Ritika Doc

Internship at Vaishali Design studio 2011

A: SYNOPSIS

During 3rd yr of Textile design dept, a internship of 8 weeks was structured. It was about gaining in-depth knowledge of the working of the industry in terms of organization structure, infrastructure, product range, materials & manufacturing processes, costing, design management, quality control, marketing & distribution and Corporate social responsibility CSR).This project was about working for the company’s benefit to undergo design process.

For me the choice of firm with which I wanted to do my internship was very important, after an internship with an industry I wanted to go for design firm to know as to go for design firm to know how a design unit works .A manufacturing unit also sees a design aspect but a design house firm stress on design thus giving me more scope for exploration .So after a lot contemplation I decided to work for Vaishali design studio.

From NIFT to VDS the difference was superlative, from a relaxed pace of college to demanding pace of industry, where the only fittest can survive.

My Internship brief consisted of a project handover by my head designer , to design bed sheets for Kurlon and to design cushion cover design for V living.

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COMPANY OVERVIEW

PROCESS

BRIEF

THEMEBOARD

FABRIC DESIGN

RODUCTSTYLING

FOLLOW UP

SERVICES

TEXTILE DESIGN

SAMPLE EXECUTIO

N

STALL DESIGN &SHOW ROOM

DESIGN

PORTFOLIO

FABRIC DESIGN

TEXTILE MADE UP

ENSEMBLES


A1: COMPANY PROFILE

INCORPORATION

Based in NOIDA, U.P, VAISHALI DESIGN STUDIO deals with designing of soft furnishings for the export market; led by Ms.Vaishali Sinha (graduated from NIDAhemedabadin1992).The textile design studio came into being in 1997 and consists of a dedicated & skilled staff & besides Noida for last 7 yrs it now has opened its operations in Mumbai too.

SYSTEM

People organize system with strong support buyers and customers that ensure a smooth work flow in the organization. It has a team for documentation & presentation & is supported by highly skilled artists. The design studio is well equipped with computers & design software to give high quality professional services.

PEOPLE

The organization strength lies in staff- versatile, creative, experienced, competitive and focused. This pool of people brings in wide spectrum of corporate experience into company therefore a practical innovative and logical functioning and versatile thinking.

SKILLS

Designing

Machine embroidery

Construction

Printing

The organization has efficient work force of employees (printing people, tailors, and technicians, embroidery technique) to churn out best product.

STRATEGY

At Vaishali the duties may be distributed but vision is shared. The organization believes in customer satisfaction, innovation & growth, process quality and people commitment.

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http://www.vaishalidesigns.com/index.htm



http://www.vaishalidesigns.com/portfolio.shtml


A2: OVERVIEW

THE MAIN WORK AREA OF THE DESIGN STUDIO ARE –

A1: Textile Design

A2:Stall design for exhibitions and showroom design

Starting from designing of fabric to styling of made-ups to display and stall design — the design studio is capable of providing a complete design solution for a furnishing export house.

The wide range of products that the studio design includes – Bedlinen ; Table linen ; Kitchen linen ; Floor coverings & Accents like Cushions ; Throws & Curtains

Textile design is the main work area where….

a) We design fabrics using textile techniques like Printing ; weaving & fabric ornamentation & provide actual scale artworks with complete details like reed/pick ; count construction; print technique embroidery tracings colour detailing etc.

b) Thereafter to help the client visualize the design as closely as our textile designers do we provide scaled down artworks of the made ups along with any required information

c) We support the client with corrections in samples during the execution of the prototypes.Stall design of the clients in the HEIMTEXTIL fair has been a regular feature for the past five years. Showroom design; art direction for professional shoots of textile products and designing Lamp shades are fields which the design studio has ventured into. Showrooms of Handfab at Panipat and V.G.W.C. at Cannanore and NOIDA have been designed by the studio. The design studio ultimately sells to a broad spectrum of prestigious buyers from all over the globe like Pottery Barn, Crate & Barrel, Ikea, Peab, Company Store,Target, Wal-MarMart,Sia Fabrics etc.

.

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http://www.vaishalidesigns.com/aboutus.shtml#b


B: PROCESS

B1: BRIEF

It is the requirement that the client provides:

Which specifies that the design is required for?

Which country?

Which buyer?

Which season?

What are the cost constraints?

What are the product lines?

Number of design required?

What is the delivery date?

What kinds of fabrics?

Any design direction provided by the client?

B2: RESEARCH

We hunt through relevant websites, international books, magazines & trends in the market and to precipitate few concepts.

