Summer training report 11 (5)
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This document provides information about the author's summer training at AYM Syntex Ltd in Palghar, Mumbai. It includes: 1) An acknowledgement thanking the institute and company for providing training opportunities and support. 2) A profile of AYM Syntex Ltd describing it as a leading manufacturer of specialty synthetic yarns established in 1985 with facilities in Silvassa and Palghar. 3) An overview of the company's textile yarn production processes including twisting, texturizing, dyeing and their various machine capabilities.
![TESTS AND MACHINSES: -
(1)- TEST
(A) Shade match
(B) Fastness test
1. Washing fastness
2. Rubbing fastness
3. Sublimation fastness
4. Perspiration fastness
DYEING M/C CAPACITY
METHOD NO. AATCC – 2A
1. Collect a hank of dyed materials of each dark batch as a party required.
2. Add the multi fabric piece [15cm×5cm]
3. Take the 1250ml pot of Laundrometer and add to it 2gpl WOB Detergent I.R. 150:1, 50
steel ball.
4. Introduce both dyed & Multi Fabric in that pot.
5. Start the m/c and set the temp 49°C±2°C and keep hold for 45 minutes.
6. Than dry the sample and observe the fastness on multi fabric and give ratting as per
fastness grey scale.](https://image.slidesharecdn.com/summertrainingreport115-211106113802/85/Summer-training-report-11-5-21-320.jpg)
Summer training report 11 (5)
- 1. SUMMER TRAINING REPORT AYM SYNTEX LTD PALGHAR MUMBAI IN THE PARTIAL FULFILLMENT OF B. TECH UNDER GUIDENCE OF UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE KANPUR BATCH: 2017- 2021 SUBMITTED TO: DR. AKS GANGWAR SUBMITTED BY: Vijay prakash 1704460060 Textile chemistry department
- 2. ACKNOWLEDGEMENT First of all we are thankful to our institute (U.P.T.T.I) for providing us the opportunity for getting the practical knowledge as well, under the direction of our most respected director Dr. Mukesh Kumar singh. We have got full support and instruction from Dr. A.K Gangwar sir and Dr. Arun Patra. For the preparation of the project. I have also got full support from Mr.Sanjeev Kr. Rajput, Prof. Kalley Singh and prof. Alka Ali of our institute. We are also thankful to whole AYM SYNTEX LIMITED for providing us the best facility and good environment during training period. We express our gratitude to each and every employee of AYM SYNTEX LIMITED for their co-operation &their most valuable time. We would like to express our gratitude towards ALOK UPADHYAY (VICE PRESIDENT) , Mr. RAGHVENDRA SINGH (H.R). We pay our thanks to Mr. Dheerendra Singh Sir. who gave their valuable time & attention during training. Their guidance was very beneficial for getting the practical knowledge. (THANKS TO ALL)
- 3. COMPANY PROFILE Established in the year 1985, AYM syntax is leading specialty synthetic yarn manufacturer with the world class manufacturing technology for multipolymer yarn. It is the largest Indian manufacturer of bulk continuous filament yarn and leading multipolymer yarn dyeing house in Asia. AYM syntax limited (formerly known as Welspun syntax limited) with its innovative approach is a pioneer in spinning, texturing, draw twisting and dyeing of polyester and nylon yarn USIn the field of specialty synthetic yarns, AYM Syntex is one of the largest manufacturers of multipolymer Textile & Bulk Continuous Filament (BCF) yarns with offices spread across India. With the largest yarn dyeing house in Asia, AYM offers world-class quality, wide range of shades, exceptional service & breakthrough innovation.
- 4. 35 YEARS OF SUCCESS With plants located at Silvassa (Dadra Nagar Haveli) and Palghar (Maharashtra), AYM Syntex is well equipped to meet both domestic and international customer demand for synthetic yarns. The company’s state-of-the-art multipolymer Textile & BCF yarn manufacturing facility at Silvassa (India) serves the diversified global textile & floor covering industry. These lines are capable to manufacture specialty yarns, first-of-its-kind across the globe. The plant is equipped with an R&D facility for master batch color development, pilot spinning and sample tufting (MTUFT) for the customer’s tailor-made needs. Our Palghar facility houses India’s largest, 100% environment-friendly automated dyeing facility with a zero liquid discharge system. GLOBAL PRESENCE Touching lives across 50+ countries.
