PABNA TEXTILE ENGINEERING COLLEGE

Industrial Attachment
At

Hypoid Composite Knit Ltd. Course Title: B.Sc. In Textile Engineering Subject Title: Industrial Attachment, Code: 408

Academic Supervisor Shib Shankar Chokrabarti Assistant Professor, Pabna Textile Engineering College

Factory Supervisor Engr. S.M. Sayeedur Rahman (Raju) General Manager (Dyeing), Hypoid Composite Knit Ltd.

Submitted by Ashik Md. Faisal, Roll- 090062 Md. Riazul Zannat, Roll- 090001

Pabna Textile Engineering College, University of Rajshahi

September, 2013

ABSTRACT

From fiber to fabric, Hypoid Composite knit Ltd is truly integrated undertaking. The Hypoid Composite Knit has the capability to offer a complete product range for the export textile market. Though it is a composite factory we are able to learn about the product process of knitting, dyeing, finishing and garments. From this document we are able to learn about dying process procedure, finishing procedure, and lap dip process. We are able to learn about the garment production process, ironing, folding of the garments, packaging process. We are able to learn about the quality, quality control process. We are able to learn how to control quality in every step in making a complete garment. We are able to learn fabric consumption, carton measurement etc. We are also known about the ETP plant and the necessity of the ETP plant for the environment. How is it works and which chemical is used in ETP plant and why it is necessary for a factory. Through this Industrial Training we are able to gather practical knowledge which will help us in our future life and which will be helpful our future career. We think this Industrial Training is a constant part for our academic stage and without this Industrial training our academic study would be incomplete.

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TABLE OF CONTENT

Title Chapter 1: Chapter 2: Chapter 3: Chapter 4: Chapter 5: Chapter 6: Chapter 7: Chapter 8: Chapter 9: Chapter 10: Chapter 11: Chapter 12: Chapter 13: Chapter 14: Chapter 15: Factory Profile Raw Materials Knitting Section Lab Dip Development Gray Quality Control Batching Dyeing Section Finishing Section Quality Control Department Store & Inventory Control Maintenance & Utility Section ETP Compliance Conclusion References

Page no. 4 16 20 44 56 60 66 96 107 112 121 130 136 141 143

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Chapter 01 Factory Profile

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1.1 About H.C.K Ltd Hypoid Composite Knit LTD is one of the new generation manufacturer and exporter of knitwear garments. Our product range includes almost all Inner & Outerwear in Knits. We started exporting from 2007 and since then, have expanded our business to various regions in North America (US, Canada etc), EU Countries (UK, Germany, Norway etc) and south Asian Countries. Since day one, company motto is to establish their selves as a reputable apparel manufacturer who is committ ed to customers satisfaction, by producing high quality products, making on time shipment and delivering efficient & Quality services. To achieve this place great emphasis on giving special attention to each of their client to accurately determine their individual requirements. Products and services are customized to meet the needs of each client.

1.2 Roots of HCK Ltd In Hypoid composite our management is held together due to its strong roots, which is the relationship between the management & the employees. Our management has vast experience in various industries which involves coordination of people and work process. Some of our associate industries include Al-haj karim spinning mills, Golden line transport ltd. and Fashion Universal. Hypoid composite employees are considered as an integral part of the company, which in turn strengthens our operation. Our Employees work with Ownership Our management and employees are our biggest assets, as the balanced mixture of these, allow us to serve our buyers effectively and with greater inspiration. In order to serve the customer right, Hypoid composite has a detailed system that starts from the customer order and ends at getting the goods shipped to the customers. Different departments in the factory interact and coordinate with each other to accomplish the above goal. 1.3 Vision Hypoid Composite Kit Ltd is is one of the upgrowing leading sustainable textile company by producing quality products and observing highest social, economic and environmental standards. His aim is to deliver the highest quality products and prompt services to our customers. Hypoid Composite Knit Ltd objective is to provide good value through a competitive atmosphere of defined systems and processes. HCKL vision is three-fold: Lead the textile industry in Bangladesh Observe highest social, economic and environmental standards Maintain a committed and satisfied clientele.

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1.4 Mission Hypoid Composite Knit Ltd mission is to create conditions and infrastructure for sustainable procurement and production of textile products. Hypoid Composite Knit Ltd wish to: Manufacture high quality yarn to withstand high levels of competitiveness. Design, manufacture and sell high quality and affordable apparels and accessories. To use latest technologies in manufacturing process. To provide a safe working environment for the employees. To operate the business with high motivation and deep commitment. Erving and supporting the society in which we work.

1.5 Aims & Objectives of HCKL To build up Hypoid Composite Knit Ltd as a one of the upgrowing and leading textile industry in Bangladesh up to five years. To build up the Hypoid Composite Knit Ltd as international standart quality export quality. To follow the all kinds of laws about labor, worker, human right, WTP, ETP, social compliance. 1.6 Location Map
JU N

SAVAR NEW MARKET SAVAR BUS STAND

HYPOID POLUR MARKET

ANDHA KOLLAN MARKET

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1.6.1 View From Google Map

1.7 Company At A Glance

Company Name: Hypoid Composite Knit Ltd. Type of Business: Manufacturer and Exporter Legal Status: Private Limited Company Year of Establishment: 2005 Corporate Office: House No.: 21/13, Babar Road, Mohammadpur, Dhaka-1205, Bangladesh. Phone: +88-02-8123893 Fax : +88-02-9133525 E-mail: hypoidck@yahoo.com Factory Address: 176, South Krishnapur, Rajashan, Savar, Dhaka Phone: +88-02-7713933 Fax : +088-02-7713899

Bank: South East Bank Ltd. Kawran Bazar, Dhaka-1215, Bangladesh SWIFT: SEBDBDDHKRN , Email: Sebdkb@gononet.com A/C 001511100003467

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Production Capacity:

Garments: 27,000 Pcs. per day (with 18 lines) Knitting: 04 Tons per day Dyeing Capacity: 05 Tons per day Finishing: 08 Tons per day Intimate: 29,000 Pcs Per day (with 16 lines)

Factory Space: Turnover: Total Manpower:

6 Acres US$ 20.00 million (RMG + Intimate) 2365

Management Personnel: 130

1.8 Management Process of HCKL

Director of Board
Merchandiser

C.E.O.

Account

Commercial

Manager (HR)

Production Manager

Dyeing Manager

Knitting Manager

Maintenance Manager

Manager

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1.9 Code of Conduct Code of conduct for members of the board and senior management: The Board of Directors (the "Board") of the company, apart from following in actual practice, has adopted the following written Code of Conduct and Ethics (the "Code") for Directors and senior management personnel of the company. Senior management personnel shall mean all senior members of the management team, one level below the Executive Directors such as Sr President / President of each Division of the company, other functional heads and the Secretary of the company. This Code is intended to focus on all the Board members and senior management personnel on areas of ethics, integrity and honesty, providing guidance to help them recongnize and deal with ethical issues; mechanisms to report unethical / dishonest conduct; and help foster a culture of honesty, integrity and accountability. The Code of Conduct as approved by the Board and subsequent amendments, if any, thereto by the Board shall be posted on the website of the company. 1.9.1 Inerpertation of Code In this code wherever the word "Director" appears, it will also include senior management personnel to the extent applicable. Any question or interpretation under this Code of Business Conduct and Ethics will be considered and dealt with by the Board or any committee or any person authorized by the Board on its behalf. The Board, in justifiable cases, for reasons to be recorded in writing may waive any condition of the Code for compliance such, that it is not prejudicial to the interest of the company. The reasons for such waiver will be available at the Registered Office of the Company for information. Each and every director and senior management personnel is expected to comply with the letter and spirit of this Code. 1. Conflict of Interest: Directors must promptly disclose to the company potential conflicts of interest regarding any matters concerning the company. A "conflict of interest" can occur when:

A. A Director's personal interest is adverse to or may appear to be adverse to the

interests of the company as a whole. B. A Director, or his / her relative, receives improper personal benefits as a result of his / her position as a Director of the company. Explanation: The expression Relatives in this Code means dependent parents, brothers, sisters, spouse, children, daughters-in-law and sons-in-law, to more or less fall in line with the definition of this term in Accounting Standard 18 prescribed by the Institute of Chartered Accountants of India.

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As illustrations only and being not exhaustive, some of the usual instances of conflicts of interest which directors should avoid, are listed below: (i) Relationship of company with third-parties Directors shall not receive a personal benefit from a person or an entity, which is seeking to do business or to retain business with the company. They shall not participate in any decision-making process involving another entity in which they have direct or indirect interest. (ii) Compensation from non-company sources Directors shall not accept compensation (in any form) for services performed for the company from any source other than the company. (iii) Gifts : Directors shall not offer, give or receive gifts from persons or entities dealing with the company, where any such gift is perceived as intended directly or indirectly, to influence any business decision. Gifts given to suppliers or customers or received from suppliers or customers should be appropriate to the circumstances and should not be of a kind that can create an appearance of impropriety. It is particularly clarified that gifts given or received on festive occasions consistent with the accepted business practices and which cannot be reasonably construed as payment or consideration for influencing or rewarding a particular decision or action, should not violate this Code. 2. Corporate Opportunities: Directors are prohibited from:

A. exploiting for their personal gain opportunities that are discovered through the
use of company property, company information or position as a director, unless the opportunity is disclosed fully in writing to the company's Board of Directors and the Board declines to pursue such opportunity; B. Using the company's property or information for personal gain. 3. Confidentiality: Directors must maintain the confidentiality of information relating to the company which comes to their knowledge in the course of the discharge of their functions and any other confidential information about the company that comes to them, from whatever source, except when such disclosure is authorized or legally mandated. For purposes of this Code, "confidential information" includes all un-published information relating to the company. 4. Compliance with laws, rules and regulations; fair dealing: Directors must comply, and oversee compliance by employees, officers and other staff, with laws, rules and regulations applicable to the company / its personnel, including insider trading regulations.

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Directors must deal fairly, and must ensure fair dealing by employees and officers, with the company's customers, suppliers, competitors and employees. No payment or transaction should be made, undertaken, by a Director or authorized or instructed to made or undertaken by any other person or the company if the consequence of that transaction or payment would be the violation of any law in force. Directors will always act to the best of their knowledge, belief and effort in the best interests of the company and all its stakeholders, including employees, shareholders and others. 5. Encouraging the Reporting of any Illegal or Unethical Behavior: Directors should promote ethical behavior and take steps to ensure that the company:

A. Encourages employees to talk to supervisors, managers and other appropriate

personnel when in doubt about the best course of action in a particular situation. B. Encourages employees to report violations of laws, rules, regulations or the company's Code of Conduct to the appropriate personnel. C. Iinforms employees that the company will not allow retaliation for reports made in good faith.

6. Compliance Standards: All suspected violations of this Code shall be promptly reported to the Board and such violations are subject to investigation by the Board or any Committee / or any person(s) so designated by the Board. Violations will be investigated by the Board or any such designated persons / committee and appropriate action will be taken in the event of any such violation. B. Directors should inform the Company immediately about the emergence of any situation which may disqualify him from directorship. C. It shall be the Endeavour of every Director to attend as far as possible and actively participate in meetings of the Board and Committee thereof on which they are members. 1.10 Social Responsibilty Hypoid Composite Knit Ltd follow the all rules of corporate social responsibilty. In the following they are described: Compliance with laws and workplace regulations: HCKL complies with the laws and regulations in regard to labor practices, welfare, health and safety, remuneration, environment and custom compliance etc Prohibition of forced labor: HCKL does not use forced or involuntary labor of any kind including prison labor, debt bondage, forced labor, or labor that is required as a political coercion or as punishment for holding or for peacefully

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expressing, political views. HCKL will not knowingly do business with the vendors or suppliers who use forced in any form. Prohibition of child labor: HCKL does not use child labor as well as will discontinue business relation with such supplier who uses child labor. Prohibition of harassment or abuse: HCKL is commited to fostering work environment where all individuals are treated with respected, professionaalism and courtesy. In our view, harassment is a conduct which leads to an intimidating, hostile workplace. HCKL strictly prohibit corporal punishment or other forms of harassment, abuse or coercion, whether mental or physical, or sextual harassment. Compensation and benefits: HCKL ensures the payment of minimum wages required by the laws of the country, including all mandated wages, bebefits and additional payments to its workers and staff. The company pays compensation and bebefits prescribed by the local law to its skillded, semi skilled and unskilled workers. Hours of work: HCKL complies with the local law as prescribed about working hours. No one is required to work more than 8 hours a day and 48 hours a week as a regular work hour. In case of OT work, total working hour will be maximum 10 hours a day and 60 hours a week. The company provides one day off in every seven day period. Prohibition of discrimination: In HCKL there is no discrimination about age, gender, caste, social group, political group etc. Health and safety: HCKL complies all laws and regulations of the land regarding health and safety and provides a safe and healthy work environment for all of its employees and workers and removes all sorts of potential hazards that may cause accidents in the workplace. Freedom of association and collective bargaining: HCKL respects the rights of employees regarding their decision of whether to associate or not associat with any group, as long as such groups are legal in Bangladesh. Environment: HCKL complies with all environment rules, regulations and standards applicable to its processes and practices in its work environment. Custom Complience: HCKL complies with all applicable custom laws and in particular establishes and comolies with laes regarding illegal transshipments. Security: HCKL maintains vigilant security system to guard against the introduction of non manifested cargo into outbound shipments. o HCKL supports all actions to discourage smugging of goods and maintains a system to monitor the shipment loading process in the factory premises.

