This document provides information about the author's summer training at AYM Syntex Ltd in Palghar, Mumbai. It includes: 1) An acknowledgement thanking the institute and company for providing training opportunities and support. 2) A profile of AYM Syntex Ltd describing it as a leading manufacturer of specialty synthetic yarns established in 1985 with facilities in Silvassa and Palghar. 3) An overview of the company's textile yarn production processes including twisting, texturizing, dyeing and their various machine capabilities.

1. SUMMER TRAINING REPORT
AYM SYNTEX LTD PALGHAR MUMBAI
IN THE PARTIAL FULFILLMENT OF B. TECH
UNDER GUIDENCE OF
UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE
KANPUR
BATCH: 2017- 2021
SUBMITTED TO:
DR. AKS GANGWAR
SUBMITTED BY:
Vijay prakash 1704460060
Textile chemistry department

2. ACKNOWLEDGEMENT
First of all we are thankful to our institute (U.P.T.T.I) for providing us the opportunity for getting
the practical knowledge as well, under the direction of our most respected director Dr. Mukesh
Kumar singh. We have got full support and instruction from Dr. A.K Gangwar sir and Dr. Arun
Patra. For the preparation of the project. I have also got full support from Mr.Sanjeev Kr. Rajput,
Prof. Kalley Singh and prof. Alka Ali of our institute.
We are also thankful to whole AYM SYNTEX LIMITED for providing us the best facility and
good environment during training period. We express our gratitude to each and every employee of
AYM SYNTEX LIMITED for their co-operation &their most valuable time.
We would like to express our gratitude towards ALOK UPADHYAY (VICE PRESIDENT) ,
Mr. RAGHVENDRA SINGH (H.R). We pay our thanks to Mr. Dheerendra Singh Sir. who
gave their valuable time & attention during training. Their guidance was very beneficial for getting
the practical knowledge.
(THANKS TO ALL)

3. COMPANY PROFILE
Established in the year 1985, AYM syntax is leading specialty synthetic yarn manufacturer with
the world class manufacturing technology for multipolymer yarn.
It is the largest Indian manufacturer of bulk continuous filament yarn and leading multipolymer
yarn dyeing house in Asia.
AYM syntax limited (formerly known as Welspun syntax limited) with its innovative approach
is a pioneer in spinning, texturing, draw twisting and dyeing of polyester and nylon yarn
USIn the field of specialty synthetic yarns, AYM Syntex is one of the largest manufacturers of
multipolymer Textile & Bulk Continuous Filament (BCF) yarns with offices spread across
India. With the largest yarn dyeing house in Asia, AYM offers world-class quality, wide range
of shades, exceptional service & breakthrough innovation.

4. 35 YEARS OF SUCCESS
With plants located at Silvassa (Dadra Nagar Haveli) and Palghar (Maharashtra), AYM Syntex
is well equipped to meet both domestic and international customer demand for synthetic yarns.
The company’s state-of-the-art multipolymer Textile & BCF yarn manufacturing facility at
Silvassa (India) serves the diversified global textile & floor covering industry. These lines are
capable to manufacture specialty yarns, first-of-its-kind across the globe. The plant is equipped
with an R&D facility for master batch color development, pilot spinning and sample
tufting (MTUFT) for the customer’s tailor-made needs.
Our Palghar facility houses India’s largest, 100% environment-friendly automated dyeing
facility with a zero liquid discharge system.
GLOBAL PRESENCE
Touching lives across 50+ countries.

