about dying and finishing process

1. INTERNSHIP DURATION:
11-JUNE-2018 TO 10-JULY-2018
SUMMER INTERNSHIP REPORT
Department – processing
SUBMITTED TO :-
Mr. ASHOK PANDEY (H.R., HEAD)
SUBMITTED BY:-
Mr.ROHIT SINGH (B.tech 3rd Year, NITRA)

2. ACKNOWLEDGEMENT
We would like to express our sincerest gratitude towards Alps Industries limited,
Meerut for providing us the best facility and working environment during our
training period, at your esteemed organization. We are grateful towards each and
every employee of the Alps Industries limited, Meerut for providing us their most
valuable time and experience. It is indeed a great pleasure for us to express our
profound and sincere thanks to Miss. Swati Yadav (Asst. Executive, HR) for his
co-operation. We would like to thanks to Mr. Naseem Ahmed (Processing Head),
and Mr. Benami Singh (Asst. Manager, HR) for giving their valuable time and
attention during our training. Their instructions proved to be quite beneficial
during the training period.
We pay our special thanks to Mr. Ram Kumar (Executive, Processing Lab) and
Mr. Harendra Chaudhary (Processing Lab Incharge). We thank all of them for
providing us a friendly and stress free learning environment in Weaving and
Designing department.
Our association with the Alps Industries limited over the past 1 month has been
immensely fruitful and we sincerely hope that this association will continue.
Thank you Alps,Approved by:-
Mr. ASHOK PANDEY
(H.R., HEAD)
Alps Industries Limited

3. CONTENT
Page no.
History of company 4
Mission 5
Our group companies 5
Company profile 6
Flow chart 7
Processing department 8-9
 Singing 8
 Ready for dyeing (RFD) 9
Dyeing & printing department 9-15
 Jigger
 Jet
 Soft flow
 Printing machine
Finishing department 15-21
 Mechanical finish
Other department 21-23
 Hot melt machine
 Foam lamination machine
Final inspection 23-25

4. History of Company
1962- Alps Industries was promoted by Mr. KK Agrawal, a Textile
Engineer & started manufacturing of Home Furnishing textile
products, primarily for domestic markets, including five star hotels.
1974- Commenced exports to USA, Europe and Far East.
1989- Managing Director Mr. SandeepAgarwal, joined the company
in the year 1974. Started interior décor products like Venetian &
Vertical Blinds, Curtain Rods in our Brand-Vista, in collaboration
with Levolor of US for domestic market as well as exports.
1995- IPO with 2.3m Equity Shares. Listing on both BSE & NSE.
1996- Set up integrated Textile Mill with in-house Spinning,
Weaving, Processing, Cut and Sew Operations.
2007- Set up Spinning plant at Haridwar with 88,000 spindles
comprising of latest state of the art compact yarn spinning frames
from Toyota and Reiter.
2009- Set up state of art Weaving and Processing unit in Meerut
including Foam Back & Blackout coating for Window Treatments
& Hot Melt Processing for Mattress ticking fabrics, etc.

5. MISSION
 To achieve a leading position in environment friendly textile
products
 To create top of the mind brand recall for its products
 To pursue innovation of new products
 To strengthen market reach in both the domestic and international
markets so as to fully capture emerging opportunities
 To reach the customers directly for improved responsiveness to
changing customer preferences
 To introduce own brands for home furnishing products in the
international market
 Position, both in domestic as well as the international market
Group Companies:-
 Vista
Offer complete range of home furnishing products for decorating your
windows & floors. Vista, the market leader in Interior Fashions is well
known in the market for its world class quality and continuous
innovations.

6.  Le Pashmina
Offer new range of Pashmina Shawls.
Company profile
Name of the company: Alps Industries Limited
Address of Registered Office: Alps Industries Ltd, 57/2, Site IV
Industrial Area, Sahibabad, Ghaziabad-201010, Phone no.-0120-
4161700

7. Supporting departments
 Human Resource Department
 Engineering Department
 MIS Department
 Quality Control Department
 General Store Department
 Accounts Department
 Designing
 Sampling

8. FLOW CHART
GREY FABRIC
SINGEING (when required)
READY FOR DYEING(RFD)
DYEING
DRYING (BY STENTER OR ZERO ZERO)
FINISH FOLDING
PACKING OR DISPATCH
In the following context brief introduction of all departments is given:

