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ANNUAL REPORT(2014-15)

THE SOUTH INDIA TEXTILE RESEARCH ASSOCIATION

COIMBATORE - 641 014

I ATRS

Printed at : M/s Shrishti Impressions, Coimbatore

Published by: The South India Textile Research AssociationPost Box No. 3205, Coimbatore Aerodrome Post,Coimbatore - 641 014, Phone : 0422-2574367-9, 4215333, 6544188 Fax :0422-2571896, 4215300 E-mail:[email protected], Website :www.sitra.org.in

? 2015 The South India Textile Research Association Coimbatore - 641 014

AN OVERVIEW OF SITRA'S R&D WORK AND SERVICES - 2014 - 15

ORGANISATION

MEMBERSHIP-5; FINANCE-5; SPONSORED PROJECTS-5; MACHINERY AND EQUIPMENT-6; STAFF-6.

RESEARCH AND DEVELOPMENT

FIBRE SCIENCE -6; CONVERSION OF FIBRE TO YARN -7; CONVERSION OF YARN TO FABRIC -17; CHEMICAL PROCESSING-23; OPERATIONAL STUDIES-27; MACHINERY DEVELOPMENT-38; MEDICAL /TECHNICAL TEXTILES-38.

TRANSFER OF TECHNOLOGY AND RESEARCH UTILISATION

SERVICES TO MILLS-67; COMPUTER AIDED TEXTILE DESIGN CENTRES-68; POWERLOOM SERVICE CENTRES-68; SITRA TEXTILE TESTING AND SERVICE CENTRE-68; SERVICES RENDERED BY THE KNITTING DIVISION-69; SITRA WEAVING CENTRE-70; SITRA CALIBRATION COTTONS-70; TEXTILE ACCESSORIES TESTING-70; CALIBRATION AND PERFORMANCE CERTIFICATION-70; SITRA MICROBIOLOGY LABORATORY-71; TRAINING SERVICES-71; STAFF TRAINING -71; LABOUR TRAINING-75; SITRA-ISDS-76; CONFERENCES AND SEMINARS-77; LIBRARY-77; PUBLICATIONS-77.

ANNEXURES

THE STAFF-78; VISITORS-79; SITRA PUBLICATIONS-80; SITRA DEVELOPMENTS-81; LIST OF STUDIES / SERVICES RENDERED TO MILLS-82; PAPERS PUBLISHED & PRESENTED-83; MEMBERS OF COUNCIL OF ADMINISTRATION-86; MEMBERS OF SUB-COMMITTEES-87; MEMBERS OF RESEARCH ADVISORY COMMITTEE-88; COMMITTEES IN WHICH SITRA STAFF REPRESENTED-89; SITRA MEMBERS-90.

FINANCIAL STATEMENTS

Page no.

CONTENTS

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93

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67

AN OVERVIEW OF SITRA’S R&D

WORK AND SERVICES - 2014-15

In the year under review, efforts were directed towards optimum utilization of the facilities that have been created in the preceding years and to consolidate them. Overall, it has been a fruitful and rewarding year for SITRA with progress and achievement in many spheres of its activity. During the year, SITRA was working on as many as 26 projects, of which 11 were completed.

The membership of SITRA at the close of the financial year stood at 195, comprising 250 units which included spinning mills, composite mills, fibre and machinery manufacturers, etc. Besides, 39 small scale textile units also availed services under the Technical Service Card holder category. The needs of the powerloom and knitting sectors were being attended to through various service centres established at different locations of Tamilnadu. The financial position of SITRA continued to be stable during the year with surplus of income over expenditure which was possible mainly because of good activity in the services front, the steadfast encouragement and excellent response from member mills as well as support from the ministry of Textiles, through grants towards recurring expenditure and for research projects.

The highlights of the research findings and work done in different areas are given below:

CONVERSION OF FIBE TO YARN AND YARN TO FABRIC

An inter-mill survey of yarn quality was initiated last year towards establishing standards -“SITRA STATISTICS” exclusively for Indian mills and attempts to create guideline values for fibre and yarn relationship characteristics. Some preliminary work towards establishing statistical models and creation of an exclusive portal for receiving data from mills for this survey, have been completed. It is planned to publish the “SITRA Statistical Survey” book every alternate year.

The major quality characteristics of compact yarns th

were studied in the 26 inter-mill survey of the quality of compact yarn. Parameters such as CVm%, imperfections (thick and thin places and neps), hairiness values (H & S3/100 m), Rkm value and breaking elongation were compared with Uster Statistics 2013. It was observed that only a few mills have achieved the Uster Statistics 5% level with respect to yarn evenness (CVm%). However, a sizable proportion of mills have achieved 50% level of Uster Statistics in the case of yarn evenness and imperfections. Nearly one-half of the participant mills have achieved the Uster Statistics

50% level in yarn hairiness (Uster ‘H' value and S3/100 m).

The study on the quality attributes of compact doubled and TFO doubled yarns has compared the hairiness, imperfections and weak spots, abrasion and dyeing behaviour of the two yarn types. The hairiness values of compact doubled yarns were lower as compared to TFO doubled yarns by about 70% in 2/60s & about 65% in 2/80s. The extent of reduction in yarn hairiness is due to doubling in the case of compact doubling & TFO doubling. Hairiness reduction due to doubling was relatively higher in compact doubling as compared to TFO doubling, the reduction being around 85% in compact mode and 50 to 65% in TFO mode (in comparison with the hairiness values of the corresponding single yarns). Imperfections were lower in TFO doubled yarns in comparison with compact doubled yarns by 25% to 60%. Similarly weak spots were also lower by as much as 70% to 75% in TFO doubled yarns. In view of the higher incidence of weak spots, the performance of compact doubled yarns in high speed looms may be expected to be relatively inferior. Further studies in this connection are in progress. Abrasion resistances of compact doubled yarns were lower as compared to that of TFO doubled yarns by as much as 75%; highlighting the fact that in compact doubling, the process is not as perfect and even as in the case of TFO doubling. The colour strength values of compact doubled materials were significantly better as compared to that of TFO doubled materials which may be due to relatively non-uniform packing of compact doubled yarns in comparison with TFO doubled yarns.

Towards creating guidelines for the quality parameters of slub yarns, the study on “Quality attributes of slub yarns” was taken up which studied the Deviation between machine set & actual slub parameters for different slub patterns and the Tensile characteristics. The factors influencing the appearance of slub yarn fabrics namely Influence of traveler mass, spacer size and top arm loading on slub yarn tenacity were also studied. In each case, guideline values were given.

OPERATIONAL STUDIES

The online survey of yarn selling price and raw material cost, initiated in May 2013, has witnessed 23 studies being completed so far. This survey provides a built-in database supported queries in the web portal, using which a participant mill can access the count-wise data quickly without going

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Annual Report 2014 - 15

through the voluminous survey report. The studies covered RMC, YSP, yarn quality, yarn realisation and ring frame production rate data of around 280 different counts and varieties of yarns with counts ranging from 4s to 120s, predominantly cotton counts. As many as 80 mills from different parts of the country had participated in each of the 12 surveys.

The study on “fibre to yarn conversion cost”, has done a detailed analysis of conversion costs of 12 different counts and varieties of yarns. The study revealed that between mills, the conversion cost differed very widely in all the counts ranging from 35% to about 90%, the overall difference being high at about 50%. Item-wise conversion cost also showed an increasing trend as the count became finer. Of the total conversion cost, power cost was found to be the single largest one with a share of 40% followed by the salaries and wages cost (20%) and interest cost (13%). The depreciation cost

thstood at 4 place (11%) followed by the stores and packing materials cost (10%) and administrative overheads (6%). The total conversion cost on the whole registered an increase of about 30% in 2014 as compared to the conversion cost that prevailed in 2010 with the increase ranging from 17% to 42% in different counts. It is interesting to observe that in the past two decades (during 1990-2010), the increase in the conversion cost was rather slow at 4.2% per year (compounded) whereas in the last 4 years, the increase was somewhat high at 7% per year (compounded).

The case study of a spinning mill that has been able to achieve a single-digit Total HOK has revealed that there is a good scope to reduce manpower and increase the machine productivity significantly. By implementing the various suggestions that were offered by SITRA, the case study mill could maintain a Total HOK of 8.7 and a production rate of 120 g per spindle per 8 hours (both the figures adjusted to 40s carded count).

Based on data from 12 spinning mills located in different parts of the country with the latest technology, the study focusing on the factors responsible for the generation of hard waste in the automatic cone winding machines has listed the reasons for hard wastes and the measures to be taken thereof by mills for their control.

MACHINERY DEVELOPMENT

Work towards making a reliable semi-automatic mobile doffing system to achieve good doffing

performance has made good progress. The system has incorporated various modifications suggested by the experts to make it a fully-rounded product. The system was licensed to a machinery manufacturer who had manufactured two units on a pilot scale.

CHEMICAL PROCESSING

A comparative study on bleaching cotton fabrics using Peracetic acid (PAA) and hydrogen peroxide attempted to find an alternate method for bleaching cotton fabrics. Preliminary test results revealed positive results for the PAA bleached samples in comparison with H O bleached samples on 2 2

Whiteness Index, spirality and strength, width-wise shrinkage and bleached fabric feel.

MEDICAL TEXTILES

The project on “Development of a leuko-depletion blood filter” attempted to develop a sub micron filter for removing impurities present in the blood components and also leukocytes and its components before blood transfusion. It was found that pore sizes in the range of 3 micron to 8 micron is suitable for leukocyte reduction filter. Uniform fibre surface and optimum mean pore size that is required for the leukocyte reduction filter are achieved at optimum solution concentrations of PET 35% and PBT 30%. Five layer and seven layer PET 35% nanomembrane coated spun lace non-wovens showed better filtration efficiency of leukocytes (WBCs) than the market samples. But PBT 30% and PA6 35% showed lower filtration efficiency when compared with both PET 35% and market samples.

The primary objective of the project on “Development of textile matrices for effective wound management” sponsored by the Ministry of Textiles, Govt, of India, was to develop a wound dressing incorporated with angiogenesis inducing growth factor. Using polyester monofilament (100 ìm diameter), a 3D structure textile architecture that combines pores of different sizes was produced using an embroidery design was created which allows the growing-in of cells and capillaries as well as the blood vessels. The study showed that SITRA's embroidery design incorporated wound dressing (SEWD) did not cause any skin irritation even after 72 hours of contact with the wound and that there is a decrease in wound area with or without the application of the dressings. The reduction in the wound area was faster in the caseof

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BEE Mandatory Energy Audit for Designated Consumers

The Accreditation Advisory Committee of the Bureau of Energy Efficiency (BEE), Ministry of Power, Government of India has recommended and recognized SITRA as an Accredited Energy Auditor to conduct mandatory energy audits for designated consumers. SITRA’s energy audits are already approved by TNEB, GEDA, KSEB, BEE & PCRA. With a professional setup comprising a BEE certified Energy Auditor and Energy Manager and multi-disciplinary specialists from Textile, Mechanical and Electrical Engineering, and equipped with the latest and sophisticated instruments, the energy audit teams of SITRA have been conducting audits in textile industry in accordance with the regulations mandated by the Bureau of Energy Efficiency (Manner and Intervals of Time for Conduct of Energy Audit) Regulations, 2010, vide their notification dt. 27.05.14 for Designated Consumers (DC).

C o n s u l t a n c y s e r v i c e o n “ P r o c e s s Standardisation (CPS)” for the benefit of textile chemical processing mills

To further improve the testing service, aimed at providing test results to the mills on a fast track, SITRA’s physical testing laboratories have started functioning in two shifts from this year. This measure will quicken the testing process by reducing the turnaround time to process a request.

This new service has been started during the year for the benefit of textile chemical processing mills. In this paid service, technical experts from SITRA shall visit the processing mill for 3 to 5 days a month depending upon the capacity and requirements of the mill and suggest measures for process standardization on a continual basis.

TESTING AND CALIBRATION SERVICES

SITRA’s physical and chemical laboratories have been accredited by NABL for ISO / IEC - 17025 for the various fibre, yarn and fabric samples tested for their properties. Several mills exporting yarns are seeking SITRA test reports with NABL logo which provides an assurance of quality of the product. The year witnessed 62879 samples of fibre, yarn and fabric being tested for their physical and chemical properties.

SEWD treated wound proving that the extent of wound healing by SEWD was better.

Self-anchoring barbed surgical sutures are essential for surgical operations to ensure free blood flow, undistorted tissue, scar free tissues and better wound healing. SITRA improved upon its earlier development of an equipment to produce sutures by designing an automated equipment to produce knotless incision closures using micro-machining technique that can produce barbed sutures with the desired barb depth & barb angle.

Under sponsorship from the Ministry of Textiles. Govt. of India, New Delhi, the project on Development of mopping Pads using Nonwoven and woven structure attempted to identify the right combination of woven and nonwoven structures that would be suitable for mopping pad application. It was found that the 8 layers mopping pad, with 4 layers woven gauze and 4 layers nonwoven gauze is the best blend for the improved performance in water and blood holding as well as tensile strength.

Under a project sponsored by the Ministry of Textiles, Government of India, it has been proposed to develop a heat and moisture exchange filter using sub micron layer non-woven to improve the filtration efficiency of the breathing system in clean anesthesia ICU circuits.

Under another MoT sponsored project, it is proposed to develop ultrahigh molecular weight polyethy lene (UHMWPE) l igaments for reconstruction of anterior cruciate ligaments (which is one of a pair of cruciate ligaments in the human knee) using braiding technology. It is planned to study the load bearing capacity and tissue compatibi l i ty of the l igaments, towards standardizing the material.

CONSULTANCY SERVICES

Under specific requests from mills, SITRA attended to consultancy assignments on wide areas of specialisation. It is gratifying to note that the requests for consultancy services have been consistent from the mills in recent years. During the year, 48 consultancy assignments were attended to.

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During the year, a total of 465 calibration certificates, in addition to 13 performance certificates were issued to 73 mills, for testing of quality control instruments. Testing the quality of spinning and weaving accessories / spares in order to select the right quality is another service being offered by SITRA. A total of 1,032 samples covering various accessories like carton boxes, paper cones, rings and travellers, tubes, kraft papers, paper cores, worm & worm gear wheel, ring spinning spindles, cots, partition pad, etc., were tested.

TRAINING

During 2014-15, SITRA conducted 19 different training programmes that were attended by 668 personnel in the supervisory and managerial cadres. Also, 633 operatives had undergone training during the year on right methods of working in textile mills for effective performance. Moreover, 1520 persons were trained under the ISDS of Ministry of Textiles, Government of India.

SERVICES TO DECENTRALISED SECTOR

The services of the 7 powerloom service centres (PSC) in Tamil Nadu, managed by SITRA, were extensively used by the various units adjacent to the service centres. A total of 35,620 samples comprising of yarn and fabrics were tested and 1,234 persons were trained in the areas of loom maintenance, operation of shuttleless looms, calculation of fabric production, etc. The PSCs had also attended to 801 consultancy assignments and created 510 designs.

PUBLICATIONS

During the year, SITRA had brought out as many as 32 publications which included one monograph in Tamil, 4 research / survey reports, 3 trends, 12 online reports, 6 focus and 6 SITRA news. SITRA scientists also contributed 13 research papers to technical journals.

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ORGANISATION

Table 1 Region-wise membership

Region Spinning Composite Fibre manufacturers, Machinery Total

mills mills manufacturers and others

SITRA zone 144 19 4 167

Other States 16 7 2 25

Overseas 2 1 - 3

Total members 162 27 6 195

Total units 197 47 6 250

MEMBERSHIP

The membership of SITRA has shown a marginal increase during the year in terms of units while it slightly declined in terms of members with the relinquishing of membership by 8 mills due to poor operating profits. Also, four mills enroled as members during the year. SITRA is pleased to extend a warm welcome to the new members.

New members

The total membership of SITRA now stands at 195, comprising of 250 units (Table 1) as against 203 members and 246 units last year. SITRA's services were also utilised by 39 small mills under the Technical Service Card holders category. In all, 289 units have access to SITRA's services, apart from many small units in the decentralised sector which utilised the services offered by 7 Powerloom Service Centres, one Textile Service Centre, 4 CAD Centres, one Jute Promotion Centre and one Textile Testing Service Centre.

FINANCE

SITRA continues to maintain its financial health, registering surplus income for the year. The total recurring expenditure of SITRA during the year after appropriation from reserves was Rs 802 lakhs. The total income, including the grants from the Ministry of Textiles, was Rs 836 lakhs.

1) Prabhat Spinners, Palladam.2) Amman Spinning Mills, Coimbatore.3) S.S.K. Textiles, Coimbatore4) Sri Saradhambika Spintex (P) Ltd., Coimbatore

SPONSORED PROJECTS

During the year under review, SITRA undertook 5 research projects sponsored by the Ministry of Textiles (MoT), Government of India and 1 project sponsored by the Department of Science and Technology, Government of India.

Work related to all the five projects sponsored by the Ministry of Textiles, which are listed below, has been completed and reports submitted to the Ministry:

1. Development of textile matrices for the effective wound management.

2. Design and development of an automated equipment to produce knotless incision closures.

3. Development of a Leuko-depletion blood filter.

4. Development of collagen coated on hernia mesh.

5. Development of mopping pads using nonwoven and woven structure.

Work relating to the following DST project is making good progress and is planned to be completed this year:

1. Development of self assembled peptide hydrogel based bioactive dressing material for chronic wounds

MACHINERY AND EQUIPMENT

SITRA has been making appreciable capital investments every year to equip its laboratories and pilot plants with the state-of-the-art machinery / instruments. During the year 2014-15, machinery/equipment and other assets close to Rs.5 crores were acquired which include, some major equipment like Splash resistance tester, Spray and impact penetration tester, Ultrasonic Cleaner 5.5 Lit "Rivotek", Cotton wool roll making machine, Raschel Warp Knitting Machine, Automatic Alcohol Pad making machine and Sanitary napkin manufacturing line.

New infrastructure for Centre of Excellence for Medical Textiles

In 2009, the Ministry of Textiles, Govt. of India identified various institutions of high performance across the country to act as Centres of Excellence in various fields of Technical Textiles with SITRA being designated as a Centre of excellence for Medical textiles. Since 2009, the centre has been actively involved in activities like formulating technical standards, creating new products, developing instruments, carrying out contract and sponsored projects, development of prototypes, Testing and evaluation, conducting training programmes and undertaking technical consultancies. The centre has also been acting as a

one-stop-shop for entrepreneurs in medical textiles, by providing them the technical support and incubation activities to create and nurture them for the manufacture of medical textile products.

Towards providing the necessary facilities for the centre’s activities, SITRA has constructed a dedicated centre with a built up area of 60,000 sq. meters that houses the incubation blocks, the latest machinery for medical textile products, the analytical and wet labs, apart from stat-of-the-art classrooms and board rooms for conducting statekholder’s meets and training programmes.

The building and its blocks were inaugurated by His Holiness, Swami Dayanandha Saraswathi, Asha Vidhya Gurukulam, Anaikatti and Smt.Kiran Soni Gupta, Textile Commissioner, Govt. of India on 9th February, 2015. Dr. S.Ramalingam, Principal, PSG Institute of Medical Sciences and Research, delivered the Special Address during the Inaugural function.

STAFF

The total staff strength of SITRA during the year was 118, slightly lower than last year's strength of 121. With the integration of the activities of the Chennimalai Textile service Centre with the Powerloom centres, the staff strength of the PSCs increased to 44 during the year against 41 last year.

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RESEARCH AND DEVELOPMENT

FIBRE SCIENCE

CONVERSION OF FIBRE TO YARN

SITRA STATISTICS ON YARN QUALITY : A SURVEY BY SITRA

The survey aims to establish a benchmark for yarn quality exclusively for Indian mills, and creating guideline values for fibre and yarn relationship characteristics.

The main objectives of the survey , based on the data collected from mills, are

- To establish a benchmark for yarn quality exclusively for Indian mills.

- To establish a relationship between fibre and yarn quality characteristics

An external statistical consultant, Chi Square Management Consultants, roped in as a knowledge partner to structure the statistical tools, plan a statistical design and optimise the software

thinputs, have done a detailed study on SITRA's 25 survey on yarn quality and submitted their preliminary report and provided some suggestions. Initially it was decided to collect the fibre and yarn samples from mills which shall be tested at SITRA's laboratories. But, considering the cost involved and logistical problems like material collection and transportation from all parts of India, and to make it hazzle-free for mills, it is proposed to conduct this statistical study initially as an online survey.

An exclusive web portal is being created for this survey. Data based on the test reports shall be

AN INTER-MILL STUDY OF THE QUALITY OF TH

COMPACT YARNS - 26 SURVEY COMPARING 43 MILLS

SITRA has been over the years conducting surveys on the quality of yarns in the Indian Textile Industry. As considerable numbers of mills are producing compact yarns in their product portfolio, SITRA undertook a study on the compact yarn quality to help the mills in bench-marking. Various yarn parameters were evaluated besides the respective sliver samples for their physical characteristics. A report based on the detailed analysis of 144 compact yarns and 62 sliver samples that were collected from 43 participant mills was published in January 2015. The results were also compared with Uster Statistics 2013. The trends in various quality characteristics in relation with the earlier survey data were also projected.

uploaded in the customized Statistical software which can be accessed from SITRA's website using an exclusive login. Mill officials can access information on the website and view changes in the moving average value of results that get uploaded at stipulated intervals when the number of participants reach an optimum level. The SITRA STATISTICAL survey book based on the data of this survey shall be published every alternate year.

It is hoped that the results of this survey would help mills in improving their process performance in the long run.

Table 2 CSP and twist of yarns

Properties

40s CW

50s CW

60s CW 80s CW 100s CW

Cops

Actual count (Ne) 39.6 49.3 59.8 79.1 98.8

Count CV% 1.5 1.5 1.7 1.9 1.9

Lea strength (lbs) 80.8 66.5 52.1 40.7 34.0

Strength CV%

5.0

4.6

4.5 5.0 5.7

CSP

3191

3265

3108 3207 3337

TPI

24.65

27.75

31.49 35.43 40.13

TPI CV%

4.49 4.43

4.30 4.70 4.37

Cones

Actual count (Ne)

39.5 49.2 60.1 79.2 99.6

Count CV% 1.7

1.6

1.8 1.9 1.7

Lea strength (lbs) 80.6 67.6 52.4 40.5 33.1

Strength CV% 5.9 5.4 5.3 5.8 4.8

CSP 3180 3315 3146 3179 3282

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Table 3 Rkm and breaking elongation of yarns

Properties 40s CW 50s CW 60s CW 80s CW 100s CWCops UsterTensorapid -3 Rkm (g/tex) Rkm CV% Breaking elongation (%) CV% of elongation

20.25 8.06 4.90

10.07

20.66 8.74 4.99

10.47

20.30 9.53 4.40

12.09

21.22 9.48 4.64

10.72

22.40 10.16 4.84

11.76

Uster Tensojet -4 Rkm (g/tex) Rkm CV% Breaking elongation (%) CV% of elongation

22.79 8.80 4.22

10.78

23.27 8.93 4.46

10.12

22.86 9.77 4.12

11.27

23.48 10.10 4.07

12.46

24.73 11.08 4.27

12.26Cones UsterTensorapid -3 Rkm (g/tex) Rkm CV% Breaking elongation (%) CV% of elongation

19.72 8.71 5.10 9.52

20.18 8.63 5.21

10.01

19.60 9.13 4.52

10.96

20.75 10.65 4.71

11.14

21.88 10.89 5.06

10.35

Uster Tensojet -4 Rkm (g/tex) Rkm CV% Breaking elongation (%) CV% of elongation

22.68 9.18 4.52 9.90

23.00 9.04 4.53 9.60

22.45 9.61 4.14

10.74

23.10 10.40 4.18

11.78

24.18 10.92 4.38

11.83

As the strength characteristics of a yarn has been established as a way to identify the extent of weak spots in the material that would affect the performance of post-spinning process, an analysis of weak spots due to strength and elongation was done.

Table 4 Hairiness values of cop yarn and cone yarn

Properties 36s CH

40s CW 50s CW 60s CW 80s CW 100s CW

Cops

Uster Tester -5 ‘H’ value

3.88

3.38

3.00 2.91 2.48 2.73

Uster Zweigle HL 400 (S1+S2)/100 m

12223

11362

8292

8174 8143 13340S3/100 m 456 310 218 199 193 378

Cones

Uster Tester -5 ‘H’ value

4.75

3.85 3.43 3.21 2.82 3.03

Uster Zweigle HL 400 (S1+S2)/100 m

20759

15026

14956

12118 11177 13509

S3/100 m 1562 721 694 572 410 719

Percentage increase in hairiness Cops Vs Cones

Uster Tester -5 ‘H’ value 22 14 14 10 14 11Uster Zweigle HL 400(S1+S2)/100 m 70 32 80 48 37 1S3/100 m 243 133 218 187 112 90

The increase in S3 value was found to be alarming and ranged from 90% in 100s CW to as high as 243% in the case of 36s CH.

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Table 5 Yarn unevenness and imperfections

Properties 40s CW 50s CW 60s CW 80s CW 100s CW

Cops

U% 9.70 9.78 10.65 11.21 11.55

CVm% 12.26 12.35 13.48 14.16 14.59

Thin places (-50%) 1 1 9 19 35

Thick places (+50%) 28 23 52 65 83

Neps (+200%) 79 66 131 168 177

Total imperfections/1000 m 108 90 192 252 295

Thin places (-40%) 56 74 189 312 440

Thick places (+35%) 248 221 400 478 559

Neps (+140%) 322 295 567 711 748

Total extra sensitivity imperfections/1000 m

626 590 1156 1501 1747

Cones

U% 9.89 9.86 10.88 11.44 11.81

CVm% 12.50 12.42 13.77 14.46 14.94

Thin places (-50%) 1 2 9 26 44

Thick places (+50%) 35 21 61 72 115

Neps (+200%) 86 61 156 180 274

Total imperfections/1000 m 122 84 226 278 433

Thin places (-40%) 64 76 201 364 497

Thick places (+35%) 297 234 456 545 699

Neps (+140%) 382 304 698 839 1185

Total extra sensitivity imperfections/1000 m

743 614 1355 1748 2381

Table 6 Classimat faults of yarns

Count

Total faults/one lakh metres

Short thick faults Long thick faults Long thin faults

Cop

yarn

Cone

yarn

Cop

yarn

Cone

yarn

Cop

yarn

Cone

yarn

36s CH 831 558 9 2 1 1

40s CW 1088 862 13 2 6 4

50s CW 887 643 7 3 5 6

60s CW 2195 2119 22 8 35 34

80s CW 2635 2498 24 9 72 101

100s CW 3007 3543 50 19 160 129

* Short thick faults – A1+A2+A3+A4+B1+B2+B3+B4+C1+C2+C3+C4+D1+D2+D3+D4 Long thick faults – E+F+G

Long thin faults – H1+H2+I1+I2

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It could be seen that there is a reduction of about 70% in the objectionable long thick faults in the yarn after winding.

The major quality characteristics of compact yarns (cone stage) such as CVm%, imperfections (thick and thin places and neps), hairiness values (H & S3/100 m, Rkm value and breaking elongation were compared with Uster Statistics 2013. It is seen that only a few mills have achieved the Uster Statistics 5% level with respect to yarn evenness (CVm%). However, a sizable proportion of mills have achieved 50% level of Uster Statistics in the case of yarn evenness and imperfections. Nearly one-half of the participant mills have achieved the Uster Statistics 50% level in yarn hairiness (Uster'H' value and S3/100 m). In the case of yarn tenacity (Rkm value), the ratings for observed averages start only at the 50% level. Yarn elongations at break values are very much lower than the Uster 5% level and mills have achieved (except a few) only the Uster 50% level.

AN INVESTIGATION ON THE QUALITY ATTRIBUTES OF COMPACT DOUBLED & TFO DOUBLED YARNS

Introduction

SITRA has conducted a number of studies to assess the various facets of yarn & fabric characteristics made using compact spinning system. However, details pertaining to quality attributes of compact spun doubled yarns and their relative advantages over conventional TFO doubled yarns are scarce in literature. The present study has been conducted to generate relevant information in this area.

Materials and methods

2/60 Ne and 2/80 Ne yarns were produced in compact doubling & TFO doubling machines. These yarns were made using viscose fibres of 1.2 Denier x 38 mm (Cut length).

The twist values maintained in doubled yarns are given in Table 7.

All the yarn samples were tested for hairiness (S3 value using zweigle hairiness tester), imperfections using Uster Tester (UT5), weak spots using tensojet and abrasion values using yarn abrasion tester. In addition, the yarn samples were converted into

S.no. Yarn details Twist

directionTurns

/Inch (TPI)

12/60s compact

doubled‘Z’ 19.74

22/60s TFO

doubledZ/S

20.09

32/80s compact

doubled‘Z’

21.13

42/80s TFO

doubled

Z/S

21.90

Table 7 Turns / Inch maintained in compact doubled & TFO doubled yarns

knitted fabrics using FAK sample knitter. The knitted fabric samples were dyed using reactive dyes in medium shades. The dyed fabric samples made using compact doubled and TFO doubled yarns were analysed for colour strength using spectrophotometer.

In the present study, a weak spot in yarn has been defined as spot in the yarn with breaking strength value lower than 50% of the average breaking strength of yarn. Weak spots are estimated using Tensojet instrument and one lakh meters of yarn constitutes a sample.

Quality attributes of compact doubled & TFO doubled yarns

1. Yarn Hairiness

Hairiness values of compact doubled &

TFO doubled viscose yarns (2/60s &

2/80s) are shown in Figure 1.

Figure 1 Hairiness value of compact doubled & TFO doubled yarn

Hairiness values of compact doubled yarns are lower as compared to TFO doubled yarns by about 70% in 2/60s & about 65% in 2/80s. The extent of reduction in yarn hairiness due to doubling in the case of compact doubling & TFO doubling is illustrated in Table 8.

11


Table 8 Extent of reduction in yarn hairiness due to doubling

S.no Count Hairiness (S3

value)

% Reduction in hairiness

Due to doubling

1. 60s – Single ‘S’ twisted 429.20 -

2. 2/60s compact doubled - ‘Z’ 65.70 85%

3. 2/60s TFO doubled - ‘Z/S’ 223.33 48%



6. 2/80s TFO doubled - ‘Z/S’ 261.50 64%

Hairiness reduction due to doubling is relatively higher in compact doubling as compared to TFO doubling, the reduction being around 85% in compact mode and 50 to 65% in TFO mode (in comparison with the hairiness values of the corresponding single yarns).

2. Yarn imperfections and Weak spots

Yarns imperfections (thin places, thick places and neps) were estimated using UT5 instrument at normal sensitivity levels (thin places – 50%, thick places +50% and Neps +200%). Similarly weak spots in yarns (No. of places in one lakh metre of yarns were breaking strength values of lower than50% of the average breaking strength of yarn) were also assessed using Tensojet tensile tester.

Total yarn imperfections and weak spots in compact doubled and TFO doubled yarns are illustrated in Figure 2.

Imperfections are lower in TFO doubled yarns in comparison with compact doubled yarns by 25% to 60%. Similarly weak spots are also lower by as much as 70% to 75% in TFO doubled yarns. This may be due to the fact that in compact doubling

No

. o

f W

ea

k s

po

ts

Ya

rn im

pe

rfe

cti

on

s

Figure 2 Imperfections and Weak spots in compact doubled and TFO doubled yarns

(which is carried out in ring frame itself with appropriate compact doubling set-up), the process of doubling is not as perfect and uniform as in the case of TFO doubling. In view of the higher incidence of weak spots, the performance of compact doubled yarns in high speed looms may be expected to be relatively inferior. However, further studies in this connections are in progress.

3. Yarn abrasion

Abrasion resistance of yarn is of great importance, since it not only affects the processing performance in post spinning operations, but also plays a significant role in the quality of the end product.

Abrasion resistance of compact doubled & TFO doubled yarns was estimated using MAG – SITRA Abratest. In this tester, a rectilinear roller covered with standard easy-fitting emery paper (P 800) moves back and forth. Upto 20 pre-tensioned threads are placed above the roller. They are all subjected to the same contact pressure and 'abrasion speed' exerted by the roller. The end point of a test is the number of cycles at which either one thread or all the 20 threads get ruptured.

12


Abrasion resistance values of compact doubled & TFO doubled yarns (2/60s & 2/80s Viscose) are shown in Figure 3.

65.95 65.55

239.9263.05

0

50

100

150

200

250

300

2/60s 2/80s

NO

. o

f st

rok

es

to b

rea

k t

he

sp

eci

me

n

Yarn Count (Ne)

Compact Doubled

TFO Doubled

Figure 3 Abrasion resistance of compact doubled & TFO doubled yarns

Abrasion resistances of compact doubled yarns are lower as compared to that of TFO doubled yarns by as much as 75%. The difference is statistically significant. This again brings forth the point that in compact doubling, the process is not as perfect and even as in the case of TFO doubling.

The extent of improvement in abrasion values due to doubling in the case of compact doubling & TFO doubling for the two counts under investigation is given in Table 9.

The relatively lower extent of improvement in abrasion strokes due to doubling in the case of compact spun materials is mainly responsible for the lower abrasion values of compact doubled yarns.

Table 9 Extent of improvement in abrasion strokes due to doubling

S.no. Count Yarn Abrasion (No. of strokes to break

the specimen)

% Improvement in Yarn Abrasion due to doubling



3. 2/60s TFO doubled - ‘Z/S’ 239.9 510%



6. 2/80s TFO doubl ed - ‘Z/S’ 263.05 916%

Hence, when it comes to selection of high performance textiles, satisfying the needs of soldiers, policemen, mountaineers and many other specific users whose life depends on good abrasion resistance of textile materials, textiles made out of compact spun doubled yarns may not be a suitable choice.

4. Dyeing behaviour

The fabric samples made out of compact doubled & TFO doubled yarns were dyed using reactive dyes in medium shades. The dyed fabric samples were a n a l y s e d f o r c o l o u r s t r e n g t h u s i n g spectrophotometer to know which fabric sample has better dye absorption in a given dye bath. The colour strength values of the fabric samples are shown in Figure 4.

