Mill Training Report (Viyellatex), Dyeing - Rafsan

Acknowledgements
First of all, our gratefulness goes to Almighty Allah who gave us strength and ability to complete
the industrial training and prepare this report; may your name be exalted, honored & glorified.
We are highly delighted to express our regards & gratitude to honorable Vice-Chancellor Prof.
Dr. Nitai Chandra Sutradhar & Prof. Dr. Md. Zulhash Uddin; Dean, Faculty of Textile
Chemical Processing Engineering & Applied Science, for providing us the opportunity to
complete our industrial attachment with Viyellatex Group.
Our heartiest gratitude to our supervising teacher, Mrs. Sharfun Nahar Arju; Head,
Department of Wet Processing Engineering to whom we are extremely indebted for her
tremendous support and guidance throughout our training period, without her help it would not
have been possible to complete the training successfully.
We also take the opportunity to express our sincere thanks to the management, administration
& personnel of Viyellatex Group for giving us permission to complete our training period in
this industry.
We are really grateful to our industrial coordinator Engr. Dewan Mahbub Kamran, Executive
Dyeing, Viyellatex Group for his encouragement, inspiration, support, supervision, special care
& co-operation during training period.
We would also like to thank specially Engr. Faridul Hasan, Executive Dyeing and also Engr.
Mr. Mahmud, Engr. Mr. Arif, Engr. Mr. Faisal, Engr. Mr. Fayez for their Cordial
Cooperation during the intern period.
Above all, we would like to acknowledge our deep debt to all teachers of our university &
particularly of Wet Processing Department for their kind inspiration & help, which remain as the
backdrop of all our efforts.

Table of Contents

S.N. Contents Page No.
1 Introduction 3
2 Project Description 4
3 Manpower Management 11
4 Knitting Section 16
5 Batch Section 27
6 Dyeing Section 30
7 Raw Materials 56
8 Finishing 60
9 Laboratory 75
10 Garments Section 86
11 Printing Section 90
12 Embroidery Section 95
13 Washing Section 96
14 Maintenance 101
15 Utilities 108
16 Effluent Treatment Plant 114
17 Inventory Control 118
18 Costing 120
19 Marketing 124
20 Recommendations 127
21 Conclusion 128

Introduction

By means of practical knowledge it is possible to apply the theoretical knowledge in the
practical field. For any technical education practical experience is almost equally important in
association with the theoretical knowledge.
The industrial attachment is the process which builds understanding skill and attitude of the
performer, which improves his/her knowledge in boosting productivity and services. Academic
education provides us vast theoretical knowledge as well as more practical attachment, despite
all these industrial attachment help us to be familiar with the technical support of modern
machinery, skill ness about various operation stages.
It also provides us sufficient practical knowledge about production management, Productivity
evaluation, work study, efficiency, industrial management, production planning & control,
production cost analysis, inventory management, purchasing, utility & maintenance of
machinery and their operation techniques etc. The above mentioned cannot be achieved
successfully by means of theoretical knowledge only. This is why it should be accomplished with
practical knowledge in which it is based on industrial attachment makes us reliable to be
accustomed with the industrial atmosphere & improve courage & inspiration to take self-
responsibility.
At Viyellatex Limited, cutting-edge technologies merge seamlessly with human ingenuity and
deep seat recommitment to ensure excellence in every stage and area of their activities. From
fiber to fabric, Viyellatex Limited is truly integrated undertaking. The Viyellatex Limited has the
capability to offer a complete product range for the export textile markets. The goal of
Viyellatex Limited is to become the preferred partner for sourcing high quality fabrics and
clothing from Bangladesh with highly advanced technology and an emphasis on developing local
human resources.

Project description

Project Description
Company Name: Viyellatex group ltd.
Status: Private Ltd. Company
Type: 100% Export oriented composite knit Dyeing Industry.
Sponsor: Mr. Rezaul Hasnat.
Annual Production Capacity for dyeing: 75000tons
Product Mix:
100% cotton
100% polyester
a) Spun
b) Filament
Nylon
Chief Value Cotton (CVC)
Polyester Cotton blend
Gray mlange (15% Viscose 85% cotton
10% Viscose 90% cotton
30% Viscose 70% cotton)
Ash mlange (1% Viscose 99% cotton)
Year of establishment: 2001
Year of starting production: 2002
Address:
Factory: 297, Khortoil, Tongi, Gazipur- 1712
Head office: 297, Khortoil, Tongi, Gazipur- 1712
Telephone no. +880-2- 9813001
Fax No. +880-2-9811400
Website: www.viyellatexgroup.com
Project cost: 20 million $ for dyeing and finishing in the year 2008.

Sections of Viyellatex:

Knitting Section
Yarn Store
Circular Knitting
V-bed Knitting
Inspection
Grey Fabric Store
Garments Section
Merchandising
Sample Section
CAD/CAM Section
Cutting Section
Sewing Section
Maintenance Section
Mechanical
Electrical
Washing Section
Embroidery Section
Printing Section
Store Section
Dyeing Section
Batch Section
Dye House
Dyeing Machine
Finishing
Quality Control

Location from Dhaka:

Physical Infrastructure:

Viyellatex Group is a Knit Composite Garments Manufacturer & Exporter, having all state of the
art facilities with the annual turnover US$ 106.6 Million (2006-2007). They have different types
of Knitting, Dyeing, Cutting, Sewing, and Finishing machines supplied by mostly Germany,
Japan, Taiwan, China, U.K, U.S.A, Singapore, etc. which are very latest. It has high production
where 30 tons of dyed and finished fabrics are produced per day. The production is controlled
by technical persons. All of the decision makers of production sector in Viyellatex Group are
textiles graduates. All the chemicals and dyes use for dyeing and finishing are well branded.

They produce product for their buyer and client coming from international market like U.K,
Sweden, Netherland, France, U.S.A, Germany and Spain. Their customer profile is big and top
end such as Esprit, M&S, S-Oliver, Puma, G-star, Gap, Tesco and Grew waver etc. They follow
all the system for their machines maintenance so production cannot hamper.

The mill is built in such a way that there is possibility for further expansion of the mill. The
structure such as mill, office buildings, record rooms, guard room etc. are made of solid hard
concrete & brick materials. . The whole area is surrounded by safety brick wall .The main set
up for m/cs are built of corrugated iron & iron sheet, transparent hard plastics with enough
ventilation & scope for passing light & air. Dyeing, finishing and knitting section have shade
roof. The garments section is in corporate building. The mill has water treatment plant and
Dhaka-Mymensingh Highway
KAI
Alluminim
Co.Ltd.
Masco
Industries
Ltd.
SMP Design
Pvt. Ltd.
FH Fabrics
Ltd.
Gajipura

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D
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ViyellaTex

effluent treatment plant also.it has a large canteen with facilities for 6000 employer. The mill
has official quarter for higher rank officers, which is build the previous year.

Vision: To be the most regarded company in Bangladesh by 2015.
Mission: We strive to provide quality services on time, based on best practices for the
satisfaction of our Partners & Stakeholders. We foster friendly working environment through
open communication and mutual respect. We encourage initiative, innovation and teamwork.
Workers welfare and right is our premier focus. We are committed for cleaner and greener
environment. We are driven by our responsibility to the society as a Corporate Body.

Viyellatex Values:
Integrity
Commitment
Customer Satisfaction
Innovativeness
Fairness
Environment

Major buyers of Viyellatex Group:

PVH
S-Oliver
Puma
Espirit
G-Star
M & S
Ito Yokoda
WoolWorths

Business Achievement of the Group:

Corporate Social Responsibility Commitments:

Execute business with transparency and integrity
Comply with all legal requirements to conduct business.
Emphasizing and rewarding for better job.
To become environment friendly as much as possible.
Emphasizing on the up-liftment of the community around the company.
Focusing on improved service to the customers and stakeholders.

Social contribution:

Green (Environment) initiative:

Viyellatex is most renowned environment friendly textile production facility in the world.
Our renowned environment initiatives have been well recognized not only by other international
business organization but also by World Bank & Asian Development Bank as well.
Our few exemplary initiatives:

More than 280000 liters of treated effluent water is being used for 7000 workers toilet
flush every day, saving 75M liters of underground water every year.
250000 square feet roof top is being used to collect approx. 45 million liters of rain
water which is later used in textile wet processing without utilizing the valuable
underground water and saving extra chemicals of water softening.
5 MW gas generator exhaust used in co-generation chiller to support 750 MT of air
cooling in the Viyellatex Spinning Mill. Also in the fabric plant, it is planning to use 3MW
generator exhaust in the Boiler. Both technology saves substantial energy and reduced
carbon emission.
Re-condensed steam water is being transported to the boiler feeder tank which
increases the temperature by 15-20C, saves hefty energy and minimizes global
warming.

Fabric dryer exhaust is being redirected to air inlet and feed into the burner to reduce
the energy consumption. A simple innovative technique which Viyellatex started to use 3
years back and now incorporated by famous GMBH Textile Machine Manufacturer,
Bruckner in their latest series of Stenter.
Per year approx. 50 Tons of food residue created during lunch of 7000 employees, are
being used to develop natural fertilizer and being distributed among the neighboring
farmers at free of cost- an initiative which avoids environment pollution and supports
the community.
Instead of air condition Viyellatex installed Energy Saving Evaporating Cooling System to
apparel production floors.
Viyellatex is constantly doing projects with International Partners to develop eco-
friendly textile products. It did the Carbon foot print project to minimize the carbon
emission in the wet processing with the assistance of world recognize company BASF.
Became self-reliant in the society & unique return for any business group of Bangladesh.

Manpower management
Viyellatex Group contains a no. of departments and each department is controlled by a chief
operating officer. The board of directors maintains control on overall departments. Viyellatex
limited possess a strong management system and all the activities are done in efficient way and
in a systematic process.

Board of Directors:
1. Mr. K. M. Rezaul Hasanat, Chairman & CEO
2. Mr. Ahasan Kabir Khan, Vice Chairman
3. Mrs. Kaniz Fatema Zareen, Director
4. Amina Salima Khan, Director

Organogram of Viyellatex Group:

Chairman & CEO

Vice Chairman
Group HR

Group
FINANCE

FABRICS

GDL

VSL

VTG

ISML

FPPL

Group IT

Group
Commercial

LM&S

Ruthna Tea
Estate

BUs Head of Viyellatex:

Organogram of Knitting department:

Mr. Syed Fatemy Ahmed Roomy Director
Mr. Md. Masudul Hoque MD & COO, GDL
Mr. Md. Abu Haider Rumi MD & COO, FPPL
Mr. Arif Bhuiyan COO, Viyellatex Garments
Mr. Kazi Monjurul Islam COO, Viyellatex Fabrics
Mr. Fateh Ul Islam COO, Interfab
Mr. Yakub Ali COO, Ruthna Tea Estate
Mr. Md. Sharif Dad Khan DGM, VSL
Mr. Kazi Shahidul Karim DGM, Commercial, VG
Mr. Ruhul Amin Chowdhury Head of ISS
DGM/AGM
Manager / Asst. Manager
(Store)
Sr. Executive
/ Executive
Jr. Executive
(Yarn)
Jr. Executive
(Grey Fabric)
Store Asst.
(Yarn)
Store Asst.
(Grey Fabric)
Loader
(Yarn)
Batch
Helper/Loade
Manager/Asst.
manager
Sr. Fitter / Fitter
Asst. Fitter
Servicing
man
Needle man
Servicing
helper
Manager / Asst. Manager
(Prod
n
& Plan)
Knitting
Master/Executive
(Flat)
Operator/Asst.
Operator
Sr. Fitter /
Fitter
Helper
Sr. Executive (Prod
n
,
Plan & Sample)
Executive/Jr. Executive
(Prod
n
, Plan & Sample)
Sr. Supervisor
/ Supervisor
Asst. operator
Sr.Operator
/ Operator
Production
Helper
Sample
supervisor
Sample asst.

Organogram of dyeing:

Organogram of finishing:

DGM/AGM
Manager
Planning
Asst. Manager

Sr. Executive/
Executive
Jr. Executive

Sr. Supervisor/
Supervisor
Production
Asst. Manager

Sr. Executive/
Executive
Jr. Executive

Sr. Supervisor/
Supervisor
Store
Asst. Manager

Sr. Executive/
Executive
Jr. Executive

Sr. Supervisor/
Supervisor
Washing
Asst. Manager

Sr. Executive/
Executive
Jr. Executive

Sr. Supervisor/
Supervisor

Management system:
Intercom telephone
Fax
Written letters &
Oral
Shift change:
Viyellatex limited maintain three shifts at every days work. So the shifts are changed at every
three hours. The shifting times are
A Shift 06:00 14:00
B Shift 14:00 22:00
C Shift 22:00 06:00
General shift & Office time:
09.00 18.00
Responsibilities of production officer:

To give dyeing program slip.
To match production sample with target shade.
To collect production sample for sample matching next production.
To observe dyed fabric during finishing running & also after finishing.
To identify disputed fabrics & report to P.M/G.M for necessary actions.
To discuss with P.M. about overall production if necessary.
To sign the store requisition & delivery challan in the absence of P.M.
Also to execute overall floor works.
To maintain loading/unloading khata.
Any other assignment given by higher authority.
Job Description of P.O & S.P.O:
Job title: Production officer & Senior Production officer
Report to: Production Manager

Purpose:
To control shift according to the plan made by the production manager
Territory:
Dyeing section (major)
Batching and Finishing section (minor)
Nature and Scope:
Responsible for the production during his own shift with good quality and minimum time.

Environment:
Production officer has to work under huge stress. He has to work in acute heat under physical
and mental pressure. Also he has to work in acute heat all the year round.

Job Description of Production Officer:
Report To: Sr. production officer
Job Summary:
To plan, execute & follows up the production activities & control the quality production with
related activities.

Duties & Responsibilities:
Overall supervision of dyeing, finishing production.
Batch preparation & PH check.
Dyes & chemical requisition issue & check.
Write fabrics loading & loading time from m/c.
Program making, sample checking, color management.
Control the supervisors, operator, asst. operator & helpers of dyeing m/c.
And also any other work as & when required by the management.

Job Description of Sr. Production Officer:
Report To: P.M (production)
Job Summary:
To plan, execute & follows up the production activities & control the quality production
with related activities.
Duties & Responsibilities:
Overall supervision of dyeing, finishing production.
Checks the different log books of different areas & report to management.
Checks the sensitive parameters of different machine for smooth dyeing.
Checks out the plan to control the best output from supervisor & workers.
To trained up & motive the subordinates how to improve the quality production.
Maintenance of machine & equipment. Any other works & when required by the
management.
Control the supervisors, operator, asst. operator & helpers of dyeing m/c.

