OBJECTIVE:

The project is based on a two week internship in Arvind Mills(Santej unit) Shirting
Department. It covers all the information and learning experiences related to manufacturing
of fine shirting fabric and all the processes involved.

The main objectives of the project/internship are:

Knowledge about the company

Understanding the companys process flow in production

Understanding of all process involved in textile production and the machinery and equipment
used

1
COMPANY PROFILE

Founded in 1930 when the world suffered the great depression, Arvind mills was setup by
Kasturbhai, Narottambhai and Chimanbhai following the swadeshi movement which left a
huge demand for super fine fabrics in india.

Sanjaybhai Lalbhai is the chairman and managing director of Arvind and Lalbhai Group.

Arvind Limited(formerly Arvind Mills) is a textile manufacturer and the flagship company of
the Arvind Group. Its headquarter is in Naroda, Ahmedabad, Gujarat, India. It has units at
Santej. It manufactures cotton shirting, denim, knits, and bottom weights(Khakis) fabrics. It
has also recently ventured into technical textiles when it started Advanced Materials Division
in 2011.It is Indias largest Denim manufacturer apart from being the worlds fourth largest
producer and exporter of denim.

Arvind also runs a value retail chain, Megamart, which stocks company brands.

2
ORGANIZATION CHART

MD / ED /CFO

CEO

DESIGN &
QUALITY
DEVELOP MANUFACTURING MARKETING HR
ASSURANCE
MENT

CASUALS
SHIRTING BOTTOMS KNITS
(INDIGO)

BUSINESS
MANAGER

QUALITY
YARN FINISHING & ENGINEE
SPINNING WARPING WEAVING PROCESSING ASSURAN
DYEING PACKAGING RING
CE

CHIEF MANAGER / SECTION

HEAD QUALITY
ASSURANCE

ASSISTANT SENIOR
MANAGER MANAGER
(M1) (M2) NEW PRODUCT CONTINUOUS DESIGN &
DEVELOPEMENT IMPROVEMENT DEVELOPEMENT

SHIFT SUPERVISER

SENIOR
EXECUTIVE
EXECUTIVE
(E1)
(E2)

FLM (FRONT
LINE
MANAGER)

3
 INTRODUCTION

ARVIND
(SANTEJ)

CASUALS(IN
SHIRTING BOTTOMS KNITS
DIGO)

Total production ( including shirting, bottoms and casuals-indigo) 1 crore m/

month(approx.)

Shirting 45 lakhs m / month

Bottoms 30 lakhs m / month
Casuals 25 lakhs m / month

Total production (knits) 600 700 metric tonnes / month.

Major Customers of Arvind

Madura Garments
Levis
GAP
H&M
JC Denims
M&S

Own brands of Arvind

Arrow
US Polo
Flying Machine
Wrangler

4
SHIRTING DIVISION

Arvind Shirting fabric is one of the most well known products of Arvind Group, selling at a
premium in the International market. Arvind Shirting has a liquid ammonia based fabric
processing plant and a state-of-the-art print house-first for India and one of the few in Asia.
Backed by the latest technology, every stage of the production process right from spinning of
the yarn to final processing and testing of the fabric, ensures that best quality standards are
met and products remain eco-friendly.

Process Flow:

QUALITY
SPINNING PROCESSING
ASSURANCE

SOFT WINDING /
DIRECT WEAVING FINISHING
WARPING

DYEING(YARN
SIZING INSPECTION
& BEAM)

WINDING WARPING PACKAGING

SPINNING:

Spinning is the first and major step of the textile manufacturing process. It is a specialised
form of creating polymer fibers from staple or short lengths of fibers (such as cotton, rayon)
by applying twist.