100 100

92.54

94.96

88

90

92

94

96

98

100

102

2/60s 2/80s

Co

lou

r s

tre

ng

th v

alu

e

Yarn Count (Ne)

Compact Doubled

TFO Doubled

Figure 4 Colour strength values of fabric samples made using compact doubled

And TFO doubled yarns.

Note:- A difference of 5.0 and above between two colour strength values can be considered as a significant difference.

13


It is evident from the figure that colour strength values of compact doubled materials are significantly better as compared to that of TFO doubled materials. This may be due to relatively non-uniform packing of compact doubled yarns in comparison with TFO doubled yarns. In materials with non-uniform packing, dye penetration may be expected to be relatively more and hence the colour strength values.

The colour strength values were calculated using K/S Vs wavelength spectrum obtained in spectrophotometer for different fabric specimens.

QUALITY ATTRIBUTES OF SLUB YARNS – AN INVESTIGATION

1.0 Introduction

Many spinning mills have started producing slub yarns as a part of diversification. The use of slub yarn enables the production of fashionable woven or knitted fabrics with a natural look. A significant application of slub yarn is denim fabrics. Slub yarn configuration varies widely between mills as the mills produce as per the customer requirements.

Guidelines for the quality parameters of slub yarns like i) Deviation between machine set & actual slub parameters for different slub patterns ii) Tensile characteristics and iii) Factors influencing the appearance of slub yarn fabrics are not available at present.

The present study was carried out to develop a database for the above.

2.0 Materials and methods

2 different slub yarn systems were considered for the study. Slub yarn counts between 16s and 60s (warp as well as hosiery) were included in the study.

3.0 Study results

3.1 Difference between machine set and actual slub parameters

Figure 5 Schematic representation of a slub yarn

Based on the results obtained, the difference between machine set and actual slub parameters was arrived at and the same is given in Table 10.

Table 10 Difference between machine set and actual slub parameters

S.no Slub parameterDifference between machine

set & actual values

System 1 System 2

1 Slub length (cm) 2 to 4% 9 to 19%2 Slub dia (%) 2 to 6% 8 to 19%3 Distance between

slubs (cm)2 to 3% 7 to 21%

The difference between machine set and actual slub parameters is lower in system 1.

3.2 Factors influencing the extent of difference between machine set & actual slub parameters

The direction & extent of influence the different slub parameters exert on “the difference between machine set & actual slub parameters”, are shown in Tables 11, 12 & 13.

Difference between machine set and actual slub parameters was calculated for 50 different slub patterns in both the makes of slub yarn systems.

A slub pattern includes,

i) Slub length

ii) Slub diameter

and

iii) Distance between slubs

14


Table 11 Difference between machine set & actual slub length for different levels of machine set “slub lengths”

S.No System 1 System 2

Machine set

slub length

(cms)

Difference between machine set & actual

slub length (%)

Machine Set

slub length

(cms)

Difference between machine set &

actual slub length (%)

1 2.8 3.92 3.0 19.002 3.5 3.32 3.5 17.873 4.0

3.41

4.0 16.01

4 4.5 3.20 4.5 14.775 5.0 3.13 5.0 13.326 5.5

3.02

5.5 11.647 6.0

2.67

6.0 10.228 7.0 2.12 7.0 9.159 8.5 1.98 8.5 9.06

With increase in machine set slub length, the difference between machine set and actual slub length tends to reduce in both the slub yarn systems.

Table 12 Difference between machine set & actual slub dia fordifferent levels of machine set slub diameters.

S.no System 1 System 2

Machine set

slub dia (%)

Difference between machine set &

actual slub dia (%)

Machine setslub dia

(%)

Difference between machine set & actual slub dia

(%)

1 110 1.94 120 7.62

2 130 2.04 130 8.03

3 150 2.07 150 9.30

4 180 2.74 180 11.63

5 200

3.31

200

13.20

6 220

4.15

220

14.73

7 250 4.98 260 15.96

8 300 5.02 300 18.46

9 380 5.77 400 19.00

With increase in machine set slub dia, the difference between machine set & actual slub dia has a tendency to increase in both the slub yarn systems.

Table 13 Difference between the machine set & actual “Distance between the slubs” for different levels of “machine set distance between slubs”

S.no System 1 System 2

Machine set distance between

slubs (cm)


distance between slubs (%)

Machine set distance between

slubs (cm)


distance between slubs (%)

1 7.0

3.09

7.0

21.43

2 11 2.80 10 19.10

3 18 2.68 18 18.28

4 25 2.58 25 17.55

5 30

2.41

30

15.10

6 40 2.11 40 11.50

7 45 2.05 51 10.76

8 52 2.00 63 8.96

9 59 1.96 76 7.08

15


With increase in machine set “Distance between slubs” the difference between “the machine set and actual distance between the slubs” tend to decrease in both the slub yarn systems.

3.3 Tensile characteristics

In a given count, the strength of slub yarn is generally lower as compared to normal yarn by 10% to 20%. This strength difference is influenced by the presence of weak places in slub yarn. Mass decrease before and after a slub can lead to severe weak places in slub yarn. They are often related to the settings of the slub yarn device. Therefore, this parameter is an important quality characteristic of a slub yarn as it can lead to problems in the further processing of the yarn. Only mass decreases within a distance of three centimeters on the left or right side of a slub (ends of the trapezoids) are evaluated. The starting points of the distance are at the ends of the slubs. A mass decrease is counted, when the mass drops below 30% of the base yarn.

Figure 6 Mass decrease before and after slub

Slub yarn tenacity is influenced by the extent of weak places in slub yarns. In order to study the effect of different slub parameters (which are determined by the setting of the slub yarn systems) on slub yarn tenacity, 3 sets of slub yarns were produced.

i) Slub yarns with different slub length, keeping “slub dia” and “Distance between slubs” nearly constant

ii) Slub yarns with different distance between slubs, keeping other parameters more or less constant

iii) Slub yarns with different slub dia, keeping other parameters constant.

Figure 7 Slub lengh Vs Slub yarn RKM

With increase in slub length, the yarn segments with lower level of twist in a given length will be relatively higher and this could be the possible reason for the reduction in slub yarn RKM.

3.3.2 Influence of “Distance between the slubs” on slub yarn RKM

With increase in “Distance between the slubs” the slub yarn RKM goes up (Figure 8) and this is attributed to the less number of interventions the slub yarn system has to make with the yarn forming process in a given length of yarn.

Figure 8 Distance between slubs Vs Slub yarn RKM

3.3.3 Influence of slub dia on Slub yarn RKM

With increase in slub diameter, the slub yarn RKM shows a tendency to come down, and the strength of association between the two parameters is the highest (Figure 9).

3.3.1 Influence of slub length on slub yarn RKM

With increase in slub length, slub yarn strength tends to reduce (Figure 7).

16


Figure 9 Slub diameter Vs Slub yarn RKM

Hence, the strength difference between normal yarn and slub yarn depends on the length of slub, distance between the slubs & slub diameter maintained by the mills.

3.4 Appearance of slub in a fabric

The slub length is measured at half of the height of the trapezoid (Figure 10). This is primarily to level out the various kinds of ramps for different slub yarn types. The slub length bottom is measured at the base line of the trapezoid.

Figure 10 Definition of slub length and mass increase

Ratio T/B

The ratio T/B (ratio top to bottom slub length) gives an indication about the steepness of the ramps of a yarn. It correlates the length of the top of the trapezoid to the length of the bottom of the trapezoid. If the two lengths are about the same, the value reaches 1. A value going toward 0 means that the length of the top is much shorter than the length on the bottom of the trapezoid. This results in a rather flat ramp. The appearance of a slub in a fabric can vary considerably depending on the length and kind of the ramp.

3.4.1 Influence of T/B ratio on fabric appearance

Three different fabrics were knitted using combed hosiery yarns of 30s to 34s. The T/B ratio in these yarns vary between 0.21 and 0.48. The appearance these slubs make in the fabrics are depicted in Figures 11, 12 & 13.

Figure 11 34 CHY, T/B ─

Figure 12 30 CHY, T/B ─

Figure 13 32 CHY, T/B ─ 0.48.

17


The presence of slubs in the knitted fabrics is rather more predominant in fabrics with higher T/B ratio.

3.5 Influence of machine variables on slub yarn quality

20sC, 30sC & 40sC slub yarns were produced using different traveler size, space size & top arm loading levels. The quality values (mainly tenacity) obtained were compared with that of normal yarns.

3.5.1 Influence of traveler mass on slub yarn tenacity

The slub yarn tenacity values obtained with different traveler sizes in 20s, 30s & 40s slub yarns are given in Table 14 together with the tenacity values of normal yarn.

Table 14 Tenacity values of slub yarns and normal yarn for different levels of traveler mass

Count

Tenacity values (g/tex)

Slub yarn Normal yarn

0.055g* (1/O)**

0.50g* (2/O)**

0.055g*(1/O)**

20s C 17.77 18.12 20.01

0.040g* (4/O)**

0.036g* (5/O)**

0.032g*(6/O)**

0.036g*(5/O)**

30s C 15.14 15.73 16.14 18.51

0.028g*

(7/O)**0.025g*

(8/O)**0.023g*(9/O)**

0.025g*(8/O)**

40s C 16.14 16.51 16.91 18.4

* - Traveler mass ** - Traveler size

It is discernible from the table that with increase in traveler mass, the slub yarn tenacity tends to decrease optimum tenacity values for slub yarns were obtained at a traveler size higher than that used for normal yarns by 1 size (2/O instead of 1/O in 20sC, 6/O instead of 5/O in 30sC and 0/O instead of 8/O in 40sC).

3.5.2 Influence of spacer size on slub yarn tenacity

With increase in spacer size, the slub yarn tenacity shows a tendency to come down. Optimum tenacity values for slub yarns were obtained at a spacer size which is higher than that used for normal yarns of equivalent count by 1mm.

Count

Tenacity values (g/tex)

Slub yarn Normal yarnSpacer Size (mm)

Spacer Size (mm)

20sC

5.5 5.0 4.5 3.517.14 17.17 18.21 20.01

30sC

Spacer Size (mm)

Spacer Size (mm)

5.5

5.0 4.5

3.515.01 15.73 16.14 18.50

40sC

Spacer Size (mm) Spacer Size (mm)

5.0 4.5 4.0 3.016.10 16.51 16.92 18.40

3.5.3 Influence of top arm loading on slub yarn tenacity

A few studies have shown that the slub yarn tenacity values in different counts are maximum at a top arm load which is more or less equal to that maintained for normal yarns.

CONVERSION OF YARN TO FABRIC

I N F L U E N C E O F W E AV E T Y P E O N BREATHABILITY OF COMPACT YARN FABRICS

1.0 Introduction

Air permeability of a fabric is an important property determining its breathability. In a preliminary study conducted at SITRA air resistance values of compact & ring yarn fabrics were evaluated using Kawabata Evaluat ion System (KES–Air permeability tester). Air resistance is the reciprocal of air permeability. Air resistance values are given in Table 16 for some plain weave fabrics made using 30s & 60s ring & compact yarns (Combed)

Table 16 Air resistance values

─ R in plain weave fabrics

Fabric Type R

i) 30s compact yarn 0.95

ii) 30s ring yarn fabrics 0.76

iii) 60s compact yarn fabrics 0.12

iv) 60s ring yarn fabrics 0.10

*Air resistance is the reciprocal of air permeability

Air resistance values of fabrics made out of compact yarns (plain construction) are higher by 20% to 25%. This would mean that plain weave fabrics made out of compact yarns are less

Table 15 Tenacity values of slub yarns and normal yarn for different sizes of spacers

18


breathable. This may be mainly due to the higher density of compact yarns. In a woven fabric, air permeability is due to the combined influence of space between adjacent yarns plus space available inside the yarn for air passage (which is influenced by the extent of packing of fibres in the yarn). In a compact yarn fabric of the type woven for the purpose of this investigation, air resistance due to tight fibre packing overrides the effect of the open space (for air passage) between adjacent yarns.

Hence, a detailed investigation was carried out at SITRA to assess the influence of type of weave on the breathability of compact yarn fabrics. 2.0 Materials and methods

Fabrics with 4 different weaves viz, plain, drill (3/1 twill), satin (5 end) and honey comb weaves were produced using 40s compact yarn (combed). The cloth constructional parameters are as follows:

Ends / Inch = 78Picks / Inch = 72Count of warp = 40s C compactCount of weft = 40s C compact

All the fabrics were tested for air permeability and water vapour transmission. Air permeability denotes the volume of air passing through the test specimen of a given area in a given time. This was assessed using FX 3300 Air Permeability Tester as per ASTM D 737 standards. It is an important property deciding the wearing comfort of the fabric specimen under question. Water vapour transmission of a fabric specimen denotes the extent to which the water vapour generated in human body gets passed on to the atmosphere through the specimen. The water vapour transmission was determined according to ASTM E96-90 standards.

In addition, the fabrics were also tested for thermal resistance, abrasion resistance & pilling resistance.

3.0 Quality attributes of compact yarn fabrics with different weave type

3.1 Air permeability & water vapour transmission

Air permeability values of the 4 fabric specimens under investigation are given in Table 17.

Table 17 Air permeability of compact yarn 3 2

fabrics with different weave (cm / cm /sec)

S.No. Type of weave Air permeability

1 Plain 98.45

2 Drill 230.70

3 Satin

263.5

4 Honey comb 274.4

Figure 14 Shows the weave type of the fabrics produced in this study.

Plain weave

Drill

5 End satin

Honey Comb

19


Air permeability values are relatively higher for satin & honey comb fabrics and it is the lowest for plain weave fabrics. In satin & honey comb fabrics, the intersection (connection) numbers of warp & weft yarns are lower which accounts for the higher level of air permeability in these fabrics; conversely, in Plain weave fabrics, in which the intersection number is the highest, the air permeability is the lowest.

Water vapour transmission rates (WVTR) for fabrics of different weave types are given in Table 18.

Table 18 Water vapour transmission rate (WVTR) for compact yarn fabrics with different

2weaves (g/m ) for 24 hrs

It was observed that in 5 end satin and honey comb fabrics, in which the weft yarns are relatively more free (intersections are less by about 50%) the water vapour transmission is higher. On the other hand, the weft yarns are not comparatively free due to more number of intersections they make with the warp yarns in plain weave and drill fabrics and therefore the water vapour transmission is relatively lower in these fabrics. On an average, satin/honey comb fabrics have about 33% higher WVTR as compared to plain weave fabrics and about 17% higher WVTR in comparison with drill fabrics.

3.2 Thermal resistance of compact yarn fabrics

Thermal resistance (Rct) is the temperature difference between the two faces of a textile material divided by the resultant heat flux per unit area in the direction of the gradient. It is a quantity specific to textile materials or composites which determines the dry heat flux across a given area in response to a steady applied temperature gradient. The dry heat flux may consists of one or more conductive, convective and radiant components.

2Thermal resistance is expressed in m K/W (Square meters Kelvin per watt).The lower the thermal

S.no. Type of weave Water vapour transmission

1 Plain 1475.12

2 Drill 1671.21

3 Satin 1975.61

4 Honey comb 2016.59

resistance, the better will be the comfort for hot climatic conditions.

The specimen to be tested is placed on an electrical heated plate with conditioned air ducted to flow across and parallel to its upper surface. The thermal resistance (Rct) is determined by substracting the thermal resistance of the boundary air layer above the surface of the test apparatus from that of a test specimen plus boundary air layer, both measured under the same conditions.

The thermal resistance values of the four fabrics under consideration are given in Table 19.

Table 19 Thermal resistance values for compact yarn fabrics with different weaves

2─ (m K/W)

S.no Type of weave Thermal reistance

1 Plain 0.019

2 Drill 0.025

3 Satin 0.025

4 Honey comb 0.041

Plain weave fabrics have maximum yarn interlacing points between warp & weft and honey comb fabrics have the minimum. Hence, one would expect higher thermal resistance to plain weave fabrics as compared to that of honey comb However, the results are exactly the reverse. This could be attributed to the difference in thickness between the fabrics. Thickness values of fabrics with different weaves are given in Table 20 together with fabric crimp.

Table 20 Thickness values of fabrics (mm) & Fabric crimp (%)

S. no Type of

weave

Fabric thicknessvalues

Fabric crimp(%)- Weft way

1. Plain

0.28

14.0

2. Drill

0.40

16.2

3. Satin

0.40

16.8

4. Honey comb

0.56

22.4

Thickness of honey comb fabrics is nearly twice as that of plain fabrics and this is mainly responsible for the higher values of thermal resistance observed for honey comb fabrics. Difference in thickness between fabrics of different weaves is largely accounted for by the respective difference in crimp values.

20


3.3 Moisture management properties

The wearer's perception of moisture comfort sensations in clothing is significantly affected by the extent of liquid moisture transmittance in the clothing. When drops of water fall on the surface of any textile material, the water spreads into the fabric radially in multiple directions. Its precise movement depends upon the chemical and physical nature of the textile material. Thus, the ability of a fabric to control the movement of moisture associated with it is called moisture management of the textile material.

Moisture management of fabric draws moisture away from the skin and disperses it over a large surface area away from the skin where it evaporates, thereby reducing the chill factor and improving comfort. Moisture management is a co-aspect of a textile's properties that always needs to be regarded in tandem with comfort. The liquid moisture management performance of fabrics results from complex properties including their absorbent capacity, absorption rate and evaporation.

The moisture management properties of the conditioned fabric samples were determined according to AATCC 195-2009 on an SDL Atlas Moisture Management Tester. The apparatus is

based on the physical principle that the surface contact electrical resistance of a fabric changes with the content of a water based liquid solution near the surface. The resistance value depends on two factors: the electrical conductivity of the liquid and the water content in the local areas of the fabric. As the electrical conductivity of the liquid is fixed, the electrical resistance measure on the surface of the fabric is determined by the water content. All

2specimens (8.0 x 8.0 ± 0.1cm ) were washed and ironed to remove excessive water and wrinkles. They were then conditioned for at least 24h prior to testing. Sweating was simulated with 0.21 x 0.01 g of synthetic sweat, which was introduced onto the top surface of the fabric during the first 20s of the test (120s ); the liquid would now begin to get transmitted in three directions, i.e. spreading radially outwards on the upper surface of the fabric, wicking through the fabric from the upper to the lower surface and spreading radially outwards on the lower surface of the fabric. The Moisture Management Tester (MMT), contained upper and lower concentric moisture sensors that enclosed the test-specimen. Based on the signals measured, a set of indexes are calculated, the descriptions of which are summarized in Table 19. The indices are graded according to AATCC Test method 195-2009 and converted from a number value to a grade on a five-grade scale. An average of five readings was taken for each sample.

Index UnitGrade

1 2 3 4 5

Wetting Time - top surface (WTt)

s≥120

No wetting

20 – 119

Slow

5 – 19

Medium

3 – 5

Fast

< 3

Very fastWetting Time –bottom surface (WTb )

Absorption Rate -

top surface (ARt)

% / s 0 –

10

Very slow

10 –

30

Slow

30 –

50

Medium

50 –

100

Fast

> 100

Very fast Absorption Rate -

bottom surface (ARb)

Maximum Wetted Radius -

top surface (MWRt)

mm

0 – 7

No wetting

7 – 12

Slow

12 – 17

Medium

17 – 22

Large

> 22

Very largeMaximum Wetted Radius - bottom surface (MWRb)

Spreading Speed -

top surface (SSt)

mm / s0 – 1

Very slow

1 –

2

Slow

2 –

3

Medium

3 –

4

Fast

> 4

Very fast Spreading Speed -

bottom surface (SSb)

Accumulative one-Way transport

index (R)

%

< –50

Poor

50 – 100

Fair

100 – 200

Good

200 – 400

Very Good

> 400

Excellent

Over all Moisture Management

Capability

(OMMC)

- 0 –0.2

Poor

0.2 –

0.4

Fair 0.4 –

0.6

Good

0.6 –

0.8

Very Good

> 0.8

Excellent

Table 21 Grading of moisture management tester indices

21


Definition of the various indices given in Table 19

i) Wetting Time (WT) - top surface andt

Wetting time (WT ) - bottom surfaceb

- The time in seconds when the top and bottom surfaces of the specimen begin to be wetted after the test is started.

ii) Absortion rate (AR ) - top surface andt

Absortion rate (AR ) - bottom surfaceb

- The average speed of liquid moisture absorption for the top and bottom surfaces of the specimen during the initial change of water content during a test.

iii) Maximum Wetted Radius (MWR) - top t

andMaximum Wetted Radius (MWR ) - bottomb

- The greatest ring radius measured on the top and bottom surfaces of the test specimen.

iv) Spreading Speed (SS) - top andt

Spreading |Speed (SS ) - bottom b

- The accumulated rate of surface wetting from the centre of the specimen, where the test solution (Saline solution) is dropped to the maximum wetted radius.

v) Accumulative one-way transport capability (R)

- The difference between the area of the liquid moisture content curves of the top and bottom surfaces of the test specimen with respect to time.

Overall Moisture Management Capability (OMMC) is calculated using the formula,

OMMC = C1 x AR + C x R + C3 x SSb 2 b

Where AR is the absorption rate

R is the one way transport capabilitySS is the spreading speed b

and C , C & C are system constants. 1 2 3

The system constants used in the development of M M T s o f t w a r e w e r e C = 0 . 2 5 , 1

C = 0.5 and C = 0.25 based on human perception 2 3

studies in which the one-way transport capability was found to be twice as important as absorption rate and spreading speed.

The fabrics with different weaves made in this investigation were tested for the various quality indices obtained in Moisture Management Tester and they are given in Table 22.

Table 22 Grading of fabrics with different weaves for moisture management quality indices

Quality Index Fabric weave

type

Grade

1 2 3 4 5

Wetting Time - top surface

(WTt)

A ?

B ?

C ?

D ?

Wetting Time – bottom surface

(WTb)

A ?

B z ?

C ?

D ?

Absorption Rate - top surface

(ARt)

A ?

B ?

C ?

D ?

Absorption Rate - bottom surface

(ARb)

A ?

B ?

C ?

D ?

22


Quality Index Fabric weave

type

Grade

1 2 3 4 5

Maximum Wetted Radius -

top surface (MWRt)

A ?

B ?

C ?

D ?

Maximum Wetted Radius - bottom surface

(MWRb)

A ?

B ?

C ?

D ?

Spreading Speed - top surface

(SSt)

A ?

B ?

C ?

D ?

Spreading Speed - bottom surface

(SSb)

A ?

B ?

C ?

D ?

Accumulative one-way

transport index (R)

A ?

B ?

C ?

D ?

Over all Moisture Management

Capability (OMMC)

A ?

B ?

C ?

D ?

Table 22 Grading of fabrics with different weaves for moisture management quality indices (Contd..)

A- Plain B- Drill C- Satin D- Honey comb

According to the grades (Table 20), the fabrics with different weaves taken for the study were ranked for OMMC and are given in Table 23.

Table 23 Ranking of fabrics with different weaves as per the OMMC

Fabric Weave Type Rank

(as per OMMC)

─ Plain Excellent

─ Drill Very Good

─ Satin Excellent

─ Honey Comb Fair

23


CHEMICAL PROCESSING

A COMPARATIVE STUDY ON BLEACHING COTTON FABRICS USING PERACETIC ACID (PAA) AND HYDROGEN PEROXIDE (H O ) 2 2

(Project funded and supported by an industrial partner)

Aim and scope of the project

To conduct bleaching / preparatory trials on cotton fabrics (especially on terry towels, twill fabrics and hosiery fabrics) using Peracetic acid (PAA) and compare the results with those obtained from bleaching with the universal bleaching agent (i.e) Hydrogen peroxide. Most of the bleaching processes for cotton materials are carried out in alkaline medium as against the acidic medium used in bleaching with peracetic acid.

Bleaching

Bleaching is a preparatory process of destroying / removal of natural and added colouring matters from the substrate in order to make the material white or make it suitable for further processes such as dyeing and / or printing.

Conventional process: Combined scouring and bleaching process using Hydrogen Peroxide

In the present scenario, most of the industries use Hydrogen peroxide (also known as the Universal bleaching agent) for bleaching of cotton materials mainly because of its versatility and effectiveness in removal of colour. Of late, scouring and bleaching processes are combined to minimize time and energy consumption. The most important ingredients of combined scouring and bleaching recipe are hydrogen peroxide and caustic soda alongwith other auxiliaries such as stabilizer, wetting agents, sequestering agents, etc. The type and concentration of these auxiliaries also play a major role in the bleaching effect obtained.

PerAcetic Acid (PAA)

Peracetic acid (C H O ) is a mixture of acetic acid 2 4 3

(CH COOH) and hydrogen peroxide (H O ) in a 3 2 2

watery solution. It is a bright, colorless liquid that has a piercing odor and a low pH value (2.8). PAA is produced by a reaction between hydrogen peroxide and acetic anhydride:

(CH CO) O + H O -> CH COOOH + CH COOH3 2 2 2 3 3

acetic anhydride + hydrogen peroxide ->

peracetic acid + acetic acid

PAA can also be produced by oxidation of acetaldehyde. It is usually produced in concentrations of 5-15%. When peracetic acid dissolves in water, it disintegrates to hydrogen peroxide and acetic acid, which will fall apart to water, oxygen and carbon dioxide. PAA degradation products are non-toxic and can easily dissolve in water. PAA is a very powerful oxidant; the oxidation potential outranges that of chlorine and chlorine dioxide

The chemical was supplied by the sponsor and they had given SITRA a tentative recipe to bleach cotton Twill & Towel fabrics.

Materials and Methods

Initially a few trials were taken on terry towels and twill fabrics as per the recipe suggested by the suppliers. The results were found to be encouraging with the whiteness index of PAA bleached fabric was almost closer to that of hydrogen peroxide and the smoothness of the PAA bleached fabric was found to be better.

Hence, further trials were planned on the single jersey fabric and bulk trial was taken on three different fabrics -Single jersey, rib and interlock, the details of which are given below:

ParametersGrey fabric

Single jersey Rib Interlock

Count 42.2 32.4 41.5

GSM 103.7 194.2 199

The above samples were bleached under similar conditions using i) Hydrogen peroxide and ii) PAA as per the recipe given below:

Recipe suggested by the chemical supplierConcentration of PAA – 4%Temperature of Treatment – 65 deg C pH of the bath – 7.0Time of Treatment - 30 to 45 minutes

Methodology

The following methodology was adapted for conducting the trials:


I. Combined scouring and bleaching process with H O 2 2

II. Combined scouring and bleaching process with PAA

With regard to the use of PAA various permutations and combinations were tried to study the effect of:

1. Concentration of PAA2. Temperature of treatment3. pH of the bath4. Time of treatment

Whiteness index of the samples was measured using Macbeth 7000A spectrophotometer.

1. Effect of concentration of PAA

Concentration of PAA was varied from 2% to 6 % (on weight of fabric) with four different recipes and the results are as follows:

pH of the bath – 7; Material to Liquor ratio – 1:6

24

Treatment Conditions

Whiteness Index (CIE)


Before OBA

After OBA

30s Grey hosiery fabric

12.20 -7.84R*

-

Scoured (Openbath)

25.06 -

6.89R

97.83 -

4.4R

PAA -

2%

PAA -

4%

PAA -

6%

PAA -

2%

PAA -

4%

PAA -

6%

Combined Scouring & Bleaching @ 95deg C with PAA

59.83 -1.35R

71.26 -0.50R

64.70 -1.09R

133.59 1.05G

140.25 1.18G

135.71 1.16G

Combined Scouring & Bleaching @ 95deg C with 10%

H2O2 72.65 - 0.54R 143.25 1.81G

Only Wetting agent and PAA @ 95deg C

52.88 -2.14R

62.71 -1.23R

65.80 -0.97R

126.36 0.21G

133.02 0.74G

136.32 0.98G

Wetting agent + H2O2

10%

71.57 -0.28R

142.21 1.60G

Arrow Scour 1% and PAA @

60 deg C

36.92 -2.46R

44.32 -1.73R

47.95 -1.32R

105.30 -2.16R

111.92 -1.59R

114.68 -1.40R

Only Arrow Scour 1%

22.81 -5.02R

89.33 -4.49R

Scoured fabric bleached with PAA @ 95deg C

68.09

-0.97R

71.04 -0.70R

73.04 -0.62R

138.18 1.22G

140.73 1.82G

140.01 1.64G

Scoured & H2O2

Bld

81.90 -0.06R

147.99 1.91G

The above results reveal that there is significant difference in whiteness index between 2% and 4 % and there is no significant difference in results between 4% and 6%. Hence, under these conditions 4% (o.w.f) of PAA seem to give the optimum results.

1. Effect of pH of the bath

pH of the bath was varied from 5 to 9 and the trials were taken using 4% and 6% of PAA

In general, the resultant whiteness index of the fabric was better in alkaline pH than that of neutral and acidic pH.

1. Effect of temperature

The temperature of the treatment was varied from

060 to 95 C.

The appearance of the fabric and absorbency of the fabric was very poor at lower temperature and the

0results were satisfactory only at 95 C.

2. Effect of time of treatment

The temperature of the treatment was varied from 20 to 60 minutes and it was found that the optimum results were obtained at duration of 30 to 40 minutes.

Bleaching of cotton fabrics with H O and PAA on 2 2

soft flow processing machine

MLR – 1:6

25


Treatment conditions

Whiteness index (CIE)

Before OBA After OBA

pH 5 pH 7 pH 9 pH 5 pH 7 pH 9

Sodium Hydroxide – 2%

Wetting agent –

0.5g/l

PAA – 4%

59.82 -0.92

58.35-0.89

54.60 -1.07

111.33-1.55

108.79 -1.66

108.21-1.61

Wetting agent –

0.5g/l

PAA – 6%

62.17-0.61

63.82-0.49

65.30 -0.47

114.30 -1.42

115.44 -1.31

119.27-1.11

Arrowscour – 1%

Wetting agent – 0.5g/l

PAA – 6%

51.33 -1.32

54.11-1.06

58.19-0.69

98.69-2.46

102.71-2.21

109.29-1.78

Arrowscour –

2%

Wetting agent –

0.5g/l

PAA –

6%

51.03 -1.24

53.19-1.11

58.30 -0.76

99.51-2.44

101.84-2.21

110.40 -1.71

Scoured fabric PAA-6%

73.84-0.16

73.04 -0.62R

74.71-0.07

130.46-0.79

140.73 1.82G

132.17-0.73

S.no Treatment Whiteness index CIE

1 H2O2 Treatment:

Wetting agent 1.5g/l @70 deg C, 10 min

NaOH – 2 g/l, Stabiliser – 0.3 g/l, H2O2 – 9g/l, OBA – 0.7g/l

Rised the temperature to 95 deg C, 60 min.

Hot washed, neutralized and dried

133.71

-0.43R

2 PAA Treatment:

Wetting agent 1 g/l @70 deg C, 10 min

NaOH – 2.5 g/l, Raised the temperature to 75 deg C, 10 min., Decreased the temperature to 55 deg C, Added PAA -2.5 g/l, Raised the temperature to 60 deg C, 20 min, Raised the temperature to 95 deg C, 30 min, drained,

Hot washed, neutralized and dried. ( With OBA)

130.75

-0.39R

26


The grey fabrics were selected and processed as per the above conditions and evaluated for their properties and the results are as follows:

Para-meters

Grey Fabric H2O2 Bleached fabric PAA Bleached Fabric

Single Jersey

Rib Inter lock

Single Jersey

Rib Inter lock

Single Jersey

Rib Inter lock

Count 42.2 32.4 41.5 43.4 33.0 43.8 42.8 33.7 44.1

GSM 103.7 194.2 199 129.5 205.8 209.8 128.0 210.2 211.4


Without OBA

8.13 -6.28 R

4.03 -8.68R

11.27 -7.13R

80.70-0.03 R

77.83-0.39R

77.69-0.28R

68.78-0.47R

62.32-0.5R

69.46-0.77R

With OBA

-

-

-

138.68-0.24R

135.80-0.43R

139.0-0.45R

128.06 1.58G

122.68 1.92G

129.76 1.16G

Yellowness Index

24.84

27.19

24.95 -

-

-

-

-

-

% Spirality (Before Wash)

18.4

Nil

Nil

18.0

Nil

Nil

18.75

Nil

Nil

% Spirality (After Wash)

36.2

Nil

Nil

23.0

Nil

Nil

19.0

Nil

Nil

Shrinkage % 40 deg Wash & Tumble dried

Length

-15.12

-8.64

-10.88

-8.0

-5.32

-6.16

-5.76 -6.0

-8.0

Width -18.64 -13.68 -14.80 +4.10 +4.72 +2.40 -1.44 +0.9 -2.64

Fabric friction

-

Surface Drag angle D(s)

6.3

6.5

7.5

11.0

14.3

7.0

14.3

14.3

10.3

Bursting Strength Kg/cm

2

6

8

9.4

6

7.8

9.8

6

8.2

10.0

Absorbency, seconds

>3

>3

>3

<1

<1

<1

<1

<1

<1

Feel & Observation

- Samples found to be brighter with harsh feel

Brightness comparatively lesser than H2O2, Soft feel

27


Conclusions

The test results reveal that there is no significant difference in weight per square metre between the H O bleached and PAA bleached samples. The 2 2

Whiteness Index of PAA bleached samples were found to be about 7% to 20% lower than H O 2 2

bleached samples. The spirality and strength results were found to be good on the PAA bleached samples and the widthwise shrinkage was also controlled. The feel of the PAA bleached samples were found to be soft when compared with the H O 2 2

bleached samples.

Scope for further study

Trials using PAA shall be carried out with bio-scouring agents and the effluent characteristics are to be studied. Further, this work may be extended to polyester and its blends as well provided we get an industrial partner to support our research activity.

OPERATIONAL STUDIES

TH30 COSTS, OPERATIONAL PERFORMANCE AND YARN QUALITY:

INTER-MILL STUDY OF KEY FACTORS (APRIL-JUNE 2014)

This study is thirtieth in the series on inter-mill study on 'Costs, Operational Performance and Yarn Quality'. In this study, 142 mills had participated.