5. BCF YARNS
AYM Syntex Limited is the leading manufacturer of Bulk Continuous Filament yarns (BCF) in
India. We are pioneers in producing specialty BCF and Microfiber yarns. We
produce POLYESTER, NYLON 6, POLYPROPYLENE and POLYESTER MICROFIBRE
yarns which are ideal for carpets, rugs & mats.
Our expertise lies in yarns for wall-to-wall carpets - (Tufted & woven) carpet tiles,
hospitality, contract, automotive mats, rugs, bath mats & CHROMOJET printed etc. We
also have yarns suitable for handmade carpet industry

6. Textile yarn
Our textile yarn include nylon, polyester, recycled polyester.
Synthetic Solution Dyed Yarn
Synthetic Package Dyed Yarn
Mother Fully Drawn Yarn (FDY)
Mono Yarn

7. Highly Oriented Yarn (HOY)
Partially Oriented Yarn (POY)
Air Covered Yarn (ACY)

8. Recycled Yarn
Raw White

9. APPLICATION
Automotive sewing thread and industrial yarn
S& Dress Materials
Shocks Home textiles

10. Medical textile Narrow fabric
Home Textiles
Sewing Thread & Industrial Yarns
Sport wear Fashion apparel

11. Flow chart for dyeing plant
Raw material
Twisting texturizing Rewinder
Twisting
Dyeing plant
Pressing m/c
Hydro extractor(drying)
Issue to conning plant

12. Fashion & app
Texturizing
Texturizing is the process by which synthetic fiber are modified to change their texture the
physical appearance of the fiber texturizing techniques can include bulking (where thermoplastic
fiber are twisted, heat set and untwisted),crimping and coiling amongst others.
Process temperature
primary heater temp ----(165 to 195C)
secondary heater temp ----(140 to 170C)
cooling rod temp ----(65C)
there are 12m/c out of 3m/c (himson) and 9 m/c (ALIDHRA)
Himson m/c capacity of spindle ---168*2 two sided
ALIDHRA m/c capacity of spindle ---112*2 two sided right and left
CONNING
Antistatic conning oils are used for texturizing synthetic yarns such as viscose acetate rayon
,nylon and polyester. We supply oils of different viscosities depending on yarn.
Polyester department
CONNING.A---11PCW (precision cone winding m/c + 1 m/c Korea (mélange)
CONING.B ----4P.C. W (32 spindle)
CONNING.D---3P.C. W
Nylon department

13. There are 6M/c (W.S.F) and 2m/c (FADIS) 29m/c (MURATA) spindle capacity -24 spindle and
one another m/c whose capacity 12.
TWISTING
Twist is the simply spiral arrangement of the fibers around the axis of the yarn through twisting
the fibers is bound together and create a stronger yarn. The number of twists involve to as
normally referred to as turn per inch or turn oer meter.
There is total 38 m/c. which different brand –LOHIA TFO, ALIDHRA, MURATA
LOHIA M/C capacity--- 240 spindle (120 upper and 120 lower)
DYEING DEPARTMENT
There are 3 dyeing department
1—Old dyeing (polyester dyeing)—There are 15 dyeing m/c and 11 hydro m/c, 7 pressing m/c
2---German dyeing (Carpet dyeing)—There are 13 dyeing m/c, 2 Rapid dryer (with steam),1
hydro (without steam)
3—Nylon department --- There are 15 dyeing m/c.

14. Dye used in department
1—Disperse dye ---(polyester)
2---ACID DYE ---(nylon)
3---Cationic dye --(silkenza)
4---Metal complex dye –(nylon)
German dyeing
1. Polyester dyeing
2. Nylon dyeing
There is 17m/c. out of17- 13dyeing m/c , 2 hydro and 2 pressing m/c.
* in this department 4 types of yarn used such as a.
1* 1200 denier (nylon)
2* 900 denier (nylon)
3* 3600 denier (polyester) ecose
4* 1600 denier (polyester) these type of yarn are called B.C.F yarn.

