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TEXTILE INTERNSHIP ALOK INDUSTRIES LTD, VAPI

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Page 1: Alok Industries_ Internship Ppt

TEXTILE INTERNSHIP

ALOK INDUSTRIES LTD, VAPI

Page 2: Alok Industries_ Internship Ppt

INTRODUCTION

• The textile internship has been completed in Alok Industries Pvt. Ltd, Vapi, Gujarat.

• The duration of the internship was of two weeks where we had covered six different sections of textile processing.

• Familiarized us with the various aspects of a Textile Processing Unit starting from its Organizational hierarchy to the functionality of the various departments.

• Introduced us to the various brands of machineries available for carrying out the different textile processes to meet global standards.

Page 3: Alok Industries_ Internship Ppt

OBJECTIVESThe textile internship was carried out to develop a clear understanding

about the following:

Flow process sequence and Technical details on machine particulars of weaving, dyeing, printing, finishing, laboratory etc.Particulars of raw material, intermediate products and final product, process details, product quality parameters.Particulars of the manufacturing environment.Human resource management.Productivity analysis for various processes.

The internship helps us to

To understand the structural and functional constituents of the industry.To adapt to real industrial situations which equips us for decision making in a realistic environment. To strengthen the relationship between the industry and students.

Page 4: Alok Industries_ Internship Ppt

COMPANY PROFILEAlok Textiles Ltd.

1986 - established as a private limited company1989 – Its first polyester texturising plant being set up

1993 - a public limited company

Alok’s Vision ▫ To be the world's best-integrated textile solutions enterprise with

leadership position across products and markets, exceeding customer & stakeholder expectation

ORGANIZATIONAL HIERARCHY

Page 5: Alok Industries_ Internship Ppt

ALOK OVERVIEW• Vertically Integrated Textile Company on Cotton as well as

Polyester stream

• Sales of Rs. 2,976.93 crores and PAT of Rs.188.37 crores in FY 2009 (Audited)

• Export of Rs. 1,054.50 crores in FY 2009 (Audited)

• State of the art manufacturing facilities with Integrated Management System Certification

• Two decades of providing wide range of quality textile products

Page 6: Alok Industries_ Internship Ppt

Expanded into weaving,knitting,processing,home textiles garments integrated backward into cotton spinning and manufacturing POY through the continuous polymerization route.

Entered the domestic retail segment through a wholly owned subsidiary, Alok Retail India Limited.

A chain of stores named ‘H&A’ that offer garments and home textiles at attractive price points.

Alok’s vision 2012To generate consolidated revenues of Rs. 75,00 crore.Consolidated PAT of Rs. 750 croresAmong top 50 Best company in the country.

Page 7: Alok Industries_ Internship Ppt

ALOK’s ADVANTAGE• Timely expansions resulting in first mover advantage

• Exports increased from Rs. 100 crores in 2004 to about 1,050 crores in 2009 at a CAGR of 60%

• Preferred Vendor status from leading retailers

• Critical supplier for the Buyer due to Quality, Cost & Delivery (QCD)

• Economies of scale coupled with low interest cost giving competitive advantage

• Sustained margins due to forward and backward Integration

• Wide range of products offered across different market segments

• Product development and designing strength

• State of the art infrastructure with modern machines

Page 8: Alok Industries_ Internship Ppt

CUSTOMER BASE

Page 9: Alok Industries_ Internship Ppt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 10: Alok Industries_ Internship Ppt

• Only the weaving of terry towels is done in the Vapi plant of Alok Industries Ltd.

• Different departments in this unit are:

▫ Design Studio▫ Preparatory department

Warping V Creel H Creel

Sizing

▫ Weaving▫ Grey▫ Processing▫ Finishing

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 11: Alok Industries_ Internship Ppt

Process Flow Chart

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

WARPING

V CREEL

SIZING

WEAVING

DOBBY JACQUARD

GREY ROOM / TESTING

H CREEL(SECTIONAL)

PROCESSING FINISHING

Page 12: Alok Industries_ Internship Ppt

Preparatory processes• V Creel warping▫ Creel installed in a 400 V shape▫ Production capacity is 5.5 tonnes per day

• H Creel warping▫ Installed parallel to each other▫ Production capacity is 3 tonnes per day▫ Sectional warping is done

• Sizing▫ The machine has a capacity of 12 beams▫ Production capacity is 10 tonnes per day▫ A raising zone is provided for separating individual yarns after being

sized

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 13: Alok Industries_ Internship Ppt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Warping: V Creel

Sizing

Page 14: Alok Industries_ Internship Ppt

Weaving• Two types of looms▫ Dobby▫ Jacquard

• Air-jet type looms i.e. use air pressure for weft insertion

• Dobby - floor loom that controls warp threads using a device known as dobby.

