Submitted by:
MOHSIN QURESHI
MUNISHWAR MESHRAM
PANKAJ RAMTEKKAR
PIYUSH BAHAD
ROSHAN MESHRAM
SAURABH KOKASH
TILAK BAMBAL

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1.0 INTRODUCTION
1.1 COMPANY PROFILE
Indo Rama Synthetics (India) Limited (IRSL) - a multinational group with its presence in Indonesia, Srilanka, Thailand, .Bangladesh etc, was established in India in 1989 with a commitment to quality and customer satisfaction for execution of spinning operations at Pitampur (lndore).
It's exposure to international operations gave it a competitive edge in adherence to global standards. In 1995-97, the integrated Polyester Complex at Butibori, near Nagpur in Maharashtra in technical collaboration with Dupont of USA was set up for production of Partially Oriented Yarn & Fully Drawn Yarn (POY/ PFY-FDY), Toyobo of Japan for Polyester Staple Fibre (PSF), Draw Texturised Yarn( DTY) and Textile grade Polyester chips.
Indo Rama Synthetics (I) Ltd. is country's 2nd largest dedicated Polyester Manufacturer with an integrated manufacturing complex at Butibori, near Nagpur (M.S.). The Butibori complex has annual production capacity of about 3,00,000 tonnes of PSF, POY / FDY, DTY and textile grade chips. The ongoing expansion at Butibori to double the capacity of both PSF and PFY / FDY to about 6,00,000 tonnes per annum is under commissioning stage- being executed in technical collaboration with Zimmer AG, a leading technology provider from Germany.
Indo Rama Synthetics (I) Ltd., Butibori - Nagpur is an integrated composite polyester complex producing Polyester Staple Fibre (PSF), Polyester Filament Yam (PFY-POY/FDY), Draw Texturised Yarn (DTY) & Chips. It is second largest after Reliance. But, it will be first largest in size at single location after expansion facilities of doubling capacity are commissioned in 2006.
Indo Rama has in place ISO-900 1 (2000) for highest standard of Quality Management System (QMS), ISO-14001 (2004) for Environment Management System (EMS) and OEKO Tex certificate to meet Human Ecological requirements. Implementation of OSHAS-18001 (Occupational Safety & Health) is taken up in year of 2005-06.
1.2 PRODUCT MANUFACTURED BY INDORAMA
The products manufactured in INDORAMA are as follows:
A) Polyester Staple Fibre (PSF):
Polyester staple fibre (PSF) has emerged as the fastest-growing fibre amongst all types of manufactured fibres. Polyest~rs are made by polymerisation of purified terephthalic acid (PTA) and mono ethylene glycol (MEG). The polymer thus obtained is melt spun and the bundle of continuous filaments obtained by melt spinning is called tow. The tow is subjected to further processes like drawing, crimping, spin finish application and then cut into fixed lengths to get cut fibres almost equal in length to cotton fibres. These cut fibres are known as polyester staple fibres (PSF).
The unique feature of PSF is that it can be blended with natural fibres (e.g., cotton and wool) and synthetic fibres (e.g., rayon) to produce polyester blended yams on the conventional cotton spinning machines. Fabrics made from polyester blended yams, also known as blended spun yam, combine the values of natural fibres with high tenacity and easy care
B) Partially Oriented Yarn (POY):
Polymer in the melted form from poly condensation section is cooled in polymer cooler, filtered and after pressure boosting it is distributed to the spinning manifolds and then to the spinning positions. The polyester melt from spinning position is extruded through spinnerets by variable speed driven spinning pumps. The extruded filaments are cooled by precisely controlled conditioned and filtered air in quench chamber. The filaments are then passed through the finish application system. The filaments are taken on take up winders and finally wound on bobbins. The yam produced is extremely fine and the unit of fineness is denier. The spinnerets and . spinning manifold are jacketed and heated with dowtherm vapour.
C) Fully Drawn Yarn (FDY):
Fully Drawn Yarn is produced by a process similar to POY manufacturing except that the yam is produced at higher spinning speeds coupled with intermediate drawing integrated in the process itself. This allows stabilisation through orientation and crystallization Yarns are produced by a continuous polymerisation process.
All critical yarn properties such as tenacity, elongation, Uster variation and boiling water shrinkage are closely monitored and controlled. Controlled interlace enables the yarns to be twisted or sized in subsequent operations.
Unique features of Indo Rama FDY are intermingled FDY yarns are suitable for direct twisting, warping and weaving. Less waste and high efficiency in subsequent processes due to higher package weight (10 kg). The fabric made from these yarns have a feel and drape similar to fabrics produced from pure silk resulting in high realization of product quality. These yams eliminate draw-twisting and sizing process reducing the cost of products for light and medium range of fabrics. There is high efficiency and low breakages in warping because of excellent package quality produced on craft winder. It has excellent dyeing consistency
D) Draw Texturised Yarn (DTY):
DTY is a fully drawn, fully oriented polyester multifilament yarn with soft crimp, high bulk and texture with cotton feel and very high durability and retention properties. This is manufactured by texturising partially oriented yarn using texturising machines. DTY is suitable for fabric end uses like outer/inner garments, skin-clinging garments, furnishings, upholstery, etc. This is a replacement of cotton and cotton blend yarns with very low moisture content
E) Polyester Chips:
The balancing stream of the polymer melt from polycondensation section is discharged through metering pumps to the casting head. The molten ribbons coming out of the casting head are taken on the cooling chambers of chips cutter where the molten ribbons are cooled by chilled DM water system. The solidified polymer ribbons are then cut in chips cutter and dried in thy dryer. The dried chips are then passed through the classifier. The properly cut chips are stored in Chips silo. The chips are conveyed to the bagging silo for bagging.
1.3 TRADING OF SURPLUS POWER
Inforama synthetic (I) Ltd. has set up Captive Power Plants (CPP) for its own consumption of power. The capacity of these CPPs after commissioning of two thermal co generation plants each of 15MW generating at 11 k V, three Diesel Generator (D.G) units each of 4MW generating at 6.6 kV & three D.G. units each of 13.5 MW generating at 11 kV. Totals to 82.5 MW this capacity is over and above their own requirement of 40MW. Hence IRSIL is availing the surplus capacity of CPPs for sell to other buyers. In this present scenario where power generation is falling short of the demand, power distribution companies are welcoming these surplus power produces though the surplus is small.
The IRSIL has made a contract with MIS Tata Power Trading Co. Ltd. Mumbai to supply power of 22 MW available after satisfying its own requirement. This surplus power is being sold @ Rs. 5/kWh. MIS Tata Power Trading Co. Ltd. Mumbai (TPTCL) may sell this power to any bulk consumer Presently TPTCL is selling this power to M/S. Reliance Energy Ltd.
Indorama synthetics (I) Ltd. has made contract with the Tata Power Trading Co. Ltd. Mumbai for the trading of power generated in excess of their own requirement using the infrastructure of MSEDTCL for transmission of this power. The Tata Power Trading Co. can sale this power to any buyer. The power available for sale after allowing a safe margin for the production activity at the plant is 22 MW. This rate per kWh supplied is Rs. 5/- to be paid by TPTCL to IRSIL. This payment is maid on weekly basis