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PREFACE
The textile market in Bangladesh is growing rapidly. To meet the extra requirement we need technical skilled persons. Industrial Attachment is an essential part of four years B.Sc in Textile Engineering course of Atish Dipankar Biggayan O Projukti Bishawbiddalay, Banani, Dhaka. As a Textile graduate one should have a practical experience in the study of Apparel Manufacturing technology, machineries, products and overall situation of the mill before work in the industry. We had the opportunity to perform the industrial attachment with Abony textile limited (Babylon Group). This is a 100% export oriented and compliance knit composite industry. The Babylon group is a modern technology integrated industry. The textile division has the capacity to offer a complete product range for the export oriented textiles markets. The goal of the textile division is to become the preferred partner for sourcing high quality fabrics and clothing from Banlgadesh. With highly advanced potential to make an important contribution to garments export sector. The ratio behind the existing structure and future expansion of the textile division is to capture value added at each stage of the textile manufacturing process. Babylon group has leveraged Bangladeshs labor cost advantage and export competitiveness to the maximum.

ACKNOWLEDGEMENT

Atish Dipankar Biggayan O Projukti Bishawbiddalay has given us the opportunity to perform the industrial attachment with Anlima Textile Limited. We are grateful to Alam Dr. S.M. Mominul, the Advisor of our University for giving our opportunity. We also like to convey our deep gratitude to our departmental teacher, (Techer Name) for his throughout support, without whose assist it would not have been possible to complete the training successfully and she also helped greatly to accomplish the attachment. We would like to express our sincerest gratitude to Anlima Textile LTD. management, administration and personnel for their kind patronization. Above all, we would like to acknowledge our deep debt to all teachers of our university and specially of Apparel Manufacturing Technology Department for their kind inspiration and help, which remain as the backdrop of all our efforts. Finally, we really would like to acknowledge that we remain responsible for the inadequacies and errors, which may remain in the report undoubtedly.

Knitting:
Knitting is a method by which thread or yarn is used to create a cloth. Knitted fabric consists of a number of consecutive rows of loops, called stitches. As each row progresses, a new loop is pulled through an existing loop. The active stitches are held on a needle until another loop can be passed through them. This process eventually results in a fabric

How To Execute Production Process In A Knitting Mill?

Textile Technologist | Knitting | 1 Knitting is the interlocking of one or more yarns through a series of loops. Knitting process is the main activities for producing knit goods. In every mill, there maintains a sequence in production processing. It is a team work. In every steps of a processing every responsive person is responsible for give best production. In a knitting mills production process runs as the following sequence.

Firstly, knitting manager gets a production sheet from the merchandiser as accordance as consumer requirements then he informs or orders production officer about it. He also gives the schedule for producing targeted production. After getting the sample knitting manager analysis the design and draw a cam setting for produce the desired designed fabrics. After getting the information, production officer informs technical in charge and knows about machine in which the production will be run.

Technical in charge calls for leader of mechanical fitter troops; they also take decision about machine for production considering machine condition, machine types, production capacity and maintenance complexity. Production officer with experienced mechanical fitter adjust required stitch length and grey G.S.M for getting final G.S.M. Supervisor checks daily production regularity and make operator conscious about finishing tin due time. They also maintain daily production report sheet. They are responsible to inform the production of that day to the knitting manager. Operators operate machine in high attention as if there were no faults in the fabrics. If he thinks or sure about any fabric faults, then he calls for the mechanical fitter in duty. Mechanical fitter then fixes it if he can or he informs it to the technical in charge. Then technical in charge observer the problem and take necessary steps to remove the problem. During production time quality department also check the fabric and if they find any faults they inform it to the technical in charge. Technical in charge also take necessary steps for reduce the knit fabric faults. After completing the gray knit fabrics production it sends for quality check. If the fabrics pass the quality then it sends for next process. Knitting division is very sensitive because performance of dyeing is completely depends on knitting. Any types of mistakes during knitting can be the resultant of rejection. A knitting manager should have deep knowledge about the dyeing, printing and finishing process as well as garment manufacturing. Others who are related with this should have the knowledge about the machine and knitting fabrics design. So, try this at your professional life. I am sure it will help for getting better production in knitting section.

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9 03 2012

List Of Top Branded Knitting Machine Of The World | Knitting Machine For Bulk Production
Textile Technologist | Knitting | 5 In modern time; various knitting machine manufacturing companies are trying to manufacture such types of machine which is cheap in price and facilities more advantage to the user. They also try to develop the present structure of knitting machine. To open a new floor of knitting or add some new machine in the old floor ones can try for the following knitting machine because most of the machines are using in most of the knitting industry.

