Madura Coats

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Submitted by… A. Arulmani (2013411001) M.Tech Textile Technology Anna University Chennai-25 MADURA COATS Pvt. Ltd.

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Industrial training report

Transcript of Madura Coats

Page 1: Madura Coats

Submitted by… A. Arulmani (2013411001) M.Tech Textile Technology Anna University Chennai-25

MADURA COATS Pvt. Ltd.

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Coats 5 Principles 3 Goals…Increase ProductivityProfitable Sale GrowthPossitive Team Work

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INTRODUCTIONThe textile industry is one of the most

important in Indian company. It contributes 35% to gross foreign exchange in merchandise trade. The Rs.1300 billion industry accounts for 20% of the country’s industrial output and provides direct employment to about 35 million people the second largest after agriculture. It also provides direct employment to another 47 million people.

Textile production increase handsomely by 8% in 2005-06(measured in terms of index of industrial production, control statistics organization), over and above the 9% growth clocked in 2004-05.such back high growth was last recorded in 1995-96 and 1996-97 when the increase were in double digits.

Madura coats limited have its origins in a cotton trading agency. It is one of the Indian largest textile companies employing more than 10,000 people with sales in excess of Rs.800 Crores. Madura coats currently operate through its two division’s coats India and Madura textiles. A third new division global thread supply India has come into existence from first January 2003.The division has responsibilities for implementing coats

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global thread supply strategy. It manages the day operations and administration of spinning and twisting facilities located in Madurai and Ambasamudram.

Coats have nearly of experience supplying quality thread in over 60 countries worldwide. Head quartered in Bangalore, coats, coats India is the thread division of Madura coats limited. Specialization in Industrial, Consumer and Handicraft threads. Operating through 14 sales offices and 8 manufacture units across India, the company caters to an exploding network of our 25,000 directs and 2, 00,000 indirect consumers.

Supplier for some leading garments brands like claireborne, lee, Lives gap, Nike and Tommy Hilfiger and exports threads to nearly 40 countries in north, South America, Europe, and Asia.

COMPANY PROFILEA hundred and twenty year ago, to brothers

from Scotland Andrew and Frank Harvey, launched their cotton trading business of belly they soon moved to virudupatti (now known as virudhunagar) and acquired a small second hand cotton press.

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Raw cotton from the districts of south India was brought pressed and exported to England from tuticorin port.

In 1883, the Harvey brothers pioneered spinning in south they dammed the water of the Thamirabarani River above the papanasam falls near Ambasamudram and used power developed by the water in its drop from the crest of the hills to the plans to run a spinning mill known as Tirunelveli Mills Company limited.

The water mill as it was popularly known started production in 1885 with 10,000 spindles, its products established a name for quality and the mill proved a highly profitable venture spurred by this success the Harvey brothers set up more mills in quick succession in tuticorin the “Coral Mills”.

In 1889 with the 24,000 spindles in the Madurai the “Old mills” in 1892 with 36,000 spindles and the new mill in 1912 with 70,000 spindles. Harvey also acquired Pandyan Mills Madurai, which under a different management till 1929. All these mills were amalgamated to from Madurai mills.

During 1990 the company launched a new division “Madura garments” and marketed branded menswear. The world famous brands like

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“Louis phillipe” and “Van huessen” were now available in India. Later of casuals wear under the brand name “Allen solly” was introduced, Madura garments progressively added more brand.

Madura coats private limited introducing lot of new type of machine for their production and they supply their products to many countries they are called as “global thread supply India (GTSI) Madurai.

