A

TECHNICAL REPORT

ON

STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

UNDERTAKEN AT

WOOLLEN AND SYNTHETIC TEXTILE MANUFACTURING INDUSTRY, OBA-

AKRAN, IKEJA, LAGOS STATE.

BY

OLUMOMI DAMILOLA ELIZABETH

ICH/19/071

SUBMITTED TO

THE DEPARTMENT OF CHEMICAL SCIENCES, OLUSEGUN AGAGU UNIVERSITY

OF SCIENCE AND TECHNOLOGY, OKITIPUPA, ONDO STATE, NIGERIA.

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF

BACHELOR OF TECHNOLOGY (B.TECH) IN INDUSTRIAL CHEMISTRY

NOVEMBER, 2023.

1
 DECLARATION
I, OLUMOMI DAMILOLA ELIZABETH, hereby declare that this report was written by me
and is a record of all activities carried out during the SIWES period. All sources of information
are clearly acknowledge by means of references.

..............................................

Signature of student

..............................................

Date

2
 CERTIFICATION
I, certify that the activities reported in this SIWES report were carried out by OLUMOMI
DAMILOLA ELIZABETH to be submitted to the Department of Chemical Sciences, having
met the standard as required by the institution and approved as to contents and styled by:

………………

SIWES Supervisor Sign/Date

………………

Departmental Siwes Coordinator Sign/Date

DR T.F EDIAGBONYA ………………

H.O.D Chemical Science Sign/Date

3
 DEDICATION
My gratitude goes to GOD ALMIGHTY for His mercies, protection, and direction and also good
health continual guidance over me throughout the Industrial Training program.

I dedicate this technical report to my parents and my siblings who have always supported and
encouraged me in my studies and all my endeavors. Without their love, support and guidance, I
would not have been able to complete this industrial training.

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 ACKNOWLEDGEMENT
I would like to express my gratitude to WOOLLEN AND SYNTHETIC TEXTILE
MANUFACTURING INDUSTRY, OBA-AKRAN, IKEJA, and LAGOS STATE. , for
providing me with the opportunity to complete my industrial training at their organization. I am
deeply grateful to the management, head of department and staffs who welcomed and supported
me throughout my time there.

I would also like to thank my industrial tutor, MR UCHE, for their guidance and mentorship.
Their patience and expertise were invaluable as I learned and grew professionally.

Finally, I would like to thank my friends and family for their support and encouragement
throughout my studies and training. Their belief in me has been a constant source of motivation
and strength for me throughout this program.

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 ABSTRACT
This report outlines the Student Industrial Work Experience Scheme (SIWES) undertaken
within the woolen and synthetic textile manufacturing industry. The primary objective of the
internship was to provide students with practical exposure to industry practices, processes, and
challenges within textile production. During the internship, students were involved in various
stages of production, including fiber preparation, yarn spinning, weaving, dyeing, and finishing,
as well as learning about quality control, machinery maintenance, and sustainable production
techniques. The experience allowed students to bridge the gap between academic knowledge and
real-world applications, gaining valuable insights into the operational dynamics of textile
manufacturing, technological innovations, and environmental considerations. The report
concludes with a reflection on the skills developed and the industry's role in shaping future
textile engineers.

Frequently used terminologies:

Fiber: The raw material used to create yarn, which can be natural (such as wool or cotton) or
synthetic (such as polyester or nylon).

Spinning: The process of turning fibers into yarn or thread through twisting or drawing.

Yarn: A continuous strand of fibers, which can be twisted or plied, used for weaving or knitting
into fabric.

Weaving: The process of interlacing yarns in a particular pattern to form fabric.

Knitting: A process similar to weaving but involves creating fabric by interlocking loops of
yarn with needles.

Dyeing: The process of adding color to fibers or fabrics using different chemical methods.

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 TABLE OF CONTENTS

CONTENTS
page
DECLARATION.............................................................................................................................2
CERTIFICATION...........................................................................................................................3
DEDICATION.................................................................................................................................4
ACKNOWLEDGEMENT...............................................................................................................5
ABSTRACT....................................................................................................................................6
TABLE OF CONTENTS................................................................................................................7
CHAPTER ONE............................................................................................................................10
INTRODUCTION.........................................................................................................................10
1.1 BRIEF OVERVIEW OF SIWES......................................................................................10
1.2 OBJECTIVES OF SIWES...................................................................................................10
1.2.1 ROLE OF ITF.............................................................................................................11
1.2.2 ROLE OF EMPLOYERS...............................................................................................11
1.2.3 ROLE OF UNIVERSITIES............................................................................................11
1.2.4 ROLE OF STUDENTS...................................................................................................12
1.2.5 SIWES GUIDELINES......................................................................................................12
1.2.6 BENEFITS OF SIWES.....................................................................................................12
CHAPTER 2..................................................................................................................................14
WOOLLEN AND SYNTHETIC TEXTILE MANUFACTURING INDUSTRY, OBA-AKRAN,
IKEJA, and LAGOS STATE.........................................................................................................14
2.0 COMPANY PROFILE.....................................................................................................14
HISTORY OF ORGANIZATION.............................................................................................14
2.1 ORGANISATION CHART OF WOOLLEN AND SYNTHETIC TEXTILE................15
MANUFACTURING INDUSTRY, OBA-AKRAN, IKEJA, and LAGOS STATE.............15
2.2 MAJOR FUNCTIONS OF MAJOR DEPARTMENTS..................................................15
2.3 MISSION STATEMENT.................................................................................................19
2.4 CORE VALUES...............................................................................................................19

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CHAPTER 3..................................................................................................................................21
INDUSTRIAL EXPERIENCE......................................................................................................21
3.1 JOBS DONE/EXPERIENCE GAINED..............................................................................21
Personal Protective Equipment (PPE)....................................................................................21
Machine Safety.......................................................................................................................22
Fire Safety..............................................................................................................................22
Chemical Handling and Safety...............................................................................................22
Housekeeping and Maintenance.............................................................................................23
Emergency Response and First Aid.......................................................................................23
Emergency Response and First Aid.......................................................................................23
Electrical Safety.....................................................................................................................24
3.3 INTRODUCTION TO WOOLLEN AND SYNTHETIC TEXTILE
MANUFACTURING.............................................................................................................24
3.3.1 OVERVIEW OF WOOLLEN AND SYNTHETIC TEXTILE MANUFACTURING 24
WOOLEN TEXTILE MANUFACTURING.........................................................................25
SYNTHETIC TEXTILE MANUFACTURING....................................................................26
TRENDS AND CHALLENGES IN WOOLEN AND SYNTHETIC TEXTILE
MANUFACTURING.............................................................................................................28
3.4 INSTRUMENTATION/EQUIPMENT UTILIZED DURING SIWES...........................29
3.5 PRODUCTION PROCESS IN THE TEXTILE INDUSTRY.........................................37
1. Fiber Production and Preparation...................................................................................37
2. Fabric Manufacturing.........................................................................................................38
3. Dyeing and Printing............................................................................................................39
4. Garment Manufacturing.....................................................................................................40
5. Packaging and Distribution................................................................................................41
3.5.1 FLOWCHART SHOWING THE PRODUCTION PROCESS AT WOOLLEN AND
SYNTHETIC TEXTILE MANUFACTURING INDUSTRY, OBA-AKRAN, IKEJA,
LAGOS STATE.....................................................................................................................42
3.6 DETAILED/ACTUAL WORKDONE, SKILLS AND KNOWLEDGE ACQUIRED...48
Production and Manufacturing Process..................................................................................48
2. Quality Control and Testing...............................................................................................50
3. Machinery and Technology................................................................................................51

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 4. Design and Innovation........................................................................................................52
CHAPTER FOUR.........................................................................................................................54
SUMMARY, RECOMMENDATION AND CONCLUSION......................................................54
PROBLEMS ENCOUNTERED AND POSSIBLE SOLUTIONS........................................54
EXPERIENCE GAINED...............................................................................................................54
RECOMMENDATION.............................................................................................................56
CONCLUSION......................................................................................................................56
REFERENCES..............................................................................................................................57

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 CHAPTER ONE

INTRODUCTION
1.1 BRIEF OVERVIEW OF SIWES
SIWES was established by ITF in 1973 to solve the problem of lack of adequate practical skills
preparatory for employment in industries by Nigerian graduates of tertiary institutions. SIWES
was established by the ITF as one of its programs. It was designed to give Nigeria students
undertaking a study in occupationally related courses in higher institutions to experience that
would supplement their theoretical learning in order to solve the problem of lack of adequate
practical skills preparatory for employment in industries by the Nigeria tertiary institutions.

