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  1. 1. Raymonda complete man Presented By Naushad Alam Rishabh Kumar Vikas Anand Kumar
  2. 2. RAYMOND  Raymond industries was established in 1925 by jugilal singhania.  Raymond ltd. Chhindwara is under the flagship of J.K. group (worsted division). They produce high quality, up market fabric in P/W & P/V blend. Raymond Chhindwara.  Output - 45000 mtrs. Fabric/ day  Unit’s turnover - Rs. 750 crores (approx.)  Area of the plot - 100 acres  Man power - Management/ officers- 469  - Workers- 2463
  3. 3. RAW MATERIAL GOWDOWN  Raw material godown is the primary and obviously integral part of any mill. It functions to receive raw material from outside and other departments and deliver the same to the respective department as per the requirement of raw material. It is also dispatches raw materials to outside branch such as Raymond Jalgaon. Function  The main function of R.M.G is to keep perfect record and also the stock of required raw material.  Receive the fresh goods or material from concerned department. Dispatch it according to requirement of the department.  Receive the waste and store according to category and pack also.
  4. 4. There are three sections in this department:  Raw Material godown  Top godown  Waste godown
  5. 5. Process flow chart Received Raw Material Allotment Of Lot Numbers Stacking - Bins/Blocks Samples Sent To The Laboratory To Verify Quality According To Specifications based on requisition sent to same {Scouring, Convertor, Combing And Dyeing} And Send To Same Received By Top Godown According To Requisition, Sent To Dyeing/ Recombing
  6. 6. GREY COMBING SECTIONCARDING MACHINE  Carding is the process to remove the small particles, short fibres, naps, etc form the material for obtaining good quality of yarn.  In this dept. procures the raw material from the RMG dept.  Grey combing is done for grey fibre prior to dyeing. Objective of carding machine  Individualization of fibre.  Removal of trash and dust.  Removal of short fibre and nap.
  7. 7. Gilling machine Types of gill boxes  Open gill box (single fallers)  Intersecting gill box (multiple fallers) Objective of gilling m/c  Parallelization of fibres.  Reduction in weight per unit length of sliver.  To prepare a sliver of required wrapping for further processing.  To lay the sliver into can.
  8. 8. Gilling machine Name of manufacture - N.S.C Input - Carding sliver Output - wool tow Production - 180-240 Kgs/hr Doublings - 8-10 Defects in gilling  Inadequate pressure on roller  Broken pins or improper density  Improper feelers  Improper Gilling
  9. 9. COMBING The main objective of combing is the removal of the shorter fibres called the noils. This process is continued in the ‘combing’ operation. Objective of combing m/c  To remove short fibres form the material  To remove all vegetable matter  To straighten and parallelize the fibre  To remove the neps  To lay the sliver into cans
  10. 10. Polyester converter section  Filament is fed to a converter and is cut into staple form as per requirement of wool fiber length.  After converter, three passages of Gilling are given for doubling and drafting, then making slivers more parallel and even. Objective of the polyester converter machine  Convert filament to staple fibre.  converts staple fibre according to wool fibre length.  Parallelization the fibre.
  11. 11. Manufacturer - N.S.C Model no - GC 14/TT11. Material - 100 % polyester Input - filament polyester Output - polyester top Denier use - 1.5d, 2d, 2.5d, 3d Staple length of fibre - 75-85mm Can content - 1200m
  12. 12. DYEING Dyeing is the process where the textile material is dyed with the use of different dyes to give that particular colour and shade for the good appearance of that material. The dyeing department is to deliver dyed fiber to recombining department, P/V department, mending department or finishing department in required shade at required time. Various type blend dyeing done here  Polyester/wool blend  Polyester/viscose blend  All wool
  13. 13. DYEING In requirement there are many type of product dyeing done here. Fiber dyeing  The bale comes from the RMG department.  Fiber and compressed with the stamping machine by applying the water.  Dye solution and other required chemical come in to the m/c automatic.  After this material goes to RF dryer for 100% drying.  Dried materials are going to P/V spinning department for further processing.
  14. 14. DYEING Top dyeing  Tops come from the grey combing  Loaded in to vertical HTHP dyeing machine  Required chemical come into the m/c automatically after giving instruction from the controller room.  Dyeing and the other treatment period depends upon the shade or light shade.  Wool dyeing they are use metal component and acid dye.  Polyester they are using disperse dye.  After complete the process method comes out and goes hydro extractor for dyeing.  The material goes to RF dryer for 100% drying  Average approx 1760 shade(TOP dyeing)  Light shade 4 hours  Medium shade 4.5 hours
  15. 15. DYEING Yarn dyeing  Cheese dyeing they are making special type of package in the winding section  Package due to the better penetration of the dye solution.  Density is 0.35-0.75 gm/cc  Feed to the vertical dyeing machine  completion of dyeing process the material comes out and goes to cheese hydro extractor for dyeing. After this material goes to RF dryer for 100% dying .These dried material are going to warping section future processing
  16. 16. DYEING Piece dying / fabric dyeing  The fabric is concerned the dyeing process is carried out either by one bath process or by two bath process.  Wool/viscose component is dyed in the jigger dyeing m/c.  Polyester fabric dye in , jet dyeing, HTHP dyeing machine.  The dyeing of polyester material is done on the basis of the HTHP dyeing method,  Rope wise dyeing,  After dyeing rope opener machine use to open width the fabric.  Dried in the stanter machine.  Dyeing of pet is done at 1300 c wool at 900 c and viscose at 600 c to 70.  Different type of dye are use  Disperse dye.  Vat dye  Reactive dye etc
  17. 17. Use of Chemical in Dyeing Lyogen DFT - Levelling agent Bileaux T - Dispersing Agent Solidogen FRI - Dye fixing agent Lycol WPN - Levelling Agent of wool Dilation POE- Carrier Lanasyn P - Wool protecting agent Belfasin GT - Antistatic of yarn Caustic soda - Washing of polyester Formic Acid - To maintain pH as add acid Sandogen PESI - Levelling agent polyester
  18. 18. RECOMBING
  19. 19. RECOMBING  The recombining department delivers tops to P/V and Worsted spinning departments in full quantity at required time. The minimum cost meeting all quantity parameters. The department is responsible for the conversion of the dyed and grey tops to recombed tops. Objective Of The Department  Blending of the fibre like Wool viscose, polyester, Lenin silk, etc.  Removal of short fibre and undesired element like slubs, neps, and pin point.  Removal of entanglement at the time of dyeing.
