Internship report in Printing and embroidery industry (Mayur-Jetpur)

Internship report for the printing and embroidery Industry

Table of Contents

Chapter 1 Overview of The Company
1.1 History
1.2 Different product
1.3 Capacity of The Plant

Chapter 2 Overview of Different Departments in the Company

2.1 Methods Used for Printing

2 2.1.1 Block Printing

2.1.2 Stencil Printing

2.1.3 Roller Printing

2.1.4 Screen Printing

2.2 Assembling of Material

2.3  Screen Printing

2.3.1 Flat screen or hand screen printing 

2.3.2 Automatic flat screen printing

2.4  Table Printing

2.5  Machine Printing

2.6  Textile Dyeing

2.6.1 Methods of Dyeing

2.7  Finishing

2.7.1 Chemical Finishing Processes

2.7.2 Mechanical Finishing Processes

2.8  Embroidery

2.9  Packaging

Chapter 3 Introduction to Internship

3.1 Objectives

3.2 Scope

Chapter 4 System Analysis

4.1 Current System

4.2 Requirements of the new system

Chapter 5 Testing

5.1 Testing analysis

Chapter 6 Conclusion

6.1 Overall Analysis of Internship

6.2 Summary

References

CHAPTER 1 OVERVIEW OF THE COMPANY 

1.1 HISTORY

Mayur Fashion was established in 1998 in Jetpur.

At first, it started with only Printing Machine. Now they have two different methods of printing and dyeing and embroidery.

1.2 DIFFERENT PRODUCTS

Supplies of: cotton dress, Anarkali dress,

Manufacturing of: unstitched dresses, catalogue suits, Cotton Dress Material

Supplier/Trading in Lady's Salwar Kameez, Cotton Dress Materials, Aishwarya Border Dress Material, Unstitched Cotton Dress Material, Anarkali Dress Material, etc.

1.3 CAPACITY OF PLANT

There are 256 Manual machines for Table printing

1 INDIAN Company Automatic Flatbed Machine

12 Embroidery machine of Silver Samurai Company. 

CHAPTER 2 OVERVIEW OF DIFFERENT DEPARTMENTS IN THE COMPANY

2.1 METHODS USED FOR PRINTING

2.1.1 Block printing method:

Wooden blocks are made by slicing logs of wood horizontally and the required designs are chiselled onto the hard, smooth block surface. The carved-out design on the block is smeared with thick dye paste and then stamped onto the fabric transferring the design as cut in the league. Each different colour will require a separate block. The process is repeated till the design covers the fabric. Hand block printing is carried out as a cottage or small-scale industry in India. It is slow and expensive but is ideal for exclusive designs on limited quantities of fabrics. 

FIG 2.1.1 BLOCK PRINTING 

2.1.2 Stencil method:

A design shape is cut out of a piece of thin, hard non-absorbent material and when this is placed on a fabric and the colour brushed or sprayed in the cutout portions, the design is traced on the fabric.

FIG 2.1.2 STENCIL PRINTING 

2.1.3 Machinerollerprinting:

Modern roller machine printing is a development of the engraved block method. The design is engraved onto a set of copper-surfaced rollers, the number depending on the number of colours in the design. The rollers are situated in sequence around the circumference of a large pressure cylinder whose surface is padded and protected from staining by dyestuff being pressed through the printed fabric.

FIG 2.1.3 ROLLER PRINTING 

2.1.4 Screen printing method:

Printing of textile materials using a screen is either done manually or with the help of machines. In the latter category, the automatic flatbed method or the rotary screen printing method is used.

