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[Audio] TABLE OF CONTENTS Sr.No. Title Page no. 1 INTRODUCTION 2 PEARLS OF WISDOM 3 FLWO CHART OF DEPARTMENT 4 DESGIN AND DEVLOPMENT 5 RM/ EXECISE & STORE 6 CCP ( CENTEALISED PRODUTION PLANNING & CONTROL) 7 AIR TEXTURING 8 YARN DYEING 9 WARPING 10 WEAVING 11 WARP KINTTING 12 CIRCULAR KINTTING 13 SQC( STATICAL QULAITY CONTROL) 14 FABRIC DYING 15 PROCESSING 16 LAMINATION 17 ENGGINEERING 18 QA INSPECTION 19 IT &HR.

About the GROUP. Ever since the great visionary and industrialist doyen Mr. L. N. Jhunjhunwala sowed the seeds in a textile mill at Bhilwara in Rajasthan in 1961, the LNJ Bhilwara Group has borne rich fruits to emerge as one of India’s leading corporate giants..

ABOUT BMD. BMD is proud to be the largest manufacturer of automotive furnishing fabric in India. BMD’s products are used as fabric for seatings and door trims for automobiles. Special fabrics manufactured by BMD are also used in aircrafts, ships and auditoriums..

COMMITMENT TO EXCELLENCE. PEARLS OF WISDOM. To me, LNJ Bhilwara Group is not a business house, I see it as an institution that is committed to seeking excellence..

GLOBAL COMPITITIVENESS. We Must Strive for increasing benchmark levels in excellence at industrial level to imbibe the ongoing process of global presence. World class standards demands a collaborative effort by people with diverse skills. Technology was the greatest change agent in the 20th Century and is going to play an important role in this Millennium. Let us all keep fully abreast of changes and create a corporate challenge for performance and excellence..

DESIGN AND DEVLOPMENT RM/ EXECISE& STORE AIR TEXTURING YARN DYEING DIRECT & SECTIONAL WARPING WEAVING WARP KINNTING CIRCULAR KNITTING SQC (SATISTICAL QUALITY CONTROL) CCP(CENTRALISED PRODUCTIION PLANNING &CONTROL FABRIC DYEING AND PROCESSING LAMINATIONN ENGINEERING QA INSPECTION IT & HR.

DESIGN AND DEVELOPMENT. OEM OEM - DESGINER TRIM – MAKER DESGINER DEVELOPMENT PRODUCTION/CPP CDISPATCY.

Average count range-750-600 Denier. RM/EXCISE & STORE.

Width 1430-1770 mm. Scrim GSM 30-50. Foam Suppliers M/S Plama Pur dd M/S Sheela Foam Pvt ltd. M/S Prime Comfort Product Pvt ltd. Dyes and Chemical Suppliers M/S Huntsman International India Pvt ltd. M/S Aechroma Management LLC M/S arugus (Shanghai) Textile Auxiiaries co. Ltd. Scrims Suppliers M/s Nagase India (P) ltd. M/s Nat Royal Ind (P) ltd. M/s Swastik Embroideries Pvt ltd..

Two yarn store 1st with capacity of 300 tons 2 nd with capacity of 350 tons.

CPPC (Centralised Production Planning and Control).

Objectives of Centralised Production Planning and Control:.

ATY (AIR TEXTURISING YARN). Air-jet texturing process is a mechanical method,where cold air stream is used to produce bulked yarns of low extensibility. Air textured yarn resemble spun yarn in their appearance and their physical characteristics..

ATY MACHINES. S. No. MACHINE SPINDLES SPEED DRAW Ratio 1. STAHILE 48 350 50-75 2. DP2T 60 350 50-75 3. TW2T 40 450-500 50-75.

STAHLE. YARN COUNT PKG WT. (KGS) LOT NO. 600 Black d/tex 2.50 3238 400 Black d/tex 2.40 3239 600 Green d/tex 2.80 3240 2100 Black , White, d/tex 2.90 0100190.

Pre- winding Company Name –Alidhar Machine Speed – 200 – 800 Rpm Spindle – 48 Auto-Clave Old Autoclave Spindle – 180 Cycle Time – 25 Min & 1 Hour For Complete Process Temperature – 130’C New Auto-Clave Spindle – 120 Temperature -130’C Cycle Time – 50 Min & 1.5 Hour For Complete Process.

Winding SSM MACHINE (SCHAFLER SCHWELTER METTELER) ➢ 60 Spindle ➢ Tube length – 290mm Twisting Machine (TFO) Company Name – WeaveTech Doffing Time – 24 Hours Spindle – 140.

YARN DYEING. Yarn dyeing is a special type of dyeing process. Yarn can dye in two forms, package or hank form..

