Community Skills In Indian Knowledge System

VISIT TO MALABAR COOPERATIVE TEXTILES LIMITED

INTRODUCTION:
Textile Industry in India is the second largest employment generator after agriculture. Indian
Textile Industry contributes about 14 percentage to industrial production, 4 percent to the
country’s Gross Domestic Product (GDP) and 16.63 percent to export earnings. Nearly 40
percent of the textiles produced in the country is exported. Indian textile industry is the largest
industry when it comes to employment that generates jobs not just within but also in various
support industries like agriculture. MALCOTEX is a major textile industry in the Kerala state.
This visit is conducted to gain practical input about the activities and situations. It helps to
understand and evaluate the various operations of the organization and production functions or
activities of each production departments.

MALABAR CO-OPERATIVE TEXTILE LIMITED (MALCOTEX)

The company situated near Valanchery town Malappuram District. The company was established
in 1994. The company is the one of the spinning mills in Kerala State with 12034 spindles. It is a
co-operative society registered under the Kerala Co- operative Societies Act. The mill produces
cotton yarn of 60s carded unit and 60s combed auto yarns from May 2006.

The mill produces different types of yarn as required by the weavers in and outside Kerala. The
yarn produced by mill is also sold to the Kerala State Handloom weaver’s co-operative societies
for distributing yarn to its members at reasonable price. Two different varieties of yarn are being
produced by the company: cotton and polyester. The company buys raw material from
Maharashtra, Andhra Pradesh and Tamil Nadu. MALCOTEX produces different types of yarns
and markets it in different states of India especially Maharashtra. Yarn marketing is different
from other product marketing as yarn has high demand. Marketing of yarn is done through
agents- Sagar Enterprise, Lokmanya Tilak Road, Mumbai. The finished goods are sent to the
agency for the selling the yarn according to market price.

1
Dept. of Mechanical Engineering
 Community Skills In Indian Knowledge System

MALCOTEX faces of competition from different organization, some of them are state level and
some of them are national level
STATE LEVEL (LOCAL):- Pats pin mills (Kanjikode), Parvath Mills (Kollam), Cannanore
Spinning Mill (Kannur)
NATIONAL LEVEL: - Mysore Spinning Mill (Bangalore), Tirupati Cotton Mill (Renigunta),
Netra Spinning Mill (Secunderabad)
INDUSTRY

Indian Textile Industry is one of the leading sector in the world. Currently it is estimated to be
around US $11.5 billion. The current domestic market of textile in India is expected to be
increased to US $ 60 billion by 2022. The textile export of the country was around US $ 22.13 in
2007-08. The share of export is also expected to increase from 4% to 7% within a few years.
Though during the year 2020-21, the industry had to face adverse agro – climatic conditions, it
succeeded in producing 307 lakh bales last year, yet managed to retain its position as world’s
second highest cotton producer.

DEMAND FORCASTING

The company said that the summer season the most demand in Cotton, because cotton is most
suitable in preventing heat better than other cloths. This time the demand of cotton has increased
and it is projected to produce more yarns.

SOURCES OF PRODUCT DESIGN

The industry is well established in their machinery, imported from Japan and Germany, and the
source of the product design copied from Varaprasad & Sons Agro Product Company, Gundoor.

REASON FOR SELECTING PRESENT LOCATION

The Company is located at Kuttippuram of Malappuram District which is near to National

Highway, so good transportation facility and availability of raw material is easy. The location
facilitates availability of resources and is a highly ecological place. Excellent infrastructure is
also available in the present location.

2
Dept. of Mechanical Engineering
 Community Skills In Indian Knowledge System

PURCHASING PRCEDURE

The company purchases different raw materials from different parts of India, namely Tamil
Nadu, Karnataka, Andhra Pradesh, Gujarat and Maharashtra. Raw cotton is bought in different
types, are LIC, LRA, MCU5, MECHI and BERMA 54. There is a purchasing committee for the
purchase of raw material.
Raw cotton is purchased from. Samples are selected from raw materials and they are sent to
KSTC, SITRA for quality check. The mill accepts them only if they are required quality.

TRAINING
There are two categories of trainees. Different stages of training are follows:-

Stage Category

A 3 months

B 3 months

Two stages of Training

Only those candidates who satisfactory full fill the work load specification and working days.in
the first stage is considered to the next stage. After the completion of fourth stage of training the
trainee are treated as casuals. After working as casuals for a certain period they treated as
badalies. The company spend large amount for the purpose of training in each year.

