Maral overseas pvt ltd,industry visit report by pooja

SDPS/ INDUSTRY RESEARCH/2017/6TH
SEM 1
INDUSTRY RESEARCH REPORT
(MARAL OVERSEAS PVT LTD)
KHULBUJURG, KHARGONE
Bachelor in Fashion Designing
(Affiliated to SNDT University, Mumbai)
Submitted By:
MS. POOJA KUMARI
Under the Guidance of
MS. SHRUTI TIWARI
Department of Fashion Design
SDPS Women’s College, Indore
March, 2017

SEM 2
ABSTRACT
This document is an account of the study and research work done during our 6th
semester, 3rd
year 2017 at Maral Overseas pvt ltd khulbujurg, khargone
(Madhya Pradesh) as a part of fulfillment of our course curriculum.
The project was carried under the guidance of Dr. SHRUTI TIWARI
,(Prof. at SDPS Women’s college Indore) and Mr. BALWANT PARMAR, vice
president as our project guides.

SEM 3
DECLARATION
“This is to certify that this Project Report titled “Industry research – Maral
Overseas Pvt ltd “is based on our original research work, conducted under the
guidance of Ms. Shruti Tiwari towards part of our course curriculum, of SDPS
Women’s College (Indore).
No part of this work has been copied from any other source. Material, wherever
borrowed has been duly acknowledged”.
Signature of author/researcher
Ms. POOJA KUMARI

SEM 4
ACKNOWLEDGEMENT
We would like to thank Mr. BALWANT PARMAR sir, Vice President Maral
Overseas Pvt. Ltd. for giving us the opportunity to their organization and
making it possible to complete this project successfully. Our sincere thanks to
Mr. PRAVEEN SINGH (HR).
We would also like to thank our project guide DR. SHURTI TIWARI for her
guidance and help whenever required through this project. A token to thanks for
Mr. HEMANT KAUSHIK, HOD, SDPS Women’s college (Indore) for providing
the appropriate atmosphere to work and complete this project successfully.
A note to thanks our families and friends for bearing with us and providing their
full support in the making of this report.

SEM 5
CERTIFICATE

SEM 6
CONTENTS
ABSTRACT……………………………………………………….……………2
DECLARATION………………………………………………………………3
ACKNOWLEDGEMENT…………………………………….……………….4
CERTIFICATE……………………………………………………………...5-6
1) CHAPTER 1
INTRODUCTION…………………………………………………….8-34
2) CHAPTER 2
REVIEW OF LITERATURE…………………………………..………………..35-37
3) CHAPTER3
METHODOLOGY…………………………………………………………......38-40
4) CHAPTER4
FUTURE AND SCOPES……………………………………………..………....43-44
CONCLUSION……………………………………………….……..……......45
QUESTIONEIR……………………………………………………..……..…46
BIBLIOGRAPHY……………………………………………………..……...47

SEM 7
CHAPTER-1
INTRODUCTION
1.1 COMPANY PROFILE………………………………………………………….9
1.2 MANUFACTURING UNIT…………………………………………………….9
1.3 COMPLIANCE…………………………………………………………………11
1.4AWARDS AND ACHIEVEMENTS………………………………………..….12
1.5 MARAL SAROVER UNIT ……………………………………………………13
1.6YARN ……………………………………………………………………..…14-19
1.7 FABRIC……………………………………………………………………..20-24
1.8 FINISHED GARMENTS ……………………………………………...…...25-26
1.9 DESIGN & DEVELOPMENT………………………………………..……27-29
1.10 MARKET………………………………………………………………...……30
1.11 CAREER…………………………………………………………………...….31
1.12 COMMITMENTS………………………………………………………....32-33
1.13 WATER TREATMENT PLANT………………………………………....34-36

SEM 8
INTRODUCTION
1.1 COMPANY PROFILE
Maral Overseas Ltd, one of India’s largest vertically integrated textile companies. This export
led company is a part of the $ 1114 million LNJ Bhilwara Group, whose leadership in textile
business is complemented by high technology sectors of graphite electrodes and power
generation.
Set up in 1991 at MaralSarovar, it is a $ 139 million (834 crore rupees) composite company
today. Its two ultra-modern units produce 1500 tons of grey yarn, 125 tons of dyed yarn, 400
tons of knitted fabric and 500,000 pieces of garments every month even as they constantly
innovate to diversify and upgrade their products.
It is a public limited company listed on the stock exchanges in India. Banking on its core
strengths, modern manufacturing technology, quality systems, quality relationships, Maral
has earned the reputation of an extremely reliable supplier in the global market.
Its conviction in leadership through quality and best business practices enables Maral to
emerge as a reliable supplier of world-class products in the global market.
1.2 MANUFACTURING UNIT
Supported by its own captive power units, the MaralSarovar plant is ideally located in Central
India's cotton heartland 500 km from Mumbai and 90 km from Indore, and its garment
factories in NOIDA near Delhi.
Maral’s entire infrastructure is geared towards achieving short lead times for its diversified
product range. State-of-the-art machinery from Spinning to Garmenting, operating in a highly
computerized environment is the pride of Maral.
http://maraloverseas.com/about_mol.html

SEM 9
MARAL SAROVAR
MADHYA PRADESH
Location: Sarovar (Established in 1991)
Production Facility
 Yarns
 Fabrics
Captive Thermal Power Plant: Capacity 10 Megawatt
Address:
MARAL OVERSEAS LTD.
MaralSarovar, V & PO, Khalbujurg,
Tehsil Kasrawad
Distt.Khargone,
M.P., India
----------------------------------------------------------------------------------------------------------------
NOIDA 1
Location: Noida 1 (Established in 2003)
Production Facility
 Garments
Address:
MARAL OVERSEAS LTD.
A-11, Hosiery Complex,
Phase II Extension,
Noida – 201305
U.P., India
http://maraloverseas.com/about_manufacturing.html

