INDUSTRIAL TRAINING REPORT 2011INDUSTRIAL TRAINING REPORT 2011INDUSTRIAL TRAINING REPORT 2011INDUSTRIAL TRAINING REPORT 2011

GIMATEX INDUSTRIES PVT. LTD

(WANI UNIT)

7 KM MILE STONE, NH-7, VILL- WANI, TAH- HINGANGHAT

DIST- WARDHA, MAHARASTRA-442301

SUBMITTED BY

ARUP NANDY

SUDIPTA DAS

JISHU RAJ MURMU

SUBHAJIT KARMAKAR

FAKHRUDDIN ALI AHMED

PRASANTA KUMAR GAHANA

GOVT. COLLEGE OF ENGG. & TEXTILE TECHNOLOGY, BERHAMPOREGOVT. COLLEGE OF ENGG. & TEXTILE TECHNOLOGY, BERHAMPOREGOVT. COLLEGE OF ENGG. & TEXTILE TECHNOLOGY, BERHAMPOREGOVT. COLLEGE OF ENGG. & TEXTILE TECHNOLOGY, BERHAMPORE

WEST BENGALWEST BENGALWEST BENGALWEST BENGAL

All through the days we passed at GIMATEX, we could always remember ourselves

and our training associated with a number of names. These were the names of people

responsible our Industrial Training-2011 which improved us technically as well as,

prepared us mentally for our personal industrial experiences. This report would be

incomplete without the mention of at least some of those people.

Firstly, the person who was responsible for our training schedule- Dr. Chakradhar

Dutta and Mr. Debraj Sarkar. They have always lent us their helping hands when we

needed them the most. They have been our greatest inspirations.

Secondly, we must thank Mr. Gautam Kumar Dhang, Vice President (Weaving) who

helped us out whenever we faced a problem inside or outside the mill complex, even being

strict in his command. We want to specialy thank Mr Shyamal Ganguly, Sr. Manager(

Weaving).

There are numerous other names which come to our minds, Mr.Umesh Singh, Mr

B.Basu Purkayasthya, Mr.Rajesh Rajput, Mr. Ramesh Yadav, Mr. Daaga, Mr S. Dey and

Mr. A. Ghosh being a few of them.

We express our heartfelt gratitude for these people and wish people like them stay

in the industry forever and make the industry a wonderful place to survive.

ABOUT THE PLANTABOUT THE PLANTABOUT THE PLANTABOUT THE PLANT

GIMATEX INDUSTRIES PVT. LTD

NH-7, VILL-WANI, HINGANGHAT

DIST- WARDHA ( M.S.)-442301

CHAIRMAN: Shri Basant Kumar Mohota

MANAGING DIRECTOR: Shri Prasant Kumar Mohota

DIRECTOR: Shri Vinit Kumar Mohota

VICE PRESIDENT: Shri. Gautam Kumar Dhang

Departments

• Boiler

• Cotton Spinning

• Synthetic Spinning

• Doubling & TFO

• Weaving

• SQC

• Store

• H.R & I.R

• Marketing

Annual turnover- about Rs.500 crores.

Manufacturing products: Grey fabric & yarn

BOILER DEPARTMENT

Aim of the department:-

To supply steam in different departments.

Area:-It is just beside the weaving department.

No. of boilers:- There is one boiler

Capacity of the boiler: - 3 Ton/hrs (Steam)

Temperature of the boiler: - 1800C

No. of workers: - There are three workers.

Name of the boiler m/c: - Thermax

Name of the boiler company:-Boiler tech Engineers.

Running time:-24 hrs.

Type of Raw material:-Coal and Husk (commonly used)

DIFFERENT TYPES OF YARN & YARN SUPPLIERS IN YARN GODOWN

Yarn Godown is a dept where yarns from different supplier are stocked. Properties of yarn vary in count,

blend, structure & packaging.

