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Singeing
Desizing and Scouring
Bleaching
Mercerizing
Dyeing
Flat Bed Printing Range
Rotary Printing Range
Print Dryer
Print Steamer (Loop ager)
Soaper and Dryer
Stenter
Calendaring
Checking and Folding
 
Conceptualization and Development of Design
Sampling
 
Grey inspection and checking
 
Quality control and tests at each stage at the manufacturing process
 
PRODUCTION PROCESS:
A flow chart of the production process is as under:
 
 
The manufacturing process as stated here in the above diagram is enumerated as under :-
 
Singeing
Singeing is a process in which all sorts of surface fibers are removed. It is basically a preparatory machine. All the grey cloth requires Singeing and Scouring before being sent for further processing. For the Proposed Manufacturing Facility in the Proposed Textile SEZ the fabric requirement is expected to be 1.00 lac meters per day. The total requirement for existing Units and the Proposed Manufacturing Facility would be around 4 Lac meters per day.
 
Desizing and Scouring
Desizing process involves removing the additives used during weaving. Sizing additives take many forms. Starch and wax with water soluble modified starches, PVA, acrylics and sometimes mixture of any or all are used. These must be removed, therefore, desizing is an essential step in fabric preparation. Scouring is a process where oil, grease, fat, waxes and brushing cotton seeds are removed from the grey cloth.
 
Bleaching
Bleaching is a process which increases absorbency of the cloth, and reflectance for pale dye shades. This is one of the essential processes involved in manufacturing of our products.
 
Mercerizing
Mercerizing increases luster, strength, dye affinity and dimensional stability.
 
Dyeing
The dying unit comprises of the pad/dry, infra-red pre drying, Thermosol, cooling, chemical padder, steamer, wash oxidised, soap and rinse, final dying, batch and fold.
 
Flat Bed Printing Range
Flat bed printing range suitable to print upto 2000 mm wide fabric with 8 to 12 colour printing is used.
 
Rotary Printing Range
Stork/Ichinos printing range suitable to print 2000 mm wide fabric with 8 to12 colour printing in 640mm repeat in one single colour is used for finer printing.
 
Print Dryer
The Rotary screen-printing machine is connected to dryer in continuous manner so that wet cloth is immediately dried after printing. This is important for the reason that if wet cloth is stored after printing then designs /colors get tampered/damaged. Drying is done by either using steam or heated thermic oil by means of heat exchangers located near fans of dryer.
 
Print Steamer (Loop ager)
After printing, colors are to be fixed on fabric, which is done by using saturated steam.
 
Soaper and Dryer
Loose colour remaining on fabrics after printing has to be washed out to achieve fastness properties and proper brilliance of prints, which is done by soaping the cloth, and then it is washed and dried in continuous machine.
 
Stenter
Stenter is a finishing machine which dries up the cloth and removes the dimensional instability that occurs during the processing. The final finishing of fabric is always done on a Stenter. The Stenters are normally provided with a padder, a bow and a weft straightener device. The cloth to be finished passes through the padder, where finishing chemicals are added and goes through bow and weft correction device before entering the drying chamber. It can be either pad or dip stenter. The pair chains hold the cloth horizontally. The process is pad-dry and drying is achieved by blowing hot air in the stenter chamber. The stenter is the most important machine in the finishing.
 
Calendaring
Calendaring is a process of drying and giving the finishing effect. While calendaring some of the additives are added for giving more value addition such as enzyme wash to the cloth. All the lab tests used after the Stenter are being used after calendaring. Few more tests are conducted as per the customer demand in the lab after finishing operation is completed. These are, oil repellency, soil release, water repellency, water resistance, wrinkle recovery, formaldehyde, durable press test.
 
Checking and Folding
Once the process is complete with the desired result, the entire fabric is checked before the folding. The folding of the cloth, in small batches is prepared prior to transferring it to stitching section. The automatic folding machines are used for this purpose.
 
Conceptualization and Development of Design
There is a continuous process of conceptualization and development of design in the Fashion market as per the liking and changing trends of the user’s habits. Our design team continuously works to make innovative designs. This process is undertaken with tastes, trends, regions and habits of the target customers.Our Company is well equipped with an in-house design studio to prepare innovative designs for our customers. Our team of designers and marketing personnel gather designs from international brands and trendsetters, magazines, latest fashion houses. After receiving the designs necessary changes/upgradations are made in our design studio and sent back with the fabric sample. The manufacturing of the product commences once the sample fabric is approved and confirmed order is received.
 
Sampling
Sampling is done by way of procuring small quantities of grey fabric of requisite quality and getting the design printed on it. Once a design/pattern is approved and interest is shown by the customers, the price negotiation, quantities, delivery schedules, terms of payment are decided and a purchase order confirmation is obtained from the customer.
 
Grey inspection and checking
Every supply of grey cloth needs a thorough check for quality of the material. The following procedure is followed by us for checking of grey material:-
 
Checking of damage made during the transit
Checking of quantity supplied
Checking of count, reed and pick
Checking of GSM of the cloth
Checking of width of the grey
Checking of knots in every meter of grey
Checking of any deformity of construction of grey
Checking of any unusual cuts in the cloth
 
After conducting all the aforementioned tests, the full and final payment to the vendor is released. These checks are essential before further processing of the grey cloth.
 
Quality control and tests at each stage at the manufacturing process:
After passing through the Singeing and Scouring process, the fabric undergoes the pilling test to determine the pilling and fuzzing characteristics of the fabric. Thereafter another test is conducted to determine the abrasion and pilling resistance of the fabric. If the sample fails this test as per specifications provided by the buyer then the grey cloth is sent back for Singeing.

De-sizing is the next step after which the TEGAWA test is conducted in a lab to check the presence of starch and other substances in the grey cloth and in the event the material fails this test then it is required to undergo the process of De-sizing.

The absorbency test, whiteness test and ph testing are carried out in the lab after completion of the processes of bleaching, washing and drying.

Subsequent to the Mercerizing process the fabric undergoes ph testing and TWEDDEL and Barium tests to check the concentration of caustic in the fabric. The operation is repeated in case the fabric fails the tests.
Post completion of the dyeing process, a number of tests are carried out to test the colour matching of the sample as per the buyer’s demand and colour fastening of the cloth. The dyeing process has to be repeated in the event the fabric fails these tests.

After completion of printing on the fabric, the tests relating to colour matching and fastening are carried out once again.
Once the Stenting process is completed, lab tests are conducted for carrying out the shrinkage tests, tensile strengths and tear strengths of the fabric.
 
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