We know that knitting machines are divided into three types; they are as follow: 1. Single Jersey Knitting Machine 2. Double Jersey Knitting Machine 3. Flat Bed Knitting Machine Now I will give some knitting machine name list with their origin country name. Circular Knitting Machine (Single & Double Jersey Knitting Machine)

FUKAHARA (Japan) ORIZIO (Italy) MAYER & CIE (Germany) HANMA (China) HUPTER (Taiwan) JIUNN LONG (Taiwan) MASA (Taiwan) DONG HO (Taiwan)

WELL (Taiwan) JINHAR (Taiwan) PAILUNG (Taiwan) LISKY (Taiwan) Tayo (Taiwan) Hun-lung (Taiwan) FUKAHAMA (Taiwan) Zentex (Singapore)

Flat Bed knitting Machine

SHIMA SEKI (Japan) STOLL (Germany) Jy-leh (Taiwan) KAUOHENG (Taiwan) JAMES (Taiwan) FLYING TIGER (Taiwan)

Before buying a knitting machine following points should be considered: 1. 2. 3. 4. 5. 6. 7. 8. Machine type Brand name Origin country Model no. Diameter in Inch No. of Feeder Gauge No. of Needle

In modern time Engineering Auto Stripe is available for producing multi-color stripe knit fabrics. Engineering Auto Stripe may be 4 colors or 6 colors. It uses when a fabric could not produce in a normal circular knitting machine. Auto stripe knitting machines are available in single jersey and double jersey form. Flat knitting machines may be semi jacquard, full jacquard or fully computerized. We know that flat knitting machines are use for producing collar and cuff for the knit wear. All of the machines are not same in price or not same in quality. When you will choose youre desired one you should give emphasis on the requirements and best quality which will give you more facility in price and quality. One should not choose such types of knitting machine which cause knitting faults. Also we should consider the availability of the knitting machine parts.

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6 03 2012

Different Parts of Knitting Machine | Functions Of Machine Parts

Textile Technologist | Knitting | 2 Knitting machines are mainly two types; they are circular knitting machine and flat bed knitting machine. This two types are hugely use in knitting machine. A knitting machine is composed of lots of parts. Every parts of a machine are important for run the machine smoothly. Every part has a specific function during operation.

Different knitting machine parts and their functions are given below:

Creel: Creel is called the holder of cone. Cone is placed in a creel for feeding the yarn to the feeder. Feeder: Yarn is feed through the feeder. No of feeder is depends on the design of the fabric. VDQ Pulley: G.S.M of the knit fabric is controlled by VDQ pulley. VDQ pulley is used for controlling the stitch length of the fabric. Guide: Guide is called the supporting element. Guide is used to guide the yarn. Sensor: Sensor is an automatic controlling system. When a yarn pass through this sensor than if any yarn break down or any problem occur than it automatically stop by this sensoring system. Cylinder: Cylinder is the main parts of a knitting machine. Adjustment of a cylinder is important. Cylinder carries needle, sinker, cam and many more.

Spreader: Spreader is used to spread the knitted fabric before take up roller. Knit fabrics may be tube or open type. Spreader is adjusted as need. Fixation Feeder: This type of feeder is used in electrical auto striper knitting machine to feed the yarn at specific finger. Rethom: Rethom is used in electrical auto stripper knitting machine.

Different well known companies are manufacturing such types of knitting machine. Day by day they are trying to add some advance technology two facilities best opportunity. In this sense we can consider auto stripe, which gives more opportunity two produce multi-color long stripe knit fabrics. Different zigzag design also can be produced by an auto stripe machine. It is note that, faulty knitting machine parts create knitting faults. To increase the knitting production we should use latest knitting machine.

What Are The Considerable Points For Producing Knit Fabrics?

Textile Technologist | Knitting | 0 Knit fabrics are the fashion of new age. Various designed fabrics are produced in knitting machine. Knitting flow chart should follow during operation. During production process following machine parameters are considered.

Machine diameter Machine rpm (revolution per minute) No. of feeder in use Machine gauge Count of yarn Required time Machine running efficiency

Considerable points to produce knit fabrics: Generally knit fabric production runs according to the order of buyer. When a buyer orders for fabric, they mention some points related to production and end product quality. Before production of knitted fabrics, these factors are needed to consider. Those are as follow: Type of fabric or design of fabric: Knitted fabrics are various in design. When a buyer order for a product they give a sample or give the specification of the end product. Different designed fabrics are produced by changing the cam setting, needle setting and size of loop shape. Finished G.S.M: It is technical term that indicates the weight of the fabric per square meter. In knitting section grey fabrics are produced but the programer should make his program for getting the finished G.S.M after dyeing. Some points are considered while setting grey G.S.M; they are enzyme level, color and suided or non suided. G.S.M of the fabric is controlled by the following way: Major controlled by VDQ pulley. Minor controlled by stitch length adjustment. By altering the position of tension pulley, G.S.M of the fabric can be changed. If pulley moves towards the positive directive then the G.S.M is decrease and in the reverse direction G.S.M will increase. This also depends on the machine type. Yarn Count: Yarn count differ on the finished G.S.M. Higher the yarn count higher the G.S.M of the fabric. Sometimes spandex or lycra is used with the cotton in thats case yarn count of cotton select with the combination of lycra. Type of yarn: Different types of yarn is used for knit production. Cotton yarns may be combed or carded. Also synthetic fiber like lycra is used with cotton for some special case. All depends on the buyer requirement. Diameter of fabric: Diamter of the fabric is another factor. Fabric may be open diameter or tube diameter. Any how grey dia. will be selected with response of finished dia. of the fabric. Stitch length and color depth: If the depth of color of the fabric is high then 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 G.S.M is adjusted then. Similarly in case of light shade loop length should be relatively smaller. Stitch length vary depending on yarn count and shade of the fabric. If stitch length is not fixed with respond to finished G.S.M then knitting faults appear.

