• slider1
  • slider1
  • slider2
  • slider4
  • slider5
  • slider6
  • slider7

Manufacturing

Our professional management understands the importance of appreciating the customer’s need and doing things accordingly.We believe we are solution providers ...

Our Process

Back To Home

Manufacture Process Details

Selection of Jute

Commercially graded jute are received by the Mill and are again assorted in the Mill according to end use, like Hessian Warp, Hessian Weft, Sacking Warp, Sacking Weft etc. and simultaniously Morahs are splitted to smaller size.
The number of bales of different marks which are selected to produce Hessain Warp yarn is called as Hessain Warp. batch. Hessain Warp batch jute should be strong, fairly long and free from all sorts of major defects, good colour and lustre.
Hessain Weft jute should be moderately strong, long and clean, reasonable free from major defects, fair colour and lustre. Sacking Warp jute should be strong, free from defects and of any colour.
Sacking Weft jute is lowest quality defect and rejected jutes are mixed with the wastages of mill to produce Sacking Weft jute yarn. Jute Morahs are also splited to smaller size in selection.
In the selection process, raw jute bales are opened to find out any defect and to remove the defective portion from the mora by experienced workers. Raw jute bales are of two types i.e. 150 kg weight and 180 kg weight with or without top portion cutting. The bales are assorted according to end use like Hessiean weft, Sacking wrap, Sacking weft etc. After selection, jute bales are carried to softning section by workers called Gariwala and Bajawala.


Softening Of Jute :

Jute is a Lignocellulosic bast fibre. Hence, torsinal rigidity is high and spinnability is poor.
During softening Jute Morahs are passed through spirally fluted rollers and oil in water emulsion is applied to make them soft and pileable. Soften Jute is stagged for certain duration for muturity when superficial moisture penetrates inside fibre swells it and "Thermofillic" action takes place which helps to grow bacteria to eat up barky hard portion of the root.
In softening process jute morahs are made soft and pliable. Two methods are used for softening; use of softening machine and use of jute good spreader. Generally an emulsion plant with jute softener machine is used to lubricate and soften the bark and gummy raw jute. The emulsion plant consists of gear pump, motor, vat, jet sprayer, nozzles, emulsion tank and the jacket. In this softening process jute becomes soft and pliable and suitable for carding.
In this process, the jute reeds are passed through a series of spirally fluted heavy rollers and are simultaneously subjected to an oil-water emulsion application with an objective to soften the rigid jute fibres as well as the fibre joints in the meshy jute reeds (strands of fibre) and also to clean the fibres from loosely adhered extraneous matter. Then emulsion added jute reeds are piled under a cover for 1 – 3 days, softening of the jute reeds take place due to some biological phenomenon. This process is known as ‘piling’. Softening is carried out by Softener machine or Spreader machine, the latter being more economical due to lower man-power requirement.


Piling and Pile Breaking :

The main function of pile breaker is to break the pile and serve it to the carding machines. The softner machine out put material carried by pilemen through a bile to the pile place for pilling. During piling a superficial moisture penetrates inside fibre and "Thermo fillic" action take place which softner the hard portion of the root. After piling for nearly 24 hours the pile breakers carry the material to the carding machine. Generally root cutting is done after piling near the hand feed breaker carding machine. The root weight varies from 5 to 7% of the total weight of jute.
Conditioning or piling refers to the rest stage, in which jute is given after the water and oil have been applied. It lasts longer with low grade batching to allow the hard barky root material to become softened before passing on the cards.
The main function of pile breaker is to break the pile and serve it to the carding machines. The softener machine output material carried by pilemen through bile to the pile place for pilling. During piling superficial moisture penetrates inside Fiber and "Thermo fillic" action take place which softener the hard portion of the root. After piling for nearly 24 hours the pile breakers carry the material to the carding machine.


