SUMMER INTERNSHIP PROJECT REPORT

On

"To Study The Different Production Process of Textile Industry"

at

"Morarjee Textile,Nagpur"
By
"Amit Rewatkar"

Under the guidance of

"Dr.Punam Kumar Hinge"

Submitted to

"Savitribai Phule Pune University"

In partial fulfillment of the requirement for the award of the degree of
Master of Business Administration (MBA)
2018-19

Suryadatta Education Foundation’s

Suryadatta Institute of Business Management
Pune- 411021
 Declaration

I, the undersigned Amit Rewatkar , declare that the Project Report title as,

“To Study the production process and production system”, submitted by me for partial

fulfillment of Master of Business Administration (M.B.A. in Operation ) is the original record

of the project work carried out by me during the period from 25 July 2018 to 25 Aug 2018 ,

under the guidance of Dr.Punamkumar Hinge internal guide and the same has not formed the

basis for the award of any degree, diploma, association, fellowship, titles – in or for any other

Statutory University or Autonomous Institutions functioning in India or abroad imparting higher

education in Management.

DATE Amit Rewatkar

Place MBA III SEMESTER
Roll no.
 Acknowledgements

At the start, I would like to express my sincere gratitude to Dr.Punamkumar Hinge my project
guide from SIBMT, Pune – 411021 for successful completion of a project in partial fulfillment
of Master of Business Administration (M.B.A.) under his able guidance to allow me to work on
such an interesting subject. He provided me proper and correct direction for completion of
project work. His continuous guidance during the course of project helped me in channelizing
my efforts, quite appropriately.

I am also thankful to Shewta Bodkhe , Morarjee Textile , for guidance given and cooperation
extended for carrying out the project.

I am also thankful to all the respondents and friends who have helped me to conclude the
contents of the project in decent and presentable manner.

Date: _________ Amit Rewatkar

Place: Pune. MBA, Semester III
Roll No. _______
 Index

Sr.no Chapter Page no.

Executive Summary
Introduction
Literature Review
Industry & Company Profile

Research Methodology

Data Analysis & Findings

Conclusions
Recommendations & Suggestions

Limitations of the study & Scope for further research

ANNEXURES
Executive summary

This study presents an interactive model based system for the management of production in textile production
systems focusing on the process. Because of the special characteristics of the industry, that is mainly the multi
process with multiple units per phase, different planning horizons and different production requirements for
each phase, the scheduling of these systems becomes quite complex. Apart from a comprehensive presentation
of the set of production system is composed of many operations together with their interrelationships, the
capacity, workforce, quality of product characteristics and analyzed, and their impact on the production control
system is explained. The system is also related to two well-known production control systems, and Optimized
Production Technology. The system’s attributes are presented with the aid of data structure diagrams, while the
complete algorithm concerning the module, in a pseudo-code form, and the corresponding part of the database
are illustrated in the Appendix.
 CHAPTER 1
Introduction

The Indian textile industry is one of the oldest industries in the country and displays a very complex sector
dispersal matrix with hand-spun and hand-woven sector on one end of the spectrum and the capital-intensive
sophisticated mill sector at the other, with the decentralized power loom and knitting sectors coming in between.
Even in the organized sector, “island of excellence” exist, using highly sophisticated information technology
based equipment with facilities for ERP/SAP which are second to none in the world.

The fibre specific configuration of the textile industry includes almost all types of textile fibres from natural
fibres like cotton, jute, silk and wool to synthetic/man-made fibres like polyester, viscose, nylon, acrylic,
polypropylene and the multiple blends of such fibres and filament yarns.

The diverse structure of the industry coupled with its close linkage with our ancient culture and tradition
provides it with the unique capacity to produce, with the help of latest technological inputs and design
capability, a wide variety of products suitable to the varying consumer tastes and preferences, both within the
country and overseas.

It is perhaps the only industry in the Indian industrial arena which is self reliant and complete in value chain, i.e.
from raw material to the highest value added products, i.e. garments/made-ups.