Uses of Flat Bed Screen Printing Machines

Since most objects are easily laid flat for printing purposes, flatbed screen printing machines are used in a wide variety of ways throughout multiple industries. Here are just a few examples of how flat-screen printing machines are used today:

Textile Industry (clothing, fabrics, bags)
Automotive Industry (dashboards, speedometers, tachometers) Banking Industry (credit cards, debit cards, business cards)
Toy Industry (souvenirs, toys, gifts)
Switches Industry (membrane switches, appliance control switches) Stationary Industry (rulers, protractors, paper designs)
Glass Industry (solar panels, tableware, window glass)
Medical Industry (medical parts, medical tools) 

2.2 ASSEMBLING OF MATERIAL

Bales are purchased from the supplier which contain 100% pure cotton. A Bale contains 16-17 Takas (Long Length of Cloth) which are cut to the length of 5.5 meters to get the length of the material equal to that of the Saree length. A Taka is a long piece of cloth made up of 100% pure cotton and with a width of 1.15 meters equal to the width of a Saree. Some workers cut the length of the saree from the Taka. The material in a Taka contains a length equal to that of seven to eight Sarees. Now it is ready for the subsequent process, i.e., printing.

FIG 2.2.1 ASSEMBLING MATERIAL 

FIG 2.2.2 TAKA

 2.3 SCREEN PRINTING

In this printing method, the fabric is spread on a large table and a design screen is placed on the fabric. The screen consists of a wooden frame covered with nylon or silk cloth and the technique is called as silk screen printing. Lacquer (hard coating) is applied on the screen to make areas other than the design opaque so that printing paste is transferred through the design only. Based on the number of colours, many numbers of screens are prepared to complete the design. The printed portion should be allowed to dry before placing the second screen. When screens are placed properly, they will produce a complete design.

The design is created by painting or making non-design portions of the screen opaque, thus preventing the print paste from passing through. The areas where the print paste passes through will create a printed pattern. The screen is placed in contact with the fabric to be printed and the print paste is forced through the screen by a squeegee. The squeegee is used to spread the dye evenly through the screen. It is moved across the screen, forcing the print paste through the mesh openings. It helps in making a clean image on the printed surface. A screen is prepared for each colour of the design. There are two types of screen printing namely Flat screen printing and Rotary screen printing.

There are two types of printing done at MAYUR FASHION: 

1. Table Printing (Hand Screen Printing)
2. Machine Printing (Automatic Flat Screen Printing) 

FIG 2.3.1 Printing Paste 

FIG 2.3.2 Squeegee 

FIG 2.3.3 Printing the Fabric 

FIG 2.3.4 Screen-Printed Fabric 

2.3.1 Flat Screen Printing or Hand Screen Printing

This method of printing is carried out manually. The design is copied onto a series of very fine, flat screens, one for each colour to be printed. Lacquer or other impermeable substance is applied to all parts of the screen that are not part of its design. Each screen is fitted onto a wooden or metal frame. The fabric to be printed is spread onto a long table. A screen is set over the fabric and the printing paste is poured on the screen and forced through its unblocked areas onto the fabric with a squeegee. The screen is then moved to the next section of the fabric and the operation is repeated until the entire fabric is printed. This process is repeated for each colour of the design. Hand screen printing is time-consuming and limited to the short lengths of fabrics.

Advantages

1 Whole width of fabric is printed at once and so the process is faster than block printing

2 Screens can be preserved for future use

Disadvantages

1. Preparation of the screen is a time-consuming process

2. Preservation of screen needs extra care

3. Small damage to the screen will spoil the entire printing 

2.3.2 Automatic Flat Screen Printing

In this method, the process is automated and therefore faster. Here the fabric moves on a wide rubberized belt. The screens are placed above the belt. As the fabric moves, the screens are automatically lowered to the cloth and the appropriate colour is applied with regulated squeegees. The cloth is dried in an oven.

Advantages

1. Prints up to twenty colours in one run

2. High production rate

3. Produces brighter and cleaner shades

4. Produces designs consisting of squares, circles and ovals

5. Designs to be repeated can be much larger.

Disadvantages

1. High cost

2. Delicate shading and gradation of colours are difficult to obtain by this method.

3. The process is slower than machine roller printing.

2.4 TEXTILE TABLE PRINTING

2.4.1 TextileTablePrintingProcessorHandPrintingProcess

Textile table printing or hand printing process is a part of the textile industry. The manual process used to print a roll of cloth with the help of manpower on the wax table is called the textile table printing process.

Textile table printing is done on a 45-meter to the 75-meter long table which is coated with wax. The wax is applied on that long 45 to 75-meter table. The purpose of applying wax on the table is to hold the cloth. The wax acts as a glue for the cloth so that it remains stretched on the table and the printing process can be done easily and accurately.