- 5. BCF YARNS AYM Syntex Limited is the leading manufacturer of Bulk Continuous Filament yarns (BCF) in India. We are pioneers in producing specialty BCF and Microfiber yarns. We produce POLYESTER, NYLON 6, POLYPROPYLENE and POLYESTER MICROFIBRE yarns which are ideal for carpets, rugs & mats. Our expertise lies in yarns for wall-to-wall carpets - (Tufted & woven) carpet tiles, hospitality, contract, automotive mats, rugs, bath mats & CHROMOJET printed etc. We also have yarns suitable for handmade carpet industry
- 6. Textile yarn Our textile yarn include nylon, polyester, recycled polyester. Synthetic Solution Dyed Yarn Synthetic Package Dyed Yarn Mother Fully Drawn Yarn (FDY) Mono Yarn
- 7. Highly Oriented Yarn (HOY) Partially Oriented Yarn (POY) Air Covered Yarn (ACY)
- 9. APPLICATION Automotive sewing thread and industrial yarn S& Dress Materials Shocks Home textiles
- 10. Medical textile Narrow fabric Home Textiles Sewing Thread & Industrial Yarns Sport wear Fashion apparel
- 11. Flow chart for dyeing plant Raw material Twisting texturizing Rewinder Twisting Dyeing plant Pressing m/c Hydro extractor(drying) Issue to conning plant
- 12. Fashion & app Texturizing Texturizing is the process by which synthetic fiber are modified to change their texture the physical appearance of the fiber texturizing techniques can include bulking (where thermoplastic fiber are twisted, heat set and untwisted),crimping and coiling amongst others. Process temperature primary heater temp ----(165 to 195C) secondary heater temp ----(140 to 170C) cooling rod temp ----(65C) there are 12m/c out of 3m/c (himson) and 9 m/c (ALIDHRA) Himson m/c capacity of spindle ---168*2 two sided ALIDHRA m/c capacity of spindle ---112*2 two sided right and left CONNING Antistatic conning oils are used for texturizing synthetic yarns such as viscose acetate rayon ,nylon and polyester. We supply oils of different viscosities depending on yarn. Polyester department CONNING.A---11PCW (precision cone winding m/c + 1 m/c Korea (mélange) CONING.B ----4P.C. W (32 spindle) CONNING.D---3P.C. W Nylon department
- 13. There are 6M/c (W.S.F) and 2m/c (FADIS) 29m/c (MURATA) spindle capacity -24 spindle and one another m/c whose capacity 12. TWISTING Twist is the simply spiral arrangement of the fibers around the axis of the yarn through twisting the fibers is bound together and create a stronger yarn. The number of twists involve to as normally referred to as turn per inch or turn oer meter. There is total 38 m/c. which different brand –LOHIA TFO, ALIDHRA, MURATA LOHIA M/C capacity--- 240 spindle (120 upper and 120 lower) DYEING DEPARTMENT There are 3 dyeing department 1—Old dyeing (polyester dyeing)—There are 15 dyeing m/c and 11 hydro m/c, 7 pressing m/c 2---German dyeing (Carpet dyeing)—There are 13 dyeing m/c, 2 Rapid dryer (with steam),1 hydro (without steam) 3—Nylon department --- There are 15 dyeing m/c.
- 14. Dye used in department 1—Disperse dye ---(polyester) 2---ACID DYE ---(nylon) 3---Cationic dye --(silkenza) 4---Metal complex dye –(nylon) German dyeing 1. Polyester dyeing 2. Nylon dyeing There is 17m/c. out of17- 13dyeing m/c , 2 hydro and 2 pressing m/c. * in this department 4 types of yarn used such as a. 1* 1200 denier (nylon) 2* 900 denier (nylon) 3* 3600 denier (polyester) ecose 4* 1600 denier (polyester) these type of yarn are called B.C.F yarn.
