?
? ?



 ? ? 

 ? ?

The textile internship has been completed in Alok Industries

Pvt. Ltd, Vapi, Gujarat.

The duration of the internship was of two weeks where we had

covered six different sections of textile processing.

Familiarized us with the various aspects of a Textile Processing

Unit starting from its Organizational hierarchy to the
functionality of the various departments.

Introduced us to the various brands of machineries available

for carrying out the different textile processes to meet global
standards.
  ? 
6 The textile internship was carried out to develop a clear understanding
about the following:

Flow process sequence and Technical details on machine particulars of

weaving, dyeing, printing, finishing, laboratory etc.
Particulars of raw material, intermediate products and final product,
process details, product quality parameters.
Particulars of the manufacturing environment.
Human resource management.
Productivity analysis for various processes.

6 The internship helps us to

To understand the structural and functional constituents of the industry.

To adapt to real industrial situations which equips us for decision making
in a realistic environment.
To strengthen the relationship between the industry and students.
 
 
6 ulok Textiles td.
1986 - established as a private limited company
1989 ± Its irst polyester texturising plant being set up
1993 - a public limited company

6 ulok¶s ision
• To be the orld's best-integrated textile solutions enterprise ith
leadership position across products and markets, exceeding customer
& stakeholder expectation

6 O
uIZuTIOu IE u 

  

Vertically Integrated Textile Company on Cotton as well as

Polyester stream

Sales of Rs. 2,976.93 crores and PAT of Rs.188.37 crores in

FY 2009 (Audited)

xport of Rs. 1,054.50 crores in FY 2009 (Audited)

State of the art manufacturing facilities with Integrated

Management System Certification

Two decades of providing wide range of quality textile

products
6 Vxpanded into
weaving,
knitting,
processing,
home textiles
garments
integrated backward into cotton
spinning and manufacturing POY
through the continuous polymerization
route.

6 Vntered the domestic retail segment through a wholly owned subsidiary, Alok
Retail India Limited.

6 A chain of stores named µH A¶ that offer garments and home textiles at

attractive price points.

6 Alok¶s vision 2012

To generate consolidated revenues of Rs. 75,00 crore.
Consolidated PAT of Rs. 750 crores
Among top 50 Best company in the country.



?


Timely expansions resulting in first mover advantage

Vxports increased from Rs. 100 crores in 2004 to about 1,050 crores in 2009 at a
CAGR of 60%

Preferred Vendor status from leading retailers

Critical supplier for the Buyer due to Quality, Cost Delivery (QCD)

Vconomies of scale coupled with low interest cost giving competitive advantage

Sustained margins due to forward and backward Integration

Wide range of products offered across different market segments

Product development and designing strength

State of the art infrastructure with modern machines

? 

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


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

Different departments in this unit are:

• Design Studio
• Preparatory department
V Warping
V V Creel
V H Creel
V Sizing

• Weaving
• Grey
• Processing
• Finishing

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


  !"#
6




 

 




6 

  



 


  

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 $""#%$

V Creel warping
• Creel installed in a 400 V shape
• Production capacity is 5.5 tonnes per day

H Creel warping
• Installed parallel to each other
• Production capacity is 3 tonnes per day
• Sectional warping is done

Sizing
• The machine has a capacity of 12 beams
• Production capacity is 10 tonnes per day
• A raising zone is provided for separating individual yarns after being
sized

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 



÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 "&'()

Two types of looms

• Dobby
• Jacquard

Air-jet type looms i.e. use air pressure for weft insertion

Dobby - floor loom that controls warp threads using a device known as dobby.

Jacquard loom - mechanical loom that simplifies the process of manufacturing

textiles with complex patterns such as brocade

Loom controlled by punch cards with punched holes, each row of which
corresponds to one row of the design.

Double beams are used:

• Top beam
• Bottom Beam

Meant for complicated designs and can weave up to 6 colors.

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


%#'(

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

Functions of grey section
• Inspection of rolls for defects
• Counting number of picks
• Rejection checking

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 ? ?   

Reactive dyes used for the dyeing of cotton fabric.

Grey section prepares rolls of fabric according to dyeing

machines¶ capacity.

Auto chemical mixing for all machines.

2 machines having 90kg capacity used for preparing samples.

Dyeing machines - 90 kg, 350 kg, 700 kg, 1050 kg and 1400 kg.

