TEXTILE INTERNSHIP

BSL SUITINGS LTD

Submitted By:
Anushka Khandelwal
Simran Arora
 COMPANY PROFILE

In the days when the idea of manufacturing poly-viscose suiting was a

unique concept in India, the second member of the LNJ Bhilwara Group,
BSL Ltd., was born in the desert state of Rajasthan. The year was 1971
and the town where this happened was Bhilwara.
Over the years, with the belief that there are no shortcuts to excellence, at
BSL we have moved from strength to strength.Today, as a multi-million
dollar company, and having put the Group firmly on the international map
of premium suiting, we are one of the prominent members of the US$ 900
million LNJ Bhilwara Group.
 OBJECTIVES
● To study the organisational structure of an integrated textile mill.
● To study the processes of spinning, weaving & processing of
textile.
● To study the equipments & machineries installed at the textile mill.
● To study the guidelines established for various divisions of textile
manufacturing unit.
● To study the procedure of development of samples.
● To study the various activities of marketing division of the unit.
 PRODUCTS

1. Yarns to Fashion Fabrics

2. BSL Yarns
3. Polyester Wool Blended Suitings
4. Polyester Viscose and Polyester Cotton Blended Suitings
5. Purewool Suitings
6. Readymade Garments
 SPINNING DEPARTMENT
Spinning is the twisting together of drawn-out strands of fibers to form
yarn, and is a major part of the textile industry. The yarn is then used to
create textiles, which are then used to make clothing and many other
products.
 RAW MATERIAL

UNPROCESSED WOOL
 MIXING AND BLENDING

In the blending process, a reproducible

homogenous mixture of different fibres is
produced ,so as to get desired
properties, is the finished product while
improving the functional properties of
product, improving the process
performance and maintaining the
economy of product.
BLOWROOM

Truzschler Blowroom
PASSAGE OF MATERIAL (LAP FEED)
 CARDING

● Individualisation and partial

parallelisation of fibre
● Fibre to fibre separation
● To affect thorough mixing of the Fibre
● Removal of remaining trash of B/R
process
● Conversion of lap or opened fibre into
sliver
 DRAW FRAMES

Breaker Draw Frame:

During this process 8 slivers produced by
carding machine are parallelized to produce
one sliver. The machinery in use for breaker
drawing frame:

● LDO/6 maker —Lakshmi industries

 RING FRAME

1.To impart twist

2.Conversion of roving into
single yarn

COGNETEX RING SPINNER-

used for worsted spinning
 LMW RING SPINNERS

USED FOR SYNTHETIC SPINNING

 AUTOCONER
To remove imperfection of spun yarn and
make big package in the form of cone.

PRERNA TFO
 CHEESE WINDING
To wind two or more threads from cone to cheese without inserting any
twist.

P.S.METLER-FMKS
 DOUBLING
The doubling twist is imparted to yam wound on cheese. There are two
processes of doubling
1. T.F.O — [n this process twisting and winding on cones is done
simultaneously to provide knot free yarns.
Objective:
To impart two twist in one rotation of the spindle.
PRERNA TFO
2. Ring doubling — Here only twist is provided to the parallel wound
yarns. These yarns are the wound in cones at cone winding. At cone
winding the yarn is cleared of defects.
 CONDITIONING
Before packing the yarns produced are subjected to a treatment in the
conditioning room to increase the moisture content of the cone according
to the requirement. It increases the weight of the cone marginally.
 VORTEX SPINNING:THE NEW TECHNOLOGY
Vortex spinning technology is a modified form

of jet spinning which has attracted a lot of

attention because of its advantages

over ring spinning, open end and air-jet spinning.

