Table of Contents
1.1 History
Chapter 2 Overview of different departments in the company
2.1 Layout of process
2.2 Ppc & Pdc
2.2.1 Roll and responsibilities of PPC
2.2.2 Order finalization
2.3 Soft winding
2.3.1 Objective Of Soft Winding
2.4 Hard winding
2.4.1 Objective of hard Winding
2.5 Warping
2.5.1 Types of warping
2.6 Sizing
2.7 Drawing-in
2.8 Loom shed
2.8.1 Airjet
2.8.2 Jacquard
2.8.3 Water jet
2.8.4 Rapier
2.9 TFO
3.1 Types of yarn dyeing
CHAPTER 1 OVERVIEW OF THE COMPANY
DONE with its three decades of expertise in the textile industry is a reputed and fastest-growing fashion fabric brand creating a wide variety of exotic; Suitings, Trouser & Shirting Fabrics.
Donear primarily caters to the middle and the premium segments with high-quality apparel fabrics that are woven with Natural Fibres, Synthetic Fibres and Various Blends.
As a brand, Donear has succeeded by maintaining pace with the changing demands of the local and global fashion trends, primarily due to the company’s; innovative approach to continuously developing newer products, using state-of-the-art-technology along with a highly-skilled workforce, strong logistics, being perpetually quality conscious, and thereby Creating World- Class Fabrics.
These highly ingenious fabrics are available in a wide range of Colours, Textures and Comfort along with Contemporary Designs. Donear fabrics are simply a luxury affordable that suits every desire!
Fabrics created by Donear have steadily captured the domestic textile markets as a result of its well-planned and expanding sales network consisting of; 44 Agents, 290 Wholesalers and 12000 Retailers, that are spread in all 29 States & 7 Union Territories of India.
Similarly, fabrics created by Donear have a wider reach in the overseas markets too, with exports to over 28 Countries across the globe.
CHAPTER 2 OVERVIEW OF DIFFERENT DEPARTMENTS IN THE COMPANY
2.1 Layout Of Process done In The Company
-
1 Ppc & Pdc
2 Soft winding
3 Hard Winding
4 Warping
5 Sizing
6 Drawing - In
7 Loom Shed
8 Yarn Dyeing
9 Fabric Processing
2.2 PRODUCTION PLANNING AND CONTOL ( PPC )
2.2.1ROLL AND RESPONSIBILITY OF P.P.C.:-
• There is an order confirmed by the marketing perform and a mutual term between the marketing person and buyer will be converted into MOF (Marketing Order Form) with all the details of quality, parameter, delivery date, order meter,, and design. The delivery date will be confirmed by the PPC department as per the current queue of existing products.
2.2.2 ORDER FINALIZATION:-
• The role of P.P.C. starts before the contract is executed and is in the stage of finalization.
Marketing departments send the sample to the P.P.C.department with a required delivery date.
Date of execution of the contract
Delivery Date
Quality number
Construction
Weave
Shade number
Shade Finish
Beam number Lot number
LOT NUMBER
• Lot number is a number given against the contract number only against this number Grey fabric can be issued. To get grey fabric issued from the store lot number is required P.P.C.number is the reference number against the particular contract.
LOTCARD:-
- A lot card is again a very important document for the production department. The following things are mentioned. P.P.C.
- Grey Information (SortNo., Construction, Finishwidth, Weight, Suppliername)
- Product Information(Shade No., Length in meters.)
Customer information (Partyname, Orderedquantity, Delivery date, Orderqualit
- y, NumberofShade.) Process Information(Planneddate,Delivery date,Processsteps)
- PDC
- Calculation of weight of total warp and weft weight as per count and giving the order as per requirement
- After yarn planning in design, plan to check the epi and PPI and check the colour shade as per the requirement
In the loom shed planning plan Beam goes in the loom machine and after empathy used it for warping or sizing.