YARN PROPERTIES CHART OF DIFFERENT SUPPLIERS

LENGTH OF A STD YARN PACKAGE (eg: PATSPIN, count: 50/2, wt: 1.875kg)

1) COUNT= 50/2

2) Wt OF 1 CONE=1.875 kg

= 1.875*2.2 lb

LENGTH OF 1 lb= 840*50 yard

1.875*2.2 lb= 840*50*1.875*2.2/2 yard

= 86625 yard

=79 km (yard to meters multiple factor 0.9144)

SUPPLIER PACKING CARTOON NET

WT:

(KG)

COUNT STD CONC

WT(KG)

1 GIMATEX CARTOON 45.36 50/2 Ne 1.89

2 TRIDENT CARTOON 45.36 40/2 CW 2.52

3 ETCO SPINNING

LTD

SACK 60 24 KW 2.54

4 DAMODAR CARTOON 35.36 290 DEN 1.97

5 RAJVIR IND LTD CARTOON 45.36 60 Ne 1.89

6 RAJVIR IND LTD SACK 38.50 50 Ne 0.96

7 RELIANCE CARTOON 61.42 5.11

8 ANNUR SATYA

TEXTILE LTD

SACK 60 40 Ne P/C 2.5

9 VARDHMAN CARTOON 34.02 30/1 CW 1.89

10 INDO RAMA CARTOON 32.75 5.45

11 PATSPIN CARTOON 50.4 70/1 1.52

12 MARUTI GTex CARTOON 45.28 40/1 CW 1.88

13 NSL TEXTILE

LTD

CARTOON 45.36 60/1 CW 1.89

WARPING

Introduction: Warping is a department, where single warp ends are combined into parallel sheets of ends.

Objective of warping:

1) Removal of yarn-faults and foreign matter, which are the main causes of warp breakage.

2) Making warpers’ beam, which are used in sizing.

WARPING

DIRECT WARPING SECTIONAl WARPING

DIRECT WARPING:

Direct warping is a warping process, where warps are prepared from V-creel simultaneously.

M/c name: BENINGER BEN-DIRECT

M/c DETAILS:

CREEL CAPACITY 784

SPEED RANGE 500-1200 rpm

PRESSURE(WARPING) 35 bar

PRESSURE(CREEL) 5 bar

TEMP, RH 34ᵒC, 64.9%

COUNTWISE SPEED AND TENSION CHART.

COUNT SPEED(mpm) PRE-TENSIONER SETTING

20ˢ O.E 1000 12 mm

2/40 C, 2/40 ELI 1000 10 mm

2/50 C, 2/60 C 1000 10 mm

2/80 PC, 2/80 C 1000 6 mm

20ˢ 1000 8 mm

30ˢ 900 4 mm

40ˢ, 40 PC 800 2 mm

45 PC, 50 PC,60 C 700 0 mm

80ˢ 600 0 mm

WARPING CHECK REPORT

SORT NO: 12360 BLEND: 100% COTTON SUPPLIER: GIMATEX

NO OF CREEL: 1 DATE: 14/06/11 TENSION: 12mm

COUNT: 20ˢ O.E LOT NO:52080012

Sl.

No.

SPEED

(M/min)

NO:

OF

CONE

LENGTH FOREIGN

MATTER

WEAK

PLACE

CUT

CONE

SLUGG

OFF

BAD

WINDING

CONE

FINISH

ENTANGLEMENT

1 900 754 8470 1 12 24 1

2 700 752 10 1 2 1

3 700 752 1 15 1

4 900 752 8 1

5 900 752 5 1

.

TIME TAKEN FOR M/C STOP & CREEL CHANGE TOTAL TIME TAKEN FOR WARPING

EVENTS TIME BEAM COMPLETE

TIME(min)

RUN TIME

(min)

FAULT

REPAIR

OLD CREEL END

CUTTING

20 sec 1 60 12 18

CLEANING 15 min 2 30 12 21

REVERSING CREEL 2 min 10

sec

3 33 10 13

DRAWING

THROUGH SENSOR

11 min 4 23 10 15

DENTING 10 min 5 25 10 14

SECTIONAL WARPING

INTRODUCTION; Sectional warping is a warping m/c, where warp yarns of different quality are used for stripe or

other warp variation in weavers’ beam. Direct weavers’ beam is created for loom-shed.( Sectional warping is

preferred for strong yarns).

M/C manufacturer name: BENINGER KARL-MAYER

M/C model: ERGOTECH 2200

CREEL MODEL: HGP-W/ISOTENS-880

Creel capacity: 880

M/C DETAILS:

DETAILS DATA DETAILS DATA

SORT NO: 14223 WORK ORDER S22

NO OF CREEL 1 SECTION WIDTH 54.28

BEAM NO: P405 COUNT 40 SLUB

DATE 13-06-11 TOTAL END 5796

NO. OF SECTION 35 SECTION LENGTH 200mm

7 LEASE YES X LEASE YES

CENTRE LEASE YES DENTING ORDER 4.4.4.3

CREEL END 166 REED SPACE 1900mm

SIZING

Objective: Sizing is specially applied to the woven fabric for the following purposes:

1) Increase it’s weavability

2) Increase the yarn strength

3) Reduce the yarn hairiness

4) Minimize the abrasion between warp threads and various loom parts, and between threads

that are adjacent to each other.