The following are some of the main findings of the study.

Comparison with last study (April-June 2013)

A comparison has been made with respect to 8 costs and operational parameters against the last

thstudy (29 study). Based on the deviations in the average values, relative changes in the individual mill's performance have been identified with respect to 86 mills which had participated in both the studies.

In the 2nd quarter of 2014, mills on the whole faced a setback in the performance by recording a significant fall of Rs 840 per spindle per year in the contribution (by 14%) as compared to the corresponding quarter of 2013 (Table 24), which was mainly due to the substantial increase in the raw material cost (by Rs 2940 per spindle per year). The sale value, however, registered a huge increase of Rs 2280 per spindle per year which was mainly due to the increase in the yarn selling price (by 5%) and partly because of the jump in the machine productivity (by 3%). The production per spindle and spindle utilisation registered respectively a marginal increase of 2% and one percentage point. While the power cost recorded a marginal drop (by Rs 110 per spindle per year), the salaries and wages cost registered a significant increase of Rs 290 per spindle per year.

The huge increase in the yarn sale value and a marginal reduction in the power cost, however, could not off-set the increase registered by the raw

Table 24 Comparison of costs and operational parameters between the two studies

Parameter

Common mills' (86) average

29th study (Apr.- June 2013)

30th study (Apr.- June 2014)

Contribution - Rs/spindle/year 6100 5260

Salaries and wages cost - Rs/spindle/year 1870 2160

Power cost

-

Rs/spindle/year

3370

3260

Raw material cost

-

Rs/kg of yarn

-

Rs/spindle/year

135

15150

158

18090

Yarn selling price

-

Rs/kg

256

268

Yarn sale value

-

Rs/spindle/year

26490

28770

Prodn./spl./8 hrs.(adj.to 40s) in g

101

103

Spindle utilisation (%)

93

94

Average count 46s 47s

28


material cost and salaries and wages cost, due to which the mills had experienced a significant drop in the contribution.

It is interesting to note that almost none of these common mills had registered a negative contribution in both the studies. Though, on the whole, these mills had experienced a drop in the contribution in the 30th study, nevertheless, the

ndaverage contribution earned by them in the 2 quarter of 2014 was fairly high at Rs 5260 per spindle per year.

Further analysis shows that out of the 86 common mills, only one-third (28 mills) registered an increase in the contribution (by Rs 990 per spindle per year) with the increase ranging from Rs 90 to Rs 4470 between mills (Figure 15). The remaining mills recorded a drop of Rs 1760 per spindle per year in the contribution, the drop ranging from Rs 40 to Rs 4930 between mills which was due to the increase in the two major input costs viz., raw material cost and salaries and wages cost which more than off-set the increase in the yarn sale value. On the other hand, the increase in the contribution in the 28 mills was largely due to the increase in the sale value (by Rs 4030 per spindle per year) and reduction in the power cost (by Rs 150 per spindle per year) which more than off-set the increase in the two other major input costs (by Rs 3190 per spindle per year).

Incr

ea

seD

rop

Incr

ea

se/d

rop

in the

co

ntr

ibutio

n (

Rs/

spl./

yr.) Rs 4470

- Rs 4930

Average: -Rs 1760

Average: Rs 990

Figure 15 Differences in the contribution between the two studies

(Q2 of 2013 and Q2 of 2014)

ONLINE SURVEY OF YARN SELLING PRICE AND RAW MATERIAL COST

SITRA had initiated this unique monthly online inter-mill study of RMC and YSP in May 2013. So far (till March 2015) 23 studies have been completed. As many as about 80 mills from different parts of the country have been participating in the study every month. The study covers the following data relating to around 250

different counts (ranging from below 10s to over 120s) and varieties of yarns (carded, combed, hosiery, compact, doubled, high twist, slub etc.), predominantly cotton counts.

Yarn selling price (YSP) (Rs/kg) Raw material cost (RMC) (clean material cost) (Rs/kg of yarn)

Net output value (NOV) (Rs/kg

of

yarn & Rs/spl./shift)

TCI (techno-commercial index)

Total fibre to yarn conversion cost (Rs/kg of yarn)

RMC as a % of YSP

Yarn realisation (%)

Production/spindle (rotor)/8 hours (g)

Yarn quality

- Count CV%

- Strength CV%

- CSP

- U%

- Imperfections/1000 m

- Hairiness Index

stOn 21 of every month, the survey report, numbering around 70 pages, is being uploaded in the web portal “rmcysp.sitraonline.org”. The specialty of this online survey is the built-in database supported queries in the web portal, using which a participant mill can access the count-wise data quickly without going through the voluminous survey report. Besides the above, trends in the movement of average YSP, RMC and NOV between months for 11 popular counts are also being uploaded every month – both tabular and graphical forms. Figures 16 and 17 show the trends in the movement of RMC, YSP and NOV of 40s C and 60s C compact yarns during the past 22 months (April 2013 to January 2015).

Figure 17 Movement of YSP, RMC and NOV between months (60s C-Comp.)

Figure 16 Movement of YSP, RMC and NOV between months (40s C)

29


INTER-MILL STUDY ON FIBRE TO YARN TH

CONVERSION COST - 4 STUDY

The study was conducted based on the conversion cost particulars that were collected from the mills in

th ndthe 30 CPQ study, covering data for the 2 quarter of 2014 (April-June). A detailed analysis has been made for 12 different counts and varieties of yarns for each of which 5 mills and above had furnished the data.

Total conversion cost in 2014

Average conversion cost, in terms of per kilogram of yarn, is found to increase steeply as the count becomes finer i.e. from as low as about Rs 50 in 24s CH-Ex. count to a high of about Rs 160 in 80s C count (Table 25).

Table 25 Count-wise total conversion costPeriod: April-June 2014

Between mills, the conversion cost differs very widely in all the counts ranging from 35% to about 90%, the overall difference being high at about 50%. Such a wide difference in the conversion cost between mills is mainly due to the differences in the operational parameters like production rate, labour productivity, capacity uti l isation, energy consumption, etc. as well as cost parameters such as wage rate, salaries, power cost per unit, stores and packing materials cost, interest commitment and investment on plant & machinery and partly because of the differences in the method of estimation of conversion cost.

In terms of per kilogram per count, the conversion cost does not show any trend between the counts. It averages at about Rs 2.0 per kg per count,

varying from Rs 1.60 to Rs 2.20 between the counts. However, in terms of per spindle shift, the total conversion cost shows a declining trend as the count becomes finer i.e. in 24s CH-Ex., it is around Rs 13 whereas in 80s C, it is only about Rs 7.

Item-wise conversion cost in 2014

Item-wise conversion cost also shows an increasing trend as the count becomes finer (Table 26). For example, the salaries and wages cost in coarse counts (24s CH) is only about Rs 9 per kg of yarn whereas in superfine counts (80s C), it is almost 4 times high at Rs 36 per kg of yarn. The power cost which is around Rs 18 per kg of yarn in 24s CH, is also 3.5 times high at about Rs 65 per kg of yarn in 80s C.

S. no.

Count

Conversion cost (Rs/kg of yarn)* Conv. cost

(Rs/kg/ count)

Conv. cost

(Rs/spl./ shift)#

No. of

mills Average Minimum Maximum

% differ -ence**

1. 24s CH-Ex. 51.3 40.4 58.1 44 2.14 12.8 5

2. 30s CH 58.5 45.3 66.4 47 1.95 11.1 5

3. 30s CH-Ex. 57.7 47.7 74.9 57 1.92 11.4 8

4. 32s K 62.1 52.6 87.5 66 1.94 8.9 5

5. 40s C 77.3 61.6 97.4 58 1.93 9.2 8

6. 40s C-Comp.

81.3 60.2 96.4 60 2.03 10.0 8

7. 40s CH 64.0 52.9 76.3 44 1.60 8.3 6

8. 50s C-Comp.

98.6 84.7 119.4 41 1.97 9.0 6

9. 50s CH-Ex. 92.0 76.9 103.4 35 1.84 8.0 5

10. 60s C 123.7 100.2 150.3 50 2.06 7.9 10

11. 60s C-Comp.

132.4 111.0 158.7 43 2.21 9.0 10

12. 80s C 162.3 99.4 186.2 87 2.03 6.5 8

30


Table 26 Item-wise conversion cost (2014) (Amount: Rs/kg of yarn)

S. no.

Count YSP RMC

Conversion cost Net profit

No. of millsSWC Power

Stores & packing

Admn. OH

Int. Dep. Total

(a) (b) (c) (a-b-c) 1.

2.

3.

4.

5. 6. 7. 8. 9.

10.

11.

12.

24s CH-Ex.

30s CH

30s CH-Ex.

32s K

40s C 40s C-Comp. 40s CH 50s C-Comp. 50s CH-Ex.

60s C

60s C-Comp.

80s C

199.0

219.6

207.5

197.2

239.4 247.9 234.8 287.8 267.1

294.2

313.9

362.1

150.3

158.9

155.6

135.4

163.0 159.5 164.8 165.6 163.3

165.6

167.4

192.0

9.1

9.3

11.9

14.8

16.8 14.6 12.4 19.4 18.5

27.2

26.1

35.7

17.7

22.5

20.7

23.1

31.8 29.6 26.9 41.1 36.4

48.0

51.9

64.9

7.0

7.6

6.9

5.8

8.0 8.1 7.9

10.0 11.4

10.5

12.3

13.2

2.5

4.2

4.0

3.4

4.5 4.0 4.2 4.4 6.6

9.9

6.7

9.1

7.6

8.6

7.5

7.1

7.8 14.4 8.1 9.9

10.4

17.5

21.2

19.3

7.4

6.3

6.7

7.9

8.4 10.6 4.5

13.8 8.7

10.6

14.2

20.1

51.3

58.5

57.7

62.1

77.3 81.3 64.0 98.6 92.0

123.7

132.4

162.3

(-)2.6

2.2

(-)5.8

(-)0.3

(-)0.9 7.1 6.0

23.6 11.8

4.9

14.1

7.8

5

5

8

5

8 8 6 6 5

10

10

8

Note: (-) sign indicates net loss

YSP: Yarn selling price; RMC: Clean raw material cost; SWC: Salaries and wages cost

Another interesting observation is that of the total conversion cost, power cost is found to be the single largest one with a share of 40% followed by the salaries and wages cost (20%) and interest cost

th(13%). The depreciation cost stands at 4 place (11%) followed by the stores and packing materials cost (10%) and administrative overheads (6%).

Changes in the total conversion cost between 2010 and 2014

The total conversion cost on the whole registered an increase of about 30% in 2014 as compared to the conversion cost that prevailed in 2010 with the increase ranging from 17% to 42% in different counts (Table 27). The increase in the conversion cost during the past 4 years works out to 7% per year compounded

Item-wise conversion cost in 2010 and 2014

An analysis of the item-wise conversion cost shows that except depreciation cost, all the 5 remaining cost items witnessed an increase during this period. The spurt in the power cost accounted for almost one-half of the overall rise in the conversion

Table 27 Increase in the total conversion cost between 2010 and 2014

S. no.

Count

Conversion cost/kg of yarn (Rs)

Increase

in the conversion

cost (%)2010 2014

1. 2.

3.

4.

5.

6.

7. 8.

24s CH-Ex. 30s CH

30s CH-Ex.

40s C

50s CH-Ex.

60s C

60s C-Comp.

80s C

38.6 43.1

45.4

65.1

68.2

92.3

93.0 138.5

51.3

58.5

57.7

77.3

92.0

123.7

132.4

162.3

33

36

27

19

35

34

42

17

cost followed by the increase in the salaries and wages cost (29%) and stores and packing materials cost (14%) (Figure 18). The rise in the interest cost amounted to 8% of the total increase in the conversion cost.

31


Interest cost

Administrative overheads + Depreciation costPower cost

Salaries and wages cost

Stores and packing materials cost

47%

29%

2%

14%

8%

Figure 18 Share of item-wise cost on the overall increase in the conversion cost in 2014 over 2010

The power cost per unit during this four years registered a jump of 27% (from Rs 4.74 per unit in

th2010 to Rs 6.0 per unit in 2014, as per the 25 and

th30 CPQ studies). The above analysis also leaves an important message that there is an urgent need to improve the labour productivity in many mills so as to control the spurt in the SWC which is somewhat alarming. The depreciation cost in fact registered a marginal drop of about 2.7% which indicates that the participant mills did not make any significant investment on modernisation of machinery which in turn may be due to the disturbed performance witnessed by the mills during the past 4 years.

Impact of increase in the conversion cost on profit margin

Profitability of a count is determined by the net out-put value (NOV) on one hand and the conversion cost on the other. The NOV is nothing but the difference between yarn selling price and raw material cost. Table 28 shows the changes that witnessed in the NOV, conversion cost and net profit in all the 8 counts between 2010 and 2014.

Table 28 Changes in NOV, conversion cost and net profit between 2010 and 2014

Amount: Rs/kg of yarn

Count

2010 2014 Inc-

rease in

NOV

(%)

Inc -

rease

in

conv.

cost (%)

Drop

in net

profit

(%) YSP RMC NOV

Conv.

cost

Net

profit YSP RMC NOV

Conv.

cost

Net

profit

24s CH -Ex.

30s CH

30s CH -Ex.

40s C

50s CH -Ex.

60s C

60s C -Comp.

80s C

149.9

162.0

161.8

185.8

195.3

222.2

239.3

285.6

98.1

103.9

99.1

100.6

101.7

102.8

103.7

120.1

51.8

58.1

62.7

85.2

93.6

119. 4

135.6

165.5

38.6

43.1

45.4

65.1

68.2

92.3

93.0

138.5

13.2

15.0

17.3

20.1

25.4

27.1

42.6

27.0

199.0

219.6

207.5

239.4

267.1

294.2

313.9

362.1

150.3

158.9

155.6

163.0

163.3

165.6

167.4

192.0

48.7

60.7

51.9

76.4

103.8

128.6

146.5

170.1

51.3

58.5

57.7

77.3

92.0

123.7

132.4

162.3

(-)2.6

2.2

(-)5.8

(-)0.9

11.8

4.9

14.1

7.8

(-)6.0

4.5

(-)17.2

(-)10.3

10.9

7.7

8.0

2.8

33

36

27

19

35

34

42

17

120

85

134

104

54

82

67

71

Note: (-)ve sign indicates net loss/drop in NOV.

The NOV, on the whole, did not register any increase in 2014 as compared to the NOV that prevailed in 2010. Of the 8 counts, 3 counts registered a drop in the NOV (24s CH-Ex., 30s CH-Ex. and 40s C) and the remaining 5 counts recorded an increase which ranged from 3% to 11%. The conversion cost, on the other hand, recorded a substantial increase of about 30% with the increase ranging from 17% to 42% between

counts. As a result of these changes, all the 8 counts put together registered a huge drop in the net profit (by about 90%) with the drop ranging from about 50% to around 130% between counts.

The commercial performance i.e. YSP and RMC, is not entirely under the control of the managements. The spurt in the conversion cost, particularly, the substantial increase in the power cost and salaries

32


and wages cost, would have affected the profit margins of many mills during this 4 years. It is interesting to observe that in the past two decades (during 1990-2010), the increase in the conversion cost was rather slow at 4.2% per year (compounded) whereas in the last 4 years, the increase was somewhat high at 7% per year (compounded).

Mills should benchmark the various operational parameters such as production rate, labour productivity, UKG, yarn recovery and invisible loss, stores and packing materials consumption and staff employment and strive for the standards. Moreover, a time has come for most of the mills to increase their labour productivity substantially so as to either reduce the SWC significantly or arrest its increase. Towards this, optimisation of man power for the existing working conditions and also investment on machinery and automation are essential.

LABOUR AND MACHINE PRODUCTIVITY IN MODERN SPINNING MILLS – A CASE STUDY

Shortage of skilled labour has become the order of the day not only for the textile industry but also for other manufacturing industries. Moreover, like other manufacturing cost, labour cost has also been in the increasing trend. It is a known fact that in the recent times spinning mills in the country have been operating with a slender profit margin, many with a negative performance. Hence, in the present scenario, to stay put in the industry every mill has to make sincere efforts to optimise the conversion cost for which maintaining the labour and machine productivity at a high level is one of the essential requirements. Mills must aim to maintain its salaries and wages cost at about 5% of sales turnover towards realising a comfortable profit margin.

Towards managing labour shortage, many mills have started introducing automations such as bale plucker, chute feed cards, automatic bobbin transportation between fly frames and ring frames, auto doffers in ring frames, automatic cone winders and link winders. These automations would result in a very high labour and machine productivity

Last year, SITRA conducted a study on labour and machine productivity in a modern spinning mill

towards identifying the scope for further improvement.

Case study mill - Profile

The Mill was established in 2013 with very hi-tech machines from reputed manufacturers - both indigenous and imported. It is a 25,000 spindle capacity unit manufacturing 100% cotton carded yarns in the count range of 20s to 34s with an average count of about 30s. Average yarn production per day was about 11 tones. The list of machinery available in the Mill is given in Table 29

Table 29 List of machinery in the case study Mill

S. no.

Machinery particulars No. of

machines

1. Blow room line with bale plucker and contamination sorter

1 line

2. Chute feed cards with auto leveler , 40”x 48” coiler and auto can changer

10

3. Breaker draw frames

- Each with 2 deliveries, 40”x 48” coiler and auto can changer

2

4. Finisher draw frames

-

Each with single delivery, 20”x 48” coiler, auto leveler and auto can changer

4

5.

Fly frames each with 200 spindles and 16”x

6”

flyers*

4

6.

Ring frames each with 1632 spindles and integrated with link winders

15

7.

Link winders each with 34 drums staff

15

Note: Blow room and cards have AWES; all the production departments are equipped with automatic humidification plants.

'*' All the fly frames and ring frames are linked with automatic bobbin transport system.

33


Existing labour and machine productivity

Table 30 shows the labour and machine productivity that was maintained by the Mill in the last one year in the ring frames and cone winding.

Parameter Mill actual SITRA

Labour productivity (HOK*) Up to ring frames

8.63 9.0

+

Automatic cone winding

1.11** 3.6

Other operatives including packers, utility operatives, SQC operatives and contamination ejection sorter

1.59 3.0

Total HOK*

11.33 15.60

Ring frame machine productivity

Production per spindle per 8 hours (g)*

112 115

Spindle utilisation (%) 93 98

Table 30 Existing labour and machine productivity

'+' SITRA Norms for very hi-tech spinning mills '*' adjusted to 40s carded count '**' Link winding

Scope for increasing productivity

SITRA conducted a detailed study at the Mill on various aspects such as operatives' employment pattern, their duties and responsibilities and skill level, ring frame and automatic cone winding production parameters, spindle utilisation and layout of machinery.

Table 31 Parameters to achieve 120 g production per spindle (target)*

Count

Spindle speed

(rpm) Tpi

Machine

efficiency (%)

Prodn./spl./

8 hrs. (g)

Mill Target Mill Target Mill Target $ Mill Target

24s K (25s) 16500 16500 21.38 21.38 86 93.0 191 207

30s K (31s) 18500 18500 24.00 24.00 88 93.0 157 167

32s K (33s) 18500 18500 24.51 24.51 90 93.0 148 153

34s K 18500 18500 25.40 25.40 87 93.5 134 144

Overall Speed Index: 100 Tpi Index: 100 Effy. Index: 93 Prodn. Index: 93

'*' Adjusted to 40s carded count; '$' also SITRA standard

Note: Figures given in brackets indicate the actual count.

Ring frame machine productivity

Overall production per spindle

In the last 1 year, the Mill had obtained an average production of 112 g per spindle per 8 hours (adjusted to 40s carded count), ranging from 106 g to 120 g between months. Since the Mill had already achieved a high production rate of 120 g in a couple of months during the above period and moreover, the machines are new and very hi-tech, the same production rate (120 g) has been considered as the target production rate for the Mill.

Count-wise production per spindle: average Vs target production rate

Table 31 shows count-wise production parameters that were maintained by the Mill to achieve 112 g production per spindle and the respective parameters to be maintained to achieve the target production rate of 120 g – both adjusted to 40s carded count.

It can be seen from Table 31 that the actual production per spindle falls short of the target production rate by 7%. The actual spindle speeds and tpi are at par with the speeds and tpi that are required to achieve the target production rates. But, the actual machine efficiency falls short of the target efficiency by 7% which means that by increasing the machine efficiency itself, the Mill could easily achieve the target production rates consistently. The lower ring frame machine efficiency is due to:

ØInadequate training given to the operatives.

34


ØInsufficient supervision and inadequate attention paid for the machine settings and parameters.

Labour productivity

Employment pattern

The Mill was employing a total of 155 workers per day (for the entire mill) (Table 32).

Table 32 Labour employment

25,000 Spindles Avg.count: 30s

Department / category Mill

actual

SITRA suggestion

Expected reduction /

day

Up to ring frames

117

98 19

Cone winding

16

13 3

Others (packers, SQC operatives, non-production operatives, etc.)

22

24 (-) 2

Total

155

135 20

Basis considered for operatives' reduction

The following aspects have been considered while arriving at the operatives' reduction.

- Changing machinery layout

- Multi-skill training

- Higher assignments

- Additional duties- Team work

Achievable labour and machine productivity

The study reveals that there is a good scope to reduce the man power and increase the machine productivity significantly. By implementing the various suggestions offered by SITRA, the Mill could maintain a Total HOK of 8.7 and a production rate of 120 g per spindle per 8 hours (both the figures adjusted to 40s carded count) (Table 33). It is the first time that SITRA has come across such a very high labour productivity level that a spinning mill in India can achieve.

Table 33 Achievable productivity levels

S. no.

Department/ parameter Existing Achievable

1. Labour productivity (HOK*)

Up to ring frames

8.63 6.33

Link winding

1.11 0.79

Others

1.59 1.53

Total HOK*

11.33 8.65

2.

Machine productivity

Prodn./spl./8 hours (g)*

112 120

Spindle utilisation (%) 93 98

3. Total number of operatives/day 155 135

'*'adjusted to 40s carded count

Fifty years ago, a good working 30,000 spindle spinning mill manufacturing 40s carded yarn had maintained a 3 digit Total HOK of over 120 with a production rate of 65 g and employed around 1000 workers per day. Presently, highly modern spinning mills can maintain a single digit Total HOK in 40s count which would also mean that these mills are closing to a target of just one worker per 100 kg of 40s carded yarn as against 15 workers engaged in the 1960s.

A STUDY ON FACTORS RESPONSIBLE FOR THE GENERATION OF HARD WASTE IN THE AUTOMATIC CONE WINDING MACHINES

The study was conducted in 12 spinning mills, located at different parts of the country, having the latest technology automatic cone winding machines with round magazine feed. The study covered a wide range of cotton counts (14s to 105s carded/ combed/compact).

1.1. Methodology

Senior technical officers of SITRA were deputed to all the 12 mills to conduct the study. During the study period, necessary trials were conducted and various factors responsible for the incidence of the hard waste were collected.

35


1.2. Makes and models of auto winders covered in the study

Makes and models of auto winders:Schlafhorst - 338, AC 5, AC X 5Muratec - 21 C, QPROSavio - Espero, Orion, PolarVeejay - Excello

Makes and models of electronic yarn clearers:Uster (UQC 2, UQC 3), Loepfe

(TK 940, Zenit), Premier (iQON)

1.3. Hard waste generation in the automatic cone winding machines

An analysis of the hard waste data that was collected from the 12 mills indicates that the incidence of waste on the whole was high at 0.65%, more than two times the SITRA standard of 0.3% for round magazine feed. Between mills, it varied from a low of 0.28% to a high of 1.36% (Table 11).

The following three major functions are responsible for the generation of hard waste in the automatic cone winding machines.

- Splicing cycle- Cop feed- Cop rejection

Of the above three functions, the 'splicing cycle' contributed for about two-thirds of the total hard waste (Figure 19). The generation of the remaining portion of the hard waste was due to cop feed and cop rejections, almost in equal proportion.

Splicing cycle

68%

Cop feed

15%

Cop rejections

17%

Figure 19 Factors contributing for the generation of hard waste

The incidence of hard waste during the splicing cycle is due to the following aspects.

1. Clearer cuts (due to yarn defects).2. Tension breaks.3. Repeater cycle.4. Cop rejections (replacing the rejected

cops with new ones).5. Cop changes (replacing the exhausted

cops with new ones).

The generation of hard waste due to cop feed and cop rejection is mainly due to wrong work practices of the ring frame and winding tenters and partly because of poor quality cop build.

1.3.1. Splicing cycle

For all the above 5 functions, considerable length of yarn which depends on machine settings, is removed from the cops/cones and collected in the suction box. But, in the case of clearer cuts, besides machine settings, type of yarn defects also influence the length of yarn to be removed. Average length of yarn that is removed during each splicing cycle was found to be 3.6 m with the length ranging from 0.8 m to 8.5 m between mills.

Machine settings

Some of the major machine settings/parameters that influence the length of yarn removal during the 'splicing cycle' include mechanical setting of package suction arm and lower suction arm, suction pressure setting, drum reverse speed, selection of length of yarn removal options in the case of special cuts and tension level.

Clearer cuts

Number of cuts involved in clearing the yarn faults is called as “clearer cuts”. They are broadly classified into two categories viz., basic cuts and special cuts. Basic cuts include clearing of yarn faults due to neps, short thick faults, long thick faults, thin places and foreign matters (or) contaminants, whereas special cuts include count channel cuts, cluster cuts, periodic faults, SFI/D cuts, additional/system cuts including monitoring cuts (due to bad splice quality, yarn jump, drum wrap etc.), quality cuts/alarms and bunch cuts. A standard length of yarn would be removed during the basic cuts which varies between makes. For the special cuts, the yarn length removal would be 3 to 30 times more than that removed for the basic cuts which in turn depends on the type of faults in the yarn, clearing length and selection of yarn removal options.

36


1.3.2. Cop rejections

Cop rejection is another parameter which has a significant impact on the incidence of hard waste. Each cop rejection will result in the removal of a considerable length of yarn, besides that removed by the upper arm during splicing cycle, either by removing the defective portion manually or cutting and removing the remnants from the cop.

Average cop rejection was noticed to be high at about 12% (standard: 5%), ranging from 3.5% to over 30% between mills. Of the total rejections, nearly one-third was due to improper gaiting in ring frames i.e. double gaiting (or) over length piecing (Table 34). The remaining rejections occurred at various stages of cop build, of which the rejections at the cop bottom (¼th stage) was the major source (30%) followed by the rejections at the full cop stage (22%). The reasons for the rejections at various stages of cop build are given in Table 34.

Table 34 Reasons for the rejections at various stages of cop build

S no.

Rejections at Reasons

1. < ¼ stage of cop

? Double gaiting and over length piecing in ring frames ? Top and bottom slough -offs ? Higher tension breaks ? Yarn entanglement due to the presence of long tail ends

2. ½ and ¾ stages of cop

? Repeated splice cuts/ start -up cuts ? Lower yarn missing during splicing cycle ? Number of cuts per cop exceeding the set limit ? Coarser/finer yarn ? Limits set for the forced cop change

3. Full cops ? Improper removal of back winding coils, tail ends and under winding coils f rom the cops

? Lower yarn missing during cop change ? Repeated start -up cuts during cop change ? Stains in yarn

4. Alarm cops ? Limits set in EYC ? Parent yarn quality

1.3.3. Cop feed

The length of yarn removed by the tenters during feeding of cops in the round magazine is the major influencing factor for the hard waste. As per the data collected from the mills, the length of yarn removed during feeding averaged high at 2.3 m per cop, ranging from 0.6 m and 3.9 m between mills. Such a wide variation in the length of yarn was largely due to wrong work methods and partly because of poor cop build.

1.3.4. Work methods

Correct work methods are very much necessary to exercise a better control over the hard waste generation. Some of the wrong work methods that followed by the tenters/doffers in spinning and winding departments which result in the generation of more hard waste in the automatic cone winding machines, are given below.

Ring spinning

- Inadequate patrol by the tenters leading to production of more number of lean cops.

- Production of defective cops due to mix-up of travellers and not pressing the cops completely on the spindles after piecing an end break.

- Poor doffing practices i.e. not performing simultaneous doffing and donning, performing double-gaiting, over length piecing, doffing cops with long tail ends, rough handling of spindles during doffing, thereby, disturbing the ring and spindle alignment, etc.

- Pre-mature doffing leading to reduced cop content

- Running the frames without overhead travelling cleaners, thereby producing inferior yarn quality.

37


Winding

- Removing more length of yarn, than required, while feeding the cops in the magazine.

- Taking more than 3 cops at a time and removing more length of yarn, than required, from all the cops before feeding the same in to the magazine.

- Using all the fingers of right hand to take the end from a cop, leading to slough-off.

- Dropping full cops on the floor, thereby staining and damaging them.

- Rough handl ing o f cops dur ing transportation/ transferring them from doff crates to feed crates.

- Using damaged crates, thereby resulting in yarn entanglement and cop damages.

- Removing the defective portion of the yarn from the cop by allowing it into the suction which would, on most occasions, increase the waste.

- Feeding frequently the rejected bad quality cops without removing the defective portion.

- Using knives for removing remnants from the rejected cops and clearing drum lapping, thereby damaging the empty cops and drums.

- Starting red light/yellow light indicating drums without rectifying the defect.

- Keeping the ring cops openly in the winding department for a long period, leading to settling of fluff over the cops.

- Cleaning the winding machines with compressed air without keeping partition boards between machines, thereby allowing fluff accumulating on the adjacent winding machines.

Not removing the hard waste from the suction chamber at regular intervals, thereby leading to drop in suction pressure of package suction arm and magazine suction tube.

Mill no.

Count

Hard waste (%) due to* Cop rejections (%) due to

Cop Rejection

Cop feed

Clearer cuts**

Cop changes

Repeater Cycles

Total hard

waste

Double Gaiting

Alarm Cops

At 1/4th

Stage

At ½ Stage

At 3/4th

Stage

At full cops

Total cop rejections

1 42s CH 0.40 0.05 0.30 0.12 0.04 0.91 3.4 0.5 7.5 0.8 0.3 0.7 13.2 2

64s C

0.10

0.05

0.15

0.04

0.04

0.38

7.6

0.4

7.8

2.9

0.3

3.4

22.4

80s C

0.06

0.06 0.20

0.07

0.04

0.43

6.4

1.5

2.3

0.3

0.2

4.3

15.0

3

40s C-Comp.

0.11

0.06 0.18

0.10

0.03

0.48

1.3

0.0

0.8

0.9

0.5

1.7

5.2

50s C-Comp.

0.10

0.07 0.21

0.10

0.04

0.52

3.4

0.2

0.7

0.7

0.5

1.3

6.8

60s C-Comp.

0.07

0.05 0.26

0.12

0.05

0.55

2.8

0.0

2.5

1.2

2.0

4.9

13.4

4

44s K

0.07

0.06 0.18

0.13

0.04

0.48

2.4

0.0

1.5

0.6

0.3

0.7

5.5

80s C-Comp.

0.23

0.07

0.43

0.14

0.13

1.00

1.6

0.0

8.3

2.2

1.1

3.2

16.4

80s C-Comp.

0.10

0.05

0.38

0.12

0.11

0.76

4.5

0.0

2.9

1.9

1.4

2.1

12.8

5

50s C

0.04

0.08

0.46

0.13

0.04

0.75

5.8

0.0

3.6

0.3

0.5

4.7

14.9

56s C

0.07

0.10

0.36

0.13

0.03

0.69

5.6

0.0

4.9

1.2

1.1

2.5

15.3

105s C

0.03

0.04

0.20

0.05

0.04

0.36

9.1

0.0

8.0

3.8

2.9

4.2

28.0

6

32s CH

0.20

0.19

0.31

0.24

0.06

1.00

2.1

1.7

1.2

0.6

0.8

5.3

11.7

40s CH

0.22

0.15

0.56

0.35

0.08

1.36

2.9

1.4

4.1

0.5

0.9

2.3

12.1

60s C-Comp.

0.12

0.10

0.31

0.11

0.07

0.71

8.8

0.7

16.8

1.4

0.1

4.3

32.1

7

40s K

0.11

0.14

0.35

0.20

0.05

0.85

3.6

0.1

5.4

0.2

2.5

1.6

13.4

40s K

0.21

0.15

0.14

0.07

0.03

0.60

6.6

0.6

3.6

0.9

1.5

4.1

17.3

40s K

0.07

0.16

0.19

0.09

0.03

0.54

7.6

0.6

1.5

0.5

0.2

0.4

10.8

8

34s K

0.17

0.08

0.07

0.11

0.01

0.44

5.8

0.1

3.7

0.4

0.2

1.5

11.7

34s K

0.45

0.09

0.05

0.06

0.01

0.66

5.3

0.0

5.7

1.1

0.6

1.3

14.0

9

30s K

0.01

0.12

0.08

0.05

0.02

0.28

0.5

1.1

1.9

0.2

0.3

1.8

5.8

30s K

0.01

0.14

0.25

0.14

0.05

0.59

2.1

1.1

1.1

0.1

0.2

0.9

5.5

30s K

0.03

0.14

0.21

0.14

0.03

0.55

3.8

0.3

2.4

0.2

0.3

0.6

7.6

60s K

0.01

0.14

0.43

0.11

0.05

0.74

0.3

0.0

1.1

1.0

1.0

2.6

6.0

80s C

0.05

0.09

0.14

0.03

0.02

0.33

0.5

1.2

2.7

1.5

2.0

3.1

11.0

10

40s CH

0.01

0.02

0.39

0.09

0.04

0.55

0.8

0.1

1.0

0.2

0.3

2.3

4.7

40s CH

0.02

0.02

0.50

0.15

0.07

0.76

1.0

0.0

0.9

0.6

0.0

1.0

3.5

11

14s K

0.23

0.43

0.27

0.20

0.11

1.24

6.5

0.2

3.7

0.0

1.1

6.5

18.0

40s CH-Comp.

0.08

0.09

0.56

0.31

0.09

1.13

3.2

0.2

3.9

0.3

0.7

4.8

13.1

40s C-Comp.

0.06

0.10

0.16

0.07

0.03

0.42

3.3

0.3

1.6

0.3

0.6

5.9

12.0

12

40s C-Comp.