SEM 10
1.3 COMPLIANCE
Maral is one of the first Indian companies to have all compliance certifications. It has
received certifications like ISO 9001-2008, ISO 14001-2004, OSHAS 18001-2007,and
GOTS, OCS-100 & Blended, BCI Cotton, Fair-trade and Oeko-tex certificate.
NOIDA GARMENT UNIT
ISO 9001:2008 certificate
GOTS, OE 100 & OE Blended certificate - CU803702
Fair-trade certificate - FLO ID 18529
WRAP certificate
Marks & Spencer Social Compliance
Sears Social & Technical Compliance
http://maraloverseas.com/compliance.html

SEM 11
1.4 AWARDS AND ACHIEVEMENTS
MaralSarovar unit won the third level Safety Award "SurakshaPuraskar" Bronze Trophy
and certificate in Group E under the manufacturing sector category for implementing
Occupational Safety and Health (OSH) Management Systems & procedures effectively and
achieving very good performance in OSH. This award will be received from the Hon’ble
Minister for Labour& Employment, Govt. of India in a function being organized along with
forthcoming `Asia Pacific Occupational Safety and Health Organisation (APOSHO)
Conference’ to be held on 5th and 6th April, 2016 in VigyanBhawan, New Delhi.
MaralSarovar unit won National Energy Conservation Award-2014 with certificate of
Merit in the Textile Sector.
Maral Overseas Limited has received numerous performance awards. The company has
received The Rajiv Gandhi National Quality award, the Greentech Safety Award, The
National Energy Conservation award, CITI Birla Award for excellence in Energy
conservation, FICCI Safety Award &Shreshth Award from National Safety Council, M.P.
Chapter.
http://maraloverseas.com/about_awards.html

SEM 12
1.5 MARAL SAROVER UNIT
MaralSarovar unit won The CITI’s Birla Award for Innovations by the Textile Mill for the
year 2013-14. The award consists of a cheque for Rs. 2 Lakh and a citation. The award
received by Shri Ashok Akade, Asstt. Vice President - QA & Compliance of Maral Overseas
Ltd in 8th Asian Textile Conference & a glittering ceremony held at Westin Hotel, Mumbai
on 23rd September 2014
MaralOverseasLtd, MaralSarovar won Health Shreshth Award 2013. The award received
by Shri Suresh Maheshwari, President and Shri R.P. Gautam, Sr. Vice-President of Maral
Overseas Ltd from the Principal Secretary (Labour), Madhya Pradesh Government in a
glittering ceremony held at Bhopal on 09th September 2014.
Maral Overseas Ltd, MaralSarovar won the FICCI Safety Award for Excellence in Safety
System in Manufacturing for the year 2013. The award received by Shri R P Gautam, Sr.
Vice-President of Maral Overseas Ltd from MrKodikunnil Suresh, the Minister of State for
Labour&Employment , Government of India in the presence of Mr. Ajay Shankar, Member
Secretary, National Manufacturing Competitiveness Council (NMCC) and Mrs.
NainaLalKidwai, President of FICCI in a glittering ceremony held at New Delhi on 10th
December 2013. Maral is First Textile Industry, who has got the FICCI safety award in
Manufacturing.
Maral Won Citi’s Birla Award
Maral Overseas Ltd, MaralSarovar won the CITI’s Birla Award for Excellence in Energy
Conservation for the year 2010-11. The award consists of a cheque for Rs. 2 Lakh and a
citation. The award received by ShriTarunBaldua, President of Maral Overseas Ltd from the
hands of CITI’s Chairman ShriShishirJaipuria in a glittering ceremony held at Hotel Trident,
Mumbai on 30th September 2011.

SEM 13
1.6YARN
OVERVIEW
Maral produces 100% cotton combed yarn in different count ranges. Our focus is on sourcing
the best quality of raw material from India/abroad. A dedicated team for cotton procurement
frequently travels across India and abroad to assess the quality before purchase.
We have a system of “on the spot passing” before we procure any cotton – be it in India or
abroad. The focus is on having a fine quality long staple fiber (29mm+) with lowest possible
contamination levels. We have also established strategic relations with some of the farmer
groups/ginners to provide us “contamination free cotton”.
HVI testing equipment has also been installed to test cotton. Every lot is religiously tested
before purchase.
In order to cater to our quality conscious customers, we have reached out to various countries
like Turkey, Greece, Brazil, USA, West Africa, Egypt etc. to source a variety of cotton
including Organic, Fair-trade, Long Staple, and contamination free cotton.
http://maraloverseas.com/product_yarn_overview.html

SEM 14
PRODUCTS
 100% Cotton combed Ecru (raw white) and Dyed Yarn
 Product Count Range (Ne)
 Single Yarn Ne 10/1 to Ne 40/1
 Double Yarn Ne 10/2 to Ne 30/2
 Multi fold Yarn Ne 10/x to Ne 30/x
Special Yarns
 Bamboo / Cotton Yarns ,Modal / Cotton Yarn
 Soya / Cotton Yarns , Organic Cotton Yarns
 Fair-trade Certified Cotton Yarns
 Long Staple Cotton yarns / Pima Cotton Yarns.
 Slub Yarns, Core Spun Lycra (Spandex) Yarn
 Compact Yarn
 Contamination Free Yarn
 Reverse Twist Yarns, Recycled Cotton Yarn
 Zero Twist yarns (PVA yarns)
Yarn Application
 Circular Knitting (Weft knits)
 Socks Knitting, Flat Knits (Sweaters)
 Towel Weaving (Base and Pile)
 Denim Fabrics
 Bottom Weight Fabrics
 Yarn Dyeing
 Sweaters
http://maraloverseas.com/product_yarn_prdrange.html