9. Grey Fabric
The Raw materials are Cotton, Polyester, Polyester/Cotton and Polyester/Cationic
used. The Grey fabric procurement is from various sources and from various
industries and stored in fabric Godown.
PROCESSING DEPARTMENT
SINGEING:
Objective:-To remove the protruding fibres from the surface of the grey fabric
with the help of burning flame.
This process is mainly used for cotton fabric.
SINGEING MACHINE:
Company Of Machine:-PoongKwang Machine Co. Ltd. Korea
Year Of Manufacturing:- 2008/12
Speed Of Machine:- Max. 100m/min
Distance from flame:- 5mm
RFD (Ready For Dyeing)
Objective:- The main objective of RFD is to make the fabric suitable for dyeing.
RFD(BLEACHING AND SCOURING)
CHEMICALS USED--
1. Scouring agent (Caustic Soda)

10. 2. Bleaching agent (Hydrogen Peroxide)
3. Wetting Agent(for proper wetting of material)
4. SequestingAgent(it make water soft)
5. Stabilizer Agent(it improves stability of hydrogen peroxide at high temp.)
6. Lubricating agent(for ease mobility in jet or soft flow m/c)
7. Peroxide Killer(it removes the peroxide from material after process)
PROCESS PARAMETER
1. For cotton on jigger , temperature is 90-95 cent. And in jet is 110 cent. and
time is 155 minute.
2. For p/c blend temp. is 100-110 cent.
3. For polyester temp is 100 cent. And time is 90 minute.
DYEING
After RFD next process is DYEING.
For cotton dyeing REACTIVE DYE is used and for polyester DISPERSE AND
CATIONIC DYE IS
USED.
Cotton dyeing is done in jigger and polyester dying is done on jet or soft flow.
The machinery plays an important role in processing. To get even and better
results in dyeing
process, the machinery used in dyeing should be fulfill the all following
conditions to utilized the

11. following form of energy
• Chemical
• Thermal
• Mechanical
• Fluid
The machine used for dyeing purpose in "Alps Industries fabric dyeing section
are almost fulfill the
that requirement. The machine used for dyeing are "High temperature, High
pressure dyeing machines.
These are fully automatic machines(jigger) which are operated by fully
computerized
control panel.
Two types are machines are mainly used in fabric dyeing section:
• jet HTHP dyeing Machine
• Soft flow HTHP dyeing Machine
• Jigger dyeing machine(closed and open)
JIGGER MACHINE
Jigger m/c--- In ALPS industry both manual and automatic jigger are use for
dyeing
The jigger provides a v shaped stainless steel vessel for containing the dye liquor.

12. A pair of upper guide rollers, a pair of immersion rollers at bottom of vessel and
two draw rollers to pull the fabric
through the dye liquor The dye liquor heated by direct heating by use of steam, a
perforated steam pipe located bottom of vessel.
The cloth is wound on draw roller such that cloth is between under tension and
without creases. One END is said be completed when the entire cloth rolls
travels' from one draw roller o another through liquor. END should be in
EVEN. This forward and backward travel of the fabric enables it to pick up more
and more dye liquor. From time time the cloth checked for shade to see whether
dyeing is over.
After dyeing is over the dye liquor is run out from the vessel, which is then filled
with cold water. The fabric is rinsed
well in the over flowing water through as many ends as are required to wash it
free of the dyeing chemicals and
wound on to a draw roller from which it can be taken for drying or other
treatment.
1. It is usual to run the fabric at least six ends in a standard dyeing cycle.
2. The M:L ratio of jigger is usually about to 1:5 or less.
3. The M:L ratio is increases during process because of direct heating.
4. Now a days closed jigger, hthp jigger used. Closed jigger is very useful in
dyeing of cellulosic
fiber with vat and sulfur dye. Also used in polyester fiber dying with carrier
method at a temp.

13. of 110. In hthp jigger temp can be rises to 140 cent.
5. IN jigger both rfd and dying process performed.
JET DYEING MACHINE
JET M/C--- This m/c is more efficient and quicker. The basic principle of jet
involves movement of
both liquor and fabric. This liquor is forced through a narrow jet or venturi and
this cause its
velocity to increase dramatically. Them/c consists of a main dyeing vessel, which
stores the fabric
and dye liquor a jet, a heat exchanger, a circulation pump and a cloth reel as the
main parts.
1. The heating system is indirect by use of heat exchanging system.
2. The maximum temp. attainable is 140 cent.
3. Any kind of fabric that has dimensional stability the forces of circulating liquor
through the jet
can be dyed on this kind of machine.
4. In spite of its obvious advantages jet dying m/c suffers from limitation that a
fabric with poor
dimensional stability can not be dyed because fabric would be distorted its shape.

