This training presentation covers the key steps in textile processing, including pre-treatment, singeing, desizing, scouring, bleaching, mercerization, dyeing, printing, and finishing. It provides details on the chemicals, parameters, and recipes used for each step. It also discusses quality control procedures like fabric testing, dye lab processes, production planning and control, and grey inspection systems. The goal is to improve fabric properties and ensure quality throughout processing.

1. TRAINING PRESENTATION
BY
ZUHAIR BIN JAWAID
MTO

2. PRE-TREATMENT

3. SINGEING
•Singeing improves the end use and wearing
properties of textiles.
•The burning-off of protruding fibers results in a
clean surface.
•The projecting fiber and the dyed fabrics appear
brighter.

4. DESIZING
Parameters:
• Temperature = 60°C
• pH = 6-7
• Concentration of the chemicals

5. RECIPE
Sr.No Chemical Concentration For Cotton (g/L) Concentration For PC (g/L)
1 Hygen SPL 2 2
2 Chromo Quest 2 2
3 Ecozyme 1 1

6. Sr.
No.
Chemical
Commercial
Name
Chemistry Funtion
1 Wetting Agent Hygen SPL
Sulphonates+organic
compounds+surfactants
Increase Wettability
2
Sequestering
Agent
Chroma Quest Organic Complex
Sequester against
metal ions
3 Enzyme ECOZYME Alpha-Amylase Desizer
4 Oxalic Acid C2H2O4 Oxalic Acid
To remove rust from
fabric

7. SCOURING
The action of alkaline scouring agent is to:
• saponify any residual oils
• to neutralize carboxylic acids
• to solubilize any sizing materials
• to cause dispersion of naturally occurring impurities in natural
fibers.

8. BLEACHING
• The object of bleaching is to produce white fabrics by destroying
the coloring matter.
• Hydrogen peroxide liberates per hydroxyl ion (HO2-) in aqueous
medium.
• HO2
- at higher pH (above 10.8) the liberation of ion is so rapid.
• an optimum pH for bleaching lies between 10.5 to 10.8.

9. Sr. No Chemical Commercial Name Chemistry Function
1 H2O2 H2O2 H2O2 Bleaching Action
2 NaOH NaOH NaOH Scouring + pH
3 Stabilizer Chroma Bleach Non- silicate peroxide
Decomposition of
Peroxide
4 Sequestering Agent Chroma Quest Organic Complex
Sequester against
metal ions
5 Wetting Agent Hygen SPL
Sulphonates+organic
compounds+surfactants
Increase Wettability

10. MERCERIZATION
• Application of caustic soda solution
• A dwell period, to permit diffusion of alkali into the fiber.
• Finally, washing-off of the traces of alkali from the treated fibers.

11. DYEING

12. DYEING
For Cotton:
Reactive Dye
Vat Dye
Sulphur Dye
FOR PC/CVC:
DISPERSE/VAT
DISPERSE/REACTIVE
PIGMENT

13. RECIPE(REACTIVE)
Sr. No.
Chemical Commercial Name Chemistry Function
1 Urea Urea Urea To retain moisture
3 Soda Ash Soda Ash Na2CO3 For dye fixation
4
Anti-migrating
agent
Chroma dye - To avoid migration
5
Anti-reducing
agent
Ultraprint RG3x -
To avoid hydrolysis of dye
molecule
6 Wetting agent Invadine PBN
Ethoxylated fatty alcohol &
araliphatic ether alcohol
For penetration

14. RECIPE(VAT DYE)
Sr.
No.
Chemical Commercial Name Chemistry Function Concentration
4
Dispersing
Agent
Perigen DLS
Modified linin
sulphonate
For dispersion of dye 5 g/l
5
Anti-migrating
Agent
Chroma dye - To avoid migration 15 g/l
6 Acetic acid Acetic acid CH3COOH To neutralize the fabric 2 g/l

15. RECIPE(VAT DEVELOPMENT)
Sr.
No.
Chemical Commercial Name Chemistry Function
1
Sodium
Hydrosulphite
Sodium
Hydrosulphite
Na2S2O4 For reduction of dye
2 Caustic Soda Caustic Soda NaOH
To maintain pH for
reduction
3 Hydrogen Peroxide Hydrogen Peroxide H2O2 For oxidation of dye
4 Acetic acid Acetic acid CH3COOH
To maintain pH for
oxidation

16. RECIPE(DISPERSE/VAT)
Sr. No.
Chemical Commercial Name Chemistry Function
4 Dispersing Agent Perigen DLS Modified linin sulphonate For dispersion of dye
5 Anti-foaming Agent Alviron VKS
Combination of esters, alcohol
and hydrocarbons
To avoid foaming
6 Acetic acid Acetic acid CH3COOH For acidic pH
7
Anti-migrating
agent
Chroma dye - To avoid migration

17. RECIPE(DISPERSE/VAT CHEMICAL PAD)
Sr.
No.
Chemical Commercial Name Chemistry Function
1
Sodium
Hydrosulphite
Sodium
Hydrosulphite
Na2S2O4
For reduction of vat
dye
2 Caustic Soda Caustic Soda NaOH
To maintain pH for
reduction
3 Hydrogen Peroxide Hydrogen Peroxide H2O2 For oxidation of dye
4 Acetic acid Acetic acid CH3COOH
To maintain pH for
oxidation

18. RECIPE(DISPERSE/REACTIVE)
Sr. No.
Chemical Commercial Name Chemistry Function
1 Dispersing Agent Perigen DLS Modified linin sulphonate For dispersion of dye
2 Acetic acid Acetic acid CH3COOH For acidic pH
3
Anti-migrating
agent
Chroma dye - To avoid migration
4 Anti-reducing Agent Ultraprint RG3X - To avoid reduction of dyes

