Documente Academic
Documente Profesional
Documente Cultură
SUPERVISED BY :-
* PROF. DR. MD. MUSTAFIZUR RAHMAN.
HEAD, DEPARTMENT OF TEXTILE TECHNOLOGY.
* ABU SAYEED MD. ATIQUZZAMAN.
Asst. Prof., DEPARTMENT OF TEXTILE TECHNOLOGY.
ACKNOWLEDGEMENT
♦INTRODUCTION:-
Sinha Textile Group is a truly integrated undertaking. The textile division has the capability to
offer a complete product range for the export & domestic textile markets. The goal of the
textile division is to become the preferred partner for sourcing high quality fabrics & clothing
from Bangladesh. With high advanced technology & an emPhasis on developing local human
resources, the textile division has the potential to make an important contribution to the
nation’s growing ready made garments export sector.
The rational behind the existing structure & future expansion of the textile division is to
capture value added at each stage of the textile manufacturing process. Despite Bangladesh’s
lack of indigenous cotton production capability, SKL has leveraged Bangladesh’s labor cost
advantage & export competitiveness to maximum level.
GENERAL INFORMATION
•HEAD OFFICE: House No. 363, road no: 02 New DOHS, Mohakhali, Dhaka-1206.
•VISION: Building a true marketing led enterprise with motivated workforce, innovative
vision, strong revenue based product portfolio, customer satisfaction & understand of global
market.
•MISSION: Each of the activities must benefit & add value to the common wealth of our
society. We firmly believe that, in the final analysis we are accountable to each of the
constituents with whom we interact; namely our employees, our customers, our business
associates, our fellow, citizens & our shareholders.
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Mosannef hossain bhuiya
OIC
Manager/D.G.M(Production)
Dyeing(84) Finishing(122)
Sample Sec(4)
1 X In Charge
3 X helper
Dyeing
Boiler Room
5.5 KW
KANCHPUR, NARAYANGANJ
SOUTH
(DYEING DIVISION)
LAYOUT OF FINISHING SECTION
COLLAR
MDB
NEW STENTER 6’ X 8’
25’
133’ X 22’
24’
Delivery
TUBE
30’
Entry / Exit
TUBETEX COMP
22’ CALENDER
27’ X 8’ 16’
71’ 16’ X 14’
OPEN
30’ Brushing 19’ SLITTING 13’ 20’
COMPECTOR
M/C 12’ X 13’
57’ X 17’
BOILER
AREA : 182’ X 72’
10’x10’
PRODUCT VARIATION
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The product , which are available in knit dyeing floor are given below :
→ Single jersey / Single jersey with lycra. .
→ Polo pique, Lacost ( Single / Double) .
→ Rib - ( 1x1), (2x2), (8x2), (9x2), (9x1) .
→ Lycra Rib , Drop needle fabric .
→ Interlock .
→ Grey mélange .
→ Stripe ( S/J, rib, interlock, grey mélange )
KNITTING
Feeding the yarn in the feeder via trip-tape positive feeding arrangement and
tension devices
Knitting
Inspection
Numbering
Lycra :
CREORA
Made in Korea
Type # H-100 (20D)
This fibre contains less than 1% di-methylacetamide( DMAC) which can be released during
processing.
FABRIC TYPES:
1) Single Jersey
a) Single jersey (Plain)
b) Single lacoste
c) Double lacoste
d) Polo pique
e) Fleece fabric
2) Double jersey
a) Rib fabric
i) 1x1 Rib
ii) 2x1 Rib
iii) 2x2 Rib
iv) Lycra Rib
v) Flat Back Rib
b) Interlock Fabric
i) Plain interlock
ii) Drop needle interlock
3) Back Brush.
4) Collar and Cuff
i) Plain Collar or Solid collar
ii) Shaving Collar.
iii) Jacquard Collar.
iv) Tipping Collar.
v) Race Collar.
vi) Stripe Collar.
5) Different decorative single and double jersey fabric.
MACHINE DESCRIPTION:
Run time
M/C PRODUCTION
No M/C BRAND M/C MODEL DIA GA TOTAL CAPACITY (HOURS)
ORIGIN UGE NEEDL
(IN E
INCH) IN COLLAR IN CUFF
This section contains 66 circular knitting machines of different types and made by different
manufacturers. In this section body fabrics for knitwear’s are produced. Specifications of the
machines are given below:
REMARKS:
Production runs with the help of mechanical fitters. For any kind of mechanical
fault of any machine the fix and work under technical in charge. Production officers take
account of daily production by running after the supervisor and workers so on.