M/C NAME: BENINGER BEN-SIZETEC

No. of machines: There is basically one sizing machine. There is a Separate part beside the machine known as

Kitchen. It consists of:-

• Premixer: Here basically the size ingredients are mixed with water.

Total capacity= 56 inch (first 6 inch = 100 L, 1inch=25 L)

• Cooker: Here the mixture is whirled around so that the size ingredients are properly mixed

with each other. Temperature maintained is 1200C and the material is processed here for

30min.(same capacity)

• Storage unit: The mixture is stored here and sent to the main unit when necessary. The

material is kept here at 90c.(approximately same capacity

Optimum size percentage

The percentage size to be applied to a warp in order to achieve a minimum number of end-breaks during

weaving is dependent mainly on:

• The end density, as this will affect the amount of end-to-end abrasion that will take place;

• The linear density of the warp, which greatly influences the strength of the yarn and will also

affect the amount of abrasion; and

• The pick density, which will affect the amount of abrasion between the warp ends and the reed

as it reciprocates.

There are other factors which may also need to be taken into consideration, such as the

fibre type, the yarn type, the yarn structure, the type of size and the type of loom.

DETAILS DATA

CREEL CAPACITY 16×2=32

2 (for sectional)

NO. OF SIZING BATH 2

CAPACITY OF SIZE BOX 12 inch (FIRST 6 inch 100L, then 25L/inch)

TEMP. OF SIZE BOX 90ᵒC

NO. OF DRYING CYLINDER 4+4+4=12

FLOW CHART OF SIZE PASTE:

FLOW CHART OF SIZING PROCESS:

SIZE COOCKER

WARPERS' BEAM

SIZE BOX

PREMIXER

SIZING M/C DETAILS:

DETAILS

6×2=32

2 (for sectional)

MAXIMUM SPEED

OPTIMUM SPEED

12 inch (FIRST 6 inch 100L, then 25L/inch)

TEMP OF DRYER

4+4+4=12

STORAGE CHAMBER SIZE BOX

CYLINDER DRYER

LEASE ROD COMB

DATA

120-160 m/min

80-100(for coarser)

50-60 (for finer)

120ᵒC

SIZE BOX

COMBWEAVERS'

BEAM

WATER

STEAM

DIFFERENT TENSION ZONES OF SIZING

TENSION ZONES: Tension imparted on warp yarns are implemented on different zones in sizing m/c. There are 5

zones in sizing m/c. Each zones have unique multiple factor, which are used to calculate the warp yarn tension.

WARP TENSION:= g/m*TENSION FACTOR

G/M = Total ends/ (1.693*count)

DETAILS OF TENSION ZONES IN SIZING M/C

ZONES ZONE NO: MULTIPLE FACTOR TENSION(N)

CREEL ZONE Z-1a, Z-1b 5-6 G/M*(5-6)

SHOW BOX ZONE Z-2a, Z-2b STRETCH

CYLINDER ZONE Z-3a, Z-3b 12 G/M*12

LEASING TENSION ZONE Z-4 12-13 G/M*12-13

WINDING ZONE Z-5 16 G/M*16

PRESSURE ROLLER Z-6 14 G/M*14

SIZING RECIEPE: Sizing recipe is the amount of chemicals used for sizing in sizing box.

COTTON 40 S COTTON 20 O.E

CHEMICALS TOTAL WEIGHT( kg) CHEMICALS TOTAL WEIGHT(kg)

ALPENAL JV 100 MAIZE STARCH 75

KETANAL 15 NIPPASOFT 4.5

NIPPA SOFT 4.5 WATER 28”

WATER 25” TOTAL VOL 31”

TOTAL VOL 28” TIME 10+35

TEMP 135’C TEMP 135’C

FINAL VOL 31” FINAL VOL 31”