SEM 15
CAPACITY
S.NO PRODUCT PRODUCTION CAPACITY IN TONS/MONTH
 Total Capacity 1500 Tons
 Double Yarn 250 Tons
 Compact Yarn 90 Tons
 Slub Yarn 45 Tons
 Cotton / PVA Zero Twist
 Yarn (PVA Twisted) 100 Tons
 Dyed Yarn 150 Tons
 Core Spun Yarn 7 Tons
 Yarn on Cylindrical Dye Tubes 30 Tons
http://maraloverseas.com/product_yarn_capacity.html

SEM 16
INNOVATION
 Organic Cotton Compact Yarn Dyed Yarn
 Core Spun Lycra Zero Twist Yarn (PVA Twisted) Blended Yarn
 Yarn on Plastic dyed cheese Slub Yarn
 Fair-trade Cotton Yarn Contamination Free Yarns
 Organic Cotton Yarn
Introduction
Cotton grown on land free of chemicals for three years is certified as 'organic.' Cotton grown
on fields which have been free of chemicals for less than three years is certified as
'transitional organic.'
Products offered
 Blends (5%, 10%, 15% and more) and 100% Organic Cotton
 Count Range - Ne 10/1 - 30/1 (Single and TFO)
Certification
 GOTS
 OCS-100 & Blended
Infrastructure
Maral has a state-of-the-art infrastructure to produce top class yarns. We have renowned
technologies from best brands like Reiter, Schlafhorst, Murata, etc. The list of machinery is
as below:
http://maraloverseas.com/product_yarn_innovation.html

SEM 17
RAW WHITE YARN
 Process Machine Brand
 Blow room Reiter
 Contamination Sorters Loptex
 Carding Reiter
 Draw Frame Reiter
 Combing Reiter
 Simplex LMW
 Ring Frame LMW
 Slub Attachment Pinter, Spain
 Core Spun Attachment Pinter, Spain
 Auto Winders Schlafhorst / Murata
 Electronic Yarn Clearers Loepfe
 TFO Murata
 Conditioning Xorella
http://maraloverseas.com/product_yarn_infrastructure.html

SEM 18
DYED YARN
PROCESS MACHINE BRAND
Soft Winding SSM, Italy
Dyeing Vessel Thies, Germany
Hydro Extractor Dettin, Italy
Radio Frequency Dryer Satalam, Italy
Yarn Winding SSM, Italy
TESTING EQUIPMENTS
NAME OF INSTRUMENT MAKE
Premeir Tester - 4 Premier Polytronics, Coimbatore
Uster Tester - 3 (With Hairiness) ZellwegerUster, Switzerland
UsterTensorapid - 5 UsterTechnologies, Switzerland
Classimat II Premier Polytronics, Coimbatore
Coeficient of Friction Meter Zweigle, Germany
Electronics Twist Tester Mesdan, Italy
Zweigle Hairiness Tester Zweigle, Germany
Splice strength Tester Mesdan, Italy
On line Classimat on AutoconerZellwegerUster&Loepfe brothers, Switzerland

SEM 19
1.7 FABRIC
OVERVIEW
Taking an advantage of our in-house spinning, we offer a strategic advantage to our
customers of better quality products at a shorter lead-time. Our product range includes fabrics
like Single Jerseys, Ribs, Interlocks, Piques, Honey Combs, Fleece, Plaited & Variegated
Structured fabrics, Feeder & Engineered stripe etc. in 100% cotton and various blends.
We specialize in supplying Body Sized seamless fabrics for both underwear as well as Active
Wear. These fabrics can be supplied in Ribs, Interlocks & Single Jerseys in various weight
ranges. To cater to the growing demands of the top end apparel brands, we have been
continuously adding on new special value added products with relevant performance finishes.
Products
Basic Products in 100% Cotton
Knit Type GSM Range Open Width Range (CMS)
Single Jersey 250-300 86 – 170
Rib 140-290 140-165
Interlock 180-250 150-170
Piquet 170-250 100-220
Fleece (Two Thread Loop back) 220-330 150-180
Fleece (Three Thread Loop back) 280-350 150-170
French Rib 180-330 140-160
Pointelle 140-240 140-165
Autostripers Engineered Stripe (In
Jersey, Rib and Piquet)
120-300 140-215
http://maraloverseas.com/product_fabric_overview.html

SEM 20
With Lycra/Elastane
Knit Type
GSM Range Open Width Range (CMS)
Single Jersey 140-240 140-170
Rib 160-280 160-200
Interlock 180-240 150-200
Piquet 170-250 100-220
Fleece (Two Thread Loop back) 220-260 150-200
Fleece (Three Thread Loop back) 280-340 150-200
French Rib 240-330 130-160
Pointelle 160-240 140-165
Autostripers/ Engineered Stripe (In
Jersey, Rib and Piquet)
160-300 140-200
Special Fiber & Yarn
Bamboo & Blends Soya & Blends Organic Cotton
Fairtrade Certified Cotton Polyester Slub Fabric
Modal & Blends Tencel& Blends
Special Finishes
Moisture Management Real Cool Wrinkle Free
Teflon Enzyme/Bio wash Anti Bacterial
UV Protection Stain repellant
http://maraloverseas.com/product_fabric_prdrange.html

