Summer training during internship Projects Manoj kumawat BTech -Manikya lal verma government textile engineering College,pur road ,bhilwara Textile chemistry branch

1. TO INCREASE THE RFT% OF
HANG JIE AND OBBDM TO
BULK
PROJECT TITLE
Project
working
Industrial
trainning
Project work
SUBMITTED TO :--
MR.TANNMAY MUKHARJEE
(R&D)
Submitted by
Manoj kumawat
MLVTEC BHL

2. What means of RFT%
RFT = RIGHT IN FIRST TIME
RFT means that process correct in first trial
at standard conditions and parameters like
temp.,time,pH,addition chemicals etc.
RFT..????
Importance of RFT%
• Time saving
• Material saving
• Dyes, chemicals and auxalaries
• Quality improve
• Production increase
• Timely dispatch
• Working load decrease
• ETC

3. PPC
INFO ABOUT ORDER OF
PARTY
R&D
TAKE RECIPE
LAB M/C
OBSERVE SHADE OR
RECIPE
PPC
INFO.ABOUT TIMEING
TO RUN IN BULK M/CS
BULK M/C
OBSERVE THE
CHANGAGE OR
DEFECTS
CHECKING
CONFIRM TO DEFECT
OR CHANGAGE
PLANNING TO DO
WORK!!!

4. HANG JIE
SPECIFICATION
• COMPANY - TIYAWAN
• MAX.HEAT CAPACITY - 140 DEGREE
CELCIUS
• STIRRER - MAGNETIC LAVELATOR
• RPM OF MAGNETIC LAVELATOR - 36
• AREA - 70*50 SQUARE CM
• TOTAL BEAKER= 18
• BEAKER CAPACITY= 360ML
• BEAKER TO BEAKER SEPERATION –METALLIC
PTATE
• HEATING ARRAGMENT-THERMOCOUPLE
• HEAT SENSOR –AT THERMOCOUPLE
• PRESSUING UNIT =ADDITIONAL WITH
GAUGE
• DIA OF BEAKER=6CM
• BEAKER TO BEAKER DISTANCE=2.5 CM

6. temerature varition
Non-uniformity of
Excess water
Package density
varition
Heat exchange
Beaker to beaker
PH Of dye dispensive
No. of stocks
of salt & soda
due to worker
RFD HINDRENCE IN HANGJIE
temerature varition
un-uniformaty of excss water
package density varition
heat exchange beaker to beaker
PH (7.54) at dispensor
salt &soda PTRN problem
due to worker

7. Wet
Chees
Pressure
unit
ON/
OFF
EXCESS WATER THROUGH OUT TO
WETTED CHEES
PRESSURE CONTROLLOR
NOT PRESENT NOW
CHEES
WINDING
10 MIN IN WATER
MAGNET ATTACH
TIGHT IT
DYEING
EXCESS WATER OUT
BEAKER SETTING Copower
Auto
Dispenser
PROBLEM
UN EVEN WATER IN CHEES
REASON
NO ANY STANDARD TO MEASURE IT
EFFECT
MLR CHANGE
SHADE VARITION
SOLUTION
SHOUD BE A STANDARD TO MEASUER IT

8. 50*c
5
10
69*C 78*C
60*c
10 20 10 50
2
50*c
5
68*C 72*C
60*c
20
2
50*c
15
83*C
90*c
10
2
50*c
13
84*C
85*c
10
2 2
50*c 50*c
10 10
salt soda castic
Green acid soaping h/w
c/w fixer
PTRN -1 REACTIVE NORMAL ON 100% COTTON
AFTER CO-POWER
DISPENSIVE REACTIVE HE DYE
IS BASIC(PH=7.3-7.5)
SO SHOULD BE ADDED ACETIC
ACID
NOTE-
AT HIGH TEMPURETURE SODA,CASTIC, SALT,ACID LOSE
THEIR STRENGTH
½ SALT ½ SODA
IN 2 TIMES DOSSING
PTRN PROBLEM ON HANG JIE M/C
STANDARD
NOW ON HANG
JIE