Textile industry is one of the few basic industries, which is characterised as a necessary component of
human life. One may classify it as a more glamorous industry, but whatever it is, it provides with the basic
requirement called clothes. There are numerous kinds of fibres and other raw materials, which are used to
produce a cloth. This paper provides an insight about the basics of textiles and the terms that are used all around
the world in context of textile industry. Regarding study of textile fabrics, meaning of the word textile must be
made quite clear. The dictionary states that the word is derived from the Latin word texerel to weave, but a
wider meaning of weaving must be accepted since it is one of the various ways to produce textile fabrics. The
initial stage of textile manufacturing involves the production of the raw material either by farmers who raise
cotton, sheep,silkworms, or flax or by chemists who produce fibre from various basic substances by chemical
processes. The fibre is spun into yarn, which is then converted into fabric in a weaving or knitting mill. After
dyeing and finishing, the woven material is ready for delivery either directly to manufacturer of textile products
where they are finally stitched into clothes.

Objective of study

 To analysis about operation management in textile industry.

 To study about production process functions in textile industry.

Scope of study

 It helps us to understand the production process of textile industry.

 It help us to know the what technology textile industry using
 CHAPTER 2

Literature Review

 Substantial Contributions to the Economy

The Indian textile industry has a significant presence in the Indian economy as well as in the international textile
economy. Its contribution to the Indian economy is manifested in terms of its contribution to the industrial
production, employment generation and foreign exchange earnings.

The Textile Sector contributes:

 About 4 percent to the gross domestic product;

 About 14 percent of the total industrial output;
 26 percent to the manufacturing sector;
 21 percent of the work force ;

About 17 percent of the gross export earnings.

It provides direct employment to about 35 million persons including substantial segments of disadvantaged
sections0. of the society and women. Besides, another 50 million people are engaged in allied and ancillary
activities. The industry has been growing at a steady rate of 9-10 percent. In the post quota period, the industry
size has expanded from US$ 37 billion in 2012-15 to US$ 49 billion in 2015-18. In this period, while the
domestic market increased from US$ 23 billion to US$ 30 billion, exports increased from around US$ 14 billion
to US$ 19 billion. Being one of the largest of its kind in the world, the Indian textiles industry has inherent
strengths that have the potential to increase its share substantially in the global trade of textiles and clothing.
Strengths of the Indian Textile sector

 Second largest producer of raw cotton

 Second largest producer of cotton yarn
 Second largest producer of cellulose fibre / yarn
 Second largest producer of silk
 Fourth largest producer of synthetic fibre / yarn
 Largest producer of jute
 Accounts for 61 percent of global loomage
 Accounts for 22 per cent of the global spindles
 Has 25 percent share in the total world trade in cotton yarn

India is one of the few countries that encompass the entire supply chain in close proximity, from diverse fibres
to a large market. It is capable of delivering packaged products to customers comprising a variety of fibres,
diverse count sizes, cloth of different weight and weave, and variety of finishes. One unique feature is of its
being extremely varied, with the hand-spun and hand-woven sector at one end of the spectrum, and the capital
intensive, sophisticated mill sector at the other. The decentralized hand looms / hosiery and knitting sectors
form the largest section of the textiles sector. The close linkage of the textile industry to agriculture and the
ancient culture and traditions of the country make the Indian textiles sector unique when compared to the
textiles industry of other countries.
Major Sectors of the Textiles Industry

1. Organized Cotton / Man-made Fibre Textiles Mill Industry: It is the largest manufacturing industry in
the country in terms of employment with nearly 1 million workers and number of units. There are more
than 1818 cotton / man-made fibre textiles mills (non-Small Scale Industry), with an installed capacity
of 35.37 million spindles and 0.45 million rotors. The production of spun yarn stood at 3791 million kg
during 2016-17.
2. Man-made Fibre / Filament Yarn Industry: The industry comprises fibre and filament yarn
manufacturing units of cellulose and non-cellulose origin. The total man-made fibre production from
April-August 2016, increased by 16 percent, as compared to the corresponding period of the previous
year. The total production of man-made filament yarn increased by 11 percent during 2016-17.
3. Decentralized Power-looms Sector: The decentralized power-looms sector plays a pivotal role in
meeting the clothing needs of the country. The power-looms industry produces a wide variety of cloth,
both grays as well as processed. There are over 1.95 million power-looms in the country that provide
employment to nearly 4.86 million workers.
 Chapter 3
Industry

The textile industry is primarily concerned with the design, production and distribution
of yarn, cloth and clothing. The raw material may be natural or synthetic using products of the chemical
industry. Cotton is the world's most important natural fibre. In the year 2007, the global yield was 25 million tons from 35
million hectares cultivated in more than 50 countries. There are five stages:

 Cultivating and Harvesting

 Preparatory Processes
 Spinning — giving yarn
 Weaving — giving fabrics
 Finishing — giving textiles

Export market share

 The worldwide market for textiles and apparel exports in 2013 according to United Nations Commodity Trade Statistics
Database stood at $772 billion.

