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INTRENSHIP REPORT AT

GTM-2

WET PROCESSING UNIT

GROUP MEMBERS:MUJAHID MEHDI ABRO

11 TE 83TANVEER HUSSAIN SOLANGI

11 TE 84MOHAMMAD YOUSIF SHAIKH

11 TE 72SADAM HUSSAIN JAKHRANI

11 TE 75WASEEM AHMED MEMON

11 TE 62

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AMEER ALI MANGRIO 11 TE 52

WET PROCESSING:It is sequence of process where fabric is treated in wet condition.

There are four departments in wet processing.

1. Pretreatment2. Dyeing3. Printing4. Finishing

PRETREATMENTIt is set of processes where fabric is make ready for dyeing or printing process. The following processes are carried out in predepartment.

SINGEING:

Singeing is a first pretreatment process in which protruding fibers are burn out through flame burning.

DESIZING:

Desizing is second process of pretreatment in which we remove the size material from the fabric. We have to necessary that we remove size material from fabric because it is insoluble in water & the next process of pretreatment and wet processing are useless without desizing.

SCOURING:

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It is process of pretreatment in which we remove oils, waxes, dust, and dirt. This is done in three steps

I. SaponificationII. Emulsification

III. Detergency

BLEACHING:

It is process of pretreatment in which we remove the natural color impurities.

MERCERIZATION:

It is process of pretreatment and used to increase the dye uptake of fabric. In mercerization actually we convert the kidney type structure of cotton fiber in to round or oval type and then it is observed that dye uptakes are increased.

MACHINES USED IN PRETREATMENT:In GTM2 following machines used for pretreatment

1. Menzel Osthof (singeing+desizing)2. Goller osthof (singeing+desizing)3. Goller bleaching (scouring+bleaching)4. J-Box (scouring+ bleaching)5. Goller mercerization (mercerization)

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MENZEL OSTHOF:In GTM 2 there are two Menzel osthof machines are installed

I. Menzel osthof -1II. Menzel osthof -2

In Menzel osthof- 1 local production is carried out while on Menzel osthof-2 imported productions are carried out.

Main machine parts:

1) Scary: It is used to store fabric for continuous production.2) Guide rollers: Used to guide fabric 3) Pre brushing: Used to clean from fluffy and fly 4) Singeing bath

I. It contains 6 burners II. Temperature=400⁰C-800⁰C

III. Speed of fabrics= 80-100IV. Distance b/w burners and fabric=100mmV. Flame intensity = 4mm

VI. Combustion airVII. Exhaust fan (to maintain the temperature of singing unit)

5) Desize bath:I. It contains five rollers for dipping and nipping

II. a) Acid desizing : Solution 4 gm of oxalic acid in 1000ml of water b) Enzymatic desizingc) Cold bleach

III. Temperature of desizing bath= 60⁰CIV. Pick up% =70%

6) Padder: It is used to squeeze the fabric uniformly. 7) Batch: Used to wind the fabric8) Rotator motor: which revolves to batch for required time.

For acid desizing 4 hr. For enzymatic desizing 8-12 hr. For cold bleach 24 hr.

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GOLLER OSTHOFF:It is latest machine in GTM2 manufactured by Germany. All working principle Menzel 1 and Menzel 2 instead of pre dry roller which used pre dry the gray fabric and here two burners are used.

GOLLER BLEACH:In this machine scouring and bleaching is carried out. In GTM 2 it is used for imported production and this is latest machine manufactured by Germany.