PROCESS DEFINITION:
Knitting is the interlocking of one or more yarns through a series of loops. The
length wise columns of stitches, corresponding to the warp in woven cloth, are called
WALES; the cross wise rows of stitches, corresponding to the filling in woven cloth, are
called COURSES, FILLING KNITS (WEFT KNITS) are those fabrics in which the courses
are composed of a single strand of yarn, while warp knits are those in which the Wales are
composed of single strand of yarn. GAUGE corresponds to the yarn in a woven fabric, and is
defined as the number of needles of yarns in half inches of cloth. The higher the gauge, the
more compact and finer is the cloth.
In every mill, there maintains a sequences in production processing. It is also followed in this
mill where we were in industrial attachment. The process sequences are in list below:
PROCESS REQUIREMENTS:
We have already discussed there are basically three kinds of machine which is used to
produce knit fabric and these are:
PRODUCTION PARAMETERS:
1. Machine Diameter;
2. Machine rpm (revolution per minute);
3. No. of feeds or feeders in use;
4. Machine Gauge;
5. Count of yarn;
6. Required time (M/C running time);
7. Machine running efficiency.
When a buyer orders for fabric then they mention some points related to production and
quality. Before production of knitted fabric, these factors are needed to consider. Those are as
follows-
Changing of GSM:
a) Cam setting
b) Set of needle
c) Size of loop shape
.Production calculation:
2. Production/shift in meter:
Course / min .
=
Course / cm
RPM × No. of Feeder × 60 × 12 × Efficiency
=
Course / cm × 100
QUALITY STANDARD:
SKL 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 at SKL
Hole mark:
Causes:
⇒ Buckling of the needle latch
⇒ Buckling the sinker
⇒ Higher G.S.M
Star mark:
Causes:
⇒ Buckling of the needle latch.
⇒ Yarn tension variation during production.
⇒ Low G.S.M.
Patta:
Causes:
⇒ Yarn comes from different lot.
⇒ Faulty cam use in the m/c.
Needle mark:
Causes:
⇒ Faulty needle use in the m/c.
Sinker mark:
Causes:
⇒ Faulty sinker use in the m/c
Fabric Shrinkage:
Causes:
⇒ Yarn twist. Twist Shrinkage
⇒ Knitting tension.
⇒ Fabric G.S.M. ` G.S.M. Shrinkage
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.
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 40 points per 100 Linear Yards.
The Second quality level (40 – 80) points per 100 Linear Yards.
The Third quality level 80 points or more per 100 Linear Yards.
1- 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.
2- All defects must be recorded and marked in final inspection and an accurate account
of points made to insure proper grading.
3- All fabric must meet specifications.
4- 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.
5- The quality control supervisor must approve the grading of all quality levels and
check the lower quality.
6- 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.
7- Open defects on the back of fabric such as drops, runs and hanging picks are to be
included in the grading of fabric.
8- Pieces can be connected together, once each piece must be the same shade.
9- All defects such as runs that extend more than a yard in length will be cut out.
10- 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.
11- Defects within one inch of the fabric edge will not be counted except on tubular
fabrics. All defects will be counted in tubular goods.
Grading procedure: -
1. All open defects or major defects counted with 4 points per defect.
2. Surface defects over 9 inch length counted with 4 points per defect.
3. Surface defects 6 to 9 inches length counted with 3 points per defect.
4. Surface defects 3 to 6 inches length counted with 2 points per defect.
5. Surface defects up to 3 inches length counted with one point per defect.
6. Running defects, such as tucks, needle lines, barre, crack marks, are judgment defects
• Other
- To send the grey fabric to the dyeing floor with batch card.
- To keep records for every fabrics before dyeing.
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.