 The largest exporters of textiles in 2013 were China ($274 billion), India ($40 billion), Italy ($36
billion), Germany ($35 billion), Bangladesh ($28 billion) and Pakistan ($27 Billion).

 In 2016, the largest apparel exporting nations were China ($161 billion), Bangladesh ($28 billion), Vietnam ($25
billion), India ($18 billion), Hong Kong ($16 billion), Turkey ($15 billion) and Indonesia ($7 billion)

Textile Industry In India

The textile industry in India traditionally, after agriculture, is the only industry that has generated huge
employment for both skilled and unskilled labour in textiles. The textile industry continues to be the second-largest
employment generating sector in India. It offers direct employment to over 35 million in the country. The share of
textiles in total exports was 11.04% during April–July 2010, as per the Ministry of Textiles. During 2009–2010, the
Indian textile industry was pegged at US$55 billion, 64% of which services domestic demand. In 2010, there were
2,500 textile weaving factories and 4,135 textile finishing factories in all of India. According to AT Kearney’s ‘Retail
Apparel Index’, India was ranked as the fourth most promising market for apparel retailers in 2009.

India is first in global jute production and shares 63% of the global textile and garment market. India is
second in global textile manufacturing and also second in silk and cotton production. 100% FDI is allowed via
automatic route in textile sector. Rieter, Trutzschler, Saurer, Soktas, Zambiati, Bilsar, Monti, CMT, E-
land, Nisshinbo, Marks & Spencer, Zara, Promod, Benetton, and Levi’s are some of the foreign textile companies
invested or working in India
 India exports yarn to Japan, United States, United Kingdom, Russia, France, Nepal, Singapore, Sri Lanka and other
countries. India has the second-largest installed capacity of spindles in the world, with 43.13 million spindles (30 March
2011)after China. Although India has a large share in world trade of cotton yarn, its trade in garments is only 4% of the world's
total.

Top five exporters of textiles—2013

($ billion)

China 274

India 40

Italy 36

Germany 35

Bangladesh 28
 Industry and Company Profile

Name of the Company – Morarjee Textile

Address –Plot G1-G2, MIDC Industrial Area post Salaidhaba

Via Hingna, Butibori Nagpur-441122 (India)

www.morarjee.com

Head Office: Mumbai

Owner of the Mill – Mrs.Urvi Piramal

Vice chairperson –Mr Harsh Piramal

Managing Director – Mr. R.K Rewari

Year of establishment: Unit -1 (1995)

Unit -2 (2003)

Unit -3 (2016)

Achievements- ISO 9001-2004 & ISO 14001-2008

Product Range – 100% Cotton, Voile Fabric, Viscose and Shirting

Power Consumption -66000 watts/day

Water consumption -1500-1700 m3/day

Vision
Enriching the lives of communities by empowering them to develop and execute sustainable social development
models.
Mission
To operate in the best interests of the community
Core Values
We abide by these enduring values that are the foundation of our business and at the heart of all we do each day.
Customer focus
We listen to our customers.
We are committed to delivering real value.
We take ownership of a customer’s problem until it is solved.
Integrity
We hold ourselves and those we work with to the highest ethical standards.
We are honest with each other and constructively give and willingly accept candid feedback.
We build relationships of trust so we can share and accept the truth, even when it is hard to say or hear. We do
the right things even when no one is watching.
Teamwork
We respect each other and value their ideas and points of view.
We work together and support each other to achieve our goals.
We incorporate fun with hard work.
We have a passion for winning.
We all play an important role.
We are one Enterprise. There is no “they” or “I”.
Accountability
We take ownership of results delivered in our area of work.
We are responsible for and committed to our own personal growth and development.
We work through challenges and obstacles to achieve a successful outcome
 RESEARCH METHDOLOGY

DATA COLLECTION METH ODS

The data has been gathered through interaction and discussions with the executives working
in the division. Some important information has been gathered through couple of
unstructured interviews of executive. Annual reports and other magazines published by the
company are used for collecting the required information.