HEAD OFFICESMadura coats India – Head office7th floor Jupiter, 2A- block, prestige Technology Park,Sarjapur – Marthahalli ring road,Bangalore- 560 087Madura coats private limited144, Mahatma Gandhi road,P.B. No. 5145,Bangalore – 560 001BRANCH OFFICE

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New jail road, P.B.No 35,Madurai,Tamil Nadu- 625 001DEPOTSAhmadabad, Bangalore–Consumer, Bangalore–Industrial, Bhubaneswar, Bombay- Consumer, Delhi- Consumer, Delhi- Industrial, Ernakulum, Goregaon, Guwahati, Howrah, Hyderabad, Indore, Jaipur, Kanpur, Kolkata, Ludhiana, Chennai- Consumer, Chennai- Industrial, Noida, Patna, Pure, Tirupur.

MADURA COATS“Coats” is the world’s largest supplier of

industrial sewing thread and crafts products. Coats India in a multinational company which was established in 1824 and it is headquartered in UK. Geographically it is organized into five regions – North America, Europe, South Asia and East Asia. Coats’ wide product range delivers solutions for every conceivable application – be it jeans and trainers, or automotive airbags and bullet-proof vests. It is the world’s second largest and fastest growing manufacturer of top quality zip fasteners.

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With 22% Global market shares and operations in 67 countries. Coats are clearly the market leader. It has the unique ability to service, creative ideas and superior technical solutions. Throughout the long history, Coats people have established a tradition of landmark innovations in products, color technology and manufacturing processes. And many of their innovations have become the global industry standard.

Coats has, by far, the most comprehensive product range catering to the needs of a multitude of industries – footwear, mattress and quilting, automotive, outdoor and camping goods, furniture and filtration, to name a few.

The manufacturing expertise and the extensive experience in servicing the needs of customers are unmatched by any of its competitors. These assets were further enhanced by the acquisition of Barbour Threads whose expertise in threads for special applications dates back to 1784 when its first linen mill was established in Northern Ireland.

‘Coats’ unswerving commitment to quality is highlighted by the fact that all the key units are accredited with QS 9000, Ford Q1 Mark, SATRA Quality Mark and many more.

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GLOBAL OFFERRecognizing the need of the apparel industry

for global supply chain partners, Coats has launched the Global Offer, a range of threads designed and manufactured to global specifications for a vast range of applications. These products are Oeko-tex certified and quality is audited by one centrally located team. Its global service network, uniform product specifications and a single color numbering system make it easy for the customers to source and use Coats Global Offer threads anywhere in the world thereby making it convenient for them to truly exploit the benefits of global sourcing. The Coats Global Retailer Services programme supports the global sourcing needs of large retailers and brand owners through many innovative services along with the Global Offer. For apparel sewing the Global Offer consists of four brands supported by the Coats Global Color Reference shade range of close to a thousand shades.GLOBAL RETAILER SERVICES

Coats Global Retailer Services programme works in partnership with retailers, brand owners, mail order companies or buying houses to deliver

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quality sewing products to their Contractors. As the world’s largest thread manufactured and distributor, Coats has the capability to serve the organization’s international sourcing needs flexibly. This service is of strategic supply chain. Whether it’s the product or the technical advice, the unrivalled worldwide ability ensures that it provide support where it’s most needed.MADURA COATS PRIVATE LIMITED

In India ‘Coats India’ is better known as ‘Madura Coats Private Limited’, which is headquartered in Bangalore. Coats India is the thread division of Madura Coats Private Limited, a subsidiary of Coats Ltd, the only truly global thread and zip supplier operating out of 65 countries. Coats India manufactures and markets a complete range of cotton, synthetic and core spun threads for the Indian and export markets. Through a network of 21 sales offices backed by six manufacturing units located close to major thread consuming centre its service is unrivalled in India. Madura Coats, with over a hundred year history in India, also operates another division, Global Thread Supply India (GTSI) which caters to the grey thread requirements of Coats companies worldwide. Coats India manufactures a complete range of cotton,

