Declaration
I, BeleteGetachew a fourth year textile engineering student have undertaken my internship
experience in ELSE ADDIS. from a period of October 2012 to January 2013 under the
guidance of [Link] (Academic Advisor) and [Link] (company advisors).
I certify that my work is original and compiled according to the internship report writing
guideline given by the Institute-Industry Linkage office of the Institute.
As the students academic advisor, I certify that the internship report written by the student is his
original work and compiled according to the guideline provided by the institutes IIL office as far
as my knowledge is concerned.
Signature Date
Name of the Academic Advisor
BELETE GETACHEW
Name of student Signature Date
1. INTRODUCTION
1.1 BRIEF HISTORY OF THE COMPANY
ELSE ADDIS industrial development P.L.C is a TURKISH textile factory was founded in 2003
E.C to meet the growing demand of textile product in Ethiopia and other countries. The company
Located in NAZRATH (Adama) city on the land of 150,000meter square and covers the area of
120,000meter square.
ELSE holds the workflow of textile from Ginning to weaving department and uses high
technology of Ginning, ring spinning, open-end and air jet weaving machine and systems to meet
the highest quality standards. All systems are controlled by computer with the supervision of
their dynamic and experienced team.
ELSE produce a yarn with the required count in the range between 12/1-40/1Ne for carded, 12/1-
80/1Ne for combed and 4/1-30/1Ne for openend machine. The yarn laboratory is equipped with
uster technology and it enable to know different property such as; count, un evenness, neps, thin
places, thick places, hairiness and elongation.
The high quality service starts with careful selection and stored cotton from the field which is
then processed with their higher technology machine.
RAW MATERIAL AND ACCESORY SUPPLIER AND RAW MATERIAL QUALITY
PARAMETER
RAW MATERIAL AND ACCESORY SUPPLIER
The raw material of the company is a raw cotton and silk. The raw cotton supplies from different
countries in ETHIOPIA.
SUPLIERS OF COTTON
Amibara
Arbaminch
Gondar
Gojam
Asayta
Umera
Sometimes they import from TURKEY for special order and quality of product.
Silk only comes from the Turkey.
Among thus suppliers the major cotton is supplied by [Link] from Amibara and
[Link] from Arbaminch.
OTHER INPUT MATERIAL SUPPLIER
[Link] part
Germany. Spare part
USA. Sizing paste
RAW MATERIAL QUALITY PARAMETER
The raw cotton tested before and during the process under HVI spectrum, uster tester 3, zweigle
twister and count tester machine. The silk comes from china is in the form of bale so it directly
inter to conditioned store house and transport to blow room by using forklift machine without
any test.
ELSE ADDIS tests the quality of raw cotton using USTER HVI spectrum machine by taking
sample of cotton from the supplier.
The most common quality parameters are;
1. Micronier value=which indicate fineness of cotton fiber.
2. Maturity index=shows the maturity level of the cotton fiber depend up on the thickness
of the cell wall and directly responsible for quality of yarn in terms of strength and
evenness.
3. Fiber length=influences yarn strength, evenness, luster of the product, yarn hairiness etc.
4. Fiber elongation=shows the ability of cotton for extension property.
5. Fiber color=color of cotton sample is determined from two parameter:-
Degree of reflectance (Rd) which shows brightness of the sample.
Degree of yellowness (+b) shows yellowness of degree of cotton pigmentation.
6. Moisture cotton=directly influence on dimensions, weight, tensile strength, elastic
recovery electrical resistance, etc.
7. Fiber Strength=it is a predominant characteristics.
To get a perfect result measure one sample for five times and the machine display on
a screen its mean, standard deviation and percentage of coefficient variation.
OVER ALL WORK FLOW OF ELSE ADDIS COMPANY
As shown in the above figure ELSE ADDIS Textile Company start their production from
Ginning and ends by forming a cloth sheet in a weaving section. The raw cotton first tested by
the machine and they compare the value of quality parameter with the standard cotton property.
If the cotton qualifies this property then the company accepts the supplier and orders the required
amount of cotton.
The raw cottons are transported by a truck from the harvesting area to the company and its
weight is measured by a big digital balance and transfer in to two raw cotton warehouses, in each
house there is a big tube for pneumatically transport the raw cotton to ginning department and
the raw cotton does not take long time on this house.
