partex holding

1. Table of Contents
Preface.................................................................................................................................... 12
Acknowledgement .................................................................................................................. 10
Introduction ................................................................................................................... 11
Company Profile ..................................................................................................................... 12
1.1 PARTEX HOLDINGS: .................................................................................................................13
1.2 Enterprises of Partex Holdings....................................................................................................14
1.3 PARTEX DENIM LTD: ................................................................................................................15
History & Evolution of Denim......................................................................................... 24
2.1 Evolution of Denim......................................................................................................................25
2.2 Define Denim ..............................................................................................................................25
Process Flow................................................................................................................................. 22
3.1 Process Flow Chart.....................................................................................................................23
Warping................................................................................................................................... 27
4.1 Definition .....................................................................................................................................28
4.2 Objects of Warping......................................................................................................................28
4.3 Importance of Warping:...............................................................................................................28
4.4 Types of Warping ........................................................................................................................28
4.4.1 Direct Warping:....................................................................................................................29
4.4.2 Machine Specifications .......................................................................................................31
4.4.3 Machine Main Parts.............................................................................................................33
4.4.4 Functions of Different Parts:................................................................................................33
Dyeing & Sizing ...................................................................................................................... 41
5.1 Definition .....................................................................................................................................42
5.2 Objects of Dyeing:.......................................................................................................................42
5.3 Denim Dyeing:.............................................................................................................................42
5.4 Denim Dyeing Process................................................................................................................47
5.4.1 Rope Dyeing:.......................................................................................................................47
5.4.2 Slasher Dyeing:...................................................................................................................49
5.4.3 Loop Dyeing: .......................................................................................................................50
5.5 Sizing:..........................................................................................................................................51
5.5.1 Definition .............................................................................................................................51
5.5.2 Objects of Sizing: ................................................................................................................51
5.5.3 Changes in Yarn due to Sizing:...........................................................................................52
5.6 Machine Specification .................................................................................................................57
5.6.1 Creel Zone...........................................................................................................................59
5.6.2 Accumulator: .......................................................................................................................60
5.6.3 Pre-treatment: .....................................................................................................................61
5.6.4 Pre-Washing (1-3 box): .......................................................................................................62
5.6.5 Dyeing: ................................................................................................................................63
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5

2. 5.6.6 Drying Zone .........................................................................................................................69
5.6.7 Accumulator:........................................................................................................................69
5.6.8 Sizing:..................................................................................................................................69
5.6.9 Size Cooking Process .....................................................................................................70
5.6.10 Drying Zone .....................................................................................................................72
5.6.11 Accumulator:....................................................................................................................72
5.6.12 Leasing Zone...................................................................................................................72
5.1.1 Expansion Comb .................................................................................................................72
5.1.2 Beaming...........................................................................................................................72
5.1.3 Transportation of Beams .................................................................................................72
Weaving.........................................................................................................................................77
6.1 Definition......................................................................................................................................78
6.2 Basic Weave Designs..................................................................................................................78
6.2.1 Plain Weave ........................................................................................................................78
6.1.1
Twill Weave .........................................................................................................................79
Table of conten
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6

3. CONTENTS Page No
 Preface 6
 ACKNOWLEDGEMENTS 7
 INTRODUCTION 8
1. MALWA INDUSTRIES LIMITED (MIL) - Denim arm of the Malwa
Group.
8
PART –1 DENIM MANUFACTURING 14 - 98
 History and introduction to denim fabric. 15
 Process flowchart for denim manufacturing. 16
17
 Spinning
18
19 – 21
22 – 23
23 – 24
25
26 – 27
27 - 28
29 – 31
32 – 34
34 – 35
35 – 36
36
37
1. Ring spinning
 Blow room
 Carding
 Draw frame
 Simplex
 Ring spinning
 Auto coner
2. Open end spinning
 Rotor spinning principle
 Blow room
 Carding
 Draw frame
 Rotor spinning
3. Finishing section
 Denim processing
38
39 – 41
42
43
44
1. Warp preparation.
 Warp preparation in malwa industries ltd.
 Sheet dyeing process sequence.
 Loop dyeing process sequence.
 Rope dyeing process sequence.

