REPORT FILE

A
REPORT ON SUMMER TRAINING
AT
VARDHAMAN YARNS AND THREADS LTD

HOSHIARPUR (UNIT -1),PUNJAB

DURATION
15th JUNE 2020 – 13th JULY 2020

GOVERNMENT POLYTECHNIC COLLEGE , HISAR

NEAR DELHI BYE PASS , HARYANA
SUBMITTED TO: SUBMITTED BY:
MR. DALJIT SINGH RUPESH KUMAR
SINGH (Manager ,Dye House) (Summer
trainee)
 ACKNOWLEDGEMENT

I am really very grateful to Mr. Daljit Singh for his kind

guidance all throughout my training. I would also like to
express my deep sense of gratitude to Vikram sir and Neeraj
sir for laying a hand of support whenever I needed it. Also I
take this opportunity to thank all the shift officers and
working staff who helped me in completing this training. I
also take this opportunity to thank my college premises for
always being by my side whenever I needed them. Again a
very thanks to all whom helped me in my training duration.
 Company Profile
VARDHAMAN was started by late LALA RATANCHAND JI
OSWAL with 14000 spindles in 1965 now extended by his son Mr.
S.P. Oswal to currently more than a million spindles.
Vardhman is a leading Indian Industry in the world of textiles having
a turnover of around 2000 crs. It started its operations in 1965 under
the name of Vardhman Spinning and general mills ltd at Ludhiana.
Since then the group has expanded and today is perhaps the largest
spinning industry in India.
Vardhman group is headed by Chairman Shri. S.P. OSWAL,a gold
medalist in Commerce who is the chairman and managing director of
the group.
There is an excellent working environment for the employees.
 1965- Vardhman started spinning and general mill under the
entrepreneurship of late Lala Oswal in Hoshiarpur and Ludhiana
(Punjab).
 1982- Entered in sewing thread market.
 1990- Started fabric processing plant in Baddi (H.P.).
 1999- Set up acrylic plant in Gujrat.

INDEX
1. Qualities of Yarn
2. Department
3. G.T.S
4. Linking
5. Mercerization
6. Scouring
7. Bleaching
8. Dumper
9. Hydroextractor
10. Steam drier
11. R.F. Drier
12. Berta hydroextractor
13. Roll Dyeing
14. Cabinet Dyeing
15. HT/HP Package Dyeing
16. P.T.S
17. Boiler
18. About project

Information of various machines available in

various sections of the department.

S. Name/Machine Capacit Make Year

No no. y of
install
ation
1. Mercerising 12-14 MMU JAEGGLI 1981
machine-1 kg/cycle

2. Mercerising 12-14 MMU JAEGGLI 2007

machine-2 kg/cycle

3. Kier-1 1 ton Venus 1980

4. Kier-2 2 ton Venus 1981
5. Bleach tank-1 3 ton In House 1981
6. Bleach tank-2 3 ton In House 1981
7. Bleach tank-3 3 ton In House 1981
8. Bleach tank-4 3 ton In House 1981
9. Dumper 2500kg Venus 1981
11 Hydro extractor-1 200kg J.K. 1980
.
12 Hydro extractor-2 200kg J.K. 1982

13 Hydroextractor-3 200 kg J.K. 1982

.
14 Hydroextractor-4 45 kg J.K. 1996
.
15 Steam drier 1&2 104 Venus
. poles
16 Berta 36 &48 Dettin
Hydroextractor packages
1&2
17 Cabinet machine 140 Swastik, Gagan ,Loris
-200kg Bellini.
18 Roll dyeing(33) 1-70 kg
19 HT/HP package 4-465 kg Ugolini,Dalal,Fongs
dyeing m/c
20 RF Drier 1&2

PROCESS ROUTE OF WET PROCESSING

↓

↓ ↓

Hank Route Soft package route

HT/HP dyeing m/c

Soft quality Mecerise Polyester Cotton

↓ ↓

Linking Mercerisation Berta hydro extractor

↓ ↓

Scouing(kier-boiling) R.F. Drier

↓ ↓

Bleaching( with Sodium hypochlorite) Examining

 ↓ ↓

Anti chlorine process P.T.S

HCl and ADA treatment

Color Off white White

Roll Cabinet Hydro extractor Dumper

Dyeing Dyeing ↓

Hydro extractor Steam drier

Steam drier P.T.S

For Examining

P.T.S (Processed Thread Store)

GTS (GREY THREAD STORAGE)

In this department all the qualities which are used for the processing
is stored. From here all the threads or yarns are delivered for linking
department.

LINKING
The objective of linking process is to make all the thread to be
processed in rope form to facilitate further process. Here 2 T shaped
pole is used link all the threads with each other by tying and knotting
them.
Linked material is used in kier boiling and then processed as per
requirement.
Care should be taken during linking such that the material is properly
linked otherwise the rope form of material could break thereby
affecting the production rate and time.

MERCERISATION

Introduction:-
Mercerisation was discovered by John Mercer in England and thus
the process is named after him. Mercerisation gives cotton a silky
lustre, and is the foundation of many improved and beautiful finishes.
Sewing and embroidery cotton yarns are mercerised in the hank form
with tension. Stretched yarns can be mercerised without tension.

Objective:-

 To improve the lustre of the material

 To improve the dimensional stability of the material
  To improve the dye uptake of the textiles
 To impart strength to the textile materials
 To improve elasticity of the textile materials.
Mechanism:-
In case of mercerisation sodium hydroxide reacts with the cellulose
present in the fibre and makes it Na-cellulose. This reaction is
exothermic in nature. It increases the area of the fibre. When cellulose
is immersed in a solution of caustic soda of mercerising strength,
water and alkali diffuses in and the material swells. The fibre hair
quickly commences to untwist from its twisted ribbon like form and
tends to become

cylindrical rod like surface de-convolution. As the diameter of the

fibre becomes more round, it tends to reflect more amount of light. As
a result the fibre becomes lustrous. As the fibre swells it shrinks in
length. Swelling and shrinkage is more when there is no tension in the
fibre, but the alteration of cross-section caused by swelling is more
when the mercerisation is carried out in tension.
The reaction that takes place during mercerisation is:

C6H9O4-OH + NaOH = C6H9O4-ONa + H2O

(Cellulose) (Na-cellulose)
The various machine parts of a MMU JAEGGLI mercerising machine
are as follows:-

 Rotating poles
 Caustic bath
 Water bath
 Squeeze roller
 Washing tube
 Washing frame
 Hood
 Motors

Process flowchart of mercerisation

Loading of hanks on rotating poles

↓
Dia-setting for the rotating rollers
↓
Lowering of hanks down on the caustic tray
↓
Pre tensioning
↓
Shrinkage
↓
Lye tensioning
↓
Caustic tray is lowered down
↓
Washing spray pipes comes down and washing tray comes up
↓
First wash and final tensioning
↓
Second wash
↓
Third wash
 ↓
Fourth wash
↓
Squeezing
↓
Lifting of rotating poles
↓
Unloading of hanks

Chemicals used and their functions:-

 Sodium Hydroxide (Caustic soda):- Cellulose undergoes
chemical, physio-chemical and structural modifications on
treatment with caustic soda solution of mercerising strength.
Chemical reactions lead to the formation of alkali cellulose due
to deprotonation. The optimum modifications in the properties
of the cellulose can be manipulated with the selection of proper
concentration of alkali, time, tension and temperature during
mercerisation.
Concentration of caustic soda: 500-540 Tw or 280-320 gpl.

 Wetmert: - A necessary condition for successful mercerisation

is rapid and uniform wetting of the grey cloth. Penetration of the
alkali is hindered by the high viscosity of the strong caustic soda
solution at the lower temperature on the one hand and the
hydrophobic nature of the fatty matter present in the size coating
as well as natural fats and waxes present in the fibre on the
other. To prevent this problem a small amount of wetting agent
is added to caustic bath. Wet mert acts as a wetting agent here.
 Pine oil:- Pine oil is used as an anti-foaming agent. If tendency
of foaming is too high then chances of uneven mercerisation is
 also higher. In that case pine oil is an important chemical in
mercerisation.

Time cycle for mercerisation(for 12/36 hank)

 Time of frame to be stationary-20 secs
 Fast tension:- 6 sec
 Lowering-13 sec
 Slow lowering-12 sec
 Dipping- 8 sec
 Pre tension- 8 sec
 Shrinkage-91 sec
 Lye tension- 76 sec
 Squeezing- 20 sec
 1st wash+ Final shrinkage-11 sec
 2nd wash- 21 sec
 3rd wash- 24 sec
 4th wash-21 sec
 Squeezing-20 sec
 Final shrinkage-3 sec
 Lifting-8 sec
 Fast shrinkage- 24 sec
 Unloading-13 sec
Total time= 6mins 34 sec

Parameters:
QUALITY: 12/30
Dia setting 2210 mm
Pre tension(-1%) 2190 mm
Shrinkage(-4%) 2120 mm
Lye tension(2%) 2255 mm
Final tension(2.5%) 2265 mm
Limit Switch setting 2275 mm

QUALITY: 12/36
Dia Setting 2220 mm
Pre tension(-1%) 2200 mm
Shrinkage(-4%) 2130 mm
Lye tension(0%) 2220 mm
Final tension(2.5%) 2230 mm
Limit switch setting 2240 mm

QUALITY:- All other

Dia. Setting 2235 mm
Pre tension(-1%) 2210 mm
Shrinkage(-4%) 2145 mm
Lye tension(2%) 2270 mm
Final tenion(2.5%) 2290 mm
Limit switch setting 2300 mm

QUALITY NO. OF HANKS HANK

WEIGHT
2/10 8 1000
2/18 16 500
2/19G 20 400
2/33G 20 400
2/37 20 400
2/41G 20 400
2/42G 20 400
2/80G 22 350
3/10 20 400
3/22 20 400
3/30 CHROMA 8 1000
3/33 20 400
3/50G 22 350
3/60G 20 400
4/10 20 400
6/21G 34 250

6/40G 34 200
12/30G 24 350
12/36G 24 250
3/40 CHROMA 8 1000
3/60 CHROMA 8 1000
4/20 CHROMA 8 1000
3/16 CHROMA 8 1000
3/50 CHROMA 16 500
3/34 8 1000
2/30G 16 500
2/25 16 500

Precautions:
 The workers should wear masks to avoid inhaling fumes.
 The workers should make use of gloves while loading or
unloading material.
 There should be equal loading of material on the pole.
 All holes of the washing pipes should be open.

CHEMICAL TESTS
 EXPERIMENT 1.
AIM: To calculate gpl of caustic solution.
APPARATUS: pipette,burette and flask
CHEMICALS USED: HCL(1N), Phenopthalein and caustic
solution.
PROCEDURE:
 Caustic sample was collected from the center lye tank
 1 ml of this was taken along with 50 ml of soft water in a
conical flask.
 1-2 drops of phenopthalein indicator was added to this
solution. The solution turned pink.
 It was then titrated against 1N HCL.
 The end point of reaction was when the solution turned
colourless.
CALCULATIONS:
Burette reading:7.2 ml
Caustic gpl=7.2 X 40=288 gpl
RESULT:
The caustic gpl was found to be 288 gl which is normally in the
range of 280-320 gpl.

 EXPERIMENT 2.
AIM: To calculate the caustic retention of mercerised
sample(3/50)
APPARATUS: Pipette, burette,flask,heating apparatus

CHEMICALS USED: HCL(1N), Phenopthalein.

PROCEDURE:
 The mercerised sample was weighed carefully.
 The sample was heated for 45 minutes in 200 ml on a hot plate.
 The sample is then cooled to room temperature.
 Titrate with standard HCL using phenopthalein as indicator.
 The sample is weighed after drying it.
 End point is when the solution turns from pink to colourless.