Ginning is the first machine where the harvested raw cottons are separated from its seed. There
are three machines where ginning process is takes place. The pneumatically transported raw
cotton inter to the first machine and it remove small stone, dust and other big impurity then it
deliver through tube to the second machine where separation of cotton seed is takes place but
they are 80 in number, finally it transport to the last machine for more cleaning and packing the
separated cotton in a bale form and it is ready for transport to bale warehouse for the next
process.
The bale from ginning house transported using forklift truck to bale storehouse and reaches to
blow room machines. The basic purpose of blow room is to supply a small, clean and
homogenously blended fiber tufts to carding machine without increasing fiber rupture, fiber neps
and broken seed particle and without removing more good fiber by separate and disentangle the
fiber, mix them, clean foreign matter and remove short fiber in the cleaning process.
In ELSE ADDIS there are two similar blow room line operations and all machines are
TRUSCHZLER. There are six clearly distinguished operating zones for each blow room line.
1. Automatic bale opening machine(Blendomat BDT 019)
Produce cotton in smaller tuft size, thus creating a large surface area for easy and
efficient removal of trash particle.
- On a machine there is a humidifier spray, this is a combination of water
and gintex chemical.
- There is a magnetic separator for each opener to remove metallic impurity.
2. Course cleaner machine(maxi flo)
Used to remove large weight of dusts like broken seed.
- On course cleaner machine sometimes waste sliver can inter to it from
separate machine which used to feed waste sliver manually.
3. Fine cleaner machine
Used to remove small weight of dust particle.
4. Intensive cleaner machine(secromat)
Used to remove very fine dusts.
There is a dropper machine which used as fine waste storage device.
5. Auto mixer machine
Used to for final cleaning and blending of cotton or silk.
6. Card feeding machine
Used to deliver the blended and cleaned cotton or silk to the carding machine.
E They can order up to 90 bales (maximum) for each machine but according to the
size of bale it may less than to thus value.
E One bale opening machine can work on two sides by rotating itself after finishing
the first side bale.
Card is the next machine after blow room in which Individualization of fiber, Elimination of
impurity, Elimination of dust due to fiber/metal, fiber/fiber friction, Disentangling(opening out)
of nep, Elimination of short fiber by flat as flat stripping, Fiber blending and finally Slivers are
formed. They are 19 in number and all are TRUTZSCHLER. The sliver formed in a card
machine coiled on a can which have 8000meter sliver holding capacity and transfer to the draw
frame machine.
Draw frame machine helps to Improve sliver evenness, Parallelizing fiber, Blending and Dust
removal. They are 11 Reiter draw frame machine and each of them uses 6 sliver as an input and
deliver one sliver on a separate can which has a capacity of 4500meter sliver length. The draw
frame operation divided in to two sections the First section (Draw frame 1) contains 5 draw
frame machines, it process the card sliver and deliver its output for either the nnn machine or the
next section of draw frame.
The second section (draw frame 2) contains the rest 6draw frame machines, it process by
accepting the output of either draw frame 1 or comber machine sliver and finally deliver its
product to either open-end or roving machine.
The card slivers are not convenient for combing machine, if we use a card sliver directly on to a
combing machine, then the waste extraction would be very high, there would be a high fiber
breakage rate and probably excessive damage So that to avoid thus problem a unilapmachine
are used. ELSE have 2 Rieterunilap machines, each of them process 24 draw frame cans and
deliver a lap of 275meter length which is compatible for combing machine.
Combing machine improves the yarn quality and increase spinability of the fiber i.e. it enable a
spinner to spin finer yarns than would be possible with the same fiber converted in to carded
yarn and it also enable the yarn manufacturer to produce more uniform, strong, lustrous, less
hairy, cleaner and finer yarn by;
Removing a predetermined amount of short fiber
Eliminating impurities remaining in the material after card
Improving parallelization of fiber
Maximum possible evenness of the sliver.
There are11 comber machines and each machine take 8 laps and deliver a combed sliver to the
second draw frame for improving quality of the sliver, Finally it transfer to the roving machine.
Roving is a continious fiber strand drafted from a sliver and give cohesion by either inserting a
small amount of twist or compacting the fiber with an oscillating apron.
There are six zinser (saurer) roving machine and two of them contains 144 spindles and the rest
four machines have 120 spindle. They use the second draw frame sliver and the main function of
the machine is attenuation of sliver, Insertion of protective twist and Winding of the roving in to
a package of bobbin. The roving bobbin transfer to the ring machines for the next process.