Total YARN Dyeing Machine. Machine Capacity Water Req. For Full Batch (Ltr) Half Batch (Ltr) YD 1000Kg 6000 3000 SD 185Kg 1000 500 MD 38Kg 250 150 AD 10Kg 45 35 BD 10Kg 45 35 DD 10Kg 45 35.

HYDRO-EXTRACTOR. 1.Galvanin Hydro Extractor Product loading – 48Kg (Max.) Drum Speed – 1250 RPM.

Process Flow chart for Polyester Dyeing. 2000 Ltrs. Water Hot water (80 ºC /10 min.) Drain 2000kg Water + Chemical Dye & Colour added Drain Dyeing at 135 ºC for 60 min. RC (80 ºC for 20 min) Drain RC (80 ºC for 20 min) Drain Acetic Acid (60 ºC for 20 min.) Drain Finishing (70 ºC for 20 min) Hydro(5-10 min) Drying (115 ºC for 2-3 hours) Inspection packing.

Warping. Type of Warping Direct Warping Sectional Warping.

Machine Manufacture Creel Capacity Speed 1 KARL MAYER 616 700 2 KARL MAYER 626 700 3 KARL MAYER 640 750 4 KARL MAYER 640 750 5 KARL MAYER 624 800.

SECTIONAL WARPING. Sectional warping denotes the transference of yarns from single-end yarn packaged, firstly to a drum then the yarn sheet is transferred from the drum onto the weaver’s beam. • Beam produce in sectional warping use in weaving..

TOTAL NO. OF MACHINES – 4 MANUFACTURE – • PRASHANT GAMMATEX (1M/C) • BENNINGER (3 M/C).

WEAVING. Weaving Is the process of Interlacement of Warp and Weft to make A woven structure..

Total no. Working Machines – 57 Total no. Dead Machines – 10 Total no. Running Machines • Date 14-09-2021 – 29 machines • Date 15-09-2021 – 37 machines.

Types of yarn used: • ATY (Used in weft) • APY (Purchased yarns DTY, FDY) Shade: Milange , Solid Machine Specification and Production • RPM-400 • Efficiency-100% • EPC-66 • Ends-11748 • Reed Width-178cm • Reed Count-16.5/4 • Production-52.23m in 8hrs • Quality No.-30383A.

WARP KNITTING Warp Knitting Is the Family of Knitting Methods in Which the Yarn Zigzags Along the Length of The Fabric That Is Following Adjacent Columns or Wales of Knitting Rather Than a Single Row or Course. Total Number of Machines-16 Running Machines-15 Manufacturer-KARL MAYER FAULTS Pin Hole Yarn tight Beam loose Double end Stop line Yarn breakage Total production per month – 15000 meter.

Machine No. Machine Type Bars Gauge Width(inch) Spacing(mm) Running Speed (Rpm) 1 HKS-4P EBC 4 28 137 0.9071 500-680 2 HKS-4P 4 28 170 0.9071 900 3 SPACER 6 22 138 1.1545 500 4 HKS-4P 4 28 170 0.9071 800 5 HKS-4P 4 28 136 0.9071 770 6 HKS-4P 4 28 170 0.9071 800 7 HKS-4P 4 28 136 0.9071 600 8 HKS-4P 4 28 136 0.9071 700 9 HKS-3M 3 28 180 0.9071 1885 10 HKS-3M 3 28 180 0.9071 2000 11 HKS-3M 3 28 180 0.9071 2000 12 HKS-3M 3 28 180 0.9071 2015 13 HKS-4P 4 28 218 0.9071 2007 14 HKS-3M 3 28 218 0.9071 2000 15 HKS-3M 3 28 218 0.9071 1600.

CIRCULAR KNITTING Circular knitting is a form of knitting that creates a seamless tube. Work in the round is begun by casting on stitches as for flat knitting but then joining the ends of that rows of stitches to form a circle. Knitting is worked in rounds which forms the tube by winding around in a helix. Total no. of machines – 18 • Classification 1. Based on manufactures • MAYER & CIE(Germany) – 8 MACHINES • FUKUHARA(Japan) – 10 MACHINES 2. Based on jersey • Single Jersey – 6 • Double Jersey - 12 3. Based on feeders • 4 Machines – 60 feeders • 4 Machines – 42 feeders • 3 Machines – 84 feeders • 1 Machines – 56 feeders • 6 Machines – 60 feeders.

Table Description automatically generated. CIRCULAR KNITTING MACHINE.