14. SOFT FLOW MACHINE
SOFT FLOW M/C--- A soft flow jet dyeing m/c is suitable for dying a wide
range ofknitted and woven construction of fabric in rope and open width form up
to 98 cent.
In soft flow m/c only a part of the dye liquor passes through jet so its
velocitythrough jet will be low . Even if the fabric transports has low dimensional
stability itwill give gentle treatment at the jet and no distortion would be occur.
1. The M:L is 1:10.
S.No MACHINE NAME MODEL CAPACITY MANUFACTURER
1. Soft flow KEMPL KRSNA-300 300 kg INDIA
2. Soft flow KEMPL KRSNA-1000 1000 kg INDIA
3. Soft flow BRAZZOLI HT 1 X C3 300kg ITALY
4. Soft flow BRAZZOLI HT 3 X C3 900 kg ITALY
5. Soft flow KEMPL KRSNA 10 kg INDIA
6. Soft flow KEMPL KRSNA 10 kg INDIA
7. Soft flow KEMPL KRSNA 10 kg INDIA
8. Soft flow KEMPL KRSNA 100 kg INDIA
9. Soft flow KEMPL KRSNA 100 kg INDIA
10. JET 1 CIRCULAR HISAKA H-200 50kg JAPAN
11. JET 2 CIRCULAR HISAKA H-200 360kg JAPAN

15. 12. JET 3 SAMILL SIDC-2200 500 kg KOREA
13. JET 4 SAMILL SIDC-2100 250 kg KOREA
14. JET 5 KEMPL 250 kg INDIA
15. JET 6 KEMPL 250 kg INDIA
16. JET 7 KEMPL 250 kg INDIA
17. JET 8 KEMPL 150 kg INDIA
18. JET 9 KEMPL 150 kg INDIA
19. JET 10 KEMPL 100 kg INDIA
20. JET 11 KEMPL 100 kg INDIA
21. JET AMJ AMU 30 kg INDIA
22. JIG. No-1 SUNG MOOUF15P23 700 kg KOREA
23. JIG. No-2 SUNG MOO UF15P23 700 kg KOREA
24. JIG No- 3 SUNG MOOUF15P23 900 kg KOREA
25. JIG. No- 4 SUNG MOO UF15P23 900 kg KOREA
26. JIG. No- 5 GILL ENGINEERS 700 kg INDIA
27. JIG. No- 6 GILL ENGINEERS 700 kg INDIA
28. JIG. No- 7 JUPITER ENG. WORKS 500 kg INDIA
29. JIG. No- 8 JUPITER ENG. WORKS 500 kg INDIA
30. JIG. No- 9 JUPITER ENG. WORKS 500 kg INDIA
31. JIG. No- 10 GILL ENGINEERS 250 kg INDIA

16. 32. JIG. No- 11 GILL ENGINEERS 250 kg INDIA
33. JIG. No- 12 GILL ENGINEERS 250 kg INDIA
34. JIG. No- 13 GILL ENGINEERS 250 kg INDIA
35. JIG. No-14 POWER BUILD LIMITED 500 kg INDIA
36. JIG. No- 15 POWER BUILD LIMITED 500 kg INDIA
37. JIG. No- 16 250 Kg INDIA
38. JIG No- 17 250 Kg INDIA
39. PRINTING MACHINE (KLIEVERIK Heli B.V.) NETHERLAND
FINISHING DEPARTMENT
Machines Used:-
1. Rope Opener
2. Stenter
3. Zero Zero Machine
4. Calendering Machine
5. Shearing Machine
6. Pitching Machine
Other Machines:-
1. Hot Melt Machine
2. Foam Lamination Machine
1. ROPE OPENER

17. Objective:- Mainly used for the opening of fabric after dyeing for
further finishing process of the fabric.
Company Of Machine;-HanayamaKoyga Co. Ltd. Japan
Year Of Manufacturing:- 2008
Speed Of Machine;- Max 100m/min
2. STENTER
Objective:-Stenter machine is not only a dryer but also used for many
other purposes. Here knitted and woven fabric in open width form is
treated. This multipurpose machine is used for the following processes.
 Drying
 Heat Setting
 Width Control
 Curing
 Finishing Chemical application
 Selvedge Printing
 Weft Straightening
 Padding Mangle
 Flocking
No. Of Stenter used in Industry:-4
1. Stenter 1:- 8 Chamber
2. Stenter 2:- 8 Chamber
3. Stenter 3:- 10 Chamber
4. Stenter 4:- 4 Chamber
FLOW CHART
Under Feed Roller

18. Over feed Roller
Pinning Drum
Photocell sensor
Hot Chamber
Cooled Chamber
Delivery Roller
Dancing Roller
Cooling Cylinder