Sites that usually referred:

www.designdiary.nic.in

www.fotosearch.com

www.totallyhome.w.wt

www.allfreedownload.com

www.musthavenews.com

www.etsy.com

www.westelm.com

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http://www.westelm.com/

http://www.etsy.com/

http://www.musthavenews.com/

http://www.allfreedownload.com/

http://www.totallyhome.w.wt/

http://www.fotosearch.com/

http://www.designdiary.nic.in/


B3: THEME BOARD

Based on brief from the client & our research; a theme board is developed which shows the colors; the ideas; the motifs & patterns; the accessories; type of fabrics; the ambience etc approximately. It helps in giving a preview to the client of the designs to be and helps the client to reflect on the concept & give his feedback so the relevance of the design is maintained. Once the story board is approved we freeze the colour palette & the concept.

B4: FABRIC DESIGN

Taking the theme board as the premises the fabrics are designed . All the fabrics are designed in actual scale & have the details of warp/weft; reed/pick; count/construction etc in case of wovens; actual print artwork with repeat in case of prints & tracings & embroidery details in case of surface ornamentations.

B5: PRODUCT STYLING

The fabrics design are then scaled down for the styling of the products. Scaled down version of all the made ups are provided which gives the client a very clear idea as to how the finished product would look even before venturing onto its execution. Ir helps in doing required changes at the artwork stage. These artworks could also be used for a presentation to the buyer & get their feed back before the sampling.

B6: FOLLOW UP

Vaishali Design Studio also keeps a track of the progress of sampling of the designs. This helps the client to visualize & achieve the best results. It also gives us a feed back of the strengths & limitations of the client & the designs

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http://www.vaishalidesigns.com/portfolio_fabrics.shtml





C: SERVICES

C1: TEXTILE DESIGNING

Designing home furnishings being the prime service area; at Vaishali Design Studio we do design development from fabric till the made ups stage. Fabrics are designed using printing; weaving & various surface ornamentation techniques which is followed by styling of various home furnishing products like quilts; pillows; curtains etc.

C2: SAMPLE EXECUTION

This service is specifically for clients that Vaishali Design Studio designs for. We design & also get the samples executed to ensure perfect conversion of design into its prototype. It also helps clients who are not equipped with their own sampling unit & also provides a complete package from "design to samples" with fabric source & cost details. VDS has an exclusive sampling unit so that the confidentiality of designs is maintained.

C3: EXHIBITION STALL DESIGN & SHOWROOM DESIGN & DISPLAY

Selling of a product is dependent not only on good designing but also on how a product is presented or displayed. As VDS has been designing textiles it also gets involved with the display of textiles at the showroom or at an exhibition; which includes designing of the showroom OR designing the stall of the exhibition also. This ensures a relevant & justified display of textiles which brings out the designs beautifully

C4: THEMES & COLOR TRENDS

Equipped with an experience of 12 years in the field of Textile design for Exports & exposure to various markets & buyers, VDS further collects information from a lot of international magazines & books ; does market surveys; visits fairs in different countries to develop its themes & colour trends

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D: PORTFOLIO

D1: FABRIC DESIGNS

D2: TEXTILE MADE UP

D3: ENSEMBLES

D1: FABRIC DESIGNS:

Fabrics like dobby, damask, jacquard, checks; stripes etc in woven’s category. Florals; geometric designs, oriental etc in prints; embroidered; texture technique etc in surface ornamented fabrics with variations & combinations are used for designing the Home furnishing Products.

The solid colour fabrics, which could be weave based textures or dyed greige fabrics like sheeting; poplin organdy; drill or polysilks; polysatins velvets etc become important in creating collections.

D2: TEXTILE MADE UPS:

Vaishali Design Studio offers contemporary textile made-ups which includes cushions, throws, curtains, quilts, rugs, bathmat, accessories, etc.

A: CREATIVE CUSHION DESIGNS

Cushions come in a wide variety of designs depending on the shapes and sizes of the cushions. These are further embellished with the help of embroidery, prints, sequin and embroidery and patch work etc. They are generally made in the colors that match the ambiance. Cushions are available in all the regular fabrics such as cotton, linen, satin and also including velvet. The designs on the cushions range from traditional to conventional & could be decorative & functional or both.

SIZE

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PRODUCT ACTUAL SIZE PRINT SIZE(height)

CUSHION 16’’*16’’ 4’’

FLOOR CUSHION 26’’*26’’ 5’’

B: DESIGNER THROWS

Throws; also know as lapshawls are a multipurpose piece puff fabric where the feel & softness plays an important role. Throws are used to decorate the home the living space or used as a shawl to provide warmth. The throws could be woven or stylized & quilted in colors of the season. Effective use of a variety of techniques in throws such as piecing, appliqué and embroidery is also done to impart a fashionable look to the decor.


