Textal Technology

1. SUMMER INTERNSHIP REPORT
(1 JUNE 2017-15 July 2017)
Grasim Bhiwani Textiles Ltd
• Submitted by:- Submitted to:-
• Salesh (39) Mr. Sudhakar Choudhary
• Sachin (38)
• Parmesh (27)
(Govt.Polytechnic,HisarHaryana)

2. ACKNOWLEDGEMENT
• I would like to thanks Mr.KULDEEP JANI (Unit
Head, Grasim Bhiwani Textiles Ltd),MR.K.K.LAHIRI
(CGN(0) Technical),MR.BALBIR SINGH (A.V.P,UNIT-
3,4&5),who give me this opportunity to work in
this esteemed organ
• I would also Thanks MR. Sudhakar Choudhary
(Executive Production ) to provide me guidance.
Also not to forget all the SHIFT OFFICERS who
support me in completion of this project.

3. PROJECT
• Designing & preparation of carpet fabric with
name of Govt.Polytechnic,Hisar

4. CONTENTS:
• INTRODUCTION
• PRINCIPLE
• OBSERVATION

5. INTRODUCTION

6. Despite the fact that some people use the words
carpet and rug interchangeably, preserving a
distinction makes floor covering easier to talk about.
For most manufacturers of such products, carpet
refers to floor covering that is installed wall-to-wall,
unlike rugs, which have a finished edge and simply
laid or placed on the floor. Although it is possible for
pieces of carpet to be edged and laid on the floor like
a rug without any installation, and although some
rugs are made to be installed over the entire surface
of the floor (sometimes called a wall-to-wall rug), it
is easier to use the terms consistently.
Some of the basic features that create a typology for
carpets are the fiber, the technique used to make it,
and the pattern

7. Hand tufting machines

8. Hand tufting machines
• Tufting is a type of textile weaving in which a thread is
inserted on a primary base. It is an ancient technique
for making warm garments, especially mittens. After
the knitting is done, short U-shaped loops of
extra yarn are introduced through the fabric from the
outside so that their ends point inwards (e.g., towards
the hand inside the mitten). Usually, the tuft yarns form
a regular array of "dots" on the outside, sometimes in a
contrasting color (e.g., white on red). On the inside, the
tuft yarns may be tied for security, although they need
not be. The ends of the tuft yarns are then frayed, so
that they will subsequently felt, creating a dense,
insulating layer within the knitted garment.

9. Observation

10. Machine-made carpets are tufted, woven,
knitted, flocked or needle-punched. Most
commonly tufting is used for machine-made
carpets. Tufted carpets are made on machines
where the yarn is stitched through a pre-
constructed backing to form a loop or a tuft. To
hold the loops in place, the back side of the
carpet is coated with latex.
Tufting is the most inexpensive and fastest
ways to manufacture a rug. Weavers can also
control the tuft size making it possible to create
carpets with varying patterns or surface
textures.

11. There are three kinds of woven carpets: Velvet, Wilton and
Axminster. Velvet is the least complicated of construction
methods. Velvet carpets usually come in one solid coloured
and a tweed effect may be noticed. Wilton carpets are more
intricate.
These are manufactured by using a Jacquard loom which
can hold up to six different coloured of yarns. The
Axminster method of weaving carpets produces the most
elaborate designs with a wide variety of coloured.
Knitted carpets are faster to make. In knitting, several sets
of needles create loops and these are stitched together
before the backing is applied. Knitted carpets come in solid
or tweed and the pile may be of the same size or of varying
heights.
• Flocked carpets are similar to Velvet carpets in
appearance. They have a dense cut pile of short fibres that
are imbedded into an adhesive-coated backing.

12. • Needle-punching is similar to hand-hooking.
Formerly used for indoor-outdoor carpets, this
process is now being used for carpets that are
only meant to be placed indoors as well. In
needle-punching, fibres are locked into a
packing by using hooked needles, which are
further compressed.

13. The Manufacturing Process
The process of manufacturing tufted
carpets can be explained in the following
steps:

14. Step 1: Preparing the yarn

15. • First, the synthetic yarns arrive at the carpet manufacturer
either in staple fibre form or in bulk continuous filament form
• The staple fibres, which are an average of 7 inches (18 cm)
long are generally loose and are individual strands that arrive
in bales. Several bales are blended together into one batch in
a hopper.
• Then, these strands are lubricated and are spun into long,
loose ropes called slivers by a carding machine. The slivers
are then pulled, straightened, and spun into single yarn that is
wound onto spools.

16. • Both the single-ply staple fibres (now spun into
filament) and the bulk continuous filament is then
twisted together to form thicker two-ply yarn suitable for
tufting.
• The yarns are then steamed to bulk them, and then
heated to 270-280°F (132-138°C). This heat setting
causes the yarn to maintain its shape by fixing its twist.
After cooling, these yarns are wound onto tubes and
transported to the tufting machines.

17. Step 2: Dyeing the yarn

18. • Generally, most carpets are dyed after tufting yet
sometimes the yarns are dyed first. The methods include
putting 500-1,000 pounds (227-455 kg) of fibre into
pressurized vats through which treated dyes are circulated,
or passing the fibre continuously through the bath, or
passing skeins of yarn through the vat of dye.
• The yarn can also be put on forms, and the heated dyes
can then be forced under pressure from inside the forms to
coloured the yarn.
Another method passes the yarn through printing rollers,
while yet another involves knitting the yarn onto a form that
is then printed with dyes before the yarn is unraveled. All
yarn that has been dyed is then steamed, washed, and dried.

19. Step3: Tufting the carpet
• At this stage, the yarn is put on a creel (a bar
with skewers) behind the tufting machine and
then fed into a nylon tube that leads to the
tufting needle.
• The needle pierces the primary backing and
pushes the yarn down into a loop.
Photoelectric sensors control how deeply the
needles plunge into the backing, so the height
of the loops can be controlled.

20. • A looper, or flat hook, seizes and releases the
loop of yarn while the needle pulls back up; the
backing is shifted forward and the needle once
more pierces the backing further on.
• Inorder to make a cut pile, a looper facing the
opposite direction is fitted with a knife that acts
like a pair of scissors, snipping the loop. This
process is carried out by several hundred needles
(up to 1,200 across the 12 foot [3.7 ml width),
and several hundred rows of stitches are carried
out per minute. Thus, one tufting machine can
produce several hundred square yards of carpets
per day.

22. Step 4: Finishing the carpet

23. • The ends of the dyed carpet are first sewn together to form a
continuous belt. This belt is then rolled under a dispenser that
spreads a coating of latex onto the bottom of the carpet.
At the same time, a strong secondary backing is also coated
with latex. Both of these are then rolled onto a marriage roller,
which forms them into a sandwich and seals them together.
The carpet is then placed in an oven to cure the latex.
• The completed carpet is then steamed, brushed, vacuumed,
and run through a machine that clips off any tufts that rise
above its uniform surface. The carpet is then rolled into 120
foot (37 m) lengths that are then packaged in strong plastic
and shipped to either the carpet manufacturer's inventory
warehouse or to a retail carpet store

24. QUESTION
AND
QUERIES

25. QUESTION
AND
QUERIES