1.11 Quality Control & Assurance At Hypoid Composite LTD, we believe that quality starts at the tip of the Needle: the cutters, stitching operators, the finishing staff and production supervisors, are all responsible in controlling and assuring quality. An entirely independent audit department makes sure that the products are being manufactured exactly as per given specifications. It has complete authority to pass or fails any consignment before presenting it to the final inspection. This process allows us to say that Rules like fit for

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purpose and do it right first time is not mere slogans rather deeply embedded culture in HCK Fabrics. 1.12 Work Place Environment As a responsible apparel producer, Hypoid composite provides employees a work environment high above the law-required level. Hypoid composite installed and has updated lighting ventilation and ergonomics of its plants using latest technologies like bus bar for electrical fitting, overhead mirror reflectors for lamps, forced duct ventilation and so on. The goal is to exceed requirements of local legislation and reach the global standards, and thereby support clients images and sourcing principles.

1.13 Certification Being duly certified from leading brands and organizations in ISO 9001:2000 WRAP, certicate No 10628 OEKOTEX: Standard , Test no 08, ID: HBD.61520 BSCI Certified Gots Certified Wall-mart evaluated. Supplier ID: 28084998 BGMEA, Registation No: 4977 BKMEA, Registation No: 979-A/2006

1.14 Achievement BSCI first audit the Hypoid Composite Knit Ltd, DBID: 20609 GOTS certificate was taken. ID: 28084998 HCKL found OEKI-TEX certificate of Standart Composite Knit Mill in Bangladesh which ID NO is HBD.61520, Test No 08

1.15 Extra Facilities That Provided By HCKL Competitive Price Highest quality level On time delivery Shortest lead time Maintain social commitments Customer satisfaction Meeting Buyers compliances

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1.16 Main Buyer SL No.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. NDT 11. 12. 13. 14. MJC BJD Inc Red Cats Holland Fashion Group JC Penny Wall mart Multiline Inditex S.A. (Zara) Kik Peter Werth Gor Factory Puig Jarner Main knitting

Buyers

1.17 Product Details Ready-made Garments Polo Shirt (Basic/ Fancy) T-Shirt (Basic/ Fancy)) Sweat Shirt & Sweat Pant Ladies Wear Childrens Wear Sports Wear Intimate Fabrics Single Jersey (S/J) S/J with Lycra Alternate/Full Feeder Heavy Jersey Autumn Jersey Honeycomb Pique

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Lycra Pique Diamond Pique Single Lacoste Double Lacoste 1 X 1 RIB 2 X 2 RIB 1 X 1 RIB with Lycra 2 X 2 RIB with Lycra Flat Back RIB Irregular RIB Interlock Interlock Double Lacoste Fleece French Terry Herringbone Thermal/ Or Waffle Yarn Dyed. Slub Yarn Nappy Yarn Viscose Cotton Modal Poly Cotton

1.18 Machineries & Amount in Dyeing Finishing & Lab Lab Section Machineries Lab Dyeing Machine Washing Machine Dryer Ph Meter Bursting Strength Tester Crock Meter Pilling Tester Data Color Light Box Amount 02 02 02 01 01 01 01 01 01

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Dyeing Section Machineries Sample Dyeing Machine Bulk Dyeing Machine Amount 02 06

Finishing Section Machineries Stenter Tumble Dryer Compactor Quality Inspection Machine Amount 01 02 01 01

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Chapter 02 Raw Materials

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2.1 Raw Material Raw material plays a vital role in continuous production and for high quality fabric. It is a unique substance in any production oriented textile industry.

2.2 Types of Raw Material 1. 2. 3. 4. Yarn Fabric Dye stuff Chemical and Auxiliaries

2.3 Source of Raw Material Yarn: All the yarns used from Al Haj Karim Sppining Mills Ltd. Also collected from Isaq Spinning Mills, Salek spinning Mills, Korotoya Spinning Mills. Lycra: Roica and Spandex from Taiwan. Imported: Loyal spinning Arunchal Precot Alps RSWM Sumruddha Protiv Cheslind

2.4 Dyestuff Dyestuff for Cotton (Reactive dye) Collected from: Oxicolour BD Dysin International RTC International Chemitech Alamgir Traders Huntsman City Chemicals

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Dyestuff for polyester (Disperse dye) Collected from:

Camitex Exim Cam Corporation Huntsman Noor International Dysin International

Brightener: Legend Dycams

2.5 Remarks The price of the product is most secret matter of the Industry. They are not interested to flash the cost related data. So we could not collect the actual price of the product.

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Chapter 03 Knitting Section

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3.1 Process Definition of Knitting Knitted fabric generally produced by form of loop. Any circular knitted fabric is composed of row after row of interloping or interlocking of loops. Different types of fabric are made of different method. The gross dimension of knitted fabric is simply a reflection of any shape & size of individual loops. There are several key variables in the production which affect the average shape & size of the loops. After knitting the gray fabric is dyed to required shade & finished to required weight & width.

3.2 Variables of Knitting During production of fabric in circular knitting machine following parameters must be maintain: Machine Diameter; Machine RPM (Revolution Per Minute); Number of feeds or feeders in use; Required time (Machine running time); Machine running efficiency. Yarn Count Yarn Twist Spinning system No of ply of the yarn Stitch length Yarn tension Take down tension Yarn quality Machine gauge

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3.3 Classification of Knitting

Knitting

Warp Knitting

Weft Knitting

Circular Knitting

Flat Knitting

Single Jersey

Interlock/Terry

Double Jersey

3.4 Different Qualities of Yarn Used for Knitting Process

Type of yarn Cotton Spandex yarn Grey Mlange (C-90% V-10%) PC (65%Polyester & 35% cotton) CVC

Count 16s, 20s, 24s, 26S, 28S, 30S, 34S, 40S 20D, 40D 24S, 26S 24S, 26S, 28S, 30S 24S, 26S, 28S, 30S

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3.5 Machine Description of Knitting Section Circular Knitting Machine Single Jersey Double Jersey Total no of M/C No. of line : Single Jersey, Double Jersey : 03 : 03 : 06 : 01

3.5.1 Circular Knitting Machine

Circular knitting m/cs. are widely used throughout the knitting industry to produce fabric. This m/c can be built in almost any reasonable diameter and the small diameter of up to five, which are used for wear. Machine for outerwear and under wear may vary from 12 inch to 60 inch in diameter according to manufactures requirement. This m/c can be used either as fabric or for making garments completely with fancy stitch. Latch needles are commonly

employed in all modern circular m/c because of their simple action and also their
ability to process more types of yarns. Plain circular m/c uses only one sets of needles, circular rib m/c uses two sets of needles i.e. Cylinder needle and Dial needle, the interlock circular knitting m/c also uses two sets of needles by needles are long and short respectively for both dial and cylinder, that is why multiple design and thick fabric can be produce with that m/c. That m/c is also called double Jersey m/c.

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 M/c. Gauge needle/inch (varies according to diameter)

Needle Type Latch Needle bed type Single cylinder, Double cylinder, Cylinder & Dial, long or short needles for cylinder and dial. Two principle operation exist: 1. English system Where the cams and yarns strands revolve by needle and fabric take down is stationary. 2. American system Where the needles and fabric take down revolves by cams and yarn strands are stationary.

3.5.2 Important Equipment of Circular Knitting m/c 1. START/STOP/INCH BUTTONS: Complete set of easily accessible start/stop/inch buttons at top in each leg. 2. RATCHET LEVER: Permit hand movement of the M/C. 3.AUTO STOP MOTION: Automatic three stages 24v yarn motion, positive feed tapes & knitting zone. Indicator lamps are on individual stop motions & on the main control panel. While the yarn is broken we can find the location which is broken as well as to repair, meanwhile the motor can brake and stop operation at once to keep the security of M/C. 4. FREE STANDING SIDE CREEL: With an active reserve package for each feed. 5. AUTOCOUNTER: Two shift revolution with display counter with predetermined stop, to settle freely the weight or yardage of fabric. 6. VARIABLE SPEED DRIVE WITH M/C BRAKE: Transistor inverter provided for free controlled, the process of V.s. motor-drive from slow operation to normal operation is quite & fast break to prevent damages in case of needles or yarn breakage. 7. FABRIC TAKE UP SYSTEM: With variable speed control by a belt drive set can be adjusted the speed for different course of fabric-constant and uniform fabric tension. 8. SAFETY GUARD SWITCH:

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Machine cannot be started with guards open; this guards have reinforced fiber glass window for easy fabric inspection. 9. AUTO LUBRICATION: The automatic central pressurized oil sprayer can be adjusted at cycling time and quantity to make cylinder, dial, sinker rings cam, needles and sinkers lubricated enough, besides it has the function cooling and clearing. 3.6 Other Machine in Knitting Section 01. Electric 02. Balance for Fabric Weight. 03. Electric Balance for GSM check. 3.7 Layout of Knitting Section

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3.8 Management Organ gram of Knitting Section

Manager of Knitting

Knitting Executive

Flat Knitting Executive

Sr. Fitter man

Production officer

Operator

Fitter man

Helper Supervisor Quality Incharge

Needle man Delivery man Quality Supervisor

Operator Operator Quality Inspection

Helper Helper Asst. Quality Inspection

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3.9 Man Power Of Knitting Section Section Manager Production officer Quality Section Knitting Master Fitter man Needle man Supervisor Operator Helper Total No. of Person 01 01 02 01 03 03 01 12 10 34

3.9.1 Shift Change Shift of twelve hours. Shift changes after a week on Saturday. 3.9.2 Responsibilities of Production Officer From getting an order of upper level all responsibilities are on the production officers. They work with a troop of operators, helpers, fitters etc. to finish the production in due time. In the meantime production officers bear all hazards, problems. They have to explain to the manager for any type of production hamper. 3.10 Recommendation Points Buyer Diameter of the fabric and Design of the fabric Total wt. of the fabric and Color of the fabric Handling & fastness property Finishing type of the fabric Types of yarn, GSM of the fabric and Yarn count 3.11 Specification of the Machines Machine No: 1, 2 & 3 (Rib Machine)

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Technical Data: Machine Diameter: 30 Machine Gauge: 18 No of Feeders: 60 No of Cam: 61 Production Range: Rib Interlock Ottoman Thermal drop Origin: Made in Taiwan Brand Name: LKM Machine No: 4, 5 & 6 Single Jersey machine: Technical Data: Machine Diameter: Machine Gauge: No of Feeders: No of Cam: Production Range: Plain & Drop Needle Lactose Pique Feeder stripes. Origin : Brand name :

30 24 90 30

Made in Taiwan LKM

3.12 Diffirent Parts of Knitting m/c 1 Legs 2 Cylinder 3 Dial 4 Needle 5 Cam Parts 6 Feeder guide 7 Cam 8 Supply Package 9 Creel 10 Top Stop motion 11 Anti Snarl Device 12 Tensioner 13 Positive feeder 14 Knitted fabric 15 Fabric spreader

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16 Fabric withdrawal roller 17 Fabric winding roller

The Needle: The hooked metal needle is the principle knitting element of the knitting machine. Prior to yarn feeding, the needle is raised to clear the old loop from the hook and to receive the new loop above it on the needle stem. The new loop is then enclosed in the needle hook as the needle stars to go down. The hook then draws the new loop down through the old loop as the latter slides over the outside of the descending bridge of the closed hook. All needles must therefore have some method of closing the needle hook to retain the new loop and exclude the old loop. Sinker: The Sinker is the second primary knitting element. It is a thin metal plate with an individual or a collective action operating approximately at right angles from the hook side of the needle bed, between adjacent needles. It may perform one or more of the following functions, dependent upon the machines knitting action and consequent sinker shape and movement: Loop formation, Holding down and Knocking-over. Cams: Cams are the devices which convert the rotary machine drive in to a suitable Reciprocating action for the needles and other elements in the circular knitting machine. They are placed in the cam box. Positive feeder: A feeder supplies yarn to needles. A positive feeder contains the following parts.

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a. Knot catcher: This part finds any fault in yarn. b. signal lamp: when knot catcher finds any fault this part light s on. c. Yarn tensioner: this part gives proper tension to yarn for proper knitting. d. Storing unit: Sufficient yarn is stored here.

Creel: This part is used to continue yarn packages.

Cylinder: The needles are set into the trick of cylinder and the cylinder moves with needles. This frame contains needles, cams, jacks, and sinkers.

Lycra Feeding Device: Lycra feeding device provides a 100 % positive yarn in feed of Lycra fibers on circular knitting machines. Lycra feeding device units are available to ensure ease of operation on different circular knitting machines. One unit can serve up to four knitting systems. Take-up roller: After producing fabric take up roller take up the fabric.

Indicator: Its indicated the any type of yarn breakage or faults in m/c. Needle detector: This part detect the any type of faults of needles.

PULSONIC Pressure Oiler: Assured even oil distribution over the entire circumference of the

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cylinder. Oil volume can be set separately for each lubricating point. Low oil consumption, since no oil is wasted at the lubrication points. Low power costs as no compressed air is required Adjustable fan: This part removes lint, hairy fibre from yarn and others. To clean the dust by air flow.

Sinker ring: Sinkers are placed in sinker ring.

VDQ pulley: This part is used to control stitch length of the knitted fabric.

Timing belt/Tooth belt: This part helps machine to stop immediately.

Air gun nozzle: To feed the yarn; sometimes it is used for cleaning purpose.

Micro processor: It is used for driving m/c & feeding yarn & delivered fabric is controlled by it.

Expander: To control the width of the knitted fabric. No distortion of the knitting courses. Even take down tension in the knitting machine. As a result, an even fabric structure is achieved over the entire fabric width. The deformation of the knitted fabric goods can be reduced. Uniwave Lubricators: The Uniwave lubricator provides uniform lubrication to needles, cam tracks, lifters and other knitting machine components. The patented nozzle construction separates the air-oil mixture into air and droplets of oil.