THROWS 50’’*60’’ 10’’

SIZE

C: DESIGNER CURTAIN

Curtains are the most appreciated and widely used means of window decorating & are important means of keeping privacy of the interiors of the house

A well designed curtain complete the look with its matching and coordinating fabrics and designs. Curtains are further decorated & styled with various styles of valances and tie backs. A huge range of contemporary & classical sheer curtains provide play of light to the room and add a delicate, flowing touch to the windows

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D: DESIGNER QUILTS

The correct choice of bedding is vital for a great night's sleep. Quilts are an important element of a bedding ensemble; specifically designed to make a bedroom look really stylish. Quilts function as a decorative bedcover & a warm coverlet & are available in the series of dyed and printed fabrics patched and embroidered.Quilt are available in all the regular cotton fabrics & polyesters like polysilks; satins; velvets etc

SIZE


QUILT 66’’*86’’ 12’’

E: DESIGNER RUGS

No furnishing or Décor can match the value, Functionality, Durability and Beauty that the Rugs give their owner. A rug can be magnificent combination of Function, Beauty

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and Value. Rugs are True Works of art that People can live on - it is what one can say, “Work on air”

SIZE


RUGS 28’’*42’’ 5’’*8’’

F: DESIGNER BATHMAT

Bath mat is used on the floor of a bathroom to provide a warm non-slip surface and to absorb small amounts of water, much like a towel. Bath mats are available in unique and creative designs.Bath mats are made of absorbent cotton materials available in a wide range of colors that are produced to suit modern, attractive and individual taste. Bath mats usually include jacquard and floral; self or other decorative designs


BATH TOWEL 20”*44” 4”*7”

BATH MAT 22”*34” 3”*6”

SIZE

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D3: ENSEMBLES

A: BED LINEN DESIGNS

Bed linen can be sold as two-piece sets with a bed sheet and a pillowcase in matching colors and prints or a whole ensemble with quilt; fitted sheet; flat sheet; pillow case; pillow sham & bed skirt. A fine bed linen collection is designed keeping the cost factor; look; ambience & the styling in trend.

SIZE

FLAT FITTED

TWIN 66’’ *108’’ 39’’*75’’

DOUBLE 81’’*108’’ 54’’*75

KING 108’’*101’’ 78’’*80’’

QUEEN 90’’*101’’ 60’’*80’’

CRIB 45’’*86’’ 29’’*84’’

WATERBED 31’’*74’’

B: DESIGNER TABLE LINEN

Table linens are usually made of cotton or flex and standards sizes do not exist for table linen as it comes in rectangular or round shapes and in different sizes.

Table linens add a unique dimension to every dining experience. No matter what is the occasion, a dining table is simply not complete without the beauty and elegance of fine

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Tablecloths, napkins, placemats & runners - in range of styles, sizes, and colors are created for any décor and for every occasion.

SIZE


TABLE CLOTH 52’’*52’’ 6’’

TABLE MAT 13’’*13’’ 2.5’’

C: KITCHEN LINEN

Kitchen Linen is manufactured in multitude of colors, patterns and designs; these are made of textiles that possess absorbing quality, durability, and dirt rejection properties. Kitchen Linen includes:

Apron Kitchen Towels Napkins Pot Holders Place mats

SIZE


KITCHEN TOWEL 20’’*28’’ 5’’*7’’

APRON SET 10’’(width)

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Analyzing client brief

making mood boards based on research

working on theme

making boards & setting colour palette

getting inspired by theme & making thumbnails

working on initial concept

communication with client for finalising the final concept

working on final concept

making final design layout

developing samples of concepts

Getting final product made


E DEPARTMENTAL STUDY

E1: DESIGNER

Total number of designer working over there: 5

Shilpi Gupta (HEAD DESIGNER)

Alpana Choudhary (AMITY SCHOOL OF DESIGNING)

Neha bansal (INTERNATIONAL POLYTECHNIQUE SCHOOL DELHI)

Priyanka maheshwari (AMITY SCHOOL OF DESIGNING)

Anjali Gupta(INTERNATIONAL POLYTECHNIQUE SCHOOL DELHI)

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INFORMATION COLLECTION_

The research starts with going through forecasts boards magazine information ,regarding colors pattern fabrics has to be collected.

DEVELOPING MOOD BOARD -

The mood board are made keeping in mind the client brief & research done.

DEVELOPING INITIAL CONCEPT -

Concepts are made and explored taking the inspiration from mood board and related colour palette which will give the way to final design.

DEVELPING FINAL DESIGN -

Keeping the client feedback final visualization of the collection starts, at this stage styling of the product is decided then it is shown to the client.

