Textile Processing

Batching

Singeing

Desizing

Scouring

Bleaching

Mercerising
Printing
Dyeing

Finishing

Folding
(Packaging)
 BATCHING

Once the process of weaving is completed, the

greige fabric is inspected and mended then is
made into lots.
The pieces of fabric that are woven from the loom
are sewn or batched together to make a bigger lot.
The lot can be made as per requirement.
By making longer lots the processing of fabric is
easy.
This process of stitching together smaller pieces
into longer pieces is called batching.
These fabrics are then rolled onto rollers and sent
forward for processing.
 FABRIC SINGEING
• Singeing is a process applied to fabrics to
produce an even surface by burning off
projecting fibers, yarn ends, and fuzz.
• This is accomplished by passing the fiber
over a gas flame or heated copper plates at
a speed sufficient to burn away the
protruding material without scorching or
burning the fabric.
• Singeing is usually followed by passing the
treated material over a wet surface to
assure that any smoldering is halted.
 SINGEING MACHINE DETAILS IN PLANT

• Number of singeing machines in Plant : 1

• Temperature : 90
• Intensity : 12 Mbar (Cotton) , 8 Mbar
(Terrycotton)
• Speed : 80 meters/minute (Cotton)
• Distance : 16mm (Cotton), 12mm
(Terrycotton)
• Roller Machine : Kusters Calico, Vadodara
• Flaming Machine : Osthoff-Senge GmbH,
Germany
 DESIZING
• Desizing is a process by which size
materials remove from woven fabric. Requirements for desizing Cotton
• It is a part of the pretreatment process
in textile wet processing. Machine : Comby Jigger – Vintech Eng
• This is the first wet processing in the Cloth : Cotton
textile finishing process used to remove Quantity : 5000m
sized materials from the warp yarn of Desizing Agent : Cynolase HT - 750gms
woven fabric. Wetting Agent : IGSURF 33Cl – 750gms
• This must be done before any
subsequent wet processing of the Process:
fabric. Hot wash
• Because of this, warp yarns are coated Chemical in two parts
with sizing elements to reduce their Four turns at 80 C
frictional properties, to reduce broken Drain bath
yarns on looms, etc. 2 Hot wash at 90C
• After desizing, the absorption of the
fabric increases.
• As a result, the fabric can easily absorb
chemicals, dye molecules.
 SCOURING
The principal aim of scouring is to remove Requirements for Scouring Cotton
textile material impurities. Some other
objectives are: Machine : Comby Jigger – Vintech Eng
• In order to make the material extremely Cloth : Cotton
hydrophilic. Quantity : 5000m
• To considerably absorb textile products Desizing Agent : Caustic lye
without suffering chemical or physical Wetting Agent : IGSURF 33Cl
harm. Process:
• A neat material is generated by adding Hot wash
alkaline. Chemical in two parts
• For cotton removal of non-cellulosic Four turns at 80 C
material. Drain bath
• In order to make the textile material 2 Hot wash at 90C
prepared for subsequent bleaching.
 BLEACHING
• Bleaching is the process of Chemical information:
decolorization of raw textile Hydrogen peroxide is the most common and
material by removing inherent and universally used bleaching agent and is applied
or acquired coloring components under specified conditions of time, temp, pH
from the fiber. and stabilizers for optimum efficacy. The
• It provides base whiteness to the generally considered advantages in its use are:
textile material which could be • Less weight loss than that with hypochlorite
further whitened with the help of bleaching
optical brighteners or dyed | • Bleached goods are more absorbent than
printed depending on the desired hypochlorite bleached goods.
end use. • Less yellowing of post bleached white
• Even in case of regenerated and goods
synthetic fibers, bleaching step is • Suitable for bleaching of cotton, wool and
incorporated for achieving full silk
white or extra bright shades. • Suitable for combined and continuous
scouring and bleaching
 MERCERISING
• Mercerization, in textiles, a chemical
treatment applied to fabrics to permanently
impart a greater affinity for dyes and
various chemical finishes.
• Mercerizing also gives cotton cloth
increased greater absorptive properties,
and a high degree of luster.
• In this process the cloth is passed from a
caustic bath at around 50 degree celcius.
• The concentration of caustic is 280 to 320
GPL.
• After passing it from the caustic bath it is
passed from water tanks where it is washed
and chemicals are taken out.
• The wash type is hot wash and the number
of washes are 5.
 COMBY JIGGER
• The machine is used for various purposes like
Deszing, Scouring, Bleaching.
• The Machine can process 5000m of fabric in
one go.
• Majorly cotton is processed in this machine.
• The jigger machines at Ankur textiles are from
M-Tex and Vintech engg.
• There are 16 Jigger machines here at Ankur
textile.
 Jumbo Jet
• This is a high pressure, high
temperature machine.
• This machine is majorly used for
synthetic fabrics like polyester
as they require high
temperature and high pressure
for their processes.
• Scouring and Bleaching are the
major process carried out in
this, often together.
• The capacity of this machine is
3000m.
• The machines here are
manufactured by devrekha.
• There are 2 such machines at
Ankur textiles in the processing
section.
 KIER BOILING
This is a high capacity machine
and is very old(about 50-60
years).
It is manufactured by Krishna.
This machine is suitable for
Scouring and bleaching.
The capacity of this machine is
30,000 machine.
And processing this quantity of
fabric takes around 24h.
Usually light fabrics are processed
in this (GLM<100)
 MACHINES OVERVIEW
Type Comby Jumbo Jet Kier Soft flow
Parameters Jigger

