Sarena Industries

Mahrosh Ilyas Bhatti Sabeen Nasar Unza Rehan

Companys Background
Commenced their business operations in 2001 located on Waris road in Lahore. one of the most leading dyeing and finishing units in Pakistan, Distribution mainly to the local and foreign customers. Sarena provides a wide range of premium quality dyed, printed and finished woven fabrics. largest embroidery unit in Pakistan, which is committed to quality and customer satisfaction.

Customers of Sarena
Well-known North America, brands like Europe, Asia Bareeze, and Africa. Kesariya, New Age is one Chinyre and of the Liesure club. international Finished fabric is markets of currently Serena Industry. exported to all corners of the globe including

Production capacity: With 3 million meters per month, Sarena finds its competitive edge in its versatility. Their range-dyeing machinery is designed to handle a wide range of Cotton/CottonLawn/Cotton-Cambric/PC/Lycra fabrics Range: a wide range of weaves including canvas, baby canvas, twills, drills, satins, ottomans, oxfords, rip stops, bed ford cords, herring bones, bull denims, cross hatches, honeycombs, broken twills and the like.

Machinery: substantial investment in machinery, to match their philosophy of continuous improvement and growth. Most reliable European brands (Italy and Swiss) Dyes and chemicals are imported from only the most respected global companies (Switzerland and China). Quality: Cater only to the highest end of the market motivates them to target only the highest of standards in quality and service. They said that Quality is our language They have never strayed from their conviction

Employees: 700 employees work at two shifts, morning and evening shift. highly trained excellent in technical expertise. Electricity: Sarena is the only textile industry which generates its own electricity through steamers and coals which provides it a competitive advantage.

Objective
To know and understand how a factory carries out its operations in an effective manner and how goods are produced, and delivered to the final customer efficiently, by keeping quality in mind.

Departments
Sampling Dept. Chemical Dept. Designing Dept. Record Keeping Dept. Health & Safety Dept. Final Dept. Dispatch Dept. Research & Development Dept

Process of dyeing and finishing

Process
1. Storage: The grey fabric is received from suppliers, Nishat, Shafi & Eshaq textiles. Placed in huge bulks. 2. Singeing: Designed to burn off the rough surface to produce smoothness. The fabric passes over brushes to raise the fibres, and then passes over a plate heated by gas flames. The cloth then also goes through the washers (heated cylinders to dry the cloth).

3. Desizing: Starch is removed through enzymes. 4. Bleaching: Turns the grey fabric in to white. It improves whiteness by removing natural coloration and remaining trace impurities from the cotton; the degree of bleaching necessary is determined by the required whiteness and absorbency. Cotton will be bleached using an oxidizing agent, such as dilute sodium hypochlorite or dilute hydrogen peroxide. If the fabric is to be dyed a deep shade, then lower levels of bleaching are acceptable.

5. Mercerizing: fabric is treated with caustic soda solution to cause swelling of the fibres. This results in improved lustre, strength and dye affinity. Cotton is mercerized under tension All alkali must be washed out before the tension is released or shrinkage will take place.

6. Colour matching: Lab testing is done for shade checking, color fastness and shrinkage of fabric to ensure that how the color turns out on the cloth. First they do light shading to check whether the color is right or not. Physical testing 7. Shrinking: Mechanical shrinking (sometimes referred to as sanforizing) is where the fabric is forced to shrink width and/or lengthwise,

8. Dyeing: Chemicals are imported from Switzerland and China There are five categories of dyes
Reactive Disperse Pigment Inks Vat Dyes

imparting color on fabrics. After color matching in the lab testing the fabric is run through the dyeing machine called thermal and steamers for one particular color.

9. Tentering: Widths are set via drying and heat treatment. Aligns the fabric and gives stable widths and dimensional stability. 10. Colour Judging: Here the dyed fabric is checked for its colour.

11. Printing
Rotary screen printing cylindrical screens are made. Engraving screens are made according to different designs via rollers on cylinders fed by the computer. As the cloth moves between the rotating drum and rollers picks up colour from the engraved area of each roller in sequence. Flat-bed screen printing fabric design is reproduced on fine mesh screens. On each screen, the areas in the design that are not to be penetrated by the dye are covered with lacquer or some other dye-resistant coating. The screens are coated with dye on the back and mounted in the proper sequence above a flat bed. As a belt carries the fabric along from screen to screen, a roller presses the dye through the open area of the screen onto the fabric.

12. Digital Screening: time saving simple process as it requires no engraving. printing is done via ink printers (MSJP7). machine imprints the pattern of various colors at one time in a repetitive manner.
13. Finishing: Thorough inspection is done. If defects, employees will inspect whether they are from grey fabrics or from processes. fabric without defects will be rolled up into a bolt. Then folded rolls tagged as finished goods and is sent for packaging for delivering it to the suppliers.

14. Folding and packaging: In this final stage the product is ready for supply.

Recommendations
Human Resources Development The Textile Board should establish a separate training wing, where training courses should be conducted for the capacity building of labour. There is also urgent need to increase the number of such Vocational Institutions where modern technical education is provided. Safety materials Provision of masks for prevention from toxic chemicals while working in the chemical department.

Expansion of digital printing Expansion. Initial cost will be high but they will have long term benefits as it is a simple and a time saving process.

Conclusion
Meeting its potential by delivering value added products. Variety and quality gives them a competitive advantage. Hoping to increase their production capacity. Reliability has brought huge reputation to them. Sarena Industries is no doubt thriving to become a leading textile industry in Pakistan.

Thank You!