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3.13 Points Should Be Considered For GSM Changing VDQ (Variable Dia, quality control) Pulley diameter. Yarn Count. Machine gauge. Cam position. Take up motion.

3.14 Factors That Should Be Considered For Changing of Fabric Design: Cam arrangement. Needle Butt setting & Needle dropping. Using of different colors in selected feeder. Using of jacquard mechanism. Size of the loop size.

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3.15 Process Flow Chart of Knitting

Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tape positive feeding arrangement and tension device

Knitting

Withdraw the rolled fabric and weighting

Inspection

Numbering

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3.16 Different Parameters in Knitting Section Machine diameter Machine rpm Number of feed or feeder in use Machine gauge Count of yarn Relationship between knitting parameter: Stitch length increase with decrease of GSM : If stitch length increase then fabric width increase . If machine gauge then fabric decreases If yarn count increase then fabric width increases For finer gauge, finer count than should use Effect of stitch length on color depth: If the depth of color of the fabric is high loop length should be higher because in case of fabric with higher loop length is less compact. In dark shade dye take up% is high so GSM is adjusted then. Similarly in case of light shade loop length should be relatively smaller.

3.18 Product Quality Check To check the quality & achieve the desired specification following measure are taken: Check yarn input tension. It Should be 4-5 gm/tex Check the stitch length in 5 different feeder, it must be same as per the required Check greige GSM Check wales/3 cm or course/3 cm if required Check the fabric whether it contains any knitting faults Check R.P.M.

3.19 Production Calculation A. Production/shift in kg at 100% efficiency:

RPM No. of Feeder No. of Needle SL(mm) 3527.80 Yarn count

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B. Production/shift in meter:

RPM No. of Feeder 60 12 Efficiency Course / cm 100

C.Fabric width in meter:

Total no. of Needles used in knitting Wales / cm 100

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3.20 Photo Gallery of Knitting Section

Cam

Circular Knitting Machine

Creel Arrangement

Production Measuring After Knitting

Spandex Yarn Arrangement on Creel

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3.21 Fabric Inspection Section The activity of fabric inspection section is found out a various types of fault. Here various types of fault such as- Hole, Barre mark, Pin Hole, slub etc are found. The specification of this machine is given below Gray Fabric Inspection M/c, Brand: Uzu cloth inspection machine Manufacturer: AATPR INDUSTRY CO.LTD. Model: UZ F series 900-3 Origin: Thailand. Speed: 20-25m

3.22 Knitting Faults and Their Causes and Remedies 1. Hole Mark: Causes: Holes are the results of yarn breakage or yarn cracks. During loop formation the yarn breaks in the rejoin of the needle hook. If the yarn count is not correct on regarding structure, gauge, course and density.

Remedies: Yarn strength must be sufficient to withstand the stretch as well as uniform. Use proper count of yarn. Correctly set of yarn feeder.

2. Needle Mark: Causes: When a needle breaks down then needle mark comes along the fabrics. If a needle or needle hook is slightly bends then needle mark comes on the fabrics.

Remedies: Needle should be straight as well as from broken latch.

3. Sinker Mark:

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Causes: When sinker corrode due to abrasion then some times can not hold a new loop as a result sinker mark comes. Remedies: Sinker should be changed.

4. Star: Causes: Yarn tension variation during production. Buckling of the needle latch. Low G.S.M fabric production.

Remedies: Maintain same Yarn tension during production. Use good conditioned needles.

5. Drop Stitches: Causes: Defective needle. If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook. Take-down mechanism too loose.

Remedies: Needle should be straight & well. Proper feeding of yarn during loop formation.

6. Oil stain: Causes: When oil lick through the needle trick then it pass on the fabrics and make a line.

Remedies: Ensure that oil does not pass on the fabrics.

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7. Rust stain: Causes: If any rust on the machine parts.

Remedies: If any rust on the machine parts then clean it. Proper maintenance as well as proper oiling.

8. Pin hole: Causes: Due to break down or bend of the latch, pin hole may come in the fabric.

Remedies: Change the needle

3.23 Quality Assurance System of Knitting Division

After collecting fabric rolls from different machines, these fabrics need to inspect thoroughly by the quality inspectors to assure required quality before dyeing. Quality assurance of knitted grey fabric is described here. Some Points Are Needed To Be Maintained For High Quality Fabric: Brought good quality yarn Machines are oiled and greased accordingly. G.S.M, Stitch length, Tensions are controlled accurately. Machines are cleaned every shift and servicing is done after a month. Grey Fabrics are checked by 4 point grading system. List of Equipment For Quality Assurance: The list of equipments to assure quality:1) Inspection m/c. 2) Electronic balance 3) GSM cutter. 4) Measuring tape. 5) Scissors. 6) Indication sticker. Quality Assurance Procedure: Body & rib inspection:

~ 39 ~

 All rolls are kept in front of the inspection m/c time to time and are inspected over the inspection m/c visually in a pre-set speed against light. For any major or minor faults like thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle line, subsets are recorded in inspection report to classify the fabric based on the four point system. Quality Standard: Hypoid maintains the ISO: 9001:2000 standards in case of quality. Therefore, the four point system is followed to inspect the body & rib fabric. The defects found and points given against are recorded in the inspection sheet. Following table shows the four point grading system followed by inspection. 3.24 4-Point System For Fault Inspection for Knitted Fabric: Knitting Fault Slub Any kind of Hole Needle Mark/Sinker Mark Needle Broken Set up Dirt, Oil Spot, Thick, Thin, Contamination up to 3 in Length Dirt, Oil Spot, Thick, Thin, Contamination up to 6 in Length Dirt, Oil Spot, Thick, Thin, Contamination up to 9 in Length Dirt, Oil Spot, Thick, Thin, Contamination above 9 in Length Point 1 4 4 4 4 1 2 3 4

3.25 Calculation of Total Fault Based On 4-Point System Fabric Length: Roll weight x 1000 x 39.37 x 1.09361 Finish Dia x Finish GSM Point of fault: Total point calculated x 100 x 36
Point yards

Finish Dia x Fabric length

3.26 Method of Increasing Production: By the following methods the production can be increased 1. By increasing m/c speed:

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Higher the m/c speed faster the movement of needle and ultimately production will be increased. 2. By increasing the number of feeder: If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time. 3. By increasing cam angle: By increasing cam angle production is increased. 4. By imposing automation in the m/c: a) Quick starting & stopping for efficient driving system. b) Automatic m/c lubrication system for smoother operation. c) Photo electric fabric fault detector. 5. By imposing other developments: a) Using creel-feeding system. b) Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage. c) Using yarn feed control device. d) Using auto lint removal.

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3.27 Production Daily Report: Here is a daily report of production which is kept in Hypoid Composite Knit Ltd. HYPOID COMPOSITE KNIT LTD. Production Daily Report

Date:25/08/2013
M/C NO O-1 O-2 O-3 O-4 O-5 O-6 O-7 O-10 O-11 O-16 T-4 T-6 T-10 T-11 T-12 T-16 T-17 T-18 T-19 T-20 T-21 T-24 C-1 C-4 F-1 L-2 P-4 B-4 M/C DIA (inch) 26 26 30 30 30 30 30 30 30 36 17 20 19 20 20 22 22 22 23 23 23 24 30 30 26 32 42 36 M/C GAUG E 24 24 24 24 24 16 18 24 24 18 24 24 24 24 24 24 24 24 24 24 24 24 28 28 24 20 24 24 YARN COUNT 24/1 CD 24/1 CD 26/1CB+2 0D 30/1CB+2 0D 34/1CB+2 0D 24/1CD+7 0D 26/1CB 26/1CB+2 0D 26/1CB+2 0D 26/1CB 26/1CD 26/1CD 26/1CD 26/1CD 26/1CD 26/1CD 26/1CD 26/1CD 24/1CD 26/CD 26/1CD 24/1CB 24/1CD 24/1CD 36/1CB 36/CB,20 D 28/CD 40/CD FABRIC TYPE S/J S/J Lycra S/J Lycra S/J Lycra S/J 1*1LyRi b Lycra Interlock Lycra S/J Lycra S/J 1*1Rib S/J S/J S/J S/J S/J S/J S/J S/J S/J S/J S/J S/J S/J S/J S/J Fleece S/J Lycra S/J ACTUA L G.S.M 152/55 152/55 200 180/85 180/90 280 210 190 200 155/80 132/35 132/35 132/35 132/35 132/35 130/32 130/32 130/32 152/55 130/32 130/32 152/55 152/55 152/55 132/35 210 130/32 180/90 FINIS H G.S.M 180 180 250 220 180 300 260 250 250 210 160 160 160 160 160 160 160 160 180 160 160 180 180 180 160 250 160 220 STITCH LENGT H 2.80 2.80 3.20 3.10 3.00 2.80 2.95 3.20 3.20 2.75 2.85 2.90 2.80 2.80 2.90 2.85 2.85 2.85 2.80 2.80 2.80 2.80 2.80 2.80 2.85 4.25,1.60 2.86 2.85 RUNNI NG S.L 2.79 2.80 3.21 3.10 3.00 2.79 2.96 3.19 3.21 2.75 2.86 2.91 2.81 2.79 2.91 2.85 2.85 2.85 2.80 2.80 2.79 2.79 2.81 2.79 2.82 4.20,1.60 2.85 2.80 BUYER

Tom Tailor Tom Tailor OBS OBS I.C company S. Oliver Tom tailor S. Oliver S. Oliver I.C company DR&S DR&S DR&S DR&S DR&S ESPRIT ESPRIT ESPRIT S. Oliver Tom Tailor Tom Tailor Tom tailor S. Oliver S. Oliver I.C Company Tom Tailor S. Oliver OBS

~ 42 ~

3.28 Remarks & Conclusion: Grey fabric in the good condition and there are no faults in which it leaves knitting section so that before any bleaching, dyeing or finishing treatment has given to it. So that there are no faults found for knitting of fabric after dyeing process. Also the GSM and diameter of the fabric should meet the requirements.

~ 43 ~

Chapter 04 Lab Dip Development

~ 44 ~

4.1 Definition Lab Dip Development means the sample which is dyed according to buyers requirements (similar shade and so on).Depending on lab dip development sample dyeing and bulk production dyeing planning done. 4.2 Objective of Lab Dip To calculate the recipe for sample dyeing. To compare dyed sample with swatch by light Box or Spectroflash/ Spectrophotometer. To calculate revise recipe for sample dyeing. Finally approved Lab Dip (Grade: A B C) 4.3 Purpose of Laboratory Laboratories can help determine the products we manufacture, sell and distribute comply with safety and performance standards and adhere to international regulations, before they hit store shelves. Our correlation testing and participation in industry studies helps ensure consistency in HCKL performance around the world. CPSC registered as an accredited laboratory for HCKL third-party testing AATCC, ASTM, ISO and other international standards testing. Accredited by the China National Accreditation Service for Conformity Assessment (CNAS) and China Metrology Accreditation (CMA) to National Safety Regulation GB 18401 .State regulation screenings including California Prop 65 .Technical consultation for federal regulations including flammability, fiber content and care labeling .Technical support covering product development, care label verification, fiber identification, and garment and fabric construction analysis .Specialty animal fiber identification (cashmere, alpaca and camel) .Lead, phthalates, heavy metal, azo dye and other restricted substances testing . 4.4 Development of Lab Dip In HCKL
Receiving standard swatch

Spectrophotometer reading

Recipe start up software

Start up recipe given

Manual dispersion (pipatting)

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Pot dyeing

Unload

Normal wash

Acid wash

Hot wash

Cold Rinsing

Drying

4.5 Colour Measurement of Standard Sample Color measurement is mainly done for the purpose of shade matching as perfectly as possible. Shade matching of the produced sample with the standard one is compulsory. Color measurement can be done by two methods

Color measurement

Manual method

Instrumental method

In manual method, the std. samples color is measured by comparing it with previously produced samples of different tri-chromatic color combination. The sample with which the color of the std. matched, that samples color recipe is being taken for shade matching .This methods accuracy completely depends on the vision of the person related to it but person must be needed gather experience about color matching. The instrumental method is more reliable if it is operated accurately to do the work of color measurement. Spectrophotometer interfaced with a PC is used for shade matching .This instrument works with the principle of reflectance measurement of light

~ 46 ~

at different wave length. When the standard sample is being subjected under spectrophotometer, then the instrument suggest a recipe with required tri-chromatic colors within the tolerance limit of color difference. In this way, color measurement of the standard sample is carried out for the purpose of shade matching. 4.6 Preparation and Storage of Stock Dyes and Chemicals Preparation of Concentration of stock dye soln Normally 0.1%, 0.5%, 1%, 1.5% and 2% stock solution of dyes are prepared in beakers for daily used. Preparation of Concentration of stock chemical solnSimilarly 25% salt and 25% soda stock solutions are prepared in beakers for daily use. 4.7 Dyes and Chemicals Measuring Formula For Laboratory The amount of dye solution (ml) is calculated as follow Fabric weight x Shade % Amount of dye soln (ml) = ---------------------------------------Concentration of stock dye soln % Example In recipe, Fabric wt. = 5gm Shade % = 2% [If used 0. 5 % stock soln of dyes] then , 5X2 Amount of dye soln (ml) = --------0. 5 The amount of chemical soln (ml) is measured as follow Fabric wt. * M : L * g/l Amount of chemical soln (ml) = -------------------------------------1000 * Conc. of stock soln% Example In recipe, Fabric wt. = 5 gm Salt = 20 g/l = 20ml .

