Sarla Fabric Pvt. Ltd. Internship

A Presentation By :

Akshay SinghDivya Kaushal

Department of Fashion TechnologyNational Institute of Fashion Technology, Hyderabad

(2008 -2012)

AcknowledgementWe would like extend our gratitude towards

Mr. Pradeep Pathak, CEO, Sarla Fabric Pvt. Ltd., who permitted us to conduct our study of the organization despite their overwhelming preoccupation.

We also like to thank Prof. Anant Phani, our esteemed mentor along with all the faculty members who have bore with our modest knowledge with ever so persevering patience in five previous semesters.

Sarla Fabric Pvt. Ltd.Established in 1994.Plant located in Mohan Nagar, Loni

Industrial Area (Ghaziabad, Uttar Pradesh)Acquired by Shahi Exports Group in 2010Company objective revolves around their

motto "Printing Excellence! Inspiring Fashion!"

Company Policy"Sarla Fabric Pvt Ltd will provide to their

esteemed customers, cost effective, consistent textile solutions of cotton and cotton derivatives benchmarked to International Quality Standards as per committed delivery terms. The organisation will achieve the same through a process of knowledge enhancement and continual improvement while ensuring strict adherance to ISO 9001:2000 QMS. "

Organizational Hierarchy

Process Flow

ClienteleGAPOld NavyTARGETWal-MartAnn TaylorH & MAbercrombie & FitchJ CrewJC Penney

EspritFederatedNEXT

DepartmentsWeavingBleachingDyeingSamplingPrintingFinishingFolding

Technical & Laboratory

Product Development

Weaving Department

Warping Section

Warping SectionRewinding machine Warping

machine

Sizing SectionIt is the application of Size (Starch or Other

Chemicals) to reinforce the warp yarns to withstand the stress during the process of weaving.

BEN-SIZETEC (Benninger, Switzerland) used for sizing.

Bleaching DepartmentFabric for Dyeing/Printing prepared.Preparatory wet processing is carried out in

the department.Department also responsible for a number of

chemical processing as per the occasional requirements.

Bleaching DepartmentFour main functions are carried out:

Singeing and DesizingSingeing literally means to burn lightly.It is done to remove protruding fibers from the

yarns within a fabric to prepare its surface to undergo several processes or treatments such as printing.

Usually done on both faces of the fabric.Desizing removes the size which is applied to

reinforce the yarns for the process of weaving.Oxidative as well as Enzymatic desizing is carried

out.Osthoff Senge machine is used for both purposes.

Osthoff Senge

BleachingBleaching removes the soluble starch

(dextrin family) as well as natural pigments and impurities that affect the color of the fabric.

Process of Scouring and Bleaching are carried out in one execution.

Continuous Bleaching Range (CBR) is employed for this purpose.

Continuous Bleaching Range

MercerizationIt is the process that imparts strength to the

fiber and improves the overall fabric by adding some other qualities.

Only Hot Mercerization is carried out in the company using the Benninger AGCH.

Dyeing DepartmentDyeing is the process of imparting color to a

textile material at its constitutional level.

Dye application can be achieved using different machines, depending upon the type and quantity of fabric.

Dyeing Department

Batch DyeingWhen the entire lot of fabric to be dyed is

dipped in the dye solution at once, it is called Batch Dyeing.

Following Batch Dyeing Machines were present:Winch x 8Maxxi JiggerMedium Jigger x 4Small Jigger x 2Jet Dyeing Machine x 4Soft Flow Dyeing Machine

Winch Dyeing Machine

Jigger Dyeing Machine

Jet Dyeing Machine

Soft Flow Machine

Continuous DyeingWhen rolls of fabric are fed sequentially to

the dye bath, it is known as continuous dyeing.

The following machines are employed for continuous dyeing of fabric:

1)Pad Dry Pad Steam (PDPS)2)Cold Pad Batch (CPB)

Pad Dry Pad Steam MachineIt is actually an association of two machines.The two units Pad Dry and Pad Steam, in

collaboration, execute the function of dyeing.

Pad Dry Unit

Pad Steam Unit

Cold Pad Batch(CPB) Machine

Cold Pad Batch Dyeing MachineIn addition to the Cold Pad Batch, a machine

called the Soaper is also present in the plant, used for the removal of any excess chemicals through washing.

Printing Department

Printing Department

Rotary printing machine

Finishing DepartmentThe department employs the usage of Stenter

Machine and Sanforiser Machine.SMECON Stenter machine improves the feel

of the fabric.Ramson Sanforiser machine controls the

shrinkage of the fabric.

Finishing Machines

Inspection and FoldingVisual inspection.4 point system is followed.Another internal system of Q# is followed to

categorize fabric.

Folding Department

Technical Department & LabA no. of tests to evaluate fabric quality are

conducted.

Technical Department & Lab

Additional MachineryPiece End Joining Machine (Sewing Machine)

WastageMinimal wastage.Rejected fabric is sold in the domestic

market.

MaintenanceScheduled Maintenance is carried out twice a

month.

Specific ObservationsNo separate merchandising department.PDC Department is involved in interaction with

the buyer, thus acting as the merchandiser.Very high noise level inside the loom-shed,

workers provided with earplugs.A maximum of 12 color prints are possible only.Internally developed Q# system for fabric

evaluation.Minimal wastage strived for.Efficient Material Flow.

“Q ” System

Malfunctioning(s) ObservedBurning of fabric during singeing.Entanglement of fabric in most of the

machines involving roller dispatch.Tearing of Fabric during curing.Breakage of yarn during weaving.Wearing off of patterns on Rotary Screens.

Overprinting Entangled Fabric

Learning OutcomeDetailed analysis of fabric manufacturing

process.Detailed study of Machinery and Equipments.Introduction to the Interdepartmental

communication.