5
Process flow:

FUNCTION:Opening,cleaning and blending

BLOW OUTPUT: Cotton Tuft
ROOM

FUNCTION:Individualisation of fiber,neps removal and sliver prepration

OUTPUT:Sliver
CARD

FUNCTION:Parallisation and improvement in sliver

PRE OUTPUT:Breaker sliver
DRAWFRAM
E

FUNCTION:To prepare Lap sheet suitable for combing

OUTPUT:Comber Lap
UNILAP

FUNCTION:Short fiber removal,individualisation and sliver prepration

OUTPUT:Combed sliver
COMBER

FUNCTION:Parallisation and improvement in sliver quality(by reducing mass variation)

POST OUTPUT:Finished sliver
DRAWFRAM
E

FUNCTION:To preapare a suitable roving for ring frame by inserting twist

SPEED OUTPUT:Roving bobbin
FRAME

FUNCTION:To produce yarn on smaller package

RING OUTPUT:Yarn
FRAME

FUNCTION:To prepare bigger package after removing faults

RANDOM OUTPUT:Cleared yarn
WINDING

FUNCTION:To assemble the yarn

ASSEMBLY OUTPUT:Assembled yarn
WINDING

FUNCTION:To impart twist in assembled yarn and produce bigger package

OUTPUT:Double yarn
T.F.O

FUNCTION:To remove the protruding fibers on the surface

OUTPUT:Singed yarn
SINGEING

6
BLOW ROOM:

The cotton seed, together with the fibers, always gets into the ginning plant where it is broken
up into trash and seed-coat fragments. The reduction of the trash content is necessary for
improving cotton grade and appearance. The basic purpose of Blow room is to supply small
fibre tufts, clean them and homogeneously blend them if more than one variety of fibre is
used without increasing fibre rupture, fibre neps, broken seed particles and without removing
good fibres.

Cotton is passed from bales to blending apron with sharp spikes which open and raise
the cotton fibers resulting in extraction of the fiber. Cotton falls on conveyor belt and
is carried to next process that is blending through an overhead duct
Conveyor belt passes cotton to another type of beater. From beater the cotton passes
to a conveyor and is carried to picker which loosens hard lumps of fiber and
disentangles them and presses the raw fibre in a temporary lap
The flow cleaner is used for separating heavy parts (impurities) from cotton. The time
(in hours) of the passage of material can be regulated. The speed range of the beaters
varies from 400-600 rpm
The dust particles are completely enclosed in the flocks and the suction units remove
these particles
A fan is used to pass on the cotton tufts to the carding machine
The trash collected from the blow room is sent to the waste collection plant

CARDING:

Carding is the process of removing impurities from fibers and producing a carded sliver of
parallelized and straightened fibers.

The lap is passed through a beater section and drawn on rapidly revolving cylinder.
As the cylinder rotates, the cotton is pulled by the cylinder through the small gap
under the brushes; the teasing action removes the remaining trashes, disentangles the
fibers, and arranges them in a relatively parallel manner in form of a thin web

This web is drawn through a funnel shaped device that molds it into a round rope like
mass called card sliver

After carding, the carded slivers go to the draw frame

7
DRAWING:

Drawing is the process where the fibres are blended, straightened and the number of fibres in
the sliver increased in order to achieve the desired linear density in the spinning process. A
single sliver is formed from eight sliver by mixing them together. The drawing process also
improves the uniformity or evenness of the sliver.

In Arvind Mills, the sliver is drawn through the draw frame twice. One is after the carding
stage (Pre-Drawing) and another after the combing stage (Post-Drawing).

After pre-drawing the cans are fed to the unilap machine for converting slivers into a lap.
This conversion is done because the fibres cannot be fed to the comber in a sliver form.

COMBING:

Combing is done to remove the short length fibres, parallise them and further clean them. It is
the finest stage of sliver.

ROVING:

In preparation for ring spinning, the sliver needs to be condensed into a finer strand known as
a roving before it can be spun into a yarn. It is an intermediate process in which fibers are
converted into low twist lea.
The roving sliver is thick and untwisted. So it is passed through speed frame to provide twist
to the fibres.

