A detailed presentation on all the processes at the textile plant in Raymonds , Vapi, Gujarat plant.

1. TEXTILE INTERNSHIP
RAYMONDS –TEXTILE DIVISION
(VAPI)
BY:- Swarnim Singh

2. OBJECTIVE
To understand the concept of spun yarn
production, grey fabric production, dyeing,
printing and finishing of fabric, textile testing
and their quality aspects for both technical as
well as for commercial purposes.

3. Estb. 1925
FIRST POLY-WOOL BLEND in India
(1959)
MNFD. WOOL/ WOOL BLENDS
STARTED MNFG. JEANS, SHIRTS
TOTAL TEXTILE SOLUTIONS

4. ChairmanandManagingdirector
oftheRaymondGroup
INTRODUCTON
 Raymond Group is an Indian branded fabric and fashion retailer,
incorporated in 1925.
 Raymond group is the world's largest producer of worsted suiting
fabric.
 Raymond Limited (Textile Division) has more than 60% market share
of the Indian market for worsted suiting fabrics.
 . It has launched its ‘Technosmart’, ‘Technostretch’ and
‘Technofresh’ in the Techno-series.
RAYMOND GROUP DIVISONS
TEXTILE
ESP.
WORSTED
SUITING
FABRIC
AVIATION
&
COSMETIC
S
ENGINEERING
FILES &
TOOLS
DENIMS
&
DESIGNER
WEAR
PROPHYLACTIC
&
TOILETRIES

5. OFFERING
BRANDS

6. ORGANISATION
STRUCTURE
Board of
Directors
Managing
Director
Marketing
Manager
Production
HOD
Work
Manager
Supervisor
Workmen
Finance
manager
ORGANISATION CHART
The installed capacity of Vapi unit
is 154 looms and 21840 spindles.
The unit has a work force of more
than 1900

7. VAPI PLANT
ABOUT VAPI PLANT
1. Industrial Area 94.4 acres
2. Residential Area 18 acres
3. Rest forest area
4. digital computer-controlled manufacturing
System
5. Automated warehouse system
6. Well connected by rail and road.
7. Fabric production: 25 million metre/annum

8. VAPI PLANT
LAYOUT

9. DEPARTMENTS
AT
VAPI
DEPARTMENTS
Production Designing Service Quality
Control
Sampling Supply Chain
Management
a. Raw Material
Godown (RMG)
b.GreyCombing
c. Dyeing
d. Recombing
e. Spinning
f. Yarn Room
g. Weaving
h. Mending
i. Finishing
j. Folding
k. Warehouse
a.Human Resource
b. Accounts
c. Commercial
d.Engineering,Civil,
Mechanical,
Electrical,Safety,
Instrumental
e. Store
f. Effluent
Treatment Plant

10. OVERVIEW
PROCESS FLOW
Scouring
• Opening
• Scouring
Grey Combing and
Converter
• Carding
• Gilling
• Combing
• Converter
Top Dyeing
• Dyeing
• Drying
Recombing
• Gilling
• Combing
• Pre-Finisher
and Finisher
Spinning
• Pre spinning
• Ring Frame
• Post Spinning
Yarn Room
Weaving
• Winding
• Warping
• Drawing in
• Weaving
Mending
• Perching
• Mending
Finishing
Folding
• Cutting
• Packing Warehouse

11. STAGEWISE INDUSTRIAL PROCESS FLOWCHART

12. RAW
MATERIALS
USED

13. SOURCINGOF
RAW
MATERIALS
SOURCED FROM OVERSEAS

14. sour
SOURCED FROM INDIA

15. 1. Raymond
raw material
store
RAW WOOL STORED FOR FURTHER PROCESSING

16. 2.WOOL
SCOURING
 Wool Scouring is the
process of washing
raw wool in an
alkaline solution
(Esteem AJ 80-48) or
detergent
 . It is done to remove
impurities like mud,
vegetable matter and
grease present in the
raw wool.
100
60
80
0 20 40 60 80 100 120
GREASE
VEGETABLE
MATTER
MUD
Removal of Waste

