YTM-Unit#1- Internship Report-Dec2020- NED University- Yunus Textile Mills Unit-1 , Karachi, Pakistan.

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
SHAHZAIB szaib2245@gmail.com +923312946081
M. FAZEEL WARSI fazeelkhanwarsi2000@gmail.com +923352770019
MIRZA ALI ABBAS ali.neduet2000@gmail.com +923362550810
DANIYAL WAHAB daniyalwahab0347@gmail.com +923472068273
FROM:Department of Industrial and Manufacturing
Engineering NEDUET, Batch (2018-19).
INTERNSHIP REPORT
PREPARED BY:

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
With great pleasure, we would like to express gratitude to the YUNUS
TEXTILE MILLS LIMITED for giving us the opportunity of Internship in
the Industry for 3 Weeks.
We would like to appreciate Mr. Imran Arain (H.O.D QMS) for giving us a
chance to get knowledge about the textile industry.
Also we are very thankful to Mr. Areeb Ahmed(Executive QMS) for
assigning us various tasks related to QAFA Audit.
Also, the name worth mentioning in making this internship advantageous, the
name includes:
➢ Mr. Jaan Alam (Manager Weaving Department)
➢ Mr. Khalil-ur-Rehman (I.E Processing Department)
➢ Miss Nimra (I.E Stitching Department)
ACKNOWLEDGEMENT

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
Yunus textile mills
Yunus Textile Mills (YTM) is the latest addition to the YBG of Companies.
YTM is a complete vertically integrated textile mill with state of the art
machinery for the home textile and garment industry.
It is also a major contender in the home textile mills and the garment export
segment of the Pakistani economy and it is the 5Th
largest exporter of
Pakistan nearly produces 140, 000, 00 meters’ fabric per month. The staff
strength at the YTM employs approximately 12,000.
Yunus Textile Mills basically deals with the home textile and has a following
international customers:
GERMANY MGB METRO, KAUFHOF
U.S.A JC PENNY, TARGET, WALL-
MART, MARMAXX, KOHL’S,
SEARS, LINEN-N-THINGS, BED
BATH AND BEYOND.
ITALY GABEL, CAMAGNOLO

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
PRODUCTS
Shower Curtain Kitchen Curtains Bed Sheet
Comforter Quilts Table Cover
Pillow

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
PROCESS FLOW OF TEXTILE INDUSTRY
SPINNING
Spinning Weaving Processing Stitching

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
WEAVING
Weaving is a process in which Yarn (Raw Material) converted into
Fabric or greige fabric (Product) with the help of Looms.
TERMS USED IN WEAVING
Warp: The Lengthwise or longitudinal fiber (thread).
Weft/Fill: The horizontal fiber (thread).
Ends: No. of Warps in 1 square inch.
Picks: No. of Wefts in 1 square inch.

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
TYPES OF WEAVING
A) SIMPLE/PLANE WEAVE:
Simple interlocking b/w 1 on 1 fiber or 1 on 2 fiber.
B) DOBBY WEAVE:
Small geometric patterns of fiber.
C) CHEQUERED WEAVE:
Pictorial Patterns of fiber.

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
TYPES OF LOOMS
Basically two types of looms are working here to produce specific
fabric.
A) AIR JET LOOM:
This is projectile less loom and air is used to throw the weft. This machine
mainly produces Cotton Fabric. There are 254 air jets.
B) WATER JET LOOM:
This machine use water to throw weft and it produces polystyrene fabric.
There are approximately 180 plus water jets.

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
PROCESS FLOW OF WEAVING
PROCESS FLOW OF WEAVING
Start
Yarn
Cone
Winding
Warping
Sizing
Weaving
loom
Greige
Inspection
ENDFolding

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
Number of Machines
Names Quantity
Air Jet Loom 254
Water Jet Loom 200
Total 454
Production
Air Jet produces approximately 100,000m of cotton fabric daily.
Water Jet produces approximately 50,000m of polyester fabric daily.

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
PROCESSING
Textile wet processing is the process that use in any finishing treatment.
Where, this process is applied on textile in form of liquid with involves some
for chemical action on the textile
Processing includes the following flow processes:
❖ Singeing and De-Sizing
❖ Scour Bleach/Solomate Bleach
❖ Mercerizing
❖ Dyeing/Printing/White
❖ Washing
❖ Cloth Pad Steamer
❖ Finishing & Fold

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
A) SINGEING AND DE-SIZING:
Singeing and De-sizing is the process is removing the hairs of fabrics or
fibers from the surface of the fabric in order to improve their surface
appearance and sharp surfaces and also remove to the size material on the
yarn to avoid breaking the yarn due to mechanical stresses.
B) SCOUR BLEACH/SOLOMATE BLEACHING:
The process of scour bleach is to make material highly and uniformly
absorbent. (I-e the removal of natural impurities like wax, fats, oils) and
bleach is applied to natural coloring which are ultimately broken down with
bleaching agents.
The Solomate bleaching is applied on the grey fabric in one go and then sent
for further processes.