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synthetic and core spun threads for the Indian and Export markets. It has two business segments – Consumer and Industrial. In Consumer segment it deals with – (1) Sewing’s, (2) Handicrafts, (3) Zips. And in Industrial segment it deals (1) Apparel Thread, (2) Embroidery, (3) Zips. The product range in Consumer Threads includes ANCHOR – the finest handicraft threads for embroidery, DOLI – a value for money embroidery range and ANCHOR QUICK STITCH KITS popular among embroidery hobbyists. For the Tailoring trade, there are premium brands like AMETO – the World Class thread, and a range of popular brands such as SPADE and MOON that have been trusted by tailors all over India for decades. For industrial customers, Coats India offers virtually every type of thread including Nylon threads branded APTAN for the shoe upper industry, Polyester threads branded ASTRA for the readymade garment industry and Core spun threads branded KOBAN for the leather garment industry. Coats India’s products are distributed through a wide network of 21 consumer and industrial sales offices across the country, supported by a base of 25,000 direct and 2,00,000 indirect customers. Coats India has its manufacturing units in 7 locations countrywide and has 25 branches across India. Coats India enjoys

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undisputed leadership in quality and service in the Indian market and is rapidly increasing its presence in export markets.

GLOBAL THREAD SUPPLY INDIA (GTSI)Global Thread Supply India (GTSI) is that

division of Madura Coats Private Limited responsible for implementing the Coats Global Thread Supply strategy in India. This division has spinning and twisting mills located in Madurai, Tuticorin and Ambasamudram. In addition to the operating these mills to exacting global standards, the division is involved with outsourcing of grey thread to bridge the gap between demand and internally available companies all over the world such as Australia, Bangladesh, Brazil, Bulgaria, Chile, Egypt, France, Hong Kong, Honduras, India, Indonesia, Malaysia, Mauritius, Mexico, Morocco, Peru, Poland, Romania, Shanghai, Spain, Sri Lanka, South Africa, Thailand, Tunisia, Turkey and Zimbabwe. The division has an in-house capacity of 150,000 spindles and produces about 240 tons grey thread per week.HISTORY OF COATS

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1755-James and Patrick Clark establish a business in Paisley Scotland.1864-The Clark family start to manufacture thread in Newark, New Jersey.1890-Coats list on the London Stock Exchange.1890-1960 Globalization of the Manufacturing

operations.1961 - Merger with Patons&Baldwins forms

Coats Patrons.1986 - Merger with VantonaViyella forms Coats

Viyella.2000 - Strategic decision to refocus on coats global threat business.2001 - Acquisition of DMC Industrial Threat. Coats viyellaplc renamed coats plc.2003 - Guinness peat group plc acquires coats plc and ordinary share are delisted from the stock exchange. 2003 - As from April 2004, the corporate structure is that Guinness Peat Group plc owns 100% of the Ordinary share in coats Group Limited, which in turn owns 100% of the Ordinary shares in Coats plc.

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MADURA COATS ORIGIN1880 – First cotton press in Virudhunagar.1883 – Water mill at Ambasamudram.1889 -tuticorin coral mills.1892 - Madurai mills.1944 - Madurai industrial textiles.1963 - Modern weaving units.1974 - Madura coats formation.1986 - Madura garments.

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Organizational structure

PROCESS FLOWCHART

Managing DirectorPresidentGenaral Manager4 Unit Mill manager Spinning ManagerExecutivesLogistics managerEngineeringManagerFinance ManagerPurchase ManagerTechnical ManagerHR ManagerIT Manager

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GODOWN

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The fibers are stored in bale form, Filament and Grey thread also stored. In this mill only using 100% polyester fibers like the fibers are,

PEN FIBER Polyester fiber Pen T333,P12(Green Sheet)

1.2denier X 38mm length Pen T333,P22(Blue sheet)

0.85 Denier X 38mm length Made In Malaysia

RECRON FIBER Polyester Staple fiber R52(White)

1.2 Denier X 40mm length Made In India

POLYESTER FILAMENT 49 dtex F16S, 61 dtex F24S, 86 dtex,

106 dtexPerformance Germany

77 dtex 24BMade In Thailand

Zhongtai 95 dtex, Made In China

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CONDITIONINGEach Pen bales weight 300kg. Recron bales

weight 400Kg.open the bales and laying them in a humidified area for relaxing the compressed fibers so that the downstream process would treat the fibers properly. The bales are conditioning at minimum 24hr.