M: L = 10

~ 47 ~

[ if taken 25 % stock soln of salt ] then , 5 x 10 x 20 Amount of chemical soln (ml) = ----------------------------------- = 4 ml 1000 x 0.25 4.8 Machineries Used For Lab Dip In Hypoid Machine no. Name of machine Company Model Origin Machine no. Name of machine Brand Origin Machine no. Name of machine Brand Type of light Machine no. Name of machine Brand Origin : 01 : Lab dyeing machine : Xiamen Rapid Company Ltd. : H-24SF : China : 02 : Lab dyeing machine : SDLATAS : UK : 03 : Light box : VERIVIDE : 5 types TL83 TL84 D65 Florescent UV : 04 : Data color machine : SAV : USA

Machine No Machine Name Origin Maximum capacity Readability Hem No

: 05 : Digital Balance : USA : 150 gm : 0.01 gm : AR1530

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4.9 Stock Solution Preparation

SHADE % 0.0001-0.009 0.10-0.99 1-1.99 2-3.99 4 to more STOCK SOLUTION % 0.1 0.5 1 2 4

FOR PRODUCTION:
SL 1 2 3 4 5 6 7 8 9 10 11 12 SHADE % 0.0001-0.01 0.01-0.08 0.08-0.15 0.15-0.8 0.8-1.5 1.5-2 2-2.5 2.5-3 3-3.5 3.5-4 4-4.5 4.5 and over SALT 7 10 12 15 18 20 30 40 50 60 70 80 SODA 5 6 7 8 9 10 13 15 16 18 20 20 WATER 1:8

1:7

1:6

4.10 Procedure of Lab Dip A. FOR 100% COTTON FABRIC (ALL IN ONE METHOD): Fabric weight measured by electric balance. Calculate the recipe. Keep the fabric in the pot. Then required amount of dyes, water, salt, soda and other chemicals are taken to the pot by pipe ting . Start the program for dyeing. The dyeing time and temperature depend on types of dyes being used. Program 1: For light shade Fixed temp. = 600c Time = 60 min.

Program 2: For dark shade Fixed temp. = 800c Time = 60 min.

After finished the dyeing time then cold wash two times.

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 Acid wash for neutralization. Then soaping by required soap solution for 10 min. at 950c. Cold wash then drying the lab dip and compare with the standards. 4.11 Dyes Used In HCKL

Brand Name Remazole

Origin India

Dyes Name Remazole red -RR Remazole Yellow -RR Remazole Blue-RR Remazole Brill Blue-R Special Remazole turquoise Blue G Remazole Orange-RR

Price (k) 690.42 692.00 840.00 1212.0 394.00 1034.0 259.00 414.00 444.00 548.00 1110.00 533.00 551.0 55.00 236.00 251.00 418.00 304.00 462.00 281.00 800.00 380.00 675.00 875.00 400.00 400.00 700.00 800.00 850.00

Remazol

India

Synozole

Korea

Synowhite 4BK 259.00 Synozole Yellow K3RS Synozole Red K3BS Synozole Nave Blue KBF

Synozole

Korea

Synozole Blue KBR Synozol Red-HB Synozol Yellow-HB Synozole Nevy Blue-HB Dychufix Red 3BXF Dychufix Yellow 3RXF Dychufix Yellow 4 GL

Dychufix

China

Dychufix Black BHC Dychufix Orange 2RXF Dychufix Black FWN Desperse Red -60 BFY Desperse Yellow-4G Desperse Blue 562 RL Desperse Blue 60 BGF Desperse navy Blue ECOG Desperse Black ECOG

Disperse

China

Dis- Orange HF Dis- Red -HF Dis- Black-HF

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Dis Navy Blue HF Dis- Blue- HF Dis-Yellow-HF Cor- Yellow RD Cor-Red RD Cor- Blue- RD Corazole India Cor- Orange- RD

1100.0 1100.00 7500.00 624.00 600.00 656.00 1000.00

Cor- Traquise Blue G Cor-Bri- Blue- R- Sp Cor- Bri Blue- BB Libafix-Amber CA Libafix Germany Libafix First Red CA Libafix- Blue -CA

360.00 1120.0 920.00 2450.0 2250.0 2500.0

4.12 Chemical Used In HCKL Aids Chemicals Name Caustic Soda Soda Ash Light H2O2 General Chemicals Globers Salts Hydrose (BASF) Common Salt LASCOUR-717 (Detergent) Acetic Acid Acid Buper Acid Liansoft-S 300 (Cationic Softener) Belsoft-200 (Non Ionic Softner) Lian Smith-2231 (Silicon) 140 214 202 324 Price (Tk/Kg) 45 34 26 17 100 12 285 65

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Softener

Power soft -180 Resoft NS- (White Softner) Resomine-3000 (Silicon) Softner V-16 Leancrease-651

380

200 10 91 36 250 175 140 140 160 22 114 450 350 220 22 28 28 304 54 380

Anticrease Rybypon-173 Lianlevel723 (Cotton) Leveling Agent Polyester leveling Rubygal CFTR Sequestering Brusquest -E Lianseq-710 Kappa Quest -FE LASSOP Ruby soap-BIF Biltex ERH Texbrite 4-BK Leanfix-706 VEXPOK-100 Peroxide Stabilized-SE Lian-PS-66 Enzyme Bleaching Kappa Tex R98

Soaping agent Brightener Fixing Agent Peroxide Killer Stabilizer Others

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4. 13 Management System of Laboratory:

Laboratory Incharge
QC Inscarge Lab Dip Incharge

Supervisor

Assistant Lab Incharge

Senior Technician

Senior Technician

Junior Technician

Junior Technician

4.14 Manpower Laboratory Incharge Lab Dip Incharge Assistant Lab Dip Incharge Senior Technisian Junior Technisian QC Incharge QC Supervisor Senior Technisian Junior Technisian Total number of manpower : 01 : 01 : 01 : 02 : 02 : 01 : 02 : 04 : 02 : 16

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4.15 Different Equipments Picture of Laboratory

Data Color m/c

Lab Dyeing m/c

Washing m/c

Sample Drying m/c

Rota Wash m/c

Wash Color m/c

~ 54 ~

Crock Meter

Non Organic Lab Dyeing m/c

Verivide Light Box

Rapid Dyeing m/c

Different Color (Dyes) & Electronic Balance

~ 55 ~

Chapter 05 Gray Quality Control

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5.1 Introduction Quality control, or QC for short, is a process by which entities review the quality of all factors involved in production. This approach places an emphasis on three aspects . Elements such as controls, job management, defined and well managed processes, performance and integrity criteria, and identification of records. Competence, such as knowledge, skills, experience, and qualifications. Soft elements, such as personnel integrity, confidence, organizational culture, motivation, team spirit, and quality relationships. Controls include product inspection, where every product is examined visually, and often using a stereo microscope for fine detail before the product is sold into the external market. Inspectors will be provided with lists and descriptions of unacceptable product defects such as cracks or surface blemishes for example. The quality of the outputs is at risk if any of these three aspects is deficient in any way. Quality control emphasizes testing of products to uncover defects and reporting to management who make the decision to allow or deny product release, whereas quality assurance attempts to improve and stabilize production (and associated processes) to avoid, or at least minimize, issues which led to the defect(s) in the first place. For contract work, particularly work awarded by government agencies, quality control issues are among the top reasons for not renewing a contract.

5.2 Objects Of Quality Control Seeking customers needs and expectations, and meeting their requirements to the fullest. Knowing and achieving the applicable regulatory requirements. Simultaneously improving market shares. Improving productivity and reducing costs. Providing necessary resources including knowledge and training to employees. Involving people at all levels. Maintaining high standard of safety, health, and environment. 5.3 Quality Management System In HCKL

QA

On-line

QA
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Off-line

On-line quality control: There are two types of online quality control. These are as follows:1. Raw material control: Raw material control means control the quality of raw materials (e.g.- quality of grey fabric, dyes chemicals and auxiliary) 2. Process control: Process control means the selection of right process and controlling of some parameters. Such as pH, water hardness, water volume, temperature, reels speed. Pump pressure etc. On-line Tests: Dyed fabric Shade check Wash fastness Water fastness

Off- line tests: Off- line tests for finished fabrics are divided into two groups. These are as follows: Physical tests Chemical tests Physical tests: GSM of fabric Abrasion resistance/pilling Dimensional stability Spirality test Color fastness to rubbing test(dry/wet)

5.4 List of Equipments The list of equipments to assure quality:Inspection machine. Electronic balance GSM cutter. Measuring tape. Scissors. Indication sticker.

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5.5 Body And Rib Inspection All rolls are kept in front of the inspection m/c time to time and are inspected over the inspection m/c visually in a pre-set speed against light. For any major or minor faults like thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle line, slubs etc are recorded in inspection report to classify the fabric based on the four point systems.

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Chapter 06 Batching

~ 60 ~

6.1 Batching Batching is the process to get ready the fabrics which should be dyed and processed for a particular lot of a particular order.

6.2 Object of Batching To receive the grey fabric roll from knitting section or other source. Turn the grey fabric if require. To prepare the batch of fabric for dyeing according to the following criteria Order sheet (Received from buyer) Dyeing shade (color or white, light or dark) M/C capacity M/C available Type of fabrics(100% cotton, PE, PC, CVC) Emergency To send the grey fabric to the dyeing floor with batch card. To keep records for every previous dyeing.

6.3 Function or Purpose of Batch Section To receive the grey fabric roll from knitting section or other source. Turn the grey fabric if require. To prepare the batch of fabric for dyeing according to the following criteria Order sheet (Received from buyer) Dyeing shade (color or white, light or dark) M/C capacity M/C available Type of fabrics(100% cotton, PE, PC, CVC) Emergency To send the grey fabric to the dyeing floor with batch card. To keep records for every previous dyeing.

6.4 Batch Grey Fabric Inspection The inspection and grading of fabric quality is one of the important functions of Quality Control in the grey or finished state, the grading of fabric is a difficult task, taking two primary considerations: as the frequency of effects and the seriousness of defects. The grading has two primary functions: First, to classify the fabrics according to standard qualities based on the end-use and costumer demands and second, to supply information as to the qualities actually being produced.

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The Knitted fabric can be classified into three levels of quality, each one have a number of points for defects as follows. The First quality level The Second quality level The Third quality level 40 points per 100 Linear Yards. (40 80) points per 100 Linear Yards. 80 points or more per 100 Linear Yards.

6.5 General Instructions for The Final Inspection a. All pieces will be graded on the base of 40 points per 100 linear yards Mapping will be done on each piece to insure proper grading. Do not count more than 4 points per one yard. b. All defects must be recorded and marked in final inspection and an accurate account of points made to insure proper grading. c. All fabric must meet specifications. d. At the end of each piece of fabric, the inspector will add up total points and decide whether the piece can be shipped as first quality or not, reworked, placed in lower quality, or cut and upgraded for shipment. Fifteen yards or more can be shipped as first quality. e. The quality control supervisor must approve the grading of all quality levels and check the lower quality. f. Major or unsightly defects in the first and last yard of a roll or piece will be cut. All defects of one yard length or more will be cut out of the piece. Defects within the first 2 inches or the last 2 inches of a piece will not be cut out or counted in the grading. g. Open defects on the back of fabric such as drops, runs and hanging picks are to be included in the grading of fabric. h. Pieces can be connected together, once each piece must be the same shade. i. j. All defects such as runs that extend more than a yard in length will be cut out. Fabric up to 70 inches will be allowed a bow of not more than 1 inch and a Bias of not more than 2 inches. k. Defects within one inch of the fabric edge will not be counted except on tubular fabrics. All defects will be counted in tubular goods.

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6.6 Grading Procedure a) All open defects or major defects counted with 4 points per defect. b) Surface defects over 9 inch length counted with 4 points per defect. c) Surface defects 6 to 9 inches length counted with 3 points per defect. d) Surface defects 3 to 6 inches length counted with 2 points per defect. e) Surface defects up to 3 inches length counted with one point per defect. f) Running defects, such as tucks, needle lines, barre, crack marks, are judgment defects Batching is the process to get ready the fabrics which should be dyed and processed for a particular lot of a particular order.