- 15. DYEING M/C CAPACITY Dyeing cycle (process) For 1600&3600denierpolyester First load the material in vessel then prepare the solution of levelling agent (TOP),accelerating agent (D.I.F),penetrating agent (C.R.I) and defoaming agent (A.R) m/c no. yarn capacity in kg co.name pressure kg/cm2 water capacity no.of spindle A2 200 thies 3.5 to 4 700ltr 14 to16 A3 100 thies 3.5 to 4 1000ltr 8 A4 100 thies 3.5 to 4 1000ltr 8 A5 100 thies 3.5 to 4 1000ltr 8 A6 100 thies 3.5 to 4 1000ltr 8 A7 100 thies 3.5 to 4 1000ltr 8 A8 30 thies 3.5 to 4 30ltr 3 A9 30 thies 3.5 to 4 30ltr 3 B3 800 thies 3.5 to 4 800ltr 39,38,54 B4 800 thies 3.5 to 4 800ltr 39,38,55 B5 600 thies 3.5 to 4 600ltr 32 B6 600 thies 3.5 to 4 600ltr 32 B7 600 thies 3.5 to 4 600ltr 32
- 16. Acidic acid and dyes. solution prepare in the room temperature. Then increase the temperature till 95⁰ c at raising rate 0.5/⁰ c and hold 10 minutes. Again, Increase the temperature 115⁰ c at rate 0.5⁰ c/min and hold 10 minutes. After 10 minute increases the temperature 135⁰ c and hold 40 minutes. After 40 minutes we drain the goods with softener Impreza. if softener use then material is soft. NYLON DYEING CYCLE FOR 1200&900 DENIER First load the material in vessel. Then scoured with scouring agent 20 minute at 110⁰ C temperature. After drain we prepare the solution in room temperature with levelling (lysogen S.E), retarder (Ammonia) and penetrating agent (C.I.R). And color. After preparing the solution we increase the temperature 60⁰ C
- 17. At rate 0.5⁰ C/min and hold 10 minutes. Then again and again increase the temperature same rate 80⁰ C to 107⁰ C. After drain we use the softening agent for smooth and soft touch OLD DYEING DYEING M/C CAPACITY HYDRO M/C
- 18. Hydro extractor or centrifugal extractor use centrifuge technology for manufacturing laundering which is used in Textile Company. Hydro extracting m/c is mainly centrifugal for generating hydropower. The wet substantial is placed in the hydro extracting m/c or centrifugal extracting m/c which has a barrier of metal generally steel. The internal drum of centrifugal extracting m/c switches at high speed thus throwing out the water contained in it. The use of this extractor considerably decreases the energy required to dry any material. It is special types of washing machine. Through our technique apartment hard work, exploit new the leading level, and the national patent. This extractor is used after dyeing machine and before tumble dryer machine. POLYESTER DYEING CYCLE NYLON DYEING
- 19. Mostly nylon dyeing is carried out in hank form, for this purpose we use Fadis m/c. M/C CAPACITY Fadis m/c Co. Name - Solbiate ARNO(VA-ITALY) ☆ This m/c convert package to hank. ☆ There are total 72 m/c,whose capacity 10 spindle , 6 spindle ,and 8 apindle ☆ The conversation of package to hank depend upon m/c speed and yarn quality (denier). The quality of threads is colored in nylon dyeing Micro denier Normal denier 70/68/1 70/24/2 70/68/2 70/24 70/48/2 111/24/2 70/48 111/24 70/24/4 70/24/3 HYDRO TIMING FOR NYLON DYED YARN FOR NORMAL DENIER TIMING 70/24/2 35 mint 70/24 35 mint 111/24/2 35 mint 111/24 35 mint 70/24/2 35 mint 111/24 35 mint 70/24/4 35 mint 70/24/3 35 mint FOR MICRO DENIER TIMING 70/68/1 45 mints
- 20. 70/68/2 45 mints 70/48/2 45 mints 70/48 45 mints DYEING CYCLE Theory Acid dyes are highly water soluble, and have better light fastness than basic dyes. The textile acid dyes are effective for protein fibers such as silk, wool, nylon and modified acrylics. They contain sulphonic acid groups, which are usually present as sodium sulphonate salts. These increase solubility in water, and give the dye molecules a negative charge. In an acidic solution, the -NH2 functionalities of the fibers are protonated to give a positive charge: -NH3+. This charge interacts with the negative dye charge, allowing the formation of ionic interactions. As well as this, Van-der-Waals bonds, dipolar bonds and hydrogen bonds are formed between dye and fiber DYEING LAB
- 21. TESTS AND MACHINSES: - (1)- TEST (A) Shade match (B) Fastness test 1. Washing fastness 2. Rubbing fastness 3. Sublimation fastness 4. Perspiration fastness DYEING M/C CAPACITY METHOD NO. AATCC – 2A 1. Collect a hank of dyed materials of each dark batch as a party required. 2. Add the multi fabric piece [15cm×5cm] 3. Take the 1250ml pot of Laundrometer and add to it 2gpl WOB Detergent I.R. 150:1, 50 steel ball. 4. Introduce both dyed & Multi Fabric in that pot. 5. Start the m/c and set the temp 49°C±2°C and keep hold for 45 minutes. 6. Than dry the sample and observe the fastness on multi fabric and give ratting as per fastness grey scale.
