ABSTRACT

This report presents a comprehensive study of Seffectzs Garment Dyeing, a

textile processing unit specializing in professional garment dyeing services.
Established in 2017 under the proprietorship of Paulsingh Jeevanantham, the
company is located at Chettipalayam, Tamil Nadu, and plays a significant
role in enhancing the appearance, quality, and market value of finished
garments. Seffectzs operates with modern machinery and well-structured
processes that include pre-treatment, dyeing, post-treatment, drying, and
finishing, ensuring consistent colour accuracy and superior product
standards.

During the course of my internship, I gained practical exposure to multiple

aspects of the dyeing industry, including fabric preparation, dye selection,
process equipment operation, quality testing, and effluent treatment. Key
learnings involved understanding the use of disperse dyes, the functioning of
essential equipment such as filter presses, agitators, and spray dryers, as well
as the implementation of environmental safeguards through effluent
treatment and reverse osmosis systems.

This study highlights the company’s commitment to technological precision,

quality control, and sustainable operations, demonstrating how Seffectzs
integrates modern techniques with eco-friendly practices to meet industry
demands while minimizing environmental impact. The experience provided
valuable technical knowledge and professional skills relevant to chemical
engineering and textile proc

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TYPES OF CONTENT

Sr. No. Title Pg. No.

1 Declaration 1

2 Acknowledgment 2

3 Certificate 3
4 Table of Content 4
5 List of Tables 6

6 List of Figures 6
7 Abbreviations 7

8 Introduction to company 8
9 Chapter 1: Introduction of Dyes and Types of Dyes. 11

Chapter 2: About Disperse Dyes and Manufacturing 17

Process.
17
2.1 Introduction of Disperse Dyes 18
2.2 Manufacturing Process of Disperse Dyes. 19
2.3 Detailed Reactions.

Chapter 3: Process Equipment. 21

3.1 Filter Press. 21

3.2 Anchor Type Agitator. 22

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 Chapter 4: Particle Size Reduction Units. 23

4.1 Kinetic Dispersion Mill. 23

4.2 Sand Mill. 23
4.3 Slurry Reactor. 25

Chapter 5: Equipment Used in the Unit 26

5.1 Pumps 26
5.2 Valves 29
5.3 Spray Dryer 32

Chapter 6: Effluent Treatment Plant 36

6.1 Properties of Sewage 36

6.2 Methods of Effluent Treatment 38

Chapter 7: Utility Specification 42

Chapter 8: Safety and Environmental Aspects 43
Chapter 9: Water Run 46
Chapter 10: Safety and Environmental Policy 47
10 Conclusion 48
11 References 49

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INTRODUCTION ( COMPANY )

The textile and apparel industry is a vital part of global manufacturing,

offering significant contributions to employment, trade, and economic
development. Within this industry, garment dyeing is a specialized process
that enhances the visual appeal, texture, and market value of fabrics and
finished garments. It demands precision, quality control, and
environmentally responsible practices to achieve consistent and vibrant
results.

Seffectzs Garment Dyeing , legally registered under the name Paulsingh

Jeevanantham, was established on 21 July 2017 as a proprietorship business.
The unit is located at 359/2, Periya Thottam, AngeriPalayam Road to Pn
Road, Mahavishnu Nagar, Angeripalayam, Chettipalayam, Tamil Nadu –
641603. Since its inception, the company has focused on providing high-
quality garment dyeing services, utilizing modern machinery and industry-
standard techniques. Its operations cover every stage of the process,
including pre-treatment, dyeing, post-treatment, drying, and finishing,
ensuring that garments meet customer requirements with consistency and
excellence.

During my internship at Seffectzs, I had the opportunity to gain hands-on

experience in various aspects of garment dyeing. From understanding fabric
preparation and dye selection to observing machine operations and quality
testing, this training provided valuable insights into the workings of a
professional dyeing facility.

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This report summarizes the company profile, key processes, and practical
knowledge acquired during the internship, highlighting the importance of
technological precision and sustainable practices in garment dyeing.

5
 CHAPTER 1

INTRODUCTION OF DYES AND TYPES OF DYES.

BASIC INFORMATION ABOUT DYES

Definition:

A Dye must be coloured substance which should also be able to impart

colour to something else on a reasonably permanent basis before it is
considered as a dye. Dyes generally have complicated structures which are
made by reaction involving building blocks as intermediates.

Most of these are aromatics compounds with substituent group such as -

NH2, NO2 & -SO3H which alter the reactivity of the cyclic compounds &
sometimes the colour dyes. Intermediates are not just used for the
manufacture of dyes but for all types of organic work where complex
structures are built up.

They are particularly useful for making agricultural chemicals, pesticides,

pharmaceuticals and rubber [Link] dyes contain considerable
unsaturation and some part of dye is usually in the form of aromatic rings
with nitrogen unsaturation of several types common to many dyes.