• Jacquard loom - mechanical loom that simplifies the process of manufacturing textiles with complex patterns such as brocade

• Loom controlled by punch cards with punched holes, each row of which corresponds to one row of the design.

• Double beams are used:▫ Top beam▫ Bottom Beam

• Meant for complicated designs and can weave up to 6 colors.

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 15: Alok Industries_ Internship Ppt

Grey Section• From weaving, towels are sent to grey section where they

are inspected for defects before processing

• Functions of grey section▫ Inspection of rolls for defects▫Counting number of picks▫Rejection checking

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 16: Alok Industries_ Internship Ppt

TERRY TOWEL DYEING• Reactive dyes used for the dyeing of cotton fabric.

• Grey section prepares rolls of fabric according to dyeing machines’ capacity.

• Auto chemical mixing for all machines.

• 2 machines having 90kg capacity used for preparing samples.

• Dyeing machines - 90 kg, 350 kg, 700 kg, 1050 kg and 1400 kg.

• The software used for dyeing is named “Orgatex Batch Scheduler”.

Page 17: Alok Industries_ Internship Ppt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 18: Alok Industries_ Internship Ppt

• GREIGE - 9▫ RANSON’s ▫ COPIWALA

• SINGEING & DESIZING – 5▫ OSTHOFF(PAD STEAM)▫ BENNINGER(PAD STEAM)▫ OSTHOFF(PAD BATCH)

• PRE-TREATMENT – 9▫ BENNINGER

(PRETREATMENT) - 4▫ BENNINGER(MERCERIZATIO

N) – 5▫ PRE WASHING (INJECTA)▫ IMPACTA (CHEMICAL

TREATMENT)▫ STEAMER▫ POST WASHING (IMPACTA)▫ VERTICAL DRYING RANGE

• DYEING▫ KUSTER’s CPB - 4▫ BENNINGER CDR - 2▫ BENNINGER PAD STEAM - 3 ▫ MONFORTS THERMOSOL – 2

• WASHING▫ ARIOLI SOAPER – 1

COLD PAD BATCH WASH COLD WASH

• FINISHING▫ MONFORTS STENTER – 4▫ KKA CALENDER – 1▫ KUSTERS CALENDER – 2▫ MONFORTS SANFORIZER – 1

• FOLDING & PACKAGING▫ COPIVALA TESTING - 12▫ TESTA PACKAGING – 1

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 19: Alok Industries_ Internship Ppt

AUTO COLOUR KITCHEN Chemical Storage Tanks – 40 Capacity - 500 liters (600 - 650 kilos) DLV Software - Liquid Product Automatic Volumetric Dozing• Color & Chemical containing tanks (Loading Junction)• Loading Junction has two connectors – delivery and feeding points.• Pneumatic pumps are used for the transfer of the liquids.• The feeding time of the liquids - 3 to 5 minutes • DAP unit – “Powder Auxiliaries Dissolving Unit”• Separate tanks for Salt and Hydrous (Capacity – 2000 -1000 kg)• Units are connected to the “load cell dissolving cycle”• Color Preparation – 12 tanks• Pressure - 6 bars ; Dissolving Temperature - 70NC.• 45 TRS tanks. (TRS – Automatic weighing for powder dye stuff.)• 40 tanks - 45 kg ; 5 tanks - 90 kg each.

▫ SGQ (6 chambers) - 450 kg each ▫ SSC - 18 kg.▫ JIT (Just in Time) – 2 kg

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 20: Alok Industries_ Internship Ppt

KNITS DYEING• GREY OPENING MACHINE

▫ HSING CHENG – 4

• MERCERIZING▫ DOMIER – 1

• SAMPLE DYEING▫ 1 machine of 10kg capacity ▫ 1 machine of 5kg capacity

• DYEING (SOFTFLOW)▫ 750kg capacity ( 3 chambers) - 4 ▫ 500kg capacity (2 chambers) - 5▫ 1500kg capacity (6 chambers) - 1▫ 1000kg capacity (4 chambers) - 2▫ 110kg capacity (1 chamber) - 2▫ 250kg capacity (1 chamber) - 2▫ 50kg capacity - 2

• FINISHING▫ SANTA STRETCH – 1▫ FONGS RELAX DRYER –1▫ SANTEX PLAITER – 1▫ OPEN WIDTH FINISHING

STENTER : CORINO

• FOLDING▫ Done on two floors, the ground floor has

one inspection and one packaging machine both of Testa.