6.7 Proper Batching Criteria To use maximum capacity of existing dyeing m/c. To minimize the washing time or preparation time & m/c stoppage time. To keep the no. of batch as less as possible for same shade. To use a particular m/c for dyeing same shade. 6.8 Batch Management Primarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing manager. Some time planning is adjusted according to m/c condition or emergency. 6.9 M/C S in Batch Section
No. of M/c Machine Name Origin : 01 : turning machine : Local

6.10 Formula for Batch Selection

Maximum time for loop revolution= 3 mins For one KG loop length, L1=(Diax2x2.54)/100 m Loop length= (1000x Gray weight)/(L 1xGray GSM)

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6.11 Organ Gram of Batch Section

Batch incharge

Batch Supervisor

Operator

Helper

6.12 Process Loss Considered For Different Products

Products Body parts Collar Cuff

Process Loss 12%-14% 5%-6% 5%-6%

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6.13 Photo Gallery of Batch Section

Fabric Stored For Performing Batching

~ 65 ~

Chapter 07 Dyeing Section

~ 66 ~

7.1 Dyeing Dyeing is usually among the last of the long line of manufacturing operations which lead to the end product. 7.2 Dyeing Classification Dyeing

Super Critical

Wet Processing

Foam

Conventional

7.3 Auxiliary Substance of Dyeing Sequestering agent Defoaming agent.(without defoaming agent dyeing may be uneven) Wetting agent Anticreasing agent Antipilling agent Leveling agent Emulsifier 7.4 Raw Materials for Dyeing The raw materials used for production are1. Grey Fabric 2. Dyes and Chemicals 7.4.1 Gray Fabric Following types of grey fabrics are dyed: Single Jersey Lycra Single jersey Slab Single jersey Interlock Lacost Pique Rib Lycra Rib

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 11 Rib 21 Rib 22 Rib & others Sources: The grey fabrics are produce from this industry. All the grey fabrics that are produce from this industry are dyed in dyeing section. After fulfill all order of this industry sometime they dyed fabric in sub contact. 7.4.2 Most Common And Usable Dyes 1. Reactive Dyes (Cotton Dyeing). 2. Disperse Dyes (Polyester Dyeing

Dyeing with reactive dye: Reactive Dye Stuff: Reactive groups are present in the molecules of the reactive dyes. These dyes chemically react with fibers hence it is called reactive dyes. These type of dyes posses reactive groups which during the process of dyeing, reacts chemically with the fiber substrate to form a covalent bond so that chemically speaking it becomes a part of the fiber itself. The reaction is as followsD-F-CH=CH2+ Cell-OH Properties of Reactive Dyes: Anionic in nature Soluble in water It forms strong covalent bond with fibre Their wet fastness & light fastness are good They have better substantivity They are used in alkaline condition 7.4.3 Influencing Factors for Dyeing The PH of the bath The temperature of bath The concentration of the electrolyte The time of dyeing The liquor ratio D-F-CH2- CH2-O-Cell

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7.4.4 Recipe for Machine Wash

Recipe For Machine Wash Detergent Caustic Hydrous 0.5 1 2 gm/l gm/l gm/l

7.5 Dyeing Parameters PH Levels for Different Stages of Cotton Dyeing: SL 1. Initial Bath pH 2. Before Enzyme, bath pH 3. After Enzyme & Aquachoron ,pH 4. Before Scouring & Bleaching, pH (With Enzyme) 5. Before Scouring & Bleaching, pH (Without Enzyme) 6. Scouring & Bleaching, bath pH 7. After Scouring & Bleaching, pH 8. Before Leveling Chemicals, pH 9. After Leveling Chemicals, pH 10. After Adding Dyes, pH 11. After Addition of Salt, pH 12. After Addition of Soda, pH 13. Before Hot Wash, Bath pH 14. Hot Wash, bath pH 15. Before Softener, bath pH 16. After Softener Addition, bath pH PH in different stage PH Range 6.5~7.0. 4.5~4.7. 5.5~6.0. 5.5~5.8. 5.5~5.8. 10.0~10.5. 8.5~9.0. 6.5~7.0. 6.7~7.0 6.2~6.35 7.5~8.0. 10.5~11.0. 6.8~7.2. 8.5~8.7. 7.2~7.8. 6.5~6.8.

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PH Levels for Different Stages of Polyester Dyeing: SL 1. 2. 3. 4. 5. 6. 7. 8. Different stages of dyeing Initial bath pH Scouring, bath pH After Scouring, bath pH Before Addition of Leveling Chemicals, pH After Addition of Leveling Chemicals, pH After Addition of Colors, bath pH During Reduction Clearing, bath pH Before Softener, bath pH After Softener Addition, bath pH

PH Range
6.5~7.0. 10.0~11.5. 8.5~9.0. 6.0~6.5. 4.5~4.7. 4.2~4.3. 10.5~11.5. 6.3~6.8.

9.

5.8~6.2.

Temperature Parameters For cotton scouring For cotton cold wash For cotton hot wash For cotton acid wash For cotton dyeing 90-98 c 60-70c 80-90 c 50-60 c 80 c(for hot brand) & 60 c(for cold brand )

Time Parameters For scouring & bleaching For reactive dyeing For disperse dyeing 60-70 min 60-80 min 60-70 min

~ 70 ~

7.6 Pre-Treatment Process 7.6.1 Scouring: Gray fabric contains fax, waxes, and other impurities. The absorbance of the fabric is adversely affected due to the presence of these impurities. This leads to improper dyeing, printing and finishing in the subsequent process. These impurities are removed from the fabric by a chemical treatment. This chemical treatment is called scouring process. 7.6.2 Bleaching: Bleaching is a process for removing natural nitrogenous coloring matters e.g.- dirt, dust, husk, broken seed, leaf etc from the fabric and make it white by oxidizing or chemical treatment. Purpose of Bleaching: To remove all the natural coloring materials. To impart adequate whiteness to the fabric. It changes the textile materials which are hydrophobic in nature. It increases the dye absorption ability of the textile materials. It helps to produce an even shade during dyeing operation.

7.6.3 Washing: Washing is a process to remove waxes, fats or to increase absorbency of the fabric by chemical treatment. Washing process is specially used only for T/C and TTC dark color shades.

7.7 Key Accessories Key accessories used in pre-treatment process are: Mixing Tank Machine Tank PH Meter Eye protecting glass

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 Hand gloves Sewing Machine Gum boot Hand lifter for carrying the batch 7.8 Scouring Process The sequence for scouring process is as follows: Take water in bath at required level Load fabric in the machine Add caustic soda solution Add detergent, sequestering agent, Anti-creasing agent Circular the fabric & raise the temperature at 100C Continue circulating the fabric for 30 min at constant temp.(100C) Rinse & Drain Add acetic acid & raise the temperature at 55C Continue circulating the fabric for 10 min at constant temp.(55C) Rinse & Drain Add detergent & raise the temperature at 80C Continue circulating the fabric for 10 min at constant temp.(80C) Rinse & Drain

7.9 Bleaching Process The steps of bleaching process are as follows Take water in bath at required level Load fabric in the machine Add detergent, sequestering agent, Anti-creasing agent, Stabilizer Add caustic soda solution Circulate the fabric & raise the temperature at 60C Add hydrogen per oxide solution Continue circulating the fabric for 5 min & raise the temperature at 95C Continue circulating the fabric for 25 min at constant temp.(95C) Continue circulating the fabric & decreased the temperature at 80C Rinse & Drain Add Acetic Acid, hydrogen per oxide killer & raise the temperature at 55C

~ 72 ~

 Continue circulating the fabric for 10 min at constant temp.(55C) Rinse & Drain Add detergent & raise the temperature at 80C Continue circulating the fabric for 10 min at constant temp.(80C) Rinse & Drain.

7.10 Product Quality Check To check the quality of products, following measures are taken Check the PH of the bath Absorbency of the fabric Hardness of the water Impurities contamination of the water Heating & Cooling of the Machine.

7.11 Dyeing Sequence With Recipes Light Color Process 100% Cotton : Machine Wash: Hydrose (2g/L) +Caustic (2g/L) +Foaming Agent (0.5g/L) 30 min at 90oc Machine Washed

A. Acid (0.7g/L) 20min at 70oc M/C Neutralized Demineralization: Detergent (1g/L) Sequestering Agent (.5 g/L) Ant creasing Agent (.5 g/L) 20min at 80oc Scouring & Bleaching:

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Detergent (1 g/L) Sequestering Agent (.5 g/L) Stabilizer (.8 g/L) Caustic (3 g/L) H2O2 (3 g/L) 60min at 98c

Neutralizations (Scouring & Bleaching): H2O2 Killer (.8 g/L) A.Acid (1 g/L) 20min at 80c

Enzyme Wash: A.Acid (1 g/L) Enzyme (1%) 55min at 50c, PH =4.5

Dyeing: Ant creasing Agent (.5 g/L) Leveling Agent (1 g/L) A. Acid (.2 g/L) Dyes (According to shade %) G. Salt (According to shade %) Soda Ash (According to shade %) 60min at

Neutralization: (Dyeing) A. Acid (1 g/L) 10min at 40-50c

Soaping: Soaping Agent (.5 g/L) 20min at 70-80c Fixing & Softening:

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Fixing Agent (.5 g/l) 15min at 40c A. Acid (.5 g/L) Softener (1.5 g/L) 20min at 40c Drain the bath

7.12 Dyeing Process of Cotton Fabric (White) Dyeing sequence of cotton: (For white)

Wetting agent (Astros Scour B10.P) Ant creasing Agent [Rocklin JES] Sequestering Agent [Astros Quest AC]

Dosing at 50 C

Fabric Loading

Caustic dosing (10 min at 60C)

Stabilizer Neorate PH -5.5 FN (Dosing time 5 min at 70C)

H2O2 (Dosing 30 min at 70 C) (Run time 10 min)

Temperature rise 90C (2C/min) (Run time 60 min)

Cooling 80C

~ 75 ~

Brightener dosing 30 min

Temps raise 98C (2C/min) (Run time 40 minutes)

Cooling 80C

Rinsing wash

Soaping (Sample cutting)

Acid (Enzyme if need)

Softener

Unload

7.13 Dyeing Sequence (Cotton Fabric) Hot wash (Detergent + caustic + Astros Quest AC)

Over flow

Temperature: 95C; Run time: 30 minutes

Drain
(Dosing at normal temperature) Run time 20 minutes at the temperature 80 C

Acid for

~ 76 ~

Neutralization

Overflow

Drain

Leveling agent
(Dosing at60 C temperature)

Run time 5 minutes at the temperature 60 C

Salt dosing

Color dosing (before dosing individual mixed properly)

Soda Dosing [dosing at 600c Temp. Run time: 20 minutes]

Cold Wash & Over flow

Drain Soaping Agent at 800C RT-20 Minutes

Fixing Agent

Softener

Unload 7.14 Dyeing Sequence of Grey Mlange Process sequence: Water load in the dyeing machine (L: R=1:10)

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Fabric load in the machine

Dosing (1-5) At 50 C

Dosing hydrogen per oxide At 70C 5 min

Steam to 80 C

Run time 10 min

Shade check (not ok)

Steam 90 C (10+10) minutes

Shade check ok

Dosing Enzyme at 80 10 min (H2O2 killer)

Over flow and drain

Softener dosing at 62 C, 70%; 30 minutes.

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Then rest 30% dosing at the same temperature 15 minutes

Steam 80 C

Over flow and drain.

Color (OBA) dosing at 60 C (10+10+10+10) minutes.

Shade check not ok

Steam 60 10 min

Shade check ok

Over flow and drain.

7.15 Process Flow Chart of P/C Blend Fabric (65/35) Color: Black M: L -1:10 Polyester Part: Sequence of polyester dyeing with curve: Dosing detergent

Acetic acid (for maintained PH =4.5)

Dosing at 60C

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Leveling agent

Buffer solution

Dyes

Color steam at 130C

Shade check at 80C

If not ok

Color add at 60C

Color steam at 130C

Shade check

If ok

Reduction Cleaning: Hydrous

~ 80 ~

Caustic

Acetic Acid Cotton Part:

Hot wash (Detergent + caustic + Astros Scour B10.P)

Temperature: 95C; Run time: 30 minutes

Over flow

Drain

Acid for Neutralization

(Dosing at normal temperature) Run time 20 minutes at the temperature 80 C

Overflow

Drain
(Dosing at60 C temperature)

Leveling agent
Run time 5 minutes at the temperature 60 C

Salt dosing at 60C 10 min

~ 81 ~

Color dosing at 25 min at 60

Soda dosing 30 min in 3 steps

Color steam 60C (For normal brand dyes)

Color wash

Acid Wash

Soaping (at 70C 25 min)

Soaping wash (20 min)

Fixing if buyers requirement 10min at 80C

Fixing wash 15 minutes

Softener (10 minutes)

UN load

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 Dyeing curve:
130C 40 min Heating 20 2 C/min 2 C/min Drain Color - Leveling Buffer soln Acid

60C

Reduction Cleaning:
20 min at 80C

60 C

Heating
Drain/BD

-Acetic Acid -caustic -Hydrous

Cotton Part:
60 min at 60C

~ 83 ~

50 C

Heating
Unload

Anticreaasin agent -Leveling agent

7.16 -Hydrous Sequence of Polyester Dyeing With Curve Dosing detergent

Acetic acid (for maintained PH =4.5)

Dosing at 60C

Leveling agent

Buffer solution

Dyes

Color steam at 130C

Shade check at 80C

If not ok

Color add at 60C

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Color steam at 130C

Shade check

If ok

Reduction cleaning

Acetic acid =1gm/L Caustic =1 gm/L

Neutralization by acetic acid (PH=5.5)

Hydrose gm/L

=2

Unload

7.17 Reserve Dyeing or Resist Dyeing (Only Polyester Part Dyed of P/C Fabric)

Water filling (1: 8)

Fabric loading

Polyester dyeing (Dispersing agent) (Ant creasing agent) :0.3g/l :1g/l Chemical &Auxiliaries at 60oC & run for 10min.

(Leveling agent) (Aromatic acid)

:0.5g/l :0.23g/l

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PH check (4.5) Disperse dyes 30 min. :x% (owf) Run at 130oC for

Reduction Clearing (RC) Hydrous Caustic Soda : 2g/l : 2g/l

7.18 Process Sequence of Viscose dyeing Water filling

Fabric loading

Hot Wash, 80C, 10min

Drain

Water filling

Chemical Auxiliaries (Anti creasing agent, Sequestering agent, Leveling agent)

pH check(6.5-7.5)

Reactive dye (dosing 30 minutes)

(Run 15 Min, Temp50 oC)

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Salt dosing 2 step,60C

Run (15+15)min Soda 60 min dosing

Run 60min Shade check

Cooling

Drain

A- Acid (Neutralization)

Drain

Soaping

Drain

Hot Wash (2 or 3 times)

Cool wash

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Shade check

Fabric unload

7.19 Common Dyeing Faults & Their Remedies 1. Uneven dyeing: Causes: - Uneven pretreatment (uneven scouring & bleaching). - Improper color dosing. - Using dyes of high fixation property. - Uneven heat-setting in case of synthetic fibers. - Lack of control on dyeing m/c Remedies: - By ensuring even pretreatment. - By ensuring even heat-setting in case of synthetic fibers. - Proper dosing of dyes and chemicals. - Proper controlling of dyeing m/c 2. Batch to Batch Shade variation: Causes: - Fluctuation of Temperature. - Improper dosing time of dyes & chemicals. - Batch to batch weight variation of dyes and chemicals. - Dyes lot variation. - Improper reel speed, pump speed, liquor ratio. - Improper pretreatment. Remedies: - Use standard dyes and chemicals. - Maintain the same liquor ratio.