CALCULATIONS:
Sample weight(after titration)=4.7
Burette reading= 2.6 ml
Caustic retention% =(N X 40 X B.R.)/(sample wt X 10)
=(1 X 40 X 2.6)/(4.7 X 10)
=2.21%

 EXPERIMENT 3
AIM: TO CALCULATE THE BARIUM ACTIVITY
NUMBER(12/36 M).
APPARATUS :BURETTE,PIPETTE, CONICAL
FLASK,MEASURING CYLINDER.
CHEMICALS: Barium Hydroxide(0.25N),
HCL(0.1N),Phenopthalein.
PROCEDURE:

 At first 2g each of mercerised and unmercerised sample is

taken and both are rubbed with each other in hard water upto
same pH.
 Then the samples are cut into very fine pieces
  Then three conical flask is taken and each of the two samples
is added to two conical flask followed by 30 ml of 0.25N
barium hydroxide [Link] flask has only the solution for
blank titration.
 The three flasks are kept for 4 hours.
 After 4 hours the three flasks are titrated against 0.1N HCL
solution with the help of phenopthaline indicator
by taking 5 ml of solution from each flask.
 Note the B.R. for each of the samples.

CALCULATION:
BAN=[ (Blank B.R.- Mercerised B.R.)/(Blank B.R.-
Unmercerised B.R.)] X 100

=[(8.5-6.9)/(8.5-7.3)] X100
=133

 EXPERIMENT 4
AIM: TO CALCULATE THE SHRINKAGE OF THE
UNMERCERISED SAMPLE WHEN INTRODUCED IN
CAUSTIC SOLUTION.

APPARATUS: Burette,10g bob,stand.

PROCEDURE: The unmercerised yarn is tied to a 10g weight
and arranged under tension in a burette. Caustic soda is added
into in the burette. As a result the yarn shrinks. The level to
which the yarn shrinks is noted and is subtracted from the total
burette reading to obtain the shrinkage percentage.

Std. Range of shrinkage=16-20 %.

 Scouring
Scouring is a process which removes all the natural impurities
like oil,wax, fat etc. from the surface of the yarn and the
produced yarn is more hydrophillic.

Scouring is done using alkali such as NaOH and Na2CO3.

Objectives:-
 To make the yarn highly hydrophillic.
 To remove impurities such as oils,waxes, gum,husk as far
as possible.
 To increase absorbancy of textile materials without
physical and chemical damage.
 To produce a clean material by adding alkali.
 To make the product ready for further processing.
During the process of scouring the following reactions takes
place:-

 Saponification:- The vegetable oil, which is immiscible

with water,is glycerine of fatty acids. When such oils
are heated with a solution of sodium hydroxide in
water,the oils splits up into its consituents fatty acids
and [Link] is miscible with water easily
and the fatty acids reacts with sodium hydroxide
present in the solution forming its sodium salt i.e. soap
which is also soluble in [Link] oil is removed.
 Emulsification:- Wax and non saponiable oils are
removed by emulsification as they are immiscible in
water. Normal washing soap is used as a emulsifying
agent which makes emulsions of them.
 Detergency:- Due to above process impurities may be
again deposited on the surface of the material so
 detergent makes them suspension and keep away from
surface of the material.

Chemicals :-
 Caustic Soda:- The caustic soda reacts with vegetable
oil in the material and forms soluble sodium salts of
fatty acid which can be removed. It also swells and
dissolves the motes( cellulose of low crystallinity).
 Klennox Baspaste:- This is the scouring agent which is
responsible for saponification of oils.
 Soda ash:- Soda ash provides an alkaline medium for
the scouring process.
 KLERIX PER:- This is sequestering agent or chelating
agent and is used to remove hardness of water.
 POLYAX TDS:- This is the non- ionic soap.

Scouring Recipie
MLR:- 1:4
S. Chemical Kier Kier2
No. used 1
1. Caustic lye 6 gpl 6gpl
2. Soda ash 0.8% 1.6%
3. Scouring 0.4% 0.8%
agent
4. Non ionic 1% 2%
soap
5. Sequestering 0.35% 0.7%
agent

Machine Operations.
Manual loading of hanks in the form of layers (20min)
 Cold water filled (12 mins)
Cold water drained (4.5 mins)
Hot water [Link] temp. reaches 60-65oC.(18-20 mins).
Addition of caustic at around 60oC
At 70 0 C, all other chemicals are added.
The scouring process continues for around 4 hrs. It takes 2 hrs to
reach 117o C and the temp. is maintained at 117oC for another 2
hours.
At 90oC , the vent valve is closed.
After 4 hours the caustic solution is drained and the temperature is
allowed to come down.
At 90oC hot wash is done for 1 hr and drained
1st cold wash (0.5 hrs)
2nd cold wash(0.5 hrs)
3rd cold wash (0.5 hrs)
Material unloaded.

CHEMICAL TESTS
Experiment 1- To find caustic gpl in scouring process.
Apparatus:- Burette, pipette, and conical flask.
Procedure:

 20 ml sample is taken. The sample is taken after the temperature

in kier has reached in the range of 60-700C.
 1-2 drops of phenolphthalein indicator are added to the sample.
The solution turns pink.
 The solution is titrated with N/2 sulphuric acid.
 The burette reading at which the solution turns colourless from
pink gives the value of caustic gpl.
Calculation:- Burette reading = 6.4 ml
Caustic gpl= 6.4 gpl
The normal range of caustic gpl is 6.1 to 6.4 gpl.

BLEACHING:-
After scouring all the impurities are removed from cotton except
natural coloring matter. To decolorise this matter bleaching of
cotton goods is performed with various oxidizing agent . Agents
like sodium hypochlorite or bleaching powder or sodium chlorite
are used.

Objective
 To increase the absorbency of material
 To produce uniform and permanent whiteness.
 To remove the residual impurities of cotton yarns.
Sodium hypochlorite is the strongest oxidising agent because it
is capable of giving oxygen at room temperature. It is also
economical in use.

