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one of the four textile research Associations located in different parts of the country was es tablished in the year 1975 with the objective to carry out scientific research in the field of textiles as well as to promote and foster scientific research studies for the extension of knowledge related to or connected with Textile Industry. NITRA occupies an area of fifty acres out of which thirty acres of land is earmarked for the cultivation of cotton.
NITRA is linked to the Ministry of Textiles and recognized by the Department of scientific and Industrial Research for providing services to centralized as well as decentralized sectors. It enjoys Govt. of India assistance through various projects.
NITRA Campus comprises of Fourteen technical divisions :
- Mechanical Processing (Wvg.)
- Chemical Quality Evalution
- Mechanical Processing (Spinning)
- Polymer and Technical Textiles
- Physics and Quality Evaluation
- Environmental Engineering
- Human Resource Development & Operation Research
- Knitting
- Engineering
- Research & Development (Product)
- Software Development Centre
- Garment Cetrer
- Customer Service Promotion Cell
- Publications
In addition to the above mentioned divisions NITRA campus also comprises of Chemical,Environmental, Physical and Quality Evaluation ,Polymer and Eco-laboratories and a Pilot Plant. Computer Aided Design (CAD) System centre is also very recently opened in NITRA. It also has a computerized library information centre with internet facility to back the R&D activities.
NITRA is rendering services to centralized sector through various R&D projects, Consultancies, Training Programmes, Publications. Services include the areas such as Energy Audit, Manpower studies, Pollution Control, Machine and Design Development, Designing of Effluent Treatment Plants, Software Development. Besides, NITRA helps the industry in solving their operational problems. NITRA is also rendering services to the decentralized sector through eight Power loom Service Centre’s established by the Ministry of Textiles ,Govt. of India in the Northern Region under administrative control of Director NITRA.
Seven Power loom Service Centre’s located at various places in Northern Region are given as under:
- Gorakhpur (U.P.)
- Tanda (U.P)
- Kanpur (U.P)
- Meerut (U.P)
- Panipat (Haryana)
- Ludhiana (Punjab)
- Bhilwara (Rajasthan)
Activities of these centers are given as under:
- Training for Jobbers, Weavers, Supervisors and Entrepreneurs
- Design Development
- Fabric Analysis
- Count, Strength, CSP of Yarn
- T.P.I of yarn and fabric strength testing.
Quality Management: This covers assistance in implementation of Management Information System (MIS), Assessing Quality Cost, various managerial suggestions which can help management to take decision on their product-mix, area of modernisation, cost conservation etc
Process House Study: This include study on process parameters, defects and damage control measure analysis, saving of water, saving of dyes and chemicals, machine efficiency and utilization, productivity standardization and performance evaluation of Textile auxiliaries etc. Setting-up test house creating awareness on latest technology are also part of this heading.
Computer Aided Textile Designing
Printing: Tracing and This includes study of the Printed designs, development of new theme based designs, analyzing the type of repeat suggesting the use of minimum number of colors to get almost same impression & final setting of repeat depending of screen size as per the requirement of printing and finally generation of film for final screen formation.
Dobby: Detail analysis and development of Dobby designs, yarns used, type of weave, drafting & peg plan formation with complete calculation sheet including count, shade, number, weight & cost of yarns and all the information about reed, pick, reed space, finish width, drafting, peg plan & selvedge.
Jacquard: Systematic and detail analysis of Jacquard design, number & types of Warp and weft yarns used, nature & number of Weaves, repeat setting, development of complete design with weave insertion, graphical output of design and formation of punch files for Paper Card punching .The endless of paper card punching facility is also available.
Defect Analysis/Technical Option : Carry out analysis of various defect related to chemical processing. After carrying out various studies on the fabric having defeat, report is given to the concerned party in the form of defect analysis report/technical option report.
Product Development and its Evaluation: Under this, we can provide assistance to the concern party for the development of new product and evaluation of newly developed product with the existing product.
Performance Evaluation of Textile Export House: Under this various problem faced by export house are taken and rectified.