PREPRATION OF LINE SHEET WITH SPECIFICATION -

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Development of mood

board

Development of initial concept

Developing final design

Preparation of line sheets

with specification

Preparation of smple with all

details of sample

development

Research done through market survey

& forecst


Speciation sheet of the design is prepared with size, color embroidery, trims specification.

SAMPLING -

Design is approved by the sponsors are then sent to prototype development it is done under supervision of designer.

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ABOUT DESIGNER’S THEME GALLERY

In “Designers Theme Gallery”, every year themes are updated on 15 th July. So, the themes updated in year 2010 that were being followed in vaishali design studio till July,2011 are as follows:

Vintage Glam

The theme talks about legends and traditions of a historical period. It says, historical influence of rich custom heritage would be translated into modern day material having a vintage look but yet fresh and crisp.

Victorian

A new mood romance looks set to persuade the season in shades belonging from pale dusty, dark, deep and mysterious palettes. Fabrics are rich and decorative or alternatively flat and matte.

Verctian Romance

It says, pale blonds, golden touches, caramel hues and deep brown makes the nearest naturals a key statement for the fall season.

Leafage

It talks about a spiritual, pure, calm and light beauty which comfortably hides away tones between the rational and the emotional non-colour with a little assent to twin them up.

Moroccan

It is all about ancient sedater and attractive colours for a sweet and refined romanticism.

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Vivid Bloom

Vivid bloom is a tonal as contrasting and stimulating combinations which creates invisibility or desire to be noticed. It is like bright summer and pleasure as a happy assent.

Fantasy

It is far away from all those every day responsibilities and duties. This is an extremely summer theme, escaping to liberty and carefree days, innocence and sensuality. Fabric and colour plays a leading role over here.

Modern Country

It creates a luxurious atmosphere in artistic and comfortable shades and narrates soft and opulent story with sophistication.

Aqua

It expresses the yellow grew of gleaming green sheen and the blushing beauty of vivid corals and offset inky blue state, grey and vegetable reflect. And also spreads around the infusion of life green brought by spring with brown and buff tones indicating the strengths of contemporary assents.

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E2: ARTIST

Amit Kumar

Minakshi Singh

All corrections of the prints approved by client are made by designer.

E3: ACCOUNT

Uma Kant tiwari

E4: SAMPLING CO ORDINATOR

Manish Singh

Dyeing, sampling, color matching, trims selection all shot of work is managed by sampling

co ordinate.

E5: DESIGN DETAILER

Kajal Singh

Documentation, fabric presentation, specifications are managed by detailer.

E6: MRECHANDISER

Anupam Singh

Apart from HR dept Mr. Anupam manages costing, quality check, merchandising, lising.

Role of the Department

. To look for the appropriate market

. To get the samples made according to the buyer’s specification

. To estimate and quote the cost of the garment to the buyer and negotiate with them

. Getting orders

. Constant interaction with the buyer for the approval

. To get the fabric and trims in-house for bulk production

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. Co-ordinating with the PPC and production

Objective of Merchandiser

. To create market

. Understanding buyers’ requirements

. Sourcing of materials, fabrics

. Select the range

. Creating the product

. Taking buyers approvals

. Negotiation with buyer

. Procuring the orders

. Materializing the order

. Execution the order

. Coordination between production and production planning department

. Dispatching the shipment

. After shipment dispatching merchandiser is also responsible for buyer claims, profit and subsequent orders. If buyer has any problem in quality of the product then it is the responsibility of the merchandiser to resolve the problem with the buyer.

Process of merchandizing

The first stage of merchandising is when buyer sends either spec, sketch or any product pieces and asks for sample with costing or only costing using different fabrics. The specs sent by the buyer are also called Tech Packs. The merchandiser gets the approval of all things like fabric, trims, label, costing etc. and either buyer gives the approval or gives the vendors’ name. Basically costing is done on the basis of the spec, sketch and garment which are sent by the buyer for making the sample.

First merchandiser does the average costing/consumption of the garment. The quotation is sent to the buyer/buying house and the approval is awaited. One thing is to be noted that while giving the consumption, the cut-able width of the fabric to be received (either mill made-developed in India or imported fabric) has to be considered while costing.

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Also the marker utilization depends on the style, which may affect the consumption greatly.

The merchandiser monitors the design from sampling to production and then final dispatch. They are a link between the buyer and the company. All correspondence that the buyer wants to do regarding his style will be done through the merchandiser. Merchandiser monitors the total sampling from development to the time the production sample is made and goods go into actual production.

They also see that the fabric is developed on time and send it for approval to the buyer and subsequently if all samples are made on time, send them to the buyer for approval too. They are also in constant touch with production to know the status of their styles.