No.s 16 2 4 1
Capacity(m) 5000 3000 30000 5000
Fabric Cotton Synthetic Fabric with Viscouse
GLM<100

Processes Desizing, Scouring, Scouring, Scouring,

scouring, bleaching bleaching bleaching
bleaching
Company M-tex, Devrekha Krishna Krishna
Vintech
Eng.
 SOFT FLOW MACHINE

This is a relatively new machine in the

plant.
This as well is a high pressure machine.
It’s capacity is 5000m.
This machine can carry out Desizing,
bleaching, scouring even for dyeing but
is majorly used for bleaching and
scouring of fabrics.
It is suitable for all fabrics but viscouse
type fabrics are processed in this.
There is only one such machine in the
plant and is manufactured by Krishna.
 DYEING
• Dyeing is the application of dyes or
pigments on textile materials such as fibers,
yarns, and fabrics with the goal of achieving
color with desired color fastness.
• Dyeing is normally done in a special solution
containing dyes and particular chemical
material.
• Dye molecules are fixed to the fiber by
absorption, diffusion, or bonding with
temperature and time being key controlling
factors.
• The bond between dye molecule and fiber
may be strong or weak, depending on the
dye used.
• In dyeing the color is applied to the entire
textile.
 Types of Dyeing
Reactive dyeing : Reactive dyes form a new chemical compound when they come
into contact with a fiber molecule. Reactive dyes are applied either from
a solution with high pH or from neutral solutions that are later alkalized through a
separate process. Sometimes different shades are brought out by applying heat
to the dyed textile. Reactive dyes are mainly used for dyeing cellulose fibers such
as cotton and viscose.

Disperse dye : Disperse dye are widely used for synthetic materials. disperse dye
are easy to dyed of synthetic materials such as polyester, polyester/cotton, nylon
and blend materials. These dyes having low solubility and it is insoluble in water.
it give even dyeing on synthetic fiber. dye give good effect on method of polyester
dyeing. and also give proper shade on polyester fiber, nylon, acrylic fiber and
blend materials such as polyester/cotton and more.
some important chemicals are used in disperse dyeing such as dispersing agent
because dispersing agent help for even or proper dyeing and it’s gives good
shade.
Process flow
Load the fabric