DYEING
Sequence of operations for each product:-
Fabric receiving
Fabric inspection
Batching
Dyeing
Fixing
Dewatering/ Squeezing
Drying
Compacting
Final Inspection
M/c No: 02
M/c No: 03
M/c No: 05
M/c No: 06
Origin : local
Capacity : 15 Kg
No. of Nozzle : 02
Max. Operating Temperature : 850 C
Max. Operating Presser :1
Manufacturing Year : 1998
Grey fabrics:
Following types of gray fabrics are dyed:
Single jersey
Single jersey with lycra
Polo pique
Single laquest
Fleece
Interlock
Interlock with lycra
Rib
Rib with lycra
Different types of collar & cuff
Dyes:
Chemicals:
Detergent:
1. Jet
2. ladiquest 1097
3. NSR
Levelling Agent:
1. ladiquest 1097
Sequestering Agent:
2. EMG
3. Heptol EMP
Anticreasing Agent:
1. Drivol PAMN
2. Biovine-109
Stabilizer:
1. Lanapex HPXT
2. STZM
Anti-foam:
1. Antimussol-HTS
Per-oxide Killer
1. OEM (oxygyme)
Enzyme:
1. Bio-polish AOL
Softener:
1. PBD (colour)
2. Tubiyal-1112 (white)
Dispersing Agent:
1. Palagel SFD
Buffering Agent:
1. Eulysin S
Reducing Agent:
1. Hydrose
Acid:
1. Acetic Acid
2. Hydrochloric Acid
Salt:
1. Gluber Salt
2. Common Salt
Fixing Agent:
1. Soda Ash
Alkali:
1. Caustic soda
2. Soda ash
Bleaching Agent:
1. Hydrogen per oxide
Brightner:
1. Uvitex BHV(for cotton fabric)
2. Uvitex EBF (For polyester fabric)
3. Bluton BBV(For polyester fabric)
Bioscouring Agent:
1. Scorgyme
Dyeing Parameter:
A. PH Check during Wet Processing:
F. Reduction clearing is done for medium and deep shade in case of PET/CO dyeing.
100
90
80
70
60
50
40
30
20
10
0
0 50 100 150 200 250
100
90
80
70
60
50
40
30
20
10
0
0 100 200 300 400 500
20 Drain 60 2
21 Desired water loading M:L = 1:12 45 5
Optical brightening agent OBBHT
22
Applying (Taiwan) 0.5% to 1% 60 30
23 Hot Rinsing 60 5
24 Drain 60 2
25 Desired water loading M:L = 1:12 45 5
26 Temperature Raising to 90ºc 45 to 90 10
27 Hot wash 90 20
28 Cooling to 70ºc 90 to 70 20
29 Hot Rinsing 70 5
30 Drain 60 2
31 Desired water loading M:L = 1:12 45 5
32 Temperature Raising 70 to 90 4
33 Detergency Agent applying Jet 0.5 90 15
34 Cooling to 70ºc 90 to 70 20
35 Hot Rinsing 70 5
36 Drain 70 2
37 Desired water loading M:L = 1:12 45 5
38 Acid Addition Acetic Acid 0.4 45 to 65 4
39 Acid treating 60 20
OEM
40
Per-oxide killer Applying (Oxygyme) 0.5 55 20
41 Hot Rinsing 60 5
42 Drain 60 2
Total
Time 409
120
100
80
60
40
20
0
0 100 200 300 400 500
BIO POLISH
After bleaching if bio polish is recommended then Acid’s Ph is checked, as if it must be in
between 4 to 4.5. The recipe is provided below:
Time
Action Chemicals Quantity(g/L) Temp. (ºc) (Minute)
1 Bio polishing Bio polish AOL 1 45 60
2 Checking hairiness 30
3 Rinsing 45 5
4 Drain 2
100
90
80
70
60
50
40
30
20
10
0
0 50 100 150 200 250 300
Time-temperature diagram
Time
c Action Chemicals Quantity(g/L) Temp. (ºc) (Minute)
1 Rinsing RT 10
2 Desired Water RT 5
3 Anti creasing Biovine-109 1 RT
Wetting & leveling agent ladiquest-
4 applying 1097 1 RT 10
5 Sequestering EMG 0.5 RT
8 Dyes addition Dyes X% RT 2
RT to 60 (1ºc /
9 Temp. Increase min) 30
10 dyeing runtime 60 10
common
6 Salt Salt 30 60 10
7 Run time for salt 60 10
60 to 85 (1ºc /
8 Migration Dyeing min) 35
9 Cooling to 45ºc 85 to 45 40
12 Soda addition Soda ash 5 45 10
13 soda runtime 45 to 60 20
14 Fixation & shade matching 60 to 80 65
15 Hot rinsing 70 5
16 Drain 70 2
17 Desired Water 45 10
18 temperature raising to 60ºc 45 to 60 10
19 Neutralizing Acetic Acid 1 60 15
20 Hot rinsing 60 10
21 cold rinsing RT 5
22 Drain RT 2
23 Desired Water 45 10
24 soaping jet 1 60 to 80 20
25 Shade matching 80 10
27 Hot rinsing 70 10
28 cold rinsing RT 5
29 Drain RT 2
90
80
70
60
50
40
30
20
10
0
0 100 200 300 400
Softening Methods:
Time
Action Chemicals Quantity(g/L) Temp. (ºc) (Minute)
1 Desired Water RT 5
2 For acidic medium Acetic acid 0.2 RT 3
3 Softening PBD 1 RT 10
4 Drain RT 2
5 Fabric un loading RT 15
Dyeing Recipe:
Pretreatment
Neutralization:
Soaping:
Dyeing:
Reduction Clearing:
Neutralization:
Soaping:
Pretreatment:
Neutralization:
Neutralization:
Soaping:
Fixing:
Softner:
• Remedies:
Pre-Heat setting
Lower rate rising and cooling the temperature
Reducing the m/c load
Higher liquor ratio
Running at a slightly higher nozzle pressure
Running problem:
a. Ballooning:
• Causes:
Seam joining with too densely sewn
• Remedies:
By cutting a vertical slit of 10-15 cm in length for escaping the air.