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- Follow the standard pretreatment procedure. - Maintain the same dyeing cycle. - Identical dyeing procedure should be followed for the same depth of the Shade. - Make sure that the operators add the right bulk chemicals at the same time and temperature in the process. The pH, hardness and sodium carbonate content of supply water should check daily. 3. Patchy dyeing effect: Causes: - Entanglement of fabric. - Faulty injection of alkali. - Improper addition of color. - Due to hardness of water. - Due to improper salt addition. - Dye migration during intermediate dyeing. - Uneven heat in the machine, etc. Remedies: - By ensuring proper pretreatment. - Proper dosing of dyes and chemicals. - Heat should be same throughout the dye liquor. - Proper salt addition. 4. Crease mark: Causes: - Poor opening of the fabric rope - Shock cooling of synthetic material - If pump pressure & reel speed is not equal - Due to high speed m/c running Remedies: - maintaining proper reel sped & pump speed. - Lower rate rising and cooling the temperature

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- Reducing the m/c load - Higher liquor ratio 5. Dye spot: Causes: - Improper Dissolving of dye particle in bath. - Improper Dissolving of caustic soda particle in bath. Remedies: - By proper dissolving of dyes & chemicals - By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the Large un-dissolved particles are removed 6. Wrinkle mark: Causes: - Poor opening of the fabric rope - Shock cooling of synthetic material - High temperature entanglement of the fabric Remedies: - Maintaining proper reel sped & pump speed. - Lower rate rising and cooling the temperature - Higher liquor ratio 7. Softener Mark: Causes: - Improper mixing of the Softener. - Improper running time of the fabric during application of softener. - Entanglement of the fabric during application of softener Remedies: - Maintaining proper reel sped & pump speed. - Proper Mixing of the softener before addition. - Prevent the entanglement of the fabric during application of softener

~ 90 ~

7.20 Machines Used In Dyeing Section Machine No: 01 Name of m/c Brand Origin Capacity Temperature : Which dyeing machine. : Tong Geng : Taiwan. : 50 Kg : Up to 140c

Machine No : 02 Name of machine Brand Origin Capacity Temperature : Winch dyeing machine : Tong Geng : Taiwan : 200kg : Up to 140C

Machine No : 03 Name of machine Brand Origin Capacity Temperature : Winch dyeing machine : Tong Geng : Taiwan : 400kg : Up to 140C

Machine No : 04 Name of machine Brand Origin Capacity Temperature : Winch dyeing machine : Tong Geng : Taiwan : 600kg : Up to 140C

Machine No : 05 Name of machine Brand Origin Capacity Temperature : Winch dyeing machine : Tong Geng : Taiwan : 800kg : Up to 98C

Machine No : 06 Name of machine Brand : Winch dyeing machine : Tong Geng

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 Origin Capacity Temperature Machine No : 07 Name of machine Brand Origin Capacity Temperature

: Taiwan : 400kg : Up to 98C

: Winch dyeing machine : Tong Geng : Taiwan : 200kg : Up to 98C

Machine No : 08 Name of machine Brand Origin Capacity Temperature : Slitting machine :ACC : turkey : 8tons/day : Up to 140C

Machine No : 09 Name of machine Brand model Origin Heater type No. of chamber Power Volt Air pressure Heater pressure Capacity : Stenter Machine : ACC : TPG 2400-6 : turkey : gas : 06 : 152kw : 380 v. : 6 Atm : 100 MBar : 8 tons/day

Machine No : 10 Name of machine Brand model Origin : Fabric Inspection Machine : OSHIMA : CCS- 2400 : Taiwan

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7.21 Layout of Dyeing Section

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7.21 Management Organ Gram of Dyeing Section

AGM

General Manager [ dyeing]

Production Manager

Dyeing Master

senior operator

superviser

operator

helper
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7.22 Photo Gallery of Dyeing Section

Winch dyeing m/c (1 nozzle)

Winch dyeing m/c (2 nozzles)

Winch dyeing m/c (3 nozzles)

Winch dyeing m/c (4 nozzles)

~ 95 ~

Chapter 08 Finishing Section

~ 96 ~

8.1 Management Organ Gram of Finishing Section

Manager

Executive

Supervisor

On Line Quality Controller

Operator

Assistant Operator

Helper

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8.2 Finishing Textile finishing , in a restricted sense , is the term used for a series of processes to which all bleached , dyed , printed and certain grey fabrics are subjected before they are put on the market . In fact , finishing includes the final treatment of every kind of fabric made from every kind of fiber . According to Textile Terms and Definition the Finishing describe as, Descriptive processes, physical or chemical, applied to a substrate to produce a desired effect. 8.3 Objective of Finishing Improving the appearance Luster, whiteness, etc. Improving the feel, this depends on the handle of the material and its softness, suppleness, fullness, etc. Wearing qualities, non soiling, ant crease, ant shrink, comfort, etc. Special properties required for particular useswaterproofing, flame proofing, etc. Covering of the faults in the original cloth. Increasing the weight of the cloth.

8.4 Types of Finishing 1) Chemical finishing: Chemical reaction of auxiliaries with fibers. Application of the handle modifying products / additives. 2) Mechanical finishing: Mechanical treatment with machines. 8.5 Finishing Effects 1. 2. 3. 4. 5. 6. 7. Easy Care. Crease recovery. Dimensional stability. Good abrasion resistance. Improved tear strength. Soft or stiff handle. Shine or luster

~ 98 ~

8.6 Slitting Machine and Squeezer Machine specification: Brand name : CORINO MACCHINE

Type/model no : Super slit Company Year : Italy : 2011

8.7 Slitter Machine Slitter machine is used for tubular knit fabric to make it in open form. In open form fabric finishing line; slitter machine is used after hydro-extractor, de-watering and drying machine. Slitting is a process that is applied for cutting the tubular fabric through the intended break Wales line on lengthwise direction prior to stenter processing. During slitting, it is required to be aware about the cutting line otherwise, fabric faults can be occurred there. 8.7.1 Objectives of Slitting: Following objectives are achieved by the slitting machine. To open tube fabric according to specific needle mark. To prepare the fabric for next stentering process. 8.7.2 Function of the Machine: Used to remove excess water after pretreatment and dyeing To slit the tube fabric by the knife for opening of the fabric and ready for stentering. Delivered fabric in crease free state. Before squeezing balloon is formed with the help of compressed air passing by a nozzle or air sprayer. It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism.

~ 99 ~

8.8 Main Parts of Slitter Machine and their Functions Following are the main machine parts and their functions. 1.Rotary Blade: Rotary blade is used for cutting the fabric through break Wales line. 2.Ring: Ring is use to help the cutting process. 3.Guide Roller: After slitting, plaiting of the fabric is done. Guide roller guides the fabric to plaiting. 4.Plaiting: Open fabric is make plait by plaiting. 5.Sensor: Sensor is used for identify the specific Wales line. It makes sense for cutting through break Waless line.

8.9 Checking Parameters of Slitter Following parameters are checked after slitting. Cutting Line Check: Fabric cutting line is checked by the operator of the slitting machine. Operator checks that the rotary blade cut fabric through break Waless line or not. Bow and Slant check: Bow and slant is checked in the delivery side of the machine by the operator. Fabric Faults: Various fabric faults also checked in slitting process.

8.10 Working Principle of Slitter Machine The slitting m/c has 4 units - initial squeezer, de-twisting, slitter and padder. After dyeing completed and falling of water from fabric the fabric is fed in slitting m/c. So it is necessary to remove some water initially for the case of further processing in this m/c. The initial squeezer does this work. The de-twisting unit removes twists that may present in tubular rope form fabric. This unit has 3 de-twisting rollers, one rotation drum and 2 feeler rollers with sensors. By these rollers it detects twist in fabric and removes by rotating rope fabric in opposite direction. Before slitting there is a blower which blows air to open the tubular fabric & makes it easy to pass over cigger. The cigger can be extended in circumference and opens the tubular fabric in full circumference. Slitting is done by using open mark detecting golden eye by around knife. Then the fabric passes through the padder where washing or chemical treatment is done. Squeezer is used to remove 60-70% of water. After removing water width is controlled by stretcher and fabric is delivered by folding device.

~ 100 ~

Line Diagram of Slitting Machine:

8.10.1 Operational parameter: Set the padder pressure as required (3-7bar) Set the speed as much as possible (30-80m/min).

Fabric Pass Through Cutting Knife 8.11 Stenter Machine Process Definition:

Fabric Pass Through Detwister

Stenter can be defined as a finishing process in which the open width forms of the fabric is treated to set up the required width weight & fabric texture as per customers specification. These requirements from the customer are achieved by a single process. 8.11.1 Functions of Stenter Machines: 1. Heat set: Heat setting is done by the stenter for lycra fabric, synthetic and blended fabric. 2. Finishing chemical: Finishing chemical apply on fabric by the stenter.

~ 101 ~

3. 4. 5. 6. 7. 8.

Loop control: Loop control of the knit fabric is controlled. Moisture: Moisture of the fabric is controlled by the stenter. Spirility: Spirality controlled by the stenter. Drying: Fabric is dried by the stentering process. Shrinkage: Shrinkage property of the fabric is controlled. Curing treatment: Curing treatmentb for resin, water repellent fabric is done by the stenter. 9. GSM control: If overfeed increases, then GSM increases and vice versa. 10. Width control: The width is controlled by means of Spreader, Expander. 11. Decrease Bowing effect 12. Softener application 13. Surface coating for Teflon finish.

8.11.2 Operations: Main operator Main operator Assistant : Totally need 8 people to work together. : 1 person : 2 person

Fabric connecting person : 2 person Fabric tidyeing up person : 1 person Fabric unloading person : 2 person

8.11.3 Components of Stenter Machine: i) ii) Feed zone Chemical padding zone

Centering device Squeezing roller Chemical tray iii) Bowing control zone Bowing roller (rubber roller, no of roller -2) Sensor (no of sensor -6) Uncurling roller iv) Chain entry zone Uncurling device (both side of the chain entry) Sensor (both side of the chain entry)

~ 102 ~

Brush roller (for attaching the fabric with the pin of the chain, no of brush roller 4) Selvedge gumming device with gum box under the chain entry v) vi) vii) viii) ix) x) xi) xii) xiii) Drying zone Cooling zone Delivery zone Relax R/r Padder Pin roller PLC profivassleeve converter. Plaiter roller Take up roller Gas rotamatic burner (10)

8.12 Working Principle of Stenter Machine

The fabric is collected from the batcher to the scary and then it is passed through the padders where the finishes are applied and sometimes shade variation is corrected. The fabric is entered into the manhole (weft straigtner) the function of the manhole is to set the bow and also weave of the fabric is gripped by the clips and pins are also provided but the pins has a disadvantage that they pins make holes at the selvedge but the stretchning of the pins are greater than the clips. These clips and pins are joined to endless chain. There are 8 to 10 chambers provided on the machine each chamber contains a burner and filters are provided to separate dust from air. The circulating fans blow air from the base to the upper side and exhaust fans sucks all the hot air within the chambers. Attraction rollers are provided to stretch the warp yarn. After stentering we can increase the width of the fabric up to 1.5-2 inch. The speed of the machine is about 7-150 m/min.3 meters fabric can run in each chamber. Temperature is adjusted that according to the fabric as for, 1. PC 210 c 2. Cotton 110-130 c After dyeing 160-170c and after print 130-140c.

8.13 Machine Specification Brand name: Platinum. Country: KOREA. Other specification:

~ 103 ~

Speed range: Max: 110m/min. Use: 10-45 m/min. Temperature range: Max: 500 C Use: 180 C-190C (For half feeder) 190C-200C (For full feeder)

No of motor in drying unit: 06 Total no of motor: 06 Max dia: 295cm. Min dia: 95cm. Steam pressure: 2 bar Air pressure: 10 bar Applied for: Open width fabric Stenter m/c

8.14 Compactor Machine Machine specification: Brand name: FERRARO Type/model no: COMPTEX-RE 2800. Company: ITALY. No of motor: 17 Over feed = Max + 35%, Min -35%. Machine speed = Max 32m/min, Min 4m/min. Temperature range: 100-2000C Maximum width =240cm Minimum width =100cm Applied for: Open fabric Left over feed: -20%+20% Right over feed: -20%+60% High production: -20%+60% Front over feeding cylinder: -20%+60% Middle belt: -20%+60% Compactor Machine

~ 104 ~

.15 Function of Compactor Machine To compact the fabric To control the shrinkage To maintain proper width and G.S.M

Heating system:

Steam

8.16 Main Parts of The Machine Heating chamber Blower (2, one at the entry chain zone for uncurling and another at the entry of compacting zone) Synthetic blanket as a conveyor, Folder Exhaust fan Unpinning cylinder (-40%+40%) Belt cylinder (-40%+40%) Uncurling device at entry of compacting zone. Sensor Brush roller 8.17 Operation Procedure Operator starts the machine & opens the main stream supply value. After half an hour of pre-hitting, he can start the fabric processing after ensuring the following points: The expreader is properly adjusted according to the width target The speed setting is correct The overfeed setting is correct The steam box are clean & condensate value is properly open

After treading the 1st roll & running it in normal position for 10-15 meters, he should check the following: Width Yield(g/m) Compaction rate In everything is found okay, in other wards if the measured width matches with the required width, weight is +/-5 g/m2 to the required weight & copaction is 8%-10% then the operation can be continued. Otherwise necessary adjustment should be done to the m/c to reach to the target.