RING FRAME:
It consists of three rollers of different speed in increasing order. This makes the fibers finer at
each stage. It provides further compression and twist to the fibers along with drafting. The
draft is needed to reduce the linear density of sliver. The packages are further formed into
bobbins.

8
WINDING:
The main purpose of winding machines that they were using is to transfer the ring yarn
obtained from ring spinning into a cone form. Random winding prepares bigger packages
after removing faults. Assembly winding mixes the yarns to improve the strength(2/3/4 plies
into single thread) .

TWO-FOR-ONE:
T.F.O twisters are used for twisting two or more single yarns which is called doubling or
folding or ply twisting. The advantages of using TFO twisters are:
production of long length of knot free yarns which facilitates better performance in
the subsequent processes
higher productivity

SINGEING:

Singeing of yarn is one in order to burn out protruding fibers and provide a clean yarn
surface. Singed yarns soil less easily and the risk of pilling is reduced. Singed fabrics allow
printing of fine intricate patterns with high clarity and detail.

YARN DYEING:

Dyeing is the process of imparting colours to a textile material through dye. When dyeing is
done after the fiber has been spun into yarn, it is called yarn dyeing.

9
Process flow:

GRIEGE YARN

SOFT PACKAGE BEAM

SOFT WINDING DIRECT WARPING

PACKAGE
DYEING(sprng/PP BEAM DYEING
tube)

CARRIER

PRESSING

DYEING
MACHINE

DRYING

SHADE
CHECKING &
FASTNESS

10
SOFT WINDING:

The soft package winding is the most important pre dying operation, which directly affects
not only the dyeing quality but also post dyeing operations such as rejects, wastages and poor
unwinding, thread breakages etc.

The yarn to be dyed is first to be wound into a package. The package dimensions and weight
are influenced by the type and construction of yarn to be processed, class of the dyestuffs,
machine flow rate, end use of the dyed substrate and package holder.

Two types of package holders are generally used :

Spring - The dye springs are most commonly used package holder, on which the yarn is
wound. It offers the advantages such as reusability, compressibility and making a
perfect column after pressing. Dye springs offers much lesser resistance to the liquor
flow through the packages. Due to high compression possibility the dyeing machines can
be loaded to a higher capacity. The density of each package is 360 gm/cc (approx).

Perforated Plastic Tube This type of package holder is generally used for lycra yarns
and for double directional dye liquor flow through the packages. There is greater wastage
of yarns during dyeing because of lesser penetration of dye liquor to the core of the PP
tube. The density of each package is 380 gm/cc (approx).

In both the package holders, a filter paper of two grams is used to enable smooth winding and
prevent entanglement of yarns.

Machines used Scharer Schweiter Mettler AG (SSM) : 43 Machines

PRESSING:

Pressing is done usually to compress the soft package (by 15%) and prepares it for
subsequent chemical operations. At first the packages are loaded on the spindles and then
pressed together. This is known as loading. These compressed packages are then sent for
dyeing. After the completion of dyeing, these packages are again brought to the pressing area
and then previously exerted pressure is released. This is known as unloading.

11
The maximum capacity of each spindle is 10 packages.

The maximum capacity of each carrier is 72 kg 6 spindles.

DYEING:

In Arvind (Shirting unit) mainly two forms of yarn dyeing- package dyeing and beam dyeing
is done. In package dyeing, the yarns are wound on spools or cones. These packages of yarn
are stacked on perforated rods in a rack and then immersed in dye tank. Package dyeing is
done for stripes and plaid fabrics. In arvind, High Temperature and High Pressure (HTHP)
package dyeing machines were used for package dyeing. In beam dyeing, the yarns are
wound on to a perforated warp beam and immersed in dye tank under pressure. Beam dyeing
is done for solid fabrics.