The scheme exposes students to industry based skills necessary for smooth transition from the
classroom to the world of work. It affords students of tertiary institutions the opportunity of
being familiarized and exposed to the needed experience in handling machinery and equipment
which are usually not available in the education institutions.

Participation in SIWES has become a necessary precondition for the award of diploma and
degree certificates in specific disciplines in most institutions of higher learning in the country, in
accordance with the education policy of the government.

• Operators: The ITF, the coordinating agencies [NUC,NCCE,NBTE], employers of labor and
the institutions

• Funding: The Federal Government of Nigeria

• Environmental, Science, Education, Medical Sciences and Pure Applied Sciences

• Duration: Four months for polytechnics and College of Education and six months for the
Universities

1.2 OBJECTIVES OF SIWES

Specifically, the objectives of the Students Industrial Work Experience Scheme (SIWES) are to:

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• Bridge the gap between theoretical knowledge acquired in classes and technical knowledge in
industries by providing students the opportunity to apply their educational knowledge in real
work situations.

• Provide an avenue for students in institutions of higher learning to acquire industrial skills and
experience in their course of study.

• Prepare students for the industrial work situation they are to meet after graduation.

• Expose students to work methods and techniques in handling equipment and machinery that
may not be available in their institutions.

• Make the transition from school to the world of work easier, and enhance students’ contacts for
later job placement.

• Enlist and strengthen employers, involvement in the entire educational process and prepare
students for employment in Industry and Commerce.

1.2.1 ROLE OF ITF

● Formulate policies and guidelines on SIWES for distribution to all the SIWES participating
bodies.

● Organize orientation programs for students prior to attachment.

● Provide information on companies for attachment and assist in industrial placement of

students.

1.2.2 ROLE OF EMPLOYERS

● Accept students and assign them to relevant on-the-job training..

● Provide tailor-made training programs for the students.

● Attach experienced staff to students for effective training and supervision.

1.2.3 ROLE OF UNIVERSITIES

• Appoint SIWES coordinator in schools

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• Prepare and submit Masters and placement lists to the respective coordinating agency and ITF

• Place students on attachment with employers

• Organise orientation programmes for students to prepare them for industrial training

1.2.4 ROLE OF STUDENTS

• Comply with the employer’s rules and regulations.

• Keep proper records of training activities and other assignments in the logbook.

• Arrange their own accommodation during the period of attachment.

• Submit Log Books, Reports and other documents related to SIWES as required by their
institution at the end of the training period.

1.2.5 SIWES GUIDELINES

• Provide experience which is in line with the student course of study.

• Use various facilities and equipment appropriate for the various works.

• Provide satisfactory working environment.

• Provide supervisors from the employer.

• Provide opportunity to gain experience in various ways.

• Give feed back to the institution.

1.2.6 BENEFITS OF SIWES

There are many benefits derived from SIWES program some of which are as follows:

• The successful operations of the SIWES program will provide an Opportunity for the
government to reduce the importation of expatriate, Engineers, technologist and other
professional.

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• It provides the opportunity for students to be in direct contact with junior, Intermediate and
senior professional staff in the industry.

• The scheme provides opportunity for the industries to evaluate the Prospective employees and
give healthy feedback to the institution.

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 CHAPTER 2

WOOLLEN AND SYNTHETIC TEXTILE MANUFACTURING INDUSTRY, OBA-

AKRAN, IKEJA, and LAGOS STATE
Woolen and Synthetic Textile Manufacturing Industry, Oba-akran, Ikeja, and Lagos State is a
key sector in the global textile market, specializing in the production of fabrics from both natural
and synthetic fibers. The woolen segment focuses on the production of high-quality fabrics
derived from natural wool, which are used in premium clothing and textiles. The synthetic
segment manufactures fabrics from man-made fibers like polyester, nylon, and acrylic, offering
versatile, durable, and cost-effective materials for a wide range of applications, from fashion to
industrial uses. This industry is vital for its significant role in the apparel, home furnishings, and
technical textiles markets, while also adapting to emerging trends in sustainability and eco-
friendly manufacturing processes.

2.0 COMPANY PROFILE

HISTORY OF ORGANIZATION
Woolen and Synthetic Textile Manufacturing Ltd is a registered company in Nigeria dedicated to
exquisite manufacture of exquisite quality textile goods. Woolen and Synthetic Textile
Manufacturing is under the Chanrai global conglomerate group of companies.

We were incorporated in 1968 and have actively been in manufacture of quality textile products
that meet up to global standards anywhere in the world. To keep up with standard, we utilize
high end weaving and ultra-modern processing machines to produce the best quality products

When it comes to maintaining quality, the Woolen and Synthetic Textile Manufacturing team
makes no compromises. The company believes in the philosophy of "A thing worth doing is
worth doing well. This is imbibed into every member of our team from production to
administrative and other tiers in the company,

Our product range comprises of premium fabrics in various weave forms: plain, dobby, satin
and twill. A comprehensive list of our products can be viewed on the product page.

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Our quality consciousness has made us foremost in the Nigerian manufacturing industry and has
attracted major’s institutions as our clients. We get patronage from both private and government
institutions in the below industries:

• Military and Law-Enforcement. Educational • Beddings • Household and Decors • Fashion •

Furniture’s

Our team is made up of experienced and quality- centered professionals. We have and yearn to
give our best in providing the best textile products in Nigeria and Africa as a whole.

2.1 ORGANISATION CHART OF WOOLLEN AND SYNTHETIC TEXTILE

MANUFACTURING INDUSTRY, OBA-AKRAN, IKEJA, and LAGOS STATE
WOOLLEN AND SYNTHETIC TEXTILE MANUFACTURING INDUSTRY, OBA-AKRAN,
IKEJA, and LAGOS STATE has a chain of officers who foresee different sectors of the
organization. These major officers ensure the proper running of the Company.

2.2 MAJOR FUNCTIONS OF MAJOR DEPARTMENTS

These departments work together to produce high-quality textiles efficiently while ensuring
product performance, durability, and sustainability across the textile manufacturing process.
Each department has specialized functions that contribute to the overall quality and functionality
of the final product.

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1. SPINNING DEPARTMENT

The Spinning Department is responsible for converting raw fibers into yarn, which serves as the
foundation for textile production.

- Key Functions:

- Fiber Preparation: Cleaning and blending raw fibers (e.g., wool, cotton, synthetic fibers) to
ensure uniformity.

- Carding: Separating and aligning fibers into a thin, even web to prepare them for spinning.

- Spinning: Twisting the prepared fibers into yarn of varying thicknesses (count) and strengths,
using spinning machines like ring-spinners or rotor spinners.

- Quality Control: Ensuring yarn consistency in terms of strength, twist, and appearance to meet
product specifications.

2. Dyeing Department

The Dyeing Department focuses on adding color to the yarn or fabric, using different dyeing
techniques suitable for the specific fibers.