  20. 20. Process Flow Chart Source Of Raw Material - Dyeing Length Wise Defelter Blending Defelter Pre-combing Gilling - 1 Pre-combing Gilling - 2 Pre-combing Gilling - 3 Combing Post Combing Gilling - 1 Post Combing Gilling - 2 Bump Press Deliver To Spinning
  21. 21. SPINNING
  22. 22. SPINNING ROVING  This is the final stage before spinning.  Roving is actually a light twisting operation to hold the thin slubbers intact. Objectives of roving  To produce wrapping (wt/unit length) as per requirement.  To produce a package suitable for subsequent machine.  To make uniform length in each package as per requirement of next machine for proper run-out.  It removes unevenness of yarn for further process.
  23. 23. SPINNING Ring Frame Ring spinning is a method of spinning fibre to make a yarn. Ring spinning is a continuous process . In ring spinning, the roving is first attenuaed by using drawing rollers, then spun and wound around a rotating spindle which in its turn is contained with in an independently ring flyer. Objectives of ring frame  To produce single yarn of required twist and count as per the instruction from ppo.  To produce good quality of yarn  To make ring cops means of building mechanism.  The rubbing and roving frame bobbins are brought to ring frame dept the roving is converted into yarn by drafting and twisting.  All the three types of yarn made in ring frame. ex:- Normal Yarn, Sarrow Yarn , Sarrow Lycra Yarn
  24. 24. SPINNING Factors for promoting good spinning  Count of yarn.  Position of spindle rate.  Correct type travellers.  Satisfactory spindle speed.
  25. 25. AUTO WINDING SECTION Objective of auto winding  Removal of objectionable yarn faults such as thick, thin place and neps, to improve the yarn quality and subsequently reduce yarn breakage in further processing.  Rewinding of ring frame cops to a larger package, which is useful for further processing.  Auto-leveller sensor is attached which removes the shorts term variation and medium term variation  Online sensor passed through which gives signal for removal of fault in the yarn
  26. 26. Doubling section  Ply winding:- Assembly of two yarns are wound parallel as per requirement such as solid to make the feed package for TFO machine.  Two for one twister:-To insert the required twist in required direction (s/z).
  27. 27. WEAVING  Weaving is the term used in relation to produce fabric by interlacing two different series of yarns known as warp and weft. Warp ends are placed longitudinal where as weft are horizontally placed. Weaving process is commenced by dividing warp into two different sheets in opposite direction and then inserting weft into the shed. By interlacing it into the shed fabric is produced.  There are total 112 looms, which includes 34 Picanol Gamma, 56 Nuovo Pignone (NP) and 22 Picanol Gammax looms.  The total output of this department is 23000 meters per day.  The machines are running with speed of in between 450-530 rpm.
  28. 28. Weaving section is divided into two sections.  Warping  Weaving Warping: The yarns which are coming from double yarn room are going for winding for preparing required amount of package. Three primary process of weaving.  Shedding- The process of separating the warp yarn into two layers by raising the harness to form an open area between two sets of warps and known as shed.  Picking- The process of inserting the filling yarn through the shed by the means of the shuttle less while the shed is opening.  Beating- The process of pushing the filling yarn into the already woven fabric at a point known as the fell and done by the reed.
  29. 29. Rapier loom  In Rapier looms, the weft insertion element resembles a rapier or a thin bladed straight sword, hence the name Rapier Weaving. There are many varieties of Rapier systems such as single, double, flexible, rigid, and two phased. A Rapier in its simplest form consists of a single rigid bar, solid and a damp device called gripper head screwed at its feed end.  Manufacture name - Picanol Gamma, Picanol Gammax looms Nuovo Pignone (NP)  No. Of machine - 112  Input type - yarn  Output type - fabric
  30. 30. Defects during weaving
  31. 31. FINISHING DEPT.  Finishing department is the place where final treatment is done to the fabric.  It includes washing, drying and application of some chemical and mechanical treatment to the fabric to make it aesthetically appealing and add features to the fabric.  The finishing dept. at Raymond Chhindwara has three sections, i.e. , grey room, wet section and dry section.  Finishing dept. at Raymond Chhindwara is equipped with modern machinery for washing, scouring, singeing, pressing etc.
  32. 32. Flow chart
  33. 33. The processes carried out in finishing dept are :  Mending: To remove defects like knots formed during weaving.  Batching: shortening each beam of fabric according to shades.  Singeing: The fabric is exposed to flames and made to pass through it.  Pre scouring: Extraction of dust and other particles.  Drying: Fabric is dried in a chamber of temp 170*C.  Heat set: Fabric is passed through a heated chamber of temp 185-190*C.  Rope scouring: Scouring is done in rope form.  Softening: To remove the harshness of fabric by adding softeners like silicon in the solution.  Pressing: It is done to remove wrinkles and make the fabric smoother.  Decatising: To remove excess of lustre and prepare the fabric for pressing and cutting.
  34. 34. For white material:
  35. 35. Machine description of finishing dept