Chemical reactions in hypochlorite bleaching

  Hydrolysis
NaOCl + H20------------------- NaOH + HOCl
 Bleaching agent release
HOCl------------------------------ HCl + [O]
 Maximum HOCl development.
NaOCl + HCl --------------------- NaCl + HOCl
 Formation of chlorine
HOCl + HCl ------------------------H 2 O + Cl2

Recipie:-
Sodium hypochlorite:-1.6 gpl
Sodium thiosulphate:- 10 kg
Fincon ADA( liquid alkali):- 2.5 kg
HCl:- 4gpl.
When cotton goods are to be bleached they are scoured or
kier boiled and then uniformly packed into cylindrical or
rectangular vessel which may be made of wood ,cement
lining stainless steel. The vessel has a perforated false
bottom with an outlet of a tank below of a similar
capacity. The liquid in the pump is made up to the desired
conc. of available chlorine with sodium hypochlorite. It is
then pumped up and spread through the sprinklers ,over
the top of the cotton goods, through which it percolates to
find its way ultimately back into the pump.
 Bleaching liquor:- 1.5 gpl of available chlorine.
 Temp :- room temperature.
 pH:- 10-11

Process flow diagram for bleaching process.

Loading of material from Kier 1 and kier 2 in tank 1 and tank 2
 Cold wash (2hrs)
Drain (20 mins)
Bleach stock solution gpl set at 1.6 [Link] bleach stock tank supplies
the stock [Link] tank takes around 22 mins. to fill.
After maintaining the level of bleach tank, bleaching is done for 45
mins.
The bleach stock is drained in 20-25 min
Cold wash is [Link] fills and drains in 20-22 mins.
Material is transferred to tank 1 for 2nd bleach cycle
The gpl of bleach stock is checked and filled in tank 1
Bleaching is proceeded for 45 mins
Cold wash given( water takes 20 mins to fill and 5 mins to drain.)
Water is filled again ; 10 kg sodium thiosulphate is added ,treated for
35-40 minutes and then drained. After washing for 15 mins ,the
material is sent for antichlor test. If traces of chlorine are still found
then more thiosulphate is added.
The material is now transferred in tank 3 or 4
HCl (4gpl) is filled inbthe tank(45 mins.)
The HCl is circulated for 1 hr and is drained back in the HCl tank in
35 mins.
Washing is done for 2 hrs
After washing ,fresh water is filled and 5 kg ADA is added. The
material is treated for 1 hr after which the solution is drained.
Washing is done for 15 mins and then pH of the material is checked
.If it is in the range of 7-8 ,it is approved.
 Material unloaded.

CHEMICAL TESTS:-
Experiment:- To calculate gpl of HCl
Apparatus:- Burette ,pipette and conical flask.
Procedure:-

 20 ml sample is taken and 1-2 drops of methyl orange is added

which acts as indicator.
 The solution is titrated with soda ash (29 gpl)
 End point is when the solution turns from orange to yellow.
 The burette reading is noted.
Result:- The burette reading came out to be 4.1 ml. Therefore HCl
gpl is 4.1 gpl.

DUMPER MACHINE
Objective of dumper machine:- The bleached material which
is not to be dyed in subsequent processes is sent to the dumper. It
makes the material whiter and softer.
CHEMICALS USED AND THEIR RECIPE
Recipie for dumper m/c for 400 kg material.
Fresh bath Standing bath
Sara whitecoloring 100 gm 90 gm
powder
Skaywhite HCE liq. 1200 gm 1100gm
Softner Quantity( Mercerised material)
Non ionic Softner 4.5% 4.5%
Emulsion 1% 1%
Mild acid 0.25gpl 0.25gpl
 Softner Quantity ( Soft material)
Non ionic softner 4.5% 4.25%
Emulsion 1% 1%
Mild acid 0.25gpl 0.25gpl
Process:-
The material is passed through the dumper machine in 6 cycles.
The material is d through optical whitening agents for 4 cycles and
is passed through softner for 2 cycles. Each cycle takes around 5-6
mins .The treatment leaves the material whiter and softer . The
material is passed through the machine in rope form . It dips in the
optical whitening agent or softner and then through squeezing
rollers which extracts excess liquids from the material. The
material ,on reaching the other side is again passed through the
same machine.
The theory behind the process is as follows:-
According to light theory,when any two complimentary colours are
mixed ,a neutral colour like white is produced. Optical brightening
agents are violet and the cotton is yellowish due to presence of
natural impurities. Violet and yellow form a pair of complementary
, which when combined result in a neutral white [Link] ,a
white material is obtained.

MACHINE DETAILS
 The capacity of the machine is 3000 litres. But 2400 litres is
filled for a lot size of 400 kg.
 The top roller is made of vulcanized rubber and bottom roller
of ebonite.
 The rotation of motor is bi directional
 2 winches are used for the operation.
 HYDROEXTRACTOR:-
Objective:- The basic objective of hydroextractor is to remove the
moisture from the wet hanks coming from the dumper, bleach line or
from roll dyeing machines.

Process:- The theory behind hydroextractor is based upon action of

centrifugal forces on the material when the machine is rotated at high
speed. The wet hanks are loaded in rope form in the hydroextractor.
After loading ,the lid of the machine is tightly locked and the machine
is subjected to a cycle of 30 mins. during which the machines rotates
at high speed generating centrifugal forces. Since the mass of the
material and water is different ,the water droplets are thrown out of
the material surface due to difference in momentum. The material is
dried to some extent. Complete drying of material occurs in the steam
drier. The principle of hydroextractor is thus same as that of a
washing machine.

MACHINE DETAILS:-
 The complete lot is not loaded in one go; instead the material is
loaded intermittently . First, some material is loaded and the
machine is run for some time .This makes the material recede
back thus making way for more material to be loaded. After the
entire material is loaded in this manner ,the machine is
continuously run for 30 mins.
 Each machine consists of 3 shock absorbers which absorb the
effect of vibrations occuring due to rotation of machine at high
speed. If the vibrations exceed beyond a safe limit ,the machine
touches the feeler of the shock absorbers which ultimately stop
the machine automatically.
 Hand brake:- The hand brake is provided so as to gradually
bring the machine to a stop. The machine runs at a high speed so
as to be stopped gradually.

Machine1 Machine Machine 3 Machine4

2
Capacity 200 kg 200 kg 35 kg 200 kg
Motor 25 25 7.5H.P./1440 25
H.P./rpm H.P./1440 H.P./1440 H.P./1440
Installation 1980 1982 1996 1982

STEAM DRIER
Objective of steam drier:- The material from the hydro extractor
is transferred to the steam drier where it is dried completely.