Process flow chart for knitting:
Yarn in package form

Place the package yarn in the yarn

Feeding the yarn

Set the machine as per design & GSM

Knitting

Withdraw the roll fabric and weighing

Roll marking

Inspection

Numbering
Yarn types:
1. 100% cotton
Carded
Combed
Rotor
2. Man made
Polyester
Lycra
3. Blended
CVC (Cotton + Polyester)
PC (Polyester + Cotton)
Mlange (Cotton + Viscose)
White/Ecru Mlange (Dyed fiber 0.2-2.0%)
Grey Mlange (Dyed fiber 2.0-15.0%)
Anthra Mlange (Dyed fiber 15.0-30.0%)
4. Regenerated cellulose
Viscose
Modal

Commonly used yarn count:
Carded yarn 18,20,24,26,30,32,34,36 Ne
Combed Yarn 20,22,24,26,28,30,32,34,36,40 Ne
Rotor yarn 7,10,12,14,16 Ne
Polyester yarn 75,100,150 Denier
Lycra yarn 20,30,40,50,70 Denier

Sources of yarn:
1. Cotton (Both Carded & Combed)
- Viyellatex Spinning Limited
2. Polyester
- Kader Synthetic
- China
3. Mlange
- Patartoli
- Prime
- Sohagpur
- Thermax
4. Lycra
- China
- Korea
- Taiwan
- Japan
List of machines:

Name of the machine Quantity
Single jersey 35
Fleece 10
Double jersey 19
Auto striper (S/J) 06
Auto striper (Rib) 02
Flatbed knitting machine 25
Fabric inspection machine 03

Brands of the machine:
Fukuhara
Matsuya
Mayer & Cie.
Keumyong
Pai Lung
Terrot
Uzu

Specification of different types of machine:
Single Jersey machine:
Brand name: Pai Lung
Origin: Taiwan
Model: PL XS 3B
Feeder: 108
Gauge: 24
Diameter: 36
No of needle: 2712
Machine speed: Up to 35 rpm

Auto Striper machine:

Origin: Taiwan
Model: PLXD CS 6U
Feeder: 546c
Gauge: 18
Diameter: 36
No of needle: 2040

Fabric Inspection machine:
Brand: Uzu cloth inspection machine
Manufacturer: AATPR Industry Co. Ltd.
Model: UZ 900-3
Origin: Thailand

Different parts of the machine:
1. Start/Stop/Inch buttons: This set of buttons is used to start/stop/slow running of
machine.
2. Ratchet lever: This lever permit the hand movement of the machine.
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 the machine.
4. Side creel: For each feed, there are two cones of yarn on the creel.
5. Tensioning device: The yarn goes to the feeder of the machine from the creel through
different tensioning devices. These devices are used to maintain the proper tension of
the yarn.
6. Feeder: Feeder is used to feed the yarn.
7. VDQ pulley: This is one of the important parts of the machine. Through VDQ pulley, the
GSM of the fabric is controlled. If the value of the VDQ pulley is increased, then the loop
Double Jersey machine:

Origin: Taiwan
Model: PL XRA CE
Feeder: 76
Gauge: 18
Diameter: 38
No of needle: 2124

Flat Bed Knitting machine:
Brand name: Matsuya
Origin: Japan
Model: M-100
Feeder: 6
Gauge: 14
Head: 2
Bed length: 102

length of the fabric will be less and the GSM of the fabric will be high. Vice versa for
make low GSM fabric.
8. Auto counter: Two shift revolution with display counter with predetermined stop, to
settle freely the weight or yardage of fabric.
9. Variable speed drive with machine break: Transistor inverter provided for free
controlled, the process of V.S. motor-drive from slow operation to normal operation
is quite & fast brake to prevent damages in case of needles or yarn breakage.
10. Fabric take up system: With variable speed control by a belt drive set canbe adjusted
the speed for different course of fabric-constant and uniform fabric tension.
Points should be considered for GSM changing:
1. VDQ (Variable Dia. Quality Control) pulley diameter.
2. Yarn count.
3. Machine gauge.
4. Cam position
5. Take up motion

Factors that should be considered for changing of fabric design:
1. Cam arrangement changing.
2. Needle butt setting & needle dropping.
3. Using of different colors in selected feeder.
4. Using of jacquard mechanism.
5. Size of the loop shape

Recommended points of buyer:
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-
1. Diameter of the fabric
2. Design of the fabric
3. GSM of the fabric
4. Total wt. of the fabric
5. Yarn count
6. Types of yarn
7. Color of the fabric
8. Finishing of fabric.
9. Handling & fastness property.

End products of the knitting machine:
1. Single Jersey machine:
- Plain jersey
- Lycra jersey
- Single Lacoste
- Double Lacoste
- Single Pique
- Double Pique
- Fleece (Three thread)
- Terry Fleece (Two thread)

Production parameters:
- Machine Diameter
- Machine rpm (revolutions per minute)
- No. of feeds or feeders in use
- Machine Gauge
- Count of yarn
- Required time (Machine running time)
- Machine running efficiency
Production calculation:
1. Production/shift in kg at 100% efficiency:
count Yarn
mm SL Needle of No Feeder of No RPM

2046 . 2 840 36 54 . 2 10
12 60 ) ( . .

count Yarn
mm SL Needle of No Feeder of No RPM
80 . 3527
) ( . .

2. Production/shift in meter:
100 /
12 60 .
/
. min /
cm Course
Efficiency Feeder of No RPM
cm Course
Course

3. Fabric width in meter:
100 /
.
100 /
.
cm Wales
knitting Needles of no Total
cm Wales
wales of no Total

2. Double Jersey machine:
- 11 Rib
- 21 Rib
- Interlock
- Mesh
- Flat back Rib
- Waffle
3. V-bed knitting machine:
- Collar
- Cuff
- Emboss

Methods of increasing production:

There are few ways of increasing production of the machine
1. By increasing m/c speed: 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 using machine of higher gauge:
The more the machine gauge, the more the production is. So by using machine of
higher gauge, production can be 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.

Commonly found fabric faults in the Knitting floor:
Needle mark:
Appearance: Spot of line is found at wales direction.
Causes:
Due to decayed needle.
Due to bended needle.
Due to old needle.
Remedies:
Change the needle.

Sinker mark:
Appearance: Spot of line is found at wales direction.
Causes:
Due to decayed sinker.
Due to faulty adjustment of sinker with sinker cam.
Remedies:
Change the sinker.
Make necessary adjustments of sinker with sinker cam as required.

Hole:
Appearance: Hole on the fabric.
Causes:
If needle latch is not working properly.
Due to uneven tension.
Due to needle head breakage.
Due to improper cam setting.
Remedies:
Change the needle.
Adjust the tension as required.
Adjust cam setting properly.

Loop:
Appearance: As like small size holes.
Causes:
Due to uneven tension.
If cam box is loose, during the cam box setting.
Any type of problem is occurred in m/c setting.
Remedies:
Change the needle & sinker.
Adjust the tension as required.

Baree Mark/Patta:
Appearance: Found stripe effect towards the coarse on knit fabric.
Causes:
If yarns of different lot are mixing together.
If different counts of yarn are mixing together.
Remedies:
Operator should be careful about that different lots of yarn cannot be mix up.
Yarn should be tested before knitting.

Slub:
Appearance: A thick place is made in a particular place on fabric surface.
Causes:
Due to using of low quality yarn.
Remedies:
Yarn quality should be good.
Yarn testing should be done very carefully.

Thick & Thin Place:
Appearance: Higher & lower counts of yarn are knitted at a time.
Causes:
Due to using of different counts of yarn during knitting.
Due to irregular yarn dia.

Remedies:
Operator should be careful during the operation that for a particular design.
Count of every cone package should be same.

Tension Mark:
Appearance: Found spot at wales direction of knit fabric.
Causes:
Due to excessive tension in yarn.
Remedies:
Tension should be adjusted as required.

Oil Spot:
Appearance: Oil spot on fabric surface.
Causes:
Due to excessive bleeding of oil in the m/c.
If there is any type of problem in needle & sinker, oil can be bled on the fabric.
Remedies:
Change the faulty needle & sinker.
Machine should be cleaned time to time.

Pin Hole:
Appearance: Small size of hole as like pin.
Causes:
Due to wrong adjustment of cam box.
If the yarn quality is low especially yarn with less strength causes pin hole in the
fabric.
Remedies:
Make required adjustment of cam box.
Use high quality yarn.

Lycra Out:
Appearance: A Lycra yarn is missing at vertical direction.
Causes:
If Lycra yarn missed or breakage happened.
Remedies:
Operator should be more cautious to make necessary adjustment or replacement
or joining the yarn.

Lycra Drop:
Appearance: Tension caused in Lycra out.
Causes:
Due to excessive tension on Lycra yarn when knitted (within its tolerance limit).
Remedies:
Make necessary adjustments to the tension of Lycra yarn.

Set Off:
Appearance: Found loop gap on knit fabric.
Causes:
Set off occurred when needle & sinker both inactive simultaneously in the
process of knitting.
Remedies:
Machine should be stopped as early as possible.

Remarks:
Grey fabrics from knitting are used in dyeing. So the quality of the fabrics should be good 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.

Batching:
Batching is the process to get ready the fabrics which should be dyed and processed for a
particular lot of a particular order. In other words
Batching means separation of fabric according to specification, Dyeing machine capacity &
availability, urgency of the order.
Batch contains body of garments as well as collar-cuffs according to the design.

Types of Batching:
1. Solid
2. Assorted

Batch Quantity = Total required quantity X Dia Quantity/ Total quantity

Batch Ratio = Total batch quantity + total parts/ Batch Quantity

Batch distribution:
Batch is distributed according to nozzle capacity.
During distribution maximum equilibrium of different parts is taken into consideration.
Lycra fabrics are slit-cut to heat-set. Thats why before dyeing they need to re-sewn.
This is done by Bag-sewing machine.
Tubular fabrics are turned into their backside by turning machine.

Function or Purpose of Batch Section:
- To receive the grey fabric roll from knitting section or other source.
- Turn the grey fabric if required.
- 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.

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.

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.
Sometime planning is adjusted according to m/c condition or emergency.

Machines used in Batching:
1. Bag Sewing machine: There are total 2 sewing machines

Brand: Juki,
Model: G39/0141
Power: 10A, 230V
Type: 2 Needle 2 Looper chain stitches. 1
Needle 2 looper in use.
Origin: Japan
Brand: Pegasus,
Model: M7S2-181
Specification: 2 Needle 4 Loopers. 1 Needle 2
Looper in use
Device: BT/88
Origin: Japan

2. Turning machine: There are two turning machines also. Both of them have same
specification.

Brand Name : Taida
M/c Speed : 300-500m/min
Model : DF 200
Max up clothing : 150 kg
Company : Shandong Taida Dyeing & Finishing Machinery Co. Ltd.
Origin : China

3. Light box:
Brand: Verivide
Model: CAC60
No. of light sources: 4, TL
84
, D
65
, F, UV
Serial no.: E 614506
Manufacturing year: 2002
Power: 220-230V, 270W
Origin: England

Layout plan of dyeing floor

Number of machine:
Turning machine: 02
Bulk dyeing machine: 15
Sample dyeing machine:
There are two brands of dyeing machine used in Viyellatex. They are:
1. Fongs
2. Thies
Fongs machines are from China and Thies machines are from Germany.

Number of Fongs Machine:
Bulk machine: 10
Sample machine: 6
Total number of Thies machine:
Bulk machine: 5
Sample machine: 1
Total length of dyeing floor: 412 feet
Total width of dyeing floor: 34 feet
Area of the dyeing floor: 41234 = 14008 square feet.

Production per day:
Maximum Loading capacity 100% (11.36 tons)
Possible maximum loading 80% (9.088 tons)
Total production per days (3 shifts) = 9.088 x 2.5 (considering 2.5 batch in 3 shifts)
= 22.72 tons.

Bulk machine specification
M/C
No.

Brand

Model
Year of
Mfg.

Origin

Capacity
Kg
No. of
Nozzle
Max
m

temp

0
C
Max
m
Pressure
KPa

Dimension
(inch)

1 Fongs ECO 38 2T 2003 China 500 2 140 380 1218
2 Thies Farbavessel
ECOSOFTPLUS
2004 Germany 1000 4 140 550 2018
3 Thies Farbavessel
ECOSOFTPLUS
2003 Germany 1000 4 140 550 2018

4 Thies Farbavessel
ECOSOFTPLUS
2002 Germany 250 1 140 550 1218
5 Thies Farbavessel
ECOSOFTPLUS
2002 Germany 500 2 140 550 1418
6 Thies Farbavessel
ECOSOFTPLUS
2002 Germany 750 3 140 550 1618
7 Fongs ECO 61T 2005 China 200 1 140 380 918
8 Fongs ECO 61T 2005 China 250 1 140 380 918
9 Fongs ECO 61T 2005 China 750 3 140 380 2018
10 Fongs HSJ-4T 2007 China 1120 4 140 350 2118
11 Fongs HSJ-3T 2007 China 840 3 140 350 1818
12 Fongs HSJ-SR-2T 2007 China 560 2 140 350 1518
13 Fongs HSJ-SR-6T 2007 China 1680 6 140 350 3318
14 Fongs HSJ-SR 2007 China 840 3 140 350 1818
15 Fongs HSJ-SR 2007 China 1120 4 140 350 2418

Sample machine specification
M/C
No.

Brand

Model
Year of
Mfg.

Origin

Capacity
Kg
Maximum
Temp.
0
C
Maximum
Pressure
KPa
Dimension
(Inch)
1 Fongs ALLFIT-30 2003 China 25 140 400 913
2 Thies N/A 2002 Germany 25 140 350 613
3 Fongs ALLFIT-30 2005 China 30 140 400 3.511

MACHINE DESCRIPTION

Technology of the dyeing machine:
Viyellatex dyeing unit used special types of dyeing machine. In these machine, the Jet and Winch
technology is combined i.e. during dyeing, dye liquor circulate through the machine like jet dyeing
machine also the fabric is circulated through the winch as like winch dyeing machine. This
combination is made for better dyeing of the fabric.
Main parts of dyeing machine:
The main parts of the dyeing machine are-
1. Main tank
2. Reserve tank/PT tank
3. Additional/Mixing tank
4. Main pump
5. Heat exchanger
6. Filter

The description of the main parts of the machine is as follows
Main tank:
Main tank is the largest part of the dyeing machine. This is the main dye bath which contains the
dye liquor & the fabric. The size of the tank depends on the capacity of the machine. Liquor &
fabric circulates in the main tank during dyeing process. There may have different number of
nozzle connected to main tank according to the machine capacity. Each nozzle may handle 300-
900m of fabric.

Fig: Main Tank
Reserve/PT tank:
This tank is mainly used for storage of hot water that will be used for the dyeing of fabric. The
temperature of water in the P.T. tank is maximum 80
0
C. By using this hot water in the machine
during dyeing there is a reduction of time for heating the water in the main tank which results in
the reduction of total dyeing time.

Additional/Mixing tank:
This tank is mainly used for storage of hot water that will be used for the dyeing of fabric. The
temperature of water in the P.T. tank is maximum 80
0
C. By using this hot water in the machine
during dyeing there is a reduction of time for heating the water in the main tank which results in
the reduction of total dyeing time.

Fig: Mixing tank
Main pump:
This is one of the essential parts of the dyeing machine. This is used for displacing of dye bath
liquor causing a flow from main tank to heat exchanger through filter. That means the pump
ensures the liquor circulation throughout the dyeing process.
Heat exchanger:
During the different stage of dyeing (also pre-treatment, after-treatment), there is a need of
increasing or decreasing the temperature of dye liquor gradually. We cannot use liquor of
required final temperature directly because there may be possibilities of thermal shocking of the
fabric. So, the temperature should be increased or decreased in a controlled manner. This
controlling is done by heat exchanger. Actually it is an indirect heater. During the circulation of
dye bath liquor, the liquor passes through the heat exchanger.
Mechanism of Heat-exchanger:
1. Heat-exchanger consists of no. of tubes surrounded by a shell body.
2. Two fluids of different temperature flow through the heat exchanger. The fluids can be
either gas or liquid on either the shell side or the tube side.
3. One flows through the tube other flows through the shell.
4. The temperature of the two fluids is different, so transfer of heat occurs from one fluid to
another through shell.