0.02

0.15

0.10

0.06

0.01

0.34

3.4

0.1

0.3

0.3

0.2

0.8

5.1

Average

0.11

0.10

0.27

0.12

0.05

0.65

3.9

0.4

3.7

0.9

0.8

2.7

12.4

Minimum

0.01

0.02

0.05

0.03

0.01

0.28

-

-

-

-

-

-

-

Maximum

0.45

0.43

0.56

0.35

0.13

1.36

-

-

-

-

-

-

-

'*' as a % of machine feed; '**' including tension breaks

Table 35 Contributing factors for the hard waste

38


MACHINERY DEVELOPMENT

DESIGN AND DEVELOPMENT OF A MOBILE DOFFING SYSTEM FOR RING SPINNING MACHINES

Existing semi-automatic mobile doffing systems have some limitations such as 20% – 30% starting end breaks, missed doffs and the need to press the cops into its proper position manually.

In order to overcome the above mentioned draw backs, suitable modifications have been carried out in the doffing system as outlined below.

a) A yarn holding device is fitted on the spindle to hold the yarn at the time of restarting.

b) A setting gauge has been designed that ensures that the machine achieves 100% doffing of cops.

c) To improve the alignment /positional stability, rails made of square pipes have been used.

d) A cam driven mechanism has been designed to press the cop on the spindle. The performance of the pressing device is under evaluation.

Performance evaluation of the mobile doffing system is being conducted in a local mill on a ring spinning frame. Our observations are as below.

1. Two mobile doffer units are required for one long frame. For a 25,000 spindle mill, about 6 - 10 units may be required based on the count pattern

2. The time required to complete doffing operation is about 3 minutes.

3. 4 persons are required to carry out the doffing operation in one machine.

4. After incorporating the cop pressing mechanism, further reduction of an operative is possible.

The cop pressing mechanism needs some fine tuning process in order to carry out the doffing operation smoothly.

As discussed in 2014 RAC meeting, it was decided

to manufacture the auto doffing system without the cop pressing mechanism and development work has been completed. License has been given to one of the textile machinery manufacturer in Coimbatore.

The Licensee has manufactured two units on a pilot basis and their evaluation is in progress.

MEDICAL TEXTILES

DEVELOPMENT OF A LEUKO-DEPLETION BLOOD FILTER(Sponsored by the Ministry of Textiles, Government of India)

The main objectives of the project are:

ØTo develop a sub micron filter for removing leukocytes from blood and its components before blood transfusion.

ØTo filter the other impurities present in the blood components

Human blood contains four most important components; red blood cells (RBCs), white blood cells (WBCs), platelets and plasma. In four components, 55% is plasma, 44% is RBCs (count

3has 5,500,000/mm of blood), 0.1% is WBCs (count

3has 8000/mm of blood) and 0.9% is platelets

3(count has 250,000/mm of blood). WBCs or leukocytes, are far less numerous than red blood cells, which are crucial to defend against diseases. Blood transfusion is associated with deleterious effects that are caused by residual leukocytes in blood. The leukocytes associated transfusion reactions are allo-immunization, non-haemolytic febrile transfusion reactions (NFHTR), immuno-suppression, transmission or re-activation of intra-cellular viruses such as cytomegalovirus (CMV), human T-cell lymphotropic virus type etc. The above transfusion reactions increase the incidence of morbidity as well as the high costs associated with transfusion complications. The above has led to the development of leukocyte reduction in blood transfusion.

A number of techniques have been developed to prepare leukocytes reduced blood components. They are differential centrifugation, sedimentation, cell washing, freezing-thawing and filtration. Among these techniques, filtration is a most widely used method for producing leukocyte reduced

39


blood components. The filtration process has advantages such as simple procedure, fast, clinically effective and does not require expensive equipment. Another important advantage of filtration technique, among others, does not require an open system handling to process the blood, which in turn will improve the shelf life of the blood.

The first leukocyte filter was cotton wool plug and then various other filter materials were developed like cellulose acetate, nylon, polyester, polyurethane etc..,. The fibre diameter is an important parameter to adhesion of cells to the filter fibres. Fibres having larger internal surface area has led to adhere cells, which can be achieved through the smaller diameter fibre. Electrospinning is the process to fabricate very smaller diameter fibres ranging from micro to nano meter in the form of nanomembrane. Electrospinning process has increased in recent years and this technology has been exploited for a wide range of applications. Among various nanomembrane processing techniques like drawing, template synthesis, phase separation and self assembly, electrospinning is the only method capable of producing continuous polymer nanofibres.

In this project, polyethylene terephthalate (PET), polybutylene terepthalate (PBT) and Nylon 6 (PA 6) materials were taken and dissolved in their solvents to produce nanomembranes, using the electrospinning technique. Electrospinning polymer fibres were deposited on 60 gsm polyester spun lace non-woven fabric using

µm. A 30 µm pore size ensures that fine aggregates are removed and prevents a distortion flow. The electrospun coated spun lace non-woven is characterized with field emission scanning electron microscopy (FESEM), pore size measurement, cytotoxicity analysis and blood filtration efficiency tests.

Methods

Spun lace non-woven method

hydro-entanglement technique. The spun lace non-woven fabric with its three dimensional network of continuous pores is most suitable for the filtration application. 60 gsm fabric was chosen to achieve an average pore size of 30

Hydro-entanglement is a process, where high-speed jets of water strike a web, so that the fibres knot about one another to form a bond as shown in Figure 20.

Figure 20 Schematic representation of Hydro-entanglement process

Electrospinning method

The electrospinning technique was used to coat the PET, PBT and PA6 nanomembranes on the spun lace non-woven fabric. In this study, the solvent form was used to prepare the solution.

Solution preparation method for electrospinning

'n' gram of polymer was weighted with the help of a weighing balance and 'm' ml of solvent was measured with the help of a micropipette.

The per cent solution concentration was determined by the formula

Concentration (%) = ‘n’ gram of polymer

X 100‘m’ mL of solvent

PET solution preparation method: PET polymer granular were dissolved in trifluoroacetic acid & dichloromethane (1:1 ratio) PBT solution preparation method: PBT polymer pellets were dissolved in trifluoroacetic acid PA6 solution preparation method: PA6 polymer pellets were dissolved in formic acid

Electrospinning method was used to produce the submicron level f ibres of polyethylene terephthalate (PET), polybutylene terephthalate (PBT) and Nylon 6 (PA 6) polymers. In this method, the polymer solution is prepared by dissolving the polymer in their solvents and poured into a disposable syringe loaded in a syringe pump as shown in Figure 21. The tip of the syringe needle is connected with a high voltage power supply (0 – 30 kV) and grounded collector for collection of submicron polymer fibres.

40


Figure 21 Schematic representation of electro-spinning set-up

Results and discussions

Spun lace non-woven fabric parameters

The polyester spun lace non-woven fabric was tested for weight per sq. meter (GSM) and pore size using capillary flow porometer. The test results are given in Table 36.

Table 36 Unit area weight and pore size of polyester spun lace non-woven fabric

S.No. Parameter Values

1. Weight per square meter (GSM) (g) 58.89

2. Mean pore size (micron)

29.75

Optimization of solution and process parameters of electrospinning technique

Table 37 Solution parameters and process parameters of electrospinning process

Polymers

(Solvents)

Solution parameters

Process parameters

Polymer

Concentration (%)

Applied voltage

(kV)

Flow rate (ml/hr)

Tip to collector distance

(cm)

PET

(Dichloromethane &

Trifluoroacetic acid)

25, 30, 35

12, 15, 18

0.2, 0.5, 1.0

7, 10, 13PA 6

(Formic acid)

PBT (Trifluoroacetic acid)

20, 25, 30

Table 38 Optimized electrospinning process parameters of Polymers

Polymers (Concentrations)

Optimized values

Avg. fibre diameter

(nm)

Applied

voltage (kV)

Flow rate

(ml/hr)

Tip to

collector distance (cm)

PET (25%)

15

1.0

13 230

PET (30%)

15

0.5

13 185

PET (35%)

18

0.5

13 480

PBT (20%)

12

1.0

10 570

PBT (25%)

15

0.5

10 1104

PBT (30%) 15 0.5 13 1420

PA6 (25%) 15 0.5 10 120

PA6 (30%) 18 0.5 13 130

PA6 (35%) 18 0.5 13 160

The morphology of the electrospun nanofibres was observed with Field Emission – Scanning Electron Microscope (FE-SEM).

Pore size analysis of electrospun nanomembrane coated spun lace non-wovens

Capillary flow porometer as shown in Figure 22, was used to test the pore diameter of electrospun nanomembrane coated spun lace non-wovens. Pore size in the range of 3 micron to 8 micron is suitable for leukocyte reduction filter; the leukocytes will selectively obstruct the small pores by a process known as pore plugging.

Figure 22 Photographic image of capillary flow

porometer

Table 38 shows the optimized electrospinning process parameters of polymers.

The pore size distribution of the nanomembrane samples is given in Table 39

41


Table 39 Pore size distribution of nanomembranes

Polymers

(Concentrations)

Avg. pore

size

micron)

Pore size distribution (%)

<3µ 3µ to 8µ >8µ

PET (25%) 1.63 84 12 4

PET (30%) 2.56

52

37 11

PET (35%) 4.29 16 75 9

PBT (20%) 4.58 12 84 4

PBT (25%) 5.39

5

77 18

PBT (30%) 6.35

0

85 15

PA6 (25%)

0.31

89

4 7

PA6 (30%)

0.51

98

1 1

PA6 (35%) 2.42 50 37 13

Optimization of polymer concentration for electrospinning

The optimization of polymer solution concentration was based on FE-SEM analysis and pore size analysis. Table 40 shows the optimized polymer parameters.

Table 40 Optimized polymer concentration parameters

Polymers

(Concentrations)

FE-SEM

analysis

Pore size

analysis

PET (35%) Uniform

fibres

obtained

Mean pore size

of around 5±2

micron achievedPBT (30%)

PA6 (35%)

Uniform fibre surface and optimum mean pore size that is required for the leukocyte reduction filter are achieved at optimum solution concentrations of PET 35% and PBT 30%. Figure 23 shows the PET nanofibres coated on a spun lace non-woven surface.

Figure 23 Photographic and SEM images of PET nanofibre coated on polyester

spun lace non-wovens

Cytotoxicity study of nanomembranes

An in vitro cytotoxicity test using direct contact method was performed using test samples PET 35%, PBT 30% and PA6 35% nanomembranes as per ISO 10993. The reactivity was graded as per Table 41.

Grade Reactivity Description of reactivity zone

0 None

No detectable zone around or

under sample

1 Slightly

Some malformed or degenerated

cells under specimen

2 Mild

Zone limited to area under

specimen

3 Moderate

Zone extending specimen size up

to 0.33 cm

4 Severe

Zone extended farther than 0.33

cm beyond specimen

Table 41 Grading of cytotoxicity

Before cytotoxicity analysis, PET 35% and PBT 30% nanomembrane samples were treated for 30 minutes with ultra-sonicator in distilled water and tested for cytotoxicity. Table 42 shows the results of cytotoxicity analysis.

42


Table 42 Cytotoxicity analysis of nanomembrane coated spun lace non-woven

S.No. Polymer

nanomembrane Grade Reactivity

1. PET 35% 0 None

2. PBT 30% 0 None

3. PA6 35% 0 None

The results show that the polymers have no detectable zone around the or under the sample. Hence, there is no cytotoxicity effect in PET 35%, PBT 30% and PA6 35% nanomembrane samples.

Blood filtration efficiency test

The blood filtration efficiency test was carried out using wristed rat blood; the rat blood cells count and size match with human blood. WBCs and RBCs count of before and after filtration were counted using automatic cell counter and the results are shown in Table 43. RBCs filtration efficiency was calculated by the following formula.

WBCs filtration =efficiency (%)

Cell count before filtration –

Cell count after filtration X 100

Cell count before filtration

RBCs recovery percentage was calculated by the following formula:

RBCs recovery = (%)

Cell count after filtrationX 100

Cell count before filtration

Table 43 Blood filtration efficiency of nanomembrane coated spun lace and

market samples

S.No. Sample particulars#

WBC filtration

efficiency(%)

RBC recovery

(%)

Sample thickness*

(mm)

1

PET 35% (1L)

31

94 0.37

2

PET 35% (3L)

44

92 1.11

3

PET 35% (5L)

85

93 1.85

4

PET 35% (7L)

90

89 2.59

5

PBT 30% (1L)

18

96 0.35

6

PBT 30% (3L)

21

93 1.05

7

PBT 30% (5L)

19

93 1.75

8

PBT 30% (7L)

60

92 2.45

9

PA635% (1L)

22

97 0.33

10

PA6 35% (3L)

55

91 0.99

11

PA6 35% (5L)

56

90 1.65

12

PA6 35% (7L)

58

88 2.31

13 Market sample A (7L) 11 98 1.62

14 Market sample B (7L) 43 95 3.42

15 Market sample C (7L) 62 96 1.51

16 Market sample D (7L) 59 94 2.31

# L – no. of layers * Thickness is measured by fabric

thickness gauge

The five layer and seven layer PET 35% nanomembrane coated spun lace non-wovens show better filtration efficiency of leukocytes (WBCs) than the market samples. But PBT 30% and PA6 35% shows lower filtration efficiency when compared with both PET 35% and market samples.

Surface morphology of filtered samples

The surface morphology of blood filtered samples was performed after the preparatory process. In the preparatory process, blood filtered samples were taken, treated with 1% glutaraldehyde for 1 hour

Table 44 Ethanol series and acetone series

Series

Concentration %

(Prepared using

distilled water)

Treatment time

for each

concentration

(minutes)

Ethanol 30%, 50%, 70%,

90% & 100% 10

Acetone 30%, 50%, 100% 10

and then treated with distilled water for 30 minutes; subsequently they were treated with ethanol series and acetone series for 10 minutes in each concentration, as shown in Table 44.

43


After the above treatment, the samples were gold sputter coated for 30 minutes and analysed in FE-SEM.

Study of hemolysis for nanomembrane coated spun lace non-woven

The interaction of devices or biomaterials with blood is an immediate and serious concern during safety assessment. Lysis of RBCs would result in leakage of free hemoglobin (Hb) into the plasma, potentially leading to severe hepatic and renal injury among other effects. ISO 10993-4, "Selection of Tests for Interactions with Blood", is used to study the hemolysis of nanomembranes.

The free hemoglobin liberated in to the plasma after exposure to samples was measured using Diode array spectrophotometer and the percentage hemolysis was calculated using formula

Percentage hemolysis =

Free Hb

X 100 Total Hb

Percentage hemolysis is less than 0.1% shows normal and greater than 0.1% shows slightly hemolysis. The polymer nanomembranes of PET 35%, PBT 30% and PA6 35% test results were given in Table 45.

Table 45 Hemolysis analysis of nanomembrane coated spun lace non-woven

S.No. Polymer

nanomembrane

Percentage

hemolysis Reactivity

1.

PET 35%

0.04

Non-hemolytic

2.

PBT 30%

0.11

Slight hemolytic

3.

PA6 35%

0.05

Non-hemolytic

From the above test results, shows there is no lysis of hemoglobin takes place in PET 35% and PA6 35%. PBT 30% shows there is slight lysis of hemoglobin.

DEVELOPMENT OF TEXTILE MATRICES FOR E F F E C T I V E W O U N D M A N A G E M E N T (Sponsored by the Ministry of Textiles, Government of India, New Delhi)

1. The major objectives of the project are

(I) To develop a wound dressing for promoting angiogenesis by mechanical stimulation.

and

(ii) To develop a wound dressing incorporated with angiogenesis inducing growth factor.

2. Rationale

Activation of pathways such as hemostasis, inflammation, proliferation and remodeling determines the rate of healing of specific type of wounds. As per available literature, there are disturbances/impairment in the orderly progression of healing process particularly angiogenesis of granulation phase when the wound encounters with diabetes or venous and arterial insufficiency. Angiogenesis is crucial for wound repair since the new vessels provide nutrients to support the active cells, promote granulation tissue formation and facilitate the clearance of debris. Approximately 60% of the granulation tissue mass is composed of blood vessels that supply the necessary oxygen to stimulate repair and vessel growth. Therefore, a study has been conducted to develop textile matrices by embroidery technology for the stimulation of angiogenesis in chronic wounds.

Two types of wound dressings have been developed for stimulation of angiogenesis and they are

1. SITRA's embroidery design incorporated wound dressing (SEWD)

2. Wound dressings developed using chemical stimulation

3. Wound dressings developed using embroidery technology

One of the key issues in tissue regeneration of chronically non-healing wounds is controlled revascularisation of the epidermal tissue. Textile materials for tissue formation and vascularisation depend on the size and distribution of pores and fibres. An arrangement of pores of different orders of magnitude, ranging from 1mm to 1000mm, will favour the tissue ingrowth and the formation of new blood vessels and capillaries. Embroidery technology allows achieving a 3-dimensionally structured textile architecture that combines pores for directed angiogenesis and elements for local mechanical stimulation.

The 3 layered wound dressing developed by SITRA (SEWD) is shown in Figure 24.

44


A

B

C

Figure 24 SITRA's 3 layered wound dressing (S3LWD)

The functions of the 3 layers are explained in Table 46.

Table 46 Functions of different layers in SEWD

Layer Functions

A

? Mechanical and biological

protection

? Control of humidity and air

transport ? Back layer

B

? Mechanical protection by shear

compliance ? Transfer of compressive forces

? Absorption and accumulation of

wound exudates ?

Absorbing layer

C

?

Angiopolar layer for tissue

ingrowth and directed

angiogenesis

?

Locally controlled mechanical

stimulation of wound area

?

This is the embroidered textile

layer

A 3D structure textile architecture that combines pores of different sizes was produced using embrosidery technology for directed angiogenesis and elements for local mechanical stimulation (Figures 25 & 26).

Pore size 500ìm

to 3000ìm

Figure 25 Embroidered textile structures with pore size 500ìm to 3000ìm.

This structure helps in uptake of blood coagula and for the formation of granulation tissue.

Pore size 100ìm

to 500ìm

Pore size

10ìm to 100ìm

Figure 26 Embroidered textile structures with pore size 10ìm to 500ìm.

Pore size 10ìm to 100ìm is primarily for ingrowth of cells & small capillaries and pore size 100 ìm to 500 ìm for ingrowth of blood vessels. Combining all the pore sizes (from 10 ìm to 3000 ìm) an embroidered textile structure was made using CAD and the same is shown in Figure 27.

Figure 27 Embroidered textile design developed by SITRA

Mechanical stimulation of the wound ground using embroidery design incorporated wound dressing is shown in Figure 28 (a,b,c & d).

Polyester monofilament (100 ìm diameter) was used for embroidery design. The Porous structure allows the growing-in of cells and capillaries as well as the blood vessels. Therefore a targeted bleeding during the change of dressings can be induced. This helps to clean the wound surface and animates the cells for further growing and eventually to heal the wound.

45


Figure 28 b Embroidery design incorporated wound dressing on wound site

Figure 28 c Wound dressing allows growing-in of cells and capillaries as well as blood vessels

Figure 28 d Continued growth of cells & blood vessels even after removal of wound dressing

from the wound site

Figure 28 (a, b, c & d) Mechanical stimulation of the wound ground

Figure 28a Wound site

3.1 Field trials

3.1.1 Skin irritation

The SEWD was evaluated for potential skin irritation when they are used for covering the wound. The evaluation was as per ASTM F 719-81 standards. The study has shown that SEWD did not cause any skin irritation even after 72 hours of contact with the wound.

3.1.2 Wound healing rate

The extent of wound healing provided by a given wound dressing was evaluated using the method proposed by Morton & Malone. As per this method, eighteen healthy rats were employed for the experimentation and they were separated into 2 groups (Group I and Group II) each with 6 rats. Excision of wounds was made on the rats as per the suggested method. The rats were anaesthetized with anaesthetic ether and placed on the operation table in their natural position. A square wound of about 1.5 cm (width) x 0.2 cm (depth) was made on the depilated ethanol-sterilized dorsal thoracic region of rats. Infection was made on wounds by

staphylococci aureus.

ØGroup I rats were left as they were without application of any wound dressing (open wound).

ØGroup II rats were treated using SEWD

and

ØGroup III rats were treated using SWD

The dressings were applied on the wounds of the rats every day till the epithelialization was complete. The extent of wound contraction was studied by tracing the raw wound area on a tracing

th th th thpaper on 6 day, 12 day, 18 day and 24 day.

Determination of wound healing rate

The weight of the traced portions of the wounded area of rats subjected to different treatments (open wound, SEWD treated wound and SWD treated wound) were measured using electronic balance. Based on the difference in weight, the superiority or otherwise of a particular wound dressing is

46


determined. Table 47 shows the weight of the traced portions of the wounds on different days.

Dressing type

Weight of traced portions of the wound

(grams)

Day 0

Day 6 Day 12 Day 18 Day 24

Open wound

12.5

13.0 9.5 4.8 2.2

SEWD treated wound 12.5 10.2 4.5 1.0 0

SWD treated wound 12.5 13.0 8.6 3.1 1.4

Table 47 Weight of the traced portions of wounds on different days

It is clear from Table 50 that there is a decrease in wound area with or without the application of the dressings. The reduction in the wound area is faster in the case of SEWD treated wound. Hence, the extent of wound healing provided by the SEWD is better.

4.0 Chemical stimulation of angiogenesis

4.1 PDGF BB encapsulation in PLGA: Poloxamer blend nanoparticles

PDGF BB, a proangiogenic growth factor was loaded in PLGA: Poloxamer blend nanoparticles using modified solvent diffusion method. The role of stabilizers on GF stability was already studied by d'Angelo et al. and reported to have more stability when the GF was encapsulated with both BSA and HP when compared to the particles loaded with either BSA or Hp stabilized PDGF BB. Hence in the present study, both the stabilizers have been used during GF preparation and loaded them on the PLGA: Poloxamer nanoparticles. Since the growth factor concentrations and the stabilizers have inf luence on the various propert ies of nanoparticles, the particles have been analysed for their yield, size, encapsulation efficiency and its physicochemical characterization.

The yield of nanoparticles loaded with 0.3 ìg to 0.6 ìg of GF was in the range of 64 to 66 mg. whereas a relatively high yield was observed when a high concentration of GF (1 and 2 ìg) was used. Literature suggests the use of 100 ìL of aqueous layer for the incorporation of 2 ìg GF. However, we used different volumes of aqueous layers to load the different concentrations of GF. Hence the availability of particle for the loading might be low as the particles are diluted in DCM. But the difference was minimal when the GF was used in concentrations of 0.3 to 0.6 µg. Irrespective of the differences in the yield, GF encapsulation efficiency

was above 80 % at all concentrations of GF (Table 48).

Table 48 Percentage yield and encapsulation efficiency of PDGF BB loaded PLGA: Poloxamer

blend nanoparticles.

Concentration of PDGF

BB loaded in

PLGA:Poloxamer (µg)

Yield

(%)

Encapsulation

efficiency (%)

0.3 66.0 83

0.4 64.7 81

0.5 65.3 88

0.6 64.3 85

1.0 74.3 86

2.0

95.3

88

The physicochemical propert ies of the nanoparticles and the PDGF-BB encapsulation efficiency are displayed in Table 13. The properties of the PLGA:poloxamer nanoparticles prepared by the solvent diffusion method and encapsulating Hp/BSA were similar to those previously reported. PLGA:poloxamer blend based nanoparticles show a mean diameter below 200 nm, an unimodal particle population (polydispersity index <0.20), and a negative zeta potential. As an exception, the zeta potential values of PLGA: Poloxamer nanoparticles encapsulating with Hp showed a significant increase compared to PLGA: Poloxamer nanoparticle. In fact, Hp-loaded nanoparticles are characterized by a zeta potential of -34.4 mV, while the other analyzed formulation show zeta potential values around -26 mV. This higher surface negative charge of the Hp-loaded nanoparticles could suggest that part of the encapsulated Hp is anchored onto the nanoparticle surface, enhancing its anionic nature. When PDGF-BB is encapsulated in the presence of Hp, the negative zeta potential value is significantly reduced. This result suggests that Hp interacts with PDGF-BB through its Hp binding domain, effectively masking the anionic nature of Hp. Coencapsulation of BSA as a second stabilizer also reduces the absolute value of the zeta potential, which hints at partial accumulation of this protein on the nanoparticles surface (Table 49).

NanoparticlesSize

(nm)

Poly dispersity

index (PI)

Zeta potential

(mV)

PLGA:Poloxamer

120 .1 ±

0.4

0.192 - 0.215 -26.0 ± 1.2

Hp, BSA, PDGF BB

loaded

PLGA:Poloxamer

177.6 ±

7.6 0.269 – 0.377 -34.4 ± 1.0

Table 49 Size, poly dispersity index (PI) and Zeta potential of PDGF BB loaded PLGA: Poloxamer

blend nanoparticles

47


PDGF BB loaded PLGA:poloxamer blend nanoparticles were also characterized for morphology by FeSEM (Figure 27). As indicated in the Figure, the nanoparticles shown a spherical and regular morphology, which was in agreement with the particles usually obtained by this preparation technique. Additionally, FeSEM images presented homogenous particle size distribution in the ranges of 100 nm – 150 nm. From the FeSEM micrographs, it is identified that these nanoparticles are swathed by a loose shell, typically observed for PLGA: poloxamer nanoparticles and that has been attributed to the presence of a fraction of the poloxamer on the surface of the nanostructure.

Figure 29 Fe SEM images of PLGA:Poloxamer blend nanoparticles loaded with PDGF BB

(colloidal suspension)

4.2 In vitro cytotoxicity and proliferation activity of PDGF BB loaded PLGA: Poloxamer blend nanoparticles

Considering the potential use of this formulation for the parenteral administration in drug delivery, it was intended to characterize the toxicity and proliferation profiles of polymer (PLGA): carrier (poloxamer) and growth factor (PDGF BB) respectively. For this assay, PLGA: poloxamer

4blend nanoparticles were incubated with 1x10 Hep

G2 cells/mL and L929 mouse fibroblase cell line for 24 hrs at 37º C. Cytotoxicity was measured by MTT reduction assay, solubilizing formazan crystals formed after 5 hrs of treatment. As reported earlier by d'Angelo et al., cell viability close to 100 % was observed for the range of nano particle concentration tested. In some cases, the readouts from the groups treated with PDGF BB loaded PLGA:poloxamer blend nanoparticles were even higher than the control. These results were in line with the previous studies on MCF-7 breast cancer cell line, and were attributed to the presence of poloxamer in the nanoparticles matrix (Figure 30).

Figure 30 Cytotoxicity and cell viability measured by a metabolic activity assay (MTT) in L929 fibroblast cell in the presence of increasing

concentrations of PDGF BB loaded PLGA:poloxamer blend nanoparticles and PLGA

nanoparticles.

The nanoparticle suspensions in cell medium were incubated with the cells for 24 hrs at 37° C.

DESIGN AND DEVELOPMENT OF AN AUTOMATED EQUIPMENT TO PRODUCE KNOTLESS INCISION CLOSURES (Sponsored by the Ministry of Textiles, Government of India, New Delhi)

The main objective of the project was to design and develop an equipment to introduce barbs into the monofilament sutures.

Surgical sutures are the most frequently used biomaterial for wound closure and tissue approximation. However, they rely on the surgeon's ability to tie secured knots, which is a challenging and time consuming process. Improper tying and handling can result in knot breakage, and potential

The project has been completed and a terminal report highlighting the major findings of the study has already been submitted to Ministry of Textiles, Govt. of India, New Delhi.

48


wound dehiscence. Further, the knot impedes wound healing, constricts blood flow, distorts tissue, and increases scar formation. To overcome these problems, attempts have been made in developed countries to design self-anchoring sutures.

SITRA has earlier developed barbed sutures using micro-machining technique. However, to produce barbed surgical sutures on a commercial scale, an automated machine with a larger production capacity needs to be fabricated.

The present project was carried out to develop one such equipment.

1. Design and fabrication of a Barb Introducer Machine

SITRA has designed and fabricated a barb introducer machine with the following features.

i) Facility to select desired barb depth & barb angle

ii) Facility to alter the distance between barbs

iii) Facility to select the helical angle of the suture on which the barbs are placed.

Figure 31 SITRA's Barb Introducer Machine (SBIM)

49


Figure 32 Rectangular sharp edge knife with the connected mechanisms

2. Quality evaluation and design optimization of the knotless suture

A barb is characterized by dimensions like a) Barb angle, b) Helical angle of the monofilament suture and c) Barb depth. Barbed sutures were produced by varying the above dimensions. Four monofilament type suture materials were selected to convert a monofilament suture into a knotless suture. They are i) Polydioxanone (PDS), ii) Polyglyco caprolactone (PGCL), iii) Polypropylene (PP) and iv) Polyamide (PA).

Totally, 240 knotless suture samples were produced. All of them were tested for their suture anchoring strength. The suture anchoring strength values are shown in Table 50.

Table 50 Suture anchoring strength for different barb dimensions and different suture materials (Kgf)

Barb depth in

mm

0.10 0.15 0.20

Helical angle (º)

10 15 20 25 30 10 15 20 25 30 10 15 20 25 30

Suture material: Polydioxanone (PDS) Barb

angle (º)

155

0.29

0.31

0.29 0.28

0.28

0.40

0.46

0.43

0.37

0.37

0.30

0.33

0.32

0.29

0.27

160

0.28

0.30

0.27

0.26

0.26

0.39

0.41

0.37

0.34

0.34

0.28

0.32

0.29

0.26

0.25

165

0.37

0.43

0.39

0.36

0.35

0.65

0.81

0.64

0.60

0.61

0.40

0.44

0.37

0.36

0.34

170

0.27

0.27

0.26

0.25

0.24

0.38

0.40

0.33

0.29

0.31

0.27

0.29

0.25

0.24

0.22

Suture material:

Polyglyco Caprolactone (PGCL)

155

0.26

0.30

0.27

0.26

0.25

0.39

0.42

0.42

0.37

0.34

0.28

0.30

0.29

0.26

0.25

160

0.25

0.27

0.26

0.25

0.23

0.38

0.39

0.36

0.33

0.31

0.26

0.28

0.27

0.25

0.24

165

0.35

0.40

0.38

0.34

0.32

0.61

0.78

0.60

0.58

0.60

0.38

0.43

0.36

0.33

0.31

170

0.24

0.27

0.26

0.24

0.24

0.37

0.40

0.32

0.28

0.29

0.24

0.29

0.24

0.23

0.22

Suture material:

Polypropylene (PP)

155

0.27

0.30

0.28

0.27

0.27

0.39

0.45

0.42

0.36

0.36

0.29

0.31

0.30

0.28

0.26

160

0.27

0.29

0.26

0.25

0.24

0.38

0.40

0.36

0.33

0.32

0.27

0.31

0.28

0.26

0.24

165

0.35

0.42

0.38

0.34

0.34

0.62

0.79

0.63

0.59

0.60

0.38

0.43

0.36

0.36

0.32

170

0.26

0.27

0.25

0.23

0.23

0.37

0.39

0.32

0.28

0.29

0.25

0.28

0.25

0.23

0.21

Suture material:

Polyamide (PA)

155

0.28

0.31

0.28

0.28

0.27

0.39

0.45

0.42

0.37

0.36

0.29

0.32

0.31

0.28

0.26

160

0.27

0.29

0.27

0.26

0.25

0.39

0.40

0.36

0.34

0.33

0.27

0.31

0.29

0.26

0.25

165

0.36

0.41

0.38

0.35

0.34

0.64

0.80

0.63

0.60

0.60

0.39

0.43

0.37

0.36

0.33

170

0.26

0.28

0.26

0.24

0.24

0.37

0.39

0.32

0.28

0.31

0.26

0.29

0.25

0.23

0.22

50


From the above table, it is discernible that for a barb depth of 0.1mm, anchoring strength is maximum for the combination of i) barb angle 165° and helical angle 15°. The same trend is observed for the barb depths of 0.15 mm as well as 0.2 mm.

However, among 0.1, 0.15 and 0.2 mm of a barb depth, higher anchoring strength is obtained at 0.15 mm barb depth. Increasing the barb depth higher than 0.2 mm makes the suture thread to eventually break.

Hence, in the present investigation, the optimum combination of barb dimensions is found to be,

I) Barb angle 165°, ii) Helical angle 15° and iii) Barb depth 0.15 mm.

Therefore, bulk samples of all the four types of sutures for implantation trails were produced with the above dimensions.

3. Comparison of properties of Knotless suture with conventional monofilament sutures

Knotless sutures produced at SITRA with optimum barb dimensions were compared with conventional sutures for 1) Tensile strength using UTM Instron tensile tester 2) Tissue holding capacity*

Tensile strength

Tensile strength of barbed and conventional sutures is shown in Figure 33. Ten samples of barbed & conventional sutures for each type of suture material were evaluated.

Figure 33 Tensile strength of barbed and conventional sutures

* As per method prescribed by “Society for Biomaterials: 29th Annual Meeting Transactions – 2003, North Carolina, USA.

It is clear from Figure 33 that the tensile strength of barbed suture is more or less same as that of conventional suture (The difference is not statistically significant).

Tissue Holding Capacity

The tissue holding capacity of barbed & conventional sutures after 14 days & 21 days of implantation are shown in Figures 34 & 35. 10 rats were taken for each sample considered for the study.

Figure 34 Tissue holding capacity after 14 days of implantation

Figure 35 Tissue holding capacity after 21 days of implantation

It is clear from Figures, that the tissue holding capacity of barbed sutures is higher than that of conventional sutures by about 35% after 14 days of implantation and about 15% after 21 days of implantation. The study suggests that, SBBSS (SITRA's Barbed Bi-directional Surgical Suture) provides improved tissue repair as compared to currently available conventional sutures.

The study was completed and a terminal report highlighting the salient findings of the study has already been submitted to Ministry of Textiles, Govt. of India, New Delhi.

DEVELOPMENT OF COLLAGEN COATED ON HERNIA MESH(Sponsored by the Ministry of Textiles. Govt. of India, New Delhi).