15. DYEING M/C CAPACITY
Dyeing cycle (process)
For 1600&3600denierpolyester
First load the material in vessel then prepare the solution of levelling agent (TOP),accelerating
agent (D.I.F),penetrating agent (C.R.I) and defoaming agent (A.R)
m/c no. yarn capacity in kg co.name pressure kg/cm2 water capacity no.of spindle
A2 200 thies 3.5 to 4 700ltr 14 to16
A3 100 thies 3.5 to 4 1000ltr 8
A4 100 thies 3.5 to 4 1000ltr 8
A5 100 thies 3.5 to 4 1000ltr 8
A6 100 thies 3.5 to 4 1000ltr 8
A7 100 thies 3.5 to 4 1000ltr 8
A8 30 thies 3.5 to 4 30ltr 3
A9 30 thies 3.5 to 4 30ltr 3
B3 800 thies 3.5 to 4 800ltr 39,38,54
B4 800 thies 3.5 to 4 800ltr 39,38,55
B5 600 thies 3.5 to 4 600ltr 32
B6 600 thies 3.5 to 4 600ltr 32
B7 600 thies 3.5 to 4 600ltr 32

16. Acidic acid and dyes.
solution prepare in the room temperature.
Then increase the temperature till 95⁰ c at raising rate 0.5/⁰ c and hold 10 minutes. Again,
Increase the temperature 115⁰ c at rate 0.5⁰ c/min and hold 10 minutes. After 10 minute
increases the temperature 135⁰ c and hold 40 minutes.
After 40 minutes we drain the goods with softener Impreza.
if softener use then material is soft.
NYLON DYEING CYCLE
FOR 1200&900 DENIER
First load the material in vessel. Then scoured with scouring agent 20 minute at 110⁰ C
temperature. After drain we prepare the solution in room temperature with levelling (lysogen
S.E),
retarder (Ammonia) and penetrating agent (C.I.R). And color.
After preparing the solution we increase the temperature 60⁰ C

17. At rate 0.5⁰ C/min and hold 10 minutes. Then again and again increase the temperature same
rate 80⁰ C to 107⁰ C.
After drain we use the softening agent for smooth and soft touch
OLD DYEING
DYEING M/C CAPACITY
HYDRO M/C

18. Hydro extractor or centrifugal extractor use centrifuge technology for manufacturing
laundering which is used in Textile Company. Hydro extracting m/c is mainly centrifugal for
generating hydropower. The wet substantial is placed in the hydro extracting m/c or centrifugal
extracting m/c which has a barrier of metal generally steel. The internal drum of centrifugal
extracting m/c switches at high speed thus throwing out the water contained in it. The use of
this extractor considerably decreases the energy required to dry any material. It is special types
of washing machine. Through our technique apartment hard work, exploit new the leading level,
and the national patent. This extractor is used after dyeing machine and before tumble dryer
machine.
POLYESTER DYEING CYCLE
NYLON DYEING

19. Mostly nylon dyeing is carried out in hank form, for this purpose we use Fadis m/c.
M/C CAPACITY
Fadis m/c
Co. Name - Solbiate ARNO(VA-ITALY)
☆ This m/c convert package to hank.
☆ There are total 72 m/c,whose capacity 10 spindle ,
6 spindle ,and 8 apindle
☆ The conversation of package to hank depend upon m/c speed and yarn quality (denier).
The quality of threads is colored in nylon dyeing
Micro denier Normal denier
70/68/1 70/24/2
70/68/2 70/24
70/48/2 111/24/2
70/48 111/24
70/24/4
70/24/3
HYDRO TIMING FOR NYLON DYED YARN
FOR NORMAL DENIER TIMING
70/24/2 35 mint
70/24 35 mint
111/24/2 35 mint
111/24 35 mint
70/24/2 35 mint
111/24 35 mint
70/24/4 35 mint
70/24/3 35 mint
FOR MICRO DENIER TIMING
70/68/1 45 mints

20. 70/68/2 45 mints
70/48/2 45 mints
70/48 45 mints
DYEING CYCLE
Theory
Acid dyes are highly water soluble, and have better light fastness than basic dyes. The textile
acid dyes are effective for protein fibers such as silk, wool, nylon and modified acrylics. They
contain sulphonic acid groups, which are usually present as sodium sulphonate salts. These
increase solubility in water, and give the dye molecules a negative charge. In an acidic solution,
the -NH2 functionalities of the fibers are protonated to give a positive charge: -NH3+. This
charge interacts with the negative dye charge, allowing the formation of ionic interactions. As
well as this, Van-der-Waals bonds, dipolar bonds and hydrogen bonds are formed between dye
and fiber
DYEING LAB