PRIMARY DATA

The primary data of m y project is collected from all department of textile industry. In the

textile industry the main work is done by the textile manufacturing and export procedures

and all the operations in textile industry. The data collected by interview, survey, discussion

with Supervisor and Operator.

SECONDARY DATA

The secondary Data of company is collected to know the advance technology of the textile

industry and this will happens it becomes more beneficiary and reliable to the economic

condition. The information is collected from Magazines, Newspapers, Internet and websites

etc.

Sample size

The sample size 30 from where the date is collected from every department of the textile

industry.
 Data Analysis

Raw material - Cotton

Spinning unit

Spinning is the twisting together of drawn -out strands of fibers to form yarn, and is a major
part of the textile industry. The yarn is then used to create textiles, which are then used to
make clothing and many other product s.

1. Step: Blow room operation here, the compressed bales of fibers is opened for making the cotton tuft in a
small size. Cleaning: This operation is used to remove dust, dirt, broken leafs, broken seeds, stalks and
other foreign materials from the fibers.
2. Step Carding process here the fibers must be disentangles, and it gets straightened. The straightening
process puts the fibers into parallel direction and the sliver is formed.
3. Step: Draw frame breaker here the draw-frame feeder rack, usually including eight pairs sliver the relative
sliver that runs between the two. Rieter - E 35 OMEGA lap machine is used for this operation which
doubles the sliver to sliver.
4. Step: Comber here the sliver is feed to the combing machine to get very fine and straight sliver.
5. Step: Draw frame breaker in this process the 6 sliver get converted into 1 sliver
6. Step: Speed frame In this process the sliver is converted into roving get twisted and bind on small cone.
7. Step: Ring Frame In this process the small robin is converted into thread bind on the bigger cone.

 The bigger cone is dried at 59 c and gets pack for shipment.

 The Production capacity is 40128 spindles
 Per day capacity 10 ton
 Weaving department
Weaving is a method of textile production in which two distinct sets of yarns or threads are interlaced at
right angles to form a fabric or cloth.
Other methods are knitting, crocheting, felting, and braiding or plaiting. The longitudinal threads are called
the warp and the lateral threads are the weft or filling.

Flow chart of Weaving

WINDING
↓
WARPING
↓
SIZING
↓
DRAWING
↓
LOOMING
↓
WEAVING

Weaving preparatory Process

There are three main steps of weaving preparatory process
1. Winding
2. Warping
3. Sizing
1. Winding
Winding is a process in which yarn from ring bobbins are wound into convenient form of package. Transferring
a yarn from one type of package, more suitable for subsequent process is also called winding. It occurs both in
spinning & weaving. Main objectives of winding include.
 Increase package size according to the requirement of subsequent process.
 Clearing yarn defects like slub, thick and thin places, neps, etc.
 Package dying
 Doubling

2. Warping
Warping is the process of transferring a number of yarns from a creel of single end packages, forming a
parallel sheet on to a beam. The main objectives of warping are:
 To get the required number of ends as per set calculation.
 To get the required length of yarn on each beam of the set.
 To wind a specific type of package required by subsequent process.

3. Sizing
The weaving requires warp yarn to be strong, smooth and elastic to a certain degree. To achieve these
properties, protective coating of a film forming agent is applied to the warp yarns prior to weaving. The
application of size material on the warp sheet, to induce the desired properties is called slashing or sizing. Sizing
is to produce Quality Fabric economically and efficiently.