b. Intensive foaming:
• Causes:
Pumping a mixture of air and water
• Remedies:
By using antifoaming agent
Dye spot:
• Causes:
Improper mixing of dyestuff in the solution, in right amount of water, at
the temperature.
• Remedies:
We should pass the dissolved dyestuff through a fine stainless steel
mesh strainer when adding it to the chemical tank, so that the large un-
dissolved particles are removed.
Patchy dyeing:
• Causes:
Uneven heat in the machine.
Improper impregnation of dye liquor due to the low wetting property of
the fabric.
Dye migration during intermediate dyeing.
• Remedies:
By proper pretreatment.
By adding extra wetting agent.
Heat should be same throughout the dye liquor.
Specky dyeing:
Mosannef hossain bhuiya (Textile engineer) 46
Mosannef hossain bhuiya
• Causes:
Excessive foam in the dye bath.
Fall of water droplets on fabric surface before or after dyeing.
In sufficient after treatment.
• Remedies:
By using antifoaming agent.
Sufficient after treatment.
By using a good wetting agent in the dye bath.
FINISHING
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Mosannef hossain bhuiya
A. Tube line
B. Open line
A. The machine that are used for open line are given bellow –
B. The machines that are used for tube line are given bellow –.
- Dewatering machine
- Dryer
- Compector machine
Tube Line:
Machine no: 01
Machine name: 02
Machine name: 03
Open line
Machine no: 01
Machine no: 02
Machine no: 03
Machine name : Stenter machine
Brand name : Brockner Stenter machine
Origin : Germany
Speed : 5 - 30 m/min
Over feed : 2 -10 % as required
Burner (Gas) : 5*2
Blower : 5*2
Temperature range : 100 - 2200C
GSM Control : By over feed
Padder roller : Single
Padder Presser range : 3 - 7 bar
Manufacturing Year : 1996
Machine no: 04
The Quality assurance department is assigned to maintain consistently uniform quality of the
material in process and various stages of its manufacturing.
- Research or analysis.
- Selection of raw materials.
- Process control and development.
- Product testing.
- Specification test.
- Should be given economic requirements.
- Quality assurance and so on.
In this topic we are going to discuss about the role & responsibilities of testing
laboratory from where it is possible to get a direction of doing bulk production of dyed fabric.
Here, we tried to present the way by which standard samples are being brought in the factories
& principle work done with the sample before bulk production of it.
Firstly, when a buyer goes to a factory with an order, he/she gives a standard sample of
fabric or mentions on the book which represents the demand of the buyer.
The type of fabric, the color of fabric everything include to their demand. This is the object of
an industry to produce the product with complete satisfaction of buyers.
The laboratory dyeing techniques & procedure are given below –
LABORATORY WORK
2. Physical test
3. Chemical test
Spectrophotometer reading
Pot dyeing
Pot dyeing
Unload
Unload
Normal wash
Normal wash
Acid wash
Acid wash
Hot wash
Hot wash
Cold Rinsing
Cold Rinsing
Drying
Drying
4. Purity test
Mosannef hossain bhuiya (Textile engineer) 53
Mosannef hossain bhuiya
Purity tests of dyes and chemicals are not done in the lab because of the good will of the
supplier. But still for dyes, especially newly introduced dyes, the sample is dyed with the new
one and then compared with previous samples by visual observation and then they check new
sample’s absorbency, strength, and fastness.
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
In manual method, the std. sample’s 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 sample’s color recipe is being taken for shade matching .This
method’s 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 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.
Normally 0.1%, 0.5%, 1%, 1.5% and 2% stock solution of dyes are
prepared in beakers for daily used.
Similarly 25% salt and 25% soda stock solutions are prepared in beakers for daily use.