The software used for dyeing is named ³Orgatex Batch

Scheduler´.
÷
÷ ÷


  
÷

÷

÷
÷
 ÷



GRVIGV - 9
DYVING
• RANSON¶s • KUSTVR¶s CPB - 4
• COPIWALA • BVNNINGVR CDR - 2
• BVNNINGVR PAD STVAM - 3

SINGVING DVSI ING ± 5 • MONFORTS THVRMOSOL ± 2

• OSTHOFF(PAD STVAM)
• BVNNINGVR(PAD STVAM)
• OSTHOFF(PAD BATCH)
WASHING
• ARIOLI SOAPVR ± 1

PRV-TRVATMVNT ± 9 V COLD PAD BATCH WASH

• BVNNINGVR V COLD WASH
(PRVTRVATMVNT) - 4
• BVNNINGVR(MVRCVRI ATIO
FINISHING
N) ± 5 • MONFORTS STVNTVR ± 4
• PRV WASHING (INJVCTA) • KKA CALVNDVR ± 1
• IMPACTA (CHVMICAL
• KUSTVRS CALVNDVR ± 2
TRVATMVNT)
• STVAMVR • MONFORTS SANFORI VR ± 1
• POST WASHING (IMPACTA)
• VVRTICAL DRYING RANGV
FOLDING PACKAGING
• COPIVALA TVSTING - 12
• TVSTA PACKAGING ± 1
÷
÷ ÷


  
÷

÷

÷
÷
 ÷



?? 
~ Chemical Storage Tanks ± 40
~ Capacity - 500 liters (600 - 650 kilos)
~ DLV Software - Liquid Product Automatic Volumetric Dozing

Color Chemical containing tanks (Loading Junction)

Loading Junction has two connectors ± delivery and feeding points.

Pneumatic pumps are used for the transfer of the liquids.

The feeding time of the liquids - 3 to 5 minutes

DAP unit ± ³Powder Auxiliaries Dissolving Unit´

Separate tanks for Salt and Hydrous (Capacity ± 2000 -1000 kg)

Units are connected to the ³load cell dissolving cycle´

Color Preparation ± 12 tanks

Pressure - 6 bars ; Dissolving Temperature - 70ÔC.

45 TRS tanks. (TRS ± Automatic weighing for powder dye stuff.)

40 tanks - 45 kg ; 5 tanks - 90 kg each.
• SGQ (6 chambers) - 450 kg each
• SSC - 18 kg.
• JIT (Just in Time) ± 2 kg

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 ?  

GRVY OPVNING MACHINV

FINISHING
• HSING CHVNG ± 4 • SANTA STRVTCH ± 1
• FONGS RVLAX DRYVR ±1

MVRCVRI ING • SANTVX PLAITVR ± 1

• DOMIVR ± 1 • OPVN WIDTH FINISHING
STVNTVR : CORINO

FOLDING

SAMPLV DYVING • Done on two floors, the ground floor has

• 1 machine of 10kg capacity one inspection and one packaging
• 1 machine of 5kg capacity machine both of Testa.
• The first floor has Hsing Cheng (Taiwan)

DYVING (SOFTFLOW) checking machine (13 )

• 750kg capacity ( 3 chambers) - 4
• 500kg capacity (2 chambers) - 5
• 1500kg capacity (6 chambers) - 1
PACKAGING
• 1000kg capacity (4 chambers) - 2
• 110kg capacity (1 chamber) - 2
• 250kg capacity (1 chamber) - 2
• 50kg capacity - 2
• Inspection method is followed.
• The four point grading system
• Automatic packaging machine (Testa) :
• 8 different types of fabric packed at a
time
• Unloading is spread across 4 trolleys in
either side of the conveyor belt

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 
  
*
??
  
+

Capacity range - 5 - 1070 kg.

Lot Card specifying the dyeing details of the yarn approved by QA lab.

There are two types of dyes used in the department.
• Vat Dye (caustic based)
• Reactive Dye (salt, soda based)

Boiling is carried out for 45 minutes
• In out function- from spindle to package (takes 3 mins.)
• Out in function- from package to spindle (takes 6 mins.)
SPINNING UNIT YARN DYVING
LOADING MACHINV
(SILVASSA) (VAPI)

APPROVAL
AFTVR TRVATMVNT DYVING PRV - TRVATMVNT
Q A

WINDING PACKING

÷
÷ ÷


  
÷

÷

÷
÷
 ÷



 , ?
? ?
• Scouring

? ?
? ?
• Yarn is put through a caustic soda bath • Chemicals - Hydrogen peroxide,
followed by hydrogen peroxide and Pervalin RS, Acetic acid and Perfil
acetic acid treatment. 210.
• Process carried out at 100°C • This process is carried out at 95°C

 
• Dyeing by Batch Process.
 *
?   +
• Yarn cheeses placed in the spindles • Soft packages winding from dyed
cheese to cones.
• Placed in respective carriers to the
dyeing, soaping and finishing of yarns • Checking is done
• Temperature
V Light - 60°C - 70°C for 40 - 60 mins.

*  +
V Medium - 80°C - 90°C for 60 ± 80 • In cartons - Less quantity of cones
mins. • Bulk packing
V Dark - 80°C - 110°C for 80 ± 90 V Packing machine used
mins. V Wounds the cones with thin
plastic sheet in a circular manner
V Cones rotated automatically on a
revolving platform for winding

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 ?

In properly printed fabrics the color is bonded with the fiber, so as to resist
washing and friction.

Whereas in dyeing proper the whole fabric is uniformly covered with one color, in
printing one or more colors are applied to it in certain parts only, and in sharply
defined patterns.