TOTAL PRODUCTION – 5000 METER PER DAY TOTAL WASTE% - 4% Bottom waste – 2.5% Grey fabric waste – 1% Finish fabric sample waste – 0.5% YARN REALISATION Yarn issued – 49953 kg Fabric produced – 46516 kg Internal Rejection – 4-5 meters per sample Bulk Produced Quality 60009J 60007E Faults In Circular Knitted fabrics Barre - Horizontal bands following courses around the tube. Vertical Lines - Following the Wales up the length of the tube-usually mechanical. Holes - Yarn or mechanical in nature. Stitch Runs - Random or continuous..

SQC (STATISTICAL QUALITY CONTROL). Sr. No. Test Item Instrument name Instrument Maker Unit Sample Size(mm)/ Load (Kg) 1 Mass Per Unit Area Weighing Balance Atco Balance, India gm/m² 113 2 Total Thickness (With Lamination and Scrim) Thickness Gauge Baker, India Mm 180*180 3 Tensile Strength Testometric Tensile Tester (UTM) Testometric Micro 350 CT England N/50mm 250*50 4 Elongation Change Testometric Tensile Tester (UTM) Testometric Micro 350 CT England % 250*50 5 Tear Strength (Trapezoidal Method) Testometric Tensile Tester (UTM) Testometric Micro 350 CT England N 250*50 6 Constant Load Elongation Change Stretch And Set Tester Swastik, India % 250*80/ 10Kg/ 10 Minutes 7 Residual Strain Rate Stretch And Set Tester Swastik, India % 250*80/ 10Kg/ 10 Minutes 8 Seam Strength Testometric Tensile Testometric Micro 350 CT England N/25.4mm 200*100 9 Seam Fatigue Seam Hole Measure Seam Fatigue Tester Daiel Kagakoo Seiki Japan mm 200*100/ 3Kg Slipping Seam Measure Slippage.

10 Bending Resistance Bending Length Tester Innoiab – India mm 200*25 11 Crumpling Resistance Crease Flex Daiel Kagakoo Seiki Japan Grade 150*25/ 1 Kg 12 Taber Abrasion Testing 1; CS-10 Taber Abrasion Tester Taber Industries, USA Grade 131/ 500gm 13 Taber Abrasion Testing 2; H-22 14 Flat Abrasion Testing; Velcro Surface Abrasion Tester Daiel Kagakoo Seiki Japan Grade 300*68/ 1Kg 15 Pilling Pilling Tester ICI-Paramount Instruments, India Grade 120*100 16 Color Fastness to Light Dir e c t Atlas CI-4000 Weather-O-Meter Atlas, UK CI 4000 Grade 125*45 In Bag 17 Color Fastness to Friction (Dry Cloth) Schap’s Gaksusin Tester Schap Specially Machine. INC USA Grade - 18 Color Fastness to Friction (Wet Cloth) Grade - 19 Snag Mag Snag Tester Yasuda, Japan Grade 330*205/ 135gm 20 Variable Load Elong a tion Change 5N Testometric Tensile Tester (UTM) Testometric Micro 350 CT England % 250*50 10N 25N 50N 100N 21 Inflammibility SES N 3245 Horizontal Flammability Tester Atlas India Mm/Min 356*100 22 Dust Adhesion Property - - Grade 113 23 Dust Removability Property - - Grade 113.

24 Dirt Adhesion Property - - Grade 100*100 25 Dirt Removability Property - - Grade 100*100 26 Coefficient Of Surface Sheet Friction Testometric Tensile Tester (UTM) Testometric Micro 350 CT England - 250*100 27 Laminated Foam Peeling Strength Testometric Tensile Tester (UTM) Testometric Micro 350 Ct England N/25.4mm 150*25 28 Lightness Data Colour Spectro Photometer Data Colour Asia Pecific Ltd - - 29 Air Permeability Air Permeability Tester Daiel Kagakoo Seiki Japan Cm³/Cm²/Second 180*180 30 Water Mark - - - 297*210 31 Friction Charged Electrostatic Property - - V - 32 Seam Breakage After Sewing Stitching Machine Juki, Japan % 500*100 33 Heat Shrinkage Hot Air Oven Presto Standard Pvt Ltd, India % - 34 Water Repellent Test Water Repellent Spray Tester Paramount Instruments, India Point 297*210 35 Corrosiveness Test SES N 3253 µm - 36 Fabric Bending Evaluation Bending Evaluation Tester In House % 100*100 37 Skew In House Mm - 38 Fabric Hard Feel Subjective N - 39 Monofilaments Yarns Pull Out Testometric Tensile Tester (UTM) Testometric Micro 350 CT England N 250*50 40 ∆E Value of Colour Data Colour Spectro Photometer Data Colour Asia Specific LTD - -.