File prepared by merchant has following details:

. Style: contains a brief description of the style.

. Style #: as mentioned by the buyer

. Movex item #: Item number of the style by Movex

. Buyer: Name of the buyer

. PCD: Production cut date for the style

. Merchant: Name of the merchant handling the style

The file contains the following:

Purchase order for the style

. Tec pack

. Relevant communication with the buyer regarding proto, fit and pre production

samples. All the comments from the buyer for various samples are included.

. Thread consumption report

. Fabric Test Report

. Fabric and trim cards: Contains swatches of the fabric and trims to be used

. Mini marker with costing average

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E7:FIELD BOY

Shayamvir

Manages display og the design house

E8: MASTER(For sampling)

Rijwan

Anil

Sampling of products is done by them for clients.

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F: SAMPLING UNIT

This is the initial step after an order is received through the first communication on an negotiation level with the client.

- DESIGN APPROVED-The Design is approved at the first place. A mock is presentated before the client or all the specifications are noted as per the demands of the buyer. It is kept under consideration that the speculations are feasible for the production house or not keeping in mind the production process and cost and other liabilities along with the probable profit.

-FABRIC DECIDED-The appropriate type of fabric in regards to factors like cost, thread count, weave, colour, durability, fiber type,EPI, PPI,charecteristic features,etc are taken into account and the most feasible

PRODUCT DEVELOPMENT-

-THREAD- The stitching thread is decided upon both for the seams and the surface manipulations. It is generally silk, cotton or polyester.

-PRICE VALUE-The probable cost of production and the total estimated turnover is calculated and accordingly the MRP is put on that including taxes and profit percentage. The profit percentage includes the amount to be distributed along the production chain and subsidiaries.

-TECHNIQUES- Surface manipulation being an important issue the type of embroidery is decided upon as well.

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STORAGE PRE STITCHING PROCESS

PRODUCT


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STITCHING EMBROIDERY

SURFACE DEVELOPMENT


G: PRINTING PROCESS:-

Vaishali design studio does not have in-house printing studio, hence, the printing part of sample development is get done from outside. The studio has contractors for screen printing and digital printing as well.

G1: CUTTING OF FABRIC

Cutting of the fabric for sample development is sometimes done before printing also, but normally fabric comes on table for cutting after printing. For the pattern cutting, layouts are made on the fabric using ruler and chalk and then it is cut leaving 1 inch projection on all the sides.

G2: EMBROIDERY

Again the embroidery part involves a number of steps which are as follows:

Needle punching : On the tracing of embroidery details developed by the artist, simply stitching machine (without inserting the thread and bobbin) is run on all the embroidery lines of the tracing sheet to make the design with needle punching in order to trace the design on to the fabric in the form of dotted lines.

Tracing of embroidery lines: Once the needle punching is done, then at the stage of tracing the design on to the fabric, the basic raw material being used are Kerosene+ Rainbow Neel/ zinc oxide (silver).

The above combination content is spread over the needle punched tracing sheet by putting the fabric below the tracing sheet, so that the design appears onto the fabric in the form of dotted lines.

Here, for dark colored base fabric, rainbow Neel is used in combination with kerosene in order to get darker visible tracing lines which stays for long while for lighter shades fabric, even the zinc oxide(silver) can be used in combination. But the drawback here with zinc oxide (silver) is that it does not stay for long, it simply gets faded after 2-3 hours.

Filling: After tracing comes is the filling part of embroidery where motifs are incorporated with different embroidery stitches using embroidery machine. With machine basically running, satin and lock stitches are done. For ‘aari’ embroidery and computerized ones, they place the orders outside. And even the hand embroidery and beads/sequins work is get done from outside. They pay craftsmen for hand embroidery and beads/sequins work. The minimum charges that the craftsmen make is Rs. 250/- , and the charges varies depending upon the quality and quantity of work. Sometimes

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vendors also take orders for such handwork. For fillings, embroidery thread and zari threads are used.

Before the filling part, sometimes a piece of fusing is attached from the back side of the embroidery sample in order to do not move away from the embroidery line while running the embroidery machine. The fusing also stiffens the base to be embroidered. It is mostly applicable for sheer and light weight fabrics and is a must in case of heavy embroidery.

Removal of tracing marks: Once, the filling part of embroidery is over, it is very important to remove all visible tracing marks from the base fabric. For removing the tracing marks “spot gun” is used.

The “spot gun” contains a solvent of white petrol inside. And the functional aspect of thee gun depends upon its arrow. By pressing the arrow, white petrol is sprinkled in order to remove the tracing marks.