Ring is a universally applicable and uncomplicated machine in which any material can be spun
to any required fineness and it deliver a yarn with optimum characteristics regarding structure
and strength. There are 20zinser ring frame machine in each of them there are 1200 roving
bobbin and can produce 1200 spinning cops. But the spinning copes are not convenient for the
next process, they directly goes to winding department.
Winding is a process in which small sizes of spinning cops are wound together on to a suitable
package which means in terms of length and shape, checking and cleaning the yarn from
spinning defects and finally deliver the winding cone on to a required place such as doubling and
twisting, knitting, warping, weaving and for export. There are 9 saurer winding machine. Each
of them has a 2.5 crosslink drum and produce 60 winding cone. On this room there is a big
cylinder machine used to wash the winding or open end cone by using high temperature steam
pressure. Mainly these kind of washed cones are packed and export to TURK or according to the
customer quality requirement they may use for local market.
The sliver from second draw frame directly inters to open end machine in which twisting and
package building mechanism are separated. There are 4 saurer open end machine and two of
them can produce 312cones but the rest two are 288 cones can produce. The cost of the cone
produced in this machine is less than the ring .
The main advantages of open end spinning over ring are;
Higher production rate.
Elimination of processing stages such as roving and winding machine.
An excellent recycling device as it spins mill waste fibers (secondary material).
A considerable reduction of in personal and space.
The open end or winding cones are used on doubling and twisting machine. Doubling refers
winding of two yarns on one cone and to have a permanent appearance in terms of strength it
must be twisted and wind on other package.
ELSE have one ARTH (SCHWELZ) doubling machine with a total 60 winding drum with a 2.5
cross link and 6 twisting machine, each of them are 120 winding drum works by cam traverse
system.
ELSE have 12 circular knitting machines in which yarn is made into a series of intermeshed loop
and needle beds are arranged in circular cylinder or dials. For knitting they use washed or un
washed open end or winding cone but most of the time they use open end product due to its low
cost and All machines uses latch needles.
From thus machines;
7 machines have a diameter of 30inch, 28 needles per inch and 96 cones holding capacity.
2 interlock machines have a diameter of 30inch, 24needles per inch and 84 cones holding
capacity.
2 machines have a diameter of 48inch, 28 needles per inch and 150 cones holding
capacity.
1 machine has a diameter of 32inch, 28 needles per inch and 99 cones holding capacity.
Beside the 12 machine there are two small circular knitting machines each of them contains 8
latch needle and produce a rope which used as a cable protector (safety) or for tying of the
exported package. They use west cones that exhaust from knitting or doubling machine.
After the knitting fabric is produced it directly inters to the inspection machine which used to
show defects of the fabric when it passes through different color light. Most of the defects are
due to; Broken or bended needle, Tension of the yarn and Machine balance.
To present a continuous length of yarn to the succeeding process that is for sizing and weaving
with all ends continuously present and with integrity and elasticity else uses modern warping
machine. The warping creel can hold a maximum 630 package capacity. Behind the working
parts of the creel it has a part which used to hold a reserve package and serves for automatically
changing the cone. In warping room there is a corchi rewinding machine which have 6 winding
drum and 6 spindles each one of them has their own small motors and it uses to rewind small
amount of yarns left in the cone during looming and warping process.
During weaving process the warp yarn is subjected to a considerable friction and to the action of
variable stretching forces. As a result the yarn becomes damaged and single fibers are detached
from it, which finally results end breakage but a process known as sizing helps the yarn to make
it more resistance for the above complex weaving stress and reduce the resulting end breakage.
The creel has a maximum 28 beam holding capacity.
ELSE uses PVA,WAX and MAIZEstarch (pendik) size pastes. The amount of thus paste
depends on the count of the yarn process in sizing machine. The steam comes from the boiler
room by combustion fuel with oxygen and control the output temperature.
Weaving is the interlacing of two systems of yarns i.e. warp and weft at right angle to each other.
ELSE uses 65 DORNIER air jet weaving machines and Each machine have five motors which
uses for shedding, let off , take up roller, pick finder and cloth winding.
In order to have a contineous interlacement of yarns the air get should have an
operation of ;
1. Shedding=indicate separation of warp thread to form an empty space for the
passage of weft yarn.
- The shedding mechanism works by grooved or slotted cam.
2. Picking=refers passing of weft thread through open shed and it transported by air.
3. Beating up=pushing the newly inserted weft in to the already woven fabric by
reed.