BLOWROOMBasic operations in the blow room are,

Opening Cleaning Dust removal Blending Even feed of material to the card

UNIFLOC – A10 (Rieter)Picks small quantity of fibers from each bale in

the lay out and feeds to the next machine. This ensures mixing of the fibers from different bales for uniformity.

Task of Unifloc, Extract the material evenly from the bales Open the material gently Open up to the smallest flocks

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Blend material right at the start of the process

Process: Opening M/c Type: Unifloc A-10Beater speed: 1440 RPMBeater to Bale setting: 0.8 To1.6mmType of fiber: Pen T333, Pen T333 Micro, R52No. of bales laying: 54 to 60

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Kg/Hr/Mc: 1600 Kg

MIXING BALE OPENER (Rieter) A sequence of machines beats open the fibers

fed from the Unifloc. The output is directly feed to the carding machine. In the way of chute feed mechanism.

Process: OpeningM/c Type: B3/3 SNo. Of M/c: MBO1 (Pin beater), MBO2 (Saw

tooth beater)MBO1 Beater speed: 500 RPMMBO2 Beater speed: 800 RPMKg/Hr/Mc: Both 400Kg

GBR BALE OPENER (Trumac)The beaters are arranged in inclined at 45 degree. Otherwise same for opening, cleaning and blending. Process: Opening and Fibers Manually FeedingBeater speed: 500 RPMKg/Hr/Mc: 300 Kg

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CARDINGOpen the blow room lap/bat and the tuft size

should be reduced. The cards mainly individualize the fibers and remove the waste. The output is a fluffy rope called “sliver”.

Task of card,

Tuft size should be reduced Individualize the fibers Elimination of impurities Disentangling of neps Fibers blending and orientation Sliver formation

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LC333 (LMW)Type of fiber: Pen T333, R52Feed material K/tex: 400-450Delivery K/tex: 4.22 Chute opener roller Speed (rpm): 846 Flats speed in mm/min: 100Draft: 80-100Chute pressure: 100 -160 PaDelivery roller speed: 130 (+ or – 10 mpm)Kg/hr/Mc at 100% efficiency: 32

SETTING (mm)Feed roller to licker-in: 1Licker-in to cylinder: 0.2

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Cylinder to flats back to front: 0.3 to 0.25Cylinder to doffer: 0.125

TC5-1 (TRUMAC) Type of fiber: Pen T333, R52

Feed material K/tex: 300-400Delivery K/tex: 4.22Chute opener roller speed (rpm): 1460 Flats speed in mm/min: 100Draft: 95Chute pressure: 150 -200 PaDelivery roller speed: 220 (+ or – 10 mpm)Kg/hr/Mc at 100% efficiency: 45

SETTING (mm)Feed roller to licker-in: 1Licker-in to cylinder: 0.225Cylinder to flats back to front: 0.3 to 0.25Cylinder to doffer: 0.225

C50 (RIETER)

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Type of fiber: Pen T333, R52Feed material K/tex: 400-450Delivery K/tex: 4.22 Draft wheel: Auto leveler Flats speed in mm/min: 90(+ or – 20)Draft: 90-100Delivery roller speed: 130 (+ or – 10 mpm)Kg/hr/Mc at 100% efficiency: 32

SETTING (mm)Feed roller to licker-in: 0.8Licker-in to cylinder: 0.25Cylinder to flats back to front: 0.35 to 0.3Cylinder to doffer: 0.15

DRAWINGDoubling and Drafting of card slivers for better

uniformity. Number of card slivers are doubled and drafted together in two stages thus making the mass more uniform.Task of drawing,

Equalizing (reduce unevenness) Parallelizing (fibers arranged parallel)

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Blending Dust removal

DRAWING DO/6The DO/6 is breaker draw frame it is removing

the tailing hooks and parallelization also doubling.