- Key Functions:

- Dye Selection: Choosing appropriate dyes based on the fiber type (e.g., reactive dyes for
cotton, acid dyes for wool, disperse dyes for synthetic fibers).

- Pre-treatment: Preparing the yarn or fabric by washing, scouring, and sometimes bleaching to
remove impurities before dyeing.

- Dyeing Process: Applying the dye using methods like batch dyeing, continuous dyeing, or
yarn dyeing, depending on the fabric's intended use.

- Post-Dyeing Treatment: Fixing the dye to ensure color fastness and resistance to fading or
bleeding.

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 - Quality Control: Ensuring uniformity of color, shade matching, and dye absorption to meet
customer requirements.

3. Weaving Department

The Weaving Department is responsible for transforming yarn into fabric by interlacing the warp
and weft yarns on weaving looms.

- Key Functions:

- Warping: Arranging the yarns lengthwise (warp) on the loom, ensuring correct tension and
alignment.

- Weaving: Interlacing the warp and weft yarns on looms to create fabric. Various weave
patterns (e.g., plain weave, twill, satin) are employed depending on the design.

- Fabric Inspection: Checking woven fabrics for defects such as holes, uneven tension, or yarn
breaks.

- Loom Maintenance: Regular upkeep of weaving machines to maintain optimal performance

and prevent downtime.

4. Finishing Department

The Finishing Department adds final treatments to fabrics to enhance their appearance, feel, and
durability. This department is crucial for imparting specific properties to the finished textile.

- Key Functions:

- Mechanical Finishing: Techniques like calendaring, singeing (removing protruding fibers),

and heat-setting to smooth, shape, or press fabrics.

- Chemical Finishing: Applying chemical treatments like flame retardants, water repellents,
softeners, and anti-wrinkle agents to improve fabric properties.

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 - Bleaching and Whitening: Lightening fabrics (usually cotton) through chemical treatment for
uniform color and brightness.

- Printing: Adding patterns or designs to the fabric using techniques like screen printing or
digital printing.

- Quality Control: Ensuring fabric softness, color retention, shrinkage control, and durability
through various finishing treatments.

5. Technical Department

The Technical Department is responsible for maintaining the machinery, optimizing production
processes, and ensuring compliance with safety and environmental standards.

- Key Functions:

- Machine Maintenance: Regular upkeep, troubleshooting, and repair of spinning, weaving,

dyeing, and finishing machinery to minimize downtime and improve efficiency.

- Process Optimization: Implementing improvements in the manufacturing processes to increase

productivity and reduce costs.

- Research and Development (R&D): Innovating new textile products, processes, and materials,
including exploring eco-friendly solutions and sustainable practices.

- Energy and Water Management: Overseeing the efficient use of energy and water in
production processes to reduce environmental impact.

- Health and Safety: Ensuring compliance with workplace safety regulations and promoting a
safe working environment.

- Environmental Compliance: Monitoring waste management, effluent treatment, and adherence

to environmental regulations to minimize the impact of production activities.

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2.3 MISSION STATEMENT
Our mission is to be a leading provider of high-quality woolen and synthetic textiles, delivering
innovative and sustainable solutions that exceed the expectations of our customers. We are
committed to fostering a culture of excellence, creativity, and responsibility in every aspect of
our business—from raw material sourcing to final product delivery.

We strive to enhance the lives of our customers by providing durable, functional, and
aesthetically superior fabrics, while upholding our responsibility to the environment and society.
Through continuous innovation, efficiency, and a customer-centric approach, we aim to be a
trusted partner in the textile industry, driving growth and sustainability for all stakeholders.

2.4 CORE VALUES

Our Brand Values:

Our brand is built on a foundation of core values that guide everything we do, from production
processes to customer interactions. These values reflect our commitment to quality,
sustainability, and innovation in the textile industry. They shape our culture and the way we
approach both challenges and opportunities.

1. Quality Excellence
We are dedicated to producing the highest quality textiles that meet the standards and
expectations of our customers. Quality is at the heart of our operations—from raw
material selection to the final product. We continuously monitor and improve our
processes to deliver superior products with consistency and reliability.
2. Innovation and Creativity
Embracing innovation is essential to our growth and success. We strive to constantly
improve our production methods, adopt new technologies, and explore creative solutions
to meet the ever-changing needs of the market. Our commitment to R&D enables us to
deliver cutting-edge designs and fabrics that push industry boundaries.
3. Sustainability
We are committed to environmentally responsible practices at every stage of our
production. Our focus on sustainability includes reducing waste, conserving water and

19
 energy, and using eco-friendly materials. We aim to create products that are not only
durable but also environmentally conscious, contributing to a greener, more sustainable
future for the textile industry.
4. Integrity and Transparency
We uphold the highest standards of integrity, transparency, and ethical conduct in all
aspects of our business. From sourcing raw materials to delivering finished products, we
operate with honesty and transparency, ensuring trust and building long-term
relationships with our stakeholders.
5. Customer-Centricity
Our customers are at the center of everything we do. We listen to their needs, provide
tailored solutions, and aim for excellence in service. By fostering strong, lasting
relationships with our clients, we ensure that their expectations are not just met, but
exceeded.
6. Collaboration and Teamwork
We believe in the power of collaboration and teamwork. Success is achieved when all
departments work in harmony, from the technical and production teams to customer
service and management. We value diversity and believe that diverse perspectives
strengthen our ability to innovate and solve challenges together.
7. Continuous Improvement
We are committed to a culture of continuous improvement, always striving to enhance
our processes, products, and services. We regularly assess and optimize our operations to
achieve greater efficiency, reduce costs, and maintain competitiveness in the market.
8. Responsibility and Accountability
We take responsibility for our actions, both in terms of product quality and environmental
impact. We hold ourselves accountable for delivering on our promises, whether to our
customers, employees, or the broader community.

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 CHAPTER 3

INDUSTRIAL EXPERIENCE
3.1 JOBS DONE/EXPERIENCE GAINED
On my first day at the company, I was provided with an overview of the company's safety
protocols and regulations. I was also introduced to the management team and given a tour of the
various departments within the organization.

3.2. SAFETY RULES AND REGULATIONS

Safety is a critical aspect of the textile manufacturing industry, especially in woolen and
synthetic textile plants where workers are exposed to various hazards due to machinery,
chemicals, and high-volume production processes. The following is a general outline of key
safety rules and regulations that should be followed to ensure the health and safety of workers in
a textile manufacturing environment.

These safety rules and regulations ensure a safe working environment for employees in a woolen
and synthetic textile manufacturing industry. Proper adherence to safety protocols not only
protects workers but also enhances overall productivity and minimizes risks to the company's
operations.

Personal Protective Equipment (PPE)

 Mandatory PPE Usage: All employees must wear appropriate personal protective
equipment (PPE) at all times, including:
o Safety helmets or hard hats in areas with overhead hazards.
o Safety goggles or face shields when working with chemicals or machinery.
o Hearing protection (earplugs or earmuffs) in noisy production areas.
o Protective gloves for handling yarns, fibers, or chemicals.
o Anti-slip footwear to prevent falls, especially in areas where spills or wet
conditions exist.
o Dust masks or respirators when handling or working around fine fibers or in areas
with airborne particulates.

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Machine Safety

 Lockout/Tagout Procedures: Before performing maintenance or repairs on machines,

workers must follow lockout/tagout procedures to ensure machinery is properly shut
down and cannot be accidentally restarted.
 Machine Guards: All moving parts of machinery, such as spindles, looms, and rollers,
must have proper safety guards in place to prevent accidental contact.
 Operator Training: Only trained personnel should operate machinery. Continuous
training on safe machine operation must be provided to all machine operators.
 Emergency Stop Mechanisms: Machines should be equipped with clearly visible and
easily accessible emergency stop buttons or pull cords to immediately stop operations in
case of an emergency.