ANTI STATIC 1 SOLID PERCENTAGE 71%

SOLID PERCENTAGE 12% VISCOSITY 6 sec

VISCOSITY 15 sec

TIME 10+35

60 VISCOSE

60 COMP

CHEMICALS TOTAL WEIGHT( kg) CHEMICALS TOTAL WEIGHT( kg)

ALPENAL JV 75 SIZANIL LV-100 100

KETANOL 12 KETANOL 21

NIPPA SOFT 6 NIPPBOND 21

WATER 33” NIPPASOFT 8

TOTAL VOL 36” WATER 27

TIME 10+30 min TIME 10+30 min

TEMP 130’C TEMP 120’C

FINAL VOL 38” FINAL VOL 36”

SOLID % 78% SOLID% 12%

VISCOSITY 6 sec VISCOSITY 9 sec

SIZE PICK-UP PERCENTAGE CALCULATATION

SIZE PICK UP PERCENTAGE: Size pick-up percentage is the amount of size paste attached to yarns

after yarn is released from squeezing rollers.

SIZE PICK UP % =[weight of size material /( Weight of unsized yarn)]×100

CALCULATION: Net weight(sized yarn) =Gross weight – Tare weight

= 619.5 – 191.0 kg

= 428.5 kg

Weight of unsized yarn = (lengtht×otal ends)/1693/avg Ne

= 4508×6090/1693/45.96

= 352.82 kg

Pick up percentage = [(428.5 – 352.82)/352.82]×100

= 21.4%

SIZING M/C TENSION CALCULATION

Sizing tension is calculated by multiplying factors of zone with gm/m. Calculated tension can be adjusted by

50N from fixed value.

Gm/m = Total ends/1.693/count = 42.15

• WINDING ZONE TENSION: gm/m*16 = 575N (fixed = 680N)

• CREEl ZONE = gm/m*6 = 252.9N (fixed = 300N)

• PRESS ROLL = gm/m*14 = 590 (fixed = 590)

DRAWING-IN

Introduction: Drawing-in is a dept. where warp ends are inserted through heald wires and reed dent with different

denting orders from weavers’ beam according to the required quality.

No of Drawing-in stand: 10

No of worker required/stand: 2

Different reed count used: 72/4, 67/5, 70/5, 80/3, 72/5, 66/5, 68/5 etc

DRAWING -IN CHART FOR DIFFERENT QUALITY

SORT NO. 14278 27206 110203

ENDS 6350 5852 5796

REED COUNT 96/2 88/2 86/2

REED SPACE 66.1” 66.5” 66.5”

TIME FOR DRAWING (hr) 5 hr 30 min (approx) 5 hr (approx) 5 hr (approx)

DENTING ORDER 1,2,3,4 1,2,3,4 1,2,3,4

ENDS/HEALD WIRE 1 end/heald wire 2 end/heald wire 1 end/heald wire

LOOM-SHED

Introduction: Loom shed is the department where fabric is weaved in loom. Warp yarns are taken from

weavers’ beam and weft yarns are inserted from another package.

FABRIC PRODUCTION PROCESS

DESIGNING DEPT.

Fabric pattern, denting order and

pegging plans are made.

SAMPLING DEPT.

A sample fabric is produced with

given preference, for testing

PREPARATORY DEPT.

Warping, Sizing and leasing process

are done to assist weaving

LOOM-SHED

Fabric produced by interlocking

warp and weft yarns. Drawing &

knotting will be required before

fabric produced sometimes for

different quality

INSPECTION & DESPATCH.

After production inspection for

fabric faults are done and mended.

After that fabric is dispatched

DRAWING-IN DEPT.

Warp ends are inserted through

heald wires & reed according to

denting order

DETAILS OF LOOM-SHED

There are two loom-sheds. Four types of air-jet looms are there:

1) PICANOL OMNI PLUS (sumo motor function) - 50 looms

2) TOYATA JAT710 – 56 looms

3) SULZER TEXTIL L5400 - 13 looms

4) SULZER TEXTIL L5500 – 1 looms

Three types of shedding mechanisms are used:

1) STAUBLI CAM SHEDDING

2) STAUBLI DOBBY SHEDDING

3) FILTEXTILES DOBBY

Two types of knotting m/c are used:

1) TODO - 2 m/c

2) STAUBLI -1 m/c

Working patterns:

1) PLAIN -1/1

2) TWILL- 2/1

3) OXFORD- 3/1

4) SATIN- 4/1

Compressor used for pressure supply in looms

1) SAMSUNG

2) ATLAS COPCO.