19. Batching Roller
For polyester pressure used is 3.5 kg, temperature is 1600
C and width
can be increased up to 5cm.
For cotton pressure used is 3kg, temperature is 1800
C and width can be
increased upto 20 cm.
Company Of Machine:-Sun-super S, South Korea
Year of Manufacturing:- 2008
Speed of Machine:- 13 mt/min
3. ZERO ZERO MACHINE
Objective:-It is the Controlled compression shrinkage or pre-shrinking of the
fabric by passing the fabric into rubber unit. This process forces the yarns closer
together and the fabric becomes thicker and heavier and the dimensional stability
of the fabric improves. This process is also called
“sanforization”.
BEFORE SANFORIZING
AFTER SANFORIZING

20. 1 - Draw roller (fabric entry). 2 - Water spray unit. 3- Steaming
drum. 4 - Skewed
fabric straightening roller. 5 - Clip type 6 - Rubber blanket
shrinking unit. 7 - Felt
calendar. 8 - Felt drying cylinder. 9 –Plaiter
Company Of Machine:- RONSON
Date of Manufacturing:- 2008/11
Speed of Machine:- Max. 50m/min
4, SHEARING MACHINE
Objective:-Suitable for general shearing of Woven and knitted fabrics fulled fabrics, non-
woven fabrics made of natural or synthetic fabrics, for manufacture of Velvet, Blankets,
Velour's, Plush, Lace. Linings, Fur imitations, Furnishings, Floor Covering. No Cloth tension
irregularities by an adjustable driven brake roller and appropriate appliance o the large draw
roller. Featured in compact design and rationalized structure.

21. FLOW CHART
Knitted Fabric
Guide Roller
Steam Roller
Scroller Roller
Cutting Roller
Glober Pressure
Embry rubber
Company Of Machine:-Mario Crosta
Year Of Manufacturing:-2008/11
Speed Of Machine:-3.5m/min

22. 5. PITCHING MACHINE:-
Objective:-The main objective of pitching machine is to polish the fabric with the
help of continuous rollers to make the fabric smooth and shiny.
Company of machine:- PARAS Ltd.
Year Of Manufacturing:- 2013/12
Speed Of Machine:- Min 13m/min
OTHER MACHINES
1, HOT MELT MACHINE
Objective:-The main purpose of hot melt machine is to coat the required fabric with other
fabric with the help of chemicals. The chemicals are padded with the help of hot rollers due
to which both the fabrics are attached.
Company Of Machine:-World F.L.Y Co. Ltd.
Year Of Manufacturing:- 2008

23. Speed Of Machine:- 10 m/min
Roller Temperature:-100 C
Chemical Temperature:- 100 C
Pressure:- 3 kg
Chemical used:- FE-93
2.FOAM LAMINATION MACHINE
Objective:-These are double belt presses with integrated contact heating and cooling. The
materials that are laminated are heated very gentle. Due to the long heating zone the
materials are laminated perfectly with high bonding strength. Right after the heating the
materials can be pressed together or calibrated to a set thickness with the pressure rollers. To
stabilize this compound the materials a cooled down before they exit the double belt press.
With the flat gap between the belts and the precise height adjustment even rigid plates with a
thickness of up to 150mm can be laminated.
Company Of Machine:-
Year Of Manufacturing:-2008
Speed Of Machine:- Max. 20m/min
Distance from flame:-23 mm
Pressure On Fabric:-2.5 bar
Pressure of Net:- 2.4 bar
Touch with Flame:-15 sec
Note:-The gas used to burn the flame is LPG.

24. Final Inspection
Object – To remove the defects manually by mending.
Following are the defects found after processing-
 Black line on coating
 Black stain
 Bowing
 Chemical stain
 Coating knot
 Color patch
 Color stain
 Color sublimation
 Crack
 Crease mark
 Handling stain
 Insects stain
 Moon mark
 Oil stain
 Pin hole in fabric
 Rope mark
 Shade variation
 Short width
 Uneven dye
 Warp patta
 Weft patta

25. Number of machines –
 ALMAC – 6
 YASH – 2
 Speed of machine – 20m/min
 Year-2008
o CALEMARD FRANCE M/C:-
Object-To cut selvedge and remove coating defect and black coating mark.
No. of machine-1
Speed- 30 to 40 m/min
 NOTE- Thinner is used to remove black coating stain and oil stain.
Quality Assurance Department
Object-To check quality of fabric.
List of testing equipment in this department are as follows-
 Air permeability tester
 De Matia Flex Tester
 Sublimation Fastness tester
 Martindale abrasion tester
 Light fastness tester (Suntest CPS)
 Yarn examination tester
 TPI tester
 Wrap reel
 Unistretch 500

26.  Spray test
Thank you so much for giving me
this opportunity