ALOK INDUSTRIES

Group Members-

Shruti Kajrolkar - 22

Prachi Lad - 27

Sumit Mehta - 30

Omkar Nemlekar - 34

Akshay Patankar - 37

Acknowledgement

We, the members of the group gratefully thank our foreign trade teacher for giving us

this fruitful opportunity to gel up well with Alok Industries and to make a difference in the near

future.

Your assistance and guidance is highly appreciated by the entire team.

INTRODUCTION

The industrial visit has been completed in Alok Industries Pvt Ltd, Vapi, Gujarat.

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.

OBJECTIVES

The textile Industrial Visit 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 industrial visit helps us 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.

COMPANY PROFILE

Alok Textiles Ltd.

1986 -established as a private limited company

1989 -Its 1st polyester texturising plant being set up

1993 -a public limited company

ALOK’S VISION

To be the world's best-integrated textile solutions enterprise having a leading position across

products and markets, exceeding customer & stakeholder expectation

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

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 2012 to generate consolidated revenues of Rs. 7,500 crore. Consolidated PAT of

Rs. 750 crores among top 50 Best companies in the country.

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 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

Wide range of products offered across different market segments

Product development and designing strength

State of the art infrastructure with modern machines

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

Different departments in this unit are:

o Design studio

o Preparatory department

o Warping

o VCreel

o HCreel

o Sizing

o Weaving

o Grey Processing

o Finishing

o Preparatory processes

o V Creel warping

Vshape- Production capacity is 5.5 tones per day

H Creel warping- Installed parallel to each other

Production capacity is 3 tones per day. Sectional warping is done.

Sizing

The machine has a capacity of 12 beams

Production capacity is 10 tones per day

Arising zone is provided for separating individual yarns after being sized

Weaving

Two types of looms-

1. Dobby

2. Jacquard

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

GREY SECTION

From weaving, towels are sent to grey section where they are inspected for defects before

processing

Functions of grey section-

o Inspection of rolls for defects

o Counting number of picks

o Rejection checking

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´

PRINTING

In properly printed fabrics the color is bonded with the fiber

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 on to the fabric.

Digital textile printing:

A process of printing on textiles and garments using specialized or modified ink jet technology.

Ink jet printing on fabric is possible with an ink jet printer by using fabric sheets with a

removable paper backing and is used for sample preparations.

The industry is mainly confined to rotary screen printing for the bulk production while flat bed

screen printing is used for sample preparation.

The mesh of the screens is in the range of 40-165 units per inch.

THE MACHINERIES

Sample making machines

Laxmi

Mimaki Digital Printer

1 Laxmi rotary machine 2 to 14 colors of pattern scan are 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.

QUALITY ASSURANCE

Functions of the Department-

o To keep step by step quality maintenance of the order that is being processed in the

unit

o Laboratories check for the physical and fastness properties

o Chemical tests might be carried out to cater buyer’s specifications

o Mini machines of each process to treat the samples and match them with the effective

results

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 visitors,

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 Industrial Visit 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 Industrial Visit 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.