4. 2. Dyeing range in malwa industries Ltd. 45
46
47 – 48
49
50
50
51
52
53
54
54
55 – 57
57
58
 Machine specification
 Color kitchen
 Rope dyeing calculation
 Chemicals and auxillaries used in the dyeing
 Dyes and color used.
 Dyeing style
3. Long chain beaming or rebeaming
 Machine specification
4. Sizing
 Objects of sizing.
 Chemicals used in sizing.
 Instrument used for process control in sizing
 Sizing in malwa industries ltd.
 Sizing calculation
 Weaving
59
60
60
61
61
62
62
1. Weave structures
2. Classification of weaving machines
3. Classification of modern weaving machines
 Airjet
 Rapier
 Projectile
 Water jet
4. Weaving in malwa industries ltd.
 Airjet loom specification
 Rapier loom specification
 Projectile loom specification
 Timing cycles
 Finishing
63
63
64
65
65
65
66
66 – 69
69
70
72
 Objects of finishing
 Finishing range in malwa industries ltd.
1. Singeing
 Flow chart
 Machine specification
2. Finishing machine
 Flow chart
 Machine specification
 Skew control
 Sanforizing
 Principle of mechanical shrinking process
 Chemicals used in the process done in the
finishing
machine.

5. 3. Soaper machine
72
72
72
73
73
74
74 – 75
75
76
76
77
77
77
78
79
79 – 80
80
81
 Purpose
 Machine specification
 Flow chart
 Desizing
 Hot wash
 Mercerization
 Over dyeing
4. Peaching machine
 Flow chart
 Machine specification
5. Sando machine
 Flow chart
 Machine specification
6. Stenter
 Function of stenter machine
 Purpose
 Flow chart
 Machine specification
 Methods of heat setting
 Coating
 Foam coating machine
 Folding and Inspection department
82
82
83
83 – 85
85 – 90
 Machine specification.
 Four point system.
 Grading system.
 Type of defects and their codes with the concern
departments.
 Some Important defects pictures
 Quality analysisdepartment
91 – 96
97 – 98
98
 Fabric testing lab
 Chemical testing lab
 R & D lab

6. Contents
PARTICULAR PAGE NO.
Preface 5
Acknowledgement 6
I. Introduction 6 – 7
II. HISTORY & Introduction of Denim Fabric
1) Evolution of Denim
2) Define Denim
3) Denim as a Fashion Trend
7 – 9
III. Process Flow
1) Process Flow of Denim Manufacturing
9 – 13
IV. Warping
1) Define Warping
2) Objects of Warping
3) Types of Warping
4) Direct Warping
5) Flow Chart
6) Machine Specifications
14 – 17
V. Dyeing
1) Define
2) Objects of Dyeing
3) Denim Dyeing
4) Denim Dyeing Process
5) Slasher Dyeing
6) Flow Chart
6) Machine Specifications
6) Machine Specifications
18 – 39

7. 6) Machine Specifications
6) Machine Specifications
VI. Sizing
1) Define
2) Objects of Sizing
3) Changes in Yarn due to Sizing
40 – 48
VII. Function of Different Parts
1) Creel Zone
2) Accumulator
3) Pre-treatment
4) Pre-Washing (1-3 Box)
5) Dyeing
6) Drying Zone
7) Accumulator
8) Sizing
9) Drying Zone
10) Accumulator
11) Leasing Zone
12) Expansion Comb
13) Pre-treatment
14) Pre-Washing (1-3 Box)
15) Beaming
16) Transportation of Beams
49 – 71
VIII. Machine Specifications 72 – 85
QUALITY ASSURANCE DEPARTMENT 86 – 89