Fire Safety

 Fire Extinguishers: Fire extinguishers should be readily accessible throughout the plant,
and employees should be trained in their proper use.
 Flammable Materials: Materials such as solvents, dyes, and oils should be stored in
properly labeled and well-ventilated areas away from ignition sources. Smoking should
be prohibited in these areas.
 Fire Exit Routes: Clearly marked and unobstructed fire exits should be maintained.
Emergency exit routes and procedures should be regularly practiced through fire drills.
 Heat Protection: Employees working with high-heat equipment (such as drying or
dyeing machines) should be provided with appropriate heat-resistant PPE, including
gloves and aprons.

Chemical Handling and Safety

 Chemical Storage: All chemicals used in the textile manufacturing process (e.g., dyes,
solvents, finishing agents) must be stored in well-ventilated, secure, and properly labeled
containers, according to safety data sheets (SDS).

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  Spill Containment: Spill containment procedures must be in place for any hazardous
materials. Workers must be trained in the proper procedures for cleaning up chemical
spills.
 Ventilation: Adequate ventilation systems must be in place to ensure the safe release of
fumes and gases from dyeing, finishing, and other chemical processes.
 First Aid for Chemical Exposure: Immediate access to eyewash stations and safety
showers should be available in areas where chemicals are handled. Workers should be
trained on how to respond to chemical exposure.

Housekeeping and Maintenance

 Cleanliness: The workplace should be kept clean and free from clutter. Spills, dust, and
debris should be promptly cleaned up to prevent slip and fall accidents.
 Flooring: Floors should be non-slip and free of any obstructions, such as loose wires or
material remnants, that could cause tripping.
 Routine Maintenance: Regular cleaning and maintenance of equipment and facilities
should be carried out to ensure everything is operating safely. This includes checking
ventilation systems, dust extraction units, and machinery.

Emergency Response and First Aid

 First Aid Kits: First aid kits must be available and easily accessible in all departments.
Employees should be trained in basic first aid and CPR.
 Emergency Procedures: Clearly defined emergency procedures should be in place for
various scenarios, such as fires, chemical spills, or equipment malfunctions. Regular
emergency drills should be conducted.
 Reporting Injuries: Any injury, no matter how minor, must be reported immediately.
All incidents should be documented and investigated to prevent future occurrences.

Emergency Response and First Aid

 First Aid Kits: First aid kits must be available and easily accessible in all departments.
Employees should be trained in basic first aid and CPR.

23
  Emergency Procedures: Clearly defined emergency procedures should be in place for
various scenarios, such as fires, chemical spills, or equipment malfunctions. Regular
emergency drills should be conducted.
 Reporting Injuries: Any injury, no matter how minor, must be reported immediately.
All incidents should be documented and investigated to prevent future occurrences.

Electrical Safety

 Electrical Inspections: Regular inspections should be conducted on all electrical

equipment and wiring to ensure compliance with safety standards.
 Qualified Electricians: Only qualified and certified electricians should be allowed to
repair or maintain electrical systems.
 Avoiding Overload: Electrical equipment and machinery should not be overloaded.
Circuit breakers and fuses should be checked regularly to prevent overheating and fire
hazards.
 Wet Conditions: Electrical equipment should never be used in wet or damp conditions
unless specifically rated for such environments.

3.3 INTRODUCTION TO WOOLLEN AND SYNTHETIC TEXTILE

MANUFACTURING
3.3.1 OVERVIEW OF WOOLLEN AND SYNTHETIC TEXTILE MANUFACTURING

The textile industry is one of the oldest and most diverse industries globally, covering the
production of various fibers, fabrics, and finished textile goods. Two primary categories of
textiles dominate the global market: woolen textiles made from natural wool fibers, and
synthetic textiles, produced from man-made fibers derived from chemical processes. Both types
of textiles play significant roles in the fashion, home furnishings, technical textiles, and industrial
sectors. The manufacturing processes for woolen and synthetic textiles, though similar in some
aspects, are distinct in terms of raw materials, machinery, techniques, and end uses.

In recent years, the textile manufacturing industry has undergone major transformations, driven
by technological innovations, sustainability concerns, and evolving consumer preferences. This

24
overview provides insights into the processes, challenges, and trends within woolen and
synthetic textile manufacturing, examining key stages from fiber production to finished goods.

WOOLEN TEXTILE MANUFACTURING

Woolen textiles are made from wool, a natural fiber harvested primarily from sheep, but also
from other animals like goats (cashmere), alpacas, and camels. Wool is considered one of the
oldest fibers used in human clothing, valued for its insulating properties, natural elasticity, and
moisture-wicking capabilities. The woolen textile manufacturing process involves several key
stages, each essential for transforming raw wool into finished products like garments, carpets,
and upholstery fabrics.

Raw Material Sourcing and Wool Preparation

The wool manufacturing process begins with the collection of raw wool. After sheep are sheared,
the wool is cleaned to remove natural grease (lanolin), dirt, and debris. This is typically done
through a process called scouring, where the wool is washed in hot water with detergents. The
cleaned wool is then carded to separate the fibers, remove any remaining impurities, and align
the fibers in a uniform direction, preparing them for spinning.

Spinning and Yarn Production

Once the wool has been prepared, it is spun into yarn. This is done through the spinning process,
where the wool fibers are drawn out and twisted into continuous strands. The quality of wool
yarn depends on factors such as the twist of the fibers, thickness, and strength. The yarn can be
spun into different thicknesses, known as count, which defines the fineness of the yarn. After
spinning, the yarn may be subjected to plying, where multiple strands of yarn are twisted
together to create a thicker, stronger yarn.

Weaving or Knitting

The next stage in woolen textile manufacturing is the transformation of yarn into fabric, which
can be done through weaving or knitting. In weaving, the yarns are interlaced on a loom to

25
create fabrics like tweeds, blankets, or suiting materials. Knitting, on the other hand, involves
interlocking loops of yarn using needles to produce fabrics like woolen sweaters or hosiery.

Dyeing and Finishing

After weaving or knitting, wool fabrics undergo the dyeing process to add color. Wool is highly
receptive to natural dyes, but in modern manufacturing, synthetic dyes are often used. Dyeing
can be done through various methods, including piece dyeing, where the entire fabric is dyed, or
yarn dyeing, where yarn is dyed before being woven or knitted into fabric. Wool is also
subjected to finishing processes such as felting, fulling, and mercerizing to enhance texture,
softness, and appearance. Waterproofing and flame retardant treatments are common in
specialized woolen fabrics.

Key Applications of Woolen Textiles

Woolen textiles have several key applications:

 Apparel: Wool is commonly used in the production of suits, coats, sweaters, and scarves
due to its warmth and durability.
 Carpets and Rugs: Wool fibers are prized for their resilience and softness, making them
ideal for high-quality carpets and rugs.
 Home Furnishings: Wool is used in upholstery fabrics and curtains due to its rich texture
and natural insulating properties.
 Technical Textiles: Wool has applications in medical and industrial textiles, where its
natural properties make it suitable for use in flame-resistant fabrics and insulation
materials.

SYNTHETIC TEXTILE MANUFACTURING

In contrast to woolen textiles, synthetic textiles are made from man-made fibers derived from
chemical processes. These fibers are typically produced from petroleum-based chemicals, and
their characteristics can be tailored for specific applications. The most common synthetic fibers

26
include polyester, nylon, acrylic, and spandex. The manufacturing of synthetic textiles involves
several key stages, from polymer production to fiber extrusion and fabric creation.

Polymerization and Fiber Production

The first step in synthetic textile manufacturing is polymerization, where raw materials (usually
derived from petrochemicals) are chemically processed to form synthetic polymers. These
polymers are long-chain molecules that can be manipulated into various forms of fiber. Common
examples of synthetic polymers include polyethylene terephthalate (PET) for polyester and
polyamide for nylon.