G3: SURFACE TECHNIQUE

Under this stage of sampling, surface manipulations are imparted onto the fabric. Ruffles and fringes are attached and also the pleats and tucks are made. This stage does not necessarily come after the printing and embroidery while it is mostly applicable to plain fabrics. Hence, the surface techniques mostly are done after the sourcing itself.

In case of surface technique, the consumption of fabric is very high as for most of the surface techniques, whatever the finished manipulated size of sample we require, we simply need to take just double/triple of fabric in lengthwise and in width wise direction as well.

G4: INTERLOCKING

The interlocking stage comes, once the embroidery, fusing and surface techniques are over. This is to finish the edges of the sample and prevent the ravelling of yarns. So, the edges from all sides of the sample are finished with interlocking stitch using over lock machine.

For the interlocking, 100% spun polyester yarn of 2/60sNe is used which they avail at Rs.120/- from ‘Vardhman’ or ‘Modi’.

G5: STITCHING

Now comes is the final stitching which is done using Single needle stitching machine. Here, they take care of stitching lines and projections to maintain the quality of sample.

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G6: QUALITY ASSURANCE

Since, the design studio does not work in the path of mass production; they only develop sample products, so the quality is checked visually.

G7: FINISHING

Once the quality is checked, then comes is the finishing part where all the extra threads are cut, tracing marks are removed and product is turned into a finished one. And also the tag of Vaishali Design studio and care label is attached to the finished products. Although, they do not put any standardized care label symbols but they follow the universal standards and specify the precautions for washing and ironing in simple text.

G8: PACKAGING

Under the packaging, finished products are packaged and sealed along with the respective documented details relevant for further mass production and then it is sent to the client.

G9: SCREEN PRINTING STUDIO

The screen printing studio is situated in Faridabad. The studio has huge market in its area of work. They get the screens developed according to their client’s consignment. The client gives their designs with size specification of one repeat and according to the design, the screens are developed.

For printing pigments are used in combination with the binders. Binders vary depending upon the kind of fabric and type of printing that has to be done. Usually, all kinds of fabrics are printed and they also have a good range for type of printing. Starting from pigment print, to khadi print, metallic print, flock print etc. are done.

The printing studio has all the machineries, equipments, resources and man power required to carry out the entire procedure.

1: PROCESS OF SCREEN PRINTING

The process of screen printing involves following steps:

Making of the printing paste

The printing paste is made by mixing the pigment with the binder. The type of binder and the composition of solution depends upon the king of fabric to be printed. The printing paste is made in big containers in bulk to avoid the shade variation. And if in case the paste starts getting dried off, then the actual solubility in paste can be achieved by mixing the kerosene in the paste as per the requirement.

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2: Printing of fabric

For carrying out the printing process, the fabric is first fixed onto the printing table using alpines. The printing table is made by fixing several layers of newspaper, a jute sheet and a coarser count cotton fabric onto the table.

Once the fabric is put onto the table and fixed with alpines, then the screen is set onto the fabric keeping the alignment of the design into account. The printing paste is then put over the screen and spread with the help of squeeze. After spreading the printing paste, the screen is removed slowly. For making the overall print, same screen is used repeatedly but to maintain the quality of print the screen is washed in between.

After printing, the fabric is dried under shade.

3: Steaming

The dried printed fabric goes through steaming at optimum temperature for specified time period. The temperature and time depends upon the type of fabric.

The process of steaming compels the dye particles to enter the molecular structure of the fabric and make permanent bond with the fibres.

4: Washing, Drying and Ironing

At last, the printed fabric is washed first with hot water and then with cold water followed by drying an ironing at optimum temperature.

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G10: DIGITAL PRINTING STUDIO

It refers to methods of printing from a digital based image directly to a variety of media. It usually refers to professional printing where small run jobs from desktop publishing and other digital sources are printed using large format and/or high volume laser or inkjet printers. The savings in labor and ever increasing capability of digital presses means digital printing is reaching a point where it will match or supersede offset printing technology's ability to produce larger print runs at a low price

1 PROCESS OF DIGITAL PRINTING

The process of digital printing involves following steps:

Pre-treatment of the fabric

The purpose of pre-treatment is increase the stability and colour fastness of the fabric to be printed. Here, the fabric is dipped into a solution of chemicals containing:

Urea

Gaur gum

Soda

Salt

Hot water

Cold water

The ratio of chemical composition depends upon the fabric to be used. For different quality of fabric, solution is prepared in different composition. Once the fabric has been coated with the paste, it is spread on table for drying. The length of table is 2.5 m, hence it can be used only for shawls and scarves.

While for the pre-treatment of running fabric, a coating machine is there wherein firstly the yardage goes through the input, i.e., chemical paste and then it automatically gets winded over the cylinder for drying.