Electrical Energy & Safety Audit Transformers & distribution analysis, power factor improvement, max. Demand analysis, solution for avoiding penalties, most economical voltage level study, lighting system, compressors study, motor load analysis, capacitor performance, calculation of specific fuel consumption (units/kg), adaptation of new technology etc. expected saving around 8-15%
Thermal Energy Audit : Overall assessment of performance level of steam/heat generating and utilization machines with respect to steam consumption/ heat balance/waste heat recovery & recycling systems, design modification and performance optimization with respect to productivity etc. Suggest measures to achieve energy conservation giving thrust to energy-efficient technology etc.This study can be extended to textiles and non-textiles like chemical/fertilizers/refineries etc.)
Thermal Insulation Audit : Detailed study of lagging condition of steam hot water/hot gas/hot liquid pipelines by sophisticated instruments like non-contacting type infra-red temperature meter, contact type temperature meter etc. and measuring the temperature at each location, working our techno-economic feasibility of efficient lagging & suggest better lagging materials.
Power Quality Audit: Detail study of load trend, voltage and current unbalancing and its effect on system efficiency, max, min & avg. power parameters study, quantifying harmonic level, effect of harmonics on equipment’s i.e. Motors, capacitors, generators, transformers, cables, switches etc. electricity bill, power factor, tripping, safety etc. analysis of qualitative and quantitative losses due to harmonics, highlight the areas of harmonic generation and it’s mitigation. Around 5% or more saving can be achieved.
D.G. Audit : Calculation of specific fuel consumption (units/liters) on existing and different load condition, load optimization on D.G. and suggest the scope of fuel saving, D.G. efficiency trials, load bearing capacity of D.G. set, checking of general maintenance and suggest measures to achieve better fuel efficiency, power factor suggestions, techno economic study of new D.G., solution for adhoc problems etc. saving expected 5-15% depending upon conditions.
Automation & Modification : Detail analysis of system, product up gradation by value engineering, study and need of drives, sensors & PLC etc. analysis of feed back control, development of integrated system, development of on line monitoring & control system, erection & commissioning projects, boiler & D.G. automation etc.
Steam Trap Maintenance Audit Steam Traps are vital devices for any process steam application. Mostly it has been found that they are leaking & a huge amount of valuable steam energy is wasted. With the help of sophisticated ultrasonic Trap Detector instruments we can very quickly detect the leaking Trap & save huge money for the industry
Humidification Audit: Study of existing plant, calculation of actual requirement in different seasons, actual measurement of C.F.M at fan end, duct, diffusers, grills, etc. study of insulation system, air washer efficiency, automation study, matching C.F.M. (actual v/s installed), scope of power saving, optimization of plant operation for power saving, study of maintenance system & scope of improvement etc. expected saving 10-20%.
Industrial Furnace Audit : We provide complete study of furnace heat balance/modification/system improvement/ waste heat recovery etc .
Package Design Consultancy on Recovery or Treatment for Textile Effluent NITRA’s Environment Division undertakes the Package Design Consultancy in the following areas:
- Decolourisation of Textile Effluent by adopting an techno-economic route with minimum sludge generation 100-150 grams/M3 in case of complicated highly/intensive colored textile effluent.
- Design of Effluent Treatment Plant with minimum operating cost say Rs.3.50 to Rs.4.00 per KL in case of cotton /polyester-cotton fabric processing unit.
- Design of Portable Effluent Treatment Plants in order to handle concentrated dye effluent with irregular flow characteristics discharged from waterproofing textiles (canvas).
- Package Design Consultancy for the recovery and recycling of textile effluent up to 60% for cotton / polyester-cotton fabric processing unit. Recovery cost of water Rs.4.00 to Rs.4.50 per KL.
Other Services in Field of Environmental Management
- Environmental Audits
- Environmental Surveys/ Rapid EI
- Air Quality Monitoring (Stack & Ambient)
- Air Pollution Abatement
- Laboratory as well as pilot plant scale R & D studies on typical effluents
- Pilot Plant Study for Specific Design relating to Paper & Beverage Industries
- E.T.P Operator's Training
- Testing (analysis) of Effluent & Water Samples
Long Term Training Package
- Selection & Recruitment of fresh trainees to ensure that the right people are being selected and put into the right job so as to develop as good performers.
- Broad training plan for new trainees - Induction Training, Observational Training, Machinery Familiarization Training, Attachment Training, Learning basic skills, Gradual skill development, Evaluation & assessment.