TESTING FOR YARN. SR. NO. PARAMTERS INSTRUMENT 1 Count Wrap reel 2 TPI/TPM/Punches per meter Twist tester 3 No. of filaments Visually 4 Moisture % Hot air oven 5 Breaking strength (N) Testometric 6 Elongation at break % Testometric 7 Tenacity (CN/Tex) Testometric 8 Boiling water shrinkage Pressure cooker 9 Heat aging at 150ºc 3min. Hot air oven 10 Heat aging at 150ºc 15min. Hot air oven 11 Heat aging at 180ºc 3min. Hot air oven 12 Heat aging at 180ºc 15min. Hot air oven 13 Package size (cm) Measuring tape 14 Package weight (kg) Weighting scale 15 Package density (gm/cm³) Manually 16 Oil content % Oil content instrument 17 Hard/ soft punches Manually 18 Snarling per meter Manually 19 Tube type Manually 20 Ply Twist tester.

TESTING FOR FOAM. Sr. No. PARAMETERS INSTRUMENT 1 Color Color matching cabinet 2 Weight (GSM) GSM Cutter 3 Thickness (mm) Thickness Gauge 4 Width (mm) Measuring Scale 5 Density (gm/m³) Manually 6 No. of cells (cells per inch) Pick Glass 7 Breaking strength (N) Length Testometric Width 8 Elongation at break (%) Length Testometric Width 9 Compression set at 50% deformation Hot air Oven 10 Flammability(mm/min.) Length Flammability tester Width 11 CFD at 70% Testometric 12 Impact Resilience (%) Impact tester.

TESTING FOR SCRIM. Sr. No. PARAMETERS INSTRUMENTS 1. Width (cm) Measuring scale 2. Thickness (mm) Thickness gauge 3. Weight (GSM) GSM Cutter 4. Wales per inch Pick Glass 5. Coarses per inch Pick Glass 6. Breaking strength (N) L e ngth Testometric W idth 7. Elongation at break (%) L e ngth Testometric W idth 8. Elongation % at 25 N L e ngth Testometric W idth 9. Elongation % at 100 N L e ngth Testometric W idth 10. Stretch % L e ngth Stretch set apparatus W idth.

SPECIFICATIONS & DETAILS Total time for process = 6.5 – 7 hours Total production = 12000-15000 kgs/day Total machines for fabric dyeing in BMD = 5 Operational dyeing machine = 4 DYEING MACHINE NAME JET DYEING MACHINES-3 JET 1 (COMPANY NAME – THIES) JET 2 (COMPANY NAME – THIES) NEW FONG’S (COMPANY NAME – FONGS) SOFT FLOW MACHINES-2 LUFT ROTO (COMPANY NAME–THIES) OLD FONG’S (COMPANY NAME –FONGS).

MACHINE SPECIFICATIONS. LUFT - ROTO. PARAMETERS VALUE Blower (%) 75-85 Pump (%) 75-85 Speed(rpm) 200-300 Water(liters) 2100 Capacity Of Material (Kgs) 350.

JET – 1. PARAMETERS VALUE Nozzle 75,80,85,99 Pump (%) 75,80,85.

NEW FONGS. PARAMETERS VALUE Nozzle 00 Pressure 80-85 Speed(rpm) 300 Water(liters) 9000 Capacity Of Material (Kgs) 1200.

5200 Ltrs. Water. Dyeing process for polyester is almost same as yarn dyeing except difference in water and chemical capacity.

TESTING AFTER FABRIC DYEING TEST FOR RUBBING FASTNESS 1. CROCKMETER Sample size – 25*5 cm Rubbing cloth to be mounted on metal nut which is to be rubbed against sample = 5*5 cm (made of cotton) Force = 9N.

PROCESSING DEPARTMENT. TOTAL MACHINES OF STENTER = 3 STENTER -1 Company Name = Bruckner Chamber Size = 5 Heat Setting = 180’c Machine Capacity = 1600kw Speed = 18-45 M/Pm Only Flame-Retardant Finishes Are Done Here.

Mechanical Finishing. We Have 3 Embossing Rollers.

BMD HAVE 3 SHEARING & 2 RAISING MACHINES Raising Machines Raising is the process of permanent mechanical finishing process that raises the surface fibers of a fabric by means of passage over rapidly revolving cylinders covered with metal points. Two main parts main cylinders (cp) & worker (p) rollers are used for napping..

Roller Gap- Foam*0.66 Running speed- 20-22m/min Automatic cooling- 2-3 hours LPG gas is used for burning Flame temperature- 800-1000°C Foam is burned around 1 to 1.2 mm for all qualities.

ENGINEERING DEPARTMENT. BOILER – Boiler is an enclosed vessel in which water is heated to produce steam. The steam is then circulated through a piping system, to transfer heat for fabric and yarn dyeing..