2. I would like to express my special thanks of gratitude to Mr. PRADEEP
SAGI(Manager- Operations), Mr. VIDUSHAN(Asst. Manager-H.R) and
Ms. VIJAYA(Executive H.R) who gave me the golden opportunity to do
this wonderful project in FINISHING , which also helped me in doing a
lot of Research and learn about so many new things related to textiles. I
am
I would like to thank my mentor in department Mr. SANJEEWA , all
FINISHING EXECUTIVES and all the people in the department and in
various other departments who helped me a lot in successfully
completing my project within the limited time frame successfully.
really thankful to them.
Acknowledgement:
3. Fi
Solid discharge print
DYEING
B/F COLOUR ASSESSMENT
FINISHING
FINISHING HEAT (ELASTAIN FABRIC) DYEING (100% cotton)
KNITTING
GFI
GWH
PREPARATION
SOLID DISCHERGE PIGMENT SUPER SOFT
DYEING FINISHING
QC
PRINTING
Company Process Flow
Chart:
4. Finishing is the last manufacturing step in the production of textile
fabrics. As an integral part of wet processing, Finishing is the
operation where the final fabric properties are developed. Finishing is
not restricted to wet processing alone since any operation for
improving the appearance or usefulness of a fabric after it leaves the
knitting machine can be considered a finishing step. Finish can be
either chemicals that change the fabric's aesthetic and/or physical
properties or changes in texture or surface characteristics brought
about by physically manipulating the fabric with mechanical devices.
It can also be a combination of the two.
7. What is PFP fabric?
PFP fabric means “PREPARE FOR PRINT” fabric.
Before printing the fabric is passed through the stenter and it is rolled on the
“A- frame”. This fabric is known as PFP/ fabric.
This process is know as PRE-STENTERING process.
What do we mean by colour rejection fabrics in finishing?
Fabric after final finish are sent to quality assurance for checking the quality, colour
and other requirements of fabric according to the customer. If few fabric rolls
colour in the bulk are different, when compared to customer approved sample ,
then the specific batch is rejected and the batch is sent back to finishing for
reprocess.
9. Observations and method to follow while preparing PFP
fabric:
After dyeing the fabric which has to be printed must be passed through slitter for
opening .
For PFP fabric , in slitting it should be passed through “water spray” to remove dust
on the fabric.
While slitting, holes and joints should removed outside the trolley . these should be
monitored by the operator and stitched properly before stentering.
After slitting the fabric is passed through stenter and rolled on a “a-frame”. This
process is known as “PRE-STENTERING PROCESS”.
In the stenter the temperature is set according to the specifications and fabric is passed
through one padder containing water and other padder with chemicals.
PFP fabric in pre stentering process is run in auto process.
10. For PFP fabric, gum should be applied so that curling doesn't take place while rolling
on a-frame.
Cutters should be activated and trimming should be perfect, so it should be monitored
properly.
According to printing coverage GSM should be maintained. So width and GSM
should be monitored properly.
For PFP fabric to check GSM , we can cut holes only 3 times.
When the PFP fabric is running than the machine is operated in auto and after
finishing we can run in manual process.
At start of the m/c the fabric is passed slowly with minimum tension to obtain the
required GSM.
If overfeed is more than 50% than gum cutting will not take place properly.
11. BATCH
NO
PFP AFTER
PRINT
GSM
AFTER
STENTER Q.C RESULT
GSM WIDTH GSM WIDTH
7043507 127 65 144 134 64.5 GSM VARIATIONS:144,145,140
7043421 169,
170
72,71 163 169,
170
69.5, 70 OK.REPEAT ALSO OK
7043681 174,
169
71.5,
71.5
164 169,
170
72, 72 OK. AVG. GSM:176
7043683 169,
170
72, 72 164 170,
171
71, 72 OK. AVG. GSM:174
7043671 158,
166
72, 72 163 168,
170
70.5,
70.5
OK. AVG. GSM:173
7043669 168,
169
71.5,
72
163 169,
170
71, 71.5 OK
7043848 141,
135
65.5,
65
WET
FORM
143,
137,
139
62, 62.5 OK. AVG GSM:147
PFP FABRIC ANALYSIS:
12. BATCH
NO
PFP AFTER
PRINT
GSM
AFTER
STENTER
Q.C RESULT
GSM WIDTH GSM WIDTH
7043895 175,
170
73, 72 179 170,
169
68.5,
68
OK. AVG GSM:173. LIGHT TOUCH
UP DONE
7043894 173,
175
71.5,
72
193 170,
169,
168
68.5,
69
OK
7043896 164,
165
72, 72 180 169,
168
68,
67.5
OK
7043891 155,
164,
168
71, 72 172 164,
174,
17
69.5,
69
OK
7043992 165,
168
73,
72.5
166 169,
169
68, 68 OK
7043977 171,
181
71.5,7
2
166 168,
183
69.5 OK
7043978 178,
180
72 165 164,
168,
180
70.5 OK
PFP FABRIC ANALYSIS:
13. LOW GSM:
• Penetration of print on the fabric will be more.