SEM 21
QUALITY CONTROL
 High Quality auto coned, spliced, SIRO cleaned, low twist yarn is used to get
highest quality fabric.
 The company goes a step further by deploying workers for removing any
contamination that may have escaped during the spinning process. We use
American cotton yarns to offer contamination free white and light fabrics.
 The dyeing and shrinkage properties have been perfected on machines from
Greece, Switzerland & Germany.
 Extra care is taken while matching colors, lot by lot on the Data Color
Computerized Color Matching System (Spectra flash SF - 600 Plus CT), which is
capable of matching colors in different media light.
 The lab dips are prepared on the Ahiba Nuance Spectra dye plus sample dyeing
machines, which imitates the exact process parameters avoiding an0y chance of
mismatch of shades.
 Equipped with all kind of latest testing machines from James H. Heal, UK such
as TITAN, WASCATOR, and GYROWASH for testing the quality parameters of
finished fabrics to meet the requirements of our valued customers.
http://maraloverseas.com/product_fabric_quality.html

SEM 22
FABRIC INFRASTRUCTURE
Process Machine Brand
Circular Knitting Fukuhara
Collar Knitting & Tapes Matsuya, Agtek, Shima Seiki
Auto Stripe / Engineered Stripe Fukuhara
Open Width Knitting Piloteli
Dyeing Machines Sclavos, Greece
Finishing Machines Santex / Bruckner
Testing Equipments
Process Machine Brand
Color Lab Datacolor USA
Accudry James H. Heals & Co. Ltd.
Pilling Tester James H. Heals & Co. Ltd.
Strength Tester James H. Heals & Co. Ltd.
Crock Meter James H. Heals & Co. Ltd.
Digital pH meter M.S. Electronics
Color Matching Cabinet Verivide (L. Hubble Ltd.)
http://maraloverseas.com/product_fabric_infrastructure.html

SEM 23
CUSTOMERS
http://maraloverseas.com/product_fabric_customers.html
Lab Accreditation
OUR FABRIC LAB ARE ACCREDITED WITH M&S, NEXT, GEORGE & ADIDAS
http://maraloverseas.com/accredited_with.html

SEM 24
1.8 FINISHED GARMENTS
OVERVIEW
Taking advantage of our in-house spinning and fabric production, we are in a unique position
to offer a quick turnaround time with highest control on product quality. We manufacture
garments for various categories like Active wear, Casual wear, and Sleepwear for Men’s and
Ladies in Conventional and Organic, Fair trade garments and soft toys for infants, kids,
besides producing a whole range of home accessories hand made by under privileged ladies.
We make Fashion wear garments too which include hand embellished tops covering Sequin /
Beads / Crochet / Ari - Embroidery besides machine embroidered logos. Overall / Rotary
Prints, Heat Transfers, Placement Prints, Tie & Dye etc. too are used by us.
Different fabric structures & textures are used such as Single Jersey, Pique, Interlock, Rib,
Honeycomb, Fleece, Jacquard, Flat Back rib, Zigzag structure, Point Elle, Mesh, etc. in 100%
cotton, Cotton blends, Polyester, Tencel, Modal, Micro Modal, Bamboo, Silk, Soya, Stretch
fabrics etc.
Different finishes such as Moisture management, RCC (Real Cool Cotton), Teflon, Resin,
Enzyme, Bio, Anti-bacteria, UV, Breeze, Fragrance, Oxyrich, Vitamin E, Liquid Stretch and
many more are used for specific needs of customers. We also do all types of Garment dyeing
& washing including Enzyme, Acid, Stone, and distress wash for giving different looks to
garments.
http://maraloverseas.com/garments.asp

SEM 25
INFRASTRUCTURE
Vertically integrated from Yarn spinning to Garments. It is one of Asia’s largest vertically
integrated plants.
Panel inspection, Mobile inspectors in line, setting standards for individual operations on
each machine are few initiatives, which help us, produce high quality garments.
There is a strict system in place for records on broken needles, metal contamination
prevention & detection of in- line & Packed products.
All sewing machines have latest auto trimmers & no loose cutters are allowed on production
floor. The placket & pocket making machines produce fine quality products.
Maral has a highly computerized environment. All plants and offices are linked via ERP for
effective & prompt communication. Our garment units have Video Conferencing facility
available to Our Group's Units, Offices and Buyers.
To supplement our flexible production lines & lead times, garment units have online
planning & monitoring system “Fast react” in place.
Maral has a strong in-house design and product development team based at its plants which
are constantly engaged in developing new product designs & processes. Customer specific
product needs are met every season through constant innovation.
http://maraloverseas.com/product_garments_infrastructure.html

SEM 26
1.9 DESIGN & DEVELOPMENT
At Maral, we believe that we have to service the needs of our client's target market as a first
step towards a successful partnership. This requires innovation of
yarns/fabrics/finishes/performance in fabrics, besides fashion and value addition. India's
unique artisanship in hand embroidery/sequin work/lace/beads etc. bring out the
sophistication in a garment. We also Endeavour to incorporate these in our garments for
ladies wear. Our vertically integrated operation of yarn and fabrics gives us the capability to
innovate on different fabric features that stand out in the market besides offering a whole
range of unique products for Menswear, Ladies wear and Kids wear.
Towards this goal, we have a proficient and talented in-house design department capable of
effectively executing specific styling and sampling needs. Composed of a team of Fashion
Designers, experienced Pattern Makers and experienced Stitching Masters, besides being
equipped with complete a CAD/CAM facility, we provide our clients with various design
support such as - trends and mood boards, and also concept development for the future
seasons. Our products exhibit the fine use of Designing- Trims & Accessories (Imported &
Indigenous) and wash effects (if required).
Our Design Head is a regular visitor to the International Fashion Events. We have an
extensive collection of our own fashion collection and an in-house fabric library.
http://maraloverseas.com/product_garments_design.html