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Fiber type: Pen T333, R52Feed material K/tex: 4.22Delivery K/tex: 4.07Ends up: 6Total Draft: 6.2Calendar roller speed (mtr/min): 240Kg/hr/Mc at 100% efficiency: 58.61

SETTING (mm)Bottom roller setting 1st to 2nd: 46

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2nd to 3rd: 50Top roller setting is 1st to 2nd: 46

2nd to 3rd: 54Top roller pressure 1st (Kg/cm2): 2.0 – 3.0

2nd (Kg/cm2): 3.0 – 4.0

DRAWING D30This is also doubling, parallelization and

leading hooks are removed.

Fiber type: Pen T333, R52Feed material K/tex: 4.07Delivery K/tex: 3.94

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Auto leveler: Open loop Ends up: 6Total Draft: 6.43Calendar roller speed (mtr/min) : 400Kg/hr/Mc at 100% efficiency: 94.56

SETTING (mm)Bottom roller setting 1st to 2nd:44

2nd to 3rd: 49Top roller setting is 1st to 2nd: 47

2nd to 3rd: 54Top roller pressure 1st (Kg/cm2): 2.0 – 3.0

2nd (Kg/cm2): 3.0 – 4.0

SPEED FRAMEPartial attenuation of the drawing slivers into

roving. Sufficient twists are inserted into the roving to hold the fibers in position and to enable further drafting.

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Task of SDF, Attenuation of the sliver Impart the twist in order to improve the

slivers strength

SDF LF1400

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Fiber type: Pen T333, R52Spindle/Mc : 120 Feed material K/tex: 3.94Delivery K/tex: 0.369

Twist (TPM): 35.68Twist Multiplier: 0.72Total Draft: 10.68Spindle speed: 840 (+or-50rpm)Kg/hr/Mc at 100% efficiency: 0.52

SETTING (mm)Bottom roller setting 1st to 2nd: 48

2nd to 3rd: 70Top roller setting is 1st to 2nd: 56

2nd to 3rd: 68 Top roller pressure 1stKg1o: 30

2o: 203o: 25

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RING SPINNING 100% of polyester yarns. Final attenuation of

roving into yarn of the required size and twist level for imparting the strength of the yarn.Core Spun yarn

In case of core spinning there is a filament in a centre position, around which the roving mass of either polyester or cotton is drafted and twisted together.

The cost structure in spinning mill graph

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LRG 5/1(Lmw)

Blowroom M/C 11%Cardings 13%Drawframes 4%Roving frames 12%Ring Spinning M/C's 60%Ringframe LRG 5/1(Lmw)LR 6S(Lmw)LR9 AX(Lmw)RIETER G 32(Rieter)KTTM RX1240e(KTTM)LR DJ(Lmw)PSL(Psl)

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Fiber type: Pen T333, R52Roving hank K/tex: 0.197Nominal count (dtex): 87Spindle speed: 12,000 rpmTotal draft: 51.8TPM: 1250100%/prod/shift/Mc: 17.3 kg

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SETTING (mm)Top roller setting: 52/72Bottom roller setting: 42.5/75

KTTM RX1240e (KTTM)Fiber type: Pen T333, R52Roving hank K/tex: 0.59Nominal count (dtex): 275Spindle speed: 15,000 rpmTotal draft: 21.2TPM: 604100%/prod/shift/Mc: 409.1kg

SETTING (mm)Top roller setting: 50/63Bottom roller setting: 46/65

LR9AX (Lmw)Fiber type: Pen T333, R52Roving hank K/tex: 0.59Nominal count (dtex): 275

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Spindle speed: 17,500 rpmTotal draft: 21.2TPM: 604100%/prod/shift/Mc: 550.7kg

SETTING (mm)Top roller setting: 52/70Bottom roller setting: 44/70

AUTOCLAVEThe standard conventional steaming treatment

for yarn is chiefly used for twist setting to avoid snarling in further processing. It does not result in lasting improvement in yarn quality. The great advantage of this process is that the moisture in the form of gas is very finely distributed throughout the yarn package and does not cling to the yarn in the form of drops.