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http://en.wikipedia.org/wiki/Inkjet

http://en.wikipedia.org/wiki/Laser_printers

http://en.wikipedia.org/wiki/Desktop_publishing

http://en.wikipedia.org/wiki/Desktop_publishing

http://en.wikipedia.org/wiki/Digital

http://en.wikipedia.org/wiki/Printing


Printing of the fabric

The process of printing the fabric starts from converting the tiff file of image into a printable copy. For that, they have a computer inside the printing studio with specialised “RIP” software.

For printing of the pre-treated fabric reactive ink is used and because of the use of reactive ink almost all types of fabrics (cotton, silk, viscose, georgette, chiffon etc.) can be printed except polyester. In digital printing 8 colours are mixed and matched to create millions of shades. The basic 8 colours are:

Yellow

Orange

Magenta

Red – 400

Cyan

Grey

Black

Blue

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Coating machine


The studio has two sampling machine and one production machine for digital printing. In all the machines, separate cartridges (each of capacity 400mm) are put for basic colors. And for all the machines, double set of colors are put to save the time of changing the cartridge (in case any colour gets over in between) and have faster rate of production.

Here, the head of printing machine picks up the colors from cartridges, mixes them up to develop the desired shade and carries out the printing process.

Inside the printing studio, they also have a drying heater which seems useful in rainy seasons for drying the printed fabric.

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Colour cartridges

Digital printer for sampling Digital printer for production


Post –treatment of the fabric

After printing the fabric is passed through a steam fixing process where the dye gets inside the fabric and makes chemical bonds with the fibers. For this process of steam fixation, they have specialized equipment called Azer.

Washing, Drying and Ironing

Once the steaming of printed fabric is done, they go for washing of fabric with hot water followed by cold water. And after washing, fabric is dried and ironed at suitable optimum temperature.

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Drying heater

Azer


H: CLIENTELE

Vaishali design Studio has a huge clientele for domestic and as well as international market. Some of its high end customers are:

Crete & Barrel

Target

Bombay Co.

Wal-Mart

Peak

IKEA

Continent

Coming to the regular clients, the list has on top:

Handfab India

Mittal International

Sapu International

Expectations

Adnani

Arasi Fabrics

Metro Fabrics

Laaz Internatinal

Art international

Linen Scape

Incotex Impex

Shri All India

Amsa

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House of Prajer

And, the major export market includes:

Amravati textiles

Virsa exporters

VSNC

Sabare International

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I: MASS PRODUCTION

As already mentioned, Vaishali Design Studio does not have its in-house mass production unit. So, the mass production of Vaishali Design Studio takes place at other manufacturing units or export houses. Mostly the mass production takes place at “VARADA” export house which is quite nearby. And in other cases, clients also get the mass productions done at their contract manufacturers.

I.1 ABOUT VARADA EXPORT HOUSE

Varada export house is a company specialized for US market. The unit works mostly for gifts and packaging and the entire design process is carried out as per the consignment. The client specifies everything starting from:

Country

Buyer

Season

The cost constraints

The product specification

Design

Number of pieces

The delivery date

Depending upon the consignment, the unit takes a decision to accept the order with possible negotiations suited to them. The recent consignment for which the unit was working was a US consignment for Christmas for which the mass production of a “tree skirt” was under process.

Apart from this consignment, another expected consignment was for packaging of a gift item. And this was also from US only.

And the last consignment which they worked for was the order of 2000 hand made baskets. This consignment was get done in the local market of Delhi. A girl belonging from Assam who used to sell such baskets in domestic market of Delhi took the consignment as a challenge and fulfilled the order on time.

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CONSTRUCTION UNIT PRODUCT


Varada export house also takes consignments for the mass production of home furnishing products for different design houses. Vaishali Design Studio is one such design unit whose almost all the mass productions are get done from Varada export house.

Varada export house has its own in-house store and stitching section. The stitching section has 7 embroidery machines, 2 over lock machines and 8 stitching machines.

The unit also caters to window display and retail.

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CUTTING UNIT


DESIGN PROCESS OF VARADA EXPORT HOUSE

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CONSIGNMENT CONFIRMATION

APPROVALOF

DESIGN

PURCHASE ORDER

SOURCINGOF

RAW MATERIAL

PRODUCTION

STORE CUTTING EMBROIDERY

STITCHINGFINISHIG

PACKAGING


J: RECENT PROJECTS

Some of the recent consignments which were seen undertaken in Vaishali Design Studio

were:

Kurl-on

(Bedsheet print designing)

Linen scape

(Cushion designing)

House of Prajer

(Cushion designing)

Plum Chutney

(Cushion designing)

Amravati Textiles

(Print and weave designing)

Metro Fabrics

(Print and weave designing)

V-living

(Cushion designing)

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K: MY WORK IN VAISHALI DESIGN STUDIO

Out of the recently undertaken consignments of Vaishali Design Studio, I got the

privileged opportunity to work on the Kurl-on consignment.