Figure: Mechanism of Heat exchanger Figure: Heat exchanger

5. The fluids which flow through the tubes come in and pass out from the heat-exchanger on
the same side. On the other hand the fluid used in shell comes in and pass out from the
different side of the shell.
Filter:
During the treatment of fabric in the machine, lots of lose fiber is produced from the fabric. To
eliminate these lose fibers, filter is used. It also reduces the lose fibers loads from the fabric. If
the lose fibers are not eliminated, then the running of fabric is disturbed & entanglement can be
occurred.
Ways of Liquor Flow from Additional Tank:
Liquor from additional tank flow to the main tank is mainly done in two ways. They are
1. Inject: In this system, all amounts of liquor flows directly to the main tank at a time. This
is done when the chemicals need to pass at short time. This system ensures high rate of
flow of the liquid.
2. Dosing: In this system, the liquor does not pass to the main tank at a time. There are few
chemicals which have very severe action to the fabric if it flows directly like sodium
hydroxide (NaOH). These chemicals pass to the main tank in an increasing or decreasing
way with time so that the harsh effect of these chemicals is minimized. There are three
3. types of dosing:

- Linear Dosing - Progressive Dosing - Decreasive Dosing

Linear dosing Progressive dosing Decreasive dosing
Liquor circulation system:
During the treatment of fabric, the liquor is circulated throughout the machine. At first, the
required amount of liquor is taken in the main tank. Then the liquor goes to the filter through
pump and then it goes to the heat-exchanger. From the heat-exchanger, the liquor goes to the
main tank through nozzle. The schematic diagram of liquor circulation system is given below-

Figure: Liquor circulation system

Types of machine according to temperature:
Atmospheric machine
High temperature machine

There are one atmospheric machine of Fongs brand in Viyellatex. Others are high
temperature machine (both Fongs and Thies). Also there are special types of high
temperature machine used in Viyellatex named as Fongs High Speed Jumbo (HSJ) Machine.
Features of Fongs atmospheric machine:
The machine is designed for pre-treatment, dyeing & after-treatment under atmospheric
condition.
Nozzle is sized for smooth passing through by the fabric and extensive exchange with the
liquid.
Two standard nozzle sizes with sufficiently large diameter are available.
Circulation pump is sized for heavy fabric
Production capacity: 500 kg maximum per batch.
Maximum temperature: 98
o
C.
Maximum pressure: 1 atm.

Figure: Fongs atmospheric machine
Features of high temperature machine (Both Thies & Fongs):
The machine is designed for the pretreatment, dyeing and after treatment which can
provide temperature up to 140
0
C.
Nozzle lead gets interlocked after temperature exceeds 80
0
C.
Loading per nozzle 250kg
Design pressure: 350-550kpa
Design Temp : 140
0
C
Hydraulic Test Pressure: 585Kpa
Manufacturer: Germany (Thies), China (Fongs)
No of nozzles: 1-8.

Figure: High temperature machine
Features of Fongs High Speed Jumbo (HSJ) machine:
Variable Loading (VL) storage chamber design gives extra capacity to carry loading up to
280 kg per tube
Heat Exchanger of extreme efficiency gives the largest heating rate with minimum heat
loss to the environment
Multi Saving Rinsing System (MSR) shortens the dye cycle and reduces the water
consumption
Advanced Intelligent Rinsing System (MIR) controls the rinsing water consumption and
shortens the rinsing process
Highly optimized machine structure reaches the lowest possible liquor ratio of 1:4.5 to
run the machine.
Dissolution pumps for proper circulation of liquor.
safety valve test:350kpa
Maximum fabric speed: 400 m/min.
Maximum working temperature: 140 C

Figure: Fongs high speed jumbo machine

Some additional features of Fongs HSJ machine:
There are few additional features of Fongs HSJ machine which gives more productivity, better
control and less stoppage times of the machine. These are
Dissolution Pump
Variable Loading Chamber
MIR Rinsing System
MSR Rinsing System
Dissolution pump:
Dissolution pump makes the chemical concentration (salt, soda, dye, auxiliaries) low
before passing it to the main tank from additional tank.
This concentration is reduced in 1:4 ratios (liquor from additional tank: liquor from main
tank).
As a result rate of chemical dosing become slow which gives better fixation.
Thus better color yield and even dyeing can obtain.

Figure: Dissolution pump

Variable Loading Chamber:
This is one of the advanced techniques of space utilization of the round shaped dyeing machine.
Experiment shows that the volume of the chamber can be increased per nozzle up to 30 Kg of
fabric depending upon the linear density of the fabric.
Few advantages of variable loading chamber are
Better alignment of the fabric.
More loading facility.
Less entanglement of the fabric.

Linear Density Variable chamber setting
Up to 350 g/m 0%
Up to 350-450 g/m 50%
Above 450 g/m 100%

MIR Rinsing System:
Multi-function intelligent rinsing system.
If the temperature is below 80C It is a Low Level Continuous Rinsing Shorten Rinsing
time.
Save Rinsing Water.
Fill and Drain at the same time at low level.

Figure: MIR Rinsing System

Figure: Schematic diagram of Variable Loading Chamber

MSR Rinsing System:
Multi- saving rinsing system.
If the temperature above 80C it is Combined cooling and Rinsing at high temperature.
Save Steam in Hot Rinsing.
Rinsing efficiency at higher temperature is faster, so rinsing time is shortened.

Comparison between Fongs and Thies dyeing machine:
Fongs Thies
Have heat-exchanger for preparation tank.
Such facilities are not present.

Liquor pass through the filter & heat-
exchanger
Filter and heat-exchanger are separate.

Have dissolution pump for mixing chemical in
1:4 ratio.
Not present.

Horizontal heat-exchanger.

Vertical heat-exchanger.

Two additional tank.

One additional tank.

Variable loading chamber.

Not present.

Loading per nozzle 280 kg (HSJ).

Loading per nozzle 250 kg

Winch speed can be above 450 m/min.

Up to 350 m/min.

Calculation of Winch Speed:
Let,
Fabric weight = 1000kg
Per nozzle fabric weight =250kg
Fabric Diameter (open) = 56 inch
Cycle time or Dwell time = 2.5-3.0 m per minute
G.S.M =180
We know, GSM = gram / meter
2

= gram / (Length Diameter)
Or, Length = gram / (GSM Diameter)
= (2501000100) / (562.54180)
= 976 meters.
So, Winch or Reel Speed = Per nozzle Fabric length / Cycle time
= 976 / 3 meter/minute
= 325 meter/minute.

Calculation of Linear Density:
Linear Density = (DiameterGSM2.54) / 100 gram/meter

Production planning and sequence of operation:
Dyeing process flow chart:

Grey fabric receive from knitting section

Batching

Turning of fabric (only for Single Jersey)

Selection machine no

Fabric loading

Select production program

Select recipe for dyeing

Pretreatment

Dyeing

After treatment

Fabric Unload

Production Parameters:
1) P
H

- Scouring P
H
12.5
- During H
2
O
2
bleaching P
H
10.5-11
- Enzyme P
H
4.5
- Before dyeing (Leveling) P
H
6.5

2) Temperature:
-For cotton fabric scouring: 105C
During NaOH addition 65
o
C
During H
2
O
2

addition 70
o
C
Peroxide killing at 80
o
C
- Sequestering at 90
o
C
- Bio-polishing at 55
o
C

- For cotton dyeing:
Low brand 45
o
C
Medium brand - 60
0
C
Hot brand 80
o
C

- Salt P
H
7-8

- During reactive dyeing P
H
10.5-11.5
- During disperse dyeing P
H
4.5-6.0

- Softener P
H
6.5

- Migration for turquoise color at 90
o
C
- Optical brightening agent (OBA) at 80
o
C
- Polyester dying: 100
0
-130
0
C
- Softener at 45
o
C

3) Time:
- For white fabric 4-5hrs
- For 100% cotton 8-10hrs
- For 100% polyester 5hrs
- CVC 2 parts 13-14 hrs.
4) M: L ratio:
- For reactive dyeing M: L ratio maintained between 1:6
Pretreatment process:
Typical recipe for scouring: (all in g/l)
Felson NOF 0.7
Kapazon H53 0.5
Caustic 2
H
2
O
2
2.5
Recorit wez/Peroxide killer 0.75
Acetic acid 0.8
Biopolish B-11 1.5
Securon 540 0.5
Pretreatment flow chart
Fresh water and fabric Load at 45
o
C

Temperature raise to 60
o
C

Detergent, Peroxide Stabilizer inject

Run for 5 min

Inject Caustic and run 5 min

Raise temperature to 70
o
C

H
2
O
2
inject and run 5 min

Temperature raise to 105
o
C

Run for 30 min

Lower the temperature to 80
o
C

Bath drain

Peroxide killer inject and run 10 min

Rinsing and unload the fabric.

Curve for scouring of fabric:

Types of shade:
Light
Medium
Dark
White

Dyeing
process
Isothermal
dyeing
Migration
dyeing

evel in at 60 C

Color dosing 60C x 35( linear dosing)

Run time 60C x 15

Salt dissolving 15 (recirculation process)

Run 15

Soda dosing for 50( 70% progressive)

Check the sample after 10

Migration Dyeing

evel in at 60 C

Color dosing for 35

Run time 10

Salt dissolving 15 min

Run time 10

Temperature rise at 80
o
C

Run time 20

Temperature drop at 60
o
C
Order of Color and Salt dissolving/dosing:
In case of 0-1.0 % (light) shade color is dosed first then salt dissolving is
performed.
In case of 1-2.5% (medium) shade salt is dissolved at first then color is dosing.
In case of 3 & above % (dark) shade salt is dissolved at first then color is dosing.
Dyeing procedure for dark shade: (Black)
Typical recipe: (all in g/l)
A41/Leveling agent 0.5
RS Yell 3RFN 0.424 %
RS Red 3BFN 0.21 %
RS Black EDGH 9.27 %
Salt 90
Soda ash 5
Caustic 1.75

Isothermal Dyeing

Process Flow Chart

Fresh Water taken at 60
o
C

Inject Leveling agent and keep for 7 min

Salt dosing 20 min & runtime 20 min

Color dosing 35 min and run for 15 min

Soda dosing for 30 min (70% progressive) and run 10 min

Caustic dosing for 25 min and run 20 min

Sample check after 10 min

Wash and unload.

Curve for black shade (dark) cotton dyeing

Dyeing procedure for Light/Medium Shade:
Typical recipe:
SV/Sequestering agent 1.5 g/l
ADM/Leveling agent 1 g/l
R Yell RR 0.106 %
R BR Blue R (SPL) 0.172 %
Salt 24 g/l
Soda ash 8 g/l

Flow Chart:
Fabric load and then Water taken

Rise temperature to 60
o
C

P
H
control to 6.5

Inject leveling agent and run for 10 min

Color dosing for 45 min + add SV

Run the bath 10 min

Other SV inject and run 20 min

Salt add and run 10 min

Extra Salt addition and run for 20 min

Soda dosing for 60 min

After 10 min Sample check

Rinsing and unloading

Curve for Cotton part Dyeing

Production flow chart for white shade:
Typical recipe: (all measurement in g/l)
Felson NOF 0.5
Kapazon H53 0.5
Caustic 2.5
H
2
O
2
6
4BK/Whitening agent 0.15
Acetic acid 1
Biopolish B-11 1.5
Securon-540 0.5
FPG/Softener 1.5
Process flow chart
Detergent, Peroxide stabilizer added at 60
0
C

Fabric load and run for 5 min

Caustic dosing for 5 min at 60
0
C

Temperature rasied to 70
o
C

Peroxide added and raise temperature to 80
o
C

Optical brightening agrnt dosing for 10 min and temperature raise to 105
o
C

Run for 50 min and lower temperature to 80
o
C

Bath drain and water taken at 80
o
C

Rinsing for 10 min then bath drain

Fresh water taken and Acetic acid at 60
o
C

Run for 10 min then again drain the bath

Acetic acid at 55
o
C and P
H
control to 4.5

Enzyme is added and run for 50 min at 55
o
C

Bath drain and fresh water at 60
o
C

Inject Sequestering agent and temperature raise to 90
o
C

Run 10 min and add Softener, againg run 20 min

Fabric unload

Curve for White shade

Dyeing of 100% Polyester
Typical recipe :
Antifoaming agent 0.15 g/l
T Yellow W-4G 0.0012826 %
DIA BR Red SF 0.1333904 %
T Blue WBLS 0.00153912 %
AB-45 0.5 g/l
Process Flow Chart :
Fabric Load

Water Level As Required

Raise temp to 60
0
C

Add Felson NOF

Raise temp.to 90
0
C & run time 10 min

Bath drain

Water in

0
C

Add acetic acid & runtime 10 min

Bath drain

Water taking

0
C

Dye dosing for 10 min

0
C & run for 45 min

Drain

Water taking

Cooling at 70
0
C & sample cheek if shade ok then bath drop

Hydrose + Caustic at 80
0
C for 20 min

Hot wash

Curve for Polyester dyeing:

Production flow chart for CVC:
For CVC fabric dyeing, at first polyester part is dyed at 130
0
C according to dyeing procedure
of 100% polyester dyeing.
Then cotton part is first scoured & bleached. Then cotton part is dyed according to
dyeing procedure of 100% cotton.
Turquois color dyeing:
Typical recipe:
Kapavon CL/Anticreasing agent 0.5 g/l
SV/Sequestering agent 1.5 g/l
R BR Yell 3GL 0.0814 %
R Turq B1G 3.4556 %
R BR Blue RSPL 3.14 %
Salt 90 g/l
Soda 5 g/l
Caustic 1.75 g/l

Flow chart of turquoise color dyeing:

Water taken at 60
o
C and P
H
= 6.5

Raise the temperature to 80
o
C

Ant creasing and Sequestering agent inject and run 10 min.

Color + SV dosing for 50 min and run 10 min.

SV inject and run for 10 min.

Salt dosing for 10 min. then run 10 min.

Again Salt dosing and run 10 min

Temperature to 90
o
C (1
o
C/min) and run 20 min

Temperature reduce to 80
o
C

Soda dosing (70% progressive) for 40 min then run 10 min

Caustic dosing (70% Progressive) for 40 min then run 10 min

Sample check
Curve for dyeing with turquoise color:

Washing of grey mlange fabric:

Level in

Wetting agent at 60C

Bath Drain

Level in

PH 5.5 and temperature 55
o
C

Enzyme

Run time 60min

Rise temperature to 80C

MIR rinse for 15

Level in

Softener 45Cx10'

Bath Drain

Cold rinse

After treatment
After treatment Process flow chart:
Wash off at 95 C*15 (soaping agent 1-1.5 g/l)

Overflow Rinse/MIR 50C x 15

Acid 0.35 g/l

Softening treatment 45 C x 20 at P
H
- 4.5~5

Rinse 15

Unload

After treatment process may vary according to byer requirement like whether softener,
anticreasing or enzyme should be applied or not.

