shivalik Prints) Ltd.
S T L Global Ltd.
Pigment Binders for Textile Printing

Pigment printed textiles represent the highest percentage of all printed textiles. This is primarily
due to the uncomplicated process and low cost of imparting colour patterns to textiles with
pigment system.

The water insoluble pigment used in most cases as an aqueous dispersion, has no affinity to
textile fibres and is not able to enter into chemical or physical reactions with the fibre. For
bonding of pigments to textile on bonding agent generally of a synthetic latex type is
incorporated is the print paste which through its film forming properties holds the embedded
pigment firmly on fibre surface.

The demand of the product is good and with the rise of growth in textile industry, the product is
bound to enjoy increased demand in future.
Dyeing on Rayon in Hanks Form & Cone Form

These dyes are so powerful that very small amounts, comparatively, are needed to colour a large
amount of material. The dyestuff should never be shaken out, but carefully dipped out in a
narrow-bowled teaspoon from the tin or glass container, and placed in a small-sized agate
saucepan.

Then a few drops of acetic acid are added, and the dyestuff is rubbed in the acid with the spoon
until every particle has been wet down. In this condition the dye is readily soluble in hot (not
boiling) water, which should be poured on it stirred well and allowed to settle, before decanting
the solution into the dye-bath, preferably through a strainer covered with a piece of wet muslin
or doubled cheesecloth, to be sure and strain out any particles of undissolved colour.

Some of the dyes, notably Methylene Blue, when wetted, have a way of making a sticky paste,
which is hard to dissolve, but by keeping it wet with acid each time, before adding more warm
water, it will sooner or later make a good clear solution. It is used to making nonwoven fabrics.
It is used to make coated fabrics.

It is best to begin with the dye-bath at a very moderate temperature, and to heat it gently,
keeping well below the boiling point. According to observation in India it is found that there is
negative growth of rayon grade fibers. In all new production of rayon grade fibre is 227000
MT/Annum. It is better to start dyeing unit of other textile fabric with rayon grade threads.
Wetting Oil (Textile Yarn Wetting Agent)

Wetting oils are wetting agents having oily consistency. Wetting agents are surface active agents
which when added to water causes it to penetrate more easily into, or to spread over the surface,
another material by reducing surface tension of the water. Wetting oils because of their growing
uses in various industries are having ever increasing demand.

The prospect of the industry is very well linked with soaps, detergents, allied products, paints,
varnishes any lacquers, leather, paper cosmetics, textiles and various other industries which are
fast developing. These industries have very bright future. A new entrepreneur can confidently
venture into this field and he will find it highly profitable.
TEXTILE WEAVING MILL

The textile industry occupies a leading position in the hierarchy of the Indian manufacturing
industry. It has witnessed several new directions in the era of liberalisation.

While textile exports are increasing and India has become the largest exporter in world trade in
cotton yarn and is an important player of readymade garments, country's international textile
trade constitutes a mere 3% of the total world textile trade.

Several mills have opted for modernization and expansion and are going in for export-oriented
units (EOUs) focused on production of cotton yarn. It has passed through cyclical oscillations
and at present, it is witnessing a recovery after a downturn.

Of the entire industry volume of about 5 mn tonnes, polyester and polyester filament yarn
account for about 1.7 mn tonnes, and acrylic, nylon, and viscose taken together for 300,000
tonnes. The balance is represented by cotton textiles.

A majority - some three fourths - of the textile mills are in the private sector. A few of the units
are in the co-operative sector with the public sector (Central and State) accounting for about
15% of the total. The textile industry is classified into (i) textile mills comprising composite and
spinning mills in the organized segment, (ii) small powerloom and handloom units in the
decentralized segment, (iii) khadi-based units, (iv) man made and synthetic fibre and spinning
units, v) knitting units, and (vi) made-ups (garments). Besides, the industry has a large number
of small units scattered all over the country which are engaged in processing, dyeing and
printing of yarn, fabrics and for conversion.

The processing units include sizing, desizing, kiering, bleaching, mercerizing, dyeing, printing
and finishing. There are a number of large mills which could be termed lead players.

The major composite mills include the industry big names like Century, Bombay Dyeing,
Mafatlals, Arvind Mills, Vardhaman group, Nahar group. A few developments may be
mentioned as trend setters. Few Indian Major Players are as under: A K C Synthetics Ltd. A R
Co-Extruded Films Ltd. Aarvee Denims & Exports Ltd. Aceelene Suitings Ltd. Adhunik
Synthetics Ltd. Agmotex Fabrics Ltd. Ahmedabad Advance Mills Ltd. Ahmedabad Jubilee Mills
Ltd. Ahmedabad Manufacturing & Calico Prtg. Co. Ltd. Ajit Mills Ltd. Akashganga Textiles
Mills Ltd. Alok Industries Ltd. Ambadi Enterprises Ltd. Amco Industries Ltd. Anjani Fabrics
Ltd. Anjani Synthetics Ltd. Ankita Knit Wear Ltd. Aparna Synthetics Pvt. Ltd. Arihant
Industries Ltd. Arthanari Loom Centre (Textile) Ltd. Aruna Mills Ltd. Arvind Ltd. Arviva
Industries (India) Ltd. Aryan Fine Fab Ltd. Ashima Ltd. Ashok Fashions Ltd. B S L Ltd.
Bhiwani Denim & Apparels Ltd. Bhungani Synthetics Pvt. Ltd. Bindal Textile Mills Ltd. Binny
Ltd. Binod Mills Co. Ltd. Black Rose Inds. Ltd. Bombay Dyeing & Mfg. Co. Ltd.
 CONCLUSION
A polymer processing and dyeing business is a relatively simple one to start, although there are
upfront costs for equipment and inventory. We can create designs with easy to use process and
allow machines to create sophisticated and high quality products for printings the fabrics. Ensure
that w have planned business carefully and that we can reach specific customers with our
products and we will be able to run a profitable business from home on our own schedule.

It is difficult to separate the development of art of dyeing and the development of the synthetic
dyestuff industry. Indigo and Alizarine also their methods of application were known the
introduction of synthetic equivalents added nothing to the dyers technique. Similarly the
development of a range of derivatives or the introduction of synthetic reducing agent merely
provided the dyers with new tools. Whether this be true or not, it is an excellent illustration of
innumerable instances of progress achieved by the chemists intelligent development of the
dyers natural opportunism. It seems clear the chemists explanation of many phenomena is no
longer tenable, and it is hoped that the physicists recently acquired interest in textile matters
generally may soon give rise to the establishment of a working hypothesis. The physics has
brought new methods, such as X-ray analysis to bear upon textile problems and this has already
resulted in a considerable clarification of the general theory of dyeing although uncertainty still
persists in many aspects. Blended yarn production which comprises mostly polyester cotton and
partly polyester viscose is only about 350 million kg. Exports of cotton yarn have traditionally
been regulated within a quantitative ceiling fixed on a year to year.

Concorde Polymer has given a change to perform the industrial attachment in ONE
COMPOSITE MILLS. This training, act as a bridge to minimize the gap between theoretical and
practical knowledge. Undoubtedly, this training taught us more about textile technology,
industrial management & production process. Besides it gave us the first opportunity to work in
an industry. We believe that, the experience of this industrial training will help us in our future
career as textile technologist/engineer.