Scouring and bleaching is done to remove impurities as the pre-treatment for dyeing. The
dyes used in this unit are mainly reactive dyes (95% - for cotton), VAT dyes (1%) and
disperse dyes( 4% - for polyester). In the dyeing section; dyeing is done according to the
approved sample dyeing recipe (Material : Liquor ratio 1:6 to 1:7). Different parameters are
maintained during dyeing like temperature, pressure, time etc. and 80-90 litres of water/ kg is
used for dyeing.

Exhaust system of dyeing (Orgatech mechanism) is used in this unit. The utilities for dyeing
are water, steam, power and air. Fully automated dyeing machines are used Theis, Then and
Fongs , which have certain disadvantages like improper calibration and bypass of necessary
chemicals.

Dyeing of Cotton:

An acidic ph of 5-6 is maintained. First a dye liquor is prepared by mixing of dyes and salts
(for improving dye affinity) and Alkali dosing is done by using an alkali buffer. The cotton
yarns are passed through the dye-bath and time is given for the dye to penetrate. Then
neutralization and soaping of the dye liquor is done ( After treatment). For dark shades, fixing
of dyes and lubrication is done (Post treatment).

Machines used: 41 machines (total)

Type: Theis (Germany)

12
 Capacity Of Machines No. Of Machines

25 kg 2

48 kg 5

72 kg 8

96 kg 10

108 kg 6

156 kg 4

168 kg 2

300 kg 2

500 kg 2

90 kg(beam) 6

HYDRO- EXTRACTION:

Hydro extractors are machines which are used in the dyeing department. The wet material is
placed in the extractor, which has a wall of perforated metal, generally stainless steel. The
internal drum rotates at high speed thus throwing out the water contained in it. The use of
hydro extractor significantly reduces the energy required to dry any material. The machines
used for hydro extraction in Arvind were capable of removing upto 25% water.

DRYING:

After dyeing of the packages and beams they are passed through drying machines for further
treatment. In Arvind, two types of drying machines are used Pressure Dryer and Radio

Frequency (RF) Dryer. The average time taken for each carrier drying is 2-2 (pressure
dryer) and 1-11/2 hrs (RF Dryer). In Pressure Dryer electromagnet generates electricity which
further condenses water into steam and helps in drying.

13
Machines Used:

Pressure Dryer (Theis)- 3 machines(total)

500 kg capacity- 1 machine

168 kg capacity-1 machine
108 kg capacity-1 machine

RF Dryer (STACAM) - 2 machines

QUALITY CHECKING:

After drying the yarns undergo quality checking for color fastness and shade variation.

Problems faced in dyeing unit:

Chances of partial dyeing, if lock of the dyeing machines opens during the process
Package to package or layer to layer (within package) shade variation may occur
Wastage of dye liquor because of pp tubes
Due to excess reprocessing the strength of yarns is reduced
Color bleeding of yarns may occur due to improper fixation
Improper drying of yarns may lead to wet yarns
Poor run ability of liquor due to harsh yarns
Over drying may lead to weak yarn formation
Yarn count mixing may occur

14
WEAVING

Weaving is the action of production fabric by interlacing of warp and weft threads.

Preparatory process for weaving:

WINDING

WARPING

SIZING

LOOM

WINDING:

Winding is the first step for the preparation of yarns for weaving. Winding takes place in two
forms- warp winding and weft winding.

Warp Winding:

Machines used 34 machine (total)

No. Of Machines Company No. of Spindles

8 Schlafhorst 60
5 Schlafhorst(old) 50
2 Muratec 60
19 Muratec(old) 50

15
Weft Winding:

Machines used- 16 machines (total)

No. Of Machines Company Type of Winding

4 Precifx Precision Winding
3 SSM Precision Winding
6 Murata Drum Winding
3 Mahavir Drum Winding

WARPING:

The parallel winding of warp ends from many winding packages (cone) onto a common
package (warp beam) is called warping.