21. TESTS AND MACHINSES: -
(1)- TEST
(A) Shade match
(B) Fastness test
1. Washing fastness
2. Rubbing fastness
3. Sublimation fastness
4. Perspiration fastness
DYEING M/C CAPACITY
METHOD NO. AATCC – 2A
1. Collect a hank of dyed materials of each dark batch as a party required.
2. Add the multi fabric piece [15cm×5cm]
3. Take the 1250ml pot of Laundrometer and add to it 2gpl WOB Detergent I.R. 150:1, 50
steel ball.
4. Introduce both dyed & Multi Fabric in that pot.
5. Start the m/c and set the temp 49°C±2°C and keep hold for 45 minutes.
6. Than dry the sample and observe the fastness on multi fabric and give ratting as per
fastness grey scale.

22. METHOD NO. ISO105/CO3
1. Collect a hank of dyed materials of each dark batch as party required.
2. Add the multi fabric piece.
3. Take the 250ml pot of loundrometer and add to it 2gpl of soda ash &5gpl of
Detergent I.R 50:1
4. Introduce both dyed & multi fabric in that pot.
5. Start the m/c and set the temp 60±2 °C and keep hold for 30 min.
6. Then dry the sample and observe the fastness on Multi Fabric and give rating as per
fastness rating table.
Rating Fastness Staining on grey yarn
0-1 V. poor Heavy stain
1-2 Poor Considerable stain
2-3 Satisfactory Noticeable stain
3-4 Good Slight stain
4-5 Very good uncertain
(2)- MACHINES
1. R&D automated dispenser m/c: -
this is fully automatic and gives dyes as we required and
we send in put to the m/c it has many pots and use full for talking different dyes and color of
different medium as me required
2. (a) Spectrophotometer-1
(b) Spectrophotometer-2
Spectrophotometer is a machine which detects the color ingredients in
the sample of fiber or fabric and gives us near amount of color which are in sample and also idea
about the color by the application of CCM.

23. 4. Hang JIE (rewinder m/c)
this is used for rewind the package for dyeing sample
5. Hang JIE (washing m/c)
this is used for washing the dyeing pot after the dyeing of sample and also cooled the pot
6. Hang JIE (dyeing m/c)
this is used for dyeing the sample by using the metal ball for the generating the pressure and it
has a heater which heat the dye pot for two hours.
7. loundrometr-2.
this is also use full for the test of washing fastness of material as given above and it is different
a little bit from first one because in this temperature will be 45+_2 where as in first one has
60+_2 degree centigrade.
8. Oven -1
this is used for burn out the water and wetting from the package
9. Sample dyeing (AHIBA-01-02)
this is used for dyeing the sample of all type may be nylon, polyester, catlon etc. polyester dyed
at 135 c, nylon 105c and catlon at 120c
10. VACCUM PUMP: -
dispersibility of disperse dye by filter test

24. OTHER DYEING M/C: -
11. IR M/C-1
this is dyeing m/c which is used for dyeing and has 6 pot and 50 gr and used only for
nylon
12. IR M/C 2: -
THIS is also use full for dyeing and has 12 pot and of capacity of pot 5 gm and used
for both nylon and polyester dyeing
13.IR M/C 3: -
This dyeing m/c is also used full for both type of yarn and have capacity of 12 pot and 5
gm
14. IR M/C4: -
THIS is also useful for both type of dyeing and capacity 12pot and of 5 gram and in
this Machin we can dyed both type of yarn and and in both form like hank and package
15.IRM/C 5:-
this m/c has 5 pot and and each have 5 gram and this is useful for only nylon in
hank form
16.IR M/C 6: -
THIs m/c has 18 pot and used for nylon and polyester in both the form hank and
package
17. IR M/C7: -
THIS M/C CAN DYE only the nylon fiber and has 24 pot of 5gram.

25. THANKYOU