~ 105 ~

8.18 Photo Gallery Of Finishing Section

De-watering m/c

Slitting m/c

Stenter m/c (Side View)

Stenter m/c (Back Side)

Compactor m/c

Tumble Dryer

~ 106 ~

Chapter 09 Quality Control Department

~ 107 ~

9.1 Quality Assurance System The Quality Assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing. 9.2 Objectives of Quality Control 1. Research. 2. Selection of raw materials. 3. Process control. 4. Process development. 5. Product testing. 6. Specification test.

9.3 Quality Assurance at Different Section Assures the quality of the products of dyeing section in the following three steps: 1. In Laboratory. 2. In Dyeing Section & 3. In Finishing Section.

9.4 Procedure of Different Section 9.4.1 In laboratory: 1. Swatch card from buyer according to their requirement. 2. Recipe prediction for sample dyeing. 3. Sample dyeing until matching with swatch card. 4. Fastness & other tests of the fabric or yarn are done here.

9.4.2 In Dyeing Section: 1. According to the buyers sample, sample dyeing is done in sample dyeing machine in dyeing shed & again matched with the approved sample. 2. If result is OK, then bulk production. 3. During dyeing, samples are taken until accurate shade matching. The interval may be 30-40 minutes. 4. After dyeing sample is collected after softening matching is done. 5. Last of all, sample is collected after fixation & matched. 6. Then allowed the fabrics to be finished.

~ 108 ~

9.4.3 In Finishing Section: 1. By using a series of finishing machines correct width, softness & appearance are maintained according to requirements. 2. Then sampling is done for several times to test GSM, Shrinkage & fastness properties. 3. Finally fabric is inspected & prepared for delivery. 9.4.4 Quality Standard: Follows the below mention quality standard: 1. 2. 3. 4. 5. 6. Dimensional Stability: BS EN 26330:1994 4A. Color Fastness to Washing: BS EN ISO 105-C06:1997. Color Fastness to Rubbing: BS EN ISO12:1995. Pilling Test: BS 5811-11,000. Light Fastness Test: ISO 105-B02:1988. Inspection: Four-Point System.

9.5 Different Quality Tests Methods Different types of fastness tests of the dyed fabric are done in quality control department. Different types of method (Standard or buyers recommended) are followed for different types of tests. There are two types of tests are done in Quality Assurance department. They are: On line Test Method. Offline Test Method. Pilot Side. 9.5.1 Online Test Method: Online test methods are very important for knit dyeing section. Online quality control included Running shade of process and final shade of the process. 9.5.2. Verivied Light Box: For shade matching of the fabric generally Verivide light box is used. Light box containing there are four types of light source are use. The light sources are use according to buyers requirements. The light sources are described as below: 1. Artificial daylight D65. 2. TL 84. 3. F (Fluorescent). 4. UV

~ 109 ~

9.5.3 Offline Test Method: Off line test methods generally included physical test of the QC. Brief descriptions of off line quality control are described as below: 9.5.4 GSM Test: First of all cut the fabric with GSM cutter, then weight the cut fabric using of electronic balance. Finally found the GSM of the fabric. 9.5.5 Width/Dia Check: Using measuring tape to measure the width/dia the fabric. 9.5.6 Crocking/Rubbing Fastness: Sample: 1. Dyed fabric -15 cm x 5 cm. 2. White Test Cloth -5 cm x 5 cm. Procedure: 1. White test cloth is put on to the grating and stag by steel wire. 2. The sample is run twenty times manually for ten seconds. And the rubbing fastness of the sample cloth and degree of staining is accessed. 3. For rubbing fastness (Wet), the rubbing cloth is placed in the water and socked and squeeze. The wet rubbing cloth is placed on to the grating and stag with stainless steel wire and run ten times manually then assesses the attaining on to the rubbing cloth and the rubbing fastness of the sample cloth is accessed. Results: Change of shade of the sample is measured with grey scale and degree of staining of the white test cloth is measured by Staining Scale.

9.5.7 Dimensional Stability (Shrinkage and Spirality): Sample: Two piece of 50 cm x 50 cm fabric is taken for test. Procedure: 1. 2. 3. Conditioning: Put the sample in the table for 4 hours for conditioning before starting test. Cut the sample 50 x 50 cm & benchmark should be 35 x 35 cm. Stitch the sample (3 sides) by over lock sewing machine. Put sample in washing machine and run according to buyers choice.

~ 110 ~

Drying: All Buyers requirement is tu mble Dry except ECHO SCOURING is flat dry. 9.5.8 Color Fastness to wash: 4. The color fastness of a colored textile is defined as its resistance to these changes when subjected to particulars of conditions. It follows that color fastness must be specified in terms of these changes and expressed in terms to the magnitude. Required Materials: Sample size 40 x 100 mm. Multi fiber at 40 x 100 mm. ECE detergent (WOB)-4g/L. Sodium Perforate (Na2BO3.H2O2-1g/L)-1g/L. Distilled water. Normal cold water. Steel balls.

Procedure: 1. 2. Cut sample & multi fiber at 40 x 100 mm. 50 ml ECE detergent (WOB) & 50 ml Sodium per borate is taken with the sample. For marks & Spencer, the solution is taken by the following formula: (Sample fabric + Multi fibre weight) x 50 ml. The sample is kept in 600C for 30 minutes in Rota Wash Machine. Rinse the sample twice with cold water. Dry at 600C by hanging or by Flat iron precision but temperature should be more than 1500C.

3. 4. 5.

Results: Dry the specimen and the change of shade & degree of staining is measured by Grey Scale & Staining Scale.

~ 111 ~

Chapter 10 Store & Inventory Control

~ 112 ~

10.1 Store & Inventory Control Inventory is planning and execution involves participation by most of the fundamental segment of business sales, production, purchase, finance and accounting. Inventory is a wider sense is defined as any idle resource of an enterprise however it is semi-finished packing spares and other stocked in order to meet an expected demand or distribution.

10.2 Objectives of Inventory Control 1) Financial activities: a) To save amount of investment b) To know the cash position 2) Property Protection: a) Preventable waste b) Insurable damage c) Unauthorized use 3) Operating: a) To obtain the best overall balance between production and inventory carrying cost. b) To minimize losses c) To avoid stock out and to keep inventory holding costs in costs in balance.

10.3 Inventory Systems 10.3.1 For Raw Materials: In this factory, raw materials are yarn of different type, different count and of different spinning mills of home and abroad. As according to knitting section demand yarn is either imported or bought from spinning mills and they are kept in the store for raw materials in accordance with type and count. As like as polyester, cotton, lycra are kept separately and also to their count variation. Inventory office keeps record of this raw materials amount, their usage and storage. 10.3.2 For Spares: Different spares parts of knitting machines and other equipments are kept in store as inventory so that there are no time and money losses while it is being used. Here is the list of spare parts as inventory:

~ 113 ~

1) Needle detector 2) Fan 3) Air gun 4) MPF belt tensioning device 5) Air nozzle 6) Fabric spreader 7) Fabric light 8) Compressor line + pipe 9) Air blower 10) Memminger 11) Oil Tanks 12) Fabric roller

13) Inverter 14) Yarn Guide feeder 15) Oil Nozzle 16) Cam box 17) Magnet 18) VDQ pulley 19) Fan broker 20) Oil Meter cover 21) Oil plutonic 22) Air meter cover 23) Knot catcher 24) Feeder ring boll

10.3.3 For Finished Goods: Finished goods in this mill are the readymade garments. All garments are being ready in the cartoon according to the piece numbers as buyers choose. Cartoons are kept prepared one upon another for dispatch. Total no. of cartoons is maintained by the inventory office for finished goods. And at last, they are sent to dispatch after counting.

10.3.4 For Others: Out of above types there are inventory systems for semi-finished goods like as dyed fabrics, garments pattern pieces, markers, sewed goods, scrap, surplus, absolute items, garments labels, packages etc. These goods are maintained by the respective inventory control office different departments this knit-composite mill. 10.4 Store Department Store is very important for textile idustry. In here every kinds of material which is used in factory keep here. It is the section where all kinds of raw materials, tools, utilities are stored.

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10.5 Organ Gram Of Store

Store manager

Officer

Store keeper

10.6 Types of Store In Hypoid Composite Knit Ltd there is found five kinds of store. They are : General store Yarn Store Grey Store Dyes, Chemical and Auxilaries Store Finished Store Accessories 10.6.1 General Store In general store different kinds and types of material are keep. In here different kinds of machines, machines parts, materials used in industry floor are keep 10.6.2 Yarn Store In yarn Store only yarn are stored. In Hypoid Composite Knit Ltd yarn store the following count of yarn are stored. 34 count 32 count 30 count 28 count 26 count 24 count. 10.6.3 Grey Fabric Store All the grey fabrics are stored in the fabric store near the batch section. Different types of fabric are listed in the sheet according to fabric types, quantity and consumers requirement.

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10.6.4 Dyes, Chemicals, And Auxiliaries Store

In dyes chemical and auxilaries store the following materials are stored: Dyes Name
Remazole red -RR Remazole Yellow -RR Remazole Blue-RR Remazole Brill Blue-R Special Remazole turquoise Blue G Remazole Orange-RR Synowhite 4BK 259.00 Synozole Yellow K3RS Synozole Red K3BS Synozole Nave Blue KBF Synozole Blue KBR Synozol Red-HB Synozol Yellow-HB Synozole Nevy Blue-HB Dychufix Red 3BXF Dychufix Yellow 3RXF Dychufix Yellow 4 GL Dychufix Black BHC Dychufix Orange 2RXF Dychufix Black FWN Desperse Red -60 BFY Desperse Yellow-4G Desperse Blue 562 RL Desperse Blue 60 BGF Desperse navy Blue ECOG Desperse Black ECOG Dis- Orange HF Dis- Red -HF Dis- Black-HF Dis Navy Blue HF Dis- Blue- HF Dis-Yellow-HF Cor- Yellow RD

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Cor-Red RD Cor- Blue- RD Cor- Orange- RD Libafix- Blue -CA Cor- Traquise Blue G Cor-Bri- Blue- R- Sp Cor- Bri Blue- BB Libafix-Amber CA Libafix First Red CA

Acetic Acid ACID: Bufer Acid

Liansoft-S 300 (Cationic Softener) Belsoft-200 (Non Ionic Softner) Softner: Lian Smith-2231 (Silicon) Power soft -180 Resoft NS- (White Softner) Resomine-3000 (Silicon) Softner V-16

Leancrease-651

Anticrease

Rybypon-173 Lianlevel723 (Cotton)

Leveling Agent
Sequestering

Polyester leveling Rubygal CFTR Brusquest -E Lianseq-710 Kappa Quest -FE LASSOP Ruby soap-BIF

Soaping agent

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Brightener Fixing Agent Peroxide Killer Stabilizer

Others

Biltex ERH Texbrite 4-BK Leanfix-706 VEXPOK-100 Peroxide StabilizedSE Lian-PS-66 Enzyme Bleaching Kappa Tex R98

10.7 Finished Store In finished store the finished fabric of Hypoid Composite Knit Ltd is stored. In HCKL finished product are as follow : Basic T -Shirt Tank Top Long Sleeve T- Shirt Polo Shirt Shorts Pajama Set Ladies and Kids Knitwear All kinds of Knit garments and knit fabrics

10.8 Accessories Store In accessories store all kinds of accessories are stored. The following accessories are found in HCKL accessories store : Sewing Thread Main Level Care Level Size Level Heat Transfer Level Elastic Polythene Photoboard Bardcud Sticker Gumtape Dosting Tagpin Tissue Metal Clip Button

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Zipper Twill Tape Hanger Sizer Cartoon Mobilontape

10.9 Equipments Used In Dyes & Chemical Hand Gloves and Apron Long Boot Shoe and goggles

10.10 Remarks

Proper inventory control of raw materials, semi-finished goods, finished goods and other miscellaneous goods lead smooth production. As Hypoid Composite Knit Limited follow the correct way of inventory control system, it can have a good and huge production as it demands.

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10.11 Photo Gallery of Store

Yarn Store

Grey Fabric Store

Finished Goods Store

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Chapter 11 Maintenance & Utility Section

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11.1 Maintenance Maintenance of machineries is very important for any type of industries and it is a must for a knit composite mill. All machines and machines parts of knitting, dyeing and garments are maintained with extreme care. Because production quality and quantity, both depends on the maintenance with regularity. There are two types of maintenance department found such as: 1.Mechanical Department. 2.Electrical Department.

11.2 Sequence of Maintenance

Problem

Inform to the maintenance Seection

Detect problem

Problem can be repare or replace

Repair can be solve immediately, replacing requires time

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11.3 Objectives of Maintenance 1. To keep the factory plants, equipments, machine tools in an optimum working condition. 2. To ensure specified accuracy to product and time schedule of delivery to customer. 3. To keep the downtime of machines to the minimum thus to have control over the production program. 3. To keep the production cycle within the stipulated range. 4. To modify the machine tools to meet the need for production

11.4 Maintenance Tools/Equipments and Their Functions Maintenance Tools/Equipments 1. Adjustable wrench 2.Air suctioner 3.Spanner 4.Socket spanner 5. Hammer 6. Screw driver 7. Punch 8. Lock opener 9. Hack saw 10. Outside calipers 11. Inside calipers 12. Cutting pliers 13. Pulley key 14. Chain ton 15. Welding machine Functions Used for setting nut & bolts. For cleaning machine. Fixed Spanner for nut & bolts fitting. Handle system for nut & bolt fitting. To apply load where required. To release any screw. Used to fit any worn out shaft. To open the clip of bearing. To cut any metallic thing. To measure outside dia. To measure inside dia. To cut thin wires. To loosen pulleys. To lift heavy load. To join metallic parts.