Example –
5X2
n
Amount of dye sol (ml) = --------- = 20ml .
0. 5
Example –
5 x 10 x 20
Amount of chemical soln (ml) = --------------------- = 4 ml
1000 x 0.25
Q.C
On-Line Off-Line
Off-line Tests:
All the Off-line tests for finished fabrics can be grouped as follows,
1) Physical test
a. GSM
b. Spirality test
c. Shrinkage test
d. Pilling test
a. Fastness to perspiration.
b. Fastness to light and perspiration.
c. Fastness to rubbing and crocking.
d. Fastness to wash.
e. Fastness to light.
On-Line Tests:
1) For Pretreatment -
- pH test.
- Absorbency test.
- Fabric width measure.
- Whiteness test.
- Water quality test.
2) For Dyeing -
3) Machine checking.
QUALITY STANDARD:
In SKL is mainly followed AATCC, Oeko-Tex Standard and ISO methods. Selection of the
method depends on the buyer requirements. Most of the American buyers prefer AATCC and
Oeko-Tex method. For the European buyers ISO method is followed.
Oeko-Tex std. 100 certificates are designed by the International Association for Research &
Testing considering the consumer safety & environment protection for the purchase of
textiles. This certificate ensures “Confidence in Textiles - tested for harmful substances” &
show to the consumer that goods bought by them are free from any hazards to health such as ,
f. Formaldehyde.
g. Toxic pesticides.
h. Penta Chloro Phenol.
i. Heavy metal traces.
j. Azo dyes which release carcinogenic amines.
k. Halogen carriers.
l. Chlorine bleaching.
m. PH of the aqueous extract.
Oeko-Tex std. 100 from ecological point on textile substrates (Yarn, Fabric, garments etc.)
marked by textile manufacturers. This does not depend solely on the dyestuffs. It also depends
on the processing conditions, various chemicals & other auxiliaries used in the manufacture of
such a substrate.
So, Oeko-Tex std. 100 is not a quality label, it is just only ensures the safety of the textile
goods and eco-labeled.
Mosannef hossain bhuiya (Textile engineer) 57
Mosannef hossain bhuiya
The scope of quality control testing in SKL LTD. is good. It has the following ability for
quality control & testing,
1. Remove any fibres or fluff from the empty boxes of the test machine by light brushing,
vacuum cleaning or using a compressed air gun and inspect the cork linings for wear or
damage.
2. Turn on the mains switch on the machine. Before testing switch off the test switch to stop
all motion of the boxes. Place four mounted specimens into each box and close the lids
securely.
3. Set the machine to run for the required number or revolutions. This number of revolutions
must be agreed by the buyer.
4. Select the number of revolutions using the blue “prog” key on the counter located on the
front of the instrument. Using the small grey buttons increase the figure shown on the
display until the required number is shown. Press the small red button on the counter face
to set. The pre-set number of revolutions will be displayed on the LED display. When
testing commences the LED will count up to the pre-set number. The machine will then
stop. If the same number of cycles is needed for the next test, simply press the small red
button on the counter to reset. If not, follow the above procedure to change the pre-set
count.
5. Care should be taken when the boxes are rotating to avoid injury to personnel.
6. The red emergency stop button can be pressed at any time to stop the test. The test can
then be resumed from where it left off by pressing the “start” button.
7. After the set number of revolutions, the machine will automatically stop. Remove the
tubes from the machine. To remove the specimens from the tubes carefully remove the
samples using a small pair of scissors.
8. When removing the specimen from the tube, special care must be taken not to damage the
tubes.
9. The sample fabric is then rated with the bobbin taster scale according to the procedure
written previously.
Perspiration tester
To test color fastness to perspiration, specimens (fabric, yarn or fiber) in contact with multi
fiber fabric are treated in two different solutions. One solution is acid and one solution is
alkaline. Then the sample is put in a beaker and placed inside the machine at temperature of
37 degree Celsius for 48 hours. Then the sample fabric is rated using the grey scale.
Solutions should be made up immediately prior to use as the chemicals can degrade over time.
And
The solution is brought to Ph 8.0 with 0.1 mol sodium hydroxide solution.
And
The solution is brought to pH 5.5 with 0.1 mol sodium hydroxide solution.
Spectro Photometer
For automatic color matching there are two software that are used,
1. Color tools.
2. DCI match.
In DCI color match the machine is first calibrated by a white and a color tiles. Then here the
color is selected or retrieved. For having the percentage of different colors for the selected
shades these soft wares are used.