DETAILS OF EACH LOOM

STAUBLI TYPE starting with 1 (eg: 1661) indicates Cam shedding, and starting with 2 (eg: 2871) indicates

DOBBY shedding.

NO OF LEVERS indicates no of heald frames.

PREWINDER indicates no of weft accumulator.

R.S means reed space.

LOOM NO. STAUBLI

TYPE

NO.OF

LEVERS

PREWINDER

LOOM TYPE

R.S.

(CM)

1,2,3,4,5,6,7,8,9,10,11,12,13,

14,15,16,17,18,19,20,21,25,

26,27,28,29,30,31,32,33,34,

35,36,37,38,39,40,41,42,43,

44,45,46,47,48

1661 7 2 TOYOTA 710 190

22,23,24 2871 16 4 TOYOTA 710 190

49,51,52,53,54,56 2861 16 4 TOYOTA 710 210

50,55 2861 16 6 TOYOTA 710 210

57,58,59,60,61,62,64,71,73,

74,75,76,78

1661 8 4 SULZER 5400 190

63 FILMTEXTILES NOT FROM

STAUBLI

6 4 SULZER 5500 190

65,66,67,68,69,70,72,113,

114,115,116,117,118,119,

120

1661 6 2 PICANOL 190

77, 2871 10 2 PICANOL 190

79,80,81, 2871 12 2 PICANOL 190

82,83,84,85,87,88 2871 16 2 PICANOL 190

86 2871 13 2 PICANOL 190

89,97,100,110 1761 6 2 PICANOL 190

90,91,92,104,111 1661 7 2 PICANOL 190

93,107,108,112 1661 7 4 PICANOL 190

94,96,98,101,102,103,105 1661 6 2 PICANOL 190

95,106 1661 4 2 PICANOL 190

99 2861 14 2 PICANOL 190

109, 1761 6 4 PICANOL 190

DETAILS OF DIFFERENT QUALITIES IN LOOM SHED

GIMATEX INDUSTRIES PVT.LTD,WANI

SL.NO QUALITY NO. WARP COUNT WEFT COUNT ENDS PER INCH PICKS PER INCH

1 18202 80 COMP. 80 CW 92 88

2 12359 20 OE 300 DENIER 112 56

3 16233 60 COMP. 80 DENIER 132 96

4 14223 40 CW. 40 CW +150 DENIER 92 80

5 14520 40 COMP. 30 CW. 175 105

6 14292 A 45 P/C 45 P/C 96 76

7 16239/A 60 VISCOSE 60 VISCOSE 94 84

8 15522 50 COMP. 20 SPANDEX 156 88

9 24338 2/4O 300 DENIER 124 56

10 16226 60 COMP. 80 DENIER + 60 CW 132 100

11 14528 40 COMP. 30 CW. 185 90

12 16236 60 COMP. 60 CW +80 DENIER 132 100

13 14278 40 P/C 40 P/C 100 84

14 14308 40 CW. 30 CW. 160 90

15 13348 30 COMP. 20 SPANDEX 132 68

16 14277 45 P/C 45 P/C 132 72

17 14273 40 P/C 40 P/C 100 78

18 14525 40 COMP. 30 SPANDEX 159 78

19 14273-A 40 P/C 40 P/C 100 76

20 14272 40 P/C 40 P/C 92 84

21 14527 40 COMP. 300 DENIER MILLENGE 172 74

22 14532 40 COMP. 30 CW.+30 SLUB 180 90

23 14533 40 COMP. 30 MILLANGE 172 90

24 12360 20 0E 300 DENIER 124 56

25 18202 60 80 92 88

26 14526 40 COMP. 300 MILLENGE 172 70

27 15924 50 DYED 50 BLEACH 136 76

28 14285 40 P/C 40 P/C 92 84

29 25317 2/50 ELI 150 DENIER 130 88

30 110203 100 COMP. 100 COMP. 92 72

31 27206 2/76 POLT. 2/30 TFO. 93 48

32 12361 20 OE. 300 DENIER 124 56

COMP: compact ring yarn,

CW: combed yarn,

P/C: polyester and cotton blend

LOOM MECHANISMS

Primary motions: 1) SHEDDING 2) PICKING 3) BEAT UP

Auxiliary motions: 1) TAKE-UP 2) LET-OFF 3) WARP STOP 4) WEFT STOP

PRIMARY MOTIONS

SHEDDING: Shedding is done either CAM or DOBBY mechanism. Shedding shaft gets movement from SUMO

MOTOR(Picanol) or Main motor(Toyata, Sulzer). Heald frames are set as some difference for staggering.