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
C) MERCERIZING:
The mercerized process is used in the clothing sector to enhance properties
such as luster, tensile strength, dye ability, fiber moisture, and dimensional
stability of cotton.
D) DYEING/PRINTING/WHITE:
After mercerizing, all the fabric always undergoes the process of dyeing or
pigments on the yarn, but fabric or yarn not always go through the process of
dyeing, they can also go direct for printing according to the requirement of
the customers.
The white fabric goes directly for washing process and then to the finishing
process after mercerization.

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
E) WASHING:
Washing is a finishing process applied to fibers, yarns and fabrics which is
used to remove impurities from the surface of fibers.
F) CLOTH PAD STEAMER:
Pad-Steam dyeing is a process of continuous dyeing in which the fabric in
open width is padded with dyestuff and is then steamed.
G) FINISHING & FOLD:
The fabric is folded and sent to the stitching department for the packaging of
the material.

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
PROCESS FLOW OF PROCESSING
singeing
Desizing
Scouring
Bleaching
Dyeing
Finishing
(Calendaring)
Rolling End
Printing
Steaming/
Cutting
Rolling
Start
Greige
Fabric
Fabric Inspection
Mercirizing
(Optional)

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
Number of Machines
BLEACHING
St. Dyeing 03
Bleaching 03
Mercerize 02
DYEING
Thermo sol 02
Pad Steamer 02
Peaching 03
PRINTING
Rotaries 05
Flat Belt 01
FINISHING
Stenter 11
Sanforizer 3
Calendar 2
FINISHING UNIT # 01
Stenter 08
Sanforizer 02
Calendar 01

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
FINISHING UNIT # 02
Stenter 03
Sanforizer 01
Calendar 01
Production
Approximately 400k of Greige fabric issue from Weaving depart
150,000m from weaving and other from outside then it is further
divided into following:
Operation Machine Quantity
Printing Jet dyeing 180k
Dyeing Jet dyeing 120k
White Jigger dyeing 50k
St. Dye Thermosol 50k

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
STITCHING
“Stitches means a single complete movement of a threaded needle in
sewing.”
The processed rolls of fabric reaches to the Stitching Department.
Yunus Textile Mills Ltd. consists of 4 Units of stitching departments. Unit: 1,
2, 3 and 7 have only stitching.
At YTM#1, we do cut-to-pack processing.
Total they have 1327 Stitching Machines, 25 Quilting Machines & 8 Texpa
Machines.
At the moment, YTM#1is producing Target Company orders.
Cut-to-pack processing includes: Receiving, Cutting, Stitching, Checking and
Packing.
PROCESSES IN STITCHING DEPARTMENT
FABRIC RECEIVING:
The fabric received from Processing Department is stored in the stitching
warehouse.
CUTTING:
There are 3 types of cutting: Manual Cutting, Machine Cut, and Pipe Range
Cutting. Cutting dimensions are implied as per the customer requirement that
what is going to be made e.g.: Bed sheets, Fitted sheets, Pillow cover, Couch
cover, Shower Curtains, Comforter etc.
STITCHING:
The stitching takes place is some different steps which are Top Hamming, 3
Sided Hamming, Kaaj, Elastic Applying and Tag Applying.

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
CHECKING:
The Checking is done by labors that if any alteration required.
PACKING:
This is the final stage where the product get ready to be shipped in
thecartons.

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
PROCESS FLOW DIAGRAM OF STITCHING
End
Start
Daily stitch
plan
preparation
Pallet/
Trolley
Receiving
Accessories
Receiving
Route
Selection
Loading on
A-Frame
Hang on
Switch Track
Attach Batch
Tickets on
Bundle of 20
Pieces
Move to
Stitching
Machine
Stitching
Off Load Pieces
from SwitchTrack
Re-Building
Move to Pillow
Section
Stitching
Move to
“Ready For
Checking”
Area
Inline
QC
Check
Reject/
Rework
PROCESS FLOW OF STITCHING

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NED UNIVERSITY OF ENGINEERING & TECHNOLOGY January 14, 2021
INFORMATION
The fabric rolls are usually of 300 meters to 320 meters and width of 100-110
inches.
Machines cuts are performed when the fabric is placed in ranges.
Time of stitching of one piece of shower curtain is 3 minutes.
Stitching department mostly rely on labor work.
The Stitching included all the procedure from Cut-to-Pack. The Stitching
Section in Unit-1 is divided into 2 lines (2A & 2b).
Total Stitching Machines are 205 in Unit 1. Average cutting per day is
21500m(approx.) The per day stitching output is 18000m(approx.) Total
average packing done in a day is 46787m.
Fabric
Receiving
Cutting
StitchingChecking
Packing