After dyeing the sample with the sample dyeing machine the specimen is putted again into the
spectro-Photometer for the assessment of the shade.
The software then gives a clear of the shade. If the shade does not match then it shows the
reason also for taking further step.
In this machine color is mixed automatically with the help of computer. There are 40 bottles
for color mixing and automatic pipetting. The percentage of color and chemicals are given
into the computer and then it is automatically mixed. This machine helps to consume time and
labor.
Brand name : Data Color Mixture Station.
Machine function : Mixture Making
Origin : Taiwan
Model : Auto lab SPS
Manufacturer : Logic Art
Manufacturing year : 2005
This machine is used for making mixture. Solutions are taken into a beaker and then putted
on the machine. The mixing is done with the help of two magnets and one of the magnets is
electric magnet. In this machine six beakers can be placed at a time. It saves time and
manpower with an
Efficiency of 100%.
Nozzle
Solution Maker
With the help of this machine it is possible to make solution with a very less time and
accuracy. There are two water tanks on the top which can supply hot and cold water according
to the program through the nozzles. Required amount of chemicals are first taken into the
beaker and then it is placed on the silver plate just under the nozzles. Hot or cold water is
mixed through the nozzles and the solution is mixture with the help of magnets.
Washing machines
These are very basic washing machines used in house hold activities. For the shrinkage test
these are used.
For shrinkage and spirallity test, two sample fabrics of 60 inches length and width are taken.
These two samples are then seamed together and in one side two lines are drawn in both the
directions at a distance of 50 inches each.
Seam line
50 inch
It is then taken into the washing machine and at temperature of 60 degree it is washed. After
that the measurements of the lines and seam movement is taken again.
Seam movement
47 inch
(50-47) X 100
Shrinkage percentage is = %=6%
50
Machine name : Dryer
The acceptable range for shrinkage test is 5%
Machine function : Drying
Origin : Taiwan
Model
Mosannef hossain : R-364
bhuiya (Textile engineer)
Manufacturer : Rapid
Manufacturing year: 2003.
Mosannef hossain bhuiya
DRYER
This machine performs drying of ample fabric right after dyeing by the sample dyer .Fabric is
dyed at a temperature of 120-130 degree.
Machine name : Dyeing Testing
Machine function : Sample Dyeing
Origin : Taiwan
Model : SD-16P
Manufacturer : Smart Dry
Capacity : 16 pots
No of Machine :2
Manufacturing year : 2003.
Rota Wash
The M228 Rota wash wheel is suitable for color fastness testing according to many standards
and methods, including ISO, AATCC, IWSTM, Marks and Spencer and Next.
The unit uses water as the heating medium and can be used in different configurations of pot
numbers and capacities. If 1200ml pots are purchased, an adaptor is supplied to enable these
to be fitted to the carrier.
For testing color fastness to wash fabric is kept for 30 min at temperature of 60 degree along
with malty fiber. Time, temperature and cooling system is automatic.
SAMPLE DYEING
It is also a sample dyeing machine but with less capacity. It has got 12 pots. It also used for
fastness test and it has an automatic cooling and heating.
PADDING MANGLE
This is also a sample dyeing machine for pigment dyeing. The fabric is first dipped into the
dyeing solution and then padded through the rollers. After that the fabric is dried. Temperature
120-130 degree and time is 2 min.
Here D65 is always used for color matching. Sometimes buyer demands a match by the TL84
also. So D65 and TL84 are used. Here white shades are observed by UV light.
Normally in SKL metamerism is not seen. In case of samples with combination colors,
metamerism is observed but single shades are free from this problem. Sometimes metemarism
is observed due to the position variation of the two fabrics.
Crock meter
The AATCC Crock meter is the official instrument of the American Association of Textile
Chemists and Colorists. The Crock meter tests the transference of color from the surface of
one material to another by either wet or dry rubbing. Test conditions are controlled and
reproducible through the use of standard pressure and motion.
M/c maintenance: Wash by Cold acetic acid two or three times in a day.
• Cold wash then drying the lab dip and compare with the standard.
0- 0.1 20 10
0.1 – 0.5 30 15
0.5 – 1 40 20
1–2 50 20
2–3 60 20
3-4 70 20
4-5 80 20
5-6 100 25
Standard value: For dry fabric staining value, grey scale = 4.5
For wet fabric staining value, grey scale = 4
G.S.M test:
At first, Cut the fabric by G.S.M cutter and then it is weighted by electric balance.
Inventory
Inventory is stock or store of good. Inventory management is a vital part for any factory
because smooth production as well as cost of storage depends on it.