Process Loss:

Fabric types Loss of percentage
Puma (CVC fleece) 14%
S.Oliver (s/j) 13.5%
G.Star (s/j) 12%
M&S (s/j) 10%
Espirit (s/j) 12%
Lycra (S/J) 14%
YID fabrics 7%
Grey mlange
( Puma & M&S)
10%
Grey mlange
(G.Star)
12%

Common dyeing faults with their remedies:
1. Uneven dyeing:
Causes:
- Uneven pretreatment (uneven scouring & bleaching).
- Rapid addition of Dyes and Chemicals.
- 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.
- Liquor ratio changed.
- Different dyeing procedure for each batch.

Remedies:
- Use standard dyes and chemicals.
- Maintain the same liquor ratio.
- 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.

2. Dye Spots:
Causes:
- Not proper agitation of dyestuffs.
- Dye bath hardness.
- Operators ignorance about mixing and dissolving the dyestuffs and
chemicals.
Remedies:
- Proper agitation of dyestuffs.
- Use adequate amount of sequestering agent to minimize hardness.

Remarks:
We have seen that in dyeing different production parameters like temperature, time, P
H
,

M:L ratio etc. are strictly followed. Sometimes the original dyeing process may not be found
according to dyeing curve as they produce some complicated shade. One thing is clearly
noticeable that production manager and officers are committed to try their best for reducing
production time.

Types of raw material:

1. Yarn
2. Fabric
3. Dye stuff
4. Chemical and auxiliaries

List of Chemicals used in Viyellatex
Serial No. Material Description Agent
1 Acetic Acid Basic Chemicals
2 Caustic Soda Basic Chemicals
3 Glauber Salt Basic Chemicals
4 Hydrogen Peroxide (H
2
O
2
) Basic Chemicals
5 Soda Ash Basic Chemicals
6 Hydrose(BASF) Reduction Clearer
7 Hydrose(China) M/C Wash
8 Feloson -NOF Detergent
9 Rucozen WBL Detergent
10 INVADINE-LUN Detergent
11 Nearpon BW-LF Detergent
12 LUBRIMAX-TL Anti-creasing
13 Kappvon -CL Anti-creasing
14 BREVIOL PAM-N Anti-creasing
15 Kappazon -H-53 Stabilizer
16 OXISTAB-C Stabilizer
17 Invatex -PC Peroxide Killer
18 Kappatex -PKS Peroxide Killer
19 Rucorit WEZ Base Peroxide Killer
20 Kilat Sequestering
21 Securon-540 Sequestering
22 GENENCOR BP NANO Enzyme
23 Genencor BF 1600L Enzyme
24 BIOPOLISH -B14 Enzyme
25 ALBAFLOW-JET Antifoam
26 PROFOAM-SLK Antifoam
27 Sarabid -LDR Leveling
28 Kappquest -A41 Leveling
29 OPTAVON SV Leveling
30 CROSCOLOR ADM Leveling
31 Rucozen -NZA Soaping
32 DEKOL-SN Soaping
33 Cycalonan -X-C-W Soaping
34 ULYSIN S Soaping
35 Protnin -FCE-375 Fixing
36 Sapamine -CWS Color Softener
37 Nearsopht JS-100 Color Softener
38 KAPPASOFT-BD Color Softener
39 SAPAMINE-FPG White Softener
40 Nearsopht -NI White Softener
41 Rucofin -GWE Silicon Softener
42 Rucofin -HHS Silicon Softener

43 Syno White 4BK Optical Brightener
44 Uvitex -CB Optical Brightener
45 Uvitex -BAM Optical Brightener
46 Uvitex -BBT Optical Brightener
47 Uvitex -BHB Optical Brightener
48 ALVATEX-AB-45 C.V.C Chemicals
49 ALBATEX-AR C.V.C Chemicals
50 UNIVADINE-DIF C.V.C Chemicals
51 Repellan SRF Stain release chemicals
52 Repellan XL-E Stain release chemicals
53 Adalin NI Stain release chemicals
54 Foryl LN Stain release chemicals
55 Common Salt WTP Chemicals
56 Cogulant ETP Chemicals
57 Lime ETP Chemicals
58 BLUE J OCEAN MAGIC R Washing Chemicals
59 AVOLAN IS Washing Chemicals

Dyes with Brand name

Serial No.
BEZEMA
1 Bezactive Yellow S-3R
2 Bezaktive Red -S2B
3 Bezaktive Red -S3B
HUNTSMAN
4 Cibacrone -Blue -FNR
5 Cibacrone Yellow -F-4G
6 Cibacrone Yellow -FN-2R
7 NOVACRON BRILL BLUE H-GR
8 NOVACRON BRILL. RED FN-3GL
9 NOVACRON SCARLET FN-6G
10 Terasil Black -WNS
11 Terasil Navy -WRS
12 Terasil Red -W-4BS
13 Terasil Yellow -W4G
14 TERASIL BLACK -SRL
JIHUA
15 Reactive Starfix Black-WM
16 Reactive Starfix Red -3-BFN
17 Reactive Starfix Red -EP
18 REACTIVE STARFIX BLACK ED HG
DYSTER
19 Dianix Yellow -SEG
20 Dianix Sport Red-SF
21 DIANIX BRILL RED SF
22 Remazol Blue-RGB

23 Remazol Navy Blue-RGB
24 Remazol Brill Red -F-3B
25 Remazol Deep Black -RGB
26 Remazol Red -RR
27 Remazol Red-RGB
28 Remazol Ultra Carmine -RGB
29 Remazol Yellow -RR
IMPOCOLOUE
30 Imcozin Brill. Blue -VR Special
31 Imcozin Golden Yellow -V-RNL
32 Imcozin Red -E-3BF
33 Imcozin Turquise -VG
34 Imcozin Brill. Yellow -V-4GL
SUNFIX
35 Sunfix Red -MF-3BD
36 Sunfix Red-SPD
37 Sunfix Yellow -SPD
38 Sunfix Navy Blue -MF-D
39 Sunfix Navy Blue -SBF

Finishing
Textile finishing, in a restricted sense, is the term used for a series of processes to which all
bleached, dyed, printed & certain greige fabrics are subjected before they are put to market.
Its one of the most important operations in knit processing.
Objectives of Finishing:
-Improving the appearance, luster, whiteness etc.
-Improving the feel, this depends on the handle of the material & its softness, suppleness,
fullness etc.
-Wearing qualities, non- soiling, anticrease, antishrink comfort etc.
-Special properties required for particular uses like water -proofing flame-proofing etc.
-Covering of the faults in the original cloth.
-Increasing the weight of the cloth.

Effects of Finishing:
-Easy care.
-Crease recovery.
-Dimensional stability.
-Good abrasion resistance.
-Improved tear strength.
-Good sew ability.
- Soft or stiff handle.
-Shine or luster.

Layout of Finishing Section:

Types of Finishing:
Mechanical Finishing (Used to control dimension to improve appearance & handle)
Chemical Finishing (Used to make glossy protection. To improve performance or
serviceability)
Finishing Process
Knit fabrics require finishing process after dyeing. During dyeing all knit fabrics are dyed in
tubular form. According to buyers requirement dyed fabrics are finished in either tubular
form or Open-width form.
Depending on which Finishing sections are separated into two sections OPEN & TUBE section.

1. Tubular finish:

Dewatering

Dryer

Tube Compactor
2. Open finish:

Slitting

Stenter

Open Compactor

3. Special Finish (Raising & Sueding):
Slitting

Stenter

Raising/Sueding

Stenter

Compacting
No. of Machines of finishing section:
Name of the m/c No. of the m/c
Dewatering 2
Slitting 2
Dryer 2
Open compactor 2
Tube compactor 2
Rasing m/c 3
Sueding m/c 1

1. Dewatering Machine
Machine Specification:
Brand - Heliot International
Model EXP 226
Origin France
Capacity 3 tones/shift
Function of Dewatering m/c:
- Removal of excess water (70-75%)
- Removal of residual dirt
- De-twisting of the rope fabric
- Make the fabric Tubular from Rope form
- Improve the hand feel of the fabric by using
softener

Controlling points:
- Width control (can be increased up to 3)
- Pressure variation according to GSM
(higher GSM-3-3.5bar, Lower GSM-2-2.5bar)
- Fabric speed - 15m/min

Checking points:
Hand feel
Color spot
Softener spot

Fabric Path of Dewatering machine

2. Slitting machine:

Fabric path of slitting machine

Parameter:
- Padder pressure (1-6 bar)
- Fabric speed (200 m/min)
- Maximum fabric width 86-88
Checking points:
- Needle mark
- Dirty spot
Power consumption:
Voltage: 400V
Frequency: 50Hz
Maximum power: 24kwatt

Machine Specification:
Brand - Corino
Model - Strada Monticell 0.231
Origin - Italy
Year - 2005
Capacity 3 tones/shift
Voltage 400V
Frequency 50Hz
Function:
- Slit the fabric to make it into open form
- Removal of excess amount of water
- De-twisting of the tube fabric

Dryer Machine:
Two types of dryer machine:
o Heliot dryer for drying only tube fabric
o Santex AG dryer for drying both tube and open fabric

Heliot Dryer:
Specification
Brand Heliot international
Model D700 HWT
No of heating chamber 3
No of burner 3
No of nozzle - 35
Capacity 8 tons/day
Origin France
Fabric path of Heliot Dryer

Function:
To dry the fabric
To control the shrinkage
Controlling points:
Overfeed
Temperature (Maximum-1700C, Min- 900C)
Fabric speed Maximum 30m/min
Checking Points:
Shade check
Fabric width
Santex Dryer

Fabric path of Santex AG dryer

Specification:
Brand: Santex AG
Type: Santashink
Year: 2008
No of chamber: 5
Capacity: 12 tones/day
Origin: Switzerland
Function:
- To dry the fabric
- To control fabric dia
- To control Fabric shrinkage
- To control the fabric GSM
(can be increased 10-15 GSM)
- To apply special chemical
finish

Controlling points:
Overfeed (0 50%)
Temperature (Maximum 1800C)
Vibration 800
Fabric speed (Maximum 80m/min)
Fabric width (open fabric
Checking Points:
Shade check
Width check
GSM check
Temperature:
White/light shade: 100-120`C
Medium shade; 110-130`C
Dark shade: 140-160`C

Stenter Machine
Two types of Stenter machine:
1. Bruckner Stenter machine
2. Sun Super Stenter machine

Bruckner Stenter machine:
Specification:
Brand name: BRUCKNER
Type/model no: 72276-0463
Country: Germany
Total no of chamber: 5
Maximum temp.: 250
0
C
Steam pressure: max. 2 bar
Air pressure: max. 10 bar
Capacity: 3 tones/shift

Main parts of the machine:
i) Feed zone
- Centering device
ii) Chemical padding zone
- 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)
- 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) Drying zone
- Gas rotamatic burner (10)
vi) Cooling zone
vii) Delivery zone

Function:
Drying
GSM control
Width control
Shrinkage control
Decrease spirality
Decrease Bowing effect
Heat setting for cotton lycra fabric

Controlling points:
- Overfeed (45-60%)
- Temperature (max 250
0
C)
- Fabric Speed (18-28m/min)
- Padder pressure (1.5 2 bar)
Checking points:
Shade
GSM
Width
Faults (Uneven, Color spot, Shrinkage, Hole, Needle mark etc.)
Finishing parameters for different types of fabrics in BRUCKNER machine:

Fabric type GSM Dia Temperature Overfeed Padder
pressure
Speed Blower
RPM
s/j 115-150 2''plus 110-140C 45-55% 2 bar 20-25 60-70
s/j 160-220 2''plus 120-170C 45-50% 2.5 bar 18-23 65-75
L.S/J 160-220 4''plus 130-160C 60% 2 bar 18-23 60-70
L.S/J 200-250 4''plus 140-160C 60% 2 bar 12-20 65-75
Pique 160-250 3''plus 130-160C 50-55% 1.5-2bar 20-25 70-80
Fleece/terry 260-300 4"plus 140-170C 50-55% 2 bar 20-25 70-80
1*1rib 160-220 2"plus 130-160C 50% 2bar 24-28 70-80
2*2rib 190-220 2"plus 140-160C 50% 2 bar 20-25 60-70
Interlock 190-220 3"plus 130-160C 50% 2 bar 20-25 70-80

Sunsuper Stenter Machine
Specification:
Brand name: SUN SUPER.
Country: KOREA.
Total no of chamber: 8
Speed: Max. 110m/min
Temperature: Max 220
0
C
Steam pressure: 2 bar
Air pressure: 10 bar

Function:
To dry the fabric.
Heat-set the synthetic fiber fabric.
Controlling the width of fabric or maintain dimensional stability.
Controlling the GSM of fabric.
Skew ness & Bowing controlling of stripe fabric.
Spirality & Twisting control.
Fabric hand-feel modification-like-Softening or Hardening.
Shade control.
Gumming & Cutting.
Controlling Points:
Overfeed (0 50%)
Temperature
Speed
Padder pressure
Checking Points:
Shade
Width
GSM
Faults
Finishing parameters for different types of fabrics in Sunsuper stenter:
Fabric type GSM Dia Temperature Overfeed Padder
pressure
Speed Blower
RPM
s/j 115-150 2''plus 110-140C 40-45% 2 bar 30-35 1100-1300
s/j 160-220 2''plus 120-170C 40-45% 2.5 bar 25-30 1200-1400
L.s/j 160-220 4'plus 130-160C 50% 2 bar 25-30 1200-1400
L.S/J 200-250 4'plus 140-160C 50% 2 bar 24-28 1200-1400

Utility for stenter machines:
Gas
Electricity
Compressed air.