1. Objective

To develop biologically active mesh by coating

collagen on the hernia meshes and tests the

mesh for its biocompatibility.

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2. Summary of the findings

a. Physical characterization of collagen coated hernia mesh (CCHM) has been completed (Table 51).

Table 51 Physical characterization of polypropylene meshes.

b. Coated meshes were analyzed for their biocompatibility through cytotoxicity, sensitization, skin irritation, acute systemic toxicity and implantation at Sree Chitra Tirunal Institute for Medical Sciences & T e c h n o l o g y ( S C T I M S T ) , Thiruvananthapuram according to ISO 10993 standard.

c. The CCHM showed no cytotoxic reactivity to L929 mouse fibroblast cell line after 24 hours contact period.

d. Similar to cytotoxicity study, CCHM is found to be non-irritant since the extract of the material did not exhibit erythema and edema on rabbits even after 72 h of treatment.

e. Skin sensitization potential of the extracts of CCHM material in Guinea pigs was determined by Maximization test (GPMT). Intra dermal and topical application of the extracts of CCHM did not show any adverse skin reaction during the induction or challenge period. This confirmed the

non irritant nature of the extracts obtained from the test material (CCHM).

f. Acute systemic toxicity of CCHM was conducted in albino mice through intra peritonial and intra venous injection of cotton seed oil and physiological saline extracts of CCHM. None of the material showed any abnormalities or weight loss during observation period.

g. To summarize, results of the present study confirms the non cytotoxic nature of the collagen coated hernia mesh.

DEVELOPMENT OF MOPPING PAD USING NONWOVEN AND WOVEN STRUCTURE (Sponsored by the Ministry of Textiles. Govt. of India, New Delhi).

To develop the mopping pad using different combination, woven and nonwoven structure and to find best combination suitable for mopping pad application.

1. Objective

Quality AttributesMesh Structures

S1 S2 S3 S4 S5 S6

Wales/inch 17 16 17 16 17 18

Course/inch 44 36 44 40 34 48

Pore area (Sq.mm) 0.39 0.42 0.44 0.38 0.37 0.46

Tensile strength (Kg.)

a) Machine direction

b) Cross direction13.66

7.55

11.24

3.31

23.84

10. 60

14.13

14.64

19.43

7.90

23.91

21.42

Elongation (°o)

a) Machine direction

b) Cross direction

54.99

89.47

30.06

114.77

43.91

134.04

60.08

101.99

42.08

105.70

124.70

111.422

Bursting strength(Kg/cm ) 5.17 2.83 9.67 8.33 7.67 13.56

Fabric weight (g/m2) 57 25 126 86 73 93

Thickness (mm) 0.47 0.38 0.62 0.58 0.56 0.874

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2. Materials used for the development of mopping pad:

Polyester/Viscose (30:70) blend aperture spunlace nonwoven material and commercial woven gauze are selected for the development of mopping pad.

3. Results & Discussion

Water holding capacity of 4 layers mopping pad

Figure 36 Water holding capacity of mopping pad with 4 layers

It is clear from Figure 35 that water holding capacity of a mopping pad made with 4 layers nonwoven (NNNN) is much higher as compared with all other combinations. The extent of difference between the NNNN and GGGG is 36%. The water holding capacity of a mopping pad with 3 layers woven and 1layer nonwoven (GGGN & GGNG) is higher by 10% when compared with GGGG. But there is no significant difference in between the results of GGGN & GGNG. Water holding capacity of NNNG and NNGN mopping pad is higher by 26% when compared to GGGG. Water holding capacity of GNNG, NGGN and NNGG mopping pad is higher by 20% when compared to GGGG. In between this combination, Woven gauze with outer layer (GNNG) shows higher water holding capacity than other two combinations (NGGN, NNGG).


Water holding capacity of a mopping pad with 6 layers is presented in Figure 37. Water holding capacity of mopping pad made with 6 layers nonwoven (NNNNNN) is much higher as compared with all other combinations. Water holding capacity of NNNNNN is higher by 38% when compared to the 6 layers of woven gauze.


There is no significant difference in between the value of water holding capacity 4 layers woven gauze and 2 layers nonwoven gauze combinations (GGNNGG, GNGGNG, NGGGGN & GGGNNG). But water holding capacity 4 layers woven/2 layers nonwoven combinations are higher by 20% when compared 6 layers woven mopping pad. Water holding capacity of 3 layers woven gauze and 3 layers nonwoven gauze combinations (GGGNNN, NNGGGN & GGNNNG) is higher by 8% when compared to 4 layers woven/2 layers nonwoven combinations. However water holding capacity of woven gauze with outer layer in this combination (GGNNNG) is higher compared with other two combinations (NNGGGN, GGGNNN). Water holding capacity of 2 layers woven gauze and 4 l aye rs nonwoven gauze comb ina t i ons (NNNNGGNN, NNGGNN & NGNNGN) is higher by 34% when compared to 6 layers woven gauze mopping pad. There is no significant difference between the value of of 2 layers woven gauze and 4 layers nonwoven gauze combinations and 6 layers nonwoven gauze mopping pad.


Water holding capacity of mopping pad with 8 layers is given in Figure 38. Water holding capacity of 8 layers nonwoven is higher by 35% when compared to the 8 layers of woven gauze. There is no significant difference in between the value of water holding capacity in between 6 layers woven gauze and 2 layers nonwoven gauze combinations.

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But water holding capacity 6 layers woven/2 layers nonwoven combinations are higher by 14% when compared 8 layers woven mopping pad. Water holding capacity 4 layers woven/4 layers nonwoven combinations are higher by 22% when compared 8 layers woven mopping pad. In this combination, GGNNNNGG shows higher water holding capacity than others. There is no significant difference in between the value of 2 layers woven gauze and 6 layers nonwoven gauze combinations and 8 layers nonwoven gauze mopping pad.

Blood holding capacity of Mopping pad

The trend of blood holding capacity of samples also follow same trend as water holding capacity. But the blood holding capacity is much higher, ranging from 10% to 25% when compared to water holding capacity for the same sample.

Tensile strength characterisation of the developed mopping pad has been also completed.

Summary and conclusions

Major findings based on the analysis of water, blood holding capacity and tensile strength of the developed mopping pad are given below

vIn the 4 layers mopping pad with different combinations, GNNG shows better water, blood holding capacity and tensile strength. Difference between the water and blood holding capacity of 2 layers woven gauze/2 layers nonwoven (GNNG) and 6 layers woven gauze mopping pad is insignificant. Tensile strength of GNNG combination mopping pad is much higher i.e 20% when compared with 4 layers nonwoven (NNNN) mopping pad and it

also matches with tensile strength of 6 layers nonwoven.

vIn the 6 layers mopping pad, GGNNNG combination is the best one when compared with all other combinations. Its water holding capacity is higher than that commercial 8 layers woven gauze mopping pad. Moreover, the difference between the tensile strengths of GGNNNG and 8 layers Nonwoven gauze mopping pad is insignificant.

vIn the 8 layers mopping pad, 4 layers woven gauze/ 4 layers nonwoven gauze is the best blend for the improved performance of water, blood holding and tensile strength. In between this combination, GGNNNNGG shows best results.

DEVELOPMENT OF SELF ASSEMBLED PEPTIDE HYDROGEL BASED BIOACTIVE DRESSING MATERIAL FOR CHRONIC WOUNDS (Sponsored by the Department of Science and Technology, New Delhi.)

Objectives

a. To select angiogenesis inducing growth factors from the literature.

b. To design and/or select self-assembled p e p t i d e s ( S A P ) t o i n c o r p o r a t e angiogenesis promoting growth factors.

c. To investigate the functional response of skin cells to the complexes of SAP hydrogel: growth factor.

d. To study the efficiency of SAP hydrogel: growth factor complex on chronic wound biofilms destruction.

Work done so far

a. Angiogenesis inducing growth factor and peptide with self assembling ability have been selected from the literature.

b. The physical characteristics and biofilm destructing ability of SAP hydrogel have been studied.

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Resultsa. Transparent and homogenous

hydrogel of RADA16-I at the concentrations of 100 ìM, 200 ìM, 500 ìM, 0.25 M and 1M were obtained.

b. The relationship between peptide concentration and time as a factor of hydrogel formation was established.

c. Structural characterization using AFM and FeSEM revealed the peptide nanofibre forming ability of RADA16-I; the sizes of the fibrils were in the ranges of few microns to few hundred nanometers.

d. Structural arrangement through FT-IR and CD confirmed stable â-sheet structure of RADA16-I.

Figure 39a Rheological properties of RADA16-I;Figure 39b Morphological characterization of the peptide hydrogel by AFM (2A and 2B) and FeSEM

(2C and 2D);

e. Attachment and migration of L929 fibroblast cells was observed in RADA16-I hydrogel.

f. Cell viability and morphological analysis confirmed the proliferation of L929 fibroblast cells in 3D environment.

Figure 39a Figure 39b

Figure 39c

Figure 39c

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Figure 40 L929 fibroblast cells grown in different concentrations of RADA 16-I hydrogel.3 3

A: Control, B: RADA only, C: 5x10 cells/ml in 2.5 mg RADA16 –I, D: 5x10 cells/ml in 5 mg RADA 16 3 3

–I, E: 50 x 10 cells/ml in 2.5 mg RADA 16-I and F: 5 x 10 cells/ml in 5 mg RADA 16-I

Figure 41 Acridine orange/EtBr staining shows the morphology of L929 fibroblast cells grown in 2D (A) 3

and 3D environment (C to F). A: Control, B: RADA 16-I hydrogel only, C: 5x10 cells/ml in 2.5 mg 3 3

RADA16 –I hydrogel, D: 5x10 cells/ml in 5 mg RADA 16 –I hydrogel, E: 50 x 10 cells/ml in 2.5 mg 3

RADA 16-I hydrogel and F: 50 x 10 cells/ml in 5 mg RADA 16-I hydrogel.

Figure 42 Cell viability assay of L929 fibroblast cells grown in 3D environment

g. Scaffold developed using RADA 16-I peptide hydrogel provided the appropriate 3D environment for the attachment and migration of L929 fibroblast cells.

h. Destruction of bacterial biofilm was observed using RADA 16-I.

Figure 43 Biofilm formed by S. aureus, P. aeroginosa and E.coli. B. Biofilm treated with 1 % hydrogel and C. Biofilm treated with 2 % hydrogel

The results of the present study suggests the hydrogel forming ability of RADA16-I peptide with the stable â-sheet structure at room temperature. However the hydrogel has to be investigated further for its secondary structure to identify the percentage of â-sheet and any unordered structures in the hydrogel. But the hydrogel once attained its structure, it did not break into monomers; rather were packed together even after sonication. Since the objective of the study is to identify hydrogel forming ability of RADA16-I peptide and its stability at room temperature, it is planned to proceed further with the incorporation of PDGF-BB to the RADA 16-I peptide hydrogel for wound healing applications.

Work relating to the functional response of skin cells to the complexes of SAP hydrogel: growth factor is to be undertaken in the coming year.

SCREENING OF COMMERCIAL WOUND DRESSING MATERIALS AGAINST BIOFILM DESTRUCTION AND THEIR POSSIBLE CYTOTOXIC EFFECT ON SKIN CELLS.

Objectives of the project

a. Collection of bacterial cultures from

diabetes patients admitted in Sri Ramakrishna Hospital, Coimbatore.

b. Morphological characterisation of bacterial biofilm.

c. Collection of wound dressing materials f rom mult i -special ty hospi ta ls of Coimbatore.

d. Screening of wound dressing materials against biofilm destruction.

e. Effect of dressing material on the peripheral lymphocytes and on the biochemical composition of bacterial biofilm.

f. Cytotoxic effect of dressing materials on skin cells.

During last year, work relating to the following were completed:

a. Bacterial cultures were collected from diabetes patients admitted in Sri Ramakrishna Hospital (SRH), Coimbatore.

56


b. Morphological characterisation of bacterial biofilm formed by the collected cultures was studied.

c. Antibacterial and cytotoxic activities of dressing materials were analyzed using AATCC standards and peripheral lymphocytes respectively.

d. Biochemical composition of bacterial bio film after treating by dressing materials has been analyzed.

During the year, work was carried out to study the Cytotoxic effect of dressing materials on skin cells.

Cultures collected from SRH were of polymicrobial in nature. Major organisms found in the cultures were S. aureus, P.aeroginosa and E.coli. Dressing materials were collected from various multi-specialty hospitals of Coimbatore (Table 52).

Wound dressing Material name

Company Active ingredient Indication Toxicity

Paraffin gauze Jelonet Soft paraffin and

cotton

Reduce the adherence of the

wound

-

Bactigauze Med life

and Health Home

Silver sulphadiazine

and Chlorhexidine

Antiseptic wound care dressing

-

Chlorhexidine gauze Cuticell Soft paraffin and

chlorhexidine Acetate

Antiseptic wound care dressing

-

Acticoat Smith and Nephew

Silver Antimicrobial

wound dressing Irritation

Biatain Alginate Coloplast Alginate Antimicrobial

wound dressing -

Hydrophilic foam silver pad

AgFix Foam

Silver nitrate

Non adhesive, absorbent

Polyurethane component

Oxidant injury

Allevyn Sacrum Smith and Nephew

Silver Antimicrobial

wound dressing Irritation for

skin

Gohnson Surgypad gohnson

and gohnson

Alginate protection from re

injury, heavily draining wound

-

No:36624 soft cloth dressing with pad

3M – USA Silicone coated

paper line Skin tear and burn

-

No:86711N soft cloth dressing with pad

3M – USA Silicone coated

paper line, Rayon Pad

Skin tear and burn -

Collagen dry sheet Xenoderm Collagen Management of

burn skin, chronic skin ulcers.

-

Table 52 List of dressing materials collected from multi-specialty hospitals of Coimbatore.

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Morphological characterization showed the biofilm forming ability of the cultures collected from the patients and their disruption when it was treated with dressing materials.

Figure 44 Biofilm formed by S. aureus, P. aeroginosa and E.coli. B. Biofilm treated with Bactigauze and C. Biofilm treated with Acticoat.

Biochemical analysis revealed elevated levels of protein and decreased levels of carbohydrate upon treatment with selected dressing materials.

Significantly elevated levels of LDH and NO were observed in the cells treated with Acticoat, Bactigauze and RADA 16-I (Figures 45 and 46). Elevation were in the order of Acticoat > Bactigauze > RADA 16-I. These results were in line with the cytotoxicity study (Figure 47).

Figure 45 Wound dressing materials showed the cytotoxocity in PBMCs in a time dependent manner. The LDH leakage in the extracellular medium of wound dressing extract treated PBMCs were assayed and expressed in % of LDH leakage. The results shown are mean ± standard error of mean (n = 6). * = P <0.05 compared to control (ANOVA followed by Tukey's multiple comparison).

Figure 46 Wound dressing materials showed cytotoxocity in PBMCs in a time dependent manner. The NO release in the extracellular medium of wound dressing extract treated PBMCs were assayed and expressed in nM of nitrite released. The results shown are mean ± standard error of mean (n = 6). * = P <0.05 compared to control (ANOVA followed by Tukey's multiple comparison); NS – Non significantly different from control.

Figure 47 Wound dressing materials decreased the cell viability of PBMCs in a time dependent manner. Cell viability was assessed by cell proliferation (MTT) assay. The results shown are mean ± standard error of mean (n = 6). * = P <0.05 compared to control (ANOVA followed by Tukey's multiple comparison).Note: ctrl: Control; D1: Acticoat and D2: Bactigauze.

Conclusions

The cytotoxic nature of commercial dressing materials such as acticoat and bactigauze is evident from the study in spite of their potential against bacterial biofilm destruction.

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C H I T O S A N A N D WAT E R S O L U B L E CELLULOSE NANO-SPEAR FOR WOUND HEALING AND HEMOSTATIC APPLICATIONS

Objectives of the study

· Preparation of Imino-Chitosan with glucose.

· Oxidation of cellulose.· Oxidation of Imino-Chitosan.· Nano spear preparation with chitosan and

water soluble cellulose.· Biocombatibility of Imino-Chitosan, water

soluble cellulose and Nano-spear.· Drug loading into Nano-spear and drug

delivery.· Self assembly of Nano-spear on bio-

compatible film.

During the year, work relating to the following were taken up and good progress made

- Preparation of Imino-Chitosan with glucose.

- Oxidation of cellulose.- Oxidation of Imino-Chitosan.- Biocombatibility of Imino-Chitosan.

Preparation of Imino-Chitosan

The Imine group of chitosan was functionalized by the reaction of amino group of chitosan with glucose. The reaction was carried out under heterogeneous phase reaction without cross-linking. 100% yield with a high purity level was achieved. The FTIR spectra of Imino-Chitosan with different ratio of glucose is given in Figure 48.

Figure 48 FTIR Spectra of Imino-Chitosan A - 1:1, B – 1:0.75, C – 1:0.5, D – 1:0.25 and E - 1:0

Oxidation of Cellulose and Imino-Chitosan

The primary alcoholic group of cellulose and Imino-Chitosan was oxidized to corresponding carboxylic acid. Selective oxidation of primary alcoholic group was carried out by using TEMPO. The yield was close to 80% with high level of purity. The full oxidization of cellulose and Imino-Chitosan was confirmed by 1H-NMR spectroscopy (Figures 49 & 50.

Figure 49 1H-NMR spectrum of Oxidized cellulose

Figure 50 1H-NMR spectrum of Oxidized Imino-chitosan

Anti-Microbial activity

Figure 51 Antimicrobial activity of Imino-Chitosan and Chitosan E-coli bactria

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Biocompatibility

Imino-Chitosan showed excellent biocompatibility nature as may be evident from Figure 52.

Figure 52 Cell viability % of chitosan and imino chitosan.

Conclusions

· Imine formation with Chitosan gives high yield with high purity.

· 1H-NMR and FTIR results are good, in line with the proposed structure of the materials

· The biocompatibility results revealed that Imine group and Glucose – Chitosan complex didn't play any toxic role.

Further work under the project is in progress/to be taken up this year, on the following areas

· Nano spear preparation with chitosan and water soluble cellulose.

· Biocompatibility of water soluble cellulose and Nano-spear.

· Drug loading into Nano-spear and drug release.

· Self assembly of Nano-spear on bio-compatible film.

DEVELOPMENT OF MULTIFUNCTIONAL HYGROSCOPIC, ANTI-MICROBIAL AND LOW CONDUCTIVE NYLON COMPOSITES AND THEIR NANOFIBRES

The objective of the project was to develop hygroscopic, antimicrobial material and nanofibres for wound dressing.

Nylon composite films were prepared successfully by blending with honey. Usually, the nylon solution starts to solidify as water is added in to it. This is due to phase separation in water as the water is nonsolvent for nylon. Hence, the blending of nylon and honey is tricky, as honey contains water. It was necessary to find out proper proportion of nylon and honey at room temperature, so that phase separation does not occur and they make clear solution.

Honey is hygroscopic by nature i.e. it has tendency to absorb water from atmosphere. Considering that the nylon composites were made to improve water absorbency. The nylon composite with honey showed more water absorbency in drop test compared to 100% nylon. The absorbency time taken by 100% nylon was more than 28 seconds, while nylon with 15% honey showed 1.3 seconds (Table 56) absorbency time (Usually absorbent textile materials takes 2 to 3 second time to absorb the droplet). At the same time the water holding capacity of 100% nylon was 1.8Grms/Grm, which was increased to 5.1 Grms/Grm for nylon with 15% honey (Figure 53).

As stated earlier, it was expected to have more absorbency due to hygroscopic nature of the honey. But interestingly, another physical phenomenon found in SEM images (Figure 54), which may also have affected the water absorbency. The 100% nylon film was found with plain surface. As the honey is added to nylon, the film surface showed highly porous structure. The porous structure also helped in increasing its water holding capacity and absorbency.

As can be seen in cross section, the 100% nylon film has big granular structure, but the nylon honey composite has very small sized granular structure. So, very smaller sized pores and many numbers of pores are formed. The increased pores may have increased the absorbency.

Specific objectives under investigation

a. Antimicrobial activity of developed material

b. Physical characterisation such as DSC, TGA, FTIR

c. Water contact angle to know hygroscopic nature of material

(It is suspected that the material is a phase change material and it can store energy)

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Figure 53 SEM images of nylon and nylon-honey composite films

The nylon-honey composite solutions were successfully electrospun into nanofibres. Figure 53 shows the SEM images of gravity electrospun nanofibres of 100% nylon and

blend of nylon-honey. As the percentage of honey increased, the fibres became thicker and sticky in nature.

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Figure 54 SEM image of electrospun nano-fibres of 100% nylon and its

composite with honey

Figure 55 Water holding capacity of 100% nylon and its composites with honey

Table 53 Drop Absorbency Test

Sample Drop Absorbency

Test (Seconds)

Ny >28

2.5% NH 5.2

5%NH 4.5

7.5%NH 4.8

10%NH 4.2

12.5%NH 1.9

15%NH 1.3

The nylon – honey composite showed conductivity in the range of semiconductors (Table 53). The conductivity is due to hygroscopic nature of honey

Table 54 Conductivity of nylon-honey composites

Sample Conductivity

(S/Cm)

2.5%NH 4 * 10-3

5%NH 1.2 * 10-2

7.5%NH 1.8 * 10-2

and the honey molecules allow free flow of electrons. Semiconductors are a class of crystalline solid intermediates in an electrical conductivity between a conductor and an insulator. Semiconductors are employed in the manufacture of various kinds of electronic devices, including diodes, transistors, and integrated circuits , power devices, optical sensors, light emitters, including solid-state lasers.

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FTIR curve () shows that nylon and honey are completely miscible in each other.

Figure 56 FT IR curve of 100% nylon and its composites with honey

DEVELOPMENT OF A HEAT AND MOISTURE EXCHANGE FILTER (Sponsored by the Ministry of Textiles, Government of India)


ØTo develop a submicron non-woven filter for breathing system in clean anesthesia oral ICU circuits to remain free of patients micro-flora.

ØTo maintain humidity and heat within the medium

The incidence of hospital acquired (nosocomial) infections has been estimated by the world health organisation to vary between 3% and 21% of all hospital admissions. Development of these infections can lead to further patient treatments and increased hospital stay, resulting in increased costs and nursing time. There are numerous infections control measures that can be employed to decrease the incidence of nosocomial infections in patients.

The use of textile filters is one approach that can be adopted. Filtration technology can be applied to numerous areas in hospital environment to aid infection control. These areas included anaesthetic and intensive care unit breathing systems, pulmonary functions equipment, gas lines, intravenous fluid therapy, blood transfusion and administration of crystalloid cadioplegia during cardiac surgery. Another important factor is the humidity; humidity, which is an important aspect in delivering gases to patients in theatres and intensive care units. Every anaesthetist is expected to understand the principles of humidification of gases. The consequences of not humidifying gases can be serious. Lack of humidification can result in cracking of mucosa, drying of secretions, keratinisation of the tracheas-bronchial tree, reduction in ciliary activity, atelectasis and infection. Over humidification has its own complication. It can result in water intoxication especially in neonates and infants in intensive care, water clogging and airway burns.

The humidity through textile filters is easy to use, efficient, has low resistance to flow of gas and should be economical and safe. Humidification can be used with any breathing circuits and may be provided for air, oxygen and a mixture of gases including anaesthetic gases.

Heat and moisture exchange filters contain materials such as ceramic fibre, paper cellulose and fine steel or aluminium fibres. The heat and moisture exchange filter is warmed by the latent heat of water condensing on it. This heat is also released during subsequent inspiration. The filtering properties of textile material may be due to direct interception, inertial interception, diffusion interception or electrostatic attraction.

In this project, it is proposed to develop a heat and moisture exchange filter using sub micron layer non-woven to improve the filtration efficiency, for flow of gas upto 2cm H O, maintain temperature in 2

the range of 29ºC to 34 ºC, act as a microbial filter, maintain 60% – 70% relative humidity, which is easy to use in breathing circuits etc.

DEVELOPMENT OF ANTERIOR CRUCIATE L I G A M E N T S ( A C L ) U S I N G T E X T I L E MATERIALS (A proposal submitted to the Ministry of Textiles, Government of India)

The main objectives of the project are to develop ultrahigh molecular weight polyethylene (UHMWPE) yarn braided l igaments for

63


reconstruction of anterior cruciate ligaments (ACL).

The anterior cruciate ligament (ACL) is one of a pair of cruciate ligaments (the other being the posterior cruciate ligament) in the human knee. They are also called cruciform ligaments as they are arranged in a crossed formation. In the quadruped stifle joint (analogous to the knee), based on its anatomical position, it is also referred to as the cranial cruciate ligament. The anterior cruciate ligament is one of the four main ligaments of the knee as shown in Figure 57.

Figure 57 Human knee ligaments and reconstruction with artificial grafts

Sportsmen can tear or injure their ACL's during a sports activity. ACL tears are one of the most common knee injuries, with over 100,000 ACL tears in the US occurring annually. Most ACL tears are a result of landing or planting in cutting or pivoting sports, with or without contact. Athletes having a serious complete tear will require an ACL reconstruction because the ACL is crucial for stabilizing the knee when turning or planting.

Women have been known to suffer ACL injuries more frequently than men; current research gives some explanations for this. The joint through which the anterior cruciate ligament passes, along with the actual size of the anterior cruciate ligament, is significantly smaller in women than in men. This makes it more susceptible to damage. Along with these aspects, women tend to not activate their hamstring muscles as much as their male counterparts during certain cutting movements, thus causing less stability in the knee joint.

If ACL is damaged, it will affect one's walking motion fully and create discomfort while walking.

ACL reconstruction is a surgical tissue graft replacement of the anterior cruciate ligament, located in the knee, to restore its function after anterior cruciate ligament injury. The torn ligament is removed from the knee before the graft is inserted.

In this project it is proposed to develop ACL ligaments using Ultra High Molecular Weight Polyethylene (UHMWPE) yarn. ACL ligament is planned to be prepared using braiding technology. The load bearing capacity and tissue compatibility will be studied, towards standardizing the material.

DYEING OF NYLON SUTURES USING HAEMATIN BLACK (LOGWOOD EXTRACT) (In-house project funded by an industrial partner)

Aim and scope of the work

To dye the given nylon mono-filament using Haematin Black natural dye and suggest a project plan for bulk production of Nylon dyed sutures.

Sutures

Suture materials can be broadly classified as naturally occurring and synthetic. They can be further classified as monofilament or multifilament (braided), dyed or undyed, coated or uncoated. Several parameters, such as tensile strength, breaking strength, elasticity, capillarity and memory are used to describe physical characteristic of sutures.

Ideal suture material should:

1. Have good handling characteristics2. Not induce significant tissue reaction3. Allow secure knots4. Have adequate tensile strength5. Not cut through tissue6. Should be sterile7. Should be non-electrolytic8. Should be non-allergenic9. Should be cost effective / cheapSutures can be broadly classified into:

a. Absorbable sutures

Natural: Catgut-plain or chromicSynthetic: Polyglactin (vicryl), polyglycolic acid (dexon)

b. Non-absorbable sutures

Natural: Silk linen

Synthetic: Polyamide (nylon), polyester (dacron), Polypropylene (prolene)

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Nylon sutures

Nylon suture materials are available in mono or multifilament forms. It is composed of long-chain aliphatic polymers of nylon 6. Due to its property of elasticity, it is useful for surface (epidermal, superficial) closure. Monofilament nylon suture has a great dealof memory (Memory is the ability of a suture material to return to previous shape after deformation.) and its proclivity for knot slippage is known. Multifilament braided nylon sutures exhibit decreased memory and they are associated with higher infection rate. In vivo, nylon loses 15- 20% of tensile strength every year by hydrolyzation.

Haematin Black

Haematin black is a natural dye extracted from logwood.

Logwood

Logwood, or Campeachy wood, is the wood of a large tree which grows abundantly in the West Indies, Mexico, and parts of Central America. Logwood was introduced as a dye soon after the discovery of America.

Preparation

Logwood is imported in logs weighing about 400 pounds. The fresh wood is colorless, or nearly so, and contains a glucoside, composed of hematoxylin and sugar.

It is cut into chips or rasped, and aged, i.e. placed in heaps to ferment, an operation which requires great care. The glucoside is decomposed, liberating haematoxylin, and at the same time a large part of the haematoxyhn is oxidized in the air to haematin, the active coloring principle. When sufficiently aged, the wood is ready for use.

Logwood extracts are prepared by extracting the wood with hot water and evaporating the solution under reduced pressure at a temperature not too high. The wood is extracted a second and a third time, yielding inferior grades of extract.

Composition

The wood contains woody fiber, water, mineral matter, haematin, haematoxylin, and other substances. It varies in composition.

The extracts contain haematin and haematoxylin in an impure form. They are sometimes adulterated with glucose, molasses, chestnut extract, and other substances.

Properties

Logwood chips or raspings appear as red, woody substances. The extract is a thick liquid, or paste. A decoction of logwood, or a solution of the extract, has a color ranging from orange-yellow to a dark reddish brown, according to the strength of the solution. The color is removed by zinc and acetic acid.

Both haematin and haematoxylin are acids, and form salts with bases. The reactions of a decoction of logwood are due to the simultaneous presence of both haematin and haematoxylin.

The salts of lead, iron, copper, tin, silver, and some others with haematin are not soluble in water and are precipitated as colored precipitates when any salts of these metals, in solution, are added to a solution of logwood.

This forms a natural black dye on silk and Nylon when mordanted with metallic salts.

MATERIALS AND METHODS

M/s. Aurolab has supplied the Haematin black dye and the Nylon monofilament which needs to be dyed. The process sequence followed is given in the next page. The initial analysis revealed that the dyed sample passes the extractable colouring matter and heavy metals tests.

Scope for future work

Further, upon grant of funds by M/s. Aurolab, this project will be continued for optimization of process parameters, scaling up of the project and then technology transfer to M/s. Aurolab.

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POLYESTER VASCULAR GRAFT IMPLANT - PROCESS OPTIMIZATION AND PRODUCTION SCALE-UP (SPONSORED BY: MINISTRY OF TEXTILES, GOVERNMENT OF INDIA)


- To produce graft with less faults (in width and picks/ inches)

- Optimize the process parameters - To develop grafts of different sizes - To perform all the relevant mechanical

tests

A vascular graft is a surgical procedure performed to redirect blood flow in a region of the body. It is commonly performed due to inadequate blood flow (ischemia) and as a part of organ transplantation. In general, someone's own vein is the preferred graft material (or conduit) for a vascular bypass, but other materials such as ePTFE, dacron or a different person's vein (allograft) are also commonly used. Arteries can also be redirected and serve as vascular grafts.

Polyester (Polyethylene terephthalate - PET) have been used in different blood contacting applications such as vascular grafts, heart valve sewing cuffs and annuloplasty rings. Because, PET biostability, sterilizability, retension of mechanical strength over long period of time, fatigue resistance, good flexibility and handling charactaristics, and suturability to the above implants. The fabric can be woven to produce the desired shapes and porosity.

Vascular graft implants are not manufactured in India. Many international companies are involved in its commercial market. Nearly all large diameter vascular prostheses are made of Dacron; Bard and Meadox. Three-quarters of these prostheses are bifurcated while one-forth are straight. The bifurcated are used to replace the lower part of the aorta where it branches. About 70% of the medium diameter market is held by Gore- Tex while Dacron and biological account for 25% and 5%, respectively.

Indigenous technology to produce fabric based vascular grafts does not exist in India. Hence SITRA is planning to develop a product and process technology for PET vascular grafts. It is proposed to develop defect-free grafts of different sizes. A new loom will be purchased and its process optimized to achieve the objectives. Necessary mechanical tests are currently in progress to meet the requirements for the operation.

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TRANSFER OF TECHNOLOGY AND

RESEARCH UTILISATION

SERVICES TO MILLS

SITRA continues to attach great importance to consultancy and other services to member mills. The range of services offered by SITRA was effectively utilised by its members during this year as well. The services availed by the mills during 2014 - 15 are given in Table 55.

Table 55 SITRA's services availed by the textile mills during 2014 - 15

Type of service No. ofunits

Fibre, yarn and fabric testing 168*

Consultancy services 61

CPQ study and

Online survey on RMC & YSP 195

Training: executives, supervisors and operatives 169

Accessories testing & instrument calibration 1967

* An additional 1,749 small textile units also availed this service

Among the various services of SITRA, testing of fibres, yarn and fabric was the most preferred service during the year (Table 60). The number of samples tested during the year (62879) registered a marginal increase of 3% as compared to the number of samples tested during the previous year (61,041).

"Costs, Operational Performance and Yarn Quality" study (CPQ) covering key areas of a mill's functioning, initiated by SITRA 18 years ago, has been receiving good appreciation from mills. During the year 2014-15, 142 units availed this service.

Monthly online survey of raw material cost and yarn selling price, initiated by SITRA in April 2013, has received a good response during 2014-15 also. Around 80 mills participated in each of the 12 surveys during the year.

The various training programmes offered by SITRA for the managerial, supervisory and operative personnel were utilised by 169 units. The details regarding the training programmes are given in the section under 'Training and Development Programmes'.

Close to 25 % of the mills had retained SITRA for consultancy assignments on various operational problems, techno-economic studies, energy conservation studies and other managerial problems. The major consultancy assignments that were handled by SITRA during the year, are listed below.

Details of the individual consultancy services that were offered to the mills are presented in Annexure V.

§Techno-economic viability study

§Machinery valuation

§Energy audit

§ACS for humidification plants & compressors

§Work assignment study

§A study on the water consumption of soft

flow dyeing machines

§Study on compressed air system

§Feasibility of setting up a training centre

§Consultancy on process standardisation

§Performance improvement study

Material Commercial Project and Others

Samples Tests Samples Tests

Fibres 34275 120055 156 1202

Yarns 16257 25123 1121 1304

Fabrics 10951 8380 119 133

Total 61483 153558 1396 2639

Table 56 Testing services offered by SITRA during 2014 - 15


COMPUTER AIDED TEXTILE DESIGN CENTRES

The first Computer Aided Textile Design Centre (CAD), established at SITRA, Coimbatore in 1995, received good appreciation from the industry. Realising its importance, SITRA established 3 more centres, as a part of the PSCs. All the 4 centres have been functioning under SITRA's control without any financial assistance from the Ministry. The CAD system facilitates the creation of numerous designs quickly which can be varied or changed instantly depending upon the requirement of the customers. Computerised card punching, an intermediate technology, which will reduce the cost in both handloom and powerloom sectors, is also offered by the CAD centres. Table 57 shows the various services of these centres that were utilised by the decentralised weaving sector.