Process: The hanks are loaded on poles (around 7 or 9 hanks on

one pole). These poles are then mounted one by one in steam
chamber where steam heats the material thus drying the material
completely. 4 fans are provided ; 2 on each side of the chamber
which circulate hot air from the bottom to top thus completely
drying the material. 4types of chains are employed fo movement of
material from the chamber entry up to delivery point. These chains
are as follows:-
Loading chain: No. Of teeth-8
Main chain: No. Of teeth-100
Lifting chain: No. Of teeth-2
Delivery chain: No. Of teeth-77
 Machine Details:-
1. The steam flows in coils situated on both sides of the
chamber. This steam is responsible for drying the hanks by
providing the required heat.
2. There are four fans ; two each situated on either side of the
chamber. These fans circulate the hot air from the bottom to
the top. Two additional fans are provided on the top portion
of the chamber which cools down the poles before they are
unloaded
3. Two temperature sensors are provided in between the two
fans, one on each side of the chamber which sense the
temperature and indicate on the temperature indicator outside
the chamber.
4. The chamber makes use of two motors for the rotation of
fans .One motor is used for the operation of lifting chain
drive.

R.F. DRIER
Introduction:
In radio frequency drying systems, RF generates an alternating
electric field between two electrodes. The material is dried in
packages form. It is placed on a conveyor belt. When the belt moves
forward , materials come in between electrodes where the water
molecules continuously re-orient themselves to face opposite poles
much like magnets would move in alternating magnetic field. This
causes the complete removal of water.
By means of radio frequency waves, heat develops inside the material
in a quantity that is proportional to the water dispersed in it. In fact
water molecules subject to an electric field are polarised in the
direction of the electric field: in an alternate electric field, each field
displacement corresponds to an inversion of the polarisation direction.
Water molecules in an alternated electric field, each field
displacement corresponds to an inversion of the polarisation direction.
Water molecules in an alternated electric field are forced to displace
by oscillating with the same frequency of the field, thus dissipating
energy by effect of molecular friction.

[Link]. Type of material Electrode Speed

1. All polyster packages, 280 mm 22MPH
p.a. winder polyster
packages.
2. T Bag 940 GM Packages 325 mm 8MPH
3. T Bag 1500 GM 330 mm 5.8MPH
Packages
4. Cotton 1000GM(4/51s) 315 mm 7.2MPH
Packages

5. Cotton Dyed and 330mm 5.2 MPH

Bleached 1250 GM
Packages

6. Cotton dyed and bleached 330mm 6MPH

1150GM Packages

7. Cotton dyed and bleached 335mm 5.8 MPH

1700GM packages
 8. Poly cotton-1000GM 310mm 10.5MP
packages H

9. Cotton dyed and 330mm 6.5MPH

bleached 1400GM
packages

BERTA HYDROEXTRACTOR
Machine Capacity Rpm
Machine 1 36 packages 1470
Machine 2 48 packages 1440

This process removes the water(the water quantity varies according to

the type of fibre) dispersed in the fibres by mechanical action; this
process aims at reducing energy consumption and is carried out
before the final fabric drying or between the various wet processing
stages.(washing,dyeing).

Process: The packages are loaded on the machine and automatically

enter the hydroextractor where centrifugal forces are responsible for
drying the packages due to separation of lighter water molecules from
the heavy packages. After the required time , the machine
automatically uplifts and takes a 1800 turn thus the dried packages
become ready for unloading while the loaded wet packages enter the
hydroextractor.
Time for hydroextraction of polyster:150 seconds
Time for hydroextraction of cotton: 360 seconds
 ROLLER HANK DYEING MACHINE
These machines are based on hussong type of hank dyeing machines
in design. These machines are very simple in operation. In the basic
design of machines there is rectangular SS tank with proper heating
mechanism (either a heating coil or direct steam injection through a
perforated steam pipe ) and have a false bottom above the heating

coil.
The tank is fitted with a temperature indicator and control sensor.
There is an array of SS rollers /poles which are fitted on a suitable
frame.
The roller can rotate both sides direction (clockwise and
anticlockwise direction ) with the gear arrangements .The machine is
fitted with a stop /start system to control the roller movement.
The hanks loaded on rollers can be lowered in the tank or lifting out
by lifting or lowering frame with the help of hydraulic system. The
speed (rpm) of roller can be varied by changing the gears and
rotation cycles are controlled by timers which change the direction of
movement of motors .
The dyeing vat has the filling and draining facility of dye liquor . The
dyes and chemicals are added directly into the dye vat.

OPERATION OF THE MACHINE :

The hanks to be dyed are loaded onto the rollers bars by avoiding
overlapping of hanks,in lifted position. The dye bath is kept ready
with proper liquor level, and mixed homogeneously,preferable with
an external circulating pumps . The hanks are lowered into the dye
bath and movement is started, approximately 40-50% part of the
hanks remain the liquor and rest is exposed to the atmosphere. The
material is lifted up for addition of the dye, chemicals, salts, alkali
etc. or for raising the temperature of the dye bath (in case of direct
steam injection ). In case of indirect heating the dye bath temperature
may be increased at set rate of heating, but in case of direct heating
the temperature rise is step by step. The sample is drawn out at the
completion of the process cycle and checked for shade,without
stopping the machine. All operations can be done on the same
machine.
Total number of roll dyeing machine =33
MLR: 1:10 , 1:12 , 1:15
Capacity of machines = 1 to 70 kg.