Textile hand printing involves a careful examination of what is to be done on a roll of cloth and when it is to be done. The hand printing process is highly dependent on climatic and weather conditions. This is so because it is mostly done under the unfinished or raw roof because it requires sunlight to absorb colour and make it dry within a time interval.

The total production capacity of the hand printing process ranges from 1500 meters to 3000 meters per day. The reason for low production capacity is the involvement of a lot of manual work, which is completely labour oriented

In Mayur fashion, the printing of sarees and dresses is done on a table. The table is coated with wax that holds the saree firmly on it. A table can accommodate 7 sarees at a time. 8 tables can accommodate 56 sarees at a time. Printing is done on them one by one and then goes for finishing and embroidery processes.

The Table Printing Process Includes The Following:

1. The design to be printed: the very first process includes the design to be printed on the roll of cloth, which means the total number of colours to be used in that particular design. Whether the design is of printed scarves, ladies'
scarf, printed pareo, etc. some special people are recruited for making the designs in orders where the designs are not provided by the customer.

FIG 2.4.1 DESIGN 

 2. Metal frame or screen: the very next step is the development of the screen. The screen is made of a metal frame with a thin layered fabric in the centre on which the design is made. The development of the screen depends on the number of colours in the design. For example, if the total number of colours is 5 in a particular design then a separate screen is made for an individual colour thus 5 screens are required for a 5-colour design.

FIG 2.4.2 SCREEN

 3. Fabric to be used: there are plenty of designs that are used in the field of textiles. it may be cotton printed, viscose printed, cambric printed, twill printed, chiffon printed, georgette printed, satin, voil, etc. generally the choice of fabric is made clear by the customer. Mayur fashion uses 100% cotton as fabric.

FIG 2.4.3 PRINTING TABLE 

4. Colour and chemicals: colour and chemicals play an important role in the production process. This process needs a very careful and detailed examination of the chemical to be used. A very minor mistake can affect the whole presentation. There is a separate staff for this process who work to provide an exact and accurate level of printing design. Reactive dyes are used for the making of colour for cotton. The colour is first weighed according to the need and then it is mixed with hot water. Then the gum is added to increase the density of the colour which also increases the quantity of colour mixture which can now be used on the cloth.

FIG 2.4.4 PRINTED CLOTH 

5. Silicate process: the next step is silicate processing. This process is done to make the printed cloth colour fastness. After passing through this silicate process the colour of the cloth gets fastened and remains intact after use. This process makes the colour of the cloth permanent.

6. Washing and drying: after the silicate processes the cloth is kept in a tank of water for more than 6 to 12 hours and then it is washed so that the silicate layer washes off and the colour gets brightened. After washing the cloth is then dried with the help of a machine or in the sunlight.

FIG 2.4.5 DESIGN PRINTING 

7. Finishing: the cloth is sent in the felt unit. A Felt unit is one where the cloth gets finished and the wrinkles get off the fabric. The felt process is machinery oriented. The range of felt machines is divided into segments like zero felt, gotta felt, etc. these segments are used according to the buyer demand.

8. Meterage: the next process is meterage which is measuring. This process involves the measurement of the cloth in terms of the meter unit. This is done manually.

9. Packing& dispatch: the last and final process is packing. Packing is normally done in polyethene bags and then in a carton as master packing. The packed goods are then dispatched.

2.5 AUTOMATIC FLAT-SCREEN PRINTING

To increase the speed of flat screen printing, it was imperative to devise a method of printing all the colours simultaneously. This entails each colour application position being fixed while the substrate moves. The colour is applied through the screens while the frame is stationary.

Flat bed screen printing machines where the fabric remains stationary and the screen moves on a carriage have also been developed for the printing of silk. The entire operation is controlled pneumatically. 