Root Cutting & Breaker Carding :

Cutting is the process where the sacking cloth is cut to the required length for making bags for different size such as A-Twill bags and B-twill bags of 100 kg capacity.
Carding is a combining operation where jute reeds are splitted and extraneous matters are removed. Jute fibres are formed into ribbon called "sliver". There are three different carding sections: (i) breaker carding (ii) inner carding (iii) and finisher carding
In different jute mills the carding operations has been carried out in two ways:
a. Hand feed breaker carding
b. Rool feed breaker carding
The material after piling more than 24 hours is used in hand feed breaker where the material after piling for 12 hours used in the rool feed carding. In the Breaker carding machine soften jute after piling is feed by hand in suitable weight. The machine by action with different rollers turns out raw jute in the form of jute sliver for finisher carding. In this process root cutting is necessary before feeding the material to the hand feed breaker carding machine.


Finisher Carding :

Finisher carding machine make the sliver more uniform and regular in length and weight obtained from the Breaker carding machine. Finisher carding machine is identical to the Breaker carding machine, having more pair of rollers, staves, pinning arrangement and speed. Nearly 4 to 12 slivers obtained from Breaker carding machine is fed on this machine. The material thus obtained is send to drawing section.
Finisher carding machine make the sliver more uniform and regular in length and weight obtained from the Breaker carding machine. Finisher carding machine is identical to the Breaker carding machine, having more pair of rollers, staves, pinning arrangement and speed. Nearly 4 to 12 slivers obtained from Breaker carding machine is fed on this machine. The material thus obtained is send to drawing section.
Breaker rolls are again carded and Rolls are mixed (generally 11 Rolls ) to make Sliver more regular.
Simultaneously rolls are drawn to reduce weight per linear measure.Simultaneously 2 or 3 slivers are mixed together and stretched to reduce weight per linear measure to suit spinning. Genarally in Hessian 3 Drawing passages and for sacking 2 Drawing passages are used.In carded sliver fibres are randomly placed and more or less meshy in appearance which is not suitable for spinning. During "Drawing" operation fibres are "combed" to make fibre parallel.
First Drawing
The slivers obtained from finisher carding machine is fed with four slivers on to the first drawing frame machine. The first drawing frame machines makes blending, equalising the sliver and doubling two or more slivers, level and provide quality and color. This machines includes delivery roller, pressing roller, retaining roller, faller screw sliders, check spring, back spring, crimpling box etc..
Second Drawing
In second drawing, the Second Drawing Frame machine obtain the sliver from the First drawing machine and use six slivers and deliveries per head. The Second Drawing machine makes more uniform sliver and reduce the jute into a suitable size for third drawing.
Third Drawing
In the third drawing, the Third Drawing frame machine uses the sliver from second drawing. The Third Drawing machine is of high speed makes the sliver more crimpled and suitable for spinning.


Spinning :

Spinning is the process for producing yarn from sliver obtained from Third drawing. The jute spinning frame machine is fitted with slip draft zone and capable of producing quality yarns at high efficiency with auto-doffing arrangements also. Spinning is the process for producing yarn from sliver obtained from Third drawing. In the spinning process slivers are elongated and fibres are twisted into yarn to impart strength. spun yarns in the spinning process are wound onto Bobbins. after to fill the empty bobbins with yarn machine is stopped, replace these bobbins by empty bobbins. The entire time is called an average cycle time. The time for replacing the bobbins full of yarn by empty bobbins is called softing time.
The surface speed of these rollers are progressively higher which drawn the sliver to finer in bulk-elongates in lengths maintaining the continuity of bunch of fibres which are then subjected to impart sprirolity along the axis. by passing through a device known as "Flyer" which compacts the bunch of fibres and impart significant strength. This twisted fibres are termed as "YARN". So the basic function of Spinning Frame is to convert bunch of fibres into yarn which is continuos one and ultimately wound on to bobbins.