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CONDITIONSCycle I Cycle II

Material

Package Vacuum

Temp.

Time

Vacuum

Temp.

Time

ppc& Cops 500m 75oC 4m 500m 90oC 26m

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pcc b in b inSsp AB

Cones 500mb

75oC 4min

500mb

90oC 26min

Ssp275x6

multiplex

500mb

75oC 4min

500mb

90oC 26min

cotton

paper tube

500mb

70oC 5min

350mb

85oC 60min

WINDINGFault clearing by electronic clearance. The

package transformed into cone or cheese of bigger size compared in previous process.

SCHLAFHORSTAC338SSP: 72Spindle per M/c: 60Package Weight: 1350gms

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Clear type: Uster Quantum Drum speed: 700 – 1000 (m/min)

SSP CORE

Quality A B & C & E

87,105,157

N% 300 500 300 S% 170/3 200/3 140/2 L% 25/70 50/10

0 25/50

T% -35/100 -35/100 -25/40

MURATEC 21CSpindle per M/c: 60Clear type: Uster Quantum-3 Drum speed: 700 – 1400 (m/min)Package Weight: 1350gmsUntwisting time: 0.71 secTwisting time: 0.12 sec

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SSP CORE

Quality A B & C & E

87,105,157

N% 300 500 300 S% 170/3 200/3 140/2 L% 25/70 50/10

0 25/50

T% -35/100 -35/100 -25/40

ASSEMBLY WINDINGParallel winding of two or more number of

singles yarns. In the portion don’t generate the twist. Number of ply depends on requirement.

M/c Modal: PPW (Precision Propeller Winding)

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Count

No.ply

Chamber

Incoming air

Speed(mpm)

Pro/spl/hr/80% efficiency

87 2 18W 8 800 5.396 2 18W 8 800 5.9400 2 251W 8 600 18.4484 2 251W 8 600 22.2

TWISTINGThe parallel wound threads are imparted twist

of the required level depending on the end usage. Some yarn makers use two-for-one twisting without assembly winding.

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Process: Twisting M/c modal: Vee-jay Lakshmi (vj150-HS)

Count/mix/Qly

365x2/PPC/E 119x2/R52/E

Spindle speed(rpm)

6,000 10,000

Tpm/direction 547/Z 831/Z

Package weight(g)

900.0 1000.0

Tension weight(g)

50 0

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INSPECTION&PACKINGThe twisted in cheese are inspected for surface

quality, weight and density and then packed into cartons or pallets for exports and in PP sacks for in land use.PACKAGE YARN CLASSIFIER

Classification Run Statistics Report Ideal weight (g): 900 (+ or – 30) Ideal Diameter (mm): 148.0 (+ or – 5.0) Ideal Density (kg/l): 0.420 (+ or – 0.030) Total Packages: 36 Total Acceptable: 35

Weight Diameter DensityOver spec. Failures

0 0 1

Under spec. Failures

0 0 0

Mini. Value 893 144.3 0.414Max. value 908 150.0 0.455Range 15 5.7 0.041Mean value 902.2 147.24 0.433

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Variance 18.8 2.44 0.000Standard Deviation

4.3 1.56 0.010

Coeff. Of variation

0 1 2

CONCLUSION During this period of training I have came across many Technical aspects in the discipline of textile engineering like functioning of machines, manufacturing of textile products etc and then safety procedures adopted in and around Madura Coats. Handling of textile materials, maintenance of machines and quality of product delivered are UNIQUE. Finally I thank Madura Coats in giving such a nice opportunity in enhancing my skills and knowledge.

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