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 ( Consumption of Dye)

CLASSIFICATION OF DYES:

It is possible to classify dyes by using an ingenious system devised some

years ago by the society of Dyes & Colourists and published as the colour
index. The colour index recognizes 25 types of dyes by chemical
classification.

[Link]. Name of Dye [Link]. Name of Dye

1 Nitroso 14 Indamine & indophenol

2 Nitro 15 Azine
3 Mono-dis-tris- & poly azo 16 Oxazine

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4 Azoic 17 Thiazine

5 Stilbene 18 Sulphur
6 Carotenoid 19 Amino ketone

7 Diphenyil methane [ketone 20 Hydroxy ketone

amine]

8 Triaryl aryl methane 21 Anthraquinone

9 Xanthene 22 Indigoid

10 Acridine 23 Phthalocyamine
11 Quinoline 24 Natural organic colouring
matter

12 Methine & polymethine. 25 Oxidation bases

13 Thiazole

(Classification of Dye)

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CLASSIFICATION BASED ON APPLICATION:

1. Acid dyes

2. Azoic dyes

3. Basic dyes

4. Direct dyes

5. Disperse dyes

6. Fiber reactive dyes

7. Fluorescent brightening agents

8. Food, drug & cosmetic color

9. Mordant dyes

[Link] dyes

11. Sulphur dyes

12. Vat dyes

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 CHAPTER 2

ABOUT DISPERSE DYES AND MANUFACTURING PROCESS.

INTRODUCTION TO DISPERSE DYES

Today disperse dyes are the most important type for the Textile Industries.
These disperse dyes are widely used for dyeing of the synthetic fibers.
These disperse dyes must exist in disperse form at the time of its
application on material and so it is insoluble in water. The very small and
finely divided particles of disperse dyes are settled down between the space
of the fibers at high temperature of about 130°C and then the temperature is
lowered down for trapping of the disperse dyes particles between the fibers
of material which is to be dyed, these dyes melt at above 150°C.

The term “disperse dye” have been applied to the organic colouring
substances which are free from ionizing groups, are of low water solubility
and are suitable for dyeing hydrophobic fibres. The dye has derived its
name for its insoluble aqueous properties and the need to apply it from an
aqueous dispersion. Of all the dyes, they are of the smallest molecular size.

Disperse dyes have substantively for one or more hydrophobic fibres e.g.
cellulose acetate, nylon, polyester, acrylic and other Synthetic Fibres. The
negative charge on the surface of hydrophobic fibres like polyester cannot
be reduced by any means, so non-ionic dyes like disperse dyes are used
which are not influenced by that surface charge.

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Properties of Disperse Dyes:

1. Disperse dyes are nonionic dyes. So they are free from ionizing
group.

2. They are ready made dyes and are insoluble in water or have very
low water solubility.

3. They are organic colouring substances which are suitable for dyeing
hydrophobic fibres.

4. Disperse dyes are used for dyeing man made cellulose ester and
synthetic fibres specially acetate and polyester fibres and sometimes
nylon and Acrylic Fibres.

5. Carrier or dispersing agents are required for dyeing with disperse

dyes.

6. Disperse dyes have fair to good light fastness with rating about 4-5.

7. The wash fastness of these dyes is moderate to good with rating

about 3-4.

8. Of all dyestuffs disperse dyes are of smallest molecular size.

9. Generally disperse dyes are derivatives of azo, anthroquinone, nitro

and quinone groups.

10. They do not undergo any chemical change during dyeing.

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MANUFACTURING PROCESS OF DISPERSE DYES

Manufacturing of
Disperse Dyes.
Diazotization

Coupling

Filtration

Size Reduction

Spray Drying

Blanding

(Manufacturing process of Disperse Dyes)

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 BOILER FORM STEAM PRODUCTION

 Wood or Coal Fired IBR Steam Boiler are Engineered for maximum
safety, highest efficiency, dependability and quit operation.

 We have emerged as the remarkable manufacturer and supplier of

Wood Coal Fired Steam Boiler.

 This steam boiler is developed with top quality material and advance
technology in accordance with set industrial standards.

 Most wood fired boilers require manual tube brushing.

 A boiler incorporates a firebox or furnace in order to burn the fuel

and generate heat. The generated heat is transferred to water to make
steam, the process of boiling.

 This produces saturated steam at a rate which can varyaccording to the

pressure above the boiling water. The higher the furnace temperature,
the faster the steam production.

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 REVERSE OSMOSIS PLANT

 A reverse osmosis plant is a manufacturing plant wherethe

process of reverseosmosis takes place. Reverse osmosis is a common
process to purify or desalinate contaminated water by forcing water
through a membrane.

 Water produced by reverse osmosis may be used for a variety of

purposes, including desalination, wastewater treatment,
concentration of contaminants, and the reclamation of dissolved
minerals.

 An average modern reverse osmosis plant needs six kilowatt-hours

of electricity to desalinate one cubic metre of water. The process also
results in an amount of salty briny waste.