9. COPPER WIRE
BISMUTH WIRE
R=pl/a
Here
R=resistance of copper wire
l=length of copper wire
a=cross-section area of copper wire
Resistance is directly perprotional to
temp.
R=Ro(1+@(T2-T1))
Here
R=resistance of copper at final
temp.(x)
Ro=resistance of copper at initial
temp
@=temp.cofficent of resistance of
copper
T2=Final temp.
T1=initial temp.
DUE TO THERMOCOUPLE TEMP. CHANGE
REASON
LOSS THEIR PROPRETIES(ACCO.TO LIFE
TIME)
DUE TO MOISTURE (WATER CONTAIN
HARDNESS PARTICLES)
SENSOR MEASURMENT IS INCORRECT
SOLUTION
CHANGE THERMOCOUPLE AND SENSOR

10. EFFECT OF TEMPERATURE ON DYEING
LOW OR ESCESS HEATING
DYE MOLICULES
KIENITIC ENERGY
INCREASE
(KE=.5*M*V*V)
KIENITIC ENERGY
DECREASE
COTTON COTTON

11. NaCl
NaCl NaCl
NaCl
Na
+
Na
+
Na
+
Na
+
Na
+
Cl
-
Cl
-
Cl
-
Cl
-
Cl
-
Equilibrium
Cotton
Dyes molecules
With water
ie;dye soiution
salt
NaCl
N
N
N
D-NH- -Cl
-Cl
+NaCl+Cell-OH -
N
N
N
+
+
+ -O-Cell
H+-Cl
N
N
N
D-NH- -O-Cell
Chemical reaction b/w cotton & reactive
salt in reactive dye
During this absorption process the total amount of dye dissolved in water is not transferred to the substrate.
Depending upon the affinity of the dye molecules for the substrate, they rush on to the substrte; thus some
amount of dye reached on the substrate.
And then an equilibrium is reached- some of the dye molecules continuously moved to the substrate from the
water and some of them are coming out of the substrate to water.
As soon as salt is added, the equilibrium gets disturbed and some more dyes are forced to move on to the
substrate.
But after some time the equilibrium is restored, with maximum dyes exhausted on the substrate.

12. Na2CO3
Na2CO3
Na2CCO3
Na
+
Na
+
Na
+
Na
+
Na
+
CO3
-
CO3
-
CO3
-2
Cotton
Dyes molecules
With water
ie;dye soiution
soda
Na2CO3
N
N
N
D-NH- -OH
-OH
+Na2CO3+Cell-OH -
N
N
N
+
+
+ -O-Cell
H+-OH
N
N
N
D-NH- -O-Cell
Chemical reaction b/w cotton & reactive
SODA (Na2CO3)
SOME DYE MOLECULES ARE HYDROLYSE IN WATER WHICH UNBONDED WITH CELLULOSE
OR THE SUPERFICIALDYE MOLECULES REMAINS FREE OF MOMENT (FORCE OF ATTRACTIO
THAT TIME THE SODA INCREASE THE FORCE OF ATTRACTION B/W DYE AND COTTON

13. BEAKER -1 BEAKER-2
I
N
S
U
L
A
T
O
R
S
H
E
E
T
INSULATOR SHEET
HEAT GAIN OR LOSE BEAKER TO
BEAKER What is heat?
Heat is a form of energy which can be sensable as hot and cool
It denoted by Q
Heat(Q) =M*C*dT
Here
M= Mass of material
C= specific heat constant
dT=temperature diffreance
REASON
SHORTER DISTANCE B/W THEM (50*70CM2)
HEAT CONVENTION(hot ->cold place)
Effect
• Temp.variation
• Heat loss and gain
Solution
• Control by insulator sheet box
• SAME DYE IN A BATCH
Now metallic plate present
replace by insulator sheet

14. HANG JIE WINDER
SPICIFICATION
•No of pkg winde=2
•For 2 pkg controllor unit or penal =1(2winder contain 1 penal)
•Pkg density=0.38 gm/cc
•Rpm = 1200
•Electrical balance= 2
•Length measurment =1.69*count(ne)*wt.of pkg
•Traverse=150mm
•Max.pkg wt =50gm
•Empty chees wt.=210gm
•Chees dia=2.5cm
•Pkg dia-3-4cm