▫ The first floor has Hsing Cheng (Taiwan) checking machine (13 )

▫ Inspection method is followed.▫ The four point grading system

• PACKAGING▫ Automatic packaging machine (Testa) :▫ 8 different types of fabric packed at a

time▫ Unloading is spread across 4 trolleys in

either side of the conveyor belt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 21: Alok Industries_ Internship Ppt

YARN DYEING (IMPARTING COLOR TO A GREIGE YARN)• Capacity range - 5 - 1070 kg.• Lot Card specifying the dyeing details of the yarn approved by QA lab.• There are two types of dyes used in the department.▫ Vat Dye (caustic based)▫ Reactive Dye (salt, soda based)

• Boiling is carried out for 45 minutes▫ In out function- from spindle to package (takes 3 mins.)▫ Out in function- from package to spindle (takes 6 mins.)

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

SPINNING UNIT(SILVASSA)

YARN DYEING (VAPI)

LOADING MACHINE

APPROVAL Q & A

PRE - TREATMENTDYEINGAFTER TREATMENT

WINDING PACKING

Page 22: Alok Industries_ Internship Ppt

• PRE - TREATMENT▫ Scouring▫ Yarn is put through a caustic soda bath

followed by hydrogen peroxide and acetic acid treatment.

▫ Process carried out at 100°C• DYEING

▫ Dyeing by Batch Process. ▫ Yarn cheeses placed in the spindles ▫ Placed in respective carriers to the

dyeing, soaping and finishing of yarns▫ Temperature

Light - 60°C - 70°C for 40 - 60 mins. Medium - 80°C - 90°C for 60 – 80

mins. Dark - 80°C - 110°C for 80 – 90

mins.

• AFTER TREATMENT▫ Chemicals - Hydrogen peroxide,

Pervalin RS, Acetic acid and Perfil 210.

▫ This process is carried out at 95°C

• WINDING (AFTER DYEING)▫ Soft packages winding from dyed

cheese to cones.▫ Checking is done

• PACKING (PENGUINE)▫ In cartons - Less quantity of cones ▫ Bulk packing

Packing machine used Wounds the cones with thin

plastic sheet in a circular manner Cones rotated automatically on a

revolving platform for winding

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 23: Alok Industries_ Internship Ppt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 24: Alok Industries_ Internship Ppt

PRINTING• In properly printed fabrics the color is bonded with the fiber, so as to resist

washing and friction. • Whereas in dyeing proper the whole fabric is uniformly covered with one color, in

printing one or more colors are applied to it in certain parts only, and in sharply defined patterns.

• Screen-printing: ▫ by far the most used technology today.▫ Two types exist: rotary screen printing and flat (bed) screen printing▫ A blade squeezes the printing paste through openings in the screen onto the

fabric.

• Digital textile printing: ▫ a process of printing on textiles and garments using specialized or modified

inkjet technology. ▫ Inkjet printing on fabric is possible with an inkjet printer by using fabric sheets

with a removable paper backing and is used for sample preparations.

NATIONALINSTITUTE OF FASHION TECHNOLOGYTEXTILE INTERNSHIP : ALOK INDUSTRIES

LTD.

Page 25: Alok Industries_ Internship Ppt

•The printing department carries out the following processes for printed products:

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

DEVELOPMENT AND APPROVAL OF SAMPLES

(WOVEN OR KNITTED) ROTARY PRINTINGPOLYMERIZER( for pigment

and reactive)

LOOP AGER(for vat dyes)INSPECTIONPACKAGING

Page 26: Alok Industries_ Internship Ppt

PRINTING• The industry is mainly confined to rotary screen printing for the bulk production while flatbed screen printing

is used for sample preparation.

• Screens are prepared in the following steps for the printing to be done through it

• The mesh of the screens are in the range of 40, 50, 60, 125, 145, 165 units per inch.