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16. Grinding machine 17. Tester 18. Pliers 19. Star driver 20. Steel tape 21. Chisel 22. L-key 23. File

To make the smooth fabrics. To test electric circuit. To grip anything & cut anything. Screw unlocking. To measure length, width & height. To cut any metal. For loosen & tighten the screw. To smooth the rough surface.

11.5 Utility Service Production and profit are closely related. In order to get quality final product it needs fresh raw materials as well as effective manpower and machinery in good condition. Utility in conjugation with the three Ms plays an important role to maximize the production as well as the profit.

11.6 Utility Ensures the Followings Activities

Power supply (By Generator). Water supply (By Pump), Hot water supply (by hot water tank). Steam supply (By Boiler). Compressed air (By A/C plant). Exhaust air handling (By vacuum planning system). Fuel & gas supply. Workshop facility. Civil work.

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11.7 Power Distribution Diagram

Generator

LT Panel
Total Power needed/Day Distribution Board

Knitting Section

Dyeing Section

Garments Section

11.8 Utilities of HCK Ltd We process our own Power plant, Generating by GAS and Diesel of capacity 1344 KW and 120 KW responsible. Water Plant which maintains water treatment procedure to utilize the water in dyeing to avoid shade effect. We have Fire Tube Boiler Generating by GAS with 14 Tons Capacity. We have Compressor with total Air Flow Rate of 21.32 m3/min 11.9 WATER 11.9.1 Water Pumps: SL No. 1 2 3 4 5 6 7 Centrifugal Pump for water supply to Dyeing & Others Section 20 H. P Pedrollo Pump each pump, 1000L/min 4 Units 10 H.P Pedrollo Pump flow rate, 600 L/Min 1 Unit 5.5 H.P Pedrollo Pump flow rate, 50 L/Min 1 Unit Spare Pump Motor Pedrollo 20 H.P1 Unit and 5.5 1 Unit H.P Jhonson Pump (30 H.P) 2 Unit KSB Pump (30 H.P) 1 Unit Submerssible Pump KSB 46 Kw Capacity 4,000.00L/min 600.00L/min 350.00L/min 1, 00L/min 100 m3/hr 100 m3/hr 150 m3/hr

11.9.2 Natural Water Quality: Water for a textile plant may come from various sources. These include surface water from rivers and lakes, and subterranean water from wells. In PPC they collect water

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from Underground. Natural and pretreated water may contain a variety of chemical species that can influence textile wet processing in general, and dyeing in particular. The various salts present in water depend on the geological formations through which the water has flowed. These salts are mainly the carbonates (CO32- ), hydrogen carbonates or bi-carbonates ( HCO3- ), Sulphates ( SO42- ) and chlorides ( Cl- ) of calcium ( Ca2+), magnesium (Mg2+) . Although calcium and magnesium carbonates in limestone are relatively insoluble in water. So in this reasons, water hardness can be divided into two ways1) Temporary Hardness : Ca(HCO3)2 , Mg(HCO3)2 , Fe(HCO3)2
.

2) Permanent Hardness : CaCl2 , CaSO4 , Ca (NO3)2 , MgCl2 , MgSO4 , Mg(NO3)2 . This water hardness causes some serious consequences in a textile dyeing and finishing industries and these are Precipitation of soaps. Redeposit ion of dirt and insoluble soaps on the fabric being washed, this can cause yellowing and lead to uneven dyeing and poor handle. Precipitation of some dyes as calcium and magnesium salts. Scale formation on equipment and in boilers and pipelines. Reduction of the activity of the enzymes used in washing. Incompatibility with chemicals in finishing recipes and so on.

Hardness expressed by parts per million (ppm) of CaCO3 which is standard hardness scale and it is also called American hardness. The hardness of raw water is 100 ppm or more. To use it in dyeing and in boiler this water must need to soft & foreign materials needs to remove. 11.9.3 Standerd Water Quality For Dye House: Parameter Color Smell Water Hardness PH value Dissolve solid Inorganic salt Iron(Fe) Manganese(Mn) Copper (Cu) Nitrate(NO3) Permissible concentration Color less No bad smell <5 ppm 7-8 (Neutral) < 1 ppm < 500 ppm < 0.1 ppm < 0.01 ppm <0.005 ppm < 50 ppm

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Nitrate(NO2)

< 5 ppm

11.9.3 Methods Of Water Softening:

There is ion exchange methods by which hardness of water is removed in Industrial scale The flow chart of water treatment plant is given below -

Hard Water Store Tank

Stone Filter

Carbon Filter

Resin Filter

Delivery Pump

Soft Water Store Tank

Soft Water Store Tank

Water treatment plan

11.10 Utility Machine Description

SL

DESCRIPTION OF MACHINE

Unit

Origin

Brand

01

Gas Generator Model: TCG2020V16K

02

Diesel Generator

Output 1344 Kwe rating at ISO 01 condition 400Volts, 0.8 PF, 1680 KVA Gas Generator 50 Hz, 1500 rpm including heat exchanger, gas preregulator and gas Regulator unit. Output 150 KVA 50 01 Hz, 1500 rpm

GERMANY DEUTZ

SWEDEN

SCANIA

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03

Gas Fired Boiler Model: Se-G-400150

04

Gas Fired Boiler Model: Se-G-500150

Capacity: 400BHP (13,800 LBS/Hr), Fuel: Natural Gas Working Pressure: 150 PSI Voltage: 400V5% / 50Hz/3 ph Capacity: 500BHP 01 (17,250 LBS/Hr) Fuel: Natural Gas Working Pressure: 150 PSI Voltage: 400V5% / 50Hz/3 ph

01

USA

HURST

USA

HURST

05

Screw Type Compressor Model: S 50 -2

Noise reduced motor IP 03 55 Air Flow Rate 6.35 m3/mim Air Flow Rate 2.27 01 m3/min Submergible Pump (41 01 Hp)

GERMANY BOGE

06

Atlas Capco Compressor Model: GA-15 PUMP

BELGIUM

ATLAS CAPCO

07

INDIA

SIGMA

Water 08 09 ETP Treatment Plant

Capacity : 100 M3/hr

01

INDIA

Capacity : 60 M3/Hour

01

INDIA

10

Pump (For Drinking Water)

Submergible Pump ( 3 Hp) Water Flow Rate 10 m3/ hr

01

ITALY

PEDROLLO

11.11 Gas PPC natural gas from Titas Gas Transmission Company. Gas is used as the fuel of Boiler, Generator and also used for heating dryer, Stenter and compactor m/cs etc.

11.12 Remarks

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As the biggest project the Hypoid Composite Knit Limited, so the vast utility systems. There is a skill manpower group of engineers and other technical staffs to look after these utility services. They have to remain aware of solution on a great sense of responsibility for any type of problem due to utility supply. 11.13 Photo Gallery of Utility Service

Boilers

Gas Generators

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Chapter 12 ETP

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12.1 Effluent Treatment Plant The effluent which is treated by a plant that is called effluent treatment plant. In fact water is the heart for dyeing industry & chemical also an important for different stage of dyeing. Now it is quite impossible without chemical continue dyeing. So which chemical we use in dyeing that mixed with water and finally drains. If the chemical mixed water goes outside through river it is very harmful for not only our environment but also all alive animals. 12.2 Types of ETP There are different types of ETP are available. Thats: Biological ETP Chemical ETP Biological & chemical ETP Physical ETP

Biological ETP: The effluent will be treated according to sequence or stage by stage. Its primary cost or set up cost is very high. Its effluent treatment will be best

Effluent treatment plant is based on combined method, biological and physicochemical treatment is accomplished together. The raw character of this plant is described below: The raw character of this plant: No Parameters 1. 2. 3. 4. Ph Suspended solids Biological oxygen demand (BOD) Chemical oxygen demand (COD) Mg/L Mg/L Mg/L Chemical characteristics Unit Amount 11.8 378.8 416 850

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Physical characteristics 5. 6. 7. Color Odor Temperature C Brown to black No distinct 40C

12.3 Consumption of Chemicals Used

Name Lime Ferrous sulphate Poly Aluminium Chloride De-coloring Agent Polymer Antifoaming Agent Acid

12.4 Function of Different Ingredient Use in ETP Lime: Lime is used to change the color of effluent and also to increase the transparency of the colored water. Ferrous sulphate (Feso4): Ferrous sulphate is basically used for the agglomeration of the colloidal matters present in the effluent. Polymer (polyelectrolytes): Poly electrolytes help to flocculate precipitate for easy deposition at the bottom of the clarifier tanks. H2SO4 or HCL: H2SO4 or HCL is used for controlling the pH of liquor Alum: Alum is used to sediment residual matters from the effluent. Antifoaming Agent: Used for reduction / controlling foam. It is used manually in the distribution tank.

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Sodium Hypochlorite: It is used to kill the harmful bacteria. It is used in the biological oxidation tank. Urea: To feed bacteria. 12.5 Standard Parameters to Be Maintained [According to Bangladesh Standards for Waste Water from industrial units, discharge to inland surface water as per ECR 1997] Parameters PH DO BOD COD Standard Values 6-9 4.5-8 mg/l 50 mg/l 200 mg/l

TDS

2100 mg/l

Parameters in ETP Parameters PH BOD COD TDS TSS DO Color Cobalt (Co) Copper (Cu) Mercury (Hg) Nickel (Ni) Arsenic (As) Cadmium (Cd) Lead (Pb) Sulphide (S2) Chromium (Cr) Before Treatment (mg/l) 9-11 250 400 3500 500 1-2 150 0.02 0.25 N/L 0.2 N/L 0.5 0.1 0.05 1 After Treatment(mg/l) 7.5 46 142 824 150 4-6 50 0.1 0.01 0.01 0.05 N/L 0.05 0.07 0.005 0.5

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12.6 Working Sequence of ETP

Raw waste water in

Screen chamber

Chemical Reaction clarifier

Settling Tank

Slag press filter

Primary Biological tank

Slag tank

Secondary Biological tank

Disposal safely

Secondary clarifier

Oxidizing Chamber

Multi garage & sand filter

Activated carbon filter

Treated water drain

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12.7 Photo Gallery of ETP:

Equalization Tank

p H Control Tank

Ferrous Sulphate Tank

Aeration Tank

Lamella

Pump Used in ETP

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Chapter 13 Compliance

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13.1 Compliance Compliance means conformity of certain standard. PPC maintain a moderate working condition for their employees. Though it is well established project, there is some lacking of proper compliance issues. Here is list of compliance in which some points are maintained fully and some are partially. Compensation for holiday Sexual harassment policy Child labor abolition policy Anti-discrimination policy Zero abasement policy Working hour policy Hiring /recruitment policy Environment policy Security policy Buyers code of conduct Health and safety committee Canteen Equal remuneration National festival holiday Overtime register Labor welfare Weekly holiday fund Time care Accident register Workman register

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Health register Leave with wag

13.2 Health Drinking water at least 4.5 L/day/employee Cup availability Drinking water supply Water cooler ,heater available in canteen Drinking water signs in Bangla and English locate min. 20 feet away from work place Drinking water vassal clean at once in a week Water reserve at least once a week Water center in charge person with cleanliness Suggestion box register

13.3 Toilet Separate toilet for women and men A seat with proper privacy and lock facility Effective water sewage system Soap toilet Water tap Dust bins Toilet white washed one in every four month Daily cleaning log sheet No-smoking signs Ladies /gents toilet signs both in bangle and English Deposal of wastes and effluent

13.4 Fire Sufficient fire extinguisher and active Access area without hindrance Fire signs in both languages Fire certified personal photo Emergency exit

13.5 Safety Guard Metal glows on good conditions Rubber mats & ironers First aid box one Ironers wearing sleepers First trained employees Motor/needle guard Eye guard Doctor

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Medicine Welfare officer

13.6 Others Room temperature Lighting facilities

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13.7 Photo gallery of Compliance

Fire Training

First Aid Box

Doctor Chamber

Doctor

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Chapter 14 Conclusion

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14.1 Conclusion Industrial training is an important and essential part of education as through this training we learn all the implementations of the processes which we have studied theoretically. It gives us an opportunity to compare the theoretical knowledge with practical facts and thus develop our knowledge and skills. This industrial training also gives us an opportunity to enlarge our knowledge of textile administration, production planning, procurement system, production process, and machineries and teach us to adjust with the industrial life. I have found myself fortunate to have my industrial training at HCK Ltd. It has a capacity with a very efficient production team. HCK Ltd has a very good, well equipped and modern laboratories and producing a wide range of color. During my training period I have noticed that HCK is very concern about their quality and they rarely have any quality complain. The management of HCK Ltd is very organized, preactive and co-operative. At the end of the day I realized that industrial training make my knowledges application practically and make me confident to face any problem of my job sector.

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Chapter 15 References

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14.1 References

1. S. M. Sayeedur Rahman (Raju), General Manager (Dyeing), Hypoid Composite Knit Ltd. 2. Shib Shankar Chokrabarti, Assistant Professor, Pabna Textile Engineering College. 3. http://www.assignmentpoint.com/science/textile 4. http://textilelearner.blogspot.com/ 5. http://www.importgenius.com/shipments/hypoid-composite-knit.html 6. http://textileweb.wordpress.com/category/ebooks/ 7. http://www.scribd.com/ 8. https://www.google.com.bd/ 9. https://maps.google.com.bd/maps 10. http://www2.hawaii.edu/~shulin/research.htm 11. http://www.wikipedia.org/ 12. http://dspace.daffodilvarsity.edu.bd:8080/bitstream/handle/123456789/860/Hyp oid%20Composite%20Knit%20Ltd.pdf?sequence=1.

Thanks...

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