Internship @Nahar

Textile internship at

Submitted by:Gourab MondalManish Prakash Dung DungManjeet PradhanSrajan Kumar SaxenaSiddharth Manu

We are driven by passion…We live by values..We are committed to quality..

Stepping ahead intoThe realm of new Challenge…

• Started in 1949 as a small hosiery factory• Spinning capacity of 0.55 millions cotton

spindles,25000 worsted spindles• Turnover of $550 million inclusive of export

turnover of $175 million.• The production facility has been certified ISO

9001:2000/ISO14002 & Okotex certification.• IN HOUSE brands- Monte Carlo, Canterbury,

Cotton County

Product Range

Fabric Products:• Blends: 100% Cotton & Cotton Blends (Poly-cotton,

Cotton-Stretch & Cotton-Tencil etc.) • Woven Vibrancy: Twills, Dobbies, Broken Twills, Ripstop,

Ottoman, Chinos, Satins , Tussors , Bedford Cord, Cavallery Twill, Canvas

Utility Products: Garments (Tops, Bottom & Outerwear)

GSM : 100 grams to 330 grams

Group of Companies

• Nahar Industrial Enterprises Ltd.-cotton county• Nahar Spinning Mills Ltd.-GAP, Arrow, Old

Navy, Pierre Cardin, Philips Van Heusen, Izod, Quicksilver, Price Costco…

• Nahar Investments & Holding Ltd.-I-AXIALLY ORIENTED POLYPROPYLENE FILMS

• Nahar Capital & Financial Services Ltd.

Export Markets-USA, Argentina, Brazil, China, Columbia, Chile, Czech Republic, Israel, Lebanon, Lithuania, Poland, Portugal, Peru, Turkey

Awards & Certifications • “Highest Exports in Cotton garments” Gold Medal (2007-08) awarded by AEPC • “Energy Conservation Award”(2007) - National Awards on Energy

Conservation for Industries • “Punjab State Safety Award”(2007) – Punjab Labor Department • ISO 9001:2000 &14001:2004 Certifications

JAW

AHAR

LAL

OSW

AL (C

.M. D

.)

DINESH OSWAL (M.D.)

NAHAR SPINNING MILLS

NSM

K. JAIN

PEARL GARMENT DIVISION

DANDARI KALAN KNITTING & DYEING

NAHAR FIBRES

NAHAR EXPORT

RISHABH SPINNING

NAHAR EXPORT (100% EOU)

KAMAL OSWAL (M.D.)

OSWAL CHEMICALS & DYES

PUNJAB CONCAST

ARHAM SPINNING MILLS

OSWAL SUGAR

NAHAR FABRICS

Company Overview

Hierarchy

CEO

VP (TECH)

PPC MANAGER

DESIGNING MANAGER

DYE HOUSE DGM

NEW SPINNING GM

POST SPINNING GM

WEAVING DGM

FINISHING DGM

INSPECTION MANAGER

QC LAB DGMENGINEERING

DGM

VP (SALES)

SALES MANAGER

INDUSTRIAL RMG SR. MANAGER

WAREHOUSE SR. MANAGER

MARKETTING DGM

REG SALES

GM(FINANCE)

ACCOUNTS DGM

COSTING SR. MANAGER

PURCHASE MANGER

LEGAL EXCISE DGM

EDP SR. MANAGER

GM(COMMERCIAL)

GM(P & A)

PERSONNEL

ADMINISTRATION

HUMAN RESOURCE

WELFARE

INDUSTRIAL RELATIONS

Spinning- Process Flow

• I:\flowchart.doc

• Raw materials- Domestic sources – J-34 ,S-6 from

Maharashtra, Mech -1 from Tamil Nadu Imported sources – PIMA & GIZA from Egypt,

FOUNDLANDS from USA • Bale size = 165 kg• Storage Area = 50 x100 m2

Blow Room Process

• Opening-M/C – LMW BALEPLUCKER LA – 23 (2 nos.).39 bales at 1 time

• Cleaning-M/C – LMW VARIOCLEAN LB9/2• MIXING-M/C – LMW UNIMIX LB 7/4R• REMOVAL OF COLOURED CONTAMINATIONS-

M/C – VETAL SCAN

Machines used for spinning Carding-• LMW LC 300 A V3 (20)• Trützschler Trumac TC 5 -3 (5) BREAKER DRAW FRAME• REITER SB-20 (For Combed line)• LMW LDO/6 (For carded line)• Trützschler Trumac TD – 03 LAP FORMER• LMW LH 10 (2) COMBING• LMW LK 54 (10)

Roving • LMW LFS 1660 V (9) Ring frame spinning• Model No: LR 6/AX(24) WINDING-AUTOCONER• OERLIKON SCHLAFHORST Autoconer

338 Type RM(3)• OERLIKON SCHLAFHORST Autoconer

338 Type D(2)• OERLIKON SCHLAFHORST Autoconer

338 Type V(5)• T.F.O. (Two for One)-M/C –RESHMI

MURATEC TFO• YARN CONDITIONING-M/C – SIEGER

YCP (Yarn Conditioning Plant) - 1

Knitting

•weft n warp.docx•Machines used in weft knitting:

Single jersey1.Basic machines2.Auto striper3.Mini jacquard4.Fully jacquard5.wrapper

Double jersey-1.Basic machines2.Auto striper3.Mini jacquard4.Fully jacquard

Machines for knittingMachines Number of machines

Basic 34Auto-stripper 16

Basic interlock 17Auto interlock 10Fully jacquard 6

Wrapper 4

Total Number of Machines = 87Machines: - Fukuhara, Terrot, Keum Yong, Mayer, Well-knitMachine Specifications:Well-knit Machinery Co Ltd (Basic Machine)Needle: 1920T Specs: 34” * 18G * 60F Terrot (Interlock Machine)Needle: 3408 T Specs: 34” * 16G Fukuhara (Auto-stepper)Needle : 2640 T Specs : 42” * 20G * 252F Fukuhara (Auto-stepper 6 Colores )Needle: 2568 specs: 36” * 24G

PROCESSING FOR DYEING AND PRINTING

• Processing section– Singeing and desizing section– Washing and bleaching section– Mercerizing section

• Finishing section• Peaching section

DYEING• In Nahar cotton is dyed with reactive dye and vat dye by padding

technique.• For polyester dyeing disperse dye is used and for polyester cotton blend

disperse & vat dye is used in the ratio 3:3.• Process: Padding Pre-drying Drying Cooling

Color fixators:• Ciba: Dichloro triazono • Remajol: vinyl sulvo• Levofin• RDPS• E-control

• Number of machines: 1• Number of dryer: 1• Production per day: 40,000-60,000 m

PRINTING FLOWCHART

• I:\flowchart.doc

Styles of Printing:• Direct ( Reactive & Pigment) for Cotton• Discharge for Polyester Methods of Printing:• Rotary Screen Maximum 16 colors can be printed. Maximum production capacity at 100%

efficiency = 15,000-20,000 m per day.

Details• Screen Making: The no. of screens needed = The no. of colours in the

design• Screen Coating: M/C – ZIMMER Austria• Screen Engraving: M/C – AGS CST ( Color Scanner Technology)• Screen Washing• Screen Stripping: Screen is fitted axially in a chamber in a solution of LU-

20 & LU-5. This chamber vibrates ,trying to shake off the ink parts/flakes • Screen Curing: Carried out in ZIMMER Screen Curing m/c at temperature

of 180oc for 2 hours• End Ring Fixing: Done for fixing the screen to the Rotary Screen Printing

m/c • Rotary Screen Printing: M/C – ZIMMER Austria ROTASCREEN (1)

Problems

• Design defects• Engraving defects• Blunt/Uneven Design• Incorrect viscosity of Photo emulsion coating• Printing over creased fabric• Incorrect speed & pressure of m/c

QUALITY ASSURANCE

1. Test of colorfastness to washing• M/Cs – IFB GYROWASH (1)• IFB EXECUTIVE PLUS TUMBLE DRYER (2)• INNOLAB INNOWASH FASTNESS TESTER (1)• WHIRLPOOL GOLD INTIMATE CARE WASHING

MACHINE (2)• Standards - AATCC 61-2A, ISO 105 C 06

2. Test of Colorfastness to Rubbing (crocking) M/C – JAMES.H.HEAL & Co. HEALINK CROCKMASTER

(1) Standards - AATCC 139, ISO 105 E 12 It is of 2 kinds:• Dry crocking• Wet crocking3. Test of Colorfastness to PerspirationM/C – JAMES.H.HEAL & Co. HEALINK PERSPIROMETER(1)Standards – AATCC 15, ISO 105 E 04

Other tests for assuring quality

• Test of resistance to pilling & abrasion• Test of tensile strength• Test of stretch & recovery• Test of heat contact• Test of wrinkle recovery• Test of water repellence

What makes NAHAR different??

• Proper markings everywhere in the industry for easy movement of Work

• Fire prevention devices/extinguishers at every nook and corner• Motivating Statements for laborers at general places• First Aid kits available at all security checks• self-power generation using Renewable Sources of Energy. The

steam generated is used for dyeing purposes. Output: 3.5 MW per day

• Banned tobacco• Effluent treatment plant• Use of trolleys and small caddy lifters wherever applicable

SWOT analysis

STRENGHTS Good Brand Image.

Nearly 0 employee turnover.

Member of wool mark and ISO 9002 and many other certifications.

Laboratories for testing the quality of the products.

WEAKNESS

OWM is dependent upon foreign producers for raw materials.

Dependent on the third party for sale and the distribution of the product.

OPPORTUNITIES

Fabrication for various companies likes NIKE, MARKS AND SPENCER, GAP, WILLS, OLD NAVY etc.

IN-HOUSE brands like MONTE CARLO and CANTERBURY.

THREATS

Mushrooming and upcoming of small hosieries in Ludhiana.

Seasonal demand for their products like pullovers.

Many big competitors like VARDHMAN, JAYASHREE TEXTILES