Dissolve colour

Add salts

Set temperature

Add Caustic soda

Sample checking

Washing and
soaping

Drying
 Machines Used

Jiggers : 46 units
Jumbo jiggers : 3 units
Padding machine : 2 units
Jumbo Jets : 7 units
CPP machine : 1 unit
Drying range : 4 units
 JIGGER DYEING MACHINE
Jigger dyeing machine is most commonly used for
dyeing. The jigger dyeing machine process is easy
for almost all kinds of cotton fabrics at full width.
The fabric is dyed in this form on the jigger to a
larger extent than in any other form. The jigger is a
simple machine which consists of a V-shape trough
fitted with two draw rollers one along each side of
the machine. At the commencement of dyeing,
cloth in open width is wound on one of these
rollers called the 'let-off roller from which it is
unwound and passed through the dye-liquor in the
trough with the help of guide rollers and an
immersion roller on to the other roller called
the take-up roller’ on which it is wound.
Most of the penetration of the dye-liquor or actual
dyeing takes place when the cloth is resting on the
roller.. before going through the liquor again and
not when the cloth is running through the liquor.
The dye-liquor is heated by perforated or closed
steam coils and the liquor can be drained off
through an outlet.
 JET DYEING MACHINE
• Jet dying machine is the most modern
machine used for dyeing of polyester using
disperse dye.
• The fabric is processed in continuous loop.
The technique is especially useful for
delicate polyester fabrics but depending on
the machine almost any weight, structure,
or fabric type can be used.
• This is a very high pressure and high
temperature machine.
• The temperature in this machine is around
130 degree Celsius.
• The polyester fabric is hydrophobic and the
high temperature and pressure make it
possible to dye polyester in this machine.
 PADDING MACHINE

• Padding machine is used to dissolve and fix

the dye on the fabric using continuous
rollers and brings evenness on the fabric
dye. There is a 60-65% color pickup if
padding is done right after dyeing.
• After the fabric has gone through the
padding machine it has to be processed on
the jier machine.
 DRYING MACHINE

• This machine is used to dry the fabric after

every wet process such as dyeing.
• It is a contact drying machine.
• It is done using hot rollers with steam.
• In addition to drying the fabric, there is an
attachment which performs rope-to-open
function in this machine after jet dyeing
where fabric is in rope form.
FINISHING
 STENTER
• A Stenter is a specialist oven used in the Stentar machines in Ankur:
textile industry for drying and heat treating There are 7 stentar machines.
fabric after wet processing. These are manufactured by Motex.
• It consists of heated chambers, adjustable This machine can process over
to the width of the fabric being treated. 60,000 meters a day.
• Fabric is fed into the heated chamber The stentar has sections joined
supported at either selvedge by a series of together called Chambers.
stentar pins or clamps which support the There are 4 machines with 6
fabric as it is moved through the drying chambers, 2 machines with 5
chambers. chambers and 1 machine with 8
• A stenter is primarily used for the following: chambers.
 Drying and adjustment of the width.
 Application of softeners and various
chemical finishes.
 Curing.
 Heat setting.
 CALENDERING
• Calendering is an optional process that Calendering machine at
involves running fabric through large Ankur:
heated rollers. There is one calendering
• The rollers are closely spaced so that machine at Ankur textile.
there is significant pressure on the This machine is
fabric as it passes through them. manufactured by Prabhat.
• This process alters the physical Mostly cotton fabrics are
characteristics of the fabric. Typically, processed in this machine.
the individual yarns are flattened and It has an average speed of
the inter-yarn gaps are reduced 40m per min.
because as the yarns flatten, they The temperature can go
become wider. up to 200 degree celsius.
• This process is done on fabrics for
shine and luster.
 SANFORIZATION
• Sanforizing is a mechanical finishing • The machine at Ankur textile
process of treating textile fabrics to prevent is from Monforts, Germany
the normal dimensional alternation of warp and is manufactured in 2007.
and weft. • The temperature is set at
• It is also called anti-shrinkage finishing around 130 degree celsius.
process. • It can process up to 50m/min.
• It is a process of treatment used for cotton
fabrics mainly and also for some other
textiles made from natural and synthetic
fibers.
• It is a method of stretching, shrinking and
fixing the woven cloth in both length and
width, before cutting and producing to
reduce the shrinkage which would
otherwise occur after wash.