SEM 27
QUALITY
Maral employs ERP to buttress its 'Q' principle right from procurement to delivery. Stringent
testing systems like HVI 9000 and USTER AFIS, online monitoring systems and state-of-the-
art BARCO and Quantum contamination detection machines ensure best raw material and
yarn quality.
The garment division implements SQC through panel inspection, mobile inspectors in line,
by setting standards for individual operations on each machine and through 100% inspection
of garments before finishing and packing.
http://maraloverseas.com/quality_assurance.html

SEM 28
INNOVATION
Yarn
Our focus has always been to create innovative yarns which are environmental friendly,
socially compliant, fashionable and add aesthetic value to the final product. Our effort has
been to bridge the gap between Fashion, Environment and Social aspects. In this pursuit, we
have successfully launched many products like:
 Organic Cotton blends with Bamboo & Modal fibers.
 Organic Cotton / Linen
 Fair-trade Organic Cotton Yarns
 Slubs&Flame in Organic, Bamboo &Fair-trade.
With our clear vision on the importance of linking Fashion with Sustainability, we were
among the first ones to commercially launch Fair-trade& Organic yarns.
Our experiments of using long & extra-long staple cotton for producing coarse counts were a
great success in the towel industry. These include PIMA, GIZA & MCU cotton spun into
counts like Ne 12s to Ne 20s.
Our infrastructure and flexibility in taking small mixing backed by ample stock of different
fibers gives us an edge to reduce lead times for such innovative blends.
We are also working on following new products:
 Soya fiber blended with various cottons.
 Milk fiber blended with various cottons.
 Recycled Cotton Yarns.
Fabric
 Developments with ELS Cottons: Considerable work is being done on
fabric developments using Extra Long Staple Cottons like Giza &Suvin
Cotton.
 Developments on new fibers like Modal &Tencel are gaining importance.
Tencel gives a very soft fabric and is an important sustainable product in
the market.
 Soya/ Bamboo & its blends with Organic Cotton &Fair-trade Cotton.
 Slubs&Flame in Organic, Bamboo &Fair-trade.
 Multitier blends of Cotton/ Polyester/Soya/ Lycra and Cotton/ Soya/ Lycra
etc.
 Special finishes like Cool & Fresh ( this is a special finish that gives anti
bacterial & wicking properties) / Anti UV / Teflon Finish / Resin Finish /
Gold Finish etc.
http://maraloverseas.com/innovation.html

SEM 29
1.10 MARKET
Maral’s service is the foundation of the trust it has enjoyed among its customers for years. No wonder Maral’s products are
appreciated by several highly reputed international brands and retail chains spread across five continents in the USA, Canada,
Europe, Japan, Hong Kong, the Middle-East, South Africa and other countries.
Maral offers one of the world’s most comprehensive and most enchanting range of knitted products like : T-shirts,
Polo shirts, Rugby shirts, Henley shirts, Hooded shirts, Jackets, Sweatshirts, Tank tops, Camisoles, Shorts,
Pyjamas, Joggers, etc. for Mens& Ladies and Organic, Fairtrade Garments for Infants and Kids.
http://maraloverseas.com/markets.html

SEM 30
1.11 CAREER
CURRENT OPENING
s..No. Designations Department Location No. of
Positions
1 Area Sales Manager-Enterprise
Business
Enterprise Business
Unit
Delhi/ Chennai/ Banglore/
Hyderabad/ Mumbai/ Pune
1
2 Database Administrator Channel Business
Unit
Delhi/ Chennai/ Banglore/
5
3 Manager Channel Sales Outbound Delhi/ Chennai/ Banglore/
2
4 Charted Accountant/ Sr. Executive
Finance and Accounts
Customer Care Delhi/ Chennai/ Banglore/
1
http://maraloverseas.com/career_openings.html

SEM 31
1.12 COMMITMENTS
SOCIAL RESPONSIBILITY
An equal opportunity employer, at Maral Overseas, we see employee welfare not merely as
an altruistic endeavour, but more as a business imperative. After all, a contented workforce is
a committed workforce. Maral Overseas is committed not only to overall employee welfare
but also lays stress on community development activities like education, health care,
community service and supporting basic infrastructure.
At Maral, ‘Q’ Welfare combines social compliance and sustainable development. Utmost
care is taken to build and nurture a green environment by planting thousands of trees,
promoting organic farming and recycling the water from the dyeing and finishing plant. To
achieve this objective, water from the dyeing & finishing unit is recycled through an ETP and
re-used.
Besides, Maral Overseas Limited actively oversees the following initiatives towards
community welfare and development:
 A school (Vivekanand Vidhya Vihar) offers subsidized education to the children of
Maral employees and neighbouring towns.
 A fully equipped dispensary, four bed hospital with a doctor and three paramedics for
round-the-clock service.
 A subsidized canteen and mess with one kitchen for both workers as well as officers.
 A housing colony with parks and playground for over 1800 workers, staff and their
families.
 A cooperative store and a bank with ATM.
 No distinction on the basis of gender, religion or ethnic origin. No child labour is
employed. A large number of women are employed in the plants.
 Apart from vegetable and fruit farming, the factory even has its own dairy unit with
40 cows to take care of the needs of residents.
 Regular meetings are conducted for the workers to foster a sense of belonging and to
encourage two-way communication amongst workers.
 Community events take place at least once a month besides celebration of religious
festivals.
 A sports club with facilities for gym, table tennis, cricket, volleyball, etc.
 Strict adherence to the laws of land with regard to minimum wage, age, over-time,
Social security etc. We have made several committees with participation of associates
which raise various issues for discussion on a common platform.
http://maraloverseas.com/csr_social_responsibility.html