Table 57 Services offered by the CAD centres during 2014 - 15

S. No. Type of service No. of services

1. Designs development

/graph printouts 1184

2. Card punching 4853. Training programmes 13

(persons trained) (25)

POWERLOOM SERVICE CENTRES

SITRA had established its first centre at Somanur, Tamil Nadu three decades ago to cater to the needs of the decentralised sector. Since then, centres were set up at various places of powerloom concentration. At present, there are 7 centres, all of which are sponsored by the Ministry of Textiles, Government of India. The centres are located in Tamil Nadu at Karur, Komarapalayam, Palladam, Rajapalayam, Salem, Somanur and Tiruchengode. SITRA also operates a textile service centre at Chennimalai for the benefit of both handloom and powerloom units in that region.

The PSCs (Powerloom Service Centres) have conducted a number of interactive sessions with powerloom entrepreneurs under the TUF scheme. Various consultancy services like National consumer's awareness day programme, seminar on technical textiles, cluster development programme, machinery buyer-seller meet, entrepreneur development programmes, etc., were offered during the year. The year witnessed many machinery inspections being carried out under the

credit linked capital subsidy scheme. Other services that were offered by the centres, like new project report preparation, machinery valuation, techno-economic viability study, project appraisal, textile extension study tour etc. also witnessed a good response from the powerloom units.

Many rapier looms were installed in Coimbatore, Erode, Namakkal and Salem districts and these units have immensely benefitted from the various services offered by the centres. Many of the shuttleless looms factory owners were supplying huge volume of fabrics for the orders received through buyer-seller meet and for meeting the ever green demand for Indian poplin and cambric fabrics. Efforts taken by the SITRA powerloom service centres to implement the welfare schemes, under the Group Insurance scheme of Government of India, have benefitted about 20,844 workers engaged in weaving, twisting, warping and sizing units.

The various services rendered by these powerloom service centres are given in Table 58.

Table 58 Services rendered by the powerloom service centres (2014 - 15)

S. Type of service No. of No. services

1. Consultations 801

2. New designs development 510

3. Yarn / cloth / chemical samples testing 35,620

4. Training programmes 213 5. No. of persons trained 1234

6. Liaison / request visits 2,618

7. Number of looms inspected 25,954

8. Number of special works 185*

* Seminars / Tuf meetings / Talks

SITRA TEXTILE TESTING AND SERVICE CENTRE, TIRUPUR

A sample collection centre has been funtioning at Tirupur since 2005, towards fulfilling the requests from the knitting industry, textile processing units,

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export houses etc. in the region. Samples collected at the centre are brought to SITRA the same day. In many cases, results are reported to the customers within 24 hours, thus reducing considerably the turn around time. Based on customers' feedback, SITRA has upgraded the centre into an extension service centre and has completed the process of setting up a laboratory with essential instruments for testing of knitted fabric / garments. During the year, the centre had moved to a spacious building which can accomodate more instruments. It is planned to expand this centre further in the coming years so as to carry out as many testings at the centre itself so as to reduce the turnaround time of sending samples to SITRA. During the year under review, the centre tested 1,063 samples with as many as 1,467 tests.

SERVICES RENDERED BY THE KNITTING

DIVISION

The export of knit garments by various countries has led to a stiff competition among the exporting nations. The intense competition has forced the garment manufacturers to produce high quality garments at competitive prices. The production of quality garments with best prices requires great technical skill in purchasing the raw materials and control of the knitting, processing and finishing parameters. The necessity to produce a quality garment has initiated the need to test the various physical parameters of raw materials. The increase in the knit garment export has encouraged the spinning mills to enter into hosiery yarn production. Unlike the yarn intended for weaving, the hosiery yarn requires high quality, since the yarn imperfections will be clearly visible in weft knitted fabrics too. Hence, the production of quality hosiery yarns requires best raw material and hi-tech machines with proper process parameters. In the meantime, the competition prevailing in the spinning industry has forced them to produce quality hosiery yarns at competitive price. To achieve this, the spinning industry is conducting several trials to produce quality hosiery yarns at the minimum cost, to earn maximum profit.

The best method to evaluate the hosiery yarns' performance, is to knit the samples in the knitting machines. Keeping this in mind, SITRA is undertaking a lot of knitting trials and suitably advising the spinning mills to produce the required


quality yarns. Apart from the above service, the knitting division is rendering several other important services like testing the knitted fabric, technical consultations, identification of the causes for the defects, sample development, machinery valuation etc., In addition to the above, the knitting department is conducting seminars focusing on the latest trends in the knitting industry and providing training at various levels. The following services were offered during 2014 - 15.

ØTesting of various quality parameters of knitted fabrics and garments

ØFabric faults and their causes

ØAssessment of the quality of hosiery yarns

ØOffering consultancy services

ØConducting training programmes

The various services offered by the division in the year under review are given in Table 59.

The major testing services that were offered by the department include Yarn Count (175), Weight per Unit Area (75), Contamination Inspection (72), Fabric Ends per Inch and Picks per Inch (59), Twist per Inch (56), Spirality % (46) Course Length / Loop Length (24), Hank to Cop Conversion (21) and Others (66).

Table 59 Services offered by the knitting division (2014 - 15)

S. Type of service No. ofNo. services

1. Testing 594

2. Defect analysis 1,024

3. Samples knitting on

FAK machine 1,534

4. Knitting performance of yarn 278

5. Consultation 2

6. Training programmes 2

(persons trained) (18)

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The testing services offered by the division continued to receive good response from the mills. Karl Mayer warp knitting and warping machines are available for mills/parties for samples development as well as product development in medical textiles.

SITRA WEAVING CENTRE

SITRA's weaving centre is fully equipped with different types of shuttleless weaving machines like, Sulzer Projectile P700 HP, Picanol GTX Plus Rapier, Toyota JAT 710 Air-jet and Dornier LWV 4/E Air-jet machines to provide the following services to the textile industry to meet the global competition.

> Conducting weavers’ training and maintenance training programmes in shuttleless weaving machines

> Entrepreneur Development Programme for new entrepreneurs to start weaving units.

> Preparation of project proposals, model project reports and technical feasibility study reports for weaving units under Technology Upgradation Fund (TUF) scheme.

> Conducting in-house training programmes for weaving units

> Consultancy services and liaison visits

> Product development and sample weaving

> Yarn performance study in shuttleless weaving machines

> Woven fabric defect analysis

> Training programme on fabric quality inspection and cloth analysis

> Management development programmes for sizing units

> Supervisory development programmes

One BC, MBC and DNC candidates skill development training programme (16 fitters), 1 weavers training programmes (5 weavers), and 2 entrepreneur development programme (12 entrepreneurs), one vocational training programme (5 persons) and one training programme on

60 students) were conducted. The weaving centre had also conducted weft yarn performance study (1) and

“Modern Developments in Weaving” (

fabricated viscosity cup (17) and offered 5 consultancy studies.

SITRA CALIBRATION COTTONS

With the quality management systems like ISO and TQM being implemented in many mills, checking of accuracy or calibration of the testing instruments has become mandatory for the textile mills. SITRA calibration cottons have been extensively used by the mills for many years. The calibration cotton marked Ll3, LM3 & HM3 are being popularly used by the mills. During the year 2014-15, a total of 401 packets of these cottons were supplied to mills in different parts of India.

TEXTILE ACCESSORIES TESTING

SITRA offers testing service to evaluate the quality of spinning and weaving accessories / spares as per BIS standards. Moreover, training is imparted to the mill technicians on aspects like evaluation of quality characteristics, sampling procedures, etc. A total of 1,032 samples covering various accessories like carton boxes, paper cones, rings and travellers, tubes, kraft papers, ring spinning bobbins, paper cores, etc., were tested during the year under review (Table 60).

Table 60 Textile accessories testing (2014 - 15)

S. Particulars No.of No. samples

1. Carton boxes 443

2. Paper cones 521

3. Rings & travellers 10

4. Tubes 39

6. Paper cores 9

7. Craft papers 7

8. Spinning bobbins 3

Total 1032

CALIBRATION AND PERFORMANCE CERTIFICATION FOR INSTRUMENTS

Calibrating testing equipment and maintaining their reports is a requirement as per quality systems like ISO and TQM. Many mills are seeking SITRA's help to get a "Calibration Certificate" for their textile testing and quality control instruments. SITRA's certificates are rated as equivalent to the national standards of the National Physical Laboratory, New Delhi. During the year under review, many weaving


& knitting units availed the service of SITRA to receive calibration certificates for 465 textile testing and quality control instruments from 73 mills. Testing the performance of instruments developed by SITRA and manufactured by its licensees is another important service rendered for many years. During the year, 13 instruments were thoroughly checked for their performance and certificates were issued.

SITRA MICROBIOLOGY LABORATORY

Towards providing diversified services under chemical testing, SITRA had started the microbiology testing facilities as an extension of its chemistry laboratory in the year 2009. The microbiology laboratory is well equipped to test the samples as per international test standard of ASTM, AATCC,APHA and IS . The laboratory has the facility to test samples for b

TRAINING SERVICES

`1. STAFF TRAINING

Training programmes conducted every year by SITRA has been extensively utilised by the industry. The beneficiaries of such programmes range from managerial personnel to operatives, who underwent the different programmes that SITRA offered. During the year 2014-15, 19 different training programmes were organised which included 17 functional programmes, 1 in-house and 1 international training. The details of the various programmes are given in Table 61.

acterial filtration efficiency, antibacterial activity assessment of textile materials : parallel streak method, antibacterial finishes on textile materials: assessment of testing for antibacterial activity and efficacy on textile products, antifungal activity, assessment on textile materials: mildew and rot resistance of textile materials, antimicrobial activity assessment of carpets, determining the antimicrobial activity of immobilized antimicrobial agents under dynamic contact conditions, antimicrobial susceptibility tests, methods of sampling and microbiological examination of water, heterotrophic plate count, ETO Sterilization, resistance of materials used in protective clothing to penetration by blood-borne pathogens using Phi X174 bacteriophage penetration as a test system, textile fabrics-determination of antibacterial activity -Agar diffusion plate test and determining the activity of incorporated antimicrobial agent(s) in polymeric or hydrophobic materials


A. Functional Programmes

SITRA's 35th Management Development Programme

The management development programme organised every year by SITRA, attracts young entrepreneurs interested in understanding the various aspects of textile mill management. Many young executives have immensely benefitted from this programme that have been held annually in previous years..

This intensive 2 months programme covers all the major aspects of mill management - material management, financial management and cost control, production and productivity, statistics and qua l i t y con t ro l , ene rgy managemen t , maintenance, personnel management, etc. Twelve young executives attended this programme which was held during October-December 2014.

Training programme on “Ratcheting quality in yarn manufacture”

A two-day programme focusing on the above topic was conducted at SITRA during 16- 17, June 2014. Forty one technicians from 32 mills attended the programme which covered topics like factors influencing yarn elongation & yarn hairiness, Roller lapping in spinning, ways and means of optimizing yarn quality with AFIS data & weak spot analysis, results of various quality improvement studies at SITRA and the quality requirements of yarns expected by weavers & knitters.

Training for Technical officers from the Directorate of Textiles, Govt. of Maharashtra

At the request of Directorate of Textiles, Govt. of Maharashtra, SITRA conducted a 5 day programme for the technical staff of the Directorate. The focus of the programme was sensitizing the participants on the various technical aspects involved in the textile industry with coverage of topics which included present textile scenario, production and productivity, work load and work assignment, introduction to weaving, project appraisal for spinning and weaving, current trends and issues in chemical processing and garment technology. Twenty seven staff of the Directorate attended the programme.

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Table 61 SITRA’s training and development programmes (2014-15)

Duration Category S. Name of the programme (in days) No. A B C

Functional programmes

1 Management development programme 60 1 11 12

In-house programmes

18 Supervisory Development Programme 3 1 1 60

International programme

rd19 SITRA’s 63 international training programme 60 1 9 33

Total - 24 291 668

2 Training programme on “Ratcheting quality in yarn manufacture” 2 1 32 41

3 Training for Technical officers from the Directorate of Textiles, Govt. of Maharashtra 5 1 1 27

4 Training programme on “Modern practices in sizing for hi-tech weaving machines” 1 1 65 82

5 Textiles for non-textile personnel 10 1 1 3

6 Training programme on functional skills in testing and quality control for lab technicians 3 1 18 25

7 Training programme on “Power Quality Management” 1 1 32 44

8 Training programme on “Defect analysis and the remedies in chemical processing” 1 1 73 110

9 Training programme on “Basics of Knitting Technology” 20 1 3 3

10 Technical Awareness programme 1 1 1 26

11 Training programme on “Testing on Analytical instruments” 3 1 1 17

12 Training Programme on “Low Voltage Switchgear Selection & Maintenance” 1 5 29 76

13 Training programme on “One credit course on Eco-testing” 3 1 1 35

14 Training programme on quality evaluation for Co-Optex 4 1 1 13

15 One credit course on Testing of textile dyes and auxiliaries 3 1 1 35

16 Training programme on ISO 50001 Energy Management System 1 1 1 15

17 Technical Entrepreneur Development programme on “Shuttleless weaving“ 5 2 9 11

Note : A - Batches B - Orgnisations C - Participants

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Training programme on “Modern practices in sizing for hi-tech weaving machines”

Sizing, being one of the important preparatory processes in weaving, plays a vital role in deciding the performance of warp during weaving. Knowledge of the properties of the various ingrediants used for sizing is necessary for formulating suitable recipes to fulfill the objectives of the process. With a focus on these aspects, SITRA conducted a programme on “Modern practices in sizing for hi-tech weaving machines” on

rd 23 January, 2015. The programme focussed on the efficiency in sizing, the type and amout of size, penetration of size in different yarn structures and the mode of different deformations in sized yarns during weaving towards better productivity in sizing units. Eighty two participants comprising of Managing Directors, senior executives and technical personnel attended the programme.

“Textiles for non-textile personnel” training programme

At the request of a member mill at Arni, SITRA conducted a ten day programme for its executives. The focus of the programme was to sensitize the participants on the various technical textile aspects involved in the spinning mills, namely, present scenario, work assignment, production and productivity, weaving process, knitting process and possib i l i t ies in unconvent ional kn i t t ing technologies, venture possibilities in various technical fabrics, etc. Visits to units of relevance to the topics covered also formed part of the programme.

Training programme on functional skills in testing and quality control for lab technicians

A 3 day training programme to impart functional skills in testing and quality control for lab technicians working in quality control / testing laboratories, merchandisers, exporters, etc was held in March 2015. Twenty five participants attended this programme which had both theoretical sessions as well as practical demonstrations.

The topics covered during this programme were, Introduction and necessity of testing, Sampling techniques, Colour theory & computer colour matching, Colour fastness, General quality parameters and specific tests for fabrics and garments, Wash care label instructions, Eco parameters, etc.

Training programme on “Ratcheting quality in yarn manufacture”Training for Technical of offices from Directorate of Textiles, Govt. of Maharashtra Training programme on “Modern practices in sizing for hi-tech weaving machines”“Textiles for non-textile personnel” training programmeTraining programme on functional skills in testing and quality control for lab technicians Training programme on “Power Quality Management”Training programme on “Defect analysis and the remedies in chemical processing”Training programme on “Basics of Knitting Technology”Technical Awareness programmeTraining programme on “Testing on Analytical instruments”Training Programme on “Low Voltage Switchgear Selection & Maintenance”Training programme on “One credit course on Eco-testing”Training programme on quality evaluation for Co-OptexOne credit course on Testing of textile dyes and auxiliariesAwareness programme on “Eco-parameters” Training programme on ISO 50001 Energy Management System Technical Entrepreneur Development programme on “Shuttleless weaving“Training programme on “Shuttleless weaving machines“

Training programme on “Power Quality Management”

SITRA organised one-day training programme on th“Power Quality Management” on 10 February,

2015 in which 44 participants from Textile Industry and other industries attended. The programme covered topics like introduction to power quality, measurement and analysis of power quality parameters, effect on quality degraded voltages, harmonics and mitigation, reactive power management and effective earthing system for electrical protection etc.

Training programme on “Defect analysis and the remedies in chemical processing”

SITRA in association with Tirupur Exporters Association organised an interactive programme on “Defect analysis and suitable remedies in chemical processing” at the TEA conference hall,

th Tirupur on 28 January, 2015.The topics covered were general causes for defects in finished yarn / fabric / garments, washing-off techniques, yarn dyeing defects, oil stains and related defects and burn-out prints and defects, etc. 110 participants attended the programme.

Training programme on “Basics of Knitting Technology”

SITRA conducted a training programme on “Basics nd th

of knitting technology” from 2 to 28 February, 2015. The programme covered technical topics like introduction to knitting, design analysis, process control in knitting, knitting calculation, modern developments in knitting, defect analysis and hands on training. Three persons attended the programme.

Technical Awareness programme

At the request of a leading machinery manufacturer, SITRA conducted a one day training programme for their service engineers. The focus of the programme was to sensitize the participants on topics like yarn properties, process machinery affecting properties of yarns, effect of yarn properties on post-spinning processes like weaving, warping and knitting. Twenty six engineers attended the programme.

Training programme on “Testing on Analytical instruments”

SITRA organised a three day value added course “Testing on Analytical instruments” for the students

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of an Arts & Sceince college in Coimbatore, from rd th

23 to 25 February, 2015. Seventeen students attended the programme. The topics covered were sample preparation techniques, principles of different analytical instruments, practical demonstration of analysis on GC-MS, HPLC, AAS, HPTLC, etc.

Training Programme on “Low Voltage Switchgear Selection & Maintenance”

With the objective of enhancing the knowledge of electrical personnel working in various industries on key aspects involved in the selection, operation and maintenance of low voltage switchgears, SITRA, in collaboration with L&T (the pioneers in switchgears) conducted a series of training programmes spread over 3 months. Five one-day training programmes were organised as independent modules on i) Circuit breakers, ii) Contactors & OLR, HRC fuses, iii) Motor starters & MPCBs, iv) MCBs, ELCBs & DBs and v) Fault level calculations, Numerical relays, BBT and MV switchgear. A total of 76 participants attended the programmes in the five modules which covered topics like introduction to switchgears, selection and operation of MCCBs, and operation and maintenance of ACBs. There was good apreciation for the programme which, apart from covering theoretical sessions, provided opportunity to the partcipants to have hands-on working on model switchgears..

Training programme on “One credit course on Eco-testing”

Towards benefitting students studying in an Engineering college, SITRA organised a three-day training programme on “One credit course on eco-testing” in March 2014. Some of the topics covered included various chemicals used in the textile supply chain, impact of hazardous chemicals and their environment effect, restricted substances and permissible limits, testing of eco-parameters, case studies, certification procedures and good laboratory practices. Totally, 35 students attended the programme that was held at SITRA.

Training programme on quality evaluation for Co-Optex

A 4 day training programme on quality evaluation of textile materials was conducted for the staff members of Co-Optex’s branches. The following topics were covered during the programme:

- Fibre identification

- Colour fastness to washing, rubbing, light and perspiration

- Determination of count of yarn from fabric

One credit course on Testing of textile dyes and auxiliaries “One credit course on Testing of textile dyes & Auxiliaries” was organised for the students of an Engineering College, as a part of their curriculum credit scheme in November, 2014. Thirty five students from this college attended this programme. Both theoretical and practical demonstrations were given. Topics covered in the course are given below:

Ø Chemical nature of auxiliaries & dyes used in wet processingØ Performance based evaluationØ Purity analysis of basic chemicals

Ø Testing of end-productsØ Impact of quality of chemicals / dyes used on the quality of fabrics

Training programme on ISO 50001 Energy Management System

SITRA conducted ISO 50001 Energy Management System Awareness programme for a Textile mill in Tamilnadu in December, 2014. Totally, 15 persons took part in the programme.

Technical Entrepreneur Development programme on “Shuttleless weaving“

The programme was organised with the objective of educating young entrepreneurs on the technologies involved in weaving, case studies relating to woven fabric defects and remedial measures, TUF scheme, various sources of availing loans, the modalities involved in setting up new units etc. Eleven persons comprising Managing Directors, senior executives and technical personnel attended the programme in two different batches.

I n - h o u s e S u p e r v i s o r y D e v e l o p m e n t Programme

At the request of a member mill, SITRA conducted an in-house supervisory development programme at their mills in April, 2014. The programme covered technical topics like quality management in spinning, process control in spinning, TQM & maintenance practices to be followed and right

B.In-house Programme

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work methods for operatives. The programme was well received by the participants, totaling 60.

Three courses, Textile Mill Management, Textile Testing & Quality Control and Managerial Skills for HRM personnel in textile Industry, were offered under this scheme. Thirty three participants from 9 countries – Bangladesh, Ethiopia, Kenya, Malaysia, Myanmar, Nigeria, Philippines, Sudan and Uzbekistan attended the two-month programme.

C. International Training Programme

International training is a regular feature of SITRA's training activity since 1974. More than 1600 participants from 67 countries have so far been benefited out of SITRA's expertise in textiles. The participants taking part in such programmes are sponsored by the Ministries of External Affairs and Economic Affairs, Govt. of India, under their sponsoring schemes viz., ITEC (Indian Technical and Economic Co-operation Plan) and Colombo Plan.

rdThe 63 batch of this programme commenced on

th 6 October 2014.

The valedictory function of the programme was held on December 2, 2014. Dr. Prakash Vasudevan, Director, SITRA presided over the valedictory function and distributed course completion certificates to the participants.

2. LABOUR TRAINING

SITRA has been regularly conducting training programmes for the textile mill workers for the past 33 years. As in the previous years, this year also many mills have utilized SITRA's services in this area. As many as 633 shop floor workers were trained. Training programmes were organized for operatives at mills' premises in the regional languages in 38 batches (Table 62).

(i) Pre-employment and retraining programmes

Pre-employment training for new entrants and retraining programmes for the experienced workers were conducted in 9 mills, covering 489 operatives in 28 batches. Significant improvement was achieved in key elemental timings, incidence of waste, production rate and quality of output in all the programmes. Details of the operatives training programmes for spinning mills conducted in 2014 - 15 are shown in Table 63.

(ii) Anillary labour training

Retraining programme was conducted for the doffers of a member mill. They were trained to doff full cops and replenish empty cops using both the hands while doffing ring frames. Significant improvement was achieved in doffing time and controlling double gaiting.

(iii) Awareness programme

One spinning mill in Tamilnadu availed SITRA's services for imparting training to its trainers towards

Table 62 Training programmes offered for shop floor workers in 2014-15

Number of S. Type of No. programme Mills Batches Partici-

pants

1. Operatives training 8 28 489

2. Ancillary labourtraining 1 2 29

3. Awareness programme 1 1 20

4. Jobbers Development Programme 1 1 20

5. Training of Trainers 2 3 39

6. Fitters training 17 3 36

Total 29 38 633

Table 63 Break-up of operatives training programmes for spinning mills

conducted in 2014-15

S. Number of No. Tenting jobs Mills Batches Partici-

pants

1. Fly frames 1 1 8 2. Ring frames 4 22 389 3. Open end

spinning 1 2 32 4. Cone winding 3 3 60

Total 8 28 489

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creating an awareness of the importance of higher production, better quality, lower waste, proper planning, right work methods etc. The programme was intended to sensitise the trainers to effectively discharge their role and functions and achieve improvement in the mill's working. A total of 20 trainers attended the programme.

(iv) Programme on “Training of trainers”

Three batches of three day “Training of trainers programme” were organized for 2 mills, one in Tamilnadu and one in Haryana. The aim of the programme was to sensitize them to effectively discharge their role and functions and achieve improvement in the mills’ working. The topics covered inc luded p roduc t i v i t y, qua l i t y management, waste reduction, proper planning and scheduling of activities, methods of training, identification of training needs, training evaluation, right work methods to be followed and effective communication and inter-personnel skills. A total of 39 trainers attended the programmes.

(v) Fitters training programme

To upgrade the skills of fitters towards managing new technologies in shuttleless weaving machines, fitters training programmes were organised. Theoretical and hands-on practical training on the mechanism of hi-tech weaving machines and their maintenance were offered during the one month programme. Totally, 20 fitters were trained in two different batches.

3. SKILLS DEVELOPMENT TRAINING PROGRAMMES UNDER SITRA – ISDS

(VI) Fitters training programme for BC, MBC and DNC candidates

To upgrade the skills of fitters towards managing new technologies in shuttleless weaving machines, a training programme was organised. Theoretical and hands-on practical training on the mechanism of hi-tech weaving machines and their maintenance were offered during the one month programme. Totally, 16 fitters took part in the programme.

The “Integrated Skill Development Scheme” initiated by the Ministry of Textiles, Govt. of India, aims to leverage the strength of institutions like SITRA to augment the skills of the personal in industry for enhancing their capabilities. Under the

thmain phase of this scheme in the 12 Plan period, SITRA is offering 9 different skill development programmes.

During the year SITRA trained a total of 1520 persons under the scheme. This included

Operative training programme and Training of Trainers programme. Under the the operative training programme, a total of 1490 persons were trained in 69 batches in spinning mills for a period of one month for the tenting jobs in preparatory, spinning, manual cone winding and Autocone winding. Also, 30 trainers were trained under the Training of Trainers progrtamme.

APTITUDE TESTS FOR TEXTILE MILL OPERATIVES

Since the jobs in textile mills are mostly semi-skilled, repetitive and monotonous, it is of utmost important to select only those individuals who would have these characteristics and would desire to do these jobs. By doing so, mills can not only ensure more productivity but also greater commitment and involvement amongst the employees.

SITRA's aptitude tests are exclusively designed to meet the specific requirements of assessing the ability or aptitude of employees to do the expected activities in the various departments of a textile mill. These tests are being effectively used by around 200 member mills for the selection of employees and they are appreciative of the effectiveness of these tests. The tests measure whether an individual has the capacity or latent ability to learn and perform a given job if adequate training is provided. The use of aptitude tests is advisable for fresh applicants who have little or no experience and may be used by the mills interested in selecting employees for whom training will result in greater performance.

The tests are designed to cover the operatives for preparatory, spinning and weaving departments. Most of the jobs in these departments involve i) visual acuity eg., ability to note end breakages, ii) two hand coordination for working at machines eg., operations like piecing and knotting, iii) finger dexterity eg., operations like piecing and knotting iv) eye and hand coordination for operating the state-of-the-art machines and v) quick reaction time to respond to emergencies at the work place. All these psychophysical attributes are measured by using the three tests in the SITRA Aptitude Test Kit.

Since 2005, SITRA has included another sub-test to the Kit - colour blindness. Many times, it is observed that operatives suffering from colour blindness are unable to distinguish the subtle differences in colour variations as also identify the basic colour combinations. In order to ensure the best fit of operatives with the job, it is essential to screen out persons with this defect.

During the year 2014-15, 14 aptitude test kits were purchased by the textile mills.

MULTIMEDIA DVDS ON WORK METHODS FOR OPERATIVES

A new version of multimedia training materials, in DVD format, for the benefit of spinning mill operatives was released by SITRA in the year 2013. Like the earlier version of VCDs released by SITRA, this DVD version also will serve as a handy tool for spinning mills to educate operatives on the right ways and means of working in spinning mills. All departments from mixing to reeling are covered. The highlight of the DVD is the option available to users to select any of the 5 languages voice-over namely, Tamil, Telugu, Malayalam, Kannada and Hindi. An English version of the DVD is also available separately.

Departments covered: Mixing, blowroom, carding, combing, drawing, speedframe, ring spinning, open end spinning, manual cone winding, auto cone winding, ring doubling, two for one twisting and reeling.

During the year 2014-15, 14 DVDs were purchased by the textile mills.

CONFERENCES AND SEMINARS

Seminar on “Energy conservation in industry”

With an aim to create an awareness among industry personnel the importance of conservating energy, SITRA organised a seminar on “Energy

thconservation in Industry” on 27 October, 2014 at SITRA. Around 300 participants representing various textile mills and other industries, apart from faculty and students from different colleges attended the seminar. A SITRA publication entitled “Fundamentals of Electricity Management in Industry” was released on the occassion.

Six different technical papers of relevance and current interest in the field of energy conservation w e r e p r e s e n t e d i n t h e s e m i n a r . Mr.N.Vasanthakumar, Junior Scientific Officer, Textile Engineering & Instrumentation Division presented a paper on “Selection of energy efficient electrical utilities”.

I n t e r n a t i o n a l w o r k s h o p o n “Biocompatibility evaluation of medical devices”

An “International workshop on biocompatibility

evaluation of medical devices” sponsored by the Ministry of Textiles, Govt. of India was organised by the Centre of Excellence for Medical Textiles,

th th SITRA at SITRA, from 15 - 18 October, 2014.

Expert speakers from the department of Microbiology and Mutagenicity, Bioneeds, Bangalore and the Skin Ethic Laboratory, France delivered lectures relating to biocompatable evaluation of medical devices with a focus on ISO 10993. Totally, 25 persons took part in the workshop.

Centre of Excellence for Medical Textiles, SITRA organized a 5-day seminar on “Coating and laminating technologies Module - I” from 23rd to 27th September, 2014 at SITRA. Specialist speakers from Pune conducted the sessions. Topics like, polymers used for the manufacture of adhesive, adhesive types, additives for PSA, combination of various resins, anti oxidants for adhesive, poly isobutene as tackifier and fire retardant additives were discussed in the seminar. Totally, 26 persons took part in the seminar.

Seminar on “Coating and laminating technologies” Module - I

COMMUNICATION

Library

Like in the previous years, SITRA library attracted many visitors from both industry and academics with close to 4000 persons having utilised SITRA’s vast collection of books, journals and periodicals during the year. Close to 400 books and pamphlets were added to the existing collection, which currently is 25858, that include books on various technical subjects, apart from textiles and management. SITRA presently subscribes to 125 journals dealing with various aspects of textiles.

Visitors

Details of some of the notable dignitaries who visited SITRA during the year are given in Annexure II.

Publications

SITRA brought out 32 publications during the year which included one monograph in Tamil, 4 research / inter-mill study reports, 3 trends, 12 online reports, 6 focus and 6 SITRA news publication (Annexure III).

SITRA scientists published 13 papers in various technical journals and presented 10 papers in conferences and seminars (Annexure VI).


77

ANNEXURE I

THE STAFF

DirectorDr.Prakash Vasudevan. M.Sc. (Textile Engineering), Ph.D

(Leeds)

SPINNING

General Manager (Projects) & Head of Division:Dr.K.P.Chellamani, M.Tech., Ph.D., C.Engg., F.I.E., F.T.A.

Junior Scientific Officers:M.K.Vittopa, M.Tech., A.M.I.E.

D.Veerasubramanian, M.Tech.

V.Vijaya Jothi, M.Tech.

WEAVING AND KNITTING

Assistant Director & Head of Division:K.Balasubramaniyan, M.Tech.

Junior Scientific Officers:S.Sounderraj, M.Tech.

P.Sundaramoorthy, M.Tech.

LIAISON AND CONSULTATION

Deputy Director & Head of Division :D.Shanmuganandam, M.Tech., M.I.E.

Research Associate:S.Mariappan, M.Tech.

Senior Scientific Officers:J.Sreenivasan, M.Tech.

N.K.Nagarajan, B.Tech.

P.Subash, M.Tech.

TEXTILE ENGINEERING & INSTRUMENTATION Head of Division:M.Muthukumaran, B.E.

Senior Scientific Officer:S.Sugumar, B.Sc., A.M.I.E., C.Engg., PGDCM, MCA.

Junior Scientific Officers:M.Muthuvelan, B.E., PGDBA., M.B.A., M.Phil (Mgmt).

N.Vasanthakumar, B.Sc., A.T.I.

V.Kumaravel, B.E.

TEXTILE PHYSICS

Assistant Director & Head of Division: S.Kadirvel, M.Tech.

Senior Scientific Officer:R.Pasupathy, M.Tech., M.B.A., A.M.I.E.

78

TEXTILE CHEMISTRY

In-charge of Division :S.Sivakumar, M.Tech., D.T.P

TRAINING DIVISION

Research Associate and Head of Division:Dr.K.Sajjan Rao, MA, M.Phil, Ph.D., PGDPM&IR, DIC.

ISDS / Powerloom Service CentreSenior Scientific Officer:M.P.S.Ravindran, B.Tech., M.B.A.

CENTRE OF EXCELLENCE FOR MEDICAL TEXTILES

Head of Division :P.Sakthivel, B.Com., M.B.A., (D.H.Tech.)

Principal Research Investigator:Dr. Ketankumar Vadodaria, M.Tech., Ph.D.

Senior Scientific Officers:S.Thiruppathi, M.Tech.

Dr.E.Santhini, M.Sc., Ph.D.

Junior Scientific Officers:T. Sureshram, M. Tech.

A.Neha, M.Text.

Dr.S.Rajasekar, M.Sc., Ph.D

ADMINISTRATION - SITRA & Power loom Service Centres

Administrative Officer:R.Ravichandran, B.Com., A.C.S., Dip. Sec. Pract.

Head - Finance and Cost Accounts:K.Vadivazhaki, B.Com., A.C.A.

Head - HR:R.Sivaram, MHRM, M.B.A.

Research Associate:R.Suganthi, M.Sc., M.C.A., M.C.S.D., Net 07,OCA & OCP.

Secretary to Director:N.Saradha Jayalakshmi, M.Sc., M.B.A.

Junior Officers:V.Gopalakrishnan, M.A., M.L.I.S.

K.Prabha, M.Com., PGDCA

CONSULTANTS:

Cyril Lourdes, B.Com.

A.Sivaramakrishnan, M.Tech., C.Text., A.T.I., A.M.I.E.

A.Sankara Namasivayam, B.Tech.