WEAVING DEPARTMENT
 RAW MATERIAL SECTION
Raw material is stored at the raw material gowdown. Most yarn required
for weaving is produced at spinning section of the BSL limited. Other
suppliers for the raw materials are:
● Reliance industries limited
● Rajasthan spinning and weaving mill
● Banswara Synthex
● Sangam India
 WARPING SECTION
Process flow in warping section:
CREELS → WARPING DRUMS → WARP BEAM
● Machinery used (warping drum & beam)
Model A: Manufacturer- Prashant Gamatex
Model- Lasertronic 1080
 WARPING CREEL
Machinery used — centrally controlled tensioner type{PRASHANT
GAMATEX)

Salient Features
● Quick and simple threading of yarn.
● Continuously rotating tensioners through motor.
● Positive spring loaded centrally controlled tensioners.
● Integrated AIR BLOW—OFF cleaning
Sample warper
● Used mainly for silk
● Auto safety stop
● Software operated
● Tensioning device to avoid loose
yarn
Model- SW-207
Drum circumference - 2 metre
Warping length - 14 — 280 metres
Production information:
Time taken to prepare 1 drum — 2 to 2.5 hours
Time taken to transfer the warp yarns from drum to beam — 40 mins.
 DRAWING-IN SECTION
● Once the beam is prepared in the warping section, it comes to the
drawing in section.
● The beam is kept on the beam stand and a person having complete
details of the design, draft and peg plan does the drawing in. Here one
end of the warp yarn is passed through the heald frame, drop pins and
reeds.
 WEAVING SECTION
Weaving is a textile craft in which two distinct sets of yarns or threads are
interlaced to form a fabric or cloth. The threads which run lengthways are
called the warp and the threads which run across from side to side are the
weft or filling.
 RAPIER LOOMS
Weft insertion mechanism:

● The key component of the machine is the set of rapier. There are two
set of rapiers in the machine having positive motion. The rapier takes
the weft yarn from the supply package.
● After picking it carries the yarn forward on a guide at the centre of the
machine another rapier receives the yarn can carry it.
● It is the cut end of the weft which is transferred {end or tip transfer).
The yarn clamps in the rapier heads is positively actuated at the
transfer (in addition to any positive actuation at weft pick—up and
release}.
 PROJECTILE LOOM
● The key to the machine is the gripper projectile. In the picking
position it takes over the thread drawn from the supply package.
After picking, it carries the thread into the shed and is braked
upon entering the receiving unit.

● The tucking needles then tuck in the thread ends, forming firm
tucked—in selvedge.
● Finally, the projectiles is ejected from the receiving unit and taken
back to the picking position by conveyor.
● The projectiles are accelerated
by a torsion bar. This is
tensioned. storing the energy
needed for a flight through the
shed. Following the release of
a lock, it accelerates the
projectile smoothly and
resumes its initial position at
once.
● The flight velocity of the
projectile is determined by the
torsion angle of the bar and
can therefore be matched.
 INSPECTION
Grey checking section
Grading of fabric on the basis of defect they contain are as follows:
● 0 —5 defects — A grade
● 6—12 defects — B grade
● 13 — 23 defects — C grade
● 24 and above defects — D grade
 PROCESSING
The department is divided into

● Tops & Fibre dyeing Department,

● Fabric dyeing & Processing Department,
● Silk dyeing
 POLYESTER VISCOSE FIBRE DYED FABRIC
Scouring: Scouring is the process of removal of natural oil substances
like waxes, fats and pectin as well as added impurities like lubricating oil,
dust/dirt and residual starch in the cotton materials .
MACHINERIES IN USES
● Pacific jigger machine
● Jigger
● Jumbo Jigger
● Relax Scouring Machine:
 DYEING MACHINES:
At Bhilwara processors limit following two types of dyeing machines are
used:

1. Beam dyeing machine

2. Jet dyeing machine
 BEAM DYEING MACHINE
In beam dyeing machine the beam is created
first by wounding the full length fabric on a
perforated beam. After creating the beam the
beam is inserted into the beam dyeing machine.
In this type of dyeing the fabric is kept
stationary and the dye liquor is circulated. This
type of dyeing have good colour fastness.
 JET DYEING MACHINE
Jet dyeing is a very efficient contact between the dye liquor and fabric is
obtained by both are in constant movement. This result improved level of
dyeing shorter dyeing time. Fabric is circulated through the dye bath in
rope form. The movement of the fabric occurs by circulating the dye—
liquor through a venture jet.
 HEAT SETTING
•A thermal process taking place mostly in either a steam atmosphere or a
dry heat environment.

•The process gives fabric dimensional stability

•Other desirable attributes like higher volume, wrinkle resistance or

temperature resistance.