FIG 2.5.1 AUTOMATIC PRINTING MACHINE DESIGN 

The machine consists of the following parts:

1. Printing table (flatbed)

2. An endless conveyer belt to bring the fabric onto the table under the screen periodically

3. Several screens

4. A special mechanism for lowering the screen on the required parts of the fabric squeegees driven by a motor

5. A special conveyer under the table to collect the extra paste

6. An arrangement for gumming the fabric to the conveyer belt and a drier.

Method:

During printing, the fabric is brought onto the printing table through a feeding arrangement and gummed to the conveyer belt on the table. For gumming, a two-shaft peddler is used in which the bottom shaft rotates in a gum box and transmits the gum onto the top shaft which transfers it to the conveyer belt. The conveyor brings the fabric periodically under the screens and stops while the screens are lowered on the required parts of the fabric by a special mechanism. The squeegee makes one or more strokes over the screen after which the screens are lifted again.

Printing paste prepared in tanks is brought through flexible hoses and poured on the screen. It is then distributed throughout the full length of the screen. The squeegee is pressed to the screen by dynamometers placed at both ends of the squeegee holders. One or more strokes of the squeegee ensure simultaneous printing of the patterns by the common action of all screens each of which applies the printing paste as required by the colour in the design. The extra paste is collected by a special conveyer running under the table. After printing, the fabric is dried by passing through a hot–air chamber. The conveyer returns to its original position where it is washed and dried and a new fabric is gummed on it. 

Greater production of printed cloth can be achieved by this machine as compared to ordinary hand screen printing and exact registration of prints with different repeats is possible. Printing can also be carried out with as many as 6 squeegee strokes. Since the process is mechanised, it is not laborious and yet has all the advantages of screen printing.

FEEDING: - feeding device consists of two guiders (roller or plate) manufactured by metal or rubber coated, and a tension roller to maintain the fabric flow in the creaseless form.

GUMMING: - Gumming device consists of two rubber-coated rollers; one is dipped in gumming tank to apply gum to another roller which is attached to the blanket.

PRINTING TABLE / SYSTEM:- The cast iron bed or wooden bed duly machine cut rest on heavy-duty cast iron structure to ensure vibration-free operation cloth feeding is tensionless with an expander or cloth guiding arrangement permanent gumming arrangement can be given with an electrical heater and thermostatic temperature controller rubber printing blanket travels on the bed very accurately, main drive through mechanical sector run by reduction gearbox and A.C. electric motor with correction device by hydraulic cylinder, screen adjustment is very handy to set design and the setting systems is located conveniently on the machine.

BLANKET WASHING UNIT: - two no’s of brush rolls are driven by an A.C. electric Motor and they are housed in an S.S. TANK. A special Design squeeze is also attached.

DRYER: - The high-capacity float dryer with suitable jets, radiators, fan assembly and insulating penal gives quick and even drying for all types of print. The dryer capacity can be increased by adding extra dryer modules.

ELECTRICAL CONTROL PANEL: - Internally fully wired electrical penal is made from best quality contactors, relays, and switches for controlling M/C Operations.

INVERTOR / SERVO CONTROL PANEL: - Invertors/servo control panel that is known for its high performance and stable nature. Made from superior quality components, these panels consume less power and provide higher outputs. These compacts are designed with highly efficient control panels which use for our fully automatic flatbed screen printing machine for quality performance.

FULLY AUTOMATIC PRINTING HEAD: - An extensive range of automatic printing heads on fully automatic flatbed screen printing machines that is an auto AC inverter drive system for flatbed printing machines.

Characteristics:

• The colours of the screen printing are characterized by their cleanliness and they exhibit a natural bloom and brilliance.
• The unprinted white portions do not get tinted.
• The total design exhibits an individualistic appearance.
• Large repeats and blotch designs can be obtained by this method. 

 

FIG 2.5.2 AUTOMATIC PRINTING MACHINE 

2.6 Textile Dyeing

Dyeing and Printing are two major wet printing techniques eventually for the colouration of fibres, yarns, and fabrics in the industry.

Consequently, only one colour produces in the dyeing process but various types of coloured designs are produced on the fabric surface during the printing process.