Raw Blow
Mixing Carding Drawing
Materials Room

Store Room Packing Winding Spinning Simplex

PRODUCTION LAYOUT
Dispatch

3
Dept. of Mechanical Engineering
 Community Skills In Indian Knowledge System

PRODUCTION PROCESS

1. MIXING:

Mixing in the first stage of production process. Mixing means the mixing raw material. Different
varieties of cotton with different characteristics are mixed together by hand mixing as per
requirement Awarding to the cotton, mixing 80%, polyester and 20% cotton are mixed layer by
hand. One lot of mixing is looking. After mixing the raw cotton it is left for blowing for 24
hours. In mixing room, after blowing for 24 hours. It is taken into processing stage that into the
room

2. BLOW ROOM:
The object of blow room is open the cotton thoroughly clean and make into lap form. After
cleaning the mixing raw material in reeled on the iron bar and gets a mat, it is known as lap.

3. CARDING:

The function of carding machine is;

a. Removal fresh
b. Individualisation of fiber

The lap from blow room is fed roller of machine. In this stage materials are opened and the
imparities are extracted through the grid bar. The materials are passed to the wire point of the
flats and short removed as waste. The long fitter is delivered from fitter in the form of web. Then

4
Dept. of Mechanical Engineering
 Community Skills In Indian Knowledge System

the web is passed through Cylinder and delivered and collected in the container. The main of
carding is to remove waste, shorten the fiber individualization of fiber and make it into sliver
form.

4. DRAWING

In this machine the sliver from card fed and blended and paraysed. After this process the final
firm is termed as ‘finished sliver’. The function of drawing are:

1 Paralysis of fibers: Eight number of sliver from carding is in fed to the drafting zone of
the machine. There it is drafted between the rollers and delivered and sliver and collected
in can. While the sliver passed through the drafting rollers due to the surface speed
difference, the fiber will stretch and get paralyzed.

2 Removal of irregularities of sliver: Since 8 slivers are fed a time thick and thin places in
different slivers may joint together from other uniform delivery. Hence remove the
irregularities.

5. SIMPLEX:

The drafting slivers is fed in bed to the back taller of the drafting zone of the machine and due to
the circumferential difference in the sliver yet drafted and form in a thin flees delivered from the
front roller passed through the flayer due to the rotation of the flayer. The fleece gets twisted and
form a role. The role is winded over the bobbins placed into the spindle and bobbin.
6. SPINNING:

The ring frame is a yarn manufacturing machine. The function of the spinning are drafting,
twisting and wending. The rolling from the bobbin is passed through the back roller due to the
surface speed difference the rolling gets drafted and form into thin stands; these stand twisted
due to the rotation of the spinner and ring traveler sand the yarn house formed is wind over the
empty bobbins places on spindle due to the weight ring traveler.
7. WINDING:

We can’t send the yarns into the market in the form of cops which are produced in ring frames.
In the market they require a continuous length and clear yarn. These functions are carried out by
winding machine, the cops frame and ring frame are fed through drawn and wind over paper
cones. The sickened imparities on the yarn are estimated by balder of cleaner. The yarn from the
cop tie one after another and make into a continuous length and according to the required weight.

5
Dept. of Mechanical Engineering
 Community Skills In Indian Knowledge System

8. PACKING:

The cones covered in polythene bags and finally packed in hessian cloths and bag will have a net weight
of 50kg, which will be sending to market. It is completely done manually, there is no help of any
machinery.

QUALITY INITIATIVE:
There is a quality control division working under the charge of mill manager. A random
selection of six yarn length of samples of sliver is made from the caring, drawing and simplex
process. The average weight of the sliver is found and compared with standard weight.
The yarn from the spinning process is subject to two tests, namely: Count Test and Lew Test.
The sample from the spinning process is subject to two tests. The sample from the spinning
process is collected in the form of cops.

PRODUCTION SCHEDULING:
THE COMPANY works 24x7 and works throughout the week in 3 shifts. The timimg of the shifts is
given below:
 8 am to 4 pm
 4 pm to 2 am
 12 am to 8 am

Each shift consists of an interval of 30 minutes. All the employees are given 8 national and 5
state holidays in total.

MALCOTEX is on a strong footing. By overcoming various problems in the earlier stage, the
company with their systematic management, good employer- employee relationship and joint
efforts have been able to retain its standard. Almost all employees working in the company are
satisfied with the present working conditions and now the company is focusing on expanding
their business.

6
Dept. of Mechanical Engineering
 Community Skills In Indian Knowledge System

IMAGE GALLERY

7
Dept. of Mechanical Engineering