(,$'(#'()-
• by far the most used technology today.
• Two types exist: rotary screen printing and flat (bed) screen printing
• A blade squeezes the printing paste through openings in the screen onto the
fabric.

')'#" #.#' $'(#'()-

• a process of printing on textiles and garments using specialized or modified
inkjet technology.
• Inkjet printing on fabric is possible with an inkjet printer by using fabric sheets
with a removable paper backing and is used for sample preparations.
÷
÷ ÷


  
÷

÷


÷
÷
 ÷



The printing department carries out the following
processes for printed products:

   ?
 



    / *0$')1(#
?
 ?
* ?? + "(2"#'&+


  ?  
 *0&"#2%+

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 ?

The industry is mainly confined to rotary screen printing for the bulk
production while flatbed screen printing is used for sample preparation.

Screens are prepared in the following steps for the printing to be done
through it


 
? 
?/ * +


   ?  
 
   

 


The mesh of the screens are in the range of 40, 50, 60, 125, 145, 165
units per inch.

÷
÷ ÷


  
÷

÷

÷
÷
 ÷



The machineries:
• Sample making machines
V Laxmi
V Mimaki Digital Printer
• 1 Laxmi rotary machine
• 3 Reggiani rotary screen printing machines
V 2 to 14 colors of patterns can be printed on the fabric
using the machines in the industry.
V The capacity of the rotary machine is 20 to 100
meters/seconds depending upon factors like design and
the number of colors in that design and the types of the
fabric (coarser takes less time as compared to finer
fabric).
÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 !"#$$

%$&$

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 • Arioli loop ager

• Arioli polymerizer

The average daily production of each of the screen printers

is 70,000 m with the rpm of each rotary screen as 150-200.
÷
÷ ÷


  
÷

÷

÷
÷
 ÷


÷
÷ ÷


  
÷

÷

÷
÷
 ÷



Functions of the Department

• To keep step by step quality maintenance of the order that is

being processed in the unit.
• Laboratories check for the physical and fastness properties
• Chemical tests might be carried out to cater buyer¶s
specifications
• Mini machines of each process to treat the samples and match
them with the effective results.

÷
÷ ÷


  
÷

÷

÷
÷
 ÷



Separate laboratories for
• 2 Woven Sections,
• Yarn Processing Section and
• Terry Towel unit.

Knits and printing section - quality tests done in the same lab used by the
narrow width woven s section.

They follow international standards for the quality assessments which

includes:
• ASTMD( mostly for physical tests)
• AATCC( mostly used for color fastness tests)
• ISO

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 !%'"?#(32-

YARN COUNT ( WARP RVVL BVVSLVY BALANCV)

ORIGINAL WIDTH

USABLV WIDTH

TPI , VPI, PPI

TVAR STRVNGTH TVSTVR

ABSORBVNCY TVST

TVNSILV STRVNGTH(WVFT AND WARP)

PILLING

SHRINKAGV

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 "#(?#

The following tests are conducted and measured on the grey scale

• RUBBING FASTNVSS( WVT AND DRY)(AATCC)

• WASHING FASTNVSS( TOP LOAD (ISO) AND FRONT LOAD
( AATCC) )
• COLOR FASTNVSS TO WATVR (AATCC)

Color Fastness to light is also conducted using the ISO Standard test
procedures

÷
÷ ÷


  
÷

÷

÷
÷
 ÷



÷
÷





  



 
÷




÷
÷ ÷


  
÷

÷

÷
÷
 ÷



The machines were mostly of the company James H. Heal.

The key features of the lab were the softwares

• Datacolor that predicted recipes for the different dyeing and other
processes using CMC Spectrophotometer and

• Auto color dispenser for solution making and dispensing




 


÷
÷ ÷


  
÷

÷

÷
÷
 ÷


"$!'"1$"'(0#!2'00(#2%'()
1"!'($23#'("$"'#%-

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


'((%!)%%*$'#**$#&
%()))+%#,($%$

÷
÷ ÷


  
÷

÷

÷
÷
 ÷


÷
÷ ÷


  
÷

÷

÷
÷
 ÷


÷
÷ ÷


  
÷

÷

÷
÷
 ÷


 

Alok Industries is an organization par excellence in the field of garments and textiles.

Its huge infrastructure yet profound attention of the higher officials offered to us, as
interns¶, bear evidence to the same fact.

The same meticulous attention given and ethics practiced in the daily production of
Alok has made it reach the zenith where it stands successfully today.

The internship has been an enterprise of much interest to us as it has exposed us to a

real working environment of a textile processing unit.

This internship has helped us learn how actually a production unit works and the
amount of impromptu decisions that has to be taken daily to keep the production
running without any hindrances.

Thus, it will lay the foundation in the array of practical knowledge gained before
stepping out of college and into a career in the textile industry.
AN VFFORT BY:
ARPIT SAXVNA
PALLAVI SRIVASTAVA
ROHAN DWIVVDI
SURVNDRA MARANDI
SURYA BAKSHI
TANIYA DUTTA

÷
÷ ÷


  
÷

÷

÷
÷
 ÷