Textile Wet Processing Technician

ITI Textile Wet Processing Technician Syllabus 

Course Overview

• Trade Name: Textile Wet Processing Technician
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Mathematics and Science
• Objective: To train candidates in textile preparatory processes, dyeing, printing, and finishing techniques, equipping them with skills for roles such as wet processing technicians, dyeing operators, printing assistants, or quality controllers in textile industries, or for self-employment in textile processing units.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Textile Wet Processing: Overview of wet processing, its role in textiles, stages (preparation, dyeing, printing, finishing).
• Textile Fibers: Types (natural: cotton, wool, silk; synthetic: polyester, nylon), properties (absorbency, strength), identification methods.
• Basic Chemistry: pH, acids, bases, salts, water quality testing, and their relevance to wet processing.
• Tools and Equipment: Hand tools (measuring cups, stirrers), machines (jiggers, padding mangles), maintenance basics.
• Safety Practices: Chemical hazards, PPE (gloves, masks), fire safety, effluent handling, workplace ergonomics.
• Preparatory Processes: Singeing, desizing, scouring; purpose and chemicals used (enzymes, alkalis).
• Workshop Organization: Inventory management, workflow planning, 5S methodology.

Trade Practical

• Fiber Identification: Testing fibers (burn test, chemical solubility) to distinguish cotton, wool, polyester.
• Water Testing: Measuring pH, hardness, and impurities in water samples.
• Tool Handling: Using measuring tools, stirrers, and weighing scales for chemical preparation.
• Safety Drills: Practicing PPE usage, spill management, and emergency response in labs.
• Preparatory Work: Performing desizing and scouring on cotton fabric samples.
• Machine Familiarization: Operating jiggers and washing machines; basic cleaning.
• Project Work: Preparing a cotton fabric sample through singeing and desizing, documenting results.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Bleaching Processes: Objectives, chemicals (hydrogen peroxide, sodium hypochlorite), bleaching techniques for cotton, wool.
• Dyeing Fundamentals: Types of dyes (direct, reactive, vat), dye selection, dyeing principles, fastness properties.
• Machinery: Dyeing machines (winch, jet dyeing), components, and operational parameters.
• Wetting Agents: Role, types, efficiency testing, environmental considerations.
• Quality Control: Inspecting fabric for whiteness, absorbency, and preparatory defects.
• Electrical Basics: Motors, starters, and electrical safety in wet processing units.
• Environmental Norms: Effluent treatment basics, pollution control in textile processing.

Trade Practical

• Bleaching: Bleaching cotton and wool samples using hydrogen peroxide; measuring whiteness index.
• Dyeing: Applying direct dyes to cotton fabric; testing color uniformity.
• Machine Operation: Running winch dyeing machines; adjusting temperature and liquor ratio.
• Wetting Agent Testing: Evaluating wetting efficiency of surfactants on fabric samples.
• Quality Checks: Inspecting bleached fabrics for defects (unevenness, pinholes).
• Electrical Skills: Testing motor connections, identifying basic electrical faults.
• Project Work: Dyeing a cotton fabric sample with reactive dyes, ensuring even shade and fastness.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Advanced Dyeing: Dyeing synthetic fibers (polyester, nylon), disperse dyes, carrier dyeing techniques.
• Printing Techniques: Block, screen, and roller printing; paste preparation, fixation methods.
• Finishing Processes: Softening, starching, calendaring; chemical and enzymatic finishing.
• Machinery Maintenance: Lubrication, calibration of dyeing and printing machines, fault diagnosis.
• Effluent Treatment: Chemical dosing, filtration, aeration in treatment plants; BOD/COD standards.
• Textile Testing: Fastness (washing, rubbing), tensile strength, fabric dimensional stability.
• Costing Basics: Material cost estimation, process optimization for dyeing and finishing.

Trade Practical

• Dyeing Synthetics: Dyeing polyester with disperse dyes; controlling temperature and pressure.
• Printing: Preparing screen printing paste, printing designs on cotton fabric.
• Finishing: Applying softeners to fabrics; performing calendaring on samples.
• Machine Maintenance: Lubricating dyeing machine parts, checking rollers and pumps.
• Effluent Testing: Measuring BOD/COD of wastewater samples; simulating chemical dosing.
• Textile Testing: Conducting wash and rub fastness tests on dyed fabrics.
• Project Work: Printing a multi-color design on fabric, followed by finishing and quality testing.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Specialized Processing: Dyeing blends (cotton-polyester), eco-friendly dyes, low-water techniques.
• Advanced Printing: Digital printing, transfer printing, automation in printing systems.
• Functional Finishes: Anti-microbial, water-repellent, and flame-retardant finishes; application methods.
• Troubleshooting: Diagnosing dyeing defects (uneven shades), printing errors, finishing faults.
• Entrepreneurship: Setting up a dyeing/printing unit, business planning, market analysis.
• Industry Trends: Sustainable wet processing, Industry 4.0, smart textiles.
• Automation: Role of PLCs, electronic controllers in dyeing and printing machines.

Trade Practical

• Blend Dyeing: Dyeing cotton-polyester blends with dual dyes; achieving uniform shades.
• Digital Printing: Operating digital printers for fabric designs; adjusting color profiles.
• Functional Finishes: Applying water-repellent finish to cotton samples; testing efficacy.
• Troubleshooting: Correcting dyeing defects (e.g., patching uneven shades) in lab setups.
• Industrial Exposure: Hands-on training in textile dyeing/printing units (4-6 weeks).
• Automation Skills: Operating machines with electronic controllers; basic PLC checks.
• Project Work: Processing a fabric through complete wet processing (preparation, dyeing, printing, finishing), with quality and cost analysis.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Dye concentration, liquor ratios, chemical dosages, steam/energy calculations.
  • Science: Chemical reactions in dyeing, thermodynamics of bleaching, pH effects on fibers.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Reading and drawing layouts of dyeing machines, printing screens, effluent treatment plants.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication, teamwork, time management, resume writing, interview skills.
  • IT literacy: Using software for process documentation, inventory tracking.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive).
  • Practical: Tasks like dyeing, printing, quality testing.
• Evaluation Criteria: Process accuracy, defect-free output, safety compliance, project quality.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters.

Career Opportunities

• Employment: Wet processing technician, dyeing operator, printing assistant, quality controller in textile mills, garment units, or dye houses.
• Self-Employment: Small-scale dyeing/printing units, consultancy for textile processing.
• Further Studies: Diploma in Textile Technology, B.Tech in Textile Chemistry, or certifications in eco-friendly processing.