15. HANG JIE CHEES
POURS OF CHEES
SHOW OUT
EFFECT OF UNUNIFORM WINDING
• NOT MAKE PROPER FLOW OF DYE SOLUTION DUE TO
THIS SHADE VARITION
• PGK DENSITY VARITION DUE TO THIS LEVELNESS OF
TMB PROBLEMS COMES OUT
• UNDYED MATERIAL PROBLEMS
• ETC
• REASIONS
• MORE VIBRATION IN CREDLE
• MORE BREAKAGE IN YARN( DUE TO VIBRATION IN
CREDLE)
• CREADLE PRESSURE IMPROPER
• SOLUTION
• CREDLE SPRING CHANGE AND CLEANING THE M/C PARTS
• CHECK IT BEFORE DEYING AND REWIND THE CHEES

16. S.N
O
COUN
T
LENGTH
HJW(IN MT)
WT. OF
CHEES(IN
GM)
CALCULATI
ON
ACCO. TO
LENGTH
CHEES WT.
1 40CW 2917 50 2917/1.693/40 43.07
2 40CW 2922 50 2922/1.693/40 43.14
3 40CW 2904 50 2904/1.693/40 42.88
4 40CW 2940 50 2940/1.693/40 43.41
5 50CW 3646 50 3646/1.693/50 43.07
6 50CW 3736 50 3736/1.693/50 44.13
7 60CW 3181 30 3181/1.693/60 31.31
8 60CW 4810 50 4810/1.693/60 47.35
9 70CW 4244 30 4244/1.693/70 35.811
10 80CW 6077 50 6077/1.693/80 44.86
11 80CW 6465 50 6465/1.693/80 47.73
12 16 S 1004 30 1004/1.693/16 37.06
13 10 S 792 50 792/1.693/10 46.78
14 20 S 1554 50 1554/1.693/20 45.89
15 24 S 1743 50 1743/1.693/24 42.89
OBSERVATION TABLE HJW CHEES FORMATION
CALCULATION-
LENGTH=1.693*NE*PKG WT
THINK ABOUT THIS…?.
SAME LENGTH
SAME COUNT
SAME SPEED WINDING
THEN…
DIFFERENCE IN WT.?
DUE TO
1.CHOCKING THE CHEESHOLDER
2.LOOSE SPRING
SOLUTION
1. CHANGE THE SPRING
2. PROPER CLEANING OF CHEES
HOLDER

17. OBBDM
OBBDM =OPEN BATH BEAKER DYEING
M/C
SPECIFICATION
TOTAL BEAKER =14
BEAKER CAPACITY= 390ML
STIRRER=ACENTERIC ROLLER ARRAGMENT
HEATING-ELECTRIC RODS AT BOTH ENDS
WATER CAPACITY IN BATH =X
HEATING SENSOR=IN WATER BATH
PRESSURING UNIT = NOT
DYEING =IN OPEN FORM

18. Weight of sample
acco. To MLR
Co-power colour dispensive
Water level in bath and set
temp .,arrange stirring system
Beaker set and dyeying
Soaping on heater
Hydro extractor
drying
Quality check
confirmaton
Scoured materal choose
OBBDM DYEING PROCSS

19. temperature
varition
78%
slight change in
MLR
5%
open RFD yarn
form &
unpressueize dying
6%
Standard of
soaping
11%
RFD HINDRENCE IN OBBDM !!!!!
temperature varition
slight change in MLR
open RFD yarn form & unpressueize
dying
Standard of soaping

20. TEMPERATURE
IN OBBDM
THE HEATING RODS IN BATH AT
BOTH END BUT NOT UNIFORM
HEATING HERE
DUE TO LONG PATH
AND SETTING OF SENSOR
HEATING
RODS
60*C
WATER
55*C
BEAKER
54*C
DYE
SOLUTION
50*C
• EFFECT
• NOT PROPER HEATING
• BEFORE CALL THE M/C AT THIS
POSITION OF TEMP.
• HEAT LOSS
• SOLUTION
• MANUALLY CHECK TEMP.
• THERMOCOUPLE JACKET
SYSTEM
• SENSOR SET AT MIDDLE
POSITION OF BATH
Hooter call