- Refresher training for old employees.
- Motivational training for semi-skilled & unskilled workers.
- Technical graduate trainees & new supervisors training.
- Training of Trainers & Instructors.
- Organisational information programme for office & general staff.
- Training for Maintenance & Engineering personnel.
- Multi-skilled Training for Workmen.
Redeployment Training Module
- Identifying & assessing the present level of skill & performance.
- Assessing the training need & requirement & designing the training programme.
- Developing knowledge & skills through appropriate training methodologies.
- Moulding up job behaviors & capabilities for building up good work culture & healthy environment
Training System Audit: To assess the effectiveness of training and development activities including suggested measures for farther growth and development
Assessment of Worker’s Turnover & Absenteeism
- Study of workers profile, job requirement past record data & information.
- Assessing & identifying causes for higher absenteeism & appropriate control measures.
- Suggesting & providing support in implementation of various measures for controlling absenteeism & turnover.
- Follow-up & monitoring the improvement & suggesting plan for future.Performance Study & System Assessment for Garment Industry
Development of Video Film on various Job Operations
- Preparation of script in Hindi/English.
- Making of video film through creating situations, shooting the scenes, editing dubbing & sound recording.
- Creating special effects for education & training.
- Final completion of the film.
Performance Study & System Assessment for Garment Industry
- Assessment of existing systems & modifying them for the improvement in productivity & quality.
- Process line study & checking quality evaluation systems & procedures
- Setting-up proper system & implementing them for developing healthy culture.
Implementation of Maintenance Management System in Spg. Mill
- Critical assessment of suitability of maintenance schedules, system of records’, maintenance & methods adopted for monitoring the all activities.
- Modifying existing schedules, methods & systems so as that would meet the exact requirements of the mills.
- Physical assessment of crucial components and accuracy of important setting & gauges involved with the machines.
- Critical comments on the deficiencies observed along with the implement able remedial measures.
- Formulation of time & performance oriented action plans based on the finding.
Setting Drive for Improvement in Productivity
- Critical assessment of systems & procedures involved and investigation of deviation in productivity
- Prioritising various components after having evaluated their degree of influence.
- Modification in quality assurance systems to make them most suited in reference to a particular mill.
- Conducting massive transformation exercises to enhance involvement & participation of employees working at all levels.
Designing suitable monitoring systems to stabilize the modified practices.
Setting Drive for Improvement in Quality
- Critical assessment of systems & procedures involved and investigation of deviation in quality.
- Prioritising various components after having evaluated their degree of influence.
- Modification in quality assurance systems to make them most suited in reference to a particular mill.
- Conducting massive transformation exercises to enhance involvement & participation of employees working at all levels.
- Designing suitable monitoring systems to stabilize the modified practices.
Improvement of Business Efficiency through Value Driven Management
The scheme provides massive human resource development programme through discourses, class-room training programme and massive transformation exercise. Specially designed for employee within an organization.
- Addressing the value system of an individual is the key success factor for this specially designed package.
- The special discourses are designed to create the values, in every individual with respect to himself, his responsibilities, his profession, his organization, his roles, his functions & his duties.
- It is a totally self supervised, self motivated system of management based on typical Indian philosophy of behavioural science
Diagnostic Survey and Remedies on Various Problems of Spinning Mills
- To analyze data relating to the problem for identifying the root causes responsible.
- To design experiments to optimise working performance.
- To develop and establish suitable system which are experimented to be full proof for such problems.
Productivity/Quality Management in Loom Shed
- Diagnostic visit
- Submission of our
- Implementation of suggested points
- Review after implementation
HRD Approach - Motivation Programme to Improve Work practices
Methodology: Four days programme. Once in a month for six months continuously for carrying out this assignment. Our team of three experts will visit your works.
Need based Software Development
Making delay in decision can cost any thing. Through better & effective programming one can have quick & appropriate decisions. NITRA has developed much new based software for different textile industry which are working well & have been proved fruitful.
Electronic Data Processing
In this fast moving world, if an organizations is to run successfully, the decisions taken in the organization should be quick and timely. For making the decision making process fast and accurate, many times a huge amount of data and many times a small amount of data has to be processed. The speed and accuracy of this processing of data should be high. In a broad view, we can say that the faster the processing of raw data, faster is the process of decision making moreover faster is the progress of the organization. Seeing the importance NITRA has developed comprehensive consultancy package, which includes introduction to computer and its I/O devices, operating system, word processing, electronic spread sheets & database, Microsoft windows and its applications etc.