Dyeing is the application of colour to a textile material with some degree of fastness or permanence. The materials which impart the colour are known as colourants. When these colourants have a natural affinity and permanence on textiles, they are referred to as dyes. Dyes actually migrate or diffuse into the chemical molecular structure of textile fibres to develop the final colour of the textile product. The dye-fibre molecular association is also responsible for the degree of fastness or permanence of the colour because of the molecular attraction between the specific dye and the specific textile fibre

The dyeing process performs on the grey fabric while the printing process performs on both pre-treated fabric and coloured fabric.

Colour is an extremely important aspect of modern textiles. The colour of a textile product is a major factor in the marketing and use of that product. The colour of textiles can be used to differentiate groups of people such as uniforms used for athletic teams, hospital personnel or military organizations. Colour can also be functional such as camouflage or protective uniforms. However, in a modern retail store, the colour of textile products is a major contributor to what is referred to as fashion. Colour is very important with apparel, carpet, upholstery, curtains, drapes, sheets and towels. All of the items are marketed with an emphasis on their specific colour. 

Dyeing versus Printing. 

2.6.1 METHODS OF DYEING

Many methods can be followed for the dyeing of different textile materials. They are described below;

1. Bale Dyeing

2. Batik Dyeing

3. Beam Dyeing

4. Burl or Speck Dyeing

5. Chain Dyeing

6. Cross Dyeing

7. Jig Dyeing

8. Piece Dyeing

9. Random Dyeing.

`

At Mayur Fashion the method used for dyeing is JIG DYEING.

In this method,, dyeing is done in a jig, kier, vat, beck or vessel in an open formation of the goods. The fabric goes from one roller to another through a deep dye bath until the desired shade is achieved. The Jig Dyeing machine operates by transferring the fabric back and forth through the dye bath between two reels. As soon as the second roller is full, the direction of fabric transfer is reversed.

The jigger machines have two main rollers which revolve on smooth bearings and are attached to a suitable driving mechanism, which can be reversed when required. The fabric is wound on one of the main rollers and fed from the other. The fabric moves from one roller to the other through the dye liquor trough located at the lower part of the machine. There are various arrangements of guide rollers at the bottom of the liquor trough, and during each passage,, the cloth passes around these guide rollers.

The concentrated dye liquor is usually introduced directly into the dye bath in two equal portions, which are added just before commencing the first and second ends. The liquor is agitated by the movement of the fabric through the dye bath. Several horizontal spray pipes are fitted across the full width of the trough to expedite fabric rinsing.

Live steam injected into the bottom of the trough through a perforated pipe across the width of the jig heats the liquor.

Fig 2.6.1 Jigger Dyeing Machine

2.7 FINISHING PROCESSES

Finishing processes can be divided into chemical processes and mechanical processes, Heat setting of textiles and surface coating may also be considered as finishing processes.

2.7.1 Chemical Finishing Processes

Chemical Finishing Processes are those processes which involve the application of chemicals to the fabric and these can lead to modification of the handle or make the fabric water-repellant, oil and soil-repellant, anti-microbial, flame-retardant, anti-static, etc.

Chemical finishes are normally applied in the form of an aqueous solution or emulsion and can be applied, for example, with the help of a padding mangle. The fabric passes through a trough of chemical finish. It is then squeezed by a pair of nip rolls to ensure the even application of a fixed amount of the finish onto the fabric. After padding, the fabric is dried to remove the water and the finish can then be fixed by subjecting the fabric to a relatively high temperature for a short period. This enables the applied chemicals to form a durable finish on the fabric.

Some of the chemical finish treatments are described as follows

• Handle modification

A dilute solution of boiled starch is applied to a woven piece of cotton and the fabric is dried, the dried starch film will make the warp and weft threads stick firmly together to give a stiff product. A crisp, smooth finish for cotton goods results from the use of modified starches.

The most common handle modifier used today is the softener which lubricates the warp and weft of woven fabrics allowing the fabric to bend more easily and this gives it a soft feel. Anionic compounds such as sulphated oils and sulphated alcohols are used as softeners. Other softening agents are oil, fat and wax emulsions, soaps and synthetic detergents and silicon compounds.

• Water-repellent and waterproof finishes
Waterproof finishes are those that coat or seal a fabric so water does not pass through the

fabric. Water-repellent finishes result in a fabric that resists wetting.