17. Scouring includes mixing, beating, cleaning, and drying
Feed
Hopper 1
Double
Drum
Opener
Feed
Hopper 2
Wing Belt Bowls6
Drum
Dryer
Stepped
Opener
Washing
and
Rinsing
Drying

18. SCHEMATIC DIAGRAM OF SCOURING MACHINE
1. scouring department capacity -14,000 kg of wool per day
2. Efficiency - 94%.
3. Machine cost- 1.8 cr
4. MACHINE CONSIST OF FOLLWING ACTION–
A.MIXING:- Inclined spiked lattice and roller setup - penetrates the raw wool fibers, opens and transport further.
B. BEATING- cleans the wool and removes the mud
C.. CLEANING -six bowl system – 3 bowl for washing with detergent (ESTEEM 48 – AJ 80) and the last three bowls
are used for rinsing the washed fibers
D. DRYING - 6 drum dryer & 3 drum stepped opener

19. 6 BOWL WASHING
DRYING
1.The wet wool is rotated over a perforated cylinder for its drying action
2. Three varying temperature at three different stages 75c , 80c, 85c
3. The drying wool is sprayed with the mixture of the oils for lubrication to provide antistatic properties b/w fiber- fiber
& fiber – metal.
4. The oils used - Selbena 4554 and Selbana 301IN , added in the ratio of 7:3.

20. WASHING , RINSING , DRYING

21. GREASE RECOVERY MACHINE
Dirty water from bowls of scouring machines is pumped to Grease Recovery Machine , which is clean in three level .
GREASE
• Grease is recovered in
drums
• Capacity of 180kg
• Used by cosmetic
companies.
MUD
• Sent to decanter
• Purified using chemicals
WATER
RECYCLED
• Sent to ETP
• Water fed back to bowls
DIRTY
WATER

22. SCOURING MACHINE AREA

23. 3.GREY
COMBING
PROCESS FLOW OF GREY COMBING
a. The Department has
1.2 carding machines, French manufacturer N.
Schlumberger.
2. 3 gill boxes , N. Schlumberger GN8 machines
3. 10 combers ,

24. CARDING
Carding performs many functions including:
 removal of vegetable impurities (like burrs)
 gradual opening of wool fibers
 Parallel arrangement of fibers as evenly as possible called card sliver.

25. CARDING MACHINE

26. GILLING
The card sliver undergoes three gilling operations that prepare the card sliver for combing. This is done:-
• To remove hooks, align, straighten and blend the fibers
• To improve sliver uniformity (by doubling) so as to reduce fiber breakage and noil during combing
• To reduce any excessive extensibility of the card sliver.
• To ensure less chances of fiber breakage during combing.
Gilling machine consists of:-
• Draw or feed rollers - put uniform tension through the sliver and opens the fibers.
• Detaching or delivery rollers- detaches the short fibers.
• A nozzle -the gilled sliver is lubricated with SelbanaUN to reduce crimp and maintain friction.

27. GILLING MACHINE

28. COMBING
The result is the sliver
consisting of only long
wool fibers parallel to
each other, combed out
noils which are sold to the
carpet industry and are
utilized in making shawls
and blankets

29. After combing, sliver is
sent to top forming
machine. This machine
automatically takes a
fixed weight of sliver,
8.5Kg and convert it
into top which is ready
for dyeing.
TOP FORMATION

30. CONVERTER MACHINE
A Converter machine is
used to cut polyester
tows of continuous
filaments into a sliver of
shorter length. This
process is known as
converting .
Converting cuts the
filaments by passing
them between 2 rollers.
Result is a top formation
of 8.5 kg.