PICKING: Picking is done by air-jet. Weft yarns are inserted by air pressure. There are two main valves and relay

nozzles for continuity of jet integration. Main and relay valves are connected with main nozzles and relay nozzles.

BEAT UP: Beat-up mechanism get motion from crank drive connected by gear with main motor.

AUXILIARY MOTION

TAKE UP: Take-up motion is controlled by individual motor. Fabric is rolled on a cloth roll which is surface driven

LET OFF: Let off motion get control by individual motor. Let-off motion is assisted with easing motion where feeler

rollers are vibrated to adjust warp tension.

WARP STOP: If warp ends get broken loom is automatically stopped by hydraulic brake. Warp stop motion is

controlled by drop pins, when a warp breaks drop pin fall on a electrode, completing the circuit and making loom

stop.

WEFT STOP: Weft stop motion is controlled by two filling detector (FD1 and FD2).

RELAY NOZZLE SETTING FOR DIFFERENT LOOMS

TYPE OF LOOM DISTANCE

FROM

LEFT OF REED

TO 1ST

RELAY

NOZZLE

DISTANCE FOR

SUBSEQUENT

RELAY NOZZLE

FROM ONE

ANOTHER

5 OR 6 RELAY NOZZLE

AT RHS. FROM ONE

ANOTHER

DISTANCE FROM FD1 TO

FD2

PICANOL OMNI

PLUS

15 MM 74 MM 37 MM 100-120 MM

SULZER TEXTIL 30 MM 65 MM 35 MM 90-120 MM

TOYOTA J710 20-25 MM 60-65 MM 35-40 MM 90-110 MM

VALVE PRESSURE: Pressure in main valve should be 6 bars.

SELVEDGE : In air-jet loom dummy selvedge are used with leno selvedge. There is a leno box for every loom.

REED: For air-jet looms profile reeds are used for jet integrity.

LOOM PRODUCTION

Loom production determines the total production of weaving. Loom production data is stored and updated on

spreadsheet and informed to MIS. Main hurdles of loom production are beam gating, knotting and warp stop and

weft stop motion.

TOTAL PRODUCTION OF LOOM-SHED: 37,000 meters/day

AVERAGE PRODUCTION

LOOM TYPE TOYATA PICANOL

AVG. PICKS/INCH 84 PPI 83 PPI

AVG. RPM 830 785

NO. OF M/C 64 56

PRODUCTION/ DAY 20, 000 METERS/DAY 16, 000 METERS/DAY

EFFICIENCY 88% 85%

PRODUCTION IN METERS / SHIFT /m/c: (RPM *60 * 8 * EFFCIENCY %) / 3937 /PPI meters/shift

PRODUCTION IN gm / SHIFT / m/c: (Production in meters/shift/ m/c * FABRIC WIDTH * GSM) gm

Fabric width in meter, GSM= gram weight of one square meter fabric

AVERAGE BEAM GATING TIME / m/c: 3-4 hr (approx.)

AVERAGE KNOTTING TIME / m/c: 1hr- 1hr 30 min

LOOM SETTINGS

LOOM TIMING DIAGRAM: Loom timing diagram is the timing settings of all motions of a loom. As for better

production and m/c stability and less wear and tear perfect loom timing diagram is essential.

PICKING PATH OF AIR-JET LOOM

MOTION STARTING (DEGREE) STOPING (DEGREE)

BEAT UP 0

CUTTER 5

SHED OPENING 10 60

DWELL PERIOD 61 319

SHED CLOSING 320 360

PICKING 80 300

FILLING DETECTOR 1 210 290

WEFT YARN

PRE-WINDER PFT TENDOM

NOZZLE

MAIN

NOZZLE

WEFT

CUTTER

RELAY

NOZZLE

SELVEDGE

CUTTER

RHS

GREY INSPECTION & DESPATH

INTRODUCTION: Inspection is the department, where fabrics are checked after production for faults and mended. In

this department grey fabrics are graded according to American 4 point checking system.

NO OF M/C: There are 4 types of inspection m/c and 4 handmade mending frames.