Two types of warping are used:

Direct Warping

Direct warping is also called Beam warping/High Speed warping. In Direct warping the yarn
is wound parallel on the warping beam. All the yarns are wound at once and simple flanged
beam is used. It is a very high speed process and is used for making fabric of single colour or
for chambray quality.

Sectional Warping

In sectional warping equal length of yarn is first wound in small sections or sheets on a drum.
Then from the drum it is transferred to the beam. By this process we directly get the weavers
beam. This is a two stage method and is used for making checked, stripped or other fancy
fabrics. As sizing is not done, so multi-ply yarns or yarns which do not require sizing are
used. It is less efficient than high speed warping
Using this method, first the no. of sections is calculated, by dividing the total ends by the
creel capacity.

Machines used 18 machines (total)

16
 Machine Brand No.of machines
Beningel 5
Ukil 1
PGT 1
Karl Mayer 1
Vavatex 10

SIZING:

Sizing of yarn is done after winding and warping and during beam preparation. Sizing is done
by applying various types of size materials on the yarn. During application of size materials
steam (95 105 C) is needed.

Purpose

To improve the weave ability of warp yarn by making it more resistance to action of
weaving like absorption, friction, tension, etc.
To maintain good quality fabric by reducing hairiness, weakness and by increasing
smoothness and absorbency of yarn.
Tensile or breaking strength of cellulosic yarn is increased by sizing
Elasticity of the yarn is also increased.
By adding size materials yarn weight is increased.
To increase the frictional resistance.
Projected fibres are removed by this process.

Machines used 8 machines (total)

Machine Brand No.of machines

Karl Mayer 2
Sucker Muller 5
Ukil 1

17
WEAVING:

In Arvind, two weaving techniques are used- Air jet weaving and Rapier weaving.

Air Jet Looms or Air Jet Weft Insertion System:

This system is most improved form of weft insertion. In this system, the mechanism and
machine parts have been totally eliminated used to drive the weft insertion source. Weft
thread is propelled using compressed air. It is simple operation with reduced mechanical parts
and hence the maintenance cost is very low.

The working principles of air jet weaving machines are based on carrying the yarn by the
friction of the air jet. During the yarns forward movement by the air in the sheds, the
velocity of the weft yarn decreases because of the decreasing pressure and the disturbance on
the air flow direction. The air jet must provide a constant speed to the weft yarn along the
weaving wideness.

Fibers which have hairy structure like cotton and cotton blends are woven using this
technique.

Advantages:

High productivity

High filling insertion system

To increase the production of loom by increasing the speed and by increasing the
width of loom

Machines are versatile and roust to produces light to heavy value added fabric

Almost all loom motions are being controlled electronically

Fully automatic lubrication system

Machines used: Toyota air jet looms (max 8 harness) and dobby(16 harness).

Generally, one machine produces 500 meters of Raw Fabric daily.

Rapier looms:

18
Rapier loom is shuttle less weaving loom in which the filling yarn is carried through the shed
of warp yarns to the other side of the loom by finger like carriers called rapiers.

A rapier is a rod or steel tape which carries the weft yarn in one end and is connected to the
controlled system in the other end. The rapier from one side carries the weft yarn to the center
and the other rapier from the opposite side carries the weft yarn from the center. The noise
level is high because this loom operates at high speed.

Fibers other than cotton like polyester, nylon are generally woven in this loom. Any type of
weave like critical dobby can be formed.

Advantages:

It is a shuttle less power loom

It operates at high speed
The weaves formed are quite flexible using picks of different colours and forming
various patterns

Machine used: Optimex(8 to 24 shafts).

Generally, one machine produces 300 meters of Raw Fabric daily.

In Arvind, there are 35 selvedge print looms(Rapier-25 & Air jet-10) with mini jacquards to
produce selvedge weaves with brand names.