• Backside of the fabric becomes darker
HIGH GSM:
• Penetration of print will be less.
• The print will be light
Holes :
• When there is a hole, the screen is lifted and almost 2 meters of the print fabric is
spoiled.
• If the screen is not lifted then colour falls in the hole and as the hole moves forward,
the colour gets stick to the other screen there by spoiling the fabric.
PFP FABRIC ISSUES:
14. Bad joint:
•When there is bad joint in the fabric, it can displace the screen there by causing
misprint.
•It spoils the screen and pores in it.
Dust/puffs:
•If there is dust or puffs on the fabric then it may block the pores of the screen which
blocks the path of the dye in the rotary screen
•This causes misprint in fabric which will cover by touch up team.
Gum and cut:
•If gum and cut does not happen properly then the fabric at edges get folded there by
causing smudges at the end. It causes narrow width also.
•Generally the edges are trimmed with scissors to avoid this.
15. AFTER PRINITNG ISSUES IN POST-STENTERING PROCESS:
If initially the fabric as low GSM, then maintaining the required GSM at final finish
will be difficult.
In final finish , the stenter is run in manual operation, so the over feed is fixed so there
may be gsm variations roll to roll.
In some designs of print we may encounter bowing lines .They are caused due to :-
1. If the pinning is tight, then the fabric in the middle area feels the pressure and
bending take place in the weft side of fabric.
2. Bowing is also caused if the fan speed inside the chambers is high then also we will
absorb bending in the weft direction of fabric.
We should also check the repeat of some designs and it should be maintained
properly. If we could not achieve the required properties in fabric than compacting
is done.
16. Steps to check the reason for colour rejections(white fabric) due to
finishing:
First we should check the ph of the fabric while unloading at dyeing.
(white fabric unload ph range at dyeing is 5-5.5)
Now check the overhead chemical tank ph.
Check the temperatures of the stenter.
After some time or after 5-7 rolls check the chemical padder ph .
Stoppages of the machine and speed of the machine must carefully
monitored as they might be the prime reasons for rejection.
COLOUR REJECTIONS:
17. BATCH NO FABRIC PH
UNLOADING
TIME
CHEMICAL
TANK PH
CHEMICAL
PADER PH
SPEED OF
M/C
(yd/m)
STOPPAGES
(in sec)
Q.C.
RESULT
7042790 5.04 4.23 4.86 28 5,8,5 OK
7044005 5.33 4.45 4.89 27 0 OK
7043799 5.25 4.41 4.91 28 7,5 OK
7043791 5.37 4.37 4.91 28 5, 3 OK
7044104
(BLACK)
UNLOAD PH NOT
NECCESSARY
4.04 4.98 27 8,6 OK
7044562 5.40 4.90 5.43 33 5, 7,10,8 Ok
7044556 5.09 5.08 5.65 32 5,7,4,5 Ok
7044558 5.11 5.05 5.77 30 5,8,6,6,7,
5
Ok
7044278 5.07 5.07 5.89 31 8,8,5,7 Ok
Colour Rejections Fabric Analysis in Finishing:
18. Why colour rejection happens?
When machine stops for more time, than the colour of the fabric inside chamber
varies because it stays more time in the chamber. This is the prime reason for colour
rejection of fabric in finishing.
Sometimes the fabric colour may get accepted in dyeing because of operator mistake
but after final finish the fabric may get rejected , so we should cross check the colour
of the fabric before stentering.
If the chemical tank ph is not within the standards than also there is chance of color
rejections.
If the temperature of the m/c is not set according to the specifications or there is
variations in temperature then rejection happens.
19. If the speed of the fabric is increased when compared to the specification than also
colour variations happens.
For cool n fresh fabric the speed must be 28 yd/m if not then colour of the fabric
becomes yellowish
Temperature range for cool n fresh should be:
170 170 170 170 165 165 165 165
For white fabric or any cool n fresh fabric we should add “citric acid” to
maintain ph and whiteness of the fabric. If this is not added properly than the
required whiteness will not be achieved.
When fabric carries the dust particles from the water padder to chemical
thereby altering the ph of the chemical padder which can cause colour
variations.
20. Conclusions:
The slitter operator must check and note down how many holes and
joints are there in the fabric very carefully, note it down and give it
stenter operator.
Stenter operator must stitch the joints and holes properly without
missing out any.
At the front side of the m/c the operator should carefully monitor
whether the gum is properly applied and cutting is properly happening ,
if not he should trim it properly with the scissors.
After printing, some designs repeat should maintained, if it is not
maintained compacting should be done.
21. For colour rejections, the important thing to monitor is speed variations
of the fabric from trolley to trolley and also for how much time the fabric
stops .
Generally to increase the production the temperature and speed of m/c
is increased respectively , this causes colour rejections so it should
monitored properly.
The pinning of the fabric must be proper or whenever the fabric
pinning misses the m/c stops and until the operator keep it right the m/c
stops and even there is speed variations for few seconds.