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

ENGRAVING

SCREEN WASHING

COATING CLIMATIZER (DRYING)

CURING AND END RING MACHINE

SAMPLE PRINTING MACHINE

Page 27: Alok Industries_ Internship Ppt

• The machineries:▫Sample making machines

Laxmi Mimaki Digital Printer

▫1 Laxmi rotary machine▫3 Reggiani rotary screen printing machines

2 to 14 colors of patterns can be printed on the fabric using the machines in the industry.

The capacity of the rotary machine is 20 to 100 meters/seconds depending upon factors like design and the number of colors in that design and the types of the fabric (coarser takes less time as compared to finer fabric).

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 28: Alok Industries_ Internship Ppt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Mimaki digital printer

Reggiani rotary printer

Page 29: Alok Industries_ Internship Ppt

▫ Arioli loop ager

▫ Arioli polymerizer

• The average daily production of each of the screen printers is 70,000 m with the rpm of each rotary screen as 150-200.

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 30: Alok Industries_ Internship Ppt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 31: Alok Industries_ Internship Ppt

• Functions of the Department

▫ To keep step by step quality maintenance of the order that is being processed in the unit.

▫ Laboratories check for the physical and fastness properties ▫ Chemical tests might be carried out to cater buyer’s

specifications▫ Mini machines of each process to treat the samples and match

them with the effective results.

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 32: Alok Industries_ Internship Ppt

• Separate laboratories for ▫ 2 Woven Sections,▫ Yarn Processing Section and

▫ Terry Towel unit.

• Knits and printing section - quality tests done in the same lab used by the narrow width woven's section.

• They follow international standards for the quality assessments which includes:▫ ASTMD( mostly for physical tests)▫ AATCC( mostly used for color fastness tests)▫ ISO

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 33: Alok Industries_ Internship Ppt

Physical Tests Include:

• YARN COUNT ( WARP REEL & BEESLEY BALANCE)• ORIGINAL WIDTH • USABLE WIDTH• TPI , EPI, PPI• TEAR STRENGTH TESTER• ABSORBENCY TEST• TENSILE STRENGTH(WEFT AND WARP)• PILLING• SHRINKAGE

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 34: Alok Industries_ Internship Ppt

Color Fastness Tests

• The following tests are conducted and measured on the grey scale

▫ RUBBING FASTNESS( WET AND DRY)(AATCC)▫ WASHING FASTNESS( TOP LOAD (ISO) AND FRONT LOAD

( AATCC) )▫ COLOR FASTNESS TO WATER (AATCC)

• Color Fastness to light is also conducted using the ISO Standard test procedures

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 35: Alok Industries_ Internship Ppt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

TENSILE STRENGTH TESTER

TEAR STRENGTH TESTER

CREASE RECOVERY TESTER

Page 36: Alok Industries_ Internship Ppt

• The machines were mostly of the company James H. Heal.

• The key features of the lab were the softwares

▫ Datacolor that predicted recipes for the different dyeing and other processes using CMC Spectrophotometer and

▫ Auto color dispenser for solution making and dispensing

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

SPECTROPHOTOMETER

Page 37: Alok Industries_ Internship Ppt

Graphical comparison of the different dyeing machine production capacity:

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 38: Alok Industries_ Internship Ppt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Graphical comparison of the different dyeing processes’ production rate:

Page 39: Alok Industries_ Internship Ppt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 40: Alok Industries_ Internship Ppt

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.

Page 41: Alok Industries_ Internship Ppt

CONCLUSION• Alok Industries is an organization par excellence in the field of garments and textiles.

• Its huge infrastructure yet profound attention of the higher officials offered to us, as interns’, bear evidence to the same fact.

• The same meticulous attention given and ethics practiced in the daily production of Alok has made it reach the zenith where it stands successfully today.

• The internship has been an enterprise of much interest to us as it has exposed us to a real working environment of a textile processing unit.

• This internship has helped us learn how actually a production unit works and the amount of impromptu decisions that has to be taken daily to keep the production running without any hindrances.

• Thus, it will lay the foundation in the array of practical knowledge gained before stepping out of college and into a career in the textile industry.

Page 42: Alok Industries_ Internship Ppt

AN EFFORT BY:ARPIT SAXENAPALLAVI SRIVASTAVAROHAN DWIVEDISURENDRA MARANDISURYA BAKSHITANIYA DUTTA

NATIONALINSTITUTE OF FASHION TECHNOLOGY TEXTILE INTERNSHIP : ALOK INDUSTRIES LTD.