Main machine parts:

1. Scary: It is used to store the fabrics for continuous process.

2. Guide/tensioning/stentor roller: It is used to guide the fabric.

3. Washing tank 1: Temperature: 90⁰C-100⁰C

SCOURING:

4. Dipset 1: Continuous showering of solution (Dosing system) 5. Recipe (Tank=300 liters of solution) we made solution according to the basis of GLM

I. Caustic soda NaOHII. Sequesting agent

III. Wetting agentIV. Fresh water

6. Steamer: It is use for specific action of scouring process like saponification, emulsification, detergency (temperature=102⁰C, time= 15 minutes)

7. Washing tank 2: (water only, Temperature=90⁰C-100⁰C)8. Washing tank 3: (Water only, Temperature=90⁰C-100⁰C)

BLEACHING:

9. Dipset 1: Continuous showering of solution (Dosing system)10. Recipe (Tank=300 liters of solution) we made solution according to the basis of GLM

I. Per oxide bleaching agentII. Stabilizer

III. Wetting agentIV. Caustic (40⁰Be)V. Sequesting agent

11. Steamer: It is use for specific action of bleaching process (temperature=102⁰C, time= 30 minutes)

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12. Washing tank 4, 5, 6, 7 : (Temperature=90⁰C-100⁰C)13. Washing tank 8 : (Temp:= room temp:) We add acetic acid to maintain the PH 14. Padder: For squeezing the fabric15. Drying rollers: 14 dryers are used to dry the fabric at 110⁰C-120⁰C temperature16. Batching: Fabric is wound on roller.

J-BOX BLEACHIn GTM2 there are two J-box bleach machines one is working for export quality and other is for local quality working principle and parts are almost same but this is old version machine.

GOLLER MERCERIZATIONIn GTM 2 there are three goller mercerization machines. One is for imported and large width of fabric second is imported but small width and third is for local quality. Mechanism is same throughout machines that is convert kidney shape of cotton structure in to round or oval type structure to increase the dye uptake. Mercerization is an optional process.

Main machines parts

1. Scary: It is used to store the fabrics for continuous process.2. Guide/tensioning/stentor roller: used to guide the fabric.3. Strong lye: It contains strong alkali of sodium hydroxide (100% ⁰Be) the strong lay

contain 60⁰C temperature. The fabric is dipped in lay so as to pick the amount of NaOH with the help of rollers which are responsible to avoid shrinkage.

4. Squeezing rollers: These rollers are used to remove the NaOH from the fabric. These rollers remove about 90% of NaOH from the fabrics

5. Weak lye: Weak lye also responsible for swelling the fabric. Chamber consists of hot water having 98⁰C temperature. In this lye remaining 10% of NaOH is react with water and is removed bit by bit. At least 99% of NaOH is being removed

6. Washing tanks 1, 2, 3 and 4: First four washing tanks having hot water temperature 98⁰C.

7. Washing tank 5: Having hot water and amount of acetic acid for neutralization of fabric. Containing less temperature than first four ones.

8. Drying rollers: Used to dry the fabrics(Temperature 100⁰C-120⁰C)9. Batch: Mercerized fabric is batched.

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DYEING Adding color to textile product such as yarns, fibers, and fabrics is known as dyeing. There are three main types of the dyes are usually used at GTM2

1. Reactive dye:2. Disperse dye:3. Pigment dye:

Dyeing Process:-1. For Cotton:

i. Pad dye chemical padii. Pad dye cure

2. For Polyester Cottoni. Pad dye chemical padii. Pad dye cure

3. For Polyester Cotton & Cottoni. Pad dye chemical pad

Recipe used in dyeing

1. For pad dye chemical pad: Reactive dye/ disperse dye/pigment dye Anti migrating agent Wetting agent Anti flow

2. For pad dye cure: Reactive dye/ disperse dye/pigment dye Wetting agent Anti migrating agent Urea Soda ash

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MACHINES

There are four machines are used in GTM-2

1. Thermosol dyeing machine2. Pad steam machine3. Bab cock dyeing machine4. Kusters dye pad

Thermosol Dyeing Machine:This machine is also known as universal dyeing machine because almost all types of dyeing can be processed. In GTM-2, mostly reactive dyeing is processed in this machine. Here we can achieve two processes:

I. Pad dry II. Pad dry cure

Machine parts:

I. Unwinding roller: These rollers are used unwind the fabric.II. Scary: it is used to store extra fabric length for continuous process.