Techno-Economic Viability Study/Performance Audit of Textile Mills
Due to liberalization and globalization lot of competition has emerged, forcing textile industries to produce products meeting global standards and offering at minimum cost. Ultimately they have to face the international products/brands. That is why merger, modernization & renovation, expansion and restructuring etc. can make the industry to survive and grow. For taking decisions in right direction, it is essential to assess the techno-economic viability/performance of the industry. NITRA having rich & practical experience in this field shall provide full fledge consultancy on such important areas.
QUALITY MANAGEMENT SYSTEM ISO 9000: 2000 NEW VERSION
The objective of revision of ISO 9000: 1994 was to develop a simplified set of standards which are equally applicable to small, medium and large organizations and to make documentation requirements less prescriptive. Now the focus of new version is "PROCESS APPROACH" as compared to "PROCEDURE APPROACH" as in the old ISO 9000: 1994 version.
Looking to the significant changes in new version, NITRA has developed full fledged consultancy package which includes right from conducting awareness programmes for Sr. Manager/Top Managers, to help in documentation and implementation as per new version and internal auditing
Total Quality Culture (TQC)
Today’s customer requires total care. This can be made possible only when every person in every department has to be involved to eliminate errors and prevent waste with the objective of creating a "quality culture: for doing things "right first time and every time". "Total Quality Culture" does not emphasis only on customer satisfaction, it equally recognizes individual employee of an organization. Implementation of TQC philosophy leads to creation of an organization culture and climate where employees are freely allowed to innovate and use their capabilities.
NITRA has developed a very comprehensive package dealing with various aspects of implementation of TQC consisting of creating a quality culture, tools and techniques for continuous improvement, control of costs of quality etc.
Costs of Quality
Lot of amount is spent on ensuring and assuring satisfactory quality and very often losses are met due to poor quality & all this is not even recognized by top management in the manner other costs are dealt. Sum of amount spent to prevent failure, inspection, testing & examination and losses incurred due to product failure are responsible for almost 30%-40% of the total sales turnover. Most of the organizations mills are taking these costs as a lab our costs/manufacturing costs/or wherever they like it to be. These costs can be controlled and managed once they are identified and analyzed. "Maximum Quality with Minimum Price" must be motto for survival and growth of business.
NITRA has come out with a comprehensive consultancy package which, if implemented religiously, would bring your money back with in a short span of time apart from tremendous improvement.
Total Productive Maintenance
TPM is a productive maintenance carried out by all employees through small group activity to build up a corporate culture that will maximise the effectiveness of the production system. The implementation of TPM can generate considerable cost saving, preventive culture through increased productivity and participation. It also helps in identification and controlling of losses with an aim to improve to overall equipment/process efficiency. Emphasizing the crucial needs NITRA has developed a very comprehensive package for dealing into the various aspects of Total Productive Maintenance (TPM) in order to help textile industry to meet out competitive global scenario.
World Class Manufacturing (WCM)
During the past few years there have been significant and dramatic changes in the world arena due to globalization, liberalization and opening of the market and no doubt demand of global market is quality products with shorter delivery times. Now time has come when industry has to excel in productivity and quality.
Looking to the present requirement NITRA has developed a full fledge consultancy package on "WORLD CLASS MANUFACTURING". Apart from dealing various topics, we shall also incorporate the subjects required by the organization as an input in the consultancy so that it may fully benefit to concerned organization.
Setting up/Up gradation of Q.C. Lab
Looking into individual mills requirement consultancy for setting-up new labs or upgradation of existing labs is provided by experienced faculty equipped with latest information, knowledge of industry trends & international requirement Productivity & Quality Analysis Consultancy is provided to determine the gaps in productivity & quality, an important performance indicator viz-a-viz leading mills in the country.
Adhoc Technical Consultancy
Numerous technical consultancies in the area of spinning like reduction of imperfections in P/C blends, reduction of classimat faults, technical viability, better yarn realisation, better material handling systems & many more have been extended in the recent past to leading textile mills of the country.