21. change
CHANGE IN FORM & RAW MATERIAL OF DYEING
IN OBBDM
THE OPEN SCOURED YARN DYEING
WHILE
IN BULK
THE PACKAGE GREY YARN DYEING
EFFECT
DUE TO PRESSERIZE PENITRATION OF DYE IN YARN
THEN DARKER SHADE OBTAIN COMPARE TO OBBDM
AT SAME CONDITION
SOLUTION
UNIFORM PRESSURE FLOW
UNIFORM FLOW RATE
RFD WILL BE SAME
(YI=65-70)
OPEN RFD YARN
DYEING
PKG GREY YARN
DYEING

22. IN BULK M/CS
SPECIFICATION
WATER CAPCITY=ACCO.TO M/C
PKG CAPACITY=ACCO.TO M/C
SIZE OF PKG=ACCO.TO M/C
HEATING SYSTEM= STEAM PIPE
PRESSURE REGULATOR UNIT(MAX P.=5-6KG
DOS. AND INJ. SYSTEM= 2 DISSOLVING TANK
AUTO.DRAIN SYSTEM=TO DRAIN
CONTROL PANEL =TO CONTROL THE SYSTEM
CARRIER=CONTAINING SPINDLES AND PKG
PUMP =TO MAKE FLOW
MOTOR=TO CONTROL THE PUMP
ETC

23. extraction
Dyeing
Prewinding
Postwinding
Route of dyeing
process
conditioning

24. package density
varition
MLR varition
carrier problem
dummy setting
chelling problem in
fong &thies
due to worker
RFD HINDRENCE IN BULK
package density varition
MLR varition
carrier problem
dummy setting
chelling problem in fong &thies
due to worker

25. CHALLING PROBLEM
PROBLEM
• THISE AND FONGS ARE PRESSURIZE M/C
WHICH NOT WORKING WITHOUT
PRESSURE SO WE DONOT CHECK THE
CHALLING BEFORE SCOURING BUT CHECK
IT BEFORE RFD
EFFECT
• SCOURING IS NOT PROPER CONDITION
• CUT THE NEAREST YARN PKG
•
SOLUTION
• CHELLING CHECK FIRST OR BEFORE SCOURING

26. CARRIER FILLING PROBLEM
GAP B/W THE TWO SPINDLE IS –IVE OR ZERO
REASONS
LOOSE WINDING
LOAD ON SPINDLE INCREASE
INCREASE THE LOT.SIZE IN UNAVILABILITY OF
M/C
• EFFECT
• PKG TO PKG VARITION
• PANITRATION OF DYE SOLUTION IS NOT
PROPER OR LEVELNESS PROBLEM
• PEEL OFF INCREASE
• PRODUCTION DECREASE(DUE TO REWINDING)
• SOLUTION
• PLACED SEPERATION PLATE TO TOP THE
SPINDLE
•

27. Tight
package Loose
package
Less flow
of liquor More flow
of liquor
Density of
package
What is density?
Density is the ratio of mass of pkg and volume of pkg
wt. of pkg
Density =
volume of pkg
Effect of density
• Loose pkg density is lower to standard
then the penetration of dye solution is
more and resultant darker shade
• Tight pkg density is higher to standard
Then the penetration of dye solution is
low and resultant lighter shade
• for levelness, uniform density requare
Standard density range
Cotton-.38-.41gm/cc
P/c -.40-.44gm/cc
Importance of density
• Increase thr RFT%
• Decrease Pkg to pkg
• Levelness
• ETC
S.NO PKG
DENSITY
1 0.39
2 0.36
3 0.38
4 0.37
5 0.40
6 0.41
7 0.38
8 0.38
9 0.36
10 0.38
OBSERVATIONS

28. The effects of
MLR:
Can’t we fix the MLR ?
The answer is
‘NO’.
1st Lot 2nd Lot Change the MLR then effect is-
-
1. darker or lighter shad
2. Utility cost effected
3. For same concentration dye,chemicals,and
auxiliaries
Amount increase or decrease then cost
also vary
But minimize to this-
1. Fixed the m/c capacities both water and material
2. Restricted the variation of pkg density
3. Variable order minimize
M/C MLR
F-18 1:13.33(160/12)
F-19 1:15.54
F-20 1:16
F-21 1:13.33
F-26 1:14.48
THIES-6 1:6.48(1400/216
F-(7-10) 1:7.5
F-(11-14) 1:9
OBSERVATION