4. Warp letoff=deliver warp thread from the weavers beam to the weaving area at
the required rate and constant tension.
5. Cloth takeup=refers withdraw of the fabric at a constant rate.
ELSE produces plain, twill and satin weave type cloth sheet and a maximum and minimum
width of 270 and 90centimeter respectively, according to the customers weave type they can
produce a required sheet.
The fabric produced on a loom are testing by passing each fabric on to a three GUVEN
CELIK(AMBEZ) quality testing machine and inspect the defect shown on the screen by using
different color light . While we start inspection the machine also start counting the length of the
fabric. To give a grade to the fabric based on the quality, first inspect all defects and record on a
table until it reaches its preset length. Then by dividing the number of defects to the total length
the multiply by 100 i.e. (Defect/length)*100. If this value is in the range given below it gets that
grade of fabric:
GRADE, A=1-10
B=10-15
C=greater than 15
If the defect is >15 or c grade then the machine that produces this fabric checked by
mechanics and make correction.
The waste generated from blow room to roving are recycled with a machine and re used on a
blow room by mixing them with other pure cottons. but the waste generated from ring to
weaving are in the form of yarn so they didnt recycled, instead they packed in bale form and
sale for local market but the waste which is not on the yarn form (from overhead cleaner) are
transported to recycling room through underground. There is an air compressor room which
supplies air to underground for transporting of wests, to air jet loom for weft picking system and
to all department or section for cleaning application.
The air conditioning system of ELSE is divided in to two sections. The first part covers from
blow room to winding department and the second part include from doubling and twisting
machine to weaving machine.
Main products and services
Else Addis produces
Plain, twill and satin woven fabric
knitted fabric
open end or winding cones for market
Main customers or end user, its product or services
The main customers of the company are,
AIKA ADDIS for plain and twill fabricproduct
Ethio-japan Modjo for knitted product
Axum and mekias garment Addis Ababa
The satin product packed and export to Turkey, similarly the cone also uses for local and
export to Turkey.
ORGANIZATIONAL STRUCTURE
CHAIRMAN OF THE
BOARD
ETHIOPIA PROJECT COORDINATOR
FACTORY AGRICULTURE CONSTRUCTION
FINANCIAL
DIRECTOR DIRECTORDIRECTORDIRECTOR
Export, import
Machinery & energy marketing
responsible
HR & Administrative manager rRresponsibility
Yarn weaving manager Accounting
responsible
Weaving manager
Legal counsel
Logistic purchaser
Accounting stock &Forwarding manager
Ginning manager
Responsibilities of Functional Area
Chairman of the board
Direct; control; and coordinate the activities of various departments in their efforts to
achieve the desired goals of the plant.
Prepare an action plan on quarterly and monthly basis and see to it that it is
effectively implemented.
Establish different motivation schemes aimed at increasing the productivity of
workers from time to time.
Ethiopia project coordinator
Factory director
Control and coordinate the activities of each departments
Check the tests of each department and if it is not normal order the manager of each
room in order to adjust it.
Plan and organize the overall activities of their proper execution.
Prepare meeting with company employees and advise them, also with other company
manager share idea and work experience.
Establish appropriate market strategy that will be enable to have a better market share
in the industry
Identify the major cost areas and devise mechanisms by which these costs are
significantly reduced
Machinery& energy manager
Checking and control spare parts of the machinery.
Prepare periodic schedule weekly, monthly, yearly.
Checking power, taking preventive maintenance and repair break down maintenance
Fulfill necessary working materials and instruments for work with the right time.
HR& Administrative manager
Develop workers social participation by respecting the workers right and benefits
within the law.
Create safe working environment for employers.
Yarn weaving manager
Weaving manager
Controlling weaving room
Check product which is produced in weaving section and report feedback to factory
manager.
Logistic purchaser
Interpret different languages (Turkish, English) etc. to guest or to staff.
Accounting stock& Forwarding manager
Ginning manager
Control raw cotton which is supplied to factory.
Keep cotton sill properly until its sale
Agriculture director
Direct and control quality of raw material (cotton, bamboo).
Construction director
Guide and prepare construction material, instruments and human power.
Financial Affairdirector
Ability to design, install, maintain, use financial control, familiarity with accounting
and control systems needed to manage, ability to set up a project cost control systems,
analyze overhead [contribution] absorption, prepare profit and loss and balance sheets
and manage a book keeper.