SEM 32
SKILLS & TRAINING
Maral’s well-trained staff is MOL’s biggest asset. Apart from regular skill development
workshops for workers, staff and executives, Maral’s experts constantly provide training to
cotton farmers and ginners to upgrade skills and work practices. Regular visits to foreign
manufacturers are scheduled to keep track of the latest trends & technology in manufacturing.
CULTURE AND ETHIC
Maral Overseas Ltd. is one of India's largest vertically integrated manufacturing companies
producing yarn, knitted fabric and knitted garments. Maral is a public limited company listed
on major stock exchanges in India. Banking on its core strengths, modern manufacturing
technology, quality systems, quality relationships, Maral has earned a reputation as a reliable
supplier of choice in the world market.
All units of Maral uphold laws and are committed to equal opportunity, fair employment
practices with due awareness on safety, health and environment friendly practices and are
approved for social and legal compliance by ITS.
http://maraloverseas.com/culture_ethics.html

SEM 33
1.13 WATER TREATMENT PLANT
EFFLUENT TREATMENT PLANT AT SAROVAR
Effluent treatment is accorded the highest priority and the latest technology is always used.
Around 800,000 litres/day of effluent is generated from our fabrics/yarn dyeing and finishing
and the entire quantity is treated chemically and biologically.
A bulk of this water is used again in the process house, while the balance is used for
horticulture around the plant. The sludge is disposed of at a government appointed disposal
site.
A part of dry sludge generated from the affluent treatment plant is used to prepare a fertilizer
by mixing manure and micro dust in appropriate ratio. This is non-hazardous in nature and
good for the development and growth of plants and vegetables.
http://maraloverseas.com/csr_environmental.html
ORGANIC FARMING
As part of our sustainable campaign, we have 1253 organic cotton farmers under contract for
production of organic cotton. The total area covered is more than 5000 acres.
A consultant along with a team of dedicated workers is on a constant move to train and assist
farmers. A complete scientific approach is used to do organic farming and the following are
its main aspects:
Organic Manure like cow dung and Neem.
Mechanically devised traps to catch pests.
Use of household natural products to make insecticides. For example, fermented curd.
Using natural predators like birds and insects.
Intercropping.
Crop rotation to maintain and replenish the nutrients of the soil.
http://maraloverseas.com/csr_organic.html
HORTICULTURE
About 7,500 trees are planted at Sarovar (Unit 1). Fruits (mango, guava, etc.) and vegetables
(cabbage, onions, spinach, potato, etc.) are also grown and are distributed among workers and
staff members at subsidized prices. We have also planted jatropha (bio-fuel) and teak trees on
10 acres of land
http://maraloverseas.com/csr_horticulture.html

SEM 34
CHAPTER2
REVIEW OF LITERATURE
SUMMARY OF PREVIOUS RESEARCH WORK …………………36-37

SEM 35
REVIEW OF LITERATURE
Recent years have been marked by a rapid development of unconventional technologies in
textile production. This Chapter is concerned with the literature review on conventional
spinning, compact spinning, doubled yarn, hybrid yarn and weft knitted fabrics. A
considerable amount of work has been carried out on yarn characteristics of conventional,
compact and hybrid spinning, bio finishing of fabrics, physical and dimensional properties of
fabrics, spirally and wicking. This literature survey is based upon the intensive search of the
journals published in textile technology. Articles from other sources are also included, and
the subject is reviewed under different captions. The concern of the previous workers with
the above aspects, namely, compact spinning, spirally, wicking of knitted fabrics is reflected
in the following literature review.
DEVELOPMENTS IN SPINNING
The art of spinning originated in prehistoric times. The technique of cotton spinning
crystallized at the beginning of the industrial revolution says Rohlena (1974). Revolutionary
changes in spinning technology took place during the 1950s and 1960s, following the post
war boom, views Lord (2004). During the 1970s, there appeared to be a myriad of spinning
systems, such as twist less spinning, self-twist spinning, fascinated yarns, composite yarns,
wrap-spun yarns, pot spinning, continuously felted yarns and the many possible variants in
open-end spinning such as rotor, electrostatic, friction spinning, and vortex spinning. At the
same time, there were continued developments in ring spinning, with ventures into rotating
ring and traveler systems, individual spindle drives, high draft systems, modified travellers,
double roving spinning, and hybrid systems. A look at today’s industry reveals that while
some systems have established a successful but small niche- wrap spinning for fancy yarns
and friction spinning for specialty industrial markets -very few systems have survived. 2.3
RING SPINNING Until the early 60s, the main type of spinning machines were ring spinning
frames, which were used in all types of spinning systems. In the 70s, open end spinning was
developed, mainly rotor spinning, with reference to cotton and cotton like yarns. However,
ring spinning frames are still competitive in relation to rotor spinning machines, and in some
systems they are impossible to replace says Lewandowski et al (2010).Today, in fact ring
spinning is by far the most widespread spinning process, setting clear standards in terms of
yarn quality, field of application and flexibility.
(http://www.novapdf.com/)