The main objectives of sizing are as follows:

 To get the required number of ends

 To increase the strength of yarn

 To cover the hairiness of yarn

 To maintain flexibility in yarn

The chemical used for sizing to increase the strength Asap cone ,SFR, Phenol, count (70),M-plast (80)
 Fig5.1 Toyota JAT 810 loom machine

 Production machine
Grey loom: 32 loom
Capacity produce: 9000 MTR/Day
Dyed loom: 80 loom
Capacity Produce: 33000 MTR/Day

5.1.5 Inspection of Loom

Inspection occurs when grey fabric gets the weaving defects. The removable defects are removed and noted
down at every meter of fabric, There is a roller attached counter which counts the number of meters inspected
and helps in location the position of the defect.
 5.1.6 Grey Fabric Defects
SR No. Denoted by Fabric Faults
1 T Torn
2 TP Thick Place
3 BP Broken Pick
4 ST Stain
5 H Hole
6 CR Crank
7 DP Double Pick
8 BE Broken Pick
9 MP Miss pick
10 TR Tail Re Entry
11 DE Double End
12 FL Float
13 WD Wrong Drawn
14 WW Wrong Weft
15 SLO Slough Off
16 SL Slub
17 LE Loose End
18 TE Tight End
19 TW Thick Warp
20 DS Dirty Splice
21 FF Foreign Fiber
22 SP Size Patch
23 QWP Oily Warp
24 OW Oily Weft
25 DST Distortion
26 FLF Fluff
27 WNR Weft Not Removed
28 TWT Thick Weft
29 M Moiré
30 TS Torn Selvedge
31 DF Dobby Fault
32 FW Free Weft
33 TC Temple cut
34 WCE Wrong Color end
35 ME Missing `End
36 CC Color Change
37 CV Color Variation
 Processing Department

Processing flow sheet

Grey fabric

Bleaching

Dyeing Finishing

Printing

Finishing

Folding

Chemical consumption
1. Peroxide -150kg/Month
2. Hypo Chloride -500 Kg/Month
3. Cotoclarina 63 -50 Kg/Month
4. Forylase AT -50 Kg/Month
5. Ran Sc -50 Kg/Month
6. Nockel -70kg/Month
7. Mega Acid -60 Kg/Month
8. Mega Tube ACA -40 Kg/Month
Processing Department
 Scouring

Scouring is the first process carried out with or without chemicals, at room temperature or at suitable higher
temperatures with the addition of suitable wetting agents, alkali and so on. Scouring removes all the waxes,
pectin’s and makes the textile material hydrophilic or water absorbent.
 Bleaching

Bleaching, a process of whitening fabric by removal of natural color, such as the tan of linen, is usually
carried out by means of chemicals selected according to the chemical composition of the fiber.CBR, Jet
Drying, Kier, Jigger Machine are used for bleaching process.

Continuous Bleaching Reactor (CBR) parameters

Cotton Linen Unit 1 Y/D Unit 1 white
Poplene
Machine Speed 100Mtr/min 100 Mtr/min 100 Mtr/min 100 Mtr/min

Temperature Fortracta 12 95oC 95oC 95oC 95oC

Washer 13 95oC 95oC 95oC 95oC
Washer 14 80oC 80oC 80oC 80oC
Reacipe
Caustic 8 ml/kg 5 ml/kg 8 ml/kg 8ml/kg
Stabilizer 2.5 ml/kg 2.5 ml/kg 4.5 ml/kg 4.5 ml/kg
wetting 3 ml/kg 3 ml/kg 3 ml/kg 3 ml/kg
Sequestering 3 ml/kg 3 ml/kg 3 ml/kg 3 ml/kg
Peroxide 10 ml/kg 10 ml/kg 22 ml/kg 22 ml/kg

Steamer

Dwell Time 10 min 5 min 10 min 10 min

Temp 94oC 94oC 94oC 94oC

Temperature
Fortracta 23 95oC 95oC 95oC 95oC

Washer 23 95oC 95oC 95oC 95oC

Washer 24 95oC 95oC 95oC 95oC

Washer 25 70oC 70oC 70oC 70oC

 Mercerization Process
The treatment of cotton fabrics or garments with a cold concentrated solution of sodium hydroxide for a minute
or less is called mercerization. It is a value added Process.
After this process the cotton fibers will swell, untwist and their beam shaped cross section will change into
round form giving smoothness to the fabric. Tension is applied to the fabrics in the machine in the vertical
direction with a tension cylinder, and in the horizontal direction with a clip tenter. The processing time by the
cylinder and the tenter in total is 30 to 60 seconds. To prevent the fabrics from shrinking after going through the
tenter, the NaOH concentration in the fabrics needs to be decreased sufficiently when the fabrics leave the
tenter. Also, since the piling on thick fabrics in a wet state leaves creases on the fabrics, the thick fabrics need to
be dried promptly. Change in a cross-section of a cotton fiber during a mercerization treatment. The capacity of
the machine is 75000 meter per day.