In the earlier days, the method for waterproofing a fabric was to coat it with rubber. This did the job but the resultant fabric was heavy, bulky and uncomfortable. Silicon compounds are the most suitable.

• Oil, stain and soil-resistant finish

Silicones and fluoro chemical finishes are very effective. A drop of oil placed on an untreated fabric spreads rapidly and stains it. A fabric treated with a fluorochemical finish does not allow these to penetrate the fabric.

Any treatments that encourage the wetting of the textile surface will act as soil-release agents. Polymers containing hydrophilic groups (say acrylic acid groups) would be readily wetted by water and the wet surface will act as a soil release agent.

Materials such as carboxy methyl cellulose (CMC) aid in preventing the re-deposition of soil during laundering and are frequently included in detergents.

• Microbiocidal finishes

These are becoming important for textile finishing. Bacteriostatic is a chemical which inhibits the growth of bacteria. Similarly, Fungistatic is a chemical which inhibits the growth of fungi. Fabrics impregnated with these chemicals will be safe and guard against infection.

• Flame retardant finishes for cotton

A phosphorous-containing material is reacted with urea. The reaction product is padded onto cotton fabric and dried. The fabric is then reacted with ammonia and finally oxidized with hydrogen peroxide. This renders the fabric flame-retardant.

• Anti-static finishes

An antistatic finish dissipates an electrical charge and does not allow it to accumulate on the fabric. An interesting development in the field of anti-static treatments has been the development of the Permolose finishes by ICI which consists of block copolymers of ethylene oxide and polyester. When polyester fibres are treated with this, the polyester portion of the copolymers is adsorbed by the polyester fibre but, the polyethene oxide portion is incompatible with the polyester fibre and so remains on the surface, where it attracts water and forms a conductive surface on the polyester fibre.

Heat-setting

To heat-set a fabric, it is subjected to selected temperatures (above the glass transition temperature and close to the maximum use temperature) for a specified length of time. Fabrics may be heat-set into a flat surface or they may be heat-set into a predetermined shape such as nylon hosiery. Heat-setting causes molecular rearrangement and relieves internal stresses. It makes the fabric dimensionally stable.

2.7.2 Mechanical finishes

Bypassing the fabric between heated rotating rollers, the surface of the fabric is rendered smooth, flattening slubs, increasing the fabric lustre, and improving the fabric handle by making it softer.

2.7.3 MECHANICAL FINISH 

2.8 EMBROIDERY

After the Finishing process, the saree goes for the Embroidery process.

Embroidery is the craft of decorating fabric or other materials using a needle and thread. Embroidery may also incorporate other materials such as pearls, beads, quills, and sequins. In modern days, embroidery is usually seen on caps, hats, coats, overlays, blankets, dress shirts, denim, dresses, stockings, and golf shirts. Embroidery is available in a wide variety of thread or yarn colours.

At Mayur Fashion there is computerized Machine Embroidery.

Machine embroidery is an embroidery process whereby a sewing machine or embroidery machine is used to create patterns on textiles. It is used commercially in product branding, corporate advertising, and uniform adornment. It is also used in the fashion industry to decorate garments and apparel. Machine embroidery is used by craftspeople to decorate gifts, clothing, and home decor. Examples include designs on quilts, pillows, and wall hangings.

Types of machine embroidery

2.8.1 Free-motion machine embroidery

In free-motion machine embroidery, embroidered designs are created by using a basic zigzag sewing machine. As this type of machine is used primarily for tailoring, it lacks the automated features of a specialized machine. To create free-motion machine embroidery, the embroiderer runs the machine and skillfully moves tightly hooped fabric under the needle to create a design. The "feed dogs" or machine teeth are lowered or covered, and the embroiderer moves the fabric manually. The embroiderer develops the embroidery manually, using the machine's settings for running stitches and fancier built-in stitches. A machine's zigzag stitch can create thicker lines within a design or be used to create a border. As this is a manual process rather than a digital reproduction, any pattern created using free-motion machine embroidery is unique and cannot be exactly reproduced, unlike with computerized embroidery.