In Arvind Shirting Division, there are total 7 weaving divisions. Total number of looms are
1005(including yarn dyed, non yarn dyed and indigo yarns).

Weaving division No. Of looms

Classical-1 158
Classical-2,3 192
Classical-4 150
Classical-5 103
Textile park 54
Bottoms 136
Design & development (sampling) 50

19
Problems faced in weaving department:

Breaks
Stop marks
Weft cut
Undyed effect
Unlevelness issues
Weft loops
Parabola (weft wise)
Streakiness (warp wise)
Wrong denting
Double picks

PROCESSING & FINISHING:

Processing refers to the processes that converts the woven or knitted cloth into a useable
material and most specifically to any process performed after dyeing the yarn or fabric to
improve the look, performance or feel of the finished material.

Finishing is carried out after processing. It takes an important role in fabric properties,
appearance, softness and residual fabric shrinkage.

The main purposes of applying various finishes may be summarized as under:

1. High sales appeal: To impart properties of attractive appearance, supple handle, softness
and good drape.

2. High wear quality: This refers to adequate tensile and abrasion strengths, dimensional
stability, crease recovery and freedom from pilling.

3. Body protection and comfort: This relates to proper heat insulation, moisture absorption
and air permeability.

4. Special effects: These include water-repellency, reduced flammability, mildew and moth-
proofing, anti-static behaviour and soil release property.

20
Process flow:

GREY WARE HOUSE STENTERING SANFORIZING

BATCHING MERCERISATION FINISHING

SINGEING DESIZE WASH

DESIZING ROTATION

The fabric is stored in lot after weaving in the grey ware house which is then issued
for processing
For further processing the grey fabric are formed in batches using batching rollers
which have dark color fabric on the inner side to prevent color bleeding (maximum
quantity-6000m/roller and no. of machines-5)
After the batch formation these are sent for singeing followed by desizing (machine
used- Osthoff-senge)
Then the batches are kept for rotation (8 hours) for the uniform distribution of desized
solution
The fabric undergoes desize wash in the Injecta machine (2 machines)
Then the fabric is mercerized using caustic soda and acid to provide lusture (machine
used- Benninger, Kyoto, 3 machines)
White fabric are passed through Continuous Bleaching Range (CBR) to improve their
optical brightness
To maintain the dimensions of the fabric it is passed through stenter(Pad-Dry-Cure)
and weft straightner(machine used-Mahlo) and further curing if required at high

21
 temperature.(Stenter machines-5,Monforts montex and Curing machines-2, Thermex
Monforts)
To prevent further shrinkage and set the dimensional stability of the fabric it is passed
through the sanforizer (machine used-4,Monforts and Mahlo)
Then the fabric is given the required finish as per the demand
After sanforization, if required the fabric roll is sent for a 3 bowl calendaring machine
made by Ramisch Guarneri
There are 3 Lafer machines for peach and carbonium finish
There are Lafer machines for raising, sueding and shearing finish
There is a Biancalani machine for arrow finish
Apart from the mechanical finishes Arvind Mills provides different chemical finishes as per
the demand (total 140-150 finishes).

TESTING DEPARTMENT:

The quality department and their testing procedures of Arvind were accredited by Next, Ralph &
Lauran, Levis, Mexx, Marks & Spencer, Debenhams, Nordstrom, Bureau Veritas, etc. The
samples are tested for/by:

1. Tensile Seam Strength: Titan Machine

2. Tear strength : Elmatear
3. Abrasion/Pilling : Martindle
4. Shade matching is done in a dark room using Verivide CAC 150, Gretagma C beth
Spectralight III
5. Washing Fastness: Gyrowash machine was used. Temperature varied from 40-48C.
6. Crocking Fastness: Jamesheal crockmeter
7. Light Colorfastness: ATLAS XENOTEST 220
8. Washing Machines: 2 Electrolux front loading machines. & 6 top loading whirlpool
machines
9. Scorching Test: Welltronix machine
10. Random Pilling: Elmendorf machine
11. Ozone Fastness Test: OTC machine

22
PRINTING

Textile printing involves the production of a pre determined pattern on a fabric with or
without a definite repeat.
Certain parameters for printing to be checked are:
pH
Absorbency
Whiteness
Width
In Arvind two styles of printing are generally done - Direct and Discharge. Sometimes burn
out printing is done.