1) SHREETEX – 3 M/C

2) YASH – 2 M/C

3) NEW BHAGWATI VIJAY ENG – 1 M/C

4) B.TEX TEXTILE MACHINERY – 2 M/C

Make of the m/c: Indiana Euro, Shreetex (Silvasa)

Motor rpm: 1415

Motor hp: 1.0

Power consumption: 0.75 KW

Length of the beam: almost 70”

AMERICAN 4 POINT SYSTEM PENALTY POINTS FOR DEFECT

WARP DEFECTS

UP TO 3 INCH 1 POINT

3 INCH TO 6 INCH 2 POINT

6 INCH 9 INCH 3 POINT

9 INCH TO UP 4 POINT

WEFT DEFECTS

UP TO 3 INCH 1 POINT

3 INCH TO 6 INCH 2 POINT

6 INCH TO HALF WIDTH 3 POINT

HALF WIDTH TO FULL WIDTH 4 POINT

1) No one meter should be penalized more than 4 points.

2) Fabric shall be inspected on one side.

3) Total no of points allowed in 100 linear meter are 24 points.

4) Deviation of 10 points per linear meter allowed.

DIFFERENT FABRIC FAULTS

QUALITY NO FABRIC FAULTS

14292 STARTING MARK, BREAKING END, BROKEN PICK, DOUBLE PICK, THICK PLACE

16239A WEFT DISTORTION,

12361 BUMP MARK, OIL STAIN,

110203 LOOSE WEFT, WARP SLUB, STICHES,

14534 DOUBLE END, THICK PLACE, STARTING MARK, LOOSE WEFT

SOME OTHERS FAULTS:

SELVEDGE DEFECT, LOOPS, SIZE PATCH, BROKEN PATERN, COARSE PICK, THIN PLACE, MISSING END, WEFT SLUB,

CONTAMINATION, HOLE/CUT/TEAR, MISSING PATTERN, WRONG DENTING

SOMETHING ABOUT THE SECTION

� Each fault is given a marking. This marking technique varies from mill to mill. Here the

marking technique is shown below.

� Maximum points given to a fault = 4.There are corresponding marking of 1, 2 & 3.

� Maximum allowable points to consider a fabric as “A” grade is 24 within 100metres of

fabric, for “B” grade this range varies for 24 - 90 within 100 meters of fabric. Above this it is

considered as “C” grade fabric.