Can decide how best to acquire fund for startup and growth, ability to forecast the
needs for funds and prepare budgets, familiarity with sources and vehicles of short
and long term financing.
Can flow analysis, break even analysis, contribution analysis, budgeting and profit
planning techniques, profit and loss, balance sheet and present value analysis of
return on investments and pay back.
Export, import marketing responsible
Direct and control the activities of purchasing, sales and stores divisions with
particular emphasis on the import of raw material, and products.
Work out an action plan on the detail activities of the department and closely follow
up its proper implementation.
Prepare tender documents both for local and international bids and finalize all the
necessary formalities in collaboration with the committee.
Forecast the volume of sales to be accomplished with a given fiscal year and perform
the necessary promotional work that could be enable the enterprises to have a better
share of the market in the industry.
Accounting responsibility
Calculate the budget of the company with finance.
Give monthly salary to the company employee.
Legal counsel
Stands for the right of all the companies employee.
Eliminate a continuous stoppage of the blendomat machines
Objectives
Increase the production of the machines
Save labor forces
Work Flow of Recycling room
Carding
waste
Draw frame
waste Manual Blow
bale room
Manual
forming
opening
Unilap machine
waste
Exaust
sliver from
different
sliver test
Blow Balkan Blow
room recycling room
waste machine
The Detailed Problem Of The Recycling room
There are two types of wastes in ELSE that are recycled waste and non-recycled waste. The
waste generated from blow room to roving are recycled with a machine and re used on a blow
room by mixing them with other pure cottons.
But the waste generated from ring to weaving are in the form of yarn so they didnt recycled,
instead they packed in bale form and sale for local market but the waste which is not on the yarn
form (from overhead cleaner) are transported to recycling room through underground and
recycled.
The blow room wastes are four parts, two of them are from the first blendomat and the
rest are from the second blendomat machines. The wastes are transported pneumatically
through four tubes to the compactor.
Each of them has their own compactor for filtering and removing of dust particles. Again
this cotton transport to BALKAN recycling machine for final intensive cleaning and
prepare the cotton in a bale form for easy usage in the blow room again.
The comber machine wastes are clean and packed in a bale form for export to TURKY.
The underground wastes are transported pneumatically from each department and reaches
to a filter room. In a filter room there is a big cylinder drum in which the waste cottons
are attached and by blowing apparatus, the waste cotton transported to recycling room.
In a blow room first bales are arranged parallel in a blendomat line and using a blendomat
machines the cotton or silk are opened and cleaned and deliver to the next processing stage for
more cleaning, mixing and opening finally, the blow room output reaches in to the carding
machines.
The bale may come from the ginning or it may import from china. In each case the treated cotton
from recycle room are mixes with the original ginning cotton.
The waste generated from blow room is treated with different recycling machine and it doesnt
matter when we reuse in a blow room even if its color is not white as the original bale.
The sliver waste from the card, draw frame, unilap, open-end machine and the sliver exhaust
during different sliver testes are came to the recycling room but as in the blow room and other
wastes it doesnt treat or pass to different machines instead by using a labor force they try to cut
and opening the sliver length to smaller.
Manual cutting and opening of the sliver using labor force causes the blending feeder machine in
a blow room stops repetitively during the process. Because cutting and opening of sliver using
hand is very tedious and the workers simply transfer the sliver to the bale forming machine and
ready for blow room. During the process in the blow room the UN opened and longer length
sliver wound to the blending feeder machine then the machine automatically stops.
There is only one blending feeder operator is assigned for two machines, When the machine
stops the operator may work on other machine so that the machines stop its production for long
times.
A continuous stopping of the machine causes the blending feeder machine productivity to be
decrease and also if separation of wound slivers from the machine take some times then
automatically it delays the production of the next machines i.e. carding, draw frame
If the sliver length wound in the blending feeder machine is long it causes more friction on the
roller since natural cottons are flammable and causes a fire to be start on the machine.
OVERALL BENEFITS FROM INTERNSHIP
This internship is such a wonderful that make me to gain valuable experience and to expand our
personal network. It will definitely help in deciding a career choice as well as getting experience
in our future career. Our internship gave me the opportunity to apply our theoretical knowledge
learned with the class room to real-world activity. It also gives me an in-depth analysis of what it
really likes to work within our field of study and it benefited in that we were able to see all the
different areas and we were given a chance to create new relationships with both organization
and staffs.