Analysis of Fabric Defect :
Division has rich experience and equipped with state of art facilities to analyse various types of fabric faults. This facility is provided at a very nominal charge ranging between 2000 - 3000/- per sample. Manpower Assessment:
Removal of Patches from the Dyed Fabric used for Tents
Following aspects are covered in the fields of polymers, textiles, plastic, rubber, chemical and formulations based on polymers and chemicals in polymer and technical textile division : -
-Products/Processes development
-Trouble shooting problems
-Substitutes of costly raw materials used in the formulations
-Improvement in the properties of products without increasing the cost
-Technical information services in the following area:
Protective cloth
Automotive & transport industry
Geotextiles
Environmental protection, filtration and cleaning
Non-woven fabrics
Non woven fabric
Medical textiles
Composites
Polymers and chemicals use in textiles finishes like :
-Water proofing
-Flame retardancy
-Softeners
-Binders for printing
-Encapsulation
-Resin finishes
-Other fields
Products/processes development in the fields of :
-Textile auxiliaries
-Adhesives
-Coatings
-Polymers like plastics, rubber, fibre etc.
-Detergents
-Chemicals and additives
Man-made Textiles -Polyester
-Polyester
-Nylon
-Polypropylene
-Acrylic
-Others
ISO 9001: 2000 Quality Systems:
NITRA is actively involved in providing consultancy services on ISO9001: 2000 Quality Management Systems (Installation &Implementation) in textile and garment manufacturing units. The consultancy package consists of-
- Conducting awareness programmes for managers, officers and staff.
- Evolving and communicating the Quality Policy and Quality objectives.
- Documentation and preparation of Quality Manual, Quality System Procedures, Work Instructions, Form &Records
- Implementation of Quality Systems.
- Training to conduct Internal Audits.
- Conducting Internal Audits and providing assistance in certification.
The certification is provided through the certifying bodies such as BIS, DNV, QMS, BVQI etc. More than 50 units have availed NITRA’S services in ISO9001:2000 certification.
SA 8000 - Social Accountability System
Social Accountability system, SA8000 is a way for companies, suppliers and organizations to maintain just and decent working conditions throughout the supply chain. SA800 standard and verification system is a credible, comprehensive and efficient tool for assuring human workplaces as it includes various requirements for documentation and system implementation. NITRA is providing consultancy services in certification of SA-8000 for textile and garment industries .The various phases of services include the following
- Conducting awareness programme on SA8000 for, officers and staff..
- Evolving and structuring Policy onSA8000 and objectives.
- Documentation and preparation of SA8000 system Manual, System Procedures, Plan & Records
- Implementation of SA8000 Systems.
- Training to conduct Internal Audits.
- Conducting Internal Audits and providing assistance in certification.
Various Textile and Garment manufacturing units have availed NITRA’S services and have been accredited by the certifying bodies.
Man Power Rationalization & Work-Load Studies:
NITRA has successfully conducted Manpower Rationalization and Workload Studies in more than 50 textile industries. These studies have been conducted on the basis of Joint Norms developed by Textile Research Associations (TRA’s) for textile industry. A data bank has been developed on work assignments for different job categories of best performing mills, which is used as benchmarks for the above study purposes. The work-study approach is also adopted for specific job categories as per requirement. It has been found that on an average the mills were engaging excess manpower ranging from 7-23%.List of few such mills are as below:
- Pasupati Spg & Wvg Mills Ltd,Dharuhera,(Haryana)
- Orient Syntex Ltd, Bhiwadi(Haryana)
- Bhiwani Textile Mills, Bhiwani(Haryana)
- PeeVee Textiles, Nagpur(Maharashtra)
- Chenab Textiles, Kathua(J&K)
- JCT Mills, Sri Ganganagar(Raj)
- Vardhan Syntex, Maharastra
- Ginni Filaments Ltd, Mathura(U.P)
- J.C.T.Mills,Hoshiarpur(Punjab)
- Recron Synthetics Ltd, Allahabad(U.P)
- Rajasthan Textile Mills, Bhawanimandi (Raj)
- Reliance Industries Ltd, Naini(U.P)
- Jayshree Textiles Ltd, Rishra(W.B)
- G.P.I.Ltd,Nalagarh(H.P)
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