MAINTAINANCE SHEDULE

MAINTAINANCE SCHEDULE FOR DIRECT WARPING M/C( 500 hr service) SIZING M/C WEEKLY MAINTAINANCE SCHEDULE

CLEAN MACHINE CLEAN THE COMPRESSOR FILTER

CLEAN WINDSHIELD CLEAN THE OIL LEVEL

CLEAN GUIDE ROLL CLEAN THE BEAM SHAFT

CLEAN PRESSURE ROLL CLEAN THE AIR FILTER AND AIR SILENCER

CLEAN TRAPEZOIDAL THREADED SPINDLE AND

LIMIT SWITCH ASSEMBLIES

CLEAN THE ALL VALVE POSITION

CHECK OIL LEVEL CLEAN THE ALL SAFETY GUIDE POSITION

CHECK SCREWED LEVEL CHECK THE ALL MANDI PUMP POSITION

CHECK DRIVE LEVEL CHECK THE ALL BEARING POSITION

RESET MAINTAINANCE INTERVAL ALL M/C GEAR BOX POSITION

LUBRICATING QUILS CHECK ALL THE NUT BOLT

CLEAN / BEAM POSITION CHECK CREEL BELT POSITION

CLEAN / LUBRICATE TRAPEZOIDAL THREADED

SPINDLE

ALL M/C GREASING

CHECK WARP BEAM STEAM LEAKAGE PROBLEM

CLEAN / LUBRICATE COMB TRAVERSE CHAIN

GREASE CYLINDER PRESSING DEVICE

RESET MAINTAINANCE INTERVAL

OIL CHANGE: REPLACING OIL FILTER

INSPECT/ REPLACE BRAKE PADS

REPLACE DRIVE BELTS

CHECK BEAM CLAMPING AXIAL PLAY

CHECK COMPENSATING SPRING

REPLACE PRESSURE ROLL BEARING

REPLACE GUIDE ROLL BEARING

REPLACE QUILL ROLL BEARING

REPLACE BRAKE CALIPER SEALS

TOYATA AIR-JET MONTHLY CHECK LIST

1. CLEANING

2. WEFT PASSAG, LEAF SPRING, TENTIONERS

3. EDP, MEASURING BAND, WINDING ARM

4. ABS, TANDOM NOZZEL, MAIN NOZZLE 180’

5. FILLING CUTTER LHS(25’-30’)

6. REED TIGHTNESS (5.9 – 6.9 Nm)

7. SUB NOZZEL PIPES

8. RHS CUTTER

9. WEFT FEELERS,(WF1 &WF2) STRCHING NOZZEL TIGHTNESS

10. BEAM LOCKING AREA

11. BACK REST BEARING AND BACK REST PLAY

12. LENO DEVICES, LENO SHAFT, WHEEL

13. EASING RAD, BEARING

14. HEALD FRAMES, SIDE SUPPORTS AND BOLT TIGHTNESS

15. WARP STOP MOTION SENSOR, SERRECTED BAR

16. TEMPLE RING CONDITION

17. TAKE UP ROLL,GEAR, PRESS ROLL

18. CATCH CORD SET

19. TAKE UP, DRIVE MOTOR, GEARS, CHAINS

20. TAPPET CAM BOX AREA & BELT TENSION

21. UNDER MOTION, JACK LEVERS

22. MAIN MOTOR AREA AND BELT TENSION

23. CONTROL PANEL

24. AIR PRESSURE AND REGULATOR AREA

25. AIR FILTER, OIL FILTER AND GREASE FILTER

26. CLUTCH GAP UP TO 0.6mm

27. OTHERS

TOYATA AIR-JET SIX MONTHLY CHECK LIST

ALL THE MAINTAINANCE PROGRAM OF 1MONTH CHECK LIST ARE INCLUDED

1. BACK ROLLER RELATED COMPONENTS IN THE LET-OFF MOTION

2. INDIRECT TAKE UP ROLLER CHAIN AND TENSION PLATE

3. FOR GLASS FIBER M/C MAIN NOZZELS

4. CENTRALIZED LUBRICATION SYSTEM

5. EASING LEVER PIN & BUSH

6. TAKE UP, DRIVE MOTOR, GEARS AND CHAINS

7. AIR AND OIL FILTER

8. OTHER DAMAGED PARTS

9. MAIN BRAKE (<0.5)

10. MIDDLE METAL SELECTION

11. BEAM HOUSING AND BEARING

ACTUAL HANDS REQUIREMENT

DEPARTMENT DESIGNATION A-SHIFT B-SHIFT C-SHIFT TOTAL SIZING SIZER 1 1 1 3

BACK SIZER 1 1 1 3

MIXING BOY 1 1 1 3

HELPER 1 1 1 3

WARPING WARPER 1 1 1 3

CREEL BOY 1 1 1 3

HELPER 1 1 1 3

S.WARPING WARPER 1 1 1 3

CREEL BOY 1 1 1 3

HELPER 2 2 2 6

DRAWING DRAWER 3 3 3 9

REACHER 3 3 3 9

F/C 1 1 1 3

HELPER 3 3 3 9

TOYOTA LOOM

AND PICANOL

LOOM

FOREMAN 1 1 1 3

CHARGEMAN 1 1 1 3

K/B/G 6 6 6 18

RELIEVER 4 4 4 12

L/C 2 2 2 6

F/C 2 2 2 6

C/F 2 2 2 6

R/D 4 4 4 12

R/FITTER 2 2 2 6

G-SHIFT 0 0 3-TOYOTA 3

MAINTENANCE FOREMAN 1

CHARGEMAN 1

FITTER 2

ASST.FITTER 2

OILER 2

M/C CLEANER 4

O/H BLOWER 2

P/FITTER 2

FOLDING CHECKER 7 7 7 21

HELPER 2 2 2 6

F/C 1 1 1 3

ACTUAL HANDS

REQU.(UTILITY)

COMPRESSOR

OPERATOR

1 1 1 3

ASST.WELDER 1

WORKSHOP ASST. 1

FITTER 1

ASST.FITTER 1

HELPER 3

BOILER ATTEND 1 1 1 3

FIREMAN 1 1 1 3

COALMAN 2 2 2 6

CARPENTER 1 1

The days we passed at Gimatex taught us a wonderful lesson in

our lives. Gimatex taught us to survive even in the most competitive

situations against the most powerful competitors. The lesson we

learnt is an experience of a lifetime. None of us has enough of

oblivion to forget it.