29. DUMMY PROBLEM
EFFECT
PRESSURE VARITION (DUE TO HIGHT OR NO.
OF PKG DISTRIBUTION)
PKG TO PKG VARITION
REASON
PUMP PRESSURE+HIGHT PRESSURE
SOLUTION
BLOCK AT BOTTOM IT
DECREASE THE PACKAGE WT. (DIA. OF PKG)

30. The ratio of the amount of substrate to be dyed
and the water volume to be used to dye the same
is called as Material to Liquor ratio (MLR).
MLR = = 1 : 6
Substrate
Liquor used
MOISTURE % EFFECTED TO
MLR
The amount of water present in any
material with respect to their oven
dry wt. is called moisture
moisture
MLR-material to
liquor ratio
Moisture(water)
50 gm cotton 300 ml water
Actual mlr=47/303=6.44
Actual material=m.wt.-moisture
Actual liquor=l.wt.+moisture

31. S.NO. LOT NO. COUNT M.WT.
(in lab)
MLR (in
lab)
PTRN M.WT.(In
bulk)
MLR(in
bulk)
M/C REMARKS
1 28924 44comp. 5gm 14 54 12*.92=
11kg
14.54 F-19 Ok
2 47933 1/30ch 7gm 10 163 12*1.08=
13kg
11.53 F-26 Add
3 47892 1/30cc 7gm 10 163 13kg 11.53 F-19 Add
4 48251 2/40cvc 8.75gm 8 5kg 10 F-16 Ok
5 48243 20kwspx 50gm 12 24 2.4kg 12.50 F-9 Ok
6 48247 40cw 50gm 7 87 6.9kg 7.24 F-15 Ok
7 48181 12cwcp/c 50gm 11 - 2.6kg 11.53 F-10 Ok
8 48180 1/30p/c 5.83gm 12 - 2.5kg 12 F-8 Ok
9 48981 1/30cc 10gm 7 18 105.3kg 7.597 T-7 Ok
10 49403 2/20AC 8.75gm 8 48 90kg 8.89 T-8 Dummy
creak
Observations

32. RESULTS
HANG JIE
• WILL BE A STANDARD TO REMOVE EXCESS WATER
• METALLIC PLATES REPLACE BY INSULATOR SHEETS
• SPRING CHANGE TO THE HANG JIE WINDER
• CLEANING OF CHEES HOLDER IN HANG JIE WINDER
• CHANGE THE THERMOCOUPLE
• NO. OF STOCKS INCREASE OF SALT AND SODA IN DYEING
• ADD A.A. IN CO-POWER DISPENSIVE COLOUR IN REACTIVE DYE
OBBDM
• IMPROVE IN TEMPERATURE VARITION
• MLR AND PH MAINTAINE EXACTLLY SAME TO BULK
• WILL BE A STANDARD OF SOAPING
IN BULK
• CHECK CHALLING IN FONGS AND THIES BEFORE RFD
• THIES 1,2 AND 6 DECREASE THE VOLUME OF WINDED YARN
• MLR WILL BE SAME TO LAB DIP(15# 15.54)
• DUMMY IS REPLACE BY LOCK
• RFD WILL BE SAME TO RFD OF LAB DIP( AS SPDM)
• NOTE
• IMPLIMENTS ALL THESE POINTS ,WILL BE SURE 20-30%RFT INCRE

33. CONCLUSION
hang jie to
bulk(<28pkg)
hang jie to
bulk(>28pkg)
obbdm to bulk
Jun-16 62 75 58
Jul-16 67 68 56
AFTER IMPLIMENT 85 85 85
62
75
58
67 68
56
85 85 85
0
10
20
30
40
50
60
70
80
90
RFT%
M/C AND MONTH
Jun-16 Jul-16 AFTER IMPLIMENT

35. Steam rate decrease by ---
1-economizer
2-solar plant
3. Vibration unit in cake outer m/c
heat =m*c*dt=1*4.2*50=21kgjoule
1kg coal produce =6kg steam
1kg husk produce=4.86kg steam
Husk gross calorific value=3200kgjoule/kg
SOME NEW IN AURO DYEING WHICH CAN BE PROFFITAB