SEM 36
Ring spinning has become a truly high-tech process reveals Stalder (2003).
According to Yafa (2006), yarn that is produced by using a ‘ring’ is ring spinning. The ring,
which spins and winds yarn in one continuous motion onto bobbins, produces yarn that has a
characteristic natural unevenness. Wulfhurst et al., (2006) reveals that the first ring spinning
frame was built in 1828 in the U.S. Ring spinning consists of three subsequent processing
steps, slubbing, ring spinning and winding. Ring spinning is used for coarser number and has
greater production and requires less labour than mule spinning. The function of ring spinning
is to draw out the rove and spin it into yarn on a continuous system, opines Dooley
(2008).The method used to produce ring- spun yarns is “a series of operations in Print to PDF
without this message by purchasing novaPDF (9 which a mass of entangled fibers are
transformed into a rope-like structure in which the fibers are more aligned than in the
entangled mass. During the last 50 years, ring spinning has a high degree of efficiency. High
draft systems have been developed and it has become possible to attain given standards of
yarn regularity at very much higher levels of draft, says Lord (2004). Grosberg and Iype
(1999) mention that only ring spinning will be considered as the most widely used method of
spinning. Because of ring spinning’s versatility in terms of fiber types that can be handled,
the range of counts that can be spun and the quality of the yarns produced, it is the standard
against which other systems of spinning are judged. A ring-spinning machine is an
uncomplicated, flexible, low cost device that is well established in the nineteenth century.
SUMMARY OF PREVIOUS RESEARCH WORK
On Compact Spinning Compact spinning has been investigated by many researchers. Most of
them have focused on two types of research; One on the types of system and its advantages
and the other research on yarn structure of compact yarn. The subject matter has been
discussed in many seminars and conferences. Recently some papers have been published
which compare the properties of compact yarns produced from various systems. However, it
is noticed that many interesting papers have been published on compact yarns which have
improved our understanding about their structure and properties. Thus research carried out on
compact spinning at Turkey has demonstrated many facets of compact yarns. A great deal of
work has also been carried out by research workers in India, USA, Honkong, Poland,
Germany, Switzerland, Czechoslovakia, Slovenia &Pakistan on compact spinning. Table 2.1
shows the research work which has been carried out on compact spinning.
http://www.novapdf.com/

SEM 37
CHAPTER 3
METHODOLOGY
3.1 PROCESS……………………………………………………………….39-40
3.2 QUALITY CONTROL…………………………………………………40

SEM 38
YARN MANUFACTURING
There are three major spinning processes: cotton, worsted or long-staple, or wool. Synthetic
staple fibers can be made with any of these processes. Since more yarn is produced with the
cotton process than the other two, its manufacture is described below.
PREPARING THE FIBERS
• Fibers are shipped in bales, which are opened by hand or machine. Natural fibers may
require cleaning, whereas synthetic fibers only require separating. The picker loosens and
separates the lumps of fiber and also cleans the fiber if necessary. Blending of different staple
fibers may be required for certain applications. Blending may be done during formation of
the lap, during carding, or during drawing out. Quantities of each fiber are measured carefully
and their proportions are consistently maintained.
CARDING
• The carding machine is set with hundreds of fine wires that separate the fibers and pull them
into somewhat parallel form. A thin web of fiber is formed, and as it moves along, it passes
through a funnel-shaped device that produces a ropelike strand of parallel fibers. Blending
can take place by joining laps of different fibers.
COMBING
• When a smoother, finer yarn is required, fibers are subjected to a further paralleling method.
A comb like device arranges fibers into parallel form, with short fibers falling out of the
strand.
DRAWING OUT
• After carding or combing, the fiber mass is referred to as the sliver. Several slivers are
combined before this process. A series of rollers rotating at different rates of speed elongate
the sliver into a single more uniform strand that is given a small amount of twist and fed into
large cans. Carded slivers are drawn twice after carding. Combed slivers are drawn once
before combing and twice more after combing.

SEM 39
TWISTING
• The sliver is fed through a machine called the roving frame, where the strands of fiber are
further elongated and given additional twist. These strands are called the roving.
SPINNING
• The predominant commercial systems of yarn formation are ring spinning and open-end
spinning. In ring spinning, the roving is fed from the spool through rollers. These rollers
elongate the roving, which passes through the eyelet, moving down
The sliver is fed through a machine called the roving frame, where the strands of fiber are
further elongated and given additional twist. The predominant commercial systems of yarn
formation are ring spinning and open-end spinning. Open-end spinning omits the roving step.
The sliver is fed through a machine called the roving frame, where the strands of fiber are
further elongated and given additional twist. The predominant commercial systems of yarn
formation are ring spinning and open-end spinning. Open-end spinning omits the roving step.
and through the traveller. The traveller moves freely around the stationary ring at 4,000 to
12,000 revolutions per minute. The spindle turns the bobbin at a constant speed. This turning
of the bobbin and the movement of the traveller twists and winds the yarn in one operation.
• Open-end spinning omits the roving step. Instead, a sliver of fibers is fed into the spinner
by a stream of air. The sliver is delivered to a rotary beater that separates the fibers into a thin
stream that is carried into the rotor by a current of air through a tube or duct and is deposited
in a V-shaped groove along the sides of the rotor. As the rotor turns, twist is produced. A
constant stream of new fibers enters the rotor, is distributed in the groove, and is removed at
the end of the formed yarn.
QUALITY CONTROL
Automation has made achieving quality easier, with electronics controlling operations,
temperatures, speeds, twists, and efficiency. The American Society for Testing of Materials
has also established standardized methods for determining such properties as draw force, bulk,
and shrinkage.