III. Guide rollers: These rollers are used to guide the fabric.IV. Tensioning rollers: These rollers are used to give the proper tension to fabric.V. Trough: It is the bath in which chemical recipe is putted and fabric dipped as to

get the chemical recipe. Max: 40-50 liters can be stored on trough.VI. Padding roller: These rollers are used to squeezing the fabric.

VII. IR Zone: it is heating zone in which fabric is passed to dry (Temp: 450⁰C-700⁰C)VIII. Drying chambers: The drying chambers are used to dry the fabric. There are five

drying chambers in this machine(Temperature 120⁰C to 200⁰CIX. Batch: Finally yarn is wound on the roller called batch.

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Pad Steam machine: In GTM-2, Pad steam machine is used for two purposes:

I. Fixation of reactive dyeing.II. Disperse dyeing

Machine parts:

i. Unwind roller: It is used to unwind the fabric.ii. Scary: It is used to store the fabric for continuous process

iii. Trough: It is a bath in which required chemical recipe is putted and maximum 40-50 liter

iv. Padding rollers: It is used to squeezing the fabric.v. Steamer: It is used for moisture absorbance. The fabric is stayed in the steamer for

30 seconds at 102C.vi. Washing machine: Washing is the process in which un fixed dyes are removed. Hot

water and detergent are used as washing substance and acetic acid is used to control pH of the fabric.

vii. Drying roller: These rollers are used to dry the fabric. There are 24 drying roller. The temp: of these roller is usually 100C.

viii. Cooling roller: These rollers are used to cool the fabric.ix. Batch: Finally fabric is wound on batch.

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Bab Cock Machine: It is a dyeing machine where we mostly pigment dyeing is processed.

Machine parts:

I. Unwinding roller: It is used for unwind the fabric.II. Scary: It is used to store the fabric for continuous process

III. Trough: It is a bath in which required chemical recipe is putted and maximum 40-50 literIV. Recipe:

a) Pigment dye. Xg/lb) Anti migrating agent: 5- 20g/lc) Antifoaming agent: 1-2g/ld) Binder: 5-50g/le) Wetting agent: 1-2g/l

V. Padding rollers: It is used for squeezing the fabric.VI. IR Zone: it is heating zone in which fabric is passed to dry (Temp: 450⁰C-700⁰C)

VII. Bianco: It is special mechanism in which we parallelize warp and weft yarns of the fabrics.

VIII. Chain: It is used to make fabric in open width form and clips are used to held the fabric width

IX. Dry & Curing chamber: It is used for dry the fabric. a) 4 drying and 2 curing chambers. b) Temp: 120⁰C for drying and 200⁰C for curing chambers.

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X. Batch: It is used for wind the fabric.

Kusters Dye Pad: It is dyeing machine where pad batch method is achieved.

Machine parts:

I. Unwinding roller: It is used to un wind the fabric.II. Guide & tensioning roller:

III. Trough: It is a bath in which required chemical recipe is putted and maximum 40-50 literIV. Padding roller: It is used for squeeze the fabricV. Batch: It is used for wind the fabric.

VI. Rotating time: 24 hours

PRINTING Coloration of fabrics on a pre determined area of the fabric OR Technical dyeing on the pre decided area of the fabrics is called printing.

TYPES OF PRINTING:

1. Pigment dyeing (paste form)2. Reactive dyeing (powder form)

SEPERATING DEPARTMENT

Separating department separates the colors which are made on the sample of papers, piece of fabric, in CD drive.

ENGRAVING DEPARTMENT

This department makes the sheets for printing.

There are two types of engraving

1. Rotary engraving2. Flat engraving

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1. ROTARY ENGRAVING: Engraving means espousing of design on the screen. These screens are made of nickel. And coated with chemical SCR 101, 102, 103. Two machines for rotary engraving are installed in GTM 2

I. Bestlene machine(Leaser exposing made up of Austria) II. Lex machine(made up of stork company)

2. FLAT ENGRAVING: Espousing of design on the flat screen. These screens are made of nylon. Two machines for flat engraving.