- 22. METHOD NO. ISO105/CO3 1. Collect a hank of dyed materials of each dark batch as party required. 2. Add the multi fabric piece. 3. Take the 250ml pot of loundrometer and add to it 2gpl of soda ash &5gpl of Detergent I.R 50:1 4. Introduce both dyed & multi fabric in that pot. 5. Start the m/c and set the temp 60±2 °C and keep hold for 30 min. 6. Then dry the sample and observe the fastness on Multi Fabric and give rating as per fastness rating table. Rating Fastness Staining on grey yarn 0-1 V. poor Heavy stain 1-2 Poor Considerable stain 2-3 Satisfactory Noticeable stain 3-4 Good Slight stain 4-5 Very good uncertain (2)- MACHINES 1. R&D automated dispenser m/c: - this is fully automatic and gives dyes as we required and we send in put to the m/c it has many pots and use full for talking different dyes and color of different medium as me required 2. (a) Spectrophotometer-1 (b) Spectrophotometer-2 Spectrophotometer is a machine which detects the color ingredients in the sample of fiber or fabric and gives us near amount of color which are in sample and also idea about the color by the application of CCM.
- 23. 4. Hang JIE (rewinder m/c) this is used for rewind the package for dyeing sample 5. Hang JIE (washing m/c) this is used for washing the dyeing pot after the dyeing of sample and also cooled the pot 6. Hang JIE (dyeing m/c) this is used for dyeing the sample by using the metal ball for the generating the pressure and it has a heater which heat the dye pot for two hours. 7. loundrometr-2. this is also use full for the test of washing fastness of material as given above and it is different a little bit from first one because in this temperature will be 45+_2 where as in first one has 60+_2 degree centigrade. 8. Oven -1 this is used for burn out the water and wetting from the package 9. Sample dyeing (AHIBA-01-02) this is used for dyeing the sample of all type may be nylon, polyester, catlon etc. polyester dyed at 135 c, nylon 105c and catlon at 120c 10. VACCUM PUMP: - dispersibility of disperse dye by filter test
- 24. OTHER DYEING M/C: - 11. IR M/C-1 this is dyeing m/c which is used for dyeing and has 6 pot and 50 gr and used only for nylon 12. IR M/C 2: - THIS is also use full for dyeing and has 12 pot and of capacity of pot 5 gm and used for both nylon and polyester dyeing 13.IR M/C 3: - This dyeing m/c is also used full for both type of yarn and have capacity of 12 pot and 5 gm 14. IR M/C4: - THIS is also useful for both type of dyeing and capacity 12pot and of 5 gram and in this Machin we can dyed both type of yarn and and in both form like hank and package 15.IRM/C 5:- this m/c has 5 pot and and each have 5 gram and this is useful for only nylon in hank form 16.IR M/C 6: - THIs m/c has 18 pot and used for nylon and polyester in both the form hank and package 17. IR M/C7: - THIS M/C CAN DYE only the nylon fiber and has 24 pot of 5gram.
- 25. THANKYOU