[Link] Capacity (Kg ) 1:10 1:12 1:15

machines
1 14 140 168 210
2 20 200 240 300
3 20 200 240 300
4 70 700 840 1050
5 7 70 84 105
6 7 70 84 105
7 35 350 420 525
7A 3 30 36 45
7B 3 30 36 45
8 70 700 840 1050
9 70 700 840 1050
10 A 3 30 36 45
10 B 3 30 36 45
11 35 350 420 525
12 7 70 84 105
13 7 70 84 105
14 7 70 84 105
15 7 70 84 105
16 70 700 840 1050
17 14 140 168 210
18 A 3 30 36 45
18 B 3 30 36 45
19 20 200 240 300
20 20 200 240 300
21 7 70 84 105

22 7 70 84 105

23 3 30 36 45

24 3 30 36 45

25 1 10 12 15

26 1 10 12 15

27 1 10 12 15

28 14 140 168 210

29 14 140 168 210

30 14 140 168 210

31 20 200 240 300
32 20 200 240 300
33 35 350 420 525

Chemicals used and their functions :

●DYES: In hank dyeing machine mainly two types of dye are used
to dye cotton yarns. They are reactive and vat dye.
● Caustic soda lye (NaOH): NaOH is mainly used for the vatting
process for the vat dye ,in which the vat dye is transferred to its
soluble form from the insoluble one . NaOH is also used for the
fixation of dyes in dark shades in case of reactive dyes.
 ● Common salt (NaCl ) or glauber salt: Common salt (NaCl ) or
glauber salt is used as exhaustion agent in case of reactive dye .The
concentration of the salt is dependent on its shade depth.
● Soda Ash (Na2CO3): soda ash is the fixation agent for the
reactive dye .It fixes the colour which has been exhausted into the
[Link] this case also the time of running and the concentration
depends upon the shade depth.
● Sodium dithionite (Hydros)(Na2s2O4): It reduces the insoluble
vat dye to its soluble form It also helps to strip the colour out in case
of defective dyeing.
● Diquest DS : It is used as sequestering agent.
● Green acid : It is used to neutralise the hanks from alkaline pH to
neutral,it is also used before dyeing in hot washing.
● Finox NIS Flakes: This is the main softener agent used to soften
the yarn after dyeing.
● Ricofix-NF: This is used for fix the dye completely to the yarn.
● Trinowax WS: This works as a soap and used for soaping for
those yarns where good to excellent fastness properties are required.
● Cotoblanc PCS: This is also a soap used for the soaping purpose
in case of good fastness requirement.

PROCESS FLOWCHART
Hot wash (10 min. In 1:10 MLR)
↓
Drain
↓
Dx treatment (10 [Link] 1:12 MLR)
 ↓
Color solution supplied and Run 15-20 mins at 50-600C.
↓
Salt 10 minutes at 40°C
↓
Salt 10 minutes at 60°C
↓
Soda ash at 60°C
↓

20 minutes if dark shades 30 minutes if light or medium shade

Caustic for 30 minutes No Caustic is used

Shade checking

Ok shade not match

Redye upto shade not match

↓
Drain
↓
Cold wash (10 minutes )
↓
 Green acid treatment (10 minutes )
↓
Drain
↓
Dye – fix (Ricofix-NF )
↓
Drain
↓
Softener
↓
Drain
↓
Unload

For mercerised quality :

Loading
↓
Green acid treatment for 10 min. 1:10 MLR
↓
Drain
↓
Diquest DS treatment for 10 min. In 1:12 MLR
 ↓
Colour solution supplied
↓
Run for 15-20 min. At 40-50°C
↓
Salt for 10 min. At 40°C
↓
Salt for 10 min. AT 60°C
↓
Soda ash at 60°C
↓
20 min. If dark shade 30 min. If light or medium shade
Caustic for 30 min. No Caustic

Shade matching

Ok shade not match

Redye in stand bath

↓
Drain
↓
Cold wash for 10 min.
 ↓
Green acid treatment for 10 min.

Hot wash for dark shade ,soaping &hot wash

Drain
↓
Ricofix-NF dye fixer
↓
Drain
↓
Softener
↓
Drain
↓
Unloading

For vat dye :

Loading
↓
Hot wash
↓
 Drain
↓
Fresh cold water with NaOH for 20 min.
↓
Color supply (Dye+Caustic +Hydro)
↓
Run in cold water for 20 min.
↓
Temperatures raise up to 60°C for 15-20 min.
↓
Sample checking
↓ ↓
Ok shade not match
↓
Redye in stand bath

Cold wash for 10 min.

Green acid treatment for 10 min.

Hot wash for dark shade, soaping

 Hot wash

Drain

Dyefix (Ricofix-NF )

Drain

Softener

Unloading Drain

CABINET DYEING MACHINE

These are the most popular hank dyeing machine, these machines are
designed to have liquor flow parallel to the yarn & they work with
low liquor ratios to save substantially in consultation of thermal
energy, water & chemicals. The material to be dyed in hanks is
loaded on the reels. Generally two sticks (reels) are used , one at the
top and other at the bottom.
The loaded carriers are then put into the dyeing machine & door is
closed. The dye liquor in these machines moves while the material
remains stationary. The flow direction is reversed frequently to ensure
level dyeing.
Objective:
  To dyeing of yarn hanks in a closed chamber with controlled
temperature. A cabinet dyeing machine consists of following
main components
●Main dyeing vessel made of SS
● Carriers for loading of hanks with SS sticks for loading the
hanks.
● An internal axial pump or an external pump for liquor
circulation.
● An indirect heating system.
● An addition tank with injector pump.
● Preparation tank.
● An external or internal sampling device.

Total number of cabinet dyeing machines= 04

M/C NO. Make Water Capacity No. of reels

(litre) (Kg)
1 Gagan 2700 200 34
2 Loris 2100 140 26
Bellini
3 Loris 2100 140 21
Bellini
4 Swastik 5400 400 47

● No. Of machine : 4
● Speed= 600 rpm
● Pressure = 2.5 kg/cm2
 ●MLR = 1:12 to 1:15

Machine details:
● It is a fully closed chamber.
● Main dyeing vessel made of stainless steel.
● Carrier for loading of hanks with stainless steel sticks for loading of
hanks.
● An internal axial pump or an external pump for liquor circulation.
● An indirect heating system, steam circulated in coils for heating
purpose.
● An addition tank with injector pump for colour addition manually.
● Preparation tank.
● An internal or external sampling device.