Kurl- On

The consignment was all about designing prints for bed sheets. For the consignment, the

specifications were already given by the client. There were eight themes given for the

consignment including:

Asian Fusion

Blooming & Foliage

Bold Checks & Stripes

Damask & Ogee

Ethnic

Geometrical

Ikat

The provided theme boards and colour palettes for above mentioned themes can be seen

in Annexure-II and the approved work for this consignment are enclosed under

worksheets

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BOARDS THAT WE REFFERED FOR DEVELOPING DESIGNS

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COLOUR BOARD

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DESIGN CATALOGUE: 1

COLOUR WAYS


DESIGN CATALOGUE: 2

COLOUR WAYS

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DESIGN CATALOGUE: 3

COLOUR WAYS

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DESIGN CATALOUGE


COLOUR WAYS

DESIGN CATALOGUE: 5

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DESIGN CATALOGUE: 6

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Apart from Kurl-On consignment, I also got the opportunity to work on two consignments of cushion designing including:

Plum chutney

V-Living

Plum Chutney

The consignment herein was well organized and offered with concerned specifications. The client had provided two themes to be worked upon including:

Stylized Floral

Chide Fest

V- Living

V- Living is the domestic brand of Vaishali Design Studio. With this brand name, the designs are developed and marketed in domestic market. So, I got the opportunity to work with their in-house consignment also. The consignment was for designing embroidered cushions and the theme/ look board for the consignment was made as per the trend forecast. For this consignment, the embroidery templates to be incorporated in the design were also provided.

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BOARDS THAT REFFERED FOR DESIGING CUSHION COVERS

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[Type a quote from the document or the summary of an interesting point. You can position the text box anywhere in the document. Use the Text Box Tools tab to change the formatting of the pull quote text box.]

THEME BOARD: 1

CUSHION: 1 CUSHION: 2

THEME BOARD: 3


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THEME BOARD: 2

CUSHION: 1 CUSHION: 2


L: SWOT ANALYSIS

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CUSHION: 1


STRENGTH:

Strong design team

Exclusive design language

Skilled and experienced labor

Understanding consumer requirement plays a major role

WEAKNESS

Little exploration with finishes on fabric

Aesthetics empower function

OPPORTUNITIES

Manufacturing unit has lot scope for expansion.

Means of publicity, marketing are plenty.

Company profile can also cater to other classes of society for increase in sales.

High export potential.

THREATS

Constant effort against competition required safety precaution.

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M: APPENDIX

N: LEARNING EXPERIENCE

This internship of two month with a well known and well established design house has been a very good learning experience wherein an exposure to the actual principles and concepts on which design studio works was achieved.

A lot difference between what is learnt theoretically and practical aspects of the same was found.

The success of project KUR-LON bedding of which I was a part depended on the main designer who were the main people for executing the ideas proposed .It took lot of effort and patience to convince them regarding my views in any design that I developed ,thus working under a Designer helped in building up the patience level and also helped in implementing ideas in a right direction as well as motivated and acknowledge the work..

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While working on project involved interaction with workers also to make them understand how to construct design without any manipulation.

Thus this internship was a blend of variety of experiences, and the learning that is obtained out of this internship is very valuable.

LEARNING OUTCOME:

Gained a thorough knowledge about various techniques used for developing a product as well as developing a product look with a software(Photoshop)with size ,colour surface detail.

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O: REFERENCES

WEBSITES

www.designdiary.nic.in

www.fotosearch.com

www.totallyhome.w.wt

www.allfreedownload.com

www.musthavenews.com

www.etsy.com

www.westelm.com

www.kaboodle.com

www.shutterstock.com

www.istock.com

www.vintageviews.com

www.the3dstudio.com

www.emblibrary.com

www.furnish.co.uk

MAGAZINES

Elle Decor’

Cosmopolitan

Home Review

Deco Home

Elle Decoration

Home style

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http://www.furnish.co.uk/

http://www.emblibrary.com/

http://www.the3dstudio.com/

http://www.vintageviews.com/

http://www.istock.com/

http://www.shutterstock.com/

http://www.kaboodle.com/

http://www.westelm.com/

http://www.etsy.com/

http://www.musthavenews.com/

http://www.allfreedownload.com/

http://www.totallyhome.w.wt/

http://www.fotosearch.com/

http://www.designdiary.nic.in/

Ritika Doc

Documents

studio design

fabric design stall

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