Knit dyeing Training Report in ARVIND mill by Sujay Majumder, created by Manojit Barman, from Institute of Jute technology ,University Of Calcutta, "Summer Vacational Industrial Training Report 2016-2017"

1. SUMMER VACATIONAL INDUSTRIAL
TRAINING 2016-2017
DURATION: - 1ST JULY – 31ST AUGUST
AT
By :- SUJAY MAJUMDER
Department of Jute & Fibre Technology
Institute of Jute Technology
UNIVERSITY OF CALCUTTA

2. ACKNOWLEDGEMENT
 It is brilliant opportunity for us to get training at “ARVIND LIMITED”, from 1st
July to 31st August - 2016, for the practical fulfillment of the course of B.Tech
in Jute & Fiber Technology.
 We have got huge during this in plant training period.
We are Specially Thankful to…
Mr. Subhanish Malhotra Sir ( Head H.R. )
Mrs. Krupa Rawal ( H.R. Manager )
Mr. Kalyan Bhattacharya Sir (H.O.D-Knitts Marketing department)
Mr. Pankaj Chauhan Sir (Manager-Knitts Dyeing )
Mr. Jiger Jaiswal Sir
Mr. Anand Panchal Sir
Mr. Purohit Sir
Finally we are thankful to our Professor, Dr. Debashis Das,
Without his help it was not possible for us to get training at this mill.

3. Brief History of Arvind:-
Arvind Mills was set up with the pioneering effort of the “Lalbhai” brothers in
the year 1931. With the best of technology and business acumen, Arvind has
become a true Indian multinational, one of the largest Denim suppliers in the
world. It is the market leader in India in Denim, shirting and branded apparels.
It is India’s largest exporter of textiles.
Arvind Mills has set the pace for changing global customer demands for
textiles and has focused its attention on selected core products. Such a focus
has enabled the company to play a dominant role in the global textile areas.
With its presence across the textile value chain, the company endeavors to be
a one-stop shop for leading garment brands.
Fore vision and Technology has brought Arvind to be one of the top three
producers of Denim in the world, and on it’s way becoming the Global Textile
Conglomerate. Arvind is already making its presence felt in Shirting’s, Knits
and Khakis fabrics apart from being all set to create ripples in the ready to
wear Garments world over.
Company Profile :-

4. KNITS MARKETING DEVISION
KNITTING DEPARTMENT
BATCHING DEPARTMENT
DYEING DEPARTMENT
FINISHING DEPARTMENT
INSPECTION DEPARTMENT

5. Dyeing department
Name of the department – dyeing department
Function of the department - Here combined scouring and bleaching, dyeing and
washing is done respectively.
Scouring
Scouring is the pretreatment process of wet processing technology. Scouring
is the first stage of pretreatment. Before dyeing or printing of textile material natural
fibre must pass through scouring.
Objective of scouring:
The main purpose of scouring is to remove natural (oil, wax, gum, fat etc) as well
as added (during fabrication process) impurities from textile material.
The textile materials are leave in a highly absorptive condition with out under
going any chemical or physical damage significantly.
After scouring process material become suitable for next bleaching process.
Type of process: batch process

6. Bleaching:
All the natural fibers contain natural color. Bleaching is done to remove the natural
color and increase whiteness.
Here peroxide bleaching is used.
Objective of bleaching:
Removal of colour impurities.
Increasing the degree of whiteness.
Type of process: Batch process
Recipe for combined scouring & bleaching
I. Alkali (NaOH) = 4.00 g/l
II. Wetting agent = 1.00 g/l
III. Bleaching agent(H²O²) = 2.50 g/l
IV. Lubricating agent = 4.00 g/l
V. Stabilising agent= 0.20 g/l
VI. Sequestering agent = 1.50 g/l
VII. Neutralising agent =1.35 g/l
VIII.MATERIAL : LIQUOR = 1:6/8/10/12(as required)
IX. Time = 1.5- 2 hrs
X. TEMPERATURE = 80-90 degree Celsius
XI. Ph = 10-11

7. NAME FUNCTION
CAUSTIC SODA FLAKES ALKALI
HYDROGEN PEROXIDES BLEACHING AGENT
GREEN ACID NEUTRALISER
EUROSCOUR HPJS WETTING AGENT
CROSPREP SFE STABILISER
DYELUBE NF CONC LUBRICANT
CROSQUEST HE SEQUESTER
NOCKCEL JET DEFOAMER
SETAVIN RCO LEVELLING
EUROSOL R SOAP
TERMINOX ULTRA 50L PEROXIDE KILLER
ACETIC ACID NUTRALISER
SODIUM SULPHATE EXHAUSTING AGENT
SODAASH FIXATION AGENT
SOME IMPORTANT CHEMICALS & FUNCTION:

8. Dyeing
Objective: dye a fabric with light shade or dark shade according to customer requirement.
Type of process: batch process.
Total no machine: 26
High temperature dyeing machine (HT):
Function of the m/c: combined scouring, bleaching & dyeing are proceed here at
high temperature.
Total no of m/c: 5 i.e. HT-1, HT-2 1, HT-2 2, HT-3, HT-4
HT DYEING M/C

9. Atmospheric temperature dyeing m/c:
Function of the m/c: combined scouring, bleaching & dyeing are proceed here at
atmospheric temperature.
Total no m/c: 4 i.e. AT-1, AT-2, AT-3, AT-4
AT DYEING M/C

10. Athena dyeing machine:
Function of the m/c: combined scouring, bleaching & dyeing are proceed here at high
temperature.
Total no m/c: 8 i.e. ATH-1, ATH-2, ATH-3/1, ATH-3/2, ATH-3/3, ATH-3/4, ATH-3/5, ATH-
3/6
ATHENA DYEING M/C

11. Thies dyeing machine:
Function of the m/c: combined scouring, bleaching & dyeing are proceed here at high
temperature.
Total no m/c: 2 i. e. THIES-1, THIES-2
THIES DYEING M/C

12. Baby dyeing machine:
Function of the m/c: combined scouring, bleaching & dyeing are proceed here at high
temperature.
Total no m/c: 8 i.e. BABY-1,2,4,5,6,7,8,9
BABY DYEING M/C

13. Workers:
•1/2 m/c in HT, AT, ATHENA & THIES.
•1/4 m/c in baby machine.
Total production/shift: 12-13 tons
Used dye: all types of dark and light shaded reactive dye are used
Example of dyeing recipe for dark blue color:
I. Synozol yellow k-bf- 0.485%
II. Synozol red k-bf- 0.875%
III. Synozol navy blue k-bf- 2.68%
IV. GLAUBER SALT: 70 g/l
V. SODA ASH: 15 g/l
VI. DISPERSING AGENT: 1-2 g/l
VII. ANTI- CREASE MARK AGENT:1-2 g/l
VIII.ANTI FOAM AGENT: 1g/l
IX. Material: liquor : 1:6
X. Temperature: 80⁰c
XI. TIME: 4-5 hrs

14. Process Flow chart of Dyeing
Fabric received from batching department
Required amount of water was taken into the m/c
The fabric was loaded and run for 5-10 minutes in normal temp
Scouring chemicals were added at normal temp for 5 minutes
Temp increased at 60 degree celsius
Hydrogen peroxide was added for 5 minutes
Temp increased at 95 degree celsius for 20 minutes

15. Then cooling at 60 degree celsius
Recall liquor ratio, level the water
At 60 degree celsius acid transfer for maintaining pH(5.5-6)
Add peroxide killer for 10 minutes
Draining
Filling with cold water
Dosing the dye liquor for 20 minutes and circulates for 10 minutes
Dosing of salts for 10 minutes

16. Recirculation for 10 minutes at 80 degree celsius
Cooling at 60 degree celsius for 10 minutes
Soda dosing for 20 minutes
m/c hold time 5 minutes
Soda dosing for 20 minutes
Hold time 60mins
Drained
Filling with cold water

17. Recall LR
Acid transfer from tank to m/c
Hold time 10 minutes at 70 degree celsius
At 95 degree celsius start soaping
Transfer the chemical to m/c
Hold time 16 minutes
At 95,90,80,60 degree celsius aquachron
Drained

18. Filling with cold water
Acid transfer to m/c
Hold time 8 minutes
Check unloading pH, if ok (5-5.5) then unload

19. DYEING FAULTS WITH ITS CAUSES AND REMEDIES
Pilling
Causes:
I. Too high mechanical stress on the surface of the fabric.
II. Excess speed during processing.
III. Excess foam formation in the dye bath.
Remedies:
I. By using of a suitable chemical lubricant.
II. By using antifoaming agent.
III. By turn reversing the Fabric before dyeing.
Uneven Dyeing
Causes:
I. Uneven pretreatment (uneven scouring, bleaching & mercerizing).
II. Uneven heat-setting in case of synthetic fibers.
III. Quick addition of dyes and chemicals.
IV. Lack of control of dyeing machine.
Remedies:
I. By ensuring even pretreatment.
II. By ensuring even heat-setting in case of synthetic fibers.
III. By slow addition of dyes and chemicals.
IV. Proper controlling of dyeing machine.

20. Dye Spot
Causes: Improper mixing of dyestuff in the solution, in right amount of water, at the
temperature.
Remedies: We should pass the dissolved dyestuff through a fine stainless steel mesh strainer
when adding it to the chemical tank, so that the large un-dissolved particles are
removed.
Patchy Dyeing
Causes:
I. Uneven heat in the machine.
II. Improper impregnation of dye liquor due to the low
wetting property of the fabric.
III. Dye migration during intermediate dyeing.
Remedies:
I. By proper pretreatment.
II. By adding extra wetting agent.
III. Heat should be same throughout the dye liquor.