Compacting machine:
Two types of compacting machines are used in Viyellatex-
1. Open compacting machine
2. Tube compacting machine
1. Brand: FERRARO 2. Brand: Heliot
Type/model: COMPTEX-RE 2800 Overfeed: 50-60%
Country: ITALY Temperature: 90-130
0
C
Year: 2006 Teflon pressure: 16-18 PSI
Capacity: 3.5 tons/shift Origin: France
Function:
Fabric compaction
Make glossy, luster effect
To maintain proper width and GSM

Controlling points:
Overfeed
Temperature
Speed

Pique 160-200 3'plus 130-160C 40-45% 1.5-2bar 25-30 1200-1400
Fleece/terry 260-300 4"plus 140-170C 40-45% 2 bar 20-25 1300-1400
1*1rib 160-220 2"plus 130-160C 45% 2bar 24-28 1300-1400
2*2rib 190-220 2"plus 140-160C 45% 2 bar 20-25 1200-1400
Interlock 190-220 3"plus 130-160C 50% 2 bar 20-25 1200-1400

Checking Points:
Fabric Diameter
GSM
Shrinkage
Fabric faults
Main parts of the machine:
1. Heating chamber
2. Blower (2, one at the entry chain zone for uncurling and another at the entry of
compacting zone)
3. Synthetic blanket as a conveyor,
4. Folder
5. Exhaust fan
6. Unpinning cylinder
7. Belt cylinder
8. Uncurling device at entry of compacting zone.
9. sensor
Finishing parameters for different types of fabrics in compactor (Ferraro, open width
compactor):
Fabric type Color Speed Overfeed Temperature Blanket
pressure
Teflon
pressure
s/j White color 15-18 25-30 90-100C 1.5-2(bar) 33(P.S.I)
L.s/j White color

12-16 12-16 90-100C 1.5-2(bar) 33(P.S.I)
Pique White color

15-18 30-35 100-110C 1.5-2(bar) 33(P.S.I)
Fleece/terry White color

15-20 25-30 100-110C 1.5-2(bar) 33(P.S.I)
1*1 rib White color

15-20 20-30 110-120C 1.5-2(bar) 33(P.S.I)
2*2 rib White color

12-15 25-30 100-110C 1.5-2(bar) 33(P.S.I)
Interlock White color

12-16 Full over
feed
100-110C 1.5-2(bar) 33(P.S.I)

Tube compactor

Specification:
Brand name: HELIOT INTERNATIONAL
Model: HC99PI
Company: France.
Function:
To maintain proper width of fabric
To control fabric GSM
Controlling Points:
Overfeed
Temperature
Fabric Speed
Special Finishing machine:
1. Sueding machine
Specification:
Brand name: Lafer SPA
Type/model no: GSI106
Company: Italy
Year: 2002
Fabric speed: 110 m/min
Function:
To make the fabric smooth(Face side of the fabric)
To increase the handle property
Improve heat insulation properties.
Controlling Points:
Drum speed
Fabric tension
Plaiter tension
Fabric path of sueding machine

Taker in
Front Drag Roller
Drum
Plaiter
Delivery
Feed
Rear Drag Roller

Checking points:
Fabric GSM
Shrinkage
Fabric diameter
Crease mark
Utility for Compacting machine:
Steam
Electricity
Compressed Air

Checking Points:
Hole
Improper Sueding
Line mark
Quality of Sueding

2. Raising machine:
Specification:
Brand name: Lafer SPA
Type/model no: GRI 224A
Country: Italy
Year: 2003
Capacity: 3.5 tones/shift
Fabric speed: 90rpm
Function:
To produce pile on fabric surface
To increase hand feel of the fabric
To make the fabric soft
Increase the warmth of the fabric.
Fabric path of raising machine

Inspection in Finishing Section
Steps of Inspection:
1
st
step- Shade Check
2
nd
step- Running Shade Check
3
rd
Step- Dia Check
4
th
Step- Faults & G.S.M Check

Controlling Points:
Pile & Counter pile speed
Drum speed
Fabric tension
Plaiter tension
Checking Points:
Hole
Uneven raised
Line mark
Quality of raising

Measurement of Fabric Faults:
Four Point System:
Defect Length Assigned Point
0-3 1 point
3.1-6 2 point
6.1-9 3 point
>9.1 4 point
Calculation:
Average points/100 yds. = total points /total inspected yds. * 100

Faults appeared in finishing
Defects Source
Hole Knitting
Oil Stain Knitting
Fly Yarn Knitting
Barrie Mark Knitting
Chemical Stain Dyeing
Dye Stain Dyeing
Patches Dyeing
Uneven Shade Dyeing
Crease Mark Dyeing + Knitting
Neps Fiber Problem
Yarn Contamination Spinning
Bowing Finishing
Crumple Mark Finishing

Working procedure of laboratory:
Sample in (Fabrics)

Check & note the Lot no, Style no, Item no & Collar

Sample Preparation

Run the test

Physical test Wet lab

Color Fastness to wash
Bursting strength
Pilling Color Fastness to washing
Crocking

Evaluate the sample Pre-production Sample Final sample

Report Making Test Test

Prepared the report prepared the report
Pass Fail

Deliver Refinish Pass Fail Pass Fail

Need to test again Go for the final Refinish

Need to test again
Dimensional Stability.

Prepare the sample

Wash the sample according to buyer method.

Tumble dry

Keep the sample flat in the conditioned temperature
At least four hours before, after measurement.

Measure the sample

Prepared the report

Pass Fail

Ready to delivery Refinish

Need to test again

Machines used in Laboratory:
1. Digital button tester
Imada, Japan
2. Apollo light & weather
James H.heal & co. Ltd. Halifax, England.

3. Incubator
Test name: Color fastness to water, sea water, perspiration &phenolic yellowing test
Test method: ISO 105-E01, ISO 105-EO2, ISO 105-E04 etc.
James H.Heal & Co ltd. Halifax, England.

4. Rubbing & Crocking tester
Healink
James H.Heal

5. Spray rating tester
James H.Heal & Co ltd.

6. Pilling & Snagging tester
M/c name: Orbitor pilling & snagging tester
Test name: Pilling resistance test
Test method: BSENISO 12945-1, B55811

7. Truburst
Brusting strength tester

8. Impulse
Random tumble pilling tester

9. Matendel abrasion tester

10. Elmatear
Digital tear tester (woven)

11. Fastness tester (color fastness to wash)
Graywash for 40C

12.Test name:Colour fastness to washing, dry cleaning
M/C name: Rota wash
Test method: ISO105-C06,ISO 105-D02

13. Washing machine
Healink

Fig: Apollo Light & Weather

Fig: Rubbing & crocking tester

14. Lap dyeing m/c
M/C name: Ahiba Nuance lab dyeing m/c

15. Perspiration tester

16. Digital PH tester

17. Lab rotator

18. Rotawash
Test name: C/F to washing dry cleaning
Test method: ISO 105-C06.ISO 105-DO2
Quality Assurance System:
The quality assurance department is assigned to maintain consistency for uniform quality of the
material in process & various stages of its manufacturing.

Objects of quality control:

Research
Selection of raw material
process control
Process development
Product testing
Specification test
Quality Control system mainly two types:
1. Online QC
2. Offline QC

1. Online QC
Online quality control comprises with the raw material quality control and the process control.
Raw material control:
As the quality of product depends on the raw materials quality so we must provide the best
quality raw material with an economical consideration. The fabric must be fault-free, with
proper absorbency, whiteness as per requirement of the subsequent process. The Grey
inspection report gives the condition of the raw fabric.

Process control:
The method chosen for the process must be provided with the necessary accurate parameters.
Here the specific gravity, water level, residual hydrogen per oxide etc. at each stage is checked.

Laboratory:
Lab is the important part of a textile industry. Higher precision in a trial can aid easily to achieve
the goal of the organization. Before bulk production a sample for the approval from industry is
sent to the buyer. As per the requirement of the buyer the shade is prepared in a lab
considering the economic aspects.

Lab line:
1. Standard sample: It is obtained from buyer. The sample is measured by the CCM to
get the recipe.
2. Lab trial: Getting the recipe the lab officer produce lab trial and match with standard
according to buyer requirement. Lab trial is made by the AHIBA dyeing machine. There are
some programs for dyeing. The programs will be described later.

2. Offline QC
Off-line tests: All the Offline tests for finished fabrics can be grouped as follows:

A. Physical tests
B. Chemical tests

Physical Tests:
GSM test
Shrinkage test
Spirality test
Tensile strength
Abrasion resistance
Pilling resistance
Button Strength Testing
Crease resistance
Dimensional stability
Bursting strength test

Fabric Inspection:
The fabric inspection is done for both grey and finished fabric.

1. Grey Fabric Inspection:
Grey fabric inspection is performed according to 4-point system.

2. Finished Fabric Inspection:
4 point numbering system is followed for finished fabric inspection. Defects found in the
final inspection:
1. Uneven shade
2. Oil spot
3. Neps
4. Crease mark
5. Machine Stoppage mark
6. Listing
7. Line mark
8. Pick missing
9. Double yarn
10. Dead cotton
11. Bowing
12. Fly yarn contamination

Chemical Tests:
Color Fastness to washing.
Color Fastness to light.
Color Fastness to heat.
Color Fastness to Chlorinated
water.
Color Fastness to water
spotting.
Color Fastness to perspiration.
Color Fastness to Sea-water.
Fiber analysis.
P
H
test.
Spray test (water repellency).

Procedure of the Different Tests:
Physical test:
1. Measuring the Dimensional Stability (Shrinkage & Spirality):
Sample: Two pieces of 50 cm 50 cm fabric is taken for test.
Procedure:
a. Conditioning: Put the sample in table for 4 hrs. for conditioning before starting
test.
b. Cut the sample 50x50 cm & benchmark should be 35x35 cm. Stitch the sample (3
sides) by over lock sewing machine.
c. Put sample in washing machine and run according to buyers choice.
d. Drying: All Buyers requirement is tumble Dry except ECHO SCOURING is flat dry.
2. Pilling test:
Procedure:
Cut the fabric 12.5 x 12.5cm & balance mark should be 10cm by using template. Then sew the
fabric so that it can be firmly fit in the tube molded polyurethane tubes. Then four tubes are
placed in a box & start 602 rev/min for 5 hrs. or according to buyer requirement. Here mainly
used 3hrs (1100 cycle). Then assess the pilling by putting tested specimen on the viewing
cabinet & compare with standard photographs
3. PH Test:
Procedure:
Take 2gm sample fabrics and cut into small pieces. Then put it conical flax with 100cc water
(M: L -1:50). Then shake it 15 min, then place it in a shaker m/c for 1 hour. Then check P
H
by
P
H
meter.
4. GSM TEST:

Procedure:
GSM is the most important factor. There is a GSM cutter. The sample is cut by the GSM
cutter is weighted in the electronic balance. The reading (in gm.) from the balance is multiplied
by 100 to get the value of GSM.
5. Bursting Strength Test:
Cut sample of 250x250 mm
2
shape and see how much air pressure is needed to tear
apart.
160-250 KPa is the allowable range for all.

Chemical Test:
1. Color Fastness to Wash Test:
Required materials:
1. Sample size 10cm x 4cm
2. Multi-fiber of 10cm x 4cm
3. ECE detergent (WOB) 4g/L
4. Sodium Perborate (Na
2
BO
3
.H
2
O
2
.3H
2
O
2
-1g/L) - 1g/L
5. Distilled water
6. Normal cold water
7. Steel balls

Required instrument:
1. Rota Wash machine
2. Scissors
3. Stitch machine
Procedure:
1. Cut sample & multi-fiber at 10cm x 4cm and then stitch.
2. 5g/l ECE detergent (WOB) & 1g/l ml Sodium per borate tetra hydrate is taken with
the sample.
For Marks & Spencer, the solution is taken by the following formula:
3. The sample is kept in 60
0
C for 30 minutes in Rota Wash Machine. Weight this
composite specimen to calculate the volume of wash liquor required to give a 1:50
liquor ratio. (i.e. 50 ml of liquor of 1gm of composite specimen.)
4. Rinse the sample twice with cold water.
5. Dry at 60C by hanging or by Flat iron pressing but temperature should not be more
than 150C.
Report:
Dry the specimen and the change of shade & degree of staining is measured by Grey
Scale & Staining Scale.

2. Color Fastness to Perspiration Test:
Test specimen:
Sample fabric 50 mm 50 mm
Multifiber fabric 50 mm 100 mm
Cut the multifiber into two pieces
Sandwich the test specimen between two pieces of multi-fiber.
Testing Solution:
1. Alkaline Solution:
Histadine monohydro chloride monohydrate (C
6
H
10
ClN
3
O
2
.H
2
O) 5.00 g/L
NaCl 5.00 g/L
Di sodium hydrogen orthophosphate (Na
2
HPO
4
.2H
2
O) 2.5 g/L
P
H
8 (Adjust by 0.1 N NaOH)
2. Acidic Solution:
Histadine monohydro chloride monohydrate (C
6
H
10
ClN
3
O
2
.H
2
O) 5.00 g/L
NaCl 5.00 g/L
Sodium di-hydrogen orthophosphate (NaH
2
PO
4
.2H
2
O) 2.5g/L
P
H
5.5 (Adjust by 0.1 N NaOH)
Method:
- The composite specimen is put in a petri dish (2 specimen of a sample).
- Solution (Alkaline & Acidic) is taken in the two petri dishes. Here, M:L is taken 1:20.
- Bubble is made out from the specimen by tapping.
- The specimen is kept for 30 minutes.
- A glass plate is placed on the composite specimen for 15 minutes at room
temperature.
- Excess solution is poured off.
- Petri dish with composite specimen & glass plate is placed into the incubator at
(372)
0
C for 4 hours.
- The specimen is dried (temp 60
0
C)

Report:
- Change of shade & degree of staining is measured by the Grey Scale & Staining
Scale.
3. Color Fastness to Water Test:
Test specimen:
Sample fabric 50 mm 50 mm
Multi fiber fabric 50 mm 100 mm
Cut the multi-fiber into two piece
Sandwich the test specimen between two pieces of multi-fiber.
Testing Solution:
Water is taken as required
Method:
- The composite specimen is put in a petri dish (2 specimen of a sample).
- Water is taken in the petri dish as required.
- Bubble is made out from the specimen by tapping.
- The specimen is kept for 30 minutes.
- A glass plate is placed on the composite specimen for 15 minutes at room
temperature.
- Excess solution is poured off.
- Petri dish with composite specimen & glass plate is placed into the incubator at
(372)
0
C for 4 hours.
- The specimen is then dried (Temp 60
0
C)
Report:
- Change of shade & degree of staining is measured by the Grey Scale & Staining Scale.
4. Color the Fastness to Rubbing (Dry & Wet) Test:
Sample:
- Dyed fabric dimension of 15 cm 5 cm
- White Test Cloth of 5 cm 5 cm
Procedure:
- White test cloth is put on to the grating and stag by steel wire.
- The sample is run twenty times manually for ten seconds and the rubbing fastness
of the sample cloth and degree of staining is accessed.
- 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 assess the staining on to the rubbing
cloth and the rubbing fastness of the sample cloth is accessed.
Report:
- 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.

Shrinkage Test Calculation:

Shrinkage % = (Before wash After wash)/Before Wash*100

Spirality test calculation:
S = (S
1
+S
2
) / 2
Spirality = (S+S L)/100.
Suppose,
S
1
= The right side distance of the specimen from the stitch line after wash.
S
2
= The left side distance of the specimen from the stitch line after wash.
L = Length before wash
Lab. Dip Dyeing
Sample:
- Weight 5gm.
Procedure:
- At first the recipe for the sample is calculated according to the sample weight.
- The fabric is kept in the dyeing chamber.
- Then the dyes, chemicals, salt & required amount of water is taken in that dyeing
chamber by digital pipetting on the basis of stock solution.
- Then the beaker is set into the lab. Dip. Dyeing machine for dyeing.
- The program for dyeing is started for 20 min at 40
0
C.
- After 20 min soda is added by pipetting.
- Then the dyeing program is set for 60 min at 60
0
C for normal colour,80C for
turquois colour,130C for PET.
- When the dyeing time is finished the sample is taken out from the machine at 40
0
C.
- Then the sample is washed off. At first cold wash & then hot wash is done. After it
soaping is done.
- Then the sample is dried and compared with standard

Dyeing Curve:
60
0
C60

40
0
C20
Wash off
Soda

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

Finished fabric Inspection:
The final product should pass against the norms given by the buyer. The following tests are
done--
-Shade check
-GSM test
-Width or diameter test
-Shrinkage test
Dyes + Salt +
Material+Water

-Crocking test
-Pilling resistance test
-Color fastness to test
-Color fastness to perspiration
-Dimensional stability

Quality Standard:
Viyellatex Ltd. maintains the ISO: 9002 standard in case of quality. Therefore, 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 Viyellatex Ltd.