Once the polymer is produced, it is melted and extruded through small holes in a device called a
spinneret. The extrusion process produces long filaments of synthetic fiber. These fibers can be
cooled and stretched to increase their strength and flexibility. The continuous filaments are then
spun into yarn, just like natural fibers.

Weaving, Knitting, and Non-Woven Fabrics

Synthetic fibers are used in various textile manufacturing processes, including weaving,
knitting, and non-woven fabric production. Weaving and knitting processes are similar to
those used for woolen textiles but with synthetic yarns that offer unique properties such as
stretchability, wrinkle resistance, and colorfastness. Non-woven fabrics are produced by
bonding fibers together using heat, chemicals, or mechanical processes, and are used for
applications like filters, insulation, and disposable garments.

Dyeing and Finishing

Synthetic fabrics are more resistant to natural dyes compared to wool, so they require synthetic
dyes. The dyeing process for synthetic fabrics is generally done at higher temperatures, often
requiring specialized equipment. Polyester and other synthetic fibers often use disperse dyes,
which are applied under high heat to allow the dye to bond with the fiber. After dyeing, synthetic
textiles undergo a variety of finishing processes to enhance performance. These may include
anti-wrinkle finishes, water-repellent treatments, and flame retardant coatings. Some

27
synthetic textiles are also engineered for special functions, such as moisture-wicking or UV
protection.

Key Applications of Synthetic Textiles

Synthetic textiles are extremely versatile, and their applications are vast:

 Apparel: Synthetic fibers are commonly used in everyday clothing, activewear, and
sportswear. Polyester and nylon are popular choices for t-shirts, jackets, leggings, and
swimwear.
 Home Textiles: Synthetic fabrics like polyester are used in upholstery, curtains, bedding,
and carpets. Their durability and easy-care properties make them ideal for home
furnishings.
 Industrial Applications: Synthetic textiles are widely used in industrial and technical
sectors, including automotive, medical, and military textiles. Applications include seat
belts, airbags, filters, and industrial ropes.
 Environmentally Friendly Alternatives: Some newer synthetic fibers are designed with
sustainability in mind, such as recycled polyester, made from post-consumer plastic
bottles, or bio-based fibers made from renewable plant materials.

TRENDS AND CHALLENGES IN WOOLEN AND SYNTHETIC TEXTILE

MANUFACTURING
Technological Innovations

The textile manufacturing industry is evolving with advancements in technology, including the
integration of automation and digitization. In woolen and synthetic textile production,
computerized knitting machines, automated weaving looms, and advanced dyeing
technologies have significantly improved efficiency and precision. 3D knitting and digital
printing are also revolutionizing the way textiles are produced, offering customization and
greater design flexibility.

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Sustainability

Environmental concerns are driving the textile industry towards more sustainable practices. Both
woolen and synthetic textile manufacturers are adopting eco-friendly materials, water-saving
techniques, and energy-efficient processes. Wool is a natural and renewable fiber, while
synthetic fibers are increasingly being recycled to reduce waste. The industry is also exploring
more sustainable alternatives to petroleum-based fibers, such as plant-based and biodegradable
textiles.

Consumer Demand for Functional Textiles

There is growing demand for functional textiles that offer enhanced performance characteristics.
This includes moisture-wicking fabrics for activewear, antimicrobial treatments for medical
textiles, and fabrics with UV protection or flame resistance. Both woolen and synthetic textiles
are evolving to meet these needs through advanced finishing and treatment processes.

3.4 INSTRUMENTATION/EQUIPMENT UTILIZED DURING SIWES

This section focuses on the analysis of physical parameters of products at various stages of
production to ensure they align with the company’s product specifications. The equipment
utilized for this analysis includes:

1. OVENS: In the woolen and synthetic textile manufacturing industry, ovens are
used for processes like drying, heat-setting, curing, and finishing fabrics. Drying
ovens remove moisture after dyeing or washing, while heat-setting ovens stabilize
synthetic fabrics, preventing shrinkage and enhancing durability. Curing ovens set
chemical finishes, such as flame retardants or water repellents, and finish ovens
apply softening and anti-wrinkle treatments to improve fabric texture and
appearance. These ovens use controlled heat to ensure the desired properties of
the fabric are achieved without damaging the material.

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Mode of Operation:

 Turn on the apparatus

 Power on the device by pressing the power button.

 Calibrate it using buffer 4 and buffer 7

 Rinse the electrode with distilled water.

 Place the electrode in buffer 4 solution and calibrate.
 Rinse the electrode again and place it in buffer 7 solution, then calibrate.

 Place the electrode into the liquid sample

 Rinse the electrode with distilled water and submerge it in the liquid sample.

 Press ENTER to read

 Press the ENTER button to initiate the reading.

 Record the steady display value

 Wait for the reading to stabilize and record the displayed value.

2. Inspecting Machines

Inspection machines in the woolen and textile industry are used to detect fabric defects, ensure
quality, and maintain production efficiency. Common machines include fabric inspection
machines for visual fault detection, automatic fault detectors with sensors for real-time

30
monitoring, and spectrophotometers for color consistency checks. These machines help identify
issues like holes, stains, or color mismatches, ensuring high-quality output and reducing waste.
Regular inspection also improves product durability and meets customer expectations.

3. Clear Film
Clear film is commonly used in the woolen and textile industry for packaging, protecting fabrics,
and enhancing their presentation. It is typically made from materials like polyethylene (PE),
polypropylene (PP), or PVC. The clear film allows for easy inspection of the fabric while
protecting it from dust, moisture, and damage during storage and transportation. It is also used
for roll wrapping, lamination, and printing on textile products for branding purposes. The
transparency ensures the fabric's appearance is visible while keeping it safe and intact.

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 Mpde of operation:
i. Unroll the clear film material from the roll.
ii. Position the fabric on the conveyor or platform for wrapping.
iii. Wrap the fabric with the clear film, ensuring full coverage.
iv. Use heat or pressure to seal the film around the fabric (if required).
v. Inspect the wrapped fabric for proper sealing and coverage.
vi. Cut and package the wrapped fabric for storage or shipment.

4. Computer system used in studio design

Computer systems in studio design for the woolen and textile industry use CAD software to
create and modify fabric patterns digitally. These systems help in color matching and design
visualization, ensuring accurate color reproduction and efficient design testing. Weaving and
knitting machines can be controlled through computers for precise pattern production. 3D
visualization tools simulate how textiles will look and behave. Overall, these systems enhance
creativity, precision, and reduce production time and waste.
i. Turn on the computer system and launch the design software (e.g., CAD).
ii. Input design parameters such as fabric type, pattern, and color scheme into the system.
iii. Create or modify textile designs digitally using the software tools.
iv. Simulate fabric behavior, colors, and textures using 3D visualization features.
v. Transfer the finalized design to weaving or knitting machines for production.
vi. Save and archive the design files for future reference or adjustments.

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 5. Air permeability machine
An air permeability machine in the textile industry measures the amount of air that passes
through a fabric, indicating its porosity and breathability. The machine applies a controlled
pressure differential across the fabric and measures the airflow rate. It is used to test fabrics for
applications in clothing, upholstery, and outdoor gear. Air permeability testing helps determine
the fabric's comfort, insulation properties, and suitability for various end-uses. This test ensures
that textiles meet required performance standards, such as moisture control and ventilation.

i. Turn on the air permeability machine.

ii. Place the fabric sample securely in the testing chamber.
iii. Set the desired pressure differential and airflow parameters.
iv. Activate the machine to allow air to pass through the fabric.
v. Record the amount of air passing through the fabric once a steady reading is achieved.
vi. Analyze the data to determine the fabric's air permeability and porosity

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 6. JET MACHINE
A JET machine in the textile and woolen industries is primarily used for dyeing and washing
fabrics. It operates by using high-pressure jets of water to circulate and move fabric through a
dyeing or finishing process. The fabric is typically loaded into a drum, and the jet of water
moves the fabric while the dye or chemical agents are applied. This method ensures even
distribution of dye and better fabric penetration, leading to high-quality results with minimal
fabric stress. Jet machines are particularly effective for dyeing delicate and lightweight fabrics,
providing efficient water usage and uniform coloration.