Winding :

Winding is a process which provides yarn as spools and cops for the requirement of beaming and weaving operations. There are two types of winding :
(i) Spool Winding
(ii) Cope Winding
(i) Spool Winding
In Spool Winding yarn is produces for warp (the longitudinal yarn). Spool winding machine consists of a number of spindles. There is wide variation in the number of spindles per machines from one make to another. Productivity of spool winding depends on the surface speed of the spindle and machine utilisation.
Spool winding machine uses the bobbins contain smaller length of yarn. This machine wound the yarn into bigger packages known as 'spool'. The Spool are used in making sheets of yarn to form warp portion used during interleecment of weaving.
(ii) Cop Winding
Cop Winding machine obtain yarns from the spinning machines. The spinning bobbins is placed on a suitable pin on top of the cop machine and yarn tension is maintained by means of a small leaver. The yarn on the bobbins are cnverted into hollow cylindrical package said to be cop. The cop is used to form Transverse thread during interlacement of weaving.Yarn from spinning bobbins is made into hollow cylindrical package to put inside the Shuttle which forms the transverse thread during interlacement of weaving.


Beaming :

Beaming process is follows after spool winding. In Beaming operation yarn from spool is wounded over a beam of proper width and correct number of ends to weave jute cloth. To increase the quality of woven cloth and weaving efficiency, the wrap yarns are coated with starch paste. Adequate moisture is essential in this process.

Quality characteristic of a beam is width of beam - number of ends and weight of stand and there is a continuous passage of yarn through starch solution from spools to the beam.
Strach solution in water contains tamerine kernel powder (TKP), antiseptic - sodium silica fluride (NaSiF4) and its concentration varies with the quality of yarn.
Warp Threads are made onto a sheet of yarn by arranging spools of yarn on creels and size paste is applied on yarn to improve upon strength to facilitate weaving process. Adequate moisture is maintained here.


Weaving :

Weaving is a process of interlacement of two series of threads called "wrap" and "weft" yarns to produce the fabric of desired quality. There are separate looms for hessian and sacking in weaving section. The Hessian looms, shuttle which contents cops (weft yarn) is manually changed. The sacking looms are equipped with eco-loader to load a cop automatically into the shuttle.
In Hessian weaving generally shuttle which contents cops i.e weft yarn is manually changed. Whereas in sacking weaving Cops are changed mechanically by a device known as "Loader".


Dumping :

Dumping is the process in which the rolled woven cloth is unrolled and water is sprinkled on it continuously to provide desired moisture. Each roll is generally104 yards or 95.976 meters. Damping is done manually.


Calandering :

Calendering is a process similar to ironing of fabric. After damping the damped fabric passes through pairs of heavy rollers rendering threads in fabric flattened and improve the quality and appearance.


Lapping :

Lapping is the process in which Hessian fabrics are folded into the required size used in "Bale press" operation on the lapping machine.
Hessian fabrics are folded to the required sizeto facilitate the Pressing operation in "Bale Press".Lapping is the process in which Hessian fabrics are folded into the required size used in "Bale press" operation on the lapping machine.


Cutting :

Cutting is the process where the sacking cloth is cut to the required length for making bags for different size such as A-Twill bags and B-twill bags of 100 kg capacity. Calendering sacking fabrics are cut to size for making bags of different dimensions.


Hemming :

In Hemming process, the raw edges of sacking cloth cut pieces are shown by folding it with sewing machine. In Hemming process, the raw edges of sacking cloth cut pieces are shown by folding it with sewing machine.The raw edges of pieces of cut sacking cloth are sewn by folding it with Sewing machine.


Herackele Sewing :

In Herackele sewing the sides of sacking cloth cut pieces are shown to make a complete bag.Sacking cloth cut to sizes are folded and sides are sewn to make a complete bag ready for use.


Balling :

Bags or Bale processing cloths are pressed compactly according to buyers need.


Branding :

Sacking or Hessian bags are either branded or unbranded. If buyers desire to get plain bags then Hiracle sewn bags are directly supplied to them. If buyers desire to get special monograms or any matter printed on bags then those matters are printed by screen printing manually. This process of printing is known as "Branding".


Bundling :

Generally 25 pieces of bags are stitched/tied with threads in one Bundle.