Four point grading system
Size of defects Penalty
3 inches or less 1 point
Over 3 inch but not over 6 inch 2 point
Over 6 inch but not over 9 inch 3 point
Over 9 inch 4 point

Following table shows common body and rib faults and response by inspection section at
Viyellatex Ltd.:-

Rejection criteria for body & ribs
No. Faults Response
1. Needle mark Major needle line is rejected
2. Stripe Major needle line is rejected
3. Barre mark Rejected
4. Contamination & fly
Approved for color but for white
shed 1 point is assigned
5. Slubs 1 point
6. Thick thin place Reject
7. Birds eye 1 point
8. Pin holes 1 point
9. Wrong design Reject
10. Mixed yarn Discuss with manager
11. Sinker mark Major sinker mark is rejected.
12. Missing yarn Use 4 point
13. Holes Do
14. Oil line/stain Do
15. Chemical Do
16. Dirt stain Do
17. Crease line Do
18. Uneven tension Discuss with manager

Following table shows common collar and cuff fault and response taken by inspection
section at Viyellatex Ltd:-

Rejection criteria for collar & cuff
No. Faults Response
1. Wrong ply Reject
2. Hole Reject
3. Needle line Reject
4. Slubs Reject
5. Wrong design Reject
6. Wrong tripping Reject
7.
Fly & contamination
Acceptable for color but not for
white
8. First round problem Reject
9. Uneven tension Discuss with manager
10. Missing yarn Reject
11. Crease line Reject
12. Rust line Reject
13. Oil stripe Reject
14. Thick-thin Reject
15. Wrong tube Reject

Remarks:
Viyellatex have a well-equipped Testing laboratory for all kinds of Textile Testing. All of them
are fully featured. The laboratory of Viyellatex is approved by world renowned buyers. Every
kind of textile testing can be done with great accuracy and ease.

Production Capacity:
Total line 80
Total floor 8
Total m/c 2600(approximately running)
Production/day 60000 pcs/day (minimum) 2.5-3 Million pcs/month
Input Process Flow Chart:
Inform The Corresponding Officer about completion of garments production Target

Corresponding Officer Forward a requisition form to the Planning Department

Planning Department Gives a token Containing new style No
.
Showing the token collect fabric from Cutting & Accessories from Store

Quality Check

Ready for Sewing

Sewing process flow Chart:
Input

Measurement Check

Print & Embroidery Check

Sewing Started

Get Full garments as output

Garments Inspection

Forward it to the Finishing Section

ist of M/cs:
Machine Name Brand
1-Needle lock Stitch
(Auto thread Time)
Juki, Brothers
4-Thread Overlock with electric chain cutter Sunstar
2/3 Needle Covering stitch Juki, Kansai
1-Needle chain stitch(flatbed) Pegasus
2-Needle Chain Stitch(flatbed) Joje
2-Needle Piping(backtape) Kansai, Joje, Zusan
2-Needle lock stitch Pegasus, Kansai
Vertical Trimmer Sunstar
Multi Needle Chain Stitch(PMD) Juki, Sunstar

Bartack Machine(Computerized) Kansai
Buttonhole(computerized) Juki, Sunstar, Brothers
Button Sewing(Computerized) Juki, Brothers
Zigzag Machine(Computerized) Juki, Brothers
Smocking Machine(12 & 33 Needle) Juki, Brothers
Shirring Machine(12 Needle elastic threads) Kansai
Picoting Machine Kansai
Shading Stitch Kansai
Blind Stitch(Overlock) Kansai
Rib Cutting Machine Joje
Heat Transfer Machine Lee Way, Loca
Hot Fixing Machine Salli
Snap Button Nyoto, Uzu, Max
Fusing Machine(Ranning)
Fusing Machine(R Hat)
Hashima

Needle Used in different Machine & Its Sizes:
Machine Name Needle Group Size
Plain Machine DB x1 9,11,14
Overlock Machine DC x1 9,11
Flatlock Machine UY x128 9,11
2-Needle Chain Stitch Machine UY x128 14
2-Needle Lock stitch DP x5 9,11
Button Hole(Two Needle) DP x5 11,14
Button Stitch DP x7 14
Kansai Special(PSF) UO x113 11
Saddle Stitch CP x12 9,11
Vertical Trimmer DB x1 9,11
Smocking DV x57 9,11

Garment finishing
Process flowchart of garment finishing:
Finishing input (style, color & size wise)

Ironing

Inspection

Hang tag

Get up change

Folding

Poly

Bar code (buyer wise sticker)

Metal check

Cartooning

Final inspection by buyer
Remarks:
We learned a lot from previous weeks visiting these sections of the garments. The Peoples
around these sections are very helpful and willingly helped us in our work. This will help in our
further visit to other sections also.

Printing Section:
There are two floors in the printing section. Here are the details about the Gothic Printing-
Gothic Printing
Details Quantity
1. Tables 24 pcs
2. Auto Screen Printing
m/c
4 pcs
3.Conveyer Dryer 4 pcs
4. Heat Press 3 pcs

Development flow chart:
Order received from customer

Different types of Printing:
Pigment Print
Rubber print
High Density Print
Plastisol Print
Puff print
Gliter print
Rainbow print
Pearl scent
Radium print
Foil print
Jel print
Metallic print
Heat transfer (this system is not used)
Flock Print (this system is not used)
Discharge print

Development
Sample make
Design
Expose room
Send to production
Sample approval

Sequence of printing:

Garment parts count

Screen preparation

Printing paste preparation

Applied garment part on the printing bed by (adhesive) gum in the marked portion

Printing the garment part by using screen

Drying the printed portion by hard dryer applying hot air flow

Curing the printed portion by passing through the conveyor dryer at 160
0
- 180
0
c

Inspection is done in qualify control department
Screen Preparation:

Mesh fabric tight with frame

Applied chemical auto sol and potassium dichromate on the mesh & dried 8 min in air.

Placed design paper under the mesh.

Light passes through the design paper & mesh fabric for 3-4 min.

Remove the colored TXR from the design area by water spraying.

Different types of print used in Viyellatex with their chemical name:
1. Pigment print:
Print perfect 226 EC (ready paste)+color basic=various types of shade are produced.
Supplier name:
Dysin
CHT
Brand name:
CHT
Seikafix
Brand name of CHT:
Red KGC
Red HBB
Violate FB
Orange RG
Yellow 3GT
Yellow RR
Violate KB
Black BDC
Turquoise GT
Green GT
Brand name of seikafix:
Seikafix red
Seikafix yellow
And so many color
Dysin:
PTSD (red,yellow,blue etc.) (Chemical group or brand name)
SERICOL (red,yellow,blue etc.)(Chemical group or brand name)
CHT:
Printop (chemical group)
Uniflux(chemical group)

3. High density & Plasticol:
Shade can be produced to mix ready color and basic. If the density of the plastisol is high then
it is called high density.
4. Puff:
Dysin chemical:
SP37(for puff)
White paste 101
Orient paste 251
Clear 594
2. Rubber:
Supplier name:
Daysin
White paste 101
Orient paste 251
Clear 594
Oxal
Rubber paste of CHT:
Balance 600(white paste)
Laclf(matty type)
Mc 230(glossy type)
Oxal

CHT chemical:
PPEXTS-2(for puff)
Balance 600(white paste)
Laclf(matty type)
Mc 230(glossy type)
5. Gliter print:
Daysin paste BF733/ST60(paste)
CHT pasteGD200
Gliter
Oxal
6. Rainbow:
Dysin paste BF733/ST60(paste)
CHT pasteGD200
Rainbow
Oxal
7. Pearlscent:
Ready paste & basic
Paste type:
Asuchem (supplier)
Asugold 80 (chemical type)
Asusilver 70(chemical type)
Printing faults:
1. Print color shading 19. Print gap
2. Print slarted 20. Print over
3. Color spot 21. Wrong side
4. Bleeding 22. Color wrong
5. Print wrong 23. Size mistake
6. Print burn 24. Bundle card mistake
7. Air hole 25.Fabric hole
8. Print bubble 26.Fabric shade
9. Print missing 27.Crease mark
10. Wrong place 28. Oil spot
11. Not properly attached 29. Fabric burn
12. Hand feels 30.Needle mark
13. Migration 31. Cutting problem
14. Dirty mark 32. Sticker wrong
15. Uneven shade 33. Dye migration
16. Shade variation 34.Yarn hole
17. Print sticky 35. Yarn contamination
18. Print not coverage 36. Fly yarn.

8. Radium:
Ready paste
9. Foil print:
Foil paste (k-40) Dysin
10. Jel paste:
CHT (supplier)
GD200 (gel paste)
11. Metallic:
Same as pearlscent
12. Discharge:
Asuchem (supplier)
Asurongent EB

Embroidery Section
Embroidery machine specification:
No. of machine: 08
(1) 7 M/C of 12 heads
(2) 1 M/C of 8 heads.
Electronic multi-head automatic Embroidery M/C
Brand: Tajima
Country: Japan
Model: TFGn-920
No. of head: 20
No. of Needle per head: 9
M/cs computer: screen touch monitor
Stitching types:
Satin stitch
Tatami stitch
Eve design
Run stitch
Single run
Double run
Fly stitch
Chain stitch
Motif run stitch
Thread information:
Threads brands Types Country Thread contain m/cone
Coats Bangladesh

Silko (polyester 120/2)
Rapose (polyester 120/2)

Bangladesh
3000
Madera

(polyester 135/2)
Super twist 135/2

Germany
2500-3000
Airplane
(polyester 120/2)
(polyester 120/2)
Korea 5000
Well (polyester 120/2) Bangladesh 3000
Metallic thread (polyester 120/2)
Bangladesh
Japan
Korea
3000-10000
Pearl thread (polyester 120/2) Bangladesh 3000
Basic thread Polyester 120/2 Bangladesh 5000
Marathons Polyester 120/2 Korea 5000
Embroidery faults:
Stitch gap
Bobbin out
Lining:
o Soft lining
o Discreet lining
o Fusing lining
o Hard lining

Oil spot
Miss thread

Measurement up-down
Needle hole

Washing

Washing Machine Layout:

1 Cosmotex sample dryer (70
0
C)
2-5 Cosmotex dryer (70
0
C)
6-9 Automatic steamer & dryer (100
0
C)
(Brand: Greenmac International Pte. Ltd.
Country: Singapore)
10-11 Centrifugal extractors
(Brand: Greenmac International Pte. Ltd.
Country: Singapore)
12,14 Cosmotex sample garments dyeing & washing m/c
(Capacity: 20 Kg)
13,15-21 Cosmotex garments dyeing & washing m/c
(Capacity: 250 Kg)

Entrance
8 7 6
5 4 3 2
1
T
a
b
l
e

13 15 16 17 18 19 20 21 14
10
9
11
12
2
T
a
b
l
e

Washing flow chart:
Garments from store house

Count

Quality check

Batch

Washing

Hydro extractor

Drying

Quality check

Packing

Delivery
M/C brand and no of M/C

1. No of washing m/c: 4

2. No of garments dyeing m/c: 4
Brand name: Cosmotex
Origin: Spain

3. Sample washing m/c: 2

Brand name :Cosmotex
Origin: Spain

Types of wash:
Normal garments wash
Vintage wash
Enzyme wash
Acid wash
Super softener wash
Spray wash
Dip dyeing wash

4. Hydro extractor: 2

Brand :Green mac
Origin : China
5. Dryer: 8
4 Cosmotex
4 Green mac

6. Sample dryer: 1
Brand name: Compotex

Recipe:
1. Normal garments wash:

M:L : 1:10
Felosan nof : 5g/l
Temperature : 50-55C
Time : 8 min
Softener : 1-2 g/l

2. Vintage wash:
Applies heavy stonewashing or a cellulose enzyme wash, with or without bleach.
Gives an old and worn look.

M : L :1:10
Felosen nof : 0.5g/l
Soda : 3-4 g/l
Caustic : 0.5g/l
Temperature: 60C
Time : 35-40
Acetic acid : 1g/l
Softener : 2g/l

4. Acid wash:

It is done by tumbling the garments with pumice stones presoaked in a solution of sodium
hypochlorite or potassium permanganate for localized bleaching resulting in a non-uniform
sharp blue/white contrast.

5. Super softener wash:

Silicon: 8g/l
Softener: 2g/l

Over dye:
Dyeing over the fabric or jeans to add another tone of color.
Also can be applied with spray gun or paintbrush for local coloring.
A typical recipe of over dyeing method:
Fabric weight 2 kg
Water 16 liter 70
0
C x5 min
NOF (Wetting agent) 8 gm
(After Normal wash)
DBC (leveling agent) 8 gm 60
0
C x5 min

R.G. Yellow- RGB 0.368% 8 gm
R.ul.Car-RGB 0.63% 12 gm 60
0
C x (10+10) min
R.Navy-RGB 1.48% 31 gm

Salt 960 gm 60
0
C x (10+10)
Soda 256 gm
(After normal wash)
R (soaping agent) 1 g/l 16 gm 60
0
C x5 min
Acetic acid 1 g/l 16 gm Room temp. for 5 min
E.C. (fixing agent) 1 g/l 16 gm 40
0
C x5 min

3. Enzyme wash
Enzyme : 0.5g/l
Fesoson nof : 0.5g/l
PH : 4.5
Time : 25-30
Temperature: 55C

Problems occur in washing:
Before wash:
Dirty spot
Dyeing/color spot.
Needle damage.
Fabric hole.
Measurement problem.
Shade variation.
Printing problem.

After wash:
Measurement problem.
Shrinkage problem.
Color bleeding.
Needle line.
Spirality problem

REMARKS:
We have learned a lot of from this section of washing. The employers and employee helped us
so much during our working. This will help further visit to other sections also.

Maintenance of machinery is a very essential mechanical effort for achieving smooth
running of different machines. Machines, buildings and other service facilities are subjected to
deterioration due to their use and expose to industrial conditions. Maintenance is a procedure
by which we can maintain active functioning in operation according to the behavior and utility
of a particular element. In engineering, we use this terminology for maintaining smooth and
uninterrupted performance of machines, tools and metallurgical characteristics in practical uses.
Necessity of maintenance:
To keep the downtime of machines to the minimum thuds to have control over the
production program.
To prolong the useful life of the factory plant and machine by retaining their acceptance
level of accuracy of performance.
To keep the factory plants, equipments, machine tools in an optimum working
condition.
To ensure specified accuracy to product and time schedule of delivery to customer.
To keep the production cycle within the stipulated range.
To modify the machine tools to meet the need for production.
Major Maintenance points for different machines:
Routes of different utilities like water, steam, gas, electricity, compressed air etc.
Dyestuff & chemical dosing system.
Drainage system of waste water, color & chemical.
Driving arrangement of different machines.
Power transmission to different machineries.
Fabric guiding system through the machineries.
Cleanliness of machine parts.

Different types of Maintenance procedure:
In Viyellatex, three types of maintenance procedure is performed
1. Routine/Schedule Maintenance.
2. Preventive Maintenance.
3. Breakdown Maintenance.

1. Routine/Schedule Maintenance:
After a particular period of operation, the machines are cleaned & reordered, that is routine or
schedule maintenance. The maintenance department does it once in a month. Routine/Schedule
maintenance varies, time in time & also depends on situation according to types of machines,
because maintenance is directly related to production.