Steamer
After that the fabric goes to the steamer which is located at a higher level where direct heating is given to the
fabric. Only steam is present in the streamer. The temperature of the steamer is usually 94`C. The fabric stays in
the steamer for 10 minute. On the sides of steamers there are four tanks having hydro caustic after A-Ring. Here
the fabric loss the strength and remove impurities.

Dyeing

Main objective in the dyeing of textile materials are:

· Color the fibers uniformly.
· Achieve acceptable durability of the color to further treatments in production and normal use. Fastness of the
color material to sunlight and multiple cleaning is of prime importance.
 Print studio
Morarjee has always played a great role in the fashion movement, for over a century. To spearhead this, it has
set up a state-of-the-art design studio in Italy and India. These studios are run by creative a team that provide
speedy solutions and ideas, customizes designs and also gives access to the latest international styles, exclusive
colors, patterns and designs.
The processes in design studio is divided into following sections

1. Creation-The design is created and designed according to the specifications given by the customer. The
people from marketing department visit the place and understand about the design that needs to be printed
according to the specifications provided by the buyer.
The design to be printed is decided by:-
 specifications given by the buyer

 Trend forecasting

 Fashion forecasting

 Magazines report

2. Separation: The colors present in the specific design are made in several specific channels. The color
components present in the design are segregated individually to understand the color requirement according to
that design. It is decided by the printing department, design studio, PPC, marketing and quality control. The
process of separation is done on the basis of availability of machines & the design specifications given by the
buyer. The finalized design is then sent for engraving or exposing.

3. Engraving or exposing: This is the process of engraving the specified design on the screens so that it can be
used for printing processes.
Process flow of exposing:
 Unpacking the screen

 Changing the curvature of screen that is flat to cylindrical

 Degreasing
4. Strike Off
 The order or design specifications are given by the buyer to the marketing department and the design
studio.

 It deals mainly with the sampling of the specified design.

 Samples are made on baby rotary printing machine ( screen -9 “X 9” )

 Ingredients used for printing is sodium alginate ,urea (10-15 %) ,sodium bicarbonate ,Turkey Red oil
(TRO ) and water (80 % ).

 10 -15 made samples are sent to the buyer for approval out of which5-7 samples are selected for bulk
printing.

This process takes a time span of 10 days for the completion of whole process.
 Printing

It is done either with flat or cylindrical screens made of silk threads, nylon, polyester, vinyon or metal. The
printing paste or dye is poured on the screen and forced through its unblocked areas onto the fabric. Based on
the type of the screen used, it is known as 'Flat Screen Printing' or 'Rotary Screen Printing.
A significant characteristic of screen printing is that a greater thickness of the color can be applied
to the substrate than is possible with other printing techniques. This allows for some very interesting effects that
are not possible using other printing methods. Because of the simplicity of the application process, a wider
range of inks and dyes are available for use in screen printing than for use in any other printing process.
Utilization of screen printing presses has begun to increase because production rates have
improved. This has been a result of the development of the automated and rotary screen printing press,
improved dryers, and U.V. curable ink. The major chemicals used include screen emulsions, inks, and solvents,
surfactants, caustics and oxidizers used in screen reclamation.
Screen printing is by far the most common technology today. Based on the type of the screen used. Two types
exist:
1) Rotary screen printing
2) Flat (bed) screen printing
.
 Rotary Screen Printing
Rotary screen printing is so named because it uses a cylindrical screen that rotates in a fixed position rather
than a flat screen that is raised and lowered over the same print location. Rotary presses place the squeegee
within the screen. These machines are designed for roll-to-roll printing on fabric ranging from narrow to
wide-format textiles. In rotary printing, the fabric travels at a consistent speed. By converting the screen-
printing process from semi continuous to continuous, higher production speeds are obtained than in flat bed
printing. Typical speeds are from 50-120 yards per minute for rotary screen printing depending upon design
complexity and fabric construction.
 Zimmer machine is used for the process.
 Engraving is done on the screen.
 Zimmer have 12 screen colors.
 After printing Ageing 102 C is done for reactive color and for pigment color curing done at 150 C.
 Printing capacity is 30000 meter at 6 mpm to 100 mpm .
 Then the fabric is send to the quality check and then to the finishing Department.
 Fig. 8.1 Rotary screen machine
 Plate and Frame Printing