 The challenge for these plants is to find ways to reduce

energy consumption, use sustainable energy sources, improve the
process of desalination and to innovate in the area of waste
management to deal with the waste.

 Self-contained water treatment plants using reverse osmosis,

called reverse osmosis water purification units, are normally used
in a military context.

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STAGE 1

COLLECTION TANK

 Effluent from the collection tank comes to the equalization tank in

wastewater treatment. The main function is to act as buffer.

 To collect the incoming raw effluent that comes at widely fluctuating

rates and position to the rest of the ETP at steady Average flow rate.

 During the peak hours ETP comes at high flow rate. The
equalization tank stores this effluent and lets it out during the non
peak time when there is no /little incoming effluent.

 The inlet pipe of equalization tank carries filtered effluent from

cooling tower. The effluent NPSH lifting pumps move the effluent
to the EC SKID.

 The delivery pipe takes the effluent to the EC SKID.

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  The coarse bubble diffusers are short length of tubes that have
holes at regular spacing.

STAGE 2

ANAEROBIC TANK

Anaerobic digestion pumps are an essential piece of equipment used in

anaerobic digestion systems. These pumps help to move the waste
materials and other liquids through the system and ensure that the
anaerobic digestion process runs smoothly.

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Proper maintenance and ownership of anaerobic digestion pumps are
crucial for ensuring that the system works correctly and that the waste
materials are processed as efficiently as possible.

If a pump is down, and any backup pump is not functional, the ability of
the whole plant to make biogas is in jeopardy. We think that this is so
essential that it is not a “tip”. Users just have to maintain their equipment.
This should be common knowledge but sadly it is often neglected.

The gravitational force used for pumping the liquids from the collection tank
.

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STAGE 3

AERATION TANK

 The same process as the collection tank is to separate the particles or

dust by pumping the blower from the downwards.

 The cowdung and the brown sugar is added into the aeration tank to

clean the bacteria from the impure liquid in the centre of the tank.

 Aeration is an important step in the process of treating wastewater,

including sewage effluent. Microorganisms in aeration wastewater

treatment tanks break down organic compounds and nutrients.

 The removal of nutrients is critical, because wastewater that is

overly rich in nutrients can cause ecosystem imbalances if released

into the environment.

 One negative effect of nutrient enriched wastewater is the

development of harmful algal blooms – or “dead zones”- in major

bodies of water, such as the Gulf of Mexico.

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STAGE 4

STORAGE TANK

 Storage is done in CLASSIFIER column by two ways of storage

tank and the sludge particles settled down in the tank by itself.

 Storage tanks are containers that hold liquids, compressed gases

(gas tank; or in U.S.A "pressure vessel", which is not typically

labelled or regulated as a storage tank) or mediums used for the

short- or long-term storage of heat or cold.

 The term can be used for reservoirs (artificial lakes and ponds), and
for

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 manufactured containers. The usage of the word tank for reservoirs

is uncommon in American English but is moderately common in

British

 English. In other countries, the term tends to refer only to

artificial

 containers.

 In the USA, storage tanks operate under no (or very little) pressure,

distinguishing them from pressure vessels. Storage tanks are often

cylindrical in shape, perpendicular to the ground with flat bottoms,

and a fixed frangible or floating roof.

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STAGE 5

OZONE GENERATOR

 From the storage tank the liquid moved to the OZONE

GENERATOR to get the pressure and filter process.

 Pressure and Filter process is done by the gears in ozone generator.

 OZONE is not used directly by the Atmosphere ,it is separately

done by the OXYGEN MOLECULES.

 The combination of Triatomic atoms of molecules to form the

OZONE.

 Ozone, also known as trioxygen, has the chemical formula O3

and is composed of three oxygen atoms. Ozone gas is naturally

unstable at normal atmospheric conditions which means that in

commercial applications, ozone must be made on-site using an ozone

generator.

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STAGE 6

FILTRATION

 In the Reverse Osmosis the Filtration is done by four stages of Filter.

 Bythe first stage of Filtration, the pure water is released out by

cleaning.

 With high pressure and room temperature the pure liquid is

separated and the sludge or remaining impurities are not filtered by

stage is moved to the second stage of filtration process.

 The filters used for filtration process, the filters changed by one and

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 half years once.

 The same process is repeated for the second and third stage of

filtration purposes.

 By the last or fourth stage of filtration the remaining waste is

separated and the sludge particles are moved to brine solution tanK.

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 STAGE 7

SLUDGE FILTER

 Sludge filter is worked by the filter press used in dyeing industry.

 The sludge particles are stored separately after filtration process takes

place.

 From the reverse osmosis plant the excess water come out the residue that
accumulates in sewage treatment plants is called sludge (or biosolids).
Sewage sludge is the solid, semisolid, or slurry residual material that is
produced as a by-product of wastewater treatment processes.

 This residue is commonly classified as primary and secondary sludge.

 Primary sludge is generated from chemical precipitation, sedimentation,

 and other primary processes, whereas secondary sludge is the activated

waste biomass resulting from biological treatments.

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