Mode of operation:
i. Load the fabric into the dyeing or washing chamber of the jet machine.
ii. Set the desired parameters for dyeing or washing, including temperature, pressure, and
chemical concentration.
iii. Start the machine to release high-pressure jets of water, which circulate the fabric in the
chamber.
iv. Introduce the dye or chemicals into the chamber as the fabric moves, ensuring even
distribution.
v. Allow the fabric to move through the cycle until the desired dyeing or washing process is
complete.
vi. Remove the fabric once the process is finished and unload it from the machine.
7. Double folding machine

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A double folding machine in the textile and woolen industry is used to fold fabrics into a precise,
uniform width for easier handling, packaging, and storage. It operates by folding the fabric in
half, then folding it again, creating a neat and compact final product. The machine typically
includes adjustable rollers, tension mechanisms, and guides to ensure consistent folding,
regardless of fabric type or thickness. This machine is widely used for finished fabrics, knitted
textiles, and woven materials, helping to prepare the fabric for shipment, display, or further
processing. Double folding machines improve efficiency and ensure consistent presentation of
textile products

Mode of Operation:

i. Load the fabric onto the machine’s feed rollers.

ii. Set the desired fold width and tension settings.
iii. The fabric is drawn through the machine, where it is first folded in half.
iv. The fabric is then folded again by the second set of rollers, creating a double fold.
v. The folded fabric is collected onto a take-up roller or conveyor for packaging.
vi. Inspect the folded fabric for uniformity and adjust settings as needed for consistency.

8. LOOM
A loom is a machine used in the textile industry to weave fabric by interlacing two sets of yarns:
the warp (lengthwise threads) and the weft (crosswise threads). The loom holds the warp threads
taut while the weft threads are passed through them, either manually or automatically, to create
woven fabric. There are different types of looms, including hand looms, power looms, and

35
Jacquard looms, each varying in automation and complexity. Looms are essential for producing a
wide range of fabrics, from simple woven materials to complex patterns used in garments,
upholstery, and textiles. They offer high-speed production and precise fabric structure.

Mode of Operation:

i. Load the warp threads onto the loom’s warp beam.

ii. Set the desired weave pattern and tension for the warp threads.
iii. The loom raises certain warp threads to create an opening (shed) for the weft to pass through.
iv. The weft thread is inserted through the shed, using a shuttle or other insertion method.
v. The loom lowers the warp threads, closing the shed, and moves the weft into place.
vi. The fabric is woven, with the process repeating for each pass of the weft until the desired
length of fabric is produced

9. Industrial sewing machine

An industrial sewing machine in the textile industry is a heavy-duty machine designed for high-
speed and efficient stitching of fabrics. Unlike domestic sewing machines, industrial machines
are built for continuous operation, handling large volumes of work with precision and durability.
They are used for tasks like seaming, hemming, stitching, and embellishing textiles in garment
manufacturing, upholstery, and other textile products. These machines are available in various
types, including lockstitch machines, overlock machines, and buttonhole machines, each
designed for specific stitching needs. They help improve production efficiency and ensure high-
quality, consistent stitching.

36
Mode of operation:

i. Load the fabric into the machine, positioning it under the presser foot.
ii. Set the desired stitching pattern, stitch length, and thread tension.
iii. Lower the presser foot to hold the fabric in place and start the machine.
iv. The needle moves up and down, interlocking the top and bottom threads to form stitches.
v. Guide the fabric through the machine while it stitches, following the pattern or seam line.
vi. Remove the fabric once the stitching is complete, trimming any excess thread if necessary.

3.5 PRODUCTION PROCESS IN THE TEXTILE INDUSTRY

The textile industry encompasses a series of processes involved in the transformation of raw
materials like fibers into finished fabric products. This complex production process involves
several stages, from the initial processing of fibers to the final stages of fabric finishing, dyeing,
and garment production. Below is a detailed breakdown of the textile production process:

1. Fiber Production and Preparation

The first stage in textile production is the production of fibers, which can be either natural
(cotton, wool, silk, etc.) or synthetic (polyester, nylon, acrylic, etc.). The fibers undergo several
steps to become usable materials for weaving, knitting, or nonwoven fabric production.

a. Fiber Extraction (Natural Fibers)

 Cotton: Cotton is harvested from cotton plants, then cleaned and separated from seeds
using ginning machines.

37
  Wool: Wool is obtained from sheep, cleaned, and carded to remove impurities.
 Silk: Silk is extracted from silkworms through a process of sericulture.
 Other natural fibers: Fibers like flax (linen), hemp, and jute are processed similarly.

b. Fiber Spinning

Once the natural fibers are cleaned and prepared, they are spun into yarn. In spinning mills, the
fibers are drawn out, twisted, and wound into yarn. This stage can also involve the use of
synthetic fibers, where polymers (such as PET or nylon) are melted and extruded to form
filaments, which are then spun into yarns.

 Carding: Fibers are separated and aligned into a loose, fibrous web.
 Combing: Fine fibers are aligned in parallel to produce a finer, stronger yarn.
 Spinning: The fibers are twisted together to form a yarn, either ring spun or open-end
spun.

c. Yarn Preparation

Once the yarn is spun, it may undergo additional processes like twisting, dyeing, and setting.
This ensures that the yarn has the required properties for the final fabric.

2. Fabric Manufacturing

Once the yarn is ready, it is woven or knitted into fabric. There are two main methods of fabric
construction: weaving and knitting.

a. Weaving

 Looms are used to interlace two sets of yarns: warp (lengthwise) and weft (crosswise).
The warp threads are held under tension on a loom, and the weft threads are inserted
between them to form a woven fabric.
 Types of Weaving: Basic weaves like plain weave, twill weave, and satin weave create
fabrics of different textures and properties.
38
  Jacquard Weaving: This technique is used for intricate, patterned fabrics, where each
warp thread can be controlled individually to create complex designs.

b. Knitting

 Knitting involves interlocking loops of yarn to form fabric. Knitting machines can
produce both weft-knitted and warp-knitted fabrics, which are more stretchable than
woven fabrics.
 Circular knitting is used for seamless fabric production, while flat knitting creates
wider, flat sheets of fabric.
 Knitting can be used for jersey fabric, ribbed fabric, and more elastic fabrics used in
apparel.

c. Nonwoven Fabric Production

Nonwoven fabrics are made by bonding fibers together using mechanical, thermal, or chemical
methods, without weaving or knitting. This process is often used for disposable items like
diapers, medical fabrics, and industrial materials.

3. Dyeing and Printing

Once the fabric is woven or knitted, it is subjected to various treatments to achieve the desired
color, texture, and finish.

a. Dyeing

 Piece Dyeing: Entire fabric pieces are dyed in a large dyeing machine, where the fabric
absorbs color evenly. This is used for solid-colored fabrics.
 Yarn Dyeing: Yarn is dyed before it is woven into fabric. This is typically used for
striped or checked fabrics.
 Solution Dyeing: Dye is added to the polymer solution before spinning the fiber,
resulting in solid-colored fibers.