P.Arumugam, B.Sc.


79

stTotal staff strength as on 31 March 2015

Officers : .....................37

Scientific/Technical assistants : .....................42

Administrative staff : .......................8

Skilled/Semi skilled &

maintenance services : .....................27

Technical assistants on contract : .......................4

Total :.............. ......118

Powerloom service centres (Govt. sponsored)

Officers : .......................4

Scientific/Technical assistants : .....................32

Technical assistants on contract : .......................2

Skilled/Semi skilled : .......................6

Total ..:......................44

ANNEXURE II

VISITORS

Smt. Kiran Soni Gupta, I.A.S.,Textile Commissioner, Ministry of Textiles, Government of India.

Dr. Krishna Gupta, Chief Executive Officer, PMI Porous Materials, Inc., New York. Ms. Richa Bagla, I.A.S., Director, Directorate of Textiles, Government of Maharashtra.


80

ANNEXURE III

SITRA PUBLICATIONS DURING 2014 - 2015

1. Research / Inter-mill study reports :

2. Focus:

3. SITRA Trends:

4. Online Survey reports:Online Survey repot of raw material cost and yarn selling price (12th to 23rd surveys) - N.K.Nagarajan, R.Subhas, G.Santhanakrishnan, S.Rajkumar and D.Shanmuganandam

5. Books:

6. SITRA News:

Numbers 1 to 6

7. Other Publications:

Annual report 2013-14

thCosts, operational performance and yarn quality: Inter-mill study of key factors (30 study) - D.Shanmuganandam, J.Sreenivasan and I.Suresh Balu

Can a spinning mill achieve a single digit total HOK? - A case study - D. Shanmuganandam, N.K. Nagarajan and P.Prabu

How can a participant mill make use of the CPQ study data to improve its performance? - A case study – D.Shanmuganandam

An inter-mill study of quality of cotton yarns (compact yarn) 26th survey - R.Pasupathy and S.Kadirvel

Lubrication practices in ring frames: A review - D.Shanmuganandam, J.Sreenivasan and N.Parthasarathy

A study on the effect of yarn conditioning on yarn characteristics - S.Kadirvel, R.Pasupathy and S.Arumugam

How RMC and YSP had fluctuated in 2013-14:An analysis - D.Shanmuganandam

Fabrics defects by knitting machines - reasons and remedial measures - Part I - S.Sounderraj

Quality assurance activities in textile mills - case study of a composite unit with a QA system - JR.Nagarajan and D.Shanmuganandam

Impact of ring frame utilisation on fibre to yarn conversion cost : an analysis - D.Shanmuganandam

How the spinning mills performed in 2013? - D.Shanmuganandam and J.Sreenivasan

thHighlights of the 30 CPQ study - D.Shanmuganandam and J.Sreenivasan

Changes in Fibre to Yarn conversion cost between 2010 and 2014 - D.Shanmuganandam and J.Sreenivasan

Fundamentals of electricity management in Industry (in Tamil)- M.Muthuvelan


81

ANNEXURE IV

SITRA DEVELOPMENTS

1. Machinery

Storage positive feed system for knitting machinesHigh speed reeling machineHigh production cutting machineHigh speed blending draw frame single delivery machine"Spinfan" system for fancy yarnsSITRA - VOLKA ring frame"Enerspin" drive system for ring spinning & doubling framesSITRA "miniSPIN" - Miniature spinning plant for test runsSITRA ENERCONER - Energy efficient drive control system for automatic cone winding machinesEnergy and production information system for ring spinning frames "SITRA EnerInfosys"SITRA ener TFOSITRA CIMSITRA MicrocontrolWeavability TesterHigh performance jute flyer spinning frame - SITRA Jute FlyspinMicro controller based energy saving & information system for air compressors used in textile mills - SITRA PCRA ENERCOMP

2. Fibre and Yarn Testing Instruments

Fibre bundle strength testerTrash separatorElectronic twist testerElectronic lea strength testerSemi - Automatic twist testerMotorised twist testerNep counterSITRA motorised multi-board yarn appearance winderElectronic load indicator for conventional lea strength tester (ELCONLEA)SITRA rapid sample conditionerSITRA- ABRATEST - Yarn abrasion resistance testerSingle yarn strength testerSchnidt model yarn tension meter

3. Others

SITRAlised energy saving spindle tapes CSP system and fabric strength testerSANTIMIT Fabric winding mechanism for powerloomsWeft feeler mechanism to stop the loom Arterial prosthetic graft for pirn changing SITRA pneuma kitEnergy efficient fans - SITRA excel fan SITRA motor relay testerInfra colour dyeing machine Lab fabric dyeing machineShore hardness tester Soxhlet extraction mantlesCyberscan bench top PH meter Microprocessor based electronic balanceFabric stiffness tester LaunderometerDrapemeter Crease recovery testerFabric thickness tester PerspirometerMRG crimp tester SITRA EnercoolFabric elongation tester Fabric compression testerFabric roughness/friction tester SITRA's Bacterial Filtration Efficiency Tester UV Photocatalytic reactor SITRA's blood penetration resistance tester

SITRA may be contacted for the addresses of the Licensees

Self anchor suturing machine


82

ANNEXURE V

LIST OF STUDIES / SERVICES RENDERED TO MILLS

Mills utilised SITRA’s services and expertise for a wide range of their requirements. Some of the

studies/services attended during 2014 - 15 were:

Consultancy on process standardisation (2) .

Apart from the above, the following studies were also undertaken: Measures to reduce invisible loss, Study on doffing end breaks in ring frames, Study on improving yarn recovery, Weavers work assignment / loom efficiency study, A method for precipitation of PVA in the combined effluent, Study on bleaching of cotton terry towel fabrics with peracetic acid, Feasibility of setting up a training centre, Powerloom machinery valuation, Technical report on generator, Process optimization at a fabric washing unit, Technical trouble shooting for a garment export unit, Selection of a suitable method to precipitate oil and grease in textile effluent, Study on MIS, Performance improvement study, Productivity and maintenance audit, Steam energy audit, Power consumption analysis for air compressor, A solution to prevent dusting-off on burn-out printed garments, Process route to eliminate oil line marks on fleece knitted fabrics, Elimination of crease marks while processing grey melange fabrics, Process route to minimize roll to roll shade variation in knitted fabrics dyed using reactive dyes, Study on yarn realisation & quality control, Flat knitting trials (2/30s yarn), Elimination of oil stains from processed fabrics, Sample warp knitting, Noise level study, Process route to eliminate black dots on bleached white fabrics, Technical study - Special process to minimise bleeding of colour and staining on adjacent portions from yarn dyed carpets, Study of high weft yarn breakages in Air-jet looms, Poor absorbency in printed fabrics and Technical touble shooting - improving colour fastness of yarn dyed materials.

In addition, more than 6,790 day-to-day problems on different areas were referred by the mills Prominent among them are designs development and card punching by CAD centres and PSC’s (1,645), Defect analysis and fabric analysis (1,024), Assessment of knitting performance (278), New designs development (609), Textile accessories testing (1,463), Calibration of testing instruments (495), Performance certification issued to testing instruments (10) and more than 23 adhoc problems dealt by the Spinning, Physics, Chemistry, Engineering and Training Divisions .

Weft yarn performance study(26), Energy audit (7), Viscosity cup fabrication (17), ACS for humidification plants & compressors (7), Humidification system study(6), Techno-economic viability study (6), Machinery valuation (5), Work assignment study(5), Sample warp knitting (3), 40s conversion factors list and method of calculation(2), Study on the water consumption of soft flow dyeing machines (2), Study on compressed air system (3), Study of high weft yarn breakages in Air-jet looms (2) and


83

ANNEXURE VI

PAPERS PUBLISHED IN JOURNALS AND PAPERS PRESENTED IN CONFERENCES

PAPERS PUBLISHED


K.P.Chellamani “Wound healing ability of herbal drug incorporated Journal of Academia andR.S.Vignesh Balaji PCL wound dressing” industrial Research (JAIR), D.Veerasubramanian April 2014, Volume 2, No.11,

pp.622-626.

K.P.Chellamani “Studies on thermally conductive filament Journal of Academia and D.Veerasubramanian incorporated hospital bed linens and its thermal industrial Research (JAIR), G.Paneerselvam comfort” April 2014, Volume 2, No.11,

pp.642-645.

K.P.Chellamani “Development of wound dressing made of electro International Journal of EmergingR.S.Vignesh Balaji spun Tetracycline hydrochloride drug incorporated Technology & AdvancedD.Veerasubramanian PCL nanomembrane” Engineering, April 2014,

Volume 4, No.4, pp.251-256.

K.P.Chellamani Inter-relationship between deviation rate (DR%) Journal of Textile Association,D.Veerasubramanian in yarn mass and variations in yarn tensile May -June 2014, Volume 74, M.K. Vittopa characteristics and fabric appearance No.6, pp.353-359.

K.P.Chellamani “Wound dressings: SITRA’s contributions” International Journal of EmergingR.S.Vignesh Balaji Technology & Advanced D.Veerasubramanian Engineering, June 2014,

Volume 4, No.6, pp.177-184.

K.P.Chellamani “Quality evaluation methods for textile substrates International Journal of EmergingR.S.Vignesh Balaji based wound dressing” Technology & Advanced D.Veerasubramanian Engineering, June 2014,

Volume 4, No.6, pp.811-817.

K.P.Chellamani “Implantable Medical Textiles: Synthetic suture Journal of Academia and D.Veerasubramanian manufacturing technology” industrial Research (JAIR), R.S.Vignesh Balaji July 2014, Volume 3, No.2,

pp.67 -72.

K.P.Chellamani “Medical Instrumentation : SITRA’s contribution” Journal of Academia and D.Veerasubramanian industrial Research (JAIR), R.S.Vignesh Balaji July 2014, Volume 3, No.2,

pp.78 - 83.

K.P.Chellamani “Textile implants: Silk suture manufacturing Journal of Academia and D.Veerasubramanian technology” industrial Research (JAIR), R.S.Vignesh Balaji July 2014, Volume 3, No.3,

pp.127 - 131.

K.P.Chellamani “Inter-fibre cohesion in imported and indigenous Asian Textile Journal,M.K. Vittopa cotton and its influence on yarn quality” August 2014, Volume 23, No.8,J.Sudharsan pp.68 - 69.

K.P.Chellamani “Studies on quality attributes of Bt-cottons” Asian Textile Journal,M.K. Vittopa cotton and its influence on yarn quality” October 2014, Volume 23, No.10,S.Sivakumar pp.68 - 72.

K.P.Chellamani “Roller lapping in spinning ? - an objective Texfair - 2015 Souvenir, SIMAV.Vijayajothi evaluation technique” January 2015, pp 26 - 31

K.P.Chellamani “Studies on comfort properties of compact yarn Texfair - 2015 Souvenir, SIMAM.K. Vittopa fabric” January 2015, pp 32 - 39R.S.Vignesh Balaji

ANNEXURE VI

PAPERS PUBLISHED IN JOURNALS AND PAPERS PRESENTED IN CONFERENCES (CONTD..)

84


D.Shanmuganandam “Impact of ring frame utilisation on fibre to yarn Asian Textile Journal, conversion cost” March 2015, pp. 69 - 72.

J.Sreenivasan “Fibre to yarn conversion cost - an analysis” Indian Textile Journal, May 2014,D.Shanmuganandam Volume 124, No.8, pp.29 - 33.

D.Ranganathan “Phytochemical analysis of Caralluma Nilagiriana” Journal of Pharmacognosy and, using GC - MS” Phytochemistry, May 2014,

Volume 3, No.1, pp.155-159.

Ketan Kumar Vadodaria Effect of solvent combination on the formation of International Journal of Advancedet.at. ethylcellulose electrospun fibre and bead Research, 2014, Vol. 2, No. 2

morphology pp. 900-914

P.Sakthivel “Opportunities in medical texiles Texfair - 2015 Souvenir, SIMAA.Neha January 2015, pp 26 - 31

PAPERS PRESENTED

K.P. Chellamani “Tensile & tearing strength of woven fabrics-D.Veerasubramanian some studies”R.S.Vignesh Balaji

K.P. Chellamani “Yarn properties influencing fabric handleM.K.Vittopa characteristics of compact yarn fabrics”R.Pasupathy

N.K.Nagarajan Impact of inter-mill variations in the techno-D.Shanmuganandam commercial parameters on the financial

performance of spinning mills

K.P. Chellamani Total Quality Management in an R&D set-up Programme - “Managerial Strategies” 2nd September, 2014, at Gandhigram Deemed University, Dindigul

K.P. Chellamani “Process-Re-engineering” “Enterpreneur’s Development Programme” 7th Oct. 2014, at Gandhigram Deemed University, Dindigul

K.P. Chellamani “Small Group Activities in a Decentralised Conference on 14th Oct. Sector” 2014, at Gandhigram Deemed

University, Dindigul

K.P. Chellamani “Technology-assistance from R&D labs and Organised by Amrita other institutions in Technology Selection” University, for the budding

entrepreneurs from various streams of engineering in Amrita University, Coimbatore

ston 01 March 2015.

K.P. Chellamani “Interpretation of test data from Modern At the “Executive Trainingtesting Instruments” and “Usefulness Program” organized of classimat quantum in producing by Lakshmi Machine Works

rdhigh quality yarns” Ltd., Coimbatore on 23 March 2015.

S.Sivakumar “Eco-friendly textiles” Meeting organised by Institution of engineers on 8th August, 2014

55th Joint Technological Conference held at NITRA, at New Delhi, 10th May, 2014

ANNEXURE VI

PAPERS PUBLISHED IN JOURNALS AND PAPERS PRESENTED IN CONFERENCES (CONTD..)

85


S.Sivakumar “Defects in knitted fabrics and their At the 16th Annual General remedies” Body meeting of the

South India Imported Machine Knitters Association (SIIMKA) on 13th Sep. 2014

S.Sivakumar “A methof for decolourisation of textile At the DBT sponsored National processing effluent” Conference on “Impact of

research & development in bio-technology for sustainable textile production” organised by KSR college of Technology, Tirchengode, 23rd Dec. 2014

N.Vasanthakumar "Improving energy efficiency in spinning mills” Technical workshop organisedby M/s Grasim Industries limited, Erode on 5th August, 2014

P.Sundaramoorthy “Development of leukocytes reduction filter Proceedings of the International conference

for human blood using nanotechnolog” on Technical Textiles and Nonwovens - 2014 Indian Institute of technolog, New Delhi,2014

K.P. Chellamani “Raw material management” “Operational Excellence for entrepreneurs Program” organized by Lakshmi Machine Works Ltd.,

thCoimbatore on 17 December 2014.

M.Muthukumaran “Energy conservation, energy efficiency” UGC sponsored faculty development programme on “Green energy solutions for sustainable development” organised by Coimbatore Institute of Technology, Coimbatore 19th Dec. 2014

M.Muthukumaran “Importance of energy audit to the textile Organised by Indian Textile manufacturing & engineering industry” Accessories & Machinery

Manufacturers Association(ITAMMA) 10th January, 2015

M.Muthuvelan “Performance Assessment in Electrical UGC sponsored faculty Systems” development programme on

“Green energy solutions for sustainable development” organised by Coimbatore Institute of Technology, Coimbatore 19thDec. 2014

Sakthivel Perumalsamy “Smart medical textiles” UGC sponsored National seminar, at GVN College, Kovilpatti, 22nd January, 2015

“Sports textiles” Avinashilingam University, Coimbatore, 19th February 2015

TALKS GIVEN

86

Elected members

1. Mr. D.Krishnamurthy, Managing Director, Sri Kumaran Mills Limited, Coimbatore (Chairman). 2. Dr. K.V.Srinivasan, Managing Director, Premier Mills Pvt. Ltd., Coimbatore.(Vice-Chairman). 3. Mr. B.Gopinath, Technical Director, Sri Venkatalakshmi Spinners (P) Ltd., Udumalpet.4. Mr.Sanjay Jayavarthanavelu, Chairman & Managing Director, Lakshmi Machine Works Ltd., Cbe.5. Mr. D.Sarath Chandran, Chairman & Managing Director, Precot Meridian Ltd., Coimbatore 6. Mr. E.Sathyanarayana, Managing Director, Sree Sathyanarayana Spinning Mills Ltd., Tanuku.7. Mr. J.Thulasidharan, Managing Director, The Rajaratna Mills Ltd., Coimbatore.8. Mr. S.Venkat Kumar, Wholetime Director, Selvaraja Mills P. Ltd., Coimbatore.

Permanent Members9. The Managing Director, National Textile Corporation, Southern Regional Office, Coimbatore.

10. The President, Madura Coats Pvt. Limited, Bengaluru.11. The Wholetime Director, The Lakshmi Mills Co. Ltd., Coimbatore.

Directors of the Textile Research Associations of India12. Dr. Prakash Vasudevan, Director, The South India Textile Research Association, Coimbatore. 13. Dr. A.K.Sharma, Director, The Ahmedabad Textile Industry's Research Association, Ahmedabad. 14. Dr. A.N.Desai, Director, The Bombay Textile Research Association, Mumbai. 15. Dr. Arindam Basu, Director General, Northern India Textile Research Association, Ghaziabad.

Representatives of the Ministry of Textiles, Government of India.16. The Additional Secretary & Financial Adviser, Ministry of Textiles, Govt. of India, New Delhi. 17. The Joint Secretary (R&D), Ministry of Textiles, Govt. of India, New Delhi.18. The Textile Commissioner, Office of the Textile Commissioner, Govt. of India, Mumbai.

Representatives of the Government of Tamil Nadu19. The Commissioner of Handlooms and Textiles, Govt. of Tamil Nadu, Chennai.

The Tamil Nadu Handloom Weavers' Co-operative Society Ltd., Chennai.20. The Managing Director, The Tamil Nadu Handloom Weavers' Co-operative Society Ltd., Chennai.

The Southern India Mills' Association21. Chairman, The Southern India Mills' Association, Coimbatore.

Special invitees 22. The Director, Central Leather Research Institute, Chennai (CSIR representative). 23. The Director, Ministry of Textiles, Govt. of India, New Delhi. 24. The Chairman, Confederation of Indian Textile Industry, New Delhi.25. Mr. Thiyagu Valliappa, Executive Director, Sree Valliappa Textiles, Ltd, Bangaluru.26. Ms. Kothai, Managing Director, Jaya Soundaram Textile Mills P. Ltd., Aruppukottai.

ANNEXURE VII

MEMBERS OF COUNCIL OF ADMINISTRATION


87

ANNEXURE VIII

MEMBERS OF SUB-COMMITTEES

(A) Finance and machinery sub-committee

Mr.D.Krishnamurthy (Chairman) Sri Kumaran Mills Limited, Coimbatore.

Dr. K.V.Srinivasan (Vice-Chairman) Premier Mills Pvt. Ltd., Coimbatore.

Mr.E.Satyanarayana Sree Satyanarayana Spinning Mills Ltd, Tanuku.

Dr. Prakash Vasudevan Director, SITRA, Coimbatore.

(B) Staff and awards sub-committee

Mr.D.Krishnamurthy (Chairman) Sri Kumaran Mills Limited, Coimbatore.

Dr. K.V.Srinivasan (Vice-Chairman) Premier Mills Pvt. Ltd., Coimbatore.

Mr.J.Thulasidaran The Rajaratna Mills Ltd., Palani.

Mr. S.Venkat Kumar (Whole Time Director) Selvaraja Mills P. Ltd., Coimbatore.

Dr. Prakash Vasudevan Director, SITRA, Coimbatore.


88

ANNEXURE IX

MEMBERS OF RESEARCH ADVISORY COMMITTEE

Members

1. Mr. D.Krishnamurthy, Sri Kumaran Mills Limited, Coimbatore. (Chairman)

2. Dr. K.V.Srinivasan, Premier Mills Private Limited, Coimbatore. (Vice Chairman)

3. Dr. Prakash Vasudevan, SITRA, Coimbatore. (Director)

4. Dr. Arindam Basu, Northern India Textile Research Association, Ghaziabad.

5. Mr. Christopher Karunakaran, Premier Fine Linens (P) Ltd., Pollachi.

6. Dr. A.N.Desai, The Bombay Textile Research Association, Mumbai.

7. Mr. S. Dinakaran, Sambandam Spinning Mills Ltd., Salem.

8. Mr. B. Gopinath, Sri Venatalakshmi Spinners Pvt. Ltd., Udumalpet.

9. Mr. J. Harish Chandravel, Ram Narayana Mills Ltd., Coimbatore.

10. Mr. T. Kannan, Thiagarajar Mills Ltd., Kappalur.

11. Ms. N. Kothai, Sree Jeya Soundaram Textile Mills Private Ltd., Madagupatti.

12. Mr. B.K. Patodia, GTN Textiles Ltd., Aluva.

13. Mr. Sanjay Jayavarthanavelu, Chairman cum Managing Director, Lakshmi Machine Works Limited, Coimbatore

14. Dr. A.K. Sharma, The Ahmedabad Textile Industry’s Research Association, Ahmedabad.

15. Mr. Sujit Gulati, I.A.S., Joint Secretary, Ministry of Textiles, Government of India.

16. The Commissioner of Handlooms and Textiles, Govt. of Tamil Nadu, Chennai.

17. The Director, Central Leather Research Institute, Chennai.

18. The Chairman & Managing Director, National Textile Corporation (TN&P) Limited, Coimbatore.

19. The Textile Commissioner, Office of the Textile Commissioner, Mumbai.

Invitees

1. Dr. V.R.

2. Dr. V.R.Giridev, AC College of Technology, Chennai.

3.

4.5. Dr R. Rajkumar, Chief Medical Officer, Kovai Diagnostic Centre, Coimbatore

6. Dr. T.Ramachandran, Karpagam Institute of Technology, Coimbatore.

7. Dr.A. Ramamoorthy, Medical Practitioner, Coimbatore.

9. Mr. A.Shanmugavasan, Managing Director, KOB Medical Textile Pvt. Ltd., Palladam

10. Dr. J.Srinivasan, Kumaraguru College of Technology, Coimbatore.

Shri A. Arulsamy, Executive Director, National Textile Corporation Ltd.,Coimbatore

Mr Sri Hari Prasad, MD, Kadri Wovens, Unit of Kadri Mills, Perundurai

Dr.R.Rajendran, Principal, PSG CAS, Coimbatore.

8. Dr. V. Sarveswaran, Head, Department of General Surgery, Sri Ramakrishna Hospital.Coimbatore

11. Dr.V.Subramaniam, Director, Dept. of Textile Technology, Jaya Engineering College, Chennai.12. Dr. S. Suresh Kumar, Registrar, Department of General Surgery,Sri Ramakrishna Hospital

Coimbatore


89

Member,Sub-committee for manpower planning for the textile engineering industry constitued by India

ITME Society, Mumbai.Member, Project management committee for Mini Mission III and Mini Mission IV of Jute Technology

Mission.Supervisor, Ph.D & M.Phil. Programmes (Textile Technology), Anna University, Chennai.

Supervisor, Ph.D & M.Phil. Programmes (Textile Physics), Bharathiar University, Coimbatore.

Member, TX 0I Committee, Bureau of Indian Standards, New Delhi.

Member, TX 05 Committee, Bureau of Indian Standards, New Delhi.

Member, Panel of Expert for the Constitution of Selection/ Assessment Committees in Textile Technology,

National Institute of Science Communication.

Member, Board of Studies of PSG College of Technology for TextileTechnology.

Chairman, Hosiery Sectional Committee, TX 10, Bureau of Indian Standards, New Delhi.

Member, Council of National Jute Board, Kolkata.

Member, All India Powerloom Board, Ministry of Textiles, Government of India, New Delhi.

Member, Advisory Committee & member, Staff Selection Board, Textile Technology Department,

Kumaraguru College of Technology, Coimbatore.

Member, Council of Administration, SIMA Cotton Development & Research Association.

Member, Cotton Advisory Board, Ministry of Textiles, Govt. of India.

Member, CITI Cotton Development & Research Association, New Delhi.

Member, Board of Examiners of Indian Institute of Handloom Technology, Salem.

Member, CII, Southern Region, Textile Sub-committee.

Expert member, Board of studies in Textile Technology, Bannari Amman Institute of Technology

(Autonomous), Sathyamangalam.

Member, Confederation of Indian Industries (CII), Coimbatore zone.

Member, Sardar Vallabhbhai Patel International School of Textiles and Management, Coimbatore.

Member, Cotton Selection/purchase committee, KVIC, Chitradurga.

Member, Technical Sectoral Expert Committee of Textile Sector under PAT Scheme of Bureau of Energy

Efficiency (BEE)

Member, Board of Studies (BoS) in Textile Technology (TT) of Karpagam University, Coimbatore

Member, Board of Studies (BoS) in Psychology at Bharathiar University, Coimbatore

ANNEXURE X

COMMITTEES IN WHICH SITRA STAFF REPRESENTED


90


ANNEXURE XI

SITRA MEMBER MILLS

Note: Figures in brackets indicate number of units, * Council decision pending ** Resignation submitted

Full Members

1 Adwaith Textiles Limited2 Alagendra Textiles Limited3 Amarjothi Spg. Mills Ltd.4 Amman Spinning Mills5 Anna Co-op. Spg. Mills Ltd.6 Annamalaiar Mills Private Ltd.7 Anugraha Fashion Mill (P) Ltd8 Ashwin Industries (P) Ltd9 Ashwinram Spinning Mills P Ltd10 B K S Textiles Private Limited11 B R T Spinnerrs Limited12 Best Cotton Mills (P) Ltd13 Cardwell Spinning Mills Limited14 Chenniappa Yarn Spinners (P) Ltd15 Cheslind Textiles Ltd.16 Chida Spg. Mills (P) Ltd.17 Classic Spinning Mills Pvt. Ltd.18 Coimbatore Polytex Private Ltd.19 D B V Cotton Mills (P) Ltd.20 Durairaj Mills Limited II21 Eastman Spinning Mills (P) Ltd.22 Edarikkode Textiles23 Emperor Textiles (P) Ltd24 Ennar Spinning Mills (P) Ltd25 G T N Industries Ltd26 G T N Textiles Ltd.27 G V D Textiles (P) Ltd28 Gangai Spinning Mills29 Gem Spinners India Ltd.30 Gokak Mills (4)31 Gopalakrishna Textile Mills Pvt. Ltd32 Harshini Textiles Ltd33 Himatsingka Seide Limited34 Hindustan Cotton Spinning Mills 35 Jagannath Textile Company Ltd36 Jai Jagadhambiga Textile Mills P. Ltd37 Jay Textiles -Unit II (Super Sales India Ltd.)38 Jayavarma Textiles (P) Ltd - Unit 239 K K P Spinning Mills Ltd40 K L R F Textiles(A Division of KLRF Ltd) (2)41 Kallam Spinning Mills Ltd42 Kandagiri Spg. Mills Ltd - Unit I43 Kaveri Yarns and Fabrics Ltd.44 Kayaar Exports Private Limited45 Kottayam Textiles46 L S Mills Ltd.47 Lakshmi Ganesha Textiles Ltd48 Lakshmi Machine Works Ltd.49 Madura Coats Private Limited (4)50 MAG Solvics (P) Ltd51 Malabar Spg. & Wvg. Mills52 Mallur Siddeswara Spg. Mills Pvt. Ltd.

53 Maris Spinners Ltd.54 Modern Cotton Yarn Spinners Limited55 N S P Knitting Mills56 Nagammai Cotton Mills (P) Ltd57 Nandhi Vardhana Textile Mills Limited 58 Narasu’s Spg. Mills59 National Textile Corporation (TN&P)

Ltd. (16)60 Prabath Spinner India61 Prabhuram Mills (India) P.Ltd62 Prachidhi Spinners Pvt. Ltd,63 Precot Meridian Ltd. (5)64 Premier Mills Private Ltd.65 Premier Spg. & Wvg. Mills Ltd.66 Premier Tex Products P.Ltd67 Prithivraj Textiles68 Ramani Textile Mills (P) Ltd69 Rasi Tex (IN) P. Ltd.70 Rithanyaa Textiles71 Rugmini Ram Raghav Spinners Ltd.72 S.A. Aanandan Spinning Mills (P) Ltd73 S C M Textile Spinners74 S P Spinning Mills Ltd.75 S.S.K.Textiles76 Salona Cotspin Limited77 Sangeeth Textiles Ltd.78 Sarmangal Synthetics Limited79 Saudagar Enterprise80 Selvaraja Mills Pvt. Ltd.81 Seyad Cotton Mills Ltd.82 Shanmugappriya Textiles Ltd.83 Shiva Texyarn Limited84 Shri Cheran Synthetics India Ltd85 Shri Govindaraja Mills Ltd,- B Unit86 Shri Ramalinga Mills Ltd.87 Shri Santhosh Meenakshi Textiles Private

Limited88 Soundararaja Mills Ltd.89 Southern Spinners and Processors Limited90 SP Superfine Cotton Mills (P) Ltd91 Sree Akkamamba Textiles Ltd.92 Sree Ayyanar Spg. & Wvg. Mills Ltd

- Unit I (2)93 Sree K N M Spg. Mills (P) Ltd.94 Sree Narasimha Textiles (P) Ltd.95 Sree Prashant Spinners Ltd.96 Sree Satyanarayana Spg. Mills Ltd.97 Sri Anjaneya Cotton Mills Pvt.Ltd98 Sri Dhanalakshmi Cotton & Rice Mills Pvt.

Ltd.99 Sri Gomathy Mills Private Limited100 Sri Kannapiran Mills Ltd.101 Sri Kannattal Mills P. Ltd.102 Sri Karthikeya Spg. & Wvg. Mills Ltd.

103 Sri Karunambikai Mills Pvt. Ltd104 Sri Kumaran Mills Limited.105 Sri Lakshmikantha Spinners Ltd 106 Sri Lakshmi Saraswathi Textiles

(Arni) Ltd.107 Sri Mahasakthi Mills Ltd108 Sri Muni Pachaiyappan Textiles (P) Ltd.109 Sri Nachammai Cotton Mills Ltd.110 Sri Ramakrishna Mills (CBE) Ltd.111 Sri Ramnarayan Mills Ltd.112 Sri Ramiah Spinners Ltd,‘B’ Unit113 Sri Ranga Textiles (P) Ltd.114 Sri Sakthi Textiles Ltd.115 Sri Saravana Spinning Mills Ltd116 Sri Sharadhambika Spintex P.Ltd117 Sri Shanmugavel Mills Pvt. Ltd.118 Sri Varadaraja Textiles Ltd.119 Sri Venkatalakshmi Spinners (P)Ltd.120 Sri Vignesh Yarns (P) Limited121 Subadra Textiles Pvt. Ltd.122 Super Spg. Mills Ltd. (3)123 Suryavanshi Spinning Mills Ltd124 T T Limited-(Unit Tirupathi

Spinning Mills)125 The Banhatti Co-op. Spg. Mills Ltd.126 The Bharathi Co-op. Spg. Mills Ltd.127 The Kadri Mills (CBE) Ltd. (12)128 The Lakshmi Mills Co.Ltd. (4)129 The National Sewing Thread Co.Ltd130 The Palani Andavar Mills Ltd.131 The Pondicherry Co-op. Spg. Mills Ltd.132 The Rajaratna Mills Ltd. (2)133 The Southern Textile Ltd134 The Sri Venkatesa Mills Ltd.135 The Tamilnadu Handloom Weavers’

Co-op.Society Ltd136 The Tamilnadu Textile Corporation Ltd137 Tirupur Textiles Private Ltd. (3)138 Tirupur Thirukkumaran Textiles (P) Ltd139 Umayal Spinners (P) Ltd140 V.R Textiles Pvt Ltd141 Veejay Lakshmi Textiles Limited (2)142 Veejay Syntex Pvt. Ltd.143 Vijay Velavan Spinning Mills (P) Ltd144 Vishnu Lakshmi Mills (P) Ltd145 Viswabharathi Textiles Ltd.146 VTM Limited147 VTX Industries Ltd

Associate Members1 Alok Industries2 Ashoka Multiyarn Mills Limited3 B L P Super Spinners,(Unit of PBM

Polytex Ltd)

91


4 Br.Sheshrao Wankhede Shetkari SahakariSoot Girni Ltd

5 Chandra Textiles Ltd.6 Cheviot Company Ltd7 Eurotex Industries & Exports Ltd.8 George Distributors (P) Ltd9 Gimatex Industries Pvt.Ltd10 Ginni Filaments Ltd11 Gloster Jute Mills Ltd12 Gujarat Heavy Chemicals Ltd. Unit :

Sree Meenakshi Mills13 Indira Sahakari Soot Girni Ltd.14 Kanco Overseas15 Kangwal Textile Company Limited,16 Keshar Multiyarn Mill Ltd17 Loyal Textile Mills Ltd.18 Mafatlal Industries Limited19 Mahalakshmi Fibres & Industries Ltd.20 Nagammal Mills Ltd.21 Nagreeka Exports Ltd.22 P B M Polytex Ltd.23 Pee Vee Textiles Limited24 Pratibha Syntex Limited25 Priyadarshini Sahakari Soot Girani Ltd26 PT. Indo Liberty Textiles27 Rajapalayam Mills Ltd.28 RSWM Limited (3)29 Reliance Industries Ltd.30 Rishab Spinning Mills

(Prop.Nahar Exports Ltd.)

ANNEXURE XI

SITRA MEMBER MILLS

31 Sambandam Spg Mills Ltd.32 Shetkari Sahakari Soot Girni Ltd.33 Sholingur Textiles Ltd.34 Shriganesh Textile & Infrastructure (I)

Pvt. Ltd 35 Sree Valliappa Textiles Ltd.36 Sri Jayajothi & Co Ltd37 STI India Limited 38 Surya Prabha Mills Private Ltd.39 Suryalakshmi Cotton Mills Ltd.40 The Gobald Textiles Pvt. Ltd.41 The Jamshri Ranjitsinghji Spg.&

Wvg.Mills Ltd.42 The Suguna Mills Pvt. Ltd.43 Thiagarajar Mills Ltd. (2)44 The Tuticorin Spinning Mills Ltd.45 Vardhman Yarns & Threads Limited46 Vippy Spinpro Ltd47 Visaka Industries Ltd.48 Voltas Ltd.