In Plate and frame screen printing, this process is an automated version of the older hand operated silk screen
printing. For each color in the print design, a separate screen must be constructed or engraved. If the design has
four colors, then four separate screens must be engraved. The flat-bed screen process is a semi-continuous, start-
stop operation. Flat screen machines are used today mostly in printing terry towels. Currently, approximately
15-18% of printed fabric production worldwide is done on flat-bed screen machines.
 Printing process a where the Plate and frame is used for printing .
 Screen design is engraved the by the machine.
 Then it is send to the printing machine where different design screen is used to print on the fabric

Fig.8.2 plate and Frame printing

 FINISHING PROCESS
Newly constructed fabric is called greige goods or grey fabric. The goods must pass various finishing processes
to make it suitable for its intended end use. Finishing may change the appearance of the fabric, its hand (feel),
its serviceability, and it durability in this unit.
6.3.1 STENTERING
This process is applied at various stages of finishing. Usually the fabric is wet when it is run into a tenter. After
being relaxed during dyeing and finishing, all fabrics are coaxed back to normal width on a tentering frame. The
endless chain of mechanical fingers, or tenter-frame clips, grips the fabric selvedges on entering the machine,
which has been set for the narrowest width of the fabric. Gently but firmly, the fingers stretch the fabric to a
predetermined width as is passes down the length of the tenter over live steam and subsequently heat, which
dries and sets the fabric.

6.3.2 Sanforising
 It is pre shrinking finishing

 Rubber belt shrinks the fabric along with it

 Shrinkage > 5 %

 Speed 50 m/min

 Steam heated roller over belt at 110 0C

 50 m fabric from in to out

 After shrinking zone, there is a setting zone to set the shrinkage in fabric

 Fabric is cooled and then batched

 Some shade variation may occur

 Pressure-9kg/cm2

 Finishing types

1. Soft finishing
2. Stiff finishing
3. ETI finishing
4. Anti Micro Bacterial
6.4 Folding
Grey Fabric Inspection occurs in fabric inspection for the weaving/ spinning defects. The removable defects are
removed and noted down, and irremovable defects’location is noted down and the frequency is noted. There is a
roller attatched counter which counts the number of metres inspected and helps in location the position of the
defect.
 Findings

Spinning Department

 Spinning department Installed capacity 40128 spindles

 There are 3 shift for working
 Target of 3550 kg
 Per day 10 tone spindles
 For handling material four lifter is used

Preparatory Department
 Winding and Warping process take place to soft cone and to warp on beam
 Sizing operation is done where chemical is used to increase the strength of beam warp yarn
 Chemical used in sizing are SFR,MPlast, Fanol (70-80) count ,Scote for 100 count .

Weaving Department
 Weaving Department installed capacity 112 looms.
 Weaving production department had 32 dyed yarns and 80 grey yarn.
 Per day production target 33000 MTR/day for 80 looms grey yarns.
 Per day production target of 9000 MTR/day 32 looms dyed yarns.
 Machine used for Loom Toyota -810

Processing Department
 Continuous Bleaching Reactor CBR is used for bleaching the grey yarn loom
 Mercerization Process provide smoothness to the loom per day cap 75000

Print studio and Printing

 Print studio here the design is created as per the customers Specification.
 Screen is engraved by SPGprint which cost RS 5500 per screen
 Zimmer Rotary printing machine is used for printing the Fabric.
 Finishing
 Finishing is the last operation in textile industry.
 Machine used for finishing 3- stranter 2- sanfors – 1calander
 Stranter used to dry the printing 190 c 1 min
 Sanfors make the fabric soft
 Calander make ironing to fabric

What the organization done for Conservation of Energy?