FIG 2.8.1 FREE MOTION M/C EMBROIDERY 

2.8.2 Cornely hand-guided embroidery

This embroidery inherited the name of the Cornely machine. Cornely embroidery is a so-called hand-guided embroidery. The operator directs his machine according to the pattern. The fabric is moved by a crank located under the machine. The Cornely also has a universal drive system controlled by a handle. Some models can embroider sequins, cords, braids, etc. There are also Cornely machines performing a classic straight stitch. 

FIG 2.8.2 CORNELY HAND-GUIDED EMBROIDERY

 2.8.3 Computerized machine embroidery

Most modern embroidery machines are computer controlled and specifically engineered for embroidery. Industrial and commercial embroidery machines and combination sewing-embroidery machines have a hooping or framing system that holds the framed area of fabric taut under the sewing needle and moves it automatically to create a design from a pre-programmed digital embroidery pattern.

Depending on its capabilities, the machine will require varying degrees of user input to read and sew embroidery designs. Sewing-embroidery machines generally have only one needle and require the user to change thread colours during the embroidery process. Multi-needle industrial machines are generally threaded before running the design and do not require re-threading. These machines require the user to input the correct colour change sequence before beginning to embroider. Some can trim and change colours automatically. 

2.8.3 COMPUTERIZED M/C EMBROIDERY 

The computerized machine embroidery process:

Machine embroidery is a multi-step process with many variables that impact the quality of the final product, including the type of fabric to be embellished, design size, stabilizer choice and type of thread utilized. The basic steps for creating embroidery with a computerized embroidery machine are as follows:

1. Create an embroidery design file or purchase a stitchable machine embroidery file. Creation may take hours depending on the complexity of the design, and the software can be costly.

2. Edit the design and/or combine it with other designs.

3. Export the design file to a (proprietary machine) embroidery file that mostly just contains commands for the embroidery machine. If you bought such a file, you may have to convert the file.

4. Load the embroidery file into the embroidery machine, ensuring it is the correct format for the device and that the stitched design will fit in the appropriate hoop.

5. Determine and mark the location of embroidery placement on the fabric to be embellished.

6. Secure the fabric in a hoop with the appropriate stabilizer, and place it on the machine.

7. Centre the needle over the start point of the design.

8. Start and monitor the embroidery machine, watching for errors and issues. Troubleshoot any problems as they arise. The operator should have plenty of needles, bobbins, a can of air (or a small air compressor), a small brush, and scissors.

9. Remove the completed design from the machine. Separate the fabric from the hoop and trim the stabilizer, loose threads, etc.

2.9 PACKAGING

The sarees ready to be dispatched according to the customer's requirement need to be packed properly to prevent any damage. The packaging department is responsible for this. Here, the sarees are packed keeping butter paper, cardboard or thermocol in between them to keep them intact. Individual sarees are then packed into polyethene bags and a set of 5 to 12 sarees are then packed in a single carton.

CHAPTER 3 INTRODUCTION TO INTERNSHIP

3.1 OBJECTIVE

• One of the main objectives of an internship is to expose me to a particular job and profession.

• Enhance and expand the student's knowledge of a particular area of weaving.

 • Expand the network of professional relationships and contacts. 

3.2 SCOPE

• An Internship Provides Real Life Experience and Exposure.

• An internship enables us to gain first-hand exposure to working in the real world.

• It also allows students to harness the skill, knowledge, and theoretical practice they learnt in university.
• The great thing about internships is that it teaches young professionals about the specific industries and companies they are interested in.

• Even the experience of trying something new is extremely beneficial.

• Partaking in an internship allows you to establish deeper relationships than you normally would talk to a stranger one-on-one.

• Being an intern gives you more opportunities to build connections with company professionals that can be very beneficial for your future career.

CHAPTER 4 SYSTEM ANALYSIS

4.1 CURRENT SYSTEM:

• In the company, there is a division of work.
• There are different people for different types of work.

• The three main divisions of printing, dyeing and embroidery have three different supervisors. The production is counted manually by the workers in a book.