I. Inkjet machineII. LED machine

MACHINES USED FOR ROTARY PRINTING:

1. KDM(sampling machine used 1 or 2 colors only)2. RD5(1-16 colors )3. Reggiani(1-18 colors)

Main parts of rotary machines:

I. Scary: It is used to store the fabric for continuous process.II. Guide, tensioning and compel setter roller: Used to guide

III. Pre brushing: It is used to remove the dust, dirt.IV. Gluing device: It is used to give uniformly glue to whole blanket for fixation of fabrics

with blanketV. Pressing roller: It is used to press the fabrics with blanket

VI. Blanket: It is like a conveyer belt which transfer the fabric through screensVII. Dry chambers: It is used to dry the fabric.

VIII. Batch: It is wind the printed fabrics.

NOTE: This fabric is then treated in steamer curing or curing machine for proper fixation of printing.

MACHINES USED FOR FLATE PRINTING:

1. Sampling machines(Used for sampling)2. Ichinose machine(1-10 color)3. Buser(1-14 color)

NOTE: Al most machine parts are same like rotary printing machines but here we use flat screens.

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FINISHING

Finishing department is the last department of wet processing. Here we give additional application to get more quality able fabric like here we increase the softness; shines luster absorbency and lot of more qualities of the fabric

The fabric treated here mainly two purposes

1. Equalizing 2. Finishing

1 Equalizing:

Equalizing is the process in which we parallelize the warp and weft yarn of the fabric. This process is mainly done after bleaching and mercerization. In this process no recipe is needed, just treated with water in trough and pass through machines parameters of finishing department.

2 Finishing:

Finishing is the process in which we give additional properties on to the fabric this is done after dyeing or printing of fabric. In this process we need proper recipe

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for making finished fabric. Recipe is depend on endure quality and customer requirements. Mainly finished goods contain more softness luster shines easy handling.

Recipe used in GTM 2. For imported material:

MW --------------------------------------------------- Softener

WRN -------------------------------------------------- Softener

1112 -------------------------------------------------- Softener

RTG --------------------------------------------------- Color fixation

SM ---------------------------------------------------- Softener

Acetic acid ------------------------------------------ PH controller

Como binder --------------------------------------- Strength GSM increase

Serniel ----------------------------------------------- Softener

For local

MGP-------------------------------------------------- For Stiffness

Lumen------------------------------------------------ Shinning

SM, MW, WRN------------------------------------- Softener

Binder------------------------------------------------ Strength

Types of Finishing

There are two types used to make finished fabric

1 Chemical

2 Mechanical

CHEMICAL METHOD:

For chemical method gul Ahmed use following machines.

1 Monfort stentor

2 Tung yung stentor

3 krantz stentor

4 Tung yung 5

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5 Tung yung 3

6 Krantz stentor 2800

Main parts of machine:

I. Scary: Scary is used to store extra fabric length as to connect new batchII. Composter: It maintains the fabric speed and gives proper tension

III. Trough: It is a box in which required chemical recipe is putted maximum 40-50 literIV. Padding: This is used to squeeze the fabric and to make even chemical pickup%

throughout fabric.V. Bianco: Bianco is a mechanism which parallelize the fabric warp and weft yarn. Bianco is

basically set of rollers. VI. Chain: It is used to make fabric in open width form and clips are used to held the fabric

widthVII. Heating chamber: It is specially mechanism in which fabric is to dried at 120C-200C

temperatureVIII. Cooling roller: It is two heavy steel drum which is used to cool down the dry fabric

IX. Batch: To wound in proper way

MECHANICAL METHOD:

In GTM2 two machines are used for mechanical finishing for mechanical method a especially setup is installed throughout machine in which we get finishing on fabric through machines parts. Through this we get softness shinning on to the fabric

1. sanfriz 2. calendar roller machine

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