Maintenance schedule for dyeing & finishing section
S.N. Machine Schedule
1 Dyeing m/c-1+sample-1 10
th
day of the month
2 Dyeing m/c-2+ dyeing m/c-9 + sample m/c-5 11
th
day of the month
3 Dyeing m/c-3+ dyeing m/c-10 12
th
day of the month
4 Dyeing m/c-4+sample-2+dyeing/c-15 13
th
day of the month
th
day of the month
th
day of the month
7 Dyeing m/c-7+ dyeing m/c -12+dyeing m/c-14 16
th
day of the month
th
day of the month
9 Open compacting m/c+tube -1 1
st
&18
th
day of the month
nd
&19
th
day of the month
11 Dewatering m/c-1&2 3
rd
&20
th
day of the month
12 Corino slitting m/c+Bianco slitting m/c 4
th
& 21
st
day of the month
13 Slitting m/c+sample dyeing m/c-4 5
th
&22
nd
day of the month
14 Sueding m/c+ sample dyeing m/c-5 6
th
&23
rd
day of the month
15 Raising m/c+ sample dyeing m/c-6 7
th
& 24
th
day of the month
16 Dryer m/c+sample dyeing m/c-7 8
th
& 25
th
day of the month
17 Santex dryer 9
th
& 26
th
day of the month
18 Stenter m/c(bruckner) Friday every week
19 Stenter m/c(sun super) Friday every week

Maintenance schedule for utility section:
1 Boiler last Friday of month
2 Substation 1
st
Friday of month

2. Preventive Maintenance:
This type of maintenance is performed periodically (or continuously) prior to functional failure to
achieve the desired level of safety and reliability for an item. These actions are performed to
prevent or reduce consequences of failures.
Maintenance schedule for dyeing & finishing section
1 Open compacting m/c-1+tube -1 1
st
&19
th
day of the month
nd
&20
th
day of the month
3 Dewatering m/c-1&2 3
rd
&21
th
day of the month
4 Slitting m/c 1&2 4
th
&22
nd
day of the month
5 Slitting m/c 03+sample dyeing m/c-4 5
th
&23
nd
day of the month
6 Sueding m/c+ sample dyeing m/c-5 6
th
&24
rd
day of the month
7 Raising m/c-1, 2, 3 7
th
& 25
th
day of the month
8 Dryer m/c-1+sample dyeing m/c-6 8
th
& 26
th
day of the month

9 Dryer m/c-2+sample dyeing m/c-7 9
th
& 27
th
day of the month
th
day of the month
12 Dyeing m/c-2&9 11
th
day of the month
13 Dyeing m/c-3&10 12
th
day of the month
th
day of the month
th
day of the month
16 Dyeing m/c-6&11 15
th
day of the month
17 Dyeing m/c-7&12 16
th
day of the month
11 Dyeing m/c-8&13 17
th
day of the month
19 Dyeing m/c-14&15 18
th
day of the month
19 Stenter m/c-1&2 every Friday

Maintenance schedule for utility section:
1 Boiler-1 +sub station 2
nd
Friday of the month
2 Boiler-2&3 last Friday of the month
3 WTP 1&2 2
nd
Friday of the month
4 ETP 1
st
Friday of the month
5 Gen unit -1 1
st
Friday of the month
6 Gen unit -2 3
rd
Friday of the month
7 Compressor unit -1&2 1
st
Friday of the month
8 LAB 1
st
Friday of the month

Maintenance schedule for Kntting section:
1 Circular knitting m/c (01-36) 1
st
Friday of month
2 Circular knitting m/c (37-72) 2
nd
Friday of month
3 Flat knitting m/c (01-25) & Cooling unit 3
rd
Friday of month

3. Breakdown Maintenance:
In breakdown maintenance, defects are rectified only when the machine cannot perform its
function any longer and the production department is compiled to call the maintenance
department for repairing the machine. After repairing the defect the maintenance engineer do
not attend the machine any longer until another failure occurs.
Breakdown of a machine occurs due to the followings two reasons
Due to unpredictable failure of components.
Due to gradual wear & tear of the parts.

Maintenance Tools, Equipments & their functions:

Name of Tools Function
Hammer To give shape
Slide Wrench Tightening and opening bolt
Spanner Tightening and opening bolt
Pliers Cutting, Holding, Joining, wire, Gripping
Hacksaw Cutting
Pipe Wrench Tightening, opening, gripping pipe
Chisel Shaping, Cutting
File Shaping
Clamp Gripping
Tester To test electric circuit

Name of Equipments Function
Grinding m/c Grinding
Cutting m/c Cutting
Drill m/c Drilling
Shaping m/c Shaping
Lathe m/c To make something
Bending m/c Bending

Maintenance of different machines:

Maintenance Mechanical
Machine Dyeing machine
S.N. Items needed to be checked and serviced
1. Greasing of the winch bearing
2. Complete cleaning of machine
3. Cleaning of drain valves, replace seals if required
4. Checking of air supply filter, regulators, and auto drain seals
5. Cleaning of filter elements
6. Greasing of unloading roller bearings
7. Checking and cleaning (if required) of addition tank level indicator
8. Checking the oil level of pump bearing and refill if required
9. Checking the function of heat and cool modulating valves
10. Checking of all belts and belt tension
11. Check circulation, reel and other pumps
12. Checking of all door seals

Machine Stenter machine
1. Removal of gas burnt deposits from chains
2. Checking of gas burners
3. Cleaning of softener application unit
4. Checking and cleaning of steam pipe lines
5. Checking and cleaning of gas pipe lines
6. Grinding of fabric gripping pins
7. Cleaning of ventilation duct
8. Cleaning of m/c cabinet
9. Checking of motors

Machine Dryer
1. Checking of gas pipe lines
2. Checking of gas burners
3. Checking of belt conveyor system
4. Checking of plaiting device
5. Checking of speed regulating unit
6. Cleaning of ventilation duct
7. Cleaning of m/c cabinet

Machine Compactor machine
1. Checking of Steam pipe lines
2. Checking of pneumatic pressure valves
3. Checking of belt conveyor system
4. Checking of plaiting device
5. Checking of speed regulating unit
6. Checking and replacement (if necessary) of compacting shoe
7. Cleaning of compacting shoe

Machine Raising machine
1. Checking of Gearing system and replacement of faulty gears
2. Cleaning of fiber deposits from the pile and counter pile rollers
3. Grinding of pins of pile and counter pile rollers
4. Lubrication of gearing system

Machine Boiler
1. Checking of gas pressure and gas supply line
2. Dosing of softening chemicals to supply water
3. Checking of all steam lines
4. Cleaning of burner tank (after six month interval)
5. Checking and replacement of valves
6. Cleaning of feed water tank
7. Checking and replacement of filters
8. Cleaning of sight glass

Maintenance Electrical

1. Check main panels
2. Check panel cooling fan & clean its filter
3. Clean main pump inverter & its cooling fan
4. Check all circuit breaker ,magnetic conductors & relays
5. Check current setting of all circuit breaker & motor over load
6. Visual checking of all power & control cables
7. Check ail motors terminals
8. Check & clean fluff & dirt at all motor fan covers
9. Check DC drive of kneel motors
10. Check all pressure switches
11. Check calibration of main vessel & all addition tank
12. Check all signal isolators
13. Check setting & operation of lid safely switches
14. Check setting of tangle sensors
15. Check all pneumatic solenoids
16. Check all indicating lamps
17. Check calibration of heating/ cooling modulating valve
18. Check all on/off switches

Remarks:

With good supervision and administration, maintenance department of Viyellatex performs their
maintenance activities. They have proper control of work. Operators are well trained. Correct,
clear and details instructions are given to the maintenance crew and to the operators by the
maintenance officer.

Utilities
Utilities services available in Viyellatex:
Electricity
Water
Gas
Steam
Compressed Air

Electricity:
There are three gas generators and one diesel generator is used to generate the power for
every section in the Factory. Gas Generator is used for supplying electricity for the dyeing,
knitting & office of the Viyellatex group ltd.
Total capacity of each generator: 1064 Kw
Technical Details Generator Data
Type Gas Generator
Manufacturer JEnvacher
No. of Generator 3+1
Model No. 315 GFBA
Manufactured Country Austria
Year of Purchasing 2002

Main Parts of a generator:
Engine Head
Mechanical part
1. Cylinder block
2. Crank cage
Electrical part

Fig: Gas Generator used in Viyellatex

Total power consumption: 2800 Kw--
1. Dyeing Section Consumption: 300-350kw
2. Finishing Section Consumption: 750-850 Kw
3. Washing Section Consumption: 100-150 Kw
4. Knitting Section Consumption: 250-300 Kw
5. Printing Section Consumption: 200-250 Kw
6. Fashion Plastic Consumption: 200-250 Kw
7. Garments Unit-1consumption: 600-700 Kw
8. Garments Unit-2 Consumption: 500-600 Kw
9. Corporate Office Consumption: 200-250 Kw
10. Utilities Consumption: 200 Kw
11. ETP Consumption: 100 Kw
Monthly Natural Gas consumption: 13-14 Lac Unit.

Water Treatment Plant
Source of water: Deep tube well.
Production capacity: 80 m3 /hrs. = 1920000 liter/day
Actual Production: 1500000 liter/day
Required water: 1300000 liter/day

Deep well water:
Water collected from below 50 feet from the surface.
Free from organic and suspended particles.
Contain salt of Ca
2+
and Mg
2+
that are responsible for the hardness of water.

There are some major impurities of water.
1. Turbidity and colors
2. Iron and Manganese
3. Alkalinity
4. Hardness
a) Temporary
b) Permanent

1. Clay and slit make the water turbid. Water may be colored by distinct coloring materials
derived mostly from peat and vegetable sources.
Water needs to be colorless, odorless and limpid.
2. Iron and Manganese (Present as bicarbonate and sulphate) are responsible for forming rust
on the fabric.
Rust depends upon the following two terms-
a. Ferrous and Magnesium bicarbonate in water when high amount of free carbon dioxide
is present.
b. Ferrous and Magnesium sulphate in river containing acid waste water.

3. Presence of mineral carbonate salts make the water basic and that bicarbonate make the
water acidic.

Carbonate: p
H
alkali
Bicarbonate: p
H
acid
4. The presence of bicarbonates of Ca and Mg or both in water creates the temporary
hardness (removed by boiling).
The presence of Chlorides and sulphates of Ca and Mg in water creates permanent
hardness.

Hardness of water:

The term Hardness is applied to water denoting a measurement of its p
H
value and metal salt
content. The presence of Ca and Mg salts as sulphates, chlorides, bicarbonates in water causes
hardness of water.
Hard water does not easily form lather with soap as the salt of Ca and Mg react with soap to
form insoluble organic salts.

CaSO
4
/ MgSO
4
+ 2R-COO-Na (RCOO)
2
Ca

/ Mg + Na
2
SO
4

Permanent hardness (Presence of chlorides and sulphates of Ca and Mg) can be removed by
converting the sulphate salts into carbonate with the help of soda ash (Na
2
CO
3
).

CaSO
4
/ MgSO
4
+ NaCO
3
Na
2
SO
4
+ CaCO
3
/ MgCO
3

Or it can be removed with the help of lime when MgSO
4
is responsible for hardness.

MgSO
4
+ Ca (OH)
2
Mg (OH)
2
+ CaSO
4

The hardness of water is expressed by the amount of CaCO
3
present in water without
considering presence of chlorides, sulphates and HCO
3
-
of Ca and Mg and also MgCO
3
.

Water treatment plant description:

Raw water goes to vessel no-1 called Multigrade filter unit. The large size particles, iron that
means solid content are removed in the multigrade filter unit. The water is transferred to the
vessel No-2 called Activated carbon filter unit. In the (vessel No-2) Activated carbon unit
chlorine is removed that means get rid from bad smell. The water then transfer into the (vessel
No-3) softener unit from the activated carbon unit at the presence of cationic resin (Zeolite) is
reacted with water to remove the hardness of water.
The water is transferred in to the reserve tank from the softener unit. The soft water is supplied
from the reserve tank by the 7 Boosting pump in the different section of the factory.

S
F
Boil
Under-
ground
Tank
Deep
Water
Oxidation
Tank
M
G
F
A
C
F
S
F
NaCl
Stones of
different sizes
Coal Resin

Here,
MGF = Multi-graded filter
ACF = Activated carbon filter
SF = Softener filter

Water required 12 lac lit/day
Hardness 2 PPM

After every 12 hours 12 sacks of salt is dosed to activate the resin because for the time being
water hardness starts to increase because of resins decreasing softening ability and within this
12 hour it reaches near about 12-15.
Hardness check:
The hardness should be checked after every 6 hrs. It is checked by the hardness test kits. If the
hardness is more than 0.5, then the process should be restarted. The capacity of the vessel is
115m
3
/ hrs. or 115 ton/hr.
Gas:
The source of Gas using Viyellatex is Titas Gas Ltd. The gas is supplied to gas generator or
different section (Boiler- for heating water) from the main line of the Titas Gas Ltd.
Boiler:
Boiler is used for generating steam from water. It also called steam generator. In Viyellatex
fire-tube boiler is used.
Steam produces form boiler is supplied by the steam line in different section.

Fig: Fire tube boiler

Classification of boilers:
1. Fire tube boiler: Low pressure, low running cost, less chance of busting but greater risk of
damage.
2. Water tube boiler: High pressure, high running cost, high chance of bursting & dont
damage the whole boiler.
In boiler house, steam is produced at high temperature and pressure. This produced steam is
supplied by the steam line in different section.
Capacity: 17tons /hr. There are three boilers in Viyellatex ltd:
1. Two boilers with capacity 6tons/hr.
2. One boiler with capacity 5tons/hr.
As this factory uses fire tube boiler ones specifications are given below
Technical Details Boiler Data
Type Fire Tube Boiler
Manufacturer Omnical borsig energy
Model No. DDHI 60 10
Manufacturer Country Germany
Year of Construction 2002
No. of boiler 2

There are total 4 boilers in Viyellatex. Between the other two boilers one is from Scheineder,
Germany & another is from Thermax, India.

Compressed air:

Compressed air is produced by air compressor. There are two air compressors for producing
compressed air.
Types of compressor:
1. Screw type
2. Piston type
Source of utilities:
Electricity : PDB & Generator
Steam : Boiler
Water : Pump
Compressed air : Compressor
Gas : Titas gas Ltd
Details of the compressor using Viyellatex:
No. of compressor 2+2
Manufacturer Atlas, Belgium & Kaeser, Germany.

Fig: One of the compressors used in Viyellatex

Special arrangement for saving Energy & Environment
Condense return
Use of rain water
Re-use of ETP water
Use of exhausted heat from dryer
Condense return:
Huge steam is generated by the boiler. The condensed steam temperature is 80-90
o
C.the
condensed water is reused in boiler feed pump & due to this hot water huge amount of
energy is saved at the same time save environment from exhausted heat.
Use of rain water:
There are two lacks square feet roof top in Viyellatex ltd. The rain water from this roof is
collected in six lacks liter tank. This water is filtered and use in pretreatment and dyeing
process. So save underground water during rainy season as well as saving energy.
Re-use of ETP water:
Recycled ETP water is use as toilet flash in Viyellatex. Two lacks liter water is saved as well as
energy is saved.
Use of exhausted heat from dryer:
After drying the hot exhausted air (temp 60
o
C) are returned to the dryer as a result
consumption of fuel is reduced. It saves Gas.