(i) The steps taken or impact on conservation of energy
• On Kier machine, manual steam controlled valves are replaced by automated steam controlled valves.
This has resulted in optimum steam utilization and savings in steam.
• Installed variable frequency drives on pumps at various places as energy conservation measure.
(ii) The Steps taken by the company for utilizing alternate sources of energy
• Steam pressure regulating stations are installed at process machine ends to regulate steam pressure and
There by reducing Steam distribution losses.
• Increase in Hot water recycling resulted saving in steam as well as water consumption.

 Technology absorption:-
(i) The efforts – made towards technology absorption
• Latest Generation Biological ETP 1400 KLD and RO of 92 % water recovery is installed.
(ii) The benefit derived as a result of above efforts.
• Improvement in quality and productivity.
• Cost reduction
• Energy conservation.
Total capacity of plant

Spinning facility 40,128 Spindles

Weaving Capacity 112 Looms
Printing Capacity 78 lac meter per annum

 Global supplier

Company has 30% domestic export and 70 % to the gulf and Europeans countries.

Quality
 Company work under 5s quality circle .Quality circle is used which regularly to identify, analyze and
solve work-related problems

 TPM –Total productive maintenance, kaizen, lean, Six Sigma are used in the industry.
 Certification: ISO 9001-2000

ISO 14001-2004

Company Achievement and Awards

1. Oeko- Tex 100
2. Egyptain Cotton
3. GOTS Sustainable textile
 Chapter 6
Conclusion

 Morarjee Textile having the good human resource. The entire employees in the company are well

trained and qualified in to the work. All the departments are well established and fulfill the need of the

employee. So the work environment is very good.

 The company is doing well in the market but have to improve the quality of the product. The machinery

used in production is updated. If company will improve in the all mentioned sector the sell of the

company will increase and the company will achieve the top rank in the competition.

 Morarjee textile is one of the leading cotton fabric and textile products companies in India. This

company produces fabrics. This company has the large share of the market. It is having more turn over

comparing then other fabric companies in India.

 The company Morarjee textile have the main competitors are not the Indian there are also the

multinational companies.

 The Morarjee textile in Nagpur is mainly produces the fabrics. The production is done on the basics of

market requirement.

Chapter 7
 Recommendation & Suggestion

1) Morarjee Textile should develop managerial skill particularly to identify the weaker section to reach the

benefits the social and economic objects.

2) Morarjee Textile must play prominent role in financing which may result in rising level of income and

employment.

3) The present official staff of Morarjee can be given a suitable management training that modern

management concept and management technologies can be vitalized in the day to day business for the further

improvement.

Chapter 8
 Limitations of the study & Scope for further research

Scope for further Research

a) To enhance the knowledge being a management trainee.
b) The training has given us idea of working of different departments like production, stores, finance,
personnel, marketing etc.
c) We can also research on supply chain of the industry
d) Further research can also done on the advance technology used in the industry .

Limitation
 There are some limitations of the study.
 Time constraint is a big factor here. Because it takes lot of time to make the report more effective and
suitable for everyone. Moreover, data availability is another big issue here because company does not
want to disclose all the confidential information regarding sales and profits

Bibliography
1. www.morarjee.com
2. Annual report MTL

3.http://admin.umt.edu.pk/Media/Site/STD/FileManager/OsamaArticle/january/jan26/Textile%20Fibre%20to%
20Fabric%20Processing.pdf
4.http://admin.umt.edu.pk/Media/Site/STD/FileManager/OsamaArticle/january/jan26/Textile%20Fibre%20to%
20Fabric%20Processing.pdf

5. Manufacturing processes in the textile industry. Expert Systems for fabrics production J. Bullón Péreza, A.
González Arrietab, A. Hernández Encinasc, and A. Queiruga-Diosc
6. Production planning and control in textile industry: A case study
7. Lean manufacturing practices in textile industries –a case study
P.G. Saleeshya* and P. Raghuram

Questionnaires

Q1 .what are the different department of textile industry ?

Q2 How many working shift for every department ?
Q3 what are the standard quality certification of the industry
Q4 What production technique used by the industry ?
Q5 how many employee and worker in industry ?
Q6 how much is the export of fabric in Indian and international market ?
Q7 how is the installed capacity of spinning Department ?\
Q8 what