39
  Batch Dyeing: The fabric is immersed in dye in a large batch and is dyed according to
desired specifications.

b. Printing

 Screen Printing: Involves pressing dye through a mesh screen onto the fabric. This is
used for repeat patterns or block printing.
 Rotary Printing: Uses cylindrical screens to apply the print on fabric, allowing for faster
printing over large areas.
 Digital Printing: Uses inkjet technology to directly print patterns onto fabric, offering
more precision and flexibility for complex designs.

c. Finishing

After dyeing and printing, fabrics often undergo finishing treatments to improve texture,
durability, or appearance.

 Mechanical Finishing: Processes such as calendering (smoothing), brushing (softening),

and sanding (creating a suede-like finish).
 Chemical Finishing: Involves the application of chemicals for specific properties such as
water-repellency, flame resistance, or anti-wrinkle treatments.
 Softening: Softening agents are applied to improve the fabric’s feel.

4. Garment Manufacturing

Once the fabric is finished, it can be used to create garments or other textile products. The
garment manufacturing process involves several stages:

a. Pattern Making

 A pattern is created based on the design specifications. This pattern is used as a template
for cutting the fabric into the required shapes for garments.

40
b. Cutting

 The fabric is spread in layers, and the pattern pieces are cut using manual scissors or
cutting machines like laser cutters or die cutters.

c. Sewing

 Fabric pieces are sewn together using industrial sewing machines. Multiple sewing
operations are required to assemble the garment (e.g., stitching, hemming, and attaching
zippers).

d. Finishing and Quality Control

 Garments are subjected to finishing treatments like pressing, ironing, or trimming.

 Quality control ensures that the final garment meets the required specifications in terms
of size, stitching quality, and fabric finish.

5. Packaging and Distribution

Once the garments or fabric are ready, they are packaged and sent for distribution. Packaging
includes folding, tagging, and placing garments into boxes or bags for shipment to retail stores or
wholesalers.

 Labeling: The final products are labeled with brand names, size information, care
instructions, and other regulatory details.
 Shipping: Packaged products are then transported to stores or directly to customers.

41
3.5.1 FLOWCHART SHOWING THE PRODUCTION PROCESS AT WOOLLEN AND
SYNTHETIC TEXTILE MANUFACTURING INDUSTRY, OBA-AKRAN, IKEJA,
LAGOS STATE

Normally, the whole textile manufacturing process is divided by four branches. These are:

1. Yarn Manufacturing or Spinning.

2. Fabric Manufacturing or Weaving.
3. Dyeing, Printing and Finishing
4. Garments / Apparel Manufacturing or Clothing.

42
Flow Chart of Textile Manufacturing Process:

Flow Chart of Spinning / Yarn Manufacturing

Blowroom
↓
Carding
↓
Drawing
↓
Combing
↓
Drawing
↓
Roving Manufacturing
↓
Ring Spinning

Flow Chart of Weaving / Fabric Manufacturing

Yarn from spinning section

↓
Doubling and Twisting
↓
Winding
↓
Creeling
↓
Warping
↓
43
 Sizing
↓
Winding on weavers beam
↓
Weaving

Flow Chart of Wet Processing / Dyeing

Inspection of grey cloth

↓
Stitching
↓
Cropping
↓
Brushing
↓
Singeing
↓
Desizing
↓
Scouring
↓
Bleaching

↓
Souring
↓
Washing
↓

44
 Drying
↓
Mercerizing
↓
Dyeing
↓
Aftertreatment
↓
Finishing

↓
Inspection
↓
Packing
↓
Baling

Flow Chart of Textile Printing

Inspection of grey cloth

↓
Stitching
↓
Cropping
↓
Brushing
↓
Singeing
↓
Desizing
↓

45
 Scouring
↓
Bleaching

Souring
↓
Washing
↓
Drying
↓
Mercerizing
↓
Printing
↓
After treatment
↓
Finishing
↓
Inspection

↓
Packing
↓
Baling

Flow Chart of Garment / Apparel Manufacturing

Design / Sketch
↓
Pattern Design
46
 ↓
Sample Making
↓
Production Pattern
↓
Grading

↓
Marker Making
↓
Spreading
↓
Cutting
↓
Sorting/Bundling
↓
Sewing/Assembling
↓
Inspection
↓
Pressing / Finishing
↓
Final Inspection
↓
Packing
↓

Despatch

47
3.6 DETAILED/ACTUAL WORKDONE, SKILLS AND KNOWLEDGE ACQUIRED
Throughout my experience in the textile industry, I gained invaluable hands-on experience,
technical skills, and industry knowledge. From fiber preparation and spinning to fabric
manufacturing, dyeing, and design, each step of the process helped me understand the
complexities of textile production. The exposure to quality control, machine operation, testing,
and digital technologies provided me with a holistic understanding of the modern textile
industry. These skills and knowledge are essential for pursuing a career in this dynamic and ever-
evolving field.

Some of which are:

Production and Manufacturing Process

During my time working in the textile industry, I was involved in several stages of the
production and manufacturing process. This exposed me to the fundamental operations that
convert raw materials like fibers into finished textiles. Here’s a breakdown of the tasks involved:

a. Fiber Preparation and Spinning

In the fiber preparation stage, I learned about the various types of fibers used in textile
manufacturing, including natural fibers (like cotton, wool, and silk) and synthetic fibers (like
polyester and nylon). I worked alongside production teams where the fiber opening process takes
place, which involves loosening and separating the fibers before they are spun into yarn.

 Skills Acquired:
o Understanding fiber types and their properties (e.g., elasticity, durability, moisture
absorption).
o Hands-on experience in operating carding machines to prepare fibers for spinning.
o Observing the process of spinning fibers into yarn using both manual and
automatic spinning machines.
o Exposure to twisting and spinning techniques, including ring spinning and open-
end spinning.

48
  Knowledge Gained:
o The importance of fiber quality and preparation in determining the final product
quality.
o Understanding the role of spinning in the final texture, strength, and appearance
of the yarn.

b. Weaving and Knitting

I was involved in both weaving and knitting operations, gaining a solid understanding of how
these techniques are used to turn yarn into fabric. I observed and assisted with setting up loom
machines and knitting machines, including manual looms, power looms, and Jacquard looms.

 Skills Acquired:
o Basic loom setup and adjustment, including controlling tension and yarn feeds.
o Experience in operating knitting machines, understanding the difference between
weft knitting and warp knitting.
o Troubleshooting common issues like thread breakage, fabric defects, and machine
malfunctions.

 Knowledge Gained:
o The differences between woven and knitted fabrics and their applications in
various textile products.
o How different types of looms and knitting machines can affect fabric structure
and quality.

c. Fabric Dyeing and Printing

In this phase, I was introduced to various dyeing techniques (piece dyeing, yarn dyeing) and
printing methods (screen printing, digital printing). This included working with batch dyeing
machines and printing machines to apply color to the fabric. I learned about different types of
dyes (reactive, disperse, acid, etc.) and their specific uses depending on the fabric type.

49
  Skills Acquired:
o Operating dyeing machines and color matching systems to achieve consistent and
accurate dye results.
o Using digital fabric printing technology for intricate patterns and designs.
o Familiarity with chemical treatments to enhance fabric properties such as flame
retardance and water resistance.

 Knowledge Gained:
o Understanding the interaction between dye types and fabric properties.
o Gaining an appreciation for color theory and its application in fabric design and
production.

2. Quality Control and Testing

Quality control is vital in ensuring that the final textile products meet the required standards for
durability, colorfastness, and overall quality. During my time in the industry, I worked alongside
the quality control team, participating in testing and inspecting fabric samples.

a. Fabric Inspection

I became familiar with fabric inspection machines used to detect defects such as holes, stains,
uneven stitching, and weaving irregularities. I assisted in the process of manual inspection and
worked with automated systems to identify and flag fabric defects in real time.

 Skills Acquired:
o Using fabric inspection machines to detect and classify defects.
o Visual inspection skills for identifying subtle issues in fabric quality.
o Knowledge of standardized grading systems for fabric defects (e.g., AQL –
Acceptable Quality Level).