  These books are checked at regular intervals by the supervisors.
• Attendance is done manually.
• Every day, stocks taken by workers are written manually.
• Efficiency is checked by supervisors daily.
• Maintenance is also done after regular intervals by the supervisor.

4.2 REQUIREMENTS OF A NEW SYSTEM

• In this system, there should be a main supervisor above the other supervisors.
• There is some extra space which can be utilized.
•  There should be an automatic attendance system during the entry and exit of the workers and the main team.
• There efficiency of the machine by using the hot pipes under the table after printing is done.
• This technique can help to increase the drying process by approximately an hour during the monsoon season.
• There is an extra space where a new machine can be installed which will help to increase the production by approximately 50 per cent.
• An extra supervisor should be installed at the washing and drying unit as it helps in the issue of rash washing of clothes.
• Therefore leads to the minimizing of defects in the material.
• This decrease in defects also leads to an increase in production. 
•  between the clothes so that the clothes do not get damaged.
• The quality of the raw material should be good so that during the printing process the material should not get clipped to the wax and get torn out.
• The screens that are used for the printing of different designs should be kept with care once they are used.
• The numbers should be given to the screens to get the required screens for the printing
• The labourers should be given proper training so that they work efficiently and don’t make any mistakes.
• The machines should be taken care of properly and should not be taken for laxity if they are working properly they will work for more time without maintenance. 

CHAPTER 5 TESTING

• Testing means checking, examining and verification of some items.
• It is a procedure to determine the quality of a product.

5.1 TESTING ANALYSIS

• Testing is done at different stages.
• At first, the testing is done at the colouring lab.
• In the colouring lab the reactive dyes are checked that they are in a proper package and weight is proper or not.
• While taking it for weighing it is examined properly.
• At last, the colour is verified by the supervisor of that department that it is according to the colour required for design.
• Secondly, it is done in the printing and dyeing department.
• In the printing and dyeing department, the material that has been bought is checked for defects and then cut according to the length of the cloth that is needed.
• Then the design is examined after the printing process is done.
• The screen is adjusted in case of any fault lines in the design.
• Or it can be done manually by placing a worker at the end of the printing machine to improve the design shape in case of defects. 

 

CHAPTER 6 CONCLUSION 

6.1 OVERALL ANALYSIS OF INTERNSHIP

• During this internship period I got a lot of knowledge and communication skills with strangers.

• I learnt many new things about weaving as well as business.

• Working as an intern may allow me to meet a potential mentor naturally and establish a relationship that helps guide my career path.

• The supervisors and mentors I met during my internship can be valuable references for me as I pursue a full-time job.

• The more positive and hardworking I am, the more likely managers are willing to recommend me for open positions.

• References generated from an internship can be valuable in my job searches because those managers will have known me personally and seen how I contributed to the company.

• The transition from college to full-time employment can fill me with excitement, anxiety, hope and ambition all at once.

• An internship is a good way to fill some transition time with the work I hope to do long-term.

• It can eliminate some pressure of quickly finding a permanent job and help me to apply the skills and knowledge I have been studying to a practical situation.

• Internships can show me how a company develops leaders rather than just learning about it in the abstract.

• I can observe excellent time management skills and make a note of those that I want to emulate. 

 

REFERENCES

1. https://textilefashionstudy.com
2. https://www.cottonworks.com
3. https://www.britannica.com/topic/textile/Printing 
4. https://textilelearner.net/textile-printing 

Continue read,

Part 1 Spinning Internship report - Alok (Spinning and Testing)
Part 2 Textile testing internship report
Part 3 Internship report in the garment Industry
Part 4 Knitting industry Internship report
Part 5 Spinning Internship report - Pashupati (Spinning and yarn Testing)
Part 6 Garment Internship report - Komal, Ahmedabad
Part 7 Internship report in Printing and embroidery industry (Mayur-Jetpur)
Part 8 Printing unit Internship report
Part 9 Spinning internship report - Vinod spinners, Ahmedabad
Part 10 Weaving Internship report (Donear mill)

Biggest textile companies in the world

Writer - Kevin Mathuiya (Textile technologist - LDCE, Ahmedabad)