31. DYEING
Wool and polyester cannot
be dyed together as they
have different properties
and affinity to different dyes.
The overall dyeing
process takes about 3-4
hours.
Parameters Wool Polyester
pH 4.5-5 4.5
Temperatur
e
90 0C 1200C
Dye
Metal Complex
Acid Dyes
Reactive Dyes
Disperse Dyes
Time
30 minutes (only dyeing) 15 minutes (only dyeing)

33. LAB SAMPLING

34. Superlab - The Sampling room
It has a dyeing machine which runs
by automated Computer Color
Matching Software (CCM).
The Superlab machine consists of
eight dyers for lab sampling with the
capacity of 20g each.
All the shades are given a Shade No.
and Reference No. along with blend
details on the shade card,
SAMPLING ROOM

35. BULK DYEING – TOP DYEING

36. BULK DYEING – PIECE DYEING

37. RADIO FREQUENCY DYEING PROCESS:
Preparation of Dye
Medium
Dyeing and Washing Hydro Extractor Radio Frequency Drier
0 0.5 1 1.5 2 2.5 3
EXTRA DARK
DARK
MEDIUM
LIGHT
Color Percentage
PERCENTAGE DISTRIBUTION OF COLORS

38. DYEING MACHINES
PIECE DYEING YARN DYEING

39. RECOMBING
 Recombing means combine or cause to combine
again or differently. Recombing is done when fine
yarns of uniform shade and high quality are to be
made.
DEFELTER BLENDER GILLING 1 GILLING 2
GILLING 3 COMBER PRE FINISHER FINISHER
PROCESS FLOW

40. RECOMBING HELP IN

41. RECOMBING PROCESS CONSIST OF

42. RECOMBING MACHINES

43. Process flow
chart from
wool
scouring to
ready-for-
spinning

44. SPINNING
Twisting together of drawn out strands of fibers to
form yarn which is further used to create fabric.

45. Spinning can be broken into three processes preparatory process ,
ring frame and post spinning
PROCESS FLOW OF SPINNING

46. PREPRATORY PROCESS- CONDITIONING AND GILLING

47. ROVING AND RING FRAME

48. POST SPINNING - STEAMING AND AUTO-CORNER

49. TFO & PLY WINDING

50. YARN ROOM
Three major purposes of yarn room are:
•Storage
•Identification
•Issue

51. WEAVING
The weaving is a process of formation of fabric
with interlacement of warp and weft yarns using
a machine called loom.
PROCESS

52. WINDING
Winding is the
process of yarn
transfer to obtain a
larger package from
several small
spinner’s packages.
. There is only one soft
winding machine with
48 heads and 3 SSM
winding machines
with 55 heads at this
unit.

53. Warping is a process by
which long length of
many yarns are winded
on a flanged bobbin to
produce a warp beam.
Warping may be carried
out directly (direct
beaming) or indirectly,
in sections (sectional
warping)
WARPING

54. DRAWING
&
DRAFTING
The warp ends are
passed through the
drop wires and
heddles of the
harness frames and
dents of the reeds
by drawing
process.
This can be
performed either
manually or by
automatic
machines.
MACHINE DRAWING MANUAL DRAWING

55. KNOTTING
It refers to dressing of
old warp sheets over
new warp sheets by
clamp knotting
process. It is done
only for same quality
material. The dressing
of the yarns is done to
get the parallel yarns
for knotting.

56. GATING
In this process the drawn beam, which is prepared in warping, is directly mounted on a loom
LOOM SPECIFICATION

57. AIR – JET LOOM RAPIER LOOM

58. FABRIC STRUCTURE

59. MENDING
 Fabric is checked on both the front and back sides i.e. 100%
inspection.
 Minor defects such as protruding fiber are corrected on the
spot manually; this Is known as general mending
 The major marked defects comes under extra work category.
 General Mending includes:
 Nods pulling and relaxing
 Nods and tails are trimmed
 Wrong end – correct end is inserted
 Broken pick – refilling by needle
 End missing – refilling by needle

60. 30,000-35,000 meter
of fabric on average
checked per day .
In the mending
department 90% of
the workers are hired
on contract basis
MENDING AREA

61. FINISHING
 Textile finishing is a term used for a series of
processes to which all bleached, mended, dyed
and certain grey fabric are subjected before they
are put into market.
 They are carried out to improve the natural
properties of the fabric
 Various finishes applied on fabrics in Raymond are
- soft finish, anti microbial, water repellent, wrinkle
free.