FUNCTION OF INVENTORY:
PROCUREMENT SYSTEM:
`
- Dyes (mostly used like Dyechufix, Remazol, Levafix dyes) and chemicals (regular
items like Sequestering agent, Anti creasing agent, Caustic, Stabilizer etc.) are
imported from CHINA, GERMANY & INDIA.
- Some dyes (from Clarient) and chemicals (from BASF) are collected by direct
purchase through indent.
- Crystal salt and Soda ash is purchase from local distributor.
Every day the sheet is updated and a copy of this sheet is supplied to the dyeing manager, dye
house and lab section.
Items Amount
Dyes 7-8 tons
Chemicals 30-35 tons
Yarn storage 300 tons
Grey fabric 120 tons
Finished fabric 200 tons
RE-ORDER POINT:
The re-order point is stated in terms of level of inventory at which an order should be placed
for replenishing the current stock of inventory. Re order quantity depends on the lead time of
the product with some additional safety period. It also depends on the store capacity of
factory. For example if the lead time of a product is two month then normally re ordering
quantity may be for two and half months.
REMARKS:
SKL has individual stores for raw materials, finished goods, etc. There is not enough
space to store the finished goods. It requires increasing the store area. In SKL the store for
inventory control is satisfactory. Sometimes, they fluctuate from ideal process otherwise they
are okay.
A planned work brings success. With out planning nothing is complete within the required
time. So planning has its own importance which is intolerable. Planning gives a scheduled
task and control completes it successfully. But production planning and control is not an easy
task. Its basic working procedure is as follows-
It is only a basic procedure. It may change according to the type of order. Sometimes the order
is placed only for finishing the materials or only for dyeing the goods. Then some steps are
minimizing for planning.
Marketing division supplied fabric orders to the planning and control division by a
specific format.
After getting the fabric order, this section analyzes the orders according to buyers order
quantity, type of orders (i.e. type of fabric, color to be dyed etc.), delivery date etc. This
section plans for required quantity of fabric to be knitted (order quantity + 10% of the
order quantity), knitting balance, fabric to be dyed, dyeing balance, RFD (ready for
delivery), RFD balance, delivery fabric & delivery balance etc.
This section plans for knitting production. It selects m/c for knitting the fabric, no of m/c
to be used, type of yarn used, from which source yarn will be collected, required GSM,
width etc. It also gives delivery date of knitted fabric.
Production planning for dyeing is called “Batch plan”. Batch plan is prepared according to
the batch no, fabric construction, color, width, GSM and priority of delivery etc and
written in a batch card.
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Finishing schedule are same as the dyeing. After dyeing, materials go to the finishing
section with the batch plan. Finishing data is written to the batch card and is informed to
the planning section. However, this section always forces to all the departments to finish
all the work within the delivery time given by the buyers. Thus, it plays a very important
role in the success of the company.
COST ANALYSIS
Costing system mainly describe how the cost of the final product is fixed by the company or
top managements. As it is a garments manufacturing factory, so according to the buyer or
customer requirements of final garments, merchandiser give the consumption of the fabric
with specifications. Then it is calculated how much dyestuffs & chemicals are required for
processing. After that, the final cost is fixed including some profit. Then the unit price is
offered to the buyer for their approval.
REMARKS:
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The costing 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 price of the product.
UTILITY SEVICE
UTILITY SERVICES
SKL is a big project. So, it required adequate utility services without the factory can’t run.
Here the following utility services are available-
- Water
- Electricity
- Steam
- Gas
- Compress air
WATER:
The plant processes 200 cubic meters per hour. The chief source of water is the surface water.
By using various pump and pipe arrangement surface water is carrying to the WTP. Water is
collected at 10 ft depth from the surface. First of all 5 ppm of hypochlorite per cubic meter is
added to the water raw water then 60 to 150 ppm of ferrous sulphate and 0.1 ppm of
polyelectrolyte is added to per cubic meter of raw water.
The water flow direction is clear at the picture. Here water flow through the first hollow
cylinder and moves under the cylinder then it passes through the second to third by means of
over flow. A few sludge is sediment at second cylinder and a lot of sludge is sediment at the
third. From third cylinder water is passing to the filter chamber is also followed by the over
flow of water. At the second cylinder water stayed for a little time as its volume is poor
enough than the third that’s why few sludge is estimated over there. In filtration chamber
water is kept for a long duration like 22 hours which is allowed to sediment a lot of sludge
remaining in the treated water. At the out late of filtration chamber there is a stone filtration
and fabric filtration system has applied. After filtration chamber water is kept at collection
tank. This water is clarified water. It is directly used for knit dyeing. And for boiler and woven
dyeing water is allowed to pass through a carbon screening chamber and a softener. For water
softening geolyte is used that means sodium permutit.