Main machine parts:

● Main Dyeing Vessel : Yarn dyeing machine contains the main
dyeing cabinet in which the steel rods with hanks are loaded. The
yarn in the hank form is loaded in rectangular array and the dyeing is
carried out using up -to-down and down -to- up flow of the liquor.
● Addition Tank: With the main dyeing tank,addition tank is
situated. All the additions of the Chemicals are done through this
[Link] contains a mixer to dissolve the chemicals.
● Water Inlet Valve: One water inlet valve is attached at the
bottom of the machine . It performs the function of water inlet to the
tank.
 ● Water outlet valve: This valve is known as drain valve . With the
help of drain valve all the is drained after use.
● Steam Inlet & Outlet Valve : Steam is used for the purpose of
heating the liquor. It comes through the steam Inlet valve & is
released with the help of outlet valve. A cold water pipe is connected
to this steam valve for the purpose of cooling.
● Dissolving Tank : A dissolving tank is also situated near the main
dyeing vessel to dissolve the dye .It is used for the addition of the dye
liquor through this tank to the dye vessel with Salt in case of dark
shades . Similar to the addition tank , it also contains a mixer.

 Main Circulation Pump : The main circulation pump performs

the function of circulating the dye liquor with up-to-down and
down -to-up flow of the liquor through hanks.
 Dosing pump: Dosing pump injects the dyes or chemicals at a
fixed rate into main tank.
● Safety valve : Maximum pressure in the machine is kept to be 4
bars .If the pressure inside the vessel exceeds this valve then excess
pressure is released by the safety valve ,to avoid mishaps.
● Air Pressure Valve : Air pressure valve increases the pressure
after lid is closed & decreases pressure before opening of the lid.
● Heat Exchanger : The function of the heat exchanger is to heat
the dye liquor by indirectly heating the coils. Another function of the
heat exchanger is to cool down the dye liquor.

Process flowcharts :
Loading
↓
 Hot wash
↓
Drain
↓
Water filling
↓
Caustic addition, 5 min. l/O, 5 min. O/l flow of liquor
↓
Hydro
↓
Colour supply within 45 min.
↓
Hold for 20 min.
↓
Temperatures raise up to 60°C
↓
Sodium thiosulphate addition
↓
20 min. Hold
↓
Sample checking
 Ok Not match

Drain Dye+Sodium thiosulphate + Caustic soda

Drain
↓
Cold wash
↓
Soda ash+ Peroxide treatment at 50-55°C for 20 min.
↓
Drain
↓
Cold wash
↓
Soaping at 90-95°C for 10-15min.
↓
Cold wash
Unloading
Dyeing process flowcharts :
Loading
↓
 Water filling
↓
Add chemicals+Run
↓
H2O2+HPS+Base Past+F Bol at boiling temperature for 20 min.
↓
Drain
↓
Water filling
↓
Hot wash with RJK at 60°C for 20 min.
↓
Drain
↓
Water filling
↓
Salt+DS Run at R.T for 30 min.
↓
Colour supply within 45 min. & run at 60°C for 20 min.
↓
Soda ash supply within 25 min. & run for 30 min.
↓
Caustic soda supply within 20 min. & run for 1 hour.
↓
Drain
↓
Water filling
↓
Cold wash for 5 min.
↓
Drain
↓
Water filling
↓
Green acid at R.T run for 20 min.
↓
Drain
↓
Water filling
↓
PCS at boiling temperature for 30 min.
↓
Drain
↓
 Water filling
↓

Hot wash at 90°C for 10 min. (2 times)

↓

Drain
↓
Water filling
↓
Dye fixer + green acid at R.T for 30 min.
↓
Drain
↓
Water filling
↓
NIAS+Emulation +Green acid 1046 at 40°C for 30 min.
↓
Drain
↓
Unloading

Ready For Dyeing Process flowcharts :

Loading
↓
 Water filling
↓
Klerix per at R.T for 5 min.
↓
Add chemicals
Caustic +Base Past +TDS/WS+H2O2+HPS at 95°C for 30 min.
↓
Drain
↓

Water filling
↓
Hot wash at 80°C for 15 min.
↓
Drain
↓
Water filling
↓
Treat with RJM+RJK at 60°C for 20 min.
↓
Drain
↓
Unloading.
● Neutralisation Process Flowcharts :
Loading
↓
Water filling
↓
Hot wash at 85°C for 15 min.
↓
Cold wash for 5 min
↓
Hcl treatment at R.T for 20 min
↓
Drain
↓

Water filling , Cold wash, Drain

↓

Soda ash at R.T for 30 min

↓
Drain
↓
Water filling ,Cold wash, Drain
↓
 Hot wash at 95°C for 20 min
↓
Drain
↓
Water filling
↓
Softener + Green acid at 45°C for 30 min.
↓
Drain
↓
Unloading