•Used to improve attributes for subsequent processes.

 SINGEING
● Fuzzy and protruding fibres are removed by
burning them off.
● The main purpose is to get a clear and
smooth surface.
● Usually performed on both sides of the fabric

Machinery in use: Manufacturer – OSTOFF singe

● Specifications: Double Jet Burner Automatic

Flame width adjustment Four singeing
positions, centring devices.
● Sequencing unit Speed – 100 m/ min
● Flame intensity can also be controlled.
 KIER DECATIZING
Model - PF – 2000 Manufacturer – TMT, Italy

Specifications:

1. Working width: 1700 meters

2. decatizing cylinders with a diameter of 460 mm

3. Two beams have wrapper above them and one of them is vacant.

4. Exit with roll device.Length of fabric rolled at once 800m.

 CALENDERING
“A finish process given to the fabric to give shine and lusture to the fabric. It
is done to enhance the aesthetic appeal of the fabric.”

Machinery in use: Model - 3 bowl calendar machine.

SUPER FINISHING MACHINES

•It has the same function as that of the Calendering machine i.e. to enhance
the physical finishes of the fabric, but the finish produced by this machine is
superior quality to that of the Calendering machine

.• It is generally done on expensive fabric or on the specification of the

buyer.
 DRYING RANGE
Drying range is used to dry the
fabric after scouring, dyeing and
several such processes. The
machine contains a tank where
washing of the fabric takes place
prior to dry on the seam heated
drums.

Machinery in use: Manufacturer:

yammuna textiles machinery.
 HT/HP DYEING MACHINE
HT/HP dyeing machine is used for following processes:

Fibre Dyeing

Tops Dyeing

Yarn dyeing

Wool Scouring.

Dyeing carriers are classified into 3 sections according to their weights: 1

kg, 1.5 kg and 2kg carriers are used for fibre and tops dyeing depending
upon the requirement of the quantity to be dyed
 DESIGN DEVELOPMENT AND MARKETING
● The weaving is done on the looms which uses Shuttle as the weft
carrier.
● The blankets produced on power looms are 3 1.6 metre in length and
35 inches in width. Each blanket comprises of 56 designs.
● The blankets are then sent to the customers. The designs approved
by the customers are then sent to various processing departments for
the mass production.
● BSL sampling section has 6 Shuttle looms.
 APPOINTMENT OF AGENT
Activities {Domestic Sector}
● Field Staff visits market and locate potential agents.
● Asst. General Manager/Marketing Manager/Sales Manager receives
communication from interested agent.
Activities {Exports}
● The management visits a fair or exhibition to identify the potential
agents/customers.
● The samples are sent with required quotation to the interested
parties.
● Their Response is received.
● If positive, then they are appointed as customers.
 PRODUCTION ACTIVITIES AND CO-ORDINATION :
Activities {Domestic sector)
1. Production advice is prepared according to the accepted and
anticipated order.
2. The advice is sent to development and commercial department.

Activities {Exports}

3. Consolidation of orders according to the delivery schedule.

4. Finalisation of shipping quality per month.
5. Preparation of production programme.
 EXPORT DEPARTMENT
● BSL exports its finished products in approximately 55 countries. The
major regions in the world where BSL exports are the Latin America
{ Peru, Equador. Chile, etc)1 Middle East (Egypt, Saudi Arabia), South
Asia (Vietnam, Thailand, Indonesia] and Europe (Spain, Germany). It
has been in the export business since 1982—88.
● The Export Department accounts for about 60% of the annual turnover
of the company which is around 250 crores.
EFFLUENT TREATMENT PLANT
 LEARNING OUTCOME

● Different detailed procedures of yarn to fibre process

● Procedure of conversion of fibres to fabric extreme care should be
taken and production process needs to be carefully monitored as
even a slight variation may cause huge loss to the organisation.
● Quality is the major key in the industry
 BIBLIOGRAPHY
· https://www.bslltd.com/

· TEXTILES AND FASHION BY ROSE SINCLAIR

· FIBRE TO FABRIC BY BERNARD P. CORDMAN

· https://textilelearner.blogspot.com/