62. DIFFERENT PROCESSES OF FINISHING

63. DIFFERENT PROCESSES OF FINISHING

64. DIFFERENT PROCESSES OF FINISHING

65. FINISHING PROCESS OF POLY - VISCOSE

66. FINISHING PROCESS OF POLY WOOL

67. FINISHING PROCESS OF ALL WOOL

68. PROCESS FLOW OF WET Vs DRY FINISH

69. FINISHING DEPARTMENT

70. FOLDING
 . The folding of the fabric is carried out according to the
requirements of the civil and exports market
 Inspection is done using the 4 point system
 Batch number, piece number, width, weight, quality and the
quantity for each roll is mentioned on a flag attached to the
package.
 Different qualities have different flags. Then selvedge
stamping, hand rolling and top-end stamping is done.
 Minimum length of each package: 15m
 Minimum Tube roll length: 20m
 Maximum length: Depends on the customer

71. FOLDING AND DEFECT MARKING

72.  Stentering Damage Press Mark  Uneven Stentering
 Water Mark  Stentering Pin Holes
 End mark  Yellow Stains/Patches
 Mildew  Draining
 Oil stains  Rub Mark
 Mud stains / rust stains  Scouring Damage
 Holes  Scouring Patches
 Steam band  Singeing Band
 Chemical / Resins spot  Colour Contact
SOME COMMON OCCURING DEFECTS

73. PROCESS FLOW OF FOLDING
Checking Perching Doffing Folding Wrapping
Bar Code Packaging Warehouse

74. WAREHOUSE
 The warehouse is spread across an area of 1 lakh square
feet with the capacity of up to 60 lakhmetres of fabric
 . This department is managed by Warehouse Management
System (WMS)
 they are packed with HDPE (High Density Poly Ethylene)
bags by the packing machine
 There are various Zones in the warehouse which enables
efficient management of the large quantity of fabrics.

75. WAREHOUSE

76. DESIGNING
 It plays a vital role in determining the quality, pattern and
color types of the fabrics to be produced for the civil as well
as export market, every season.
Design Sample
Approval Final Order
PROCESS FLOW

77. DESIGNING

78. WEAVES USED AT RAYMOND FOR SUITING

79. SAMPLING
 Once the design has been made, it goes for sample
production. During this time, the master card containing all
the necessary and vital information regarding the fabric
construction, draft, peg plan, shade, warp & weft
arrangement, yarn count, twist direction, TPI & tentative
calculated fabric specifications.

80. PROCESS FLOW OF SAMPLING

81. SAMPLING

82. QUALITY
CONTROL
 The purpose of quality control laboratory is to ensure the level
of quality at the different stages of the production.
 The standards followed by the Quality Control laboratory at
Raymond are: ASTM,AATCC, ISO and JISL.
 The machines have been purchased from various
manufacturers across the globe

83. TEST SPECIMEN

84. FIBER STAGE

85. YARN STAGE

86. YARN STAGE

87. FABRIC STAGE

88. FABRIC STAGE

89. FABRIC STAGE

90. FABRIC STAGE

91. FABRIC STAGE

92. FABRIC STAGE

93. QUALITY CHECKING LAB

94. SUPPLYCHAIN
MANAGEMENT
Supply chain management means management of the
material flow from customer to customer. It includes
various attributes –
• Production target
• Sales
• Marketing
• Factory planning
•Warehouse
• Logistics At Raymond,Vapi supply chain management
is mainly used for FACTORY PLANNING

95. EFFLUENT
TREATMENT
PLANT
 Waste water effluent that comes from dyeing, finishing,
pre treatment of fabric is treated.
PROCESS FLOW

96. EFFLUENT TREATMENT PLANT

97. GENERAL PROBLEM FACED

98. WHATS NEW?

99. SOME NEW EVENTS AND PROJECTS OF RAYMONDS

100. THANKYOU