Technical Service Centers

1 Lakshmi Fine Yarns Coimbatore Pvt. Ltd.2 Sri Gomuki Tex Chem Pvt. Ltd.,3 Jayanthi Textile Products4 A.R.Appasamy5 Thirumurugan Spinners,6 Hanjung Exim Private Limited.7 Habasit Iakoka Pvt. Ltd.,8 Techno Electronics & Instruments,

9 Muthu Spinning Mills Private Ltd.,10 Kanakalakshmi Mills (P) Ltd.,11 Sri Choleeswarar Spg. Mills,12 PEE AAA Impex,13 Yuvraj Lube & Petrochemical Pvt Ltd.,14 East India Commercial Co. Ltd.,15 Sky Cotex India Private Limited,16 Lakshmi Spinners17 Jacquard Fabrics (India) Pvt.Ltd.,18 JVS Spinners (India) Limited,19 Veejay Terry Products Ltd.,20 Fab Yarns21 Kikani Exports Pvt.Ltd.,22 Sri Krishna Textiles,23 Sri Jagannatha Spinners Pvt. Ltd.,24 Jai Sakthi Mills25 Global Spinners26 Micrro Cotspinn India (P) Ltd.,27 Nilgiri Textiles (P) Ltd.,28 Gomathi Textiles31 Sre Venkatachalapathy Textiles32 Prathishta Weaving & Knitting Co. Ltd.,33 Rimtex Engineering Pvt. Ltd.,34 Thiruvarangan Spintex Private Limited.35 Proklean Technologies Pvt. Ltd.,36 Ess Kay Yarn Dyeings.37 Shre Srinivasa Spinners.38 BHF International Pvt Ltd39 Pon Pure Chem (P) Ltd

93

FINANCIAL STATEMENTS

AS ON

st

31 MARCH 2015

I ATRS


COIMBATORE - 641 014


94

Independent Auditor's Report

To

The Members of The South India Textile Research Association

Report on the Financial Statements

1. We have audited the accompanying financial statements of The South India Textile

Research Association (the “Association”), which comprise the Balance Sheet as at March 31,

2015 and Income and Expenditure Account for the year then ended.

Management's Responsibility for the Financial Statements

2. The Association's Management is responsible for the preparation of these financial

statements that give a true and fair view of the financial position and financial performance of

the Association. This responsibility includes the design, implementation and maintenance of

internal control relevant to the preparation and presentation of the financial statements that

give a true and fair view and are free from material misstatement, whether due to fraud or

error.

Auditor's Responsibility

3. Our responsibility is to express an opinion on these financial statements based on our

audit. We conducted our audit in accordance with the Standards on Auditing issued by the

Institute of Chartered Accountants of India. Those Standards require that we comply with

ethical requirements and plan and perform the audit to obtain reasonable assurance about

whether the financial statements are free from material misstatement.

4. An audit involves performing procedures to obtain audit evidence, about the amounts

and disclosures in the financial statements. The procedures selected depend on the auditors'

judgment, including the assessment of the risks of material misstatement of the financial

statements, whether due to fraud or error. In making those risk assessments, the auditors

consider internal control relevant to the Association's preparation and fair presentation of the

financial statements in order to design audit procedures that are appropriate in the

circumstances, but not for the purpose of expressing an opinion on the effectiveness of the

entity's internal control. An audit also includes evaluating the appropriateness of accounting

policies used and the reasonableness of the accounting estimates made by Management, as

well as evaluating the overall presentation of the financial statements.


95

5. We believe that the audit evidence we have obtained is sufficient and appropriate to

provide a basis for our audit opinion.

Opinion

6. In our opinion, and to the best of our information and according to the explanations given

to us, the accompanying financial statements give a true and fair view in conformity with the

accounting principles generally accepted in India:

(a) in the case of the Balance Sheet, of the state of affairs of the Association as at March 31,

2015; and

(b) in the case of the Income and Expenditure Account, of the Excess of Expenditure over

Income for the year ended on that date.

7. We report that:

(a) We have obtained all the information and explanations which, to the best of our

knowledge and belief, were necessary for the purpose of our audit;

(b) The Balance Sheet and Income and Expenditure Account dealt with by this Report are in

agreement with the books of account;

For P.N.RaghavendraRao & Co.,

Chartered Accountants

Firm Registration Number: 003328S

Sd/-M.Bhaskar

Partner

Membership Number: 025073

Coimbatore

August 20, 2015


96


BALANCE SHEET AS AT 31ST MARCH 2015

Particulars Schedule

No. 2014-15 2013-14

LIABILITIES

Corpus/Capital Fund 1 2,78,17,326

2,77,39,023

Capital Grant from Ministry 2 36,88,88,601

36,79,31,902

Reserves and Surplus 3 53,64,76,155 49,28,87,952

Current Liabilities and Provisions 4 8,36,77,872 7,68,77,264

TOTAL (A) 1,01,68,59,954 96,54,36,142

ASSETS

Fixed Assets - Net Block 5 & 6 50,16,68,915 45,82,64,883

Investments 7 39,30,41,533 38,90,99,739

Sponsored Projects 8 1,95,78,924 2,57,24,190

Current Assets, loans, Advances etc 9 10,25,70,582 9,23,47,331

TOTAL (B) 1,01,68,59,954 96,54,36,142

Place : Coimbatore

DATE: 20/08/2015

(Sd/-) D. Krishnamurthy (Chairman) (Sd/-) Prakash Vasudevan (Director)

" J. Thulasidharan " B.Gopinath

Sd/-

(M.Bhaskar)

Partner

Amount in "Rs."

For P.N.Raghavendra Rao & Co.,



97


INCOME AND EXPENDITURE ACCOUNT FOR THE YEAR ENDED 31ST MARCH 2015

Particulars Schedule

No. 2014-15 2013-14

INCOME

Income from Services 10 5,14,03,210 4,53,90,875

Membership/Ministry Contribution 11 1,68,31,373 1,96,30,058

Sponsored Projects - Overhead Recoveries 12 42,58,616 70,45,118

Other Income 13 1,11,24,222 1,08,38,119

TOTAL (A) 8,36,17,421 8,29,04,170

EXPENDITURE

Establishment Expenses 14 5,63,40,269 4,83,62,666

Administrative Expenses 15 1,26,15,772 1,71,83,817

Repairs and Maintenance 16 65,73,361 52,71,300

Stores Consumed 17 17,25,875 14,81,137

Finance Charges 18 1,14,407 22,184

Sponsored Projects - SITRA Contribution 19 17,55,093 29,26,577

Depreciation 20 55,79,189 56,07,535

TOTAL (B) 8,47,03,967 8,08,55,217

Balance being excess of Income over Expenditure for the year (10,86,546) 20,48,954

Appropriated from Asset Stabilisation Reserve 3,76,604 -

Appropriated from Infrastructure Devel. & Maintenance Reserve 11,39,012 19,19,095

Appropriated from Staff Benefit Reserve( Payment of Terminal Benefits ) 30,16,874 29,75,036

Balance Surplus 34,45,944 69,43,085

Transfer to Staff Benefit Reserve (Terminal Benefits) - SITRA 31,00,000 35,00,000

Transfer to Corpus Reserve for R & D - 31,00,000

Transfer to General Reserve 3,45,944 3,43,085

Place : Coimbatore

DATE: 20/08/2015

(Sd/-) D. Krishnamurthy (Chairman)

" J Thulasidharan

(Sd/-) Prakash Vasudevan (Director)

" B.Gopinath

Sd/-

(M.Bhaskar)

Partner

Amount in "Rs."




98


Schedules to Balance Sheet for the year ended 31.03.2015Amount in "Rs."

Schedules 2014-15 2013-14

Sch - 1

Corpus/Capital Fund

Contribution from Member Mills 2,77,39,023 2,75,22,115

Add: Received during the year 96,400 2,58,080

2,78,35,423 2,77,80,195

Less: Loss on Disposal of Assets 18,097 41,172

Total 2,78,17,326 2,77,39,023

Sch - 2

Capital Grant from Ministry

Cotton Textile Fund Committee 12,53,791 12,53,791

Council of Scientific and Industrial Research 22,69,513 22,69,513

Ministry of Textiles - Capital Grant 29,66,019 29,66,019

MOT/Office of the Textile Commissioner - Spon Projects 10,88,79,005 10,66,57,064

Ministry of Textiles - Sponsored CAD Centre 48,82,780 48,82,780

Ministry of Textiles - Centre of Excellence - Meditech 19,68,87,006 19,99,87,830

MOT/Office of the Textile Commissioner - PLSC 5,17,50,486 4,99,14,905

Total 36,88,88,601 36,79,31,902

Sch - 3

Reserves & Surplus

General Reserve 7,78,33,087 6,51,13,788

Asset Stabilisation Reserve 6,53,01,050 8,18,49,399

Corpus fund for Research and Development Reserve 7,84,57,319 6,79,64,259

Infrastructure Development and Maintenance Reserve 6,08,63,532 5,39,11,438

Staff Benefit Reserve - SITRA 6,61,61,876 5,53,15,613

Staff Benefit Reserve - PLSC 81,72,060 84,58,605

Centre of Excellence Building Reserve 7,61,66,275 5,79,09,505

Depreciation Reserve Invt.Interest 10,44,44,418 10,06,33,480

PLSC/CAD Centre Reserve (9,23,462) 17,31,864

Total 53,64,76,155 49,28,87,952

Sch - 4

Current Liabilities & Provisions

Current Liabilities

Unspent grant

Unspent Grant - Upgradation PSC 27,45,514 45,81,096

Unspent grant - ISDS 3,92,80,695 4,70,03,941

Unspent grant - COE 2,13,57,752 56,35,797

Unspent Grant -SSY 24,18,000 1,19,50,800

Advance from Debtors 28,43,197 21,36,372

Liability for Finance 6,59,630 2,61,766

Liability For Expenses & Others 19,46,814 10,70,148

Total (A) 7,12,51,601 7,26,39,919

Provisions

Provision for Expenses - ISDS 73,76,416 4,68,389

Provision for Expenses Sitra & COE 25,06,724 18,28,972

Provision for Expenses -PLSC 25,43,130 19,39,984

Total (B) 1,24,26,270 42,37,345

Total (A + B) 8,36,77,872 7,68,77,264


99


Schedules to Balance Sheet for the year ended 31.03.2015Amount in "Rs."

Schedules 2014-15 2013-14

Fixed Assets

Sch - 5

Gross Assets

Lands 5,11,107 5,11,107

Buildings 3,43,50,903

3,43,50,903

Plant and Machinery 10,19,56,568

8,99,71,419

Furniture & Fittings 45,05,873

43,04,720

Computer And Accessories 58,26,658

50,43,608

Library 25,37,816

25,01,417

Vehicle 15,07,934

15,07,934

COE Building Capital Work in Progress 7,96,05,267

6,22,61,580

COE Building Equipment & Electrical 1,23,39,396

37,45,432

COE Building Furniture & Fittings 26,17,044

-

Total 24,57,58,567

20,41,98,120

Sch - 6

Fixed Assets under Sponsored Projects

The South India Textile Research Association 7,11,38,165

7,11,38,165

Integrated Skill Development Scheme 2,42,84,638

2,20,62,697

Centre of Excellence - Meditech 20,55,26,230

20,23,41,806

Powerloom Service Centre 5,32,52,179

5,12,55,072

Total 35,42,01,212

34,67,97,740

Total Gross Block 59,99,59,778

55,09,95,860

Depreciation Reserve

Depreciation Reserve - Building 90,70,389

86,68,696

Depreciation Reserve - Computer & Accessories 23,56,950

22,10,272

Depreciation Reserve - Furniture And Fixtures 20,12,268

16,82,656

Depreciation Reserve - Plant & Machinery 8,22,63,612

7,85,31,968

Depreciation Reserve - Vehicles 1,87,727

87,256

Depreciation Reserve - ISDS 23,99,918

15,50,129

Total 9,82,90,863

9,27,30,977

Net Block 50,16,68,915

45,82,64,883

Sch - 7

Investments

Depreciation Reserve Investment - SITRA 19,32,63,000

19,01,56,267

Corpus Reserve for Research and Development Investment 5,29,87,000

4,24,98,395

Infrastructure Development & Maintenance Reserve Investment 5,27,88,670

4,62,16,484

Staff Benefit Reserve Investment - SITRA 5,53,45,295

5,15,59,694

Staff Benefit Reserve Investment - PLSC 81,72,060

84,58,605

General Reserve Investment 2,95,20,508

4,92,45,294

PLSC/CAD Centre Reserve Investment 9,65,000

9,65,000

Total 39,30,41,533

38,90,99,739

Sch -8

Sponsored Projects - Grant Receivable

As per Schedule 1,87,01,293

2,48,46,559

Grant Not Realised 8,77,631

8,77,631

Total 1,95,78,924

2,57,24,190


100


Schedules to Balance Sheet for the year ended 31.03.2015

Amount in "Rs."

Schedules 2014-15 2013-14

Sch - 9

Current Assets, loans, Advances etc

Sundry Debtors

Sundry Debtors 11,87,689 11,29,677

Total 11,87,689 11,29,677

Cash & Bank Balances

Cash on Hand 3,82,304 71,847

Cash at Bank 5,28,84,123 6,18,75,829

Cash at Bank PLSC 40,78,972 19,98,203

Cash at Bank CoE 2,19,91,566 1,09,90,118

Total 7,93,36,965 7,49,35,996

Loans & Advances

Deposits - Others 22,02,375 17,95,638

Advances for Purchases and Others 1,45,11,672 1,03,85,724

Tax Deducted at Source 53,31,880 41,00,295

Total 2,20,45,928 1,62,81,657

Grand Total 10,25,70,582

9,23,47,331


101

THE SOUTH INDIA TEXTILE RESEARCH ASSOCIATIONSchedules to Income and Expenditure Account for the year ended 31.03.2015

Schedules 2014-15 2013-14

Sch - 10

Income from Services

Testing and Investigation Fee 4,61,30,621

4,00,15,233

HRD Education Receipts 38,98,710

41,22,642

Publication Income 13,73,879

12,53,000

Income from COE

5,14,03,210

4,53,90,875

Sch - 11

Membership/Ministry Contribution

From Ministry of Textiles 1,11,00,000

1,06,13,000 From Membership Contribution 55,42,373

54,91,387

From Technical Service Card Membership Fees 1,89,000

1,85,000

From Buyers Sellers meet Grant -

18,20,000

From Meditex & Medineeds 2014 -

15,20,671

1,68,31,373 1,96,30,058

Sch - 12

Sponsored Projects - Overhead Recoveries 42,58,616 70,45,118

42,58,616 70,45,118

Sch - 13

Other Income

Interest Income from Investment and Advances 29,05,521

27,42,050

Rent Receipts 7,39,073

7,23,881

Miscellaneous Income 47,98,943

46,66,584

Allocation of Expenses incurred by SITRA for COE 5,42,935

7,65,620

Allocation of Expenses incurred by SITRA for PLSC 21,37,750

19,39,984

1,11,24,222

1,08,38,119

Sch - 14

Establishment Expenses

Salary and Other Allowances 5,60,42,416

5,29,19,702

Staff Welfare Expenses -

Sitra Contributory PF and other Funds 44,99,527

40,84,383

6,05,41,943

5,70,04,085

Less: Allocated to Sponsored Projects 13,06,210

24,17,848

Allocated to Integrated Skill Development Scheme 28,95,464

18,11,880

Provision for Terminal Benefits Appropriation -

44,11,691

5,63,40,269

4,83,62,666

Total

Amount in "Rs."

Total

Total

Total

Total


102

Schedules 2014-15 2013-14


Schedules to Income and Expenditure Account for the year ended 31.03.2015

Amount in "Rs."

Sch - 15

Administrative Expenses

Travelling Expenses 12,76,027

10,21,416

Printing & Stationery 6,96,138

6,21,777

Publication Expenses 4,26,012

2,13,730

Postage, Telegrams and Telephone Charges 10,83,738

10,21,932

Journals and Periodicals 86,471

1,77,532

Electricity Charges 46,25,905

39,73,980

Building & Fire Insurance 8,68,474

6,41,862

Rent, Rates and Taxes 39,251

4,80,253

Advertisement Charges 3,83,259

68,507

Training Course Expenses 6,63,849

14,57,055

Conferences, Seminars and Meetings 8,19,447

7,24,519

Audit Fees 75,000

50,000

Internal Audit Fees 1,03,000

1,28,500

Professional Charges 90,081

57,000

Office Expenses 5,04,407

7,55,064

SITRA Textile Service Centre Expenses 3,31,778

1,69,244

Buyers-Sellers Meet Expenses -

29,15,842

Allocation of Admin Overheads incurred by SITRA for COE 5,42,935

7,65,620

Allocation of Admin Overheads incurred by SITRA for PLSC 21,37,750

19,39,984

Less: Transferred to General Reserve (21,37,750)

-

1,26,15,772

1,71,83,817

Sch - 16

Repairs & Maintenance

Maintenance of Motor Cars and Vehicles 1,69,989

1,27,693

Maintenance of Machinery 34,51,691

10,25,188

Maintenance of Office Equipment 2,56,241

4,70,275

Maintenance of Building & Staff Quarters 26,27,295

36,14,027

Maintenance of Furniture 68,145

34,117

65,73,361

52,71,300

Sch - 17

Stores Consumed 17,25,875

14,81,137

17,25,875

14,81,137

Sch - 18

Finance Charges

Bank Charges and Commission 25,261

22,184

Interest 89,146

-

1,14,407

22,184

Sch - 19

Sponsored Projects - SITRA Contribution 17,55,093

29,26,577

17,55,093

29,26,577

Place : Coimbatore

DATE: 20/08/2015


" J Thulasidharan " B.Gopinath


Partner

Sd/-

(M.Bhaskar)

Total

Total

Total

Total



Total

Annual R

eport 2

014 - 1

5

103

Schedule 20 D E P R E C I A T I O N F O R T H E Y E A R 2014-2015 Amount in "Rs."

Value Additions Deletion Value Depreciation Deletion Depreciation W.D.V Closing W.D.V

as on During During as on As on During for the year As on As on

01.04.2014 2014-2015 2014-15 31.03.2015 01.04.2014 2014-15 2014-15 31.03.2014 31.03.2015

1 Land 5,11,107

5,11,107

-

5,11,107

5,11,107

2 Library 25,01,417

36,399

25,37,816

3 ISDS - Library 34,04,659

8,000

34,12,659

4 Building 3,35,28,818

3,35,28,818

5 ISDS - Building Renovation 10,03,177

10,03,177

6 Auditorium 5,03,235

5,03,235

1,99,639

4,949

3,03,596

2,98,647

7 Staff Quarters 2,37,543

2,37,543

1,06,563

2,135

1,30,980

1,28,845

8 Furniture 43,04,720

8,793

43,13,513

9 ISDS - Furniture 17,00,000

7,49,677

24,49,677

10 Electrical Fittings 81,307

81,307

66,287

502

15,020

14,518

11 PLSC - Furniture 27,685

27,685

16,299

380

11,386

11,006

12 Machinery 8,95,09,524

1,14,43,227

62,400

10,08,90,351

13 Sponsored Projects - Assets 4,05,54,676

4,05,54,676

14 ISDS - Machinery 1,19,99,338

14,64,264

1,34,63,602

12,39,078

5,99,272

1,07,60,260

1,16,25,252

15 ISDS-PSC-Machinery 36,00,001

36,00,001

3,58,979

1,66,913

32,41,022

30,74,109

16 ISDS - Machinery Phase II 3,55,523

3,55,523

18,309

17,367

3,37,214

3,19,847

17 PLSC- Machinery 4,33,949

4,33,949

1,82,860

12,931

2,51,089

2,38,158

18 Computer 50,43,608

40,450

50,84,058

22,10,272

1,46,678

28,33,336

27,27,108

19 Motor Cars 13,78,119

13,78,119

53,106

93,678

13,25,013

12,31,335

20 Motor Cycles & Scooters 1,29,815

1,29,815

34,182

6,761

95,633

88,872

21 CoE Building Electrical Equipments 37,45,432

85,93,964

1,23,39,396

1,25,097

1,20,919

36,20,335

1,20,93,380

22 COE Building Work-In Progress 6,22,61,580

1,73,43,687

7,96,05,267

-

-

6,22,61,580

7,96,05,267

23 COE Furniture & Fixtures 26,17,044

26,17,044

-

21,373

-

25,95,671

24 COE Assets 12,98,645

2,40,638

15,39,283

-

51,412

12,98,645

14,87,871

Sponsored Projects -Assets

25 UNDP Jute Project Machinery 1,71,49,069

1,71,49,069

-

-

1,71,49,069

1,71,49,069

26 Assets under Sponsored Projects - SITRA 1,34,34,420

1,34,34,420

-

-

1,34,34,420

1,34,34,420

27 PLSC Assets 5,12,55,332

19,97,107

5,32,52,439

1,91,56,113

-

3,20,99,219

3,40,96,326

28 COE Sponsored Assets 20,10,43,161

44,83,069

20,55,26,230

20,10,43,161

20,55,26,230

Total 55,09,95,860

4,90,26,318

62,400

59,99,59,778

9,27,30,977

19,303

55,79,189

45,82,64,883

50,16,68,915

5,89,20,134

19,303

37,55,188

7,11,44,066

7,87,89,008

2,57,74,892

17,14,049

1,51,639

42,90,672

48,97,502

-

-

59,06,075

59,50,474

83,30,011

4,27,092

2,62,01,985


S.No. Name of the Asset

C O S T D E P R E C I A T I O N WDV

Schedules to Balance Sheet for the year 2014-15

Annual R

eport 2

014 - 1

5

104

1 Ministry of Textile Sponsored Research Projects

a Devlopment of Rotator Cuff Repair Devices for Shoulder (19,20,000)

(19,20,000)

-

-

-

(19,20,000)

bDevelopment of Special wound care Dressing made of

PVA/chito(36,221)

(36,221)

-

-

-

(36,221)

c Development of wound dressing made of electro spun herbal (17,85,000)

7,65,000

(10,20,000)

-

-

-

(10,20,000)

d Hospital Bed Linens with Enhanced Thermal Properties (17,37,500)

7,45,000

(9,92,500)

-

-

-

(9,92,500)

e Design & Fabrication of an instrument to assess the resistance (18,99,500)

8,13,900

(10,85,600)

-

-

-

(10,85,600)

f Development of Textile Matrices for the effective wound (10,10,220)

(10,10,220)

5,33,008

15,99,025

21,32,033

-

-

(26,09,245)

gDesign & Dev. Of an Automated Equipment to produce

Knotless(3,44,362)

(3,44,362)

6,52,396

19,57,188

26,09,584

-

-

(23,01,550)

h Development of a Leukodepletion Blood Filter (4,75,064)

(4,75,064)

5,69,689

17,09,066

22,78,755

-

-

(21,84,130)

(92,07,867)

23,23,900

(68,83,967)

17,55,093

52,65,279

70,20,372

-

-

(1,21,49,246)

Total

Expenditure

Expenditure as at 31.03.2015

Sl.No.

Funds

Received

during the year

2014-15

Total Receipts SITRA

Contribution



Schedule 8 Financial Status of Sponsored Projects : 01/04/2014 - 31/03/2015 Amount in "Rs.”

Name of Sponsored Project

Opening

Balance 2014-15

(Due)

Receipts Balance as at 31/03/2015

MOT

Contribution Unspent

SITRA

ContributionDue from MOT

Annual R

eport 2

014 - 1

5

105

Schedule 8 Financial Status of Sponsored Projects : 01/04/2014 - 31/03/2015 Amount in "Rs"

IA MOT

2 Ministry sponsored powerloom service centre receipts - 1,14,00,000

1,08,57,312

1,08,66,803

1,14,00,000

-

2,22,66,803

-

-

a) Regional Office of the Textile Commissioner

Phase I 6,78,252

6,78,252

6,78,252

-

-

-

Phase II 6,42,905

6,42,905

-

-

(6,42,905)

b) Tamilnadu Skill Development Programme 13,98,880

13,98,880

-

-

(13,98,880)

c)Department of Handlooms & Textiles (Training on

Powerloom& Weaving)24,57,872

24,57,872

24,57,872

-

-

-

d)Commisioner of Backward Classes Welfare,Chennai ( BC / MBC

Training Programme)31,13,400

49,40,000

49,40,000

(18,26,600)

3 SITRA Integrated Skill Development Scheme -

Phase I (1,25,95,000)

1,25,95,000

-

-

-

-

-

-

Phase II 4,70,03,941

43,79,997

-

48,43,155

96,27,816

24,75,427

1,69,46,398

3,92,80,695

(48,43,155)

-

4 International Training Programme (28,24,647)

95,79,497

-

-

87,76,220

-

87,76,220

-

(20,21,370)

5 CoE Projects

-

i Office of the Textile Commissioner -

Development of Collagen coated hernia mesh (1,09,777)

4,00,000

2,12,089

3,18,134

-

5,30,223

(2,40,000)

Development of Moppings pads using non woven & Woven

structure(1,09,268)

4,00,000

2,12,293

3,18,439

-

5,30,732

(2,40,000)

ii Department of Science & Technology 3,76,859

2,50,000

-

-

8,09,148

-

8,09,148

-

(1,82,289)

iii Engagement of Consultant under TMTT 52,58,938

-

-

-

14,29,137

-

14,29,137

38,29,801

-

iv Establishment of Training Facilities -

1,91,50,000

-

-

-

16,22,050

16,22,050

1,75,27,950

-

3,70,01,046

6,44,04,018

1,08,57,312

1,61,34,340

4,27,96,803

40,97,477

6,30,28,620

6,06,38,446

(48,43,155)

(65,52,044)

(1,87,01,293)



Sl.No. Name of Sponsored Project

Opening

Balance

2014-2015

(Due)/Unspent

Receipts Expenditure Total

Expenditure

As At

31/03/2015

Balance as at 31/03/2015

Due from MOT

Funds

Received

during the year

2014-15

Revenue /

Appropriation

Recurring

Capital UnspentSITRA

Contribution

Annual R

eport 2

014 - 1

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106

31.03.2014 LIABILITIES DETAILS 31.03.2015 31.03.2014 ASSETS DETAILS 31.03.2015

Rs. Rs. Rs. Rs. Rs. Rs.

Capital Grant Fixed Assets (Grant)

19,36,00,000 Contribution from Ministry 19,54,00,451

Opening Balance 20,10,43,161 63,87,830

Interest Earnings 14,86,555

19,68,87,006

20,23,41,806

Add: Additions during the year 44,83,069

20,55,26,230

56,35,797

Unspent Grant 2,13,57,752

Fixed Assets (own funds)

Opening Balance 12,98,645

-

Depreciation Fund 51,412

Add: Additions during the year 2,40,638

15,39,283

Current Assets

Current Liabilities 1,09,90,118

Bank Balance 2,19,91,566

1,13,28,466

Due to SITRA 1,46,10,863

-

Prepaid Expenses 4,66,881

2,69,984

Sundry Creditors 1,41,294

3,06,990

EMD CoE Machinery - Phase II 20,090

Advance & Deposits

-

Advance from Debtors 68,407

10,000

Gas Cylinder Advance 13,400

9,36,496

Provision for Expenses 9,36,498

1,57,77,150

4,04,252

Advance for Purchases & Others 3,36,260

17,677

Debtors -

2,28,08,107

13,20,000

Income Receivable(BSM) -

2,19,045

Grant receivable 6,62,289

Income and Expenditure Account


31,62,665

Excess of Expenditure over Income

for the year 3,74,746

35,37,411

21,84,65,563 Total 23,40,73,320

21,84,65,563

Total 23,40,73,320

Place : Coimbatore

Date : 20-08-2015


" B.Gopinath

-


" J Thulasidasan

Chartered Accountant

The South India Textile Research Association, Coimbatore - 641 014

Centre of Excellence Medical Textiles

Balance Sheet as at 31st March 2015

"Vide our Report of even date"


Sd/- M Bhaskar

Partner

Annexure

Annual R

eport 2

014 - 1

5

107

31.03.2014 EXPENDITURE 31.03.2015 31.03.2014 INCOME 31.03.2015

Rs. Rs. Rs. Rs.

Rs.

Salary 49,27,681 40,15,295 Testing fees 41,05,893

Less : Salary Transferred - Dev. Of Moping 1,60,361

3,34,459 Training Fees 2,05,379

Dev.of Self Assessmbled Peptide 1,61,335 16,55,104 Other Income 9,97,976

Dev. Of Collagen coated hernia mesh 1,13,143 25,757 Consultancy Income 1,27,435

29,85,576 Salary transferred for BSM - 44,92,842

4,69,375 Publication Income 6,65,264

64,442

Training Course Expenses 50,783 17,634 Interest received 35,745

1,75,212

Travelling Expenses 1,69,069 1,24,433 Cont. to meet Overheads from Spon. Projects 1,76,657

7,40,647

Stores Consumed 4,44,093 18,20,000 Buyer Seller Meet - Grant -

1,29,035

Maintenance of Machinery 1,24,001 9,52,043 Meditex 2014 -

2,95,032

Repairs & Maintenance 71,443 5,03,628 Medineeds 2014 -

3,150

Advertisement Expenses - 65,000 Meditex 2014 Advertisement -

57,544

Printing & Stationery 21,430 -

Seminar on Emerging oppourtinities in

32,618

Seminar Expenses 4,01,370 technical Textiles 3,90,000

2,09,930

Office Expenses 90,318

3,97,398

Electriciy Charges 4,75,944 -

Excess of Expenditure Over Income for the Period 3,74,746

53,967

Building & Fire Insurance 86,844

12,850

Internal Audit Fees 10,300

81,960

Postage & Telephone charges 46,312

5,000

Subscription & Periodicals -

7,65,620

Allocation of Expenses incurred by SITRA for the

project5,42,935

29,15,842 Buyer Sellers Meet Expenses -

-

Depreciation 51,412

10,56,906 Excess of Income over Expenditure for the Period -

99,82,728 Total 70,79,095

99,82,728

Total 70,79,095

Place : Coimbatore

Date : 20-08-2015


" B. Gopinath

-


" J Thulasidasan

Sd/- M Bhaskar

Partner


Centre of Excellence Medical Textiles

Income & Expenditure Account for the Period ending 31st March 2015

"Vide our Report of even date"


Chartered Accountant

Annual R

eport 2

014 - 1

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108

31.03.2014 31.03.2015 31.03.2014 ASSETS 31.03.2015

Rs. Rs. Rs. Rs. Rs.

4,99,14,905 5,17,50,486

5,12,55,072 FIXED ASSETS (AT COST) 5,32,52,439

9,65,000 PSC/CAD CENTRE FUND II INVESTMENT 9,65,000

POWERLOOM / CAD SERVICE CENTRES FUND II

Closing Balance 13,12,280

ADVANCES AND DEPOSITS

17,31,864 Less: Staff Terminal Benefits Apportioned for the year 22,35,742

(9,23,462)

10,80,572 Sundry Deposits (PSC / CADCs) 10,80,572

4,49,319 Advance for Purchases 2,000


22,993 Advances for Expenses 1,10,126

3,07,388 Add: Provision for Staff Benefit Expenses for the year 22,35,742

25,43,130

CURRENT ASSETS


47,500 Cash on Hand 43,000

11,03,664 Add: Current year Utilisation 1,61,267

12,64,931

19,98,203 Cash at Bank 40,78,972

19,46,868 Provisions - Income 43,926

45,81,096 Unspent Grant from Ministry for S.P 27,45,514

-

Grant Receivable 20,41,785

-

Sundry Debtors 1,67,231

CURRENT LIABILITIES 1,23,04,831 Branches & Divisions -

2,59,000 Liability for Finance

3,53,229

2,21,642 Sundry Creditors 9,039

1,19,50,800 Unspent amount from SSY 24,18,000

-

Branches & Division 16,24,184

7,00,70,358 6,17,85,051

7,00,70,358 6,17,85,051

Place : Coimbatore

Date : 20-08-2015

(Sd/-) Prakash Vasudevan(Director)

" D. Krishnamurthy (Chairman)

" J Thulasidasan

B Gopinath"

STAFF BENEFIT FUND APPROPRIATION FOR TERMINAL


Ministry of Textiles Sponsored Powerloom Service Centres

Balance Sheet as at 31st March 2015

LIABILITIES

CONTRIBUTION FROM GOVERNMENT AND GOVERNMENT

DEPARTMENTS

Partner

PSC FUND II APPROPRIATION FOR CAPITAL EXPENDITURE

Total Total



Sd/- (M.Bhaskar)

Annual R

eport 2

014 - 1

5

109

31.03.2014 31.03.2015 31.03.2015

Rs. Rs. Rs. Rs.

1,43,57,408 To Salaries 1,63,21,095

1,14,00,000 By Revenue Grant from Ministry 1,14,00,000

15,93,406 „ General office expenses 22,55,047

72,47,320 " Income from Services 1,04,92,662

21,28,323 " Rent, Rate & Taxes 25,79,299

5,68,372 " Interest on Bank and Others 3,64,650

1,78,214 " Spares, store & Consumbles 1,32,824

10,67,209 " AMC/Maintenance of Equipement 9,78,538

1,08,868 " Excess of Expenditure over Income 9,491

1,93,24,560 Total 2,22,66,803

Total 2,22,66,803

1,08,868

To Excess of Income over Expenditure for the

year b/d9,491

3,07,388By Appropriated from Fund for Terminal

Benefits (2014-15)22,35,742

1,98,520 " Surplus Transferred to PSC/ CAD Fund II 22,26,251

3,07,388 22,35,742

3,07,388 22,35,742

Place : Coimbatore

Date : 20-08-2015

(Sd/-) D. Krishnamurthy (Chairman) (Sd/-) Prakash Vasudevan (Director)

" J Thulasidasan " B.Gopinath



Sd/-

(M.Bhaskar)

Partner

EXPENDITURE INCOME31.03.2014

1,93,24,560


Income & Expenditure Account for the Period ending 31st March 2015

Ministry of Textiles Sponsored Powerloom Service Centres

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