 Knowledge Gained:
o Understanding the importance of quality control in ensuring consistency and
customer satisfaction.

50
 o Familiarity with defect classification and how defects affect fabric usability and
performance.

b. Testing Machine Operation

I learned about the operation of various testing machines to measure fabric properties such as
strength, abrasion resistance, and color fastness. Some machines tested the air permeability,
bursting strength, and shrinkage of the fabric.

 Skills Acquired:
o Operating testing machines such as tensile strength testers, abrasion testers, and
color fastness testers.
o Familiarity with testing standards such as ISO and ASTM that ensure fabric
compliance with industry norms.

 Knowledge Gained:
o The critical importance of testing to ensure fabric meets performance criteria like
durability, comfort, and safety.
o The role of international standards in maintaining consistency and quality across
markets.

3. Machinery and Technology

One of the most significant aspects of working in the textile industry was learning to operate and
maintain various machines that are essential in fabric production. I was exposed to both
traditional mechanical equipment and modern digital machinery, gaining technical knowledge
along the way.

a. Operating Looms and Knitting Machines

I became proficient in the operation of various looms, including Jacquard looms, which produce
complex patterns. I was also involved in managing knitting machines, adjusting settings for
speed, tension, and pattern. This hands-on experience enhanced my understanding of the link
between machine settings and the resulting fabric.

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  Skills Acquired:
o Setting up loom machines and knitting machines for specific fabric production.
o Understanding machine mechanics, including troubleshooting and maintenance.
o Adjusting machinery for various fabric types, such as woven, knitted, or
nonwoven fabrics.

 Knowledge Gained:
o The correlation between machine settings (tension, speed, warp/weft yarn feed)
and fabric properties.
o The importance of machine maintenance to prevent downtime and ensure
consistent production quality.

b. Software and Automation

I was also introduced to CAD software for textile design and automated systems used to control
machinery. For example, I worked with computerized Jacquard looms and digital fabric printing
systems that allowed for real-time pattern adjustments and precise fabric production.

 Skills Acquired:
o Using CAD software for designing patterns, colors, and textures for textile
production.
o Operating digital printing machines and learning the integration of digital
technology with textile manufacturing.
o Understanding automation in textile production, including machine programming
and real-time monitoring.

 Knowledge Gained:
o The role of digital technology in enhancing design capabilities and production
speed.
o How automation has increased efficiency, reduced human error, and improved
fabric consistency.

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4. Design and Innovation

One of the most exciting aspects of my work was the involvement in textile design. I gained
hands-on experience in designing woven and knitted fabrics and understanding the importance of
innovation in fabric creation.

a. Designing Textile Patterns

I worked with the design team to develop textile patterns, using both manual sketching and CAD
software to create new designs for various products such as clothing, upholstery, and industrial
fabrics.

 Skills Acquired:
o Knowledge of design principles, such as balance, proportion, and color theory.
o Familiarity with CAD tools for textile pattern creation.
o Understanding how to translate a design idea into a woven or knitted fabric.

 Knowledge Gained:
o The key differences between various fabric designs and their end-use
applications.
o How design impacts fabric performance, texture, and appearance.

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 CHAPTER FOUR

SUMMARY, RECOMMENDATION AND CONCLUSION

PROBLEMS ENCOUNTERED AND POSSIBLE SOLUTIONS
Difficulty in finding a place for industrial training is a big problem for students on the
SIWES program. There are situations whereby you will write a company’s aptitude test, but
because you do not know anybody within the company or that no one can speak on your
behalf then you lose the placement.
Nigerian government in collaboration with SIWES should help students when it comes to
securing a place for the training; or provide a policy that gives a Nigerian student right to be
taken in any company he/she applied for the training. By so doing, the time wasted at home
while searching for a place by the student will be minimized

1. Finance: There were some financial challenges since the organization does not pay
industrial training students and this had some effect on IT students in terms of
transportation and otherwise.
2. There was no much of a practical training/work since most of the machines and
equipment were in good working conditions.
3. Lack of precise training was another problem encountered because there was no precise
order of training program for industrial training student.

EXPERIENCE GAINED
- Fiber Preparation: Assisted in the cleaning, carding, and blending of fibers for spinning.

- Spinning Process: Observed and assisted in operating spinning machines like ring spinning and
open-end spinning.

- Yarn Testing: Conducted tests to measure yarn strength, elasticity, and quality.
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- Weaving & Knitting Operations: Participated in setting up and operating weaving looms and
knitting machines.

- Fabric Dyeing: Assisted in piece dyeing and yarn dyeing processes, ensuring proper dye
application.

- Chemical Finishing: Gained experience in applying softeners, flame-retardant treatments, and

other finishing chemicals to fabrics.

- Fabric Quality Control: Performed manual inspections and operated testing equipment to
evaluate fabric quality.

- Pattern Design: Assisted in creating digital fabric designs using CAD software for textile
design.

- Production Scheduling: Worked with the production team to schedule and monitor fabric
manufacturing processes.

- Machine Calibration: Helped calibrate and adjust machines for optimal performance in textile
production.

- Inventory Tracking: Assisted in managing raw material and finished product inventories.

- Team Collaboration: Worked closely with cross-functional teams to ensure smooth production
flow.

- Data Analysis: Collected and analyzed production data to monitor performance and suggest
improvements.

- Safety Practices: Trained in industry safety standards and participated in safety drills and
emergency response procedures.

- Troubleshooting: Identified and assisted in troubleshooting machine malfunctions and quality

issues.

- Production Documentation: Assisted in preparing production reports and documenting daily

activities.

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- Customer Feedback: Participated in gathering feedback on finished products to improve quality
and meet consumer expectations.

- Lean Manufacturing Techniques: Learned and assisted in implementing lean manufacturing

practices to reduce waste and improve efficiency.

- Regulatory Compliance: Gained knowledge of textile industry regulations regarding

environmental and safety standards.

- Machine Maintenance: Helped with routine maintenance and upkeep of textile production
machines to prevent breakdowns.

- Technical Skill Development: Developed technical skills in textile machinery operation and
maintenance.

RECOMMENDATION
I recommend that SIWES (Student Industrial Working Experience Scheme), Should provide
a place for industrial attachment for students, Industrial Training Fund (ITF) should pay
some allowances to students, and companies/industries should provide more safety
equipment to prevent further health hazards.

CONCLUSION
My internship at the Woolen and Textile Manufacturing Company provided me with invaluable
hands-on experience in the textile industry. I gained a thorough understanding of textile
production processes, from fiber preparation to final fabric finishing. Through active
involvement in machinery operation, quality control, and safety protocols, I was able to enhance
my technical skills and deepen my knowledge of industry standards. Working alongside
experienced professionals and contributing to team projects also improved my communication,
teamwork, and problem-solving abilities. Overall, this experience has been instrumental in my
professional development and has significantly prepared me for a successful career in the textile
industry.

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 REFERENCES

1. LOGBOOK
2. https://www.scribd.com/document/521122371/INDUSTRIAL-TRAINING
3. Choudhury, M. A., & Hasan, M. M. (2020). Advancements in textile manufacturing
technologies: Trends and innovations in the global textile industry. Springer.
4. Smith, R. J., & Anderson, P. L. (2018). Introduction to textile fibers and their properties:
Applications in modern manufacturing. Wiley.
5. Begg, R., & Bristow, D. (2019). Quality control and management in the textile industry:
A practical guide. Elsevier.
6. Kumar, S., & Singh, A. (2017). The textile industry and sustainable practices:
Environmental challenges and solutions. CRC Press.
7. Jones, T., & Williams, K. (2021). Textile manufacturing: Process, technologies, and
innovations. Oxford University Press.

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