2.3 SOFT WINDING
- Soft winding is the first section in the yarn dyeing process. Yarn dyeing is a special type of dyeing. Package yarn dyeing is done in package form. For this reason, it needs to transfer the yarn from the paper cone to the spring tube or plastic tube. This function is done in a soft winding section where re-winding is done. Different modern winding machine is used for winding function. Here different parameter is maintained which affect the dyeing process directly.
- The soft winding section is an important part of the yarn dyeing industry. It is the first step for preparing yarn for dyeing. If the winding process is not accurate then it affects the dyeing process.
2.3.1 Objects
- To make the soft package
- To transfer yarn from cone to plastic tube
- To reduce the density of a package
Spindles per machine– 110
Total spindles - 760
 |
SMEW-FILCONOSOFTWINDINGMACHINE |
2.4 HARD WINDING (REWINDING)
2.4.1 OBJECTIVE
1. First transfer the dyed yarn from the tube or spring to the cone package2. secondly it uses to clean the yarn
3. thirdly to make yarn in a continuous form
4. Lastly prepare the cone package for delivery
Machine | Creel capacity |
E-1 | 720 |
E-2 | 720 |
ST-4 | 540 |
ST-5 | 560 |
ST-6 | 576 |
ST-8 | 568 |
St-9 | 300 |
D-1 | 564 |
Direct | 720 |
2.5.1 Types of warping
-
direct warping
-
sectional warping
Direct warping
-
In direct warping, the yarns are withdrawn from the single-end yarn packages on the creel and directly wound on a beam.
-
Direct warping can be used to produce the weaver's beam in a single operation. This is suitable for strong yarns that do not require sizing and when the number of warps on the warp beam is relatively small. This is also called direct beaming. It can also be used to make smaller, intermediate beams called warpers beams. These smaller beams are combined later at the slashing stage to produce the warpers beam. This process is called beaming.
In indirect warping, a section beam is produced first. It is also called band warping or drum warping. The section beam is tapered at one end. Warp yarn is wound on the beam in sections, starting with the tapered end of the beam. Each section has multiple ends that are traversed together slowly during winding along the length of the section to form an angle. Due to the geometry of yarn sections, the last section on the beam will have a tapered end that will make the whole yarn on the beam stable. Each layer on the beam must contain the same number of yarns. The same length of yarn is wound on each section. After all the sections on the beam are wound completely, then the yarn on the beam is wound onto a regular beam with flanges, before slashing. This process is called re-beaming
 |
| Indirect or sectional warping |
H-creel
-
Parallel warping is used for sectional warping as Suitable for comparatively low-speed warping.
-
Needs proper yarn guides.
-
Provide low tension on the whole beam.
2.6 Sizing
process of applying a protective adhesive coating upon the yarn surface is called
sizing. This is the most important operation to attain maximum weaving efficiency, especially for blended and filament yarns
- To improve the weave ability of warp yarn.
- To increase the tensile or breaking strength of cellulose yarn.
- To maintain the good quality fabric.
- To reduce hairiness, and weakness of textile materials.
- To remove electrolytic formation for synthetic or blended yarn.
- To increase elasticity.
 |
| Sizing machine |
- The train drawing-in refers to the operation involved in preparing the weaver’s beam to weave fabrics on the loom.
- The drawing-in process primarily consists of drawing ends from the weaver’s beam through Heald's
eyes of different harnesses.
- Then through The dents of a Reed in the order that is determined by the design of the fabric.
Sr no. | Machine | Width | Quantity |
Airhet | |||
1 | Toyota 710 | 210 cm | 16 |
2 | Toyota 710 | 190 cm | 64 |
3 | Toyota 610 | 190 cm | 21 |
Jacquard | |||
1 | Picanol | 36 | |
Rapier | |||
1 | Picanol GAMMA | 190 cm | 36 |
2 | Some | 220 cm/190cm | 82 |
Waterjet | |||
1 | Staubli | 180com/210cm/230cm | 69 |
- 80 Toyota air-jet machine( JAT 710 ) cam shedding
- 10 Toyota air-jet (JAT 610 ) dobby shedding
- Speed 900- 1000 rpm
- Tuck in selvedge
 |
| Airjet weaving |
2.8.2 JACQUARD (PICANOL)
- 36 jacquard machine & Weft inserted to repair.