ELECTRICITY:
In SKL there are 6 generators for electricity supply and they supply current through bus bars
to different sections.
TYPES OF MODEL MANF.NO BRAND RATING(KW ORIGIN
MACHINE NO )
Generator -01 G3412 7DB0094 CATERPILLA 380 USA
4 R
Generator – G3412 7DB0114 CATERPILLA 390 USA
02 0 R
Generator – G3412 AFE00362 CATERPILLA 360 USA
03 R
Generator-04 G3412 5NA1100 CATERPILLA 360 USA
7 R
Generator-05 G3412 5NA0959 CATERPILLA 385 USA
3 R
Generator – D3412 5NA0957 CATERPILLA 360 USA
06 5 R
Generator – D3406 5N18- CATERPILLA 166 USA
06 458H461 R
0
Total 2401
GENERATORS
Boiler:
The equipment used for producing steam is called steam generator or boiler. The boiler used
for producing steam is a fire tube type boiler. Fire tube type is mainly used in small plant
requiring small quantity of steam and where floor area is limited.
Here, gas is fed to the burner which run by thermo motor and produce flame. The flame
produces hot flue gases, which pass through the tubes that are surrounded by water. This
water is supplied from the soft water tank to the feed water tank, which is situated above the
boiler. The heat energy of the flue gas is transfer to water which is converted into steam. This
steam is supplied to the whole plant. The spent gases are then discharged to the atmosphere
through chimney.
BOILERS
Compress air:
COMPRESSORS
Gas:
SKL uses 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.
Sl CHEMICAL CHARACTERISTICS
NO
PARAMETERS UNIT AMOUNT
1. pH 11.8
2. Suspended solids mg/L 378.8
3. Biological Oxygen Demand(BOD) mg/L 416
4. Chemical Oxygen Demand(COD) mg/L 850
PHYSICAL CHARECTERISTICS
5. Color Brown to black
6. Odour Not distinct
7. Temperature 40
First of all raw effluent is allowed to pass through the screening chamber. Here the filtration
system to separate the suspended solids. Then it is allowed to keep in collection tank for 1 hrs
and then to the equalization tank for 12 hrs. Here effluent is mixed properly. After the
equalization tank effluent is followed to treat at flocculation chamber for 2 hrs. Here 1.66 ppm
of ferrous sulPhate solution, 0.5 ppm of lime solution and 0.0016 ppm (1.6 µgm / L) of poly
electrolyte solutions are prepared to react with effluent solution. These solutions are flowed to
effluent continuously. After the flocculation chamber treated effluents are allowed to sediment
the sludge. Effluent without sludge is passed by over flow and the sludge is separated by
pumping action described in picture. This chamber is known as clarification-1. Then the
effluent is followed to the FAB-1 & FAB-2 here the biological action is going on. There are
bio reactors (is a plastic residence for bacteria) those are used to keep bacteria. FAB means
fluidus attached bed. And here the aeration is carried on by means of blower diffuser
arrangement. After this chamber
there are another clarifier used to sediment sludge. All the sludge goes to central sludge tank
where centrifugal action is applied for de-watering sludge. And the sludge is kept in bag to
sludge store. Treated water from second clarifier is directly discharged to the river finally.
COMPLIENCE
Sinha Textile group is maintaining a lot of compliance issues since its starting. There is a
hospital inside factory. Also there are schools, collage and quarters for all kinds of employee.
For fire issue there is a fire brigade truck and a fire team is employed. There is an ambulance
per 6 units. To control fire problems there is a dry powder spray cylinder after every 15 meters
in floor. There is a day care centre for ladies operators. In salary they are paying ceremony
bonuses, health bonuses and a lot. In one word it can be an ideal compliance industry.
To inspire students they facilitate different training programs for the students. It is not only
facilitating for the student of textile faculty but also for the Electrical, Mechanical, Business
and chemistry faculty.
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 SKL. It has a huge production
capacity with a very efficient production team. SKL has a very good, well equipped and
modern laboratories and producing a wide range of color. During my training period I have
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noticed that SKL is very concern about their quality and they rarely have any quality
complain. The management of SKL is very organized, pre-active and co-operative.
At the end of the day I realized that industrial training make my knowledge’s application
practically and make me confident to face any problem of my job sector.