Effluent Treatment Plant:
Effluent is the stream of excess chemical liquor extracted from the industry after using in
original operation such as the excess dye liquor, effluent of pretreatment, after treatment etc.
The effluent contains various chemicals that are harmful for the environment. Industrial effluent
generated from different processes are treated with various chemicals to remove or neutralize
the environmentally toxic materials present in it, before discharging it to surface or ground
water. This is called effluent treatment.
There are generally three types of ETP found in our country
1. Chemical ETP
2. Biological ETP
3. Bio-chemical ETP.
Viyellatex has Bio-chemical ETP in the factory premises. The output of the ETP is about 1650
m
3
/day. The effluents produced from different process are collected in a tank. Then this effluent
goes through different steps to make it acceptable discharge level.
Characteristics of waste water:

Govt. tolerance for the quality of waste water:

Parameter Amount
BOD >100-150
COD >250
TDS >2500 mg/l
TSS >250-300 mg/l
DO <0.1
Color Dark
P
H
10-11
Temperature About 80
o
C
Parameter Amount
BOD 50
COD 200
TDS 2100
TSS 150
DO 4.5-8
Color clear
P
H
6-8
Temperature 40-45

Flow chart of ETP

Description of the ETP:
Equalization Tank: The waste water are collected and treated in the equalization tank. This
waste water is alkaline in nature. Solution of H2SO4 or HCL is dosed here to neutralize the
waste water from alkaline condition.
pH control tank: In this tank, ferrous sulphate is used to control the pH of the effluent. The
pH of the effluent comes down to 6-7 from the value 10-11.
Flocculation tank: In this tank, polyelectrolyte & alum is used so that the smaller particle of
the effluent agglomerated. Thus sludge is produced in this tank.
Primary Clarifier: In this tank, the sludge is separated also the measure the amount of sludge
to monitor performance of the flocculation clarifier. The sludge is taken outside and buried
down.
Aeration tank: In this tank, air is introduced in the effluent and cow dung present in this tank
increase the production of bacteria. The air is passing from under the tank. This helps in
reducing the amount of BOD & COD value and also high oxidation efficiency is got for diffused
aeration system.
Secondary clarifier: Primary clarifier cannot separate sludge alone from the effluent. The
remaining sludge is separated in this tank as well as the TDS value of the effluent is reduced.
Chlorination tank: In this tank, sodium hypochlorite is used. As a result, the color of the
effluent is changed into color less or in pale yellow color. Also the disinfection of the effluent is
done through chlorination in this tank.

Multi Filter: In this filter, extra suspended impurities are separated through passing the
effluent is sand bath. The water got from this tank is now reserved for using it in the toilet flash
and the remaining water is discharged into the land.
Consumption of the chemical used:

Chemical Name Chemical Used
H2SO4 & HCl 25 Kg/day
Lime 250Kg/shift
Alum 250 Kg/day
Polyelectrolyte 1 Kg/day
H3PO4 1 Kg/shift
Urea 1 Kg/shift

Discharge water quality of Viyellatex:

pH = 6-9
BOD = 50 mg/ L
COD = 220 mg / L
Suspended solid = 145 mg/L
Color = color less.

Functions of different chemicals:
H
2
SO
4
& HCL:
Neutralize the water from alkaline state.
Ferrous Sulphate/Aluminium sulphate:
To control the pH.
Lime:
To vanish the color of the effluent.
Alum & Polyelectrolyte:
To agglomerate the smaller particles.
For sedimentation of the smaller particle.
H3PO4/Urea:
For increasing the production of the bacteria.

Remarks:
Following the regulation of environmental protection law, Viyellatex treats the produced effluent
in a controlled manner in ETP so that the discharged water does not cause any harmful effect
to the environment.

Inventory Control
Store is the place where every type of raw materials, spares, finished goods are kept in proper
system. Inventory control means the accurate calculation and data of every type of raw
materials spares and finished goods in time to time in the store. Inventory control is necessary
for effective running of the production. The main objectives of inventory control are given
below
To know about the required amount of raw materials.
To finish the production in time.
To continue the production process.
To find out the profit or loss of a company.
Stock and stock value for consumption measuring.
Scope of Inventory Control

- Raw materials
Dyes store.
Other chemicals.
Grey fabrics.
- Finished fabric.
- Spare parts.
- General store:
Capital equipments.
Accessories.
Stationary.
Maintenance parts.

Frequency update
Monthly inventory control
Annual inventory control

Inventory Control System for Raw Materials:
Dye store & other chemicals store
Both of these are received by the store in charge.
First he sends these to quality in-charge for inspection. If they are found to be of
required quality then they are taken to store by the storekeeper.
Store in-charge supplies these when required and records the date, type of material,
quantity and section in which supplied, in his register book.

Grey fabric store
Grey fabric is usually stored in another store room, which is separate from dyeing shade.
Grey fabric is first sent to the QC department for quality assurance and then taken to
the store room.
Grey fabric is received by fabric store in-charge.
He supplies the fabric as per requirement and records the date, type of material,

Stages of grey fabric inventory control
After knitting production.
Grey inspection.
Warehouse.
Batch preparation.
Dye house.

Inventory Control System for Finished fabric
Finished fabric from the compactor or Stenter goes to inspection room. Here inspection
is done by four points system.
Required GSM, width (diameter), shrinkage, spirality, wash fastness, rubbing fastness
etc. are tested from the lab before packaging.
After finishing the fabric is kept in package before their transfer to the garments
department.
It is controlled by the finishing in-charge who keeps a list of total finished product. He
also keeps a list of delivery products.
He supplies the fabric as per requirement and records the date, type of material,

Stages of finished fabric inventory control
Finishing section.
After final inspection.
Warehouse.

Inventory Control System for Spare Parts:

Spare store officer keeps the spare parts in store and makes a list of spare parts.
If the spare parts are little in stock he gives requisition to maintenance manager.
Maintenance manager gives requisition to head office. Head office imports spare parts
or buys from local market as per requirements.
As new spare parts arrive to store officer, he receives and catalogues them.
He supplies the spare parts as per requirement and records the date, type of material,

Others:
There is a central store at Viyellatex. In that store, various types of forms, papers; stationary &
other necessary goods are kept.

Inventory Procedure:
Bin Card.
Store Requisition.
Store Ledger Account.
Daily Inspection & Package Report.
Monthly Stock & Consumption Report.
Monthly L/C wise Delivery Report.
Received Delivery & Balance Stock.

Costing

The data of costing is one of the most confidential data of the industry. Generally these data
are not provided by the authority. The data of costing given here is just a representation of
general price. The actual data might be different from the given price.
1. Latest Yarn Price: Date - 23.09.2010
S.L
#
Description Of
Goods
VTL
Price
Euro- 90
Days
Cmia Fair
Trade
Organic
01. 20/1 COMB $4.75 3.17 $5.35 $5.45 $5.45
02. 22/1 COMB $4.80 3.20 $5.40 $5.50 $5.50
03. 24/1 COMB $4.80 3.20 $5.40 $5.50 $5.50
04. 26/1 COMB $4.80 3.20 $5.40 $5.50 $5.50
05. 28/1 COMB $4.85 3.24 $5.45 $5.55 $5.55
06. 30/1 COMB $4.85 3.24 $5.45 $5.55 $5.55
07. 32/1 COMB $5.00 3.34 $5.60 $5.70 $5.70
08. 34/1 COMB $5.15 3.44 $5.75 $5.85 $5.85
09. 36/1 COMB $5.45 3.64 $6.05 $6.15 $6.15
10. 40/1 COMB $5.75 3.84 $6.35 $6.45 $6.45

S.L
#
Description Of
Goods
VTL
Price
Euro-90
Days
Cmia Fair
Trade
Organic
01. 20/1 CARD $4.45 2.97 $5.05 $5.15 $5.15
02. 22/1 CARD $4.50 3.00 $5.10 $5.20 $5.20
03. 24/1 CARD $4.50 3.00 $5.10 $5.20 $5.20
04. 26/1 CARD $4.50 3.00 $5.10 $5.20 $5.20
05. 28/1 CARD $4.55 3.04 $5.15 $5.25 $5.25
06. 30/1 CARD $4.55 3.04 $5.15 $5.25 $5.25
07. 32/1 CARD $4.75 3.17 $5.35 $5.45 $5.45
08. 34/1 CARD $4.95 3.30 $5.55 $5.65 $5.65

S.L # Description Of Goods VTL Price Euro 90
Days
Cash Lbs Cash P Kg
01. 07/1 O/E $2.90 $2.50 49.44 109.00
02. 10/1 O/E $2.95 $2.60 51.00 112.43
03. 12/1 O/E $3.00 $2.85 -
04. 14/1 O/E $3.10 $2.90
05. 16/1 O/E $3.20 $2.95 66.22 145.99
06. 20/1 O/E $3.30 $3.00 70.76 156.00

2. Knitting cost of different Types of Fabric:
Serial No. Fabrication Knitting Price(Tk./Kg)
1. Single Jersey 8-10
2. Lacoste/PK 14
3. Terry 14
4. Fleece 18-20
5. 1x1 Rib 14
6. Interlock 18
7. Single Jersey E. Stripe 100
8. Lacoste/PK E. Stripe 120

3. Dyeing & Finishing Cost:
Sl. No. Types Of Shade Type Of Finishing Price/Kg
1 Light Color Tube Finish 65 Tk
2 Light Color Open Finish 75 Tk
3 Medium Color Tube Finish 75 Tk
4 Medium Color Open Finish 85 Tk
5 Dark Color Tube Finish 85 Tk
6 Dark Color Open Finish 95 Tk
7 Black Color Or Extra Dark Tube Finish 110 Tk
8 Black Color Or Extra Dark Open Finish 125 Tk
9 Deep Black Or Deep Royal Tube Finish 115 Tk
10 Deep Black Or Deep
Royal
Open Finish 125 Tk
11 Only Wash Tube Finish 25 Tk
12 Only Wash Open Finish 35 Tk
13 White Tube Finish 40 Tk
14 White Open Finish 50 Tk

Serial
No.
Clarification Depth Of The
Shade
Shade Percentage

1. Light Color Upto 1%
2. Medium Color Above 1% To 3%
3. Dark Color Above 3% To 8%
4. Extra Dark Above 8%
5. Deep Black Or Deep Royal Above 12%

Serial no. Category Of Bio-Polishing Price
1. LIGHT ENZYME 5 TK/KG
2. HEAVY ENZYME 10 TK/KG
3. DOUBLE ENZYME 20 TK/KG

Serial No. PRICE QUOTATION OF
FINISHING
PRICE
1 ONLY STENTER 20 TK/KG
2 ONLY OPEN COMPACTING 15 TK/KG
3 STENTER + OPEN COMPACTING 30 TK/ KG
4 ONLY TUBE DRY 8 TK/KG
5 TUBE COMPACTING 8 TK/KG
6 ONLY SUEDING 25 TK/KG
7 SUEDING+ STENTER+ OPEN COMPACTING 55 TK/KG
8 ONLY BRUSH 15-20 TK/KG

Marketing
Introduction:
Marketing is the heart of a companys turnover. Viyellatex group has a strong and skilled
marketing team and under their effective direction it is now one of the prominent groups in the
country. Here are the details of marketing activities:
Major buyers of Viyellatex group:

Consumers of product:

Viyellatex group LTD is a 100% export oriented industry. All the goods produced in this
industry are exported into various foreign countries. There is no local sell.

Exporting countries:
There are some countries which are importing goods from Viyellatex. Which are given below-
Germany
France
UK
Netherland.

Marketing strategy:
Marketing strategy is a very important factor to sale the products to the buyer. If the
marketing strategy is not so developed, it will be very hard to reach the goal. In case of
garments marketing the dealings with the buyer is a very important factor.
Viyellatex group ltd maintain senior marketing officers, merchandiser & higher officials
deal with the buyer. There are some fixed buyers of the industry. The buyers give their orders
continuously all over the year. The marketing officers & the merchandisers communicate with
the buying houses to collect the orders.
By both side understanding the rate & the order quantity are fixed.

A well-defined marketing strategy has the following characteristics:
Good quality
Low price or competitive price
Prompt service
Good commitment
Good business communication

Duties & Responsibilities of Marketing Officer:
Job summary:
i) Market search
ii) Market development
iii) Customers motivation
iv) Production follow up
v) Technical assistance of customer

Dealing with the buyer & convince the buyer is the main duty of marketing officer. A marketing
officer also has some other duties. The main duties & responsibilities of a marketing officer are
given bellow-
To prepare cost sheet by dealing with the buyer.
To take different steps by discussing with the high officials & merchandisers
To maintain a regular & good relationship between commercial officer & merchandisers
To maintain a communication with the buyers and buying houses
Communicate with better criteria of the products

Actually the responsibilities & duties of marketing officer begins from getting order of buyer &
ends after receiving foods by the buyer. So, he should be always smart, energetic & sincere.

Marketing Information:
In an uncertain world market, Viyellatex group Ltd doubled their efforts with their design team
leading the way; they increased their calls as the customers & looked for ways to add new ones
also. Having established a strong relationship Viyellatex group added new and dynamic
designers to the existing team & can proudly say that their collections were hailed as some of
the best to be presented. These meetings boosted the confidence of existing buyers and
attracted new customers. Viyellatex group continued with their strategy to market value added
products like dyed fabrics with special finishes. This is reflected in the increase in average price
per linear meter.
Viyellatex group now in a strong position to take on the challenge of WTO in the end of 2004
when quotes will be abolished and only those companies with a reputation for innovative,
creativity and reliability and the ones having strong strategic relationships and business
alliances will survive and benefit.

Buyer's Compliance:
The factory is full compliance with ILO and Bangladesh Labor Law. Their company policy
is as follows:

No child labor.
No forced labor.
Transport facilities for worker.
Hours of work.
Voluntary over time.
Intervals for rest.
Weekly holidays.
Annual leave.
Festival holidays & leaves with bonus.
Maternity protection.
Worker's welfare committee.
Mineral drinking water.
Sanitary facilities.
First aid box.

Remarks:
Viyellatex Group has a well learned marketing & merchandising team. They always
communicate with the buyers. The Group has some fixed buyers. The marketing section also
looks the quality & quantity buyers and this section is successful in this respect.

Recommendation

The working condition of Viyellatex is very much better than most of the textile manufacturing
industry in Bangladesh. But there are few points that might be considered for improving the
current quality and productivity.

Dyeing
i. Operators should be warned to be careful about maintaining proper time of dyeing.
ii. Wastage of water should be reduced.
iii. During the transportation of the fabric in the dyeing floor & also during the loading of the
machine, fabrics are soiled for the contact with floor. This makes the fabric/part of the
fabric dirty. It may require more scouring/bleaching agent or may create stain.

Finishing
i. Use of vacuum cleaner to reduce dust during cleaning machines.
ii. Online quality control system should be introduced for greater performance.
iii. Removing of unused machine or machine part from finishing and inspection floor.
iv. Workers and staffs of finishing and inspection should be compelled to wear mask during
work.

Printing
I. Introduce modern flatbed screen printing machine & transfer printing machine to
increase productivity.
II. Inception of modern screen preparation system.

Common suggestions:
I. Drainage system should be improved to displace the rain water efficiently in front of
dyeing floor.
II. Color of ribbon of ID card must be different for executives, interns, staffs & operators so
that everyone can identify themselves easily.

Conclusion
We are enough fortunate that we have got an opportunity of having a training in this mill during
the training period.

Weve received co-operation & association from the authority fully. All the machines & materials
found on appreciable working condition. All the stuffs & officers were very much helpful to us.

We apologize for our any behavior which may disappoint the officers and personnel. Due to
secrecy act, all the data on costing & marketing activities has not been supplied & hence the
data given regarding to this do not resemblance to the actual data.

The whole process is not possible to bind in such a small frame as this report, hence our effort
spent on summarizing, not describing them.

Mill Training Report (Viyellatex), Dyeing - Rafsan

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