19. RECIPE(DISPERSE/REACTIVE CHEMICAL PAD)
Sr.
No.
Chemical Commercial Name Chemistry Function
1 Sodium Chloride Salt NaCl To avoid bleeding
2 Caustic Soda Caustic Soda NaOH For fixation of dye
3 Soda Ash Soda Ash Na2CO3 For fixation of dye

20. RECIPE(PIGMENT)
Sr. No.
Chemical Commercial Name Chemistry Function
1 Anti-migrating agent Migrosol Mi - To avoid migration
2 Binder Binder Tow Aqueous acrylate dispersion For fixation of pigment
3 Anti-masking Agent Padicoll Dye Ethylene oxide adduct
To avoid deposition of binder on
padder
4 Liquor Ammonia Liquor Ammonia NH4OH
To give basic pH to avoid pre-cross
linkage of binder
5 Softener Cepreton Fatty amide To give softness to fabric
6 Anti-foaming Agent Alviron VKS
Combination of esters, alcohol and
hydrocarbons
To avoid foaming

21. PRINTING

22. DESIGN STUDIO
Creation
Separation

23. ENGRAVING
• Rotary Screen Engraving
• Flat Screen Engraving

24. PRINTING
For Cotton:
Reactive Print
pigment
FOR PC/CVC:
DISPERSE/VAT PRINTING
PIGMENT PRINTING

25. MACHINES
• Flat screen printing machine
• Rotary screen printing machine

26. FLAT SCREEN
• Reggiani
• 8 colors capacity
• Rubber blades
• 1 screen for 1 color
• Semi continuous

27. ROTARY SCREEN
• Stork:
9 colors
Metal Blade squeegee
Impression rollers
continuous
• REGGIANI:
8 COLORS
ROD SQUEEGEE

28. REACTIVE PRINTING
• First stock paste was made by ½ tank of water and 4-5% of
NaHCO3.
• Then stirred for some time after that 2-3% of Na Alginate was
added and then again stir for 20-25 minutes.
• Then add 10-15% of urea (20% for viscose) then stir for 5-7
minutes.
• Then anti-reducing agent was added and again stirred for 5-7
minutes.
• Now the stock paste was ready.

29. FINISHING

30. FINISHING
Mechanical Finishing:
• Sanforizing
• Peaching
• Pentek softening
CHEMICAL FINISHING:
• RESIN FINISH
• WATER REPELLENT
• FR
• SOFTENERS
• ANTI-PILLING

31. FINAL INSPECTION & FOLDING

32. FINAL INSPECTION & FOLDING
• The system used for inspection was 4-point system.
• Maximum 4 penalty points can be assigned per linear meter.
• Standard by customer for acceptance criteria of passing criteria
• otherwise it will be considered as ‘B’ Grade.

33. FAULTS
• Shade variation
• Elephant Skin
• Crease
• Design Out
• Color Bleeding
• Miss Print
• Color Stain
• COLOR STREAKS
• COLOR RAGGAR
• BLACK RAGGAR
• WHITE SPOT
• STEAMER MARK
• FOLD MARK
• YELLOW STAIN.

34. QUALITY CONTROL LAB

35. QUALITY ASSURANCE LAB
• Width: ASTM D-3774
• Fabric construction: ASTM D-
3775
• Blend: AATCC 20A
• Shrinkage:ISO-6330
• Skewness: AATCC 179
• Tear strength: ASTM D-1424.
• Tensile strength: ASTM D-
5034
• Wrinkle recovery: AATCC 128
• Ph: ISO 3071
• ELONGATION:ISO-14704-1
• FORMALDEHYDE: ISO EN 14184-1
• CREASE RETENTION: AATCC 88
• SOIL RELEASE: AATCC 130
• WATER REPELLENCY: AATCC 193
• OIL REPELLENCY: AATCC 118
• FIRE RETARDANCY: ISO 15025
• CHEMICAL PROTECTION: EN ISO
13034
• PERSPIRATION FASTNESS: ISO 105
E04
• WASH FASTNESS: ISO 105 CO6

36. DYEING LAB
• Lab Dips
• Strike offs
• Shade matching
• Keeping records of dips

37. PRODUCTION PLANNING AND CONTROL
• Main aim of ppc is to keep processing smooth
• Processing advice from marketing
• Advance planning of production is done
• Processing is prioritize according to delievery date
• Machine planning
• Lab dips , strike offs
• Reports ( workin progress, machine progress)

38. • Balance of issuance
. Input=output
• fabric issuance according to capacity of machines
• Costing

39. GREY INSPECTION

40. GREIGE STORE
• Receiving
. Gatepass, purchase order
• Stock
Valuated stock = sarena (green card)
Non valuated stock = Commercial(white card)
• Issuance
. Issuance according to ppc production plan

41. FOUR POINT INSPECTION SYSTEM
Length of defect Points allotted
Up to 3 inches 1
Over 3 up to 6 inches 2
Over 6 up to 9 inches 3
Over 9 inches 4
Openings and holes
1 inch or less 2
Over 1 inch 4

42. FAULTS
• Double end
• Loose end
• Hard size
• Size stains
• Sizing balls
• Miss pick
• Double pick
• Hanging thread
• Wrong drawing
• BROKEN END
• FLUFF
• TEMPLE MARKS
• KNOTS
• SLUB
• HOLES
• CUT
• TEAR