SEM 40

SEM 41
CHAPTER 4
FUTURE AND SCOPE
FUTURE AND SCOPE…………………………………………………44

SEM 42
4.1 FUTURE AND SCOPE
Spinning systems and yarn manufacturing machinery will continue to become more
automated and will be integrated as part of a manufacturing unit rather than as a separate
process. Spinning machines have already been developed that combine carding and drawing
functions. Production rates will increase by orders of magnitude as machines become
available with even more spindles. Robot-controlled equipment will become standard.
Domestic yarn producers will continue to be threatened by competition from Asian countries,
as these countries continue to buy the latest textile machinery technology. Higher domestic
material prices will not help, since the cost of the raw material can represent up to 73% of the
total cost of producing the yarn. U.S. yarn producers will continue to form alliances with their
customers and customers' customers to remain competitive. The textile industry is also
forming unique partnerships. The American Textile Partnership is a collaborative research
and development program among industry, government, and academia aimed at strengthening
the competitiveness of the U.S. industry.
Another continuing challenge for the industry will be compliance with stricter environmental
regulations. Recycling is already an issue and processes are under development to
manufacture yarn from scrap material, including denim. Yarn producers will have to
incorporate pollution prevention measures to meet the air and water quality restrictions.
Equipment manufactures will continue to play an important role in this endeavour.
Genetic engineering will become more widely used for developing fibers with unique
properties. Researchers have developed genetically-altered cotton plants, whose fibers are
especially good at retaining warmth. Each fiber is a blend of normal cotton and small
amounts of a natural plastic called polyhydroxybutyrate. It is predicted that dye-binding
properties and greater stability will be possible with new fibers in the next generation.
New synthetic fibers will also be developed that combine the best qualities of two different
polymers. Some of these fibers will be produced through a chemical process, whereas others
will be generated biologically by using yeast, bacteria, or fungi
.
http://www.madehow.com/Volume-3/Yarn.html

SEM 43
CONCLUSION
Final conclusion It would appear that stickiness is on the increase. Many authors in the
bibliography give different reasons for this increase change e.g. changes in insecticides,
possible resistance to insecticides, changes in processing machines etc. Many producing
countries are affected by stickiness, and ICAC decided to sponsor a first project in 1993 to
control insect-induced stickiness in the field. The project was known as « Sticky cotton:
possible control methods from the plant to yarn ». In parallel, some kind of stickiness
evaluation was required to assess bale quality for commercial purposes. Thus, a new project,
entitled « Improvement of the Marketability of the Cotton Produced in Zones Affected by
Stickiness » was designed to address some of the basic questions and develop a method for
characterizing stickiness. This project, also sponsored by the International Cotton Advisory
Committee, and funded by the Common Fund for Commodities, was carried out by ARC and
SCC in Sudan, and by IFTH and Cirad in France with the support of ICAC. The central
objective of the project was to increase cotton producer revenues through the development of
reliable methods to evaluate the stickiness of cotton bales, and determine (under factory
conditions) the operational thresholds for the processing of contaminated sticky cotton. A
bale is declared as “sticky” if, during a processing step, e.g. spinning, its stickiness disrupts
the spinning process, reduces spinning machines performances or decreases final product
quality. It should be noted here that classification requires a measuring tool, appropriate
conditions for that tool, and good cotton production organization. All these conditions will
impact on the success of such a classification system.

SEM 44
QUESTIONIER
Q.1 The fibre that contains nitrogen and sulphur is
Q.2 Condensation polymerization is not used to produce
Q.3 Wet spinning technique is commercially used to produce filament yarn of
Q.4 The fibre that dissolves in 59% (w/w) sulphuric acid solution is
Q.5 Surface features of a fibre can be obtained by
Q.6 Birefringence of filament yarn is related to its
Q.7 A machine that does not improve the mass evenness is
Q.8 Fibre individualization in a card will increase by increasing
Q.9 Softer cots on drafting rollers result in
Q.10 Compared to the spinning of finer cotton yarns, the preferred rotor
diameter for the production of
very coarse cotton yarns would
Q.11 Amongst the following, the suitable technology for producing core spun
yarn is
Q.12 Increase in taper angle on sectional warping drum will normally require
Q.13 Increase in the ratio of the length of crank to the length of connecting rod
leads to
Q.14 Shuttle remains on the race board during its flight in the shed because of
Q.15 In weft knitted fabrics of the same mass per unit area produced from the
same yarns, the structure
Q.16 The nonwoven process which has the highest production rate is

SEM 45
BIBLIOGRAPHY
http://maraloverseas.com/about_mol.html
http://maraloverseas.com/product_yarn_overview.html
http://maraloverseas.com/product_yarn_prdrange.html
http://maraloverseas.com/product_yarn_capacity.html
http://maraloverseas.com/product_yarn_innovation.html
http://maraloverseas.com/product_fabric_overview.html
http://maraloverseas.com/product_fabric_prdrange.html
http://maraloverseas.com/product_fabric_quality.html
http://maraloverseas.com/product_fabric_customers.htm
http://maraloverseas.com/accredited_with.html
http://maraloverseas.com/product_garments_infrastructure.html
http://maraloverseas.com/product_garments_design.html
http://maraloverseas.com/career_openings.html
http://maraloverseas.com/csr_social_responsibility.html

SEM 46
http://maraloverseas.com/culture_ethics.html
http://maraloverseas.com/csr_environmental.html
http://maraloverseas.com/csr_organic.html
http://maraloverseas.com/csr_horticulture.html
http://www.novapdf.com/
http://www.madehow.com/Volume-3/Yarn.html

SEM 47
THANK YOU….

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