- Design via card upload program in machine
- Mostly used 4 – 6 yarn
- 9000 harnesses used in jequard
- Speed 300 – 500 rpm
- Use of complicated and heavy design
 |
| Jacquard machine |
2.8.3 Water jet (Staubli)
- Speed 300- 500 rpm
- Only filament yarn can be used
- Mostly polyester yarn used
- Weft Capacity 2 yarn
- Leno selvedge
- Yarn inserted via water gun
- The blower is mounted for drying the fabric
 |
| Water-jet machine |
- Speed 300- 450 rpm
- Mini jacquard for monogram
A stationary package of yarn is used to supply the weft yarns in the rapier
- machine. One end of a rapier, a rod or steel tape, carries the weft yarn. The other end of the rapier is connected to the control system. The rapier moves across the width of
- the fabric, carrying the weft yarn across the shed to the opposite side. 2.9 TFO (TWO FOR ONE TWIST)
Machine | Spindle | RPM |
4-Soosan | 1280 | 8500 |
2-Alidhra | 768 | 10500 |
2-Mira | 28 | 9500 |
 |
| SOMET |
CHAPTER 3 YARN DYEING
3.1 TYPES OF YARN DYEING
3.1.1. Vertical dyeing (top dyed)(HTHP)
 |
| Top yarn dyeing |
Production Parameter for Yarn Dyeing:
-
Time
-
Pressure
-
Temperature
-
Machine Capacity
-
Dye&Chemical Quality
-
Process:-The yarn to be processed may be bleached or dyed and first wound onto a perforated tube at low tension, termed a soft package. The soft package is loaded on the spindles of the carrier of the dyeing machine.
-
The carrier is inserted in the main dyeing vessel. The lid is closed and locked. The main vessel when closed becomes airtight. The body of the machine is made with a thick sheet which can withstand high pressures.
-
The processing is done at high temperature and high pressure, hence the name H.T.H.P.Dyeing.
-
The dyeing machine has one main tank, one dosing tank and one preparation tank. The material is loaded into the main tank. The colour solution shall be put in the dosing tank. The preparation tank shall be filled with water, which shall be heated and kept ready for use as needed.
-
During the operation, the dye liquor moves from inside out and outside several times while keeping the yarn package on the spindle.
CAPACITY (kg) | Quantity (m/c) | PKG Capacity (no) |
600 | 1 | 559 |
400 | 2 | 390 |
200 | 1 | 240 |
150 | 4 | 154 |
100 | 5 | 96 |
50 | 5 | 45 |
30 | 4 | 35 |
20 | 1 | 20 |
6 | 4 | 5 |
3 | 2 | 4 |
1 | 6 | 1 |
300 gm | 2 | 6/6 |
3.1.2 SPACE DYEING
• Definition: Yarn dyed with at least two different colours on one yarn package is called space-dyed. When woven together. Patterns can emerge depending on the length and variation of each colour block. At Donmar, we have the facility to dye Eight colours in one package.
 |
| Space dyeing |
3.1.3 HYDRO-EXTRACTOR
- Hydro-Extractors are also called Centrifuges. Centrifuges are used for water extraction (dewatering, pre-drying) of textile materials.
 |
| Hydro-extractor |
3.1.4 RADIO FREQUENCY DRYER
- The RF Web Dryer rapidly removes moisture from the web at low temperatures and prevents the migration of coating solids caused by conventional drying which increases web strength and product quality.
 |
| Radiofrequency dryer |
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)