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5 03 2012

Knit Fabric Faults In Production | Causes And Way Of Remedies Of Knitting Faults
Textile Technologist | Knitting, Quality Control (Q.C) | 1 Knit fabric is produced from loop formation. So it needs to be careful during production. Different types of faults could be found in knit fabric, which could be the cause of fabric rejection. If we can find out the defects of fabric during production, than we can take steps to remove it from the next knitting production process.

In practical; following knitting faults could be found in the knit fabric. Some knitting faults and their remedies are given bellow: Hole Mark Causes:

During loop formation the yarn breaks in the rejoin of the needle hook. Holes are the results of yarn breakage or yarn cracks. If the yarn count is not correct on regarding structure, gauge, course and density. Badly knots or splicing. Badly set of yarn feeder.

Needle Mark Causes:

When a needle breaks down then needle marks come along the fabrics. If a needle or needle hook is slightly bends then needle mark comes on the fabrics.

Star Causes:

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

Sinker Mark Causes:

When sinker corrodes due to abrasion then sometimes it cannot hold a new loop as a result sinker mark comes. If sinker head bend then sinker mark comes.

Drop Stitches Causes:

If yarn is not properly feed during loop formation. Use of defective needle. Too loose of take down mechanism. If yarn tension is insufficient. If yarn feeder is badly set.

Oil Stain Cause:

When oil lick through the needle trick then it pass on the fabrics and make a line.

Rush Stain Cause:

If any rush in the machine.

Pin Hole Cause:

Pin hole may come to fabric due to break down or bend of the latch.

Grease Stain Causes:

Improper greasing in the machine IF greasing is excess.

Cloth Fall Out Cause:

Cloth fall out can occur after a drop stitch especially when an empty needle with an empty needle with close latch runs into the yarn feeder and remove the yarn out of the hook of the following needles.

Barre Causes:

Yarn fault is responsible for this fault. If different micro near value of fiber content in yarn. Different luster and dye affinity of fiber content in yarn. During spinning different similar classes of fiber is mixed specially in carded yarn and these fibers have similar characteristics. In draw frame different similar classes sliver is mixed and make one sliver.

Yarn Contamination Causes:

If yarn contains foreign fiber then it remains in the fabric even after finishing. Lot mixing and count mixing is responsible for these faults.

Fly Dust Cause:

In knitting section too much lint or short fiber is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attached to the fabric surface tightly during knit fabric manufacturing.

Yarn Faults Causes: Different yarn faults also are cause for knitting faults.

Neps Slubs Yarn count variation Thick/Thin place in yarn Hairiness

Now, if we want to remove these knitting faults we should be aware before yarn selection and during knitting of fabric. Knitting machine conditions should be perfect. Needle, Sinker, Feeder and other equipments, which is used, should be fault free. So, Management related person should be aware about the causes of knitting faults and try to reduce the knitting faults.

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20 01 2013

On Line Quality Assurance System || Types Of On Line Quality Control System

Textile Technologist | Quality Control (Q.C) | 3 There are two types of quality assurance system; one is off line quality assurance system and another is off line quality assurance system. Online Quality Assurance System: Online quality control comprises with the raw material quality control and the process control. On line quality control cosist of

Raw Material Control Process Control

Raw Material Control: As the quality product depends on the raw material quality so we must be provided with the best quality raw material with an economical consideration.

The fabric must be without fault, with proper absorbency, whiteness as per requirement of the subsequent process. The Greige inspection report gives the condition of the raw fabric. The information found on a greige report is given belowPenalty point legends Hole Oil stain Chemical stain Water spot Fly yarn Rub mark Dye stain Dirt stain Rust stain Yarn contamination Inspect spot Grease stain Missing yarn Drop stitch Code H OS CS WS FY R DS D RS YC IS GS MY DS

Needle line Uneven tension Stripe Thick & thin place Slubs Sinker mark Birds eye Wrong design Pin holes Barre mark

NL UT S TT Sl SM BE WD PH BM

The chemical should be of known concentration with a higher degree of purity. The entire machine should be higher precisions.

Process Control: The method chosen for the process must be provided with the necessary accurate parameters. The specific gravity, water level, residual hydrogen per oxide etc. at each stage should checked. On line quality control is a system which is performed during manufacturing. During this checking, if any faults are found in materials, one should take necessary steps to reduce the fault or to stop the process and take necessary steps to recover it. So, be careful during quality checking.