Process flow:

QUALITY
DESIGNING WASHING
CHECK

ENGRAVIN STEAMING
FINISHING
G / AGEING

SAMPLING PRINTING

First the designs are prepared based on the buyers requirements ( specified sharpness
and repeat size) in the Design Studio
The designs are further transferred to the nickel screen known as Engraving
(Machines used 2 laser machines, 1 CST machine and 1 DLE machine)
Sampling is done according to the buyer which on approval order for bulk production
is made (sometimes revised samples are made)
Bulk production is further carried out
The fabric after printing the fabric is passed through loop agers for fixing of the dyes
which is known as steaming or ageing (100% pigment fixation occurs)
Then the fabric is washed to remove any residual unfixed dyes

23
 The fabric undergoes quality check for various fastness properties
Final finishing of the fabric is done in the stenter

Recipes for printing are provided by the sampling department and prepared in the color
room. First a lot is printed (sample) and then if approved bulk production is carried out.

Printing Paste :

A thickener is the basic requirement for all dyes. For reactive dyes an alginate paste
(gum+ dyes) is prepared. For pigment dyeing a pigment paste (binder+ dyes) is used.

Production: 32 lakhs m/ month.

Machined Used: Four printing machines

Machine Brand No. of machines

Jimmer (Austria) 2
Eichones (Japan) 1
Lakshmi (India) 1

Problems Faced in the Printing Department:

Centre to selvedge variation in the prints

Misprints
Printed bands on the fabric
Dye- Stains on the fabric

INSPECTION & QUALITY ASSURANCE DEPARTMENT:

Arvind is committed at providing the best quality of fabric to the consumers for over 80 years
now. The quality control is an integrated process that starts when the customer gives the
order, and the Design & Development Department develops the samples accordingly, it is
checked for quality assurance measures and compliances with customer needs. At later stages
the fabric is inspected and testing of parameters of fabric is done.

24
 Quality
Assurance

Testing Inspection

Physical Testing In process

Chemical Testing Final

Shade testing

Process Control

Shipment clearance

Arvind follows 100 percent inspection procedures. The acceptance level of the fabric depends
on the customer preferences.

Inspection department uses 17 MAAG machines to find such defects in fabrics and 5 cutting
machines for removing the defects from the fabrics.

4-point grading system is used for inspection of fabrics:

Size of defect Penalty Points

3 or less 1 Point
3 to 6 2 Points
6 to 9 3 Points
More than 9 4 Points
Holes or Openings(Largest
Dimension)
1 or less 2 Points
More than 1 4 Points

25
Points per 100 square yards = Total points scored in the roll x 3600
Fabric width in inches x Total yards inspected

Fabric containing more than 40 points per 100 square yards is considered as SECONDS.

The fabric is further sent to the automatic folding and packaging machine (PLM machine) for
the final process.

Best achieved target in the shirting division : 97.28%

Average Target: 96.2% - 96.5%
Defect Precent Department
0.3% Yarn Dyeing
0.1% Spinning
1.3% Weaving
0.6% Processing
0.7% Excess or others

26
CONCLUSION:

In this internship module we have learnt a lot. We have gone through seven departments that are
spinning department, yarn dyeing department, warping department, sizing department, weaving
department and processing and finishing department in this time period. At the end of the
internship we come to know about minute details of textile industry and how it works. We learnt
manufacturing and planning process of the industry. Under this internship schedule, all the
qualified appointed people helped and guided us in understanding and learning different aspects
of the industry.

27