HTHP Package dyeing machine

 Introduction : Package dyeing machines are the most widely used
now a days for dyeing of almost all type of yarns, due to economical,
automatic and accurate dyeing results. The term package dyeing
usually denotes for dyeing of any type yarns wound on the
compressible dye spring/perforated solid dyeing tubes or cones. Yarn
dyeing in package mounted on hollow spindles. These spindles are
fixed on the dyeing carriers, which is inserted into the dyeing vessel
after closing the lid of the machine,the dyeing liquor is forced
through the packages in two way pattern (inside to out and outside to
inside) and goes on circulating throughout the vessel and yarn. Heat is
applied to the dye liquor to achieve the dyeing temperature, time –
temperature and flow reversal are Controlled through a programme.
Objective :
● To dye the yarn in package form.
Machineries :
● Number of machines = 40
● Make by :
1. Dalal Engineering Pvt . Ltd. (12)
2. Fongs National Engineering (Shenzhen) [Link]. (19)
3. Ugolini ,Italy (9)
Pressure of the machine :
1. Dalal: [Link] = 4 kg/cm2
Test pressure = 6kg/cm2
2. Fongs : Design pressure = 5.2 bar
Hydraulic test pressure = 8.0 bar
3. Ugolini : Maximum allowable pressure = 6 bar
Hydraulic test pressure = 10 bar
● Temperature of the machine : 135 -140°
Flow Reversal
● In – Out time = 4 minutes
● Out -in time = 6 minutes
● IN -OUT Pressure = 2-4 bar
● OUT-IN Pressure = 2-4 bar
● Differential Pressure = 0.5- 0.8 bar
Machi Capaci Water Make No. Spindles/Car Package/spin
ne ty capaci By Of rier dles
Numb (Kg) ty car
er. (Ltr) rier
s
01 8 45 Dalal 1 1 6
02 410 2600 Fongs 2 38 8
03 45 250 Fongs 2 4 9
04 66 400 Fongs 2 7 7
05 95 600 Fongs 2 7 9
06 66 450 Dalal 2 6 8
07 92 630 Dalal 2 12 7
08 300 2500 Dalal 2 37 7
09 178 1400 Dalal 2 22 6
10 465 3000 Fongs 1 43 8
11 255 2000 Dalal 2 21 9
12 218 1600 Dalal 2 18 9
13 260 2000 Dalal 2 24 8
14 66 450 Dalal 2 6 8
15 150 1080 Fongs 2 10 12
16 66 400 Fongs 2 7 12
17 ☆
18 41 350 Dalal 1 5 6
19 66 400 Fongs 2 7 7
20 41 350 Dalal 1 5 6
21 27 250 Dalal 1 5 4
22 47 294 Fongs 2 5 7
23 47 294 Fongs 2 5 7
24 27 168 Fongs 2 5 4
25 27 168 Fongs 2 5 4
26 27 168 Fongs 2 5 4
27 27 168 Fongs 2 5 4
28 47 294 Fongs 2 5 7
29 47 294 Fongs 2 5 7
30 47 294 Fongs 2 5 7
31 4 25 Ugolini 1 1 3
32 9.45 60 Ugolini 1 1 7
33 9.45 60 Ugolini 2 1 7
34 9.45 60 Ugolini 2 1 7
35 9.45 60 Ugolini 2 1 7
36 8 45 Dalal 1 1 6
37 9.45 60 Ugolini 1 1 7
38 9.45 60 Ugolini 2 1 7
39 9.45 60 Ugolini 2 1 7
40 9.45 60 Ugolini 2 1 7

● Recipe :
● Chemicals for polyester dyeing :
1. Dye : As per shade
2. Stock solution (or, Green acid, Dispersing agent
Sequestering agent)
● Chemicals for reduction clearing
1. Sodium dithionite (Hydros)
2. Sodium hydroxide/Sodium carbonate
 3. Thinowax WS

● Recipe for stock solution :

Dispersing agent : 44 kg
DFT : 10 kg
Green acid : 16 kg
Water : 10 kg
Total amount of liquor : 80 kg .

Process time for different programmes :

Programm Number Shade specification Time
1,6,31 1 hour 10 minutes
3,8,33 1 hour 50 minutes
4,9,34 2 hours 06 minutes
5,10,35 2 hours 20 minutes
11,18 1 hour 35 minutes
12 Medium shade 2 hours 05 minutes
12 Darker shade 2 hours 36 minutes
13 Mixed black 4 hours 30 minutes
Lubricated
13 Fresh/Mix black 3 hours 15 minutes
15,17 40 minutes
19 1 hour 40 minutes
20 ( fully Light shade 1 hour 54 minutes
automated )
20 ( fully Medium shade 2 hours 35 minutes
automated )
20 ( fully Darker shade 3 hours
automated )
20 ( semi Light shade 2 hours 10 minutes
automated )
20 ( semi automate Medium shade 3 hours
20 ( semi automate Darker shade 3 hours 15 minutes

● Processed Thread Store (PTS)

In the PAST. T.S department all the white & colour processed
threads collected & then it go for reeling according to the end
product. Packages are also go to winding after complete process.

BOILER
1. Specifications :
● Make by : CATHER VESSEL LTD (CVL)
● Production : 8.3 Ton/hr.
● Pressure : 10.54 kg/cm2.
● Type : BI – Drum tube Boiler.
● Fluidised Bed combustion boiler.
● Raw material (Fue) : Rice Husk.
2. Air and Fuel Gases System :
● FD ( Forced Draft ) fan.
● PA ( Per Air ) fan.
● ID ( Induced Draft ) fan.
● Air pre heater.
● Spark pre heater.
● Boiler furnace.
● Bag filter.
 ● Stalk.
3. Fuel supply system :
● Rice Husk.
● Vibrator & Conveyer belt.
● Hopper.
● PA fan.
● Fuel nozzle.
4. Steam Supply System :
● Steam drum.
● Steam main head.
5. Bed material :
● Size : 2.36 mm – 0.85 mm.
● Composition : Almina 35-45 % , Silica 55-65 %.
● Fusion temperature – 1400°C.
6. Furnace :
● Bed size : 1350 × 2828 mm2.
● Bed hight : 700 mm.
● Heat input : 5684211 kCl/hr.
7. Heating Surface :
● Water fall : 86 m2.
● Bed coil : 30
● Bank tube : 166
8. Light up of Boiler :
● Whenever the boiler is started charcoal, kerosene & bed
material is used.
9. Features of Boiler :
● Super heated steam is produced here with temperatures of
800-850°C .
● In Boiler house steam having pressure of 10.54 kg/cm2 . But
in various department steam is required for lesser pressure
generally of 3.5-4.5 kg/cm2. Therefore PRV (Pressure
reducing valve ) is mounted.
● Steam reaches of various department of 30°C lesser Temp.
● In furnace for continuity of firing oxygen is supplied of 8 %
rate.
● 23-24 ton per day fuel is used .
● 6 Kg steam is used to dye 1 kg material.
● TRAP System is used to utilise maximum amount of steam.
● GCV (Gross Calorific Value) in KCl
Rice Husk 3400-3500
Coal – 4000
LPG Gass – 10000
10. Problems Occur During Operations :
● Start – up failure .
 ● Clinker formation.
● Choking.
● Adequate temperature not achieved.
● Lesser steam.
● Jerking feeder.
● Back flow of air throw.
● Leakage of steam.
● Scale formation.
● Bursting of pipe line.

Conclusion :

 The phase of practical training has proved to be quite fruitful.

 The controlled working way of whole plant makes the student
realize that technologies are not just learning the Structured
description & working of various machines, but the greater
part is of planning proper management.
 It provides opportunities to learn how technology used at
proper place , time & can save a lot of labour.