Boiling
Boiling process is done for removing the impurities present in the yarn used for bleaching and dyeing. The yarns of different counts are procured from the spinning mills in hanks. In order to remove the impurities the yarn is boiled for 8 to 9 hours adding washing soda.Then the yarn thoroughly washed 3-4 times using clean water and is dried in the sun. We are using copper vessels for the processes and wood is used as a fuel. The processed yarn is bleached using bleaching powder/Hydrogen peroxide. According to the requirement, this yarn is dyed or is used directly for weaving. After each and every process the yarn is washed with water and dried in the sun.
Dyeing
When the yarn is made into fabric, the interesting and intricate constructions begin to add beauty of appearance as well as serviceability. The various finishing processes suggest additional means of enhancing the appearance of the newly formed fabric. It remains for dyeing and printing process to provide lasting beauty and delight to the beholder by adding colour to fabrics
Dyeing is the process of impregnating the fiber, yarn or fabric with the dye stuff. Dyeing can be done of the fiber, yarn or fabric. Dyeing is the method by which colour is applied to the fabric. In the dyeing process, fiber, yarn or fabric is impregnated with the dye stuff. Usually we are dyeing the material on the yarn stage and it gives the fabric even shades of colours and desired depth. We are manufacturing white and coloured fabric. We are weaving the fabric using dyed yarn. We are selecting the correct dyes for getting various shades.
Different dyes for different colours have different degrees of fastness to various conditions like perspiration, dry cleaning, bleach, salt water, swimming pool additives, atmospheric gases, or air pollutants. Dyes may sometimes bleed too.
Winding
This converts the package of the yarn. The hank yarn is wounded on the pirm( small bobbin used in handloom weaving) for preparing the weft. It is done manually; especially ladies are engaged in this work. The yarn for weft is winded to the bobbin. The next process is preparing of the yarn for warp and it is called winding.
Warping
Warping is the preparatory stage for weaving, which prepares the yarn for weaving. Cones of yarn are creeled on to a machine and a sheet of yarn on beam is produced by winding about 500 to 700 threads together. Its length is precise and preset to avoid wastage at subsequent stage. Warp yarns have to withstand tension and chafing in the weaving stage. It is therefore necessary to strengthen them and import surface smoothness. This is done in sizing process whereby several beams of yarn depending on the number of threads required in a warp sheet (which is determined in fabric width and density) are passed through a starch based solution. After passing through this solution it is wounded on beams. This is called weaver̢۪s beam and now the final yarn is ready for weaving.
Weaving
Weaving is interlacing of vertical yarn (warp) and horizontal yarn (weft). Depending on the type of weave, warp yarn sheet is divided and lifter. An opening is created which left yarn is inserted.
Then the other portion of the warp sheet is lifted and weft yarn is passed again. This gives the binding as interstices are created through this process. Weft yarn is carried across in pirm, held in a shuttle. This is the basis weaving process the shuttle is thrown from one end of the warp sheet to another by hand.
Quality inspection
Quality is the totality of features and the characteristics of a product or service that bears on its ability to satisfy the stated or implied needs. Qualify of the product is through checked by our trained and qualified professional. The inspection is carried out at various stage such as purchase of raw materials, during the manufacturing process and final stage assess the status of the products for acceptance or otherwise. The products are inspected to appraise the quality of the products in terms of manufacturing defects and adherence to the specification and other requirements.
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