Industrial

Knowledge for Innovation and Change
Department of Textile Engineering
Industrial Attachment
(8th February to 8th April)
At
NRG Composite Yarn Dyeing Ltd
Jamirdia, Masterbari, Valukla
Mymensingh, Bangladesh.
Prepared by
Name
ID
Batch
MD. Tauhidul Islam
BTX-120200212
9th
Supervisor: Prof. Dr. M. A. Jalil

Head
Northern University Bangladesh
N.R. Group
In the name of GOD

The most BENEFICIENT
The most MARCIFUL
Knowledge for Innovation and Change
Name & Designation of Supervising Teacher

Prof. Dr. M. A. Jalil
Head

Cell No.: 01711269630
Name & Designation of Supervising Officer of

the Mill
MD. Akhtaruzzaman (Asstt. General Manager, Dyeing)
NRG Composite Yarn Dyeing Ltd.
Cell No.: 01710892942
Letter of Transmittal
To,
Head
Northern University Bangladesh.
Subject: Submission of the Industrial attachment Report.

Dear Sir,
I am pleased to submit my Industrial attachment Report This is submitted under the
program of B.Sc. in Textile Engineering in Northern University Bangladesh. The Report has
been completed in accordance with the knowledge that I have gathered during my Industrial
Training and the guidelines received from my honorable teachers. I tried to make this Report
is to give a clear picture on Wet processing Technology practically used on NRG
Composite Yarn Dyeing Ltd. However, I will always be ready to provide any further
clarification that you may require.
I, therefore, request and expect that, you will appreciate me with any sort of
recommendation & valued suggestion & will cordially receive this Industrial Attachment for
your kind assessment.
Sincerely Yours
Md. Tauhidul Islam

ID: BTX 120200212
Batch: 8th, Sec: WPT
5
Supervising Facultys Approval

Head
Banani, Dhaka
Supervising Mill Authoritys

Approval
MD. Akhtaruzzaman
Assistant General Manager
Jamirdia Masterbari, Valuka
Mymensingh, Bangladesh
7
DEDICATED TO
MY PARENTS AND THE RESPECTED
TEACHERS WHO ALWAYS TRY TO
FIND WAYS AND THINKS TO
PROVIDE WHICH I DO NOT KNOW
AND DONT HAVE
Abstract
Textile technology education is based on

industrial ground. Theoretical background is not
sufficient so, industrial training is an essential
part of study to make a technologist technically
sound in this field. Industrial training provides us
that opportunity to gather practical knowledge.
NRG Composite Yarn Dyeing Ltd. is a truly
integrated undertaking. The textile division has
the capability to offer a complete product range
for the export & domestic textile markets. The
goal of this textile factory is to become the
preferred partner for sourcing high quality
fabrics & clothing from Bangladesh. With highly
advanced technology & an emphasis on
developing local human resources, the textile
division has the potential to make an important
contribution to the nations growing readymade
garments export sector. The rationale behind the
existing structure & future expansion of the
textile division is to capture value added at each
stage of the textile manufacturing process.
Despite Bangladeshs lack of indigenous cotton
production capability, NRG Composite Yarn
Dyeing Ltd has leveraged Bangladeshs labor
cost advantage & export competitiveness to
maximum level.
Acknowledgement
10
All the praises are for the almighty, Allah who

bestowed us with the ability and potential to complete
this Internship. I also pay my gratitude to the Al-mighty
for enabling me to complete this Internship Report
within due course of time.
Project paper is an academic function of the Northern
University. We are highly delighted to express our
regards & gratitude to honorable Professor supervising
teacher: Prof. Dr. M. A. Jalil for providing us the
chance to complete our internship and completion our
project work in NRG Composite Yarn Dyeing Limited.
We take this opportunity to record my deep sense of
gratitude and appreciation to our Project Advisor Md.
Tanjim Hossain (Lecturer & co-ordinator)
Department of Textile engineering, Northern
University for his constant encouragement and
inspiring guidance with his wisdom. We also take the
opportunity to express our sincerest gratitude to the
management, administration & personnel of NRG
Composite Yarn Dyeing Limited for their kind
assistance. Cordial thanks goes Md.Akhtaruzzaman
(Assistant General Manager) NRG Composite
Yarn Dyeing Limited for their excellent co-operation
during the period of our training. We would also like to
thank Mushfikur Rahim Executive, knit Fabrics
dyeing section for his sincere support. 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.
Finally, we would like to acknowledge that we remain
responsible for the in-adequacies & errors, which
doubtless remain in the following report.
11
Content Summary
Chapter No.
Chapter Name
Page Range
01
Organizational Overview
02
Project Description
15-19
03
Man Power Management
20-25
04
Raw Materials
25-44
05
Literature Review
45-56
06
Chemical Laboratory
46-82
07
Production Planning Sequence

Operations
83-115
08
Quality Assurance
Department (QAD)
115-153
09
Effluent Treatment Plant

(ETP) & Caustic Recovery
Plant (CRP)
154-162
10
Maintenance
163-171
11
Utility Services
172-175
12
Store & Inventory Control
176-178
13
Conclusion
12
12-14
Chapter-1
Organizational Overview
13
Introduction:
From fiber to fabric, the Textile division of N.R GROUP is a truly integrated undertaking.
The Textile Division has the capability to offer a complete product range for the export
textile markets. The goal of the Textile Division is to become the preferred partner for
sourcing high quality fabrics and clothing from Bangladesh. With this goal NRG Composite
Yarn Dyeing Ltd. is advancement of this journey. With highly advanced technology and an
emphasis on developing local human resources, the Textile Division has the potential to
make an important contribution to the nation's growing readymade garments export sector
keeping green environment into close consideration. The ration behind the existing structure
and future expansion of the Textile Division is to capture value-added at each stage of the
textile manufacturing process. Despite lack of indigenous cotton production capability of
Bangladesh, N.R Group has leveraged labor of Bangladesh cost advantage and export
competitiveness to the maximum.
Journey of N.R GROUP:
N.R GROUP today symbolizes a name a state of mind. But its journey to the growth and
prosperity has been no bed of roses. NRG is proud of its exceptional staff and team
members.
Managing director and CEO of the group is a hand on leader, engaged in planning, directing
and executing from production to marketing. His 35 years of experience in knitwear,
sweater, yarn manufacturing and trading and his global networks is an asset to the company.
The dynamic leadership of the managing director motivates the group to achieve increasing
targets of turnover and diversify in to new ventures. In recognition of his outstanding
contribution in business and export, the Government of Bangladesh has declared him a
Commercially Important Person (CIP) since 1992.
NRGs executives bring to the company a wealth of experience, professionalism and areas
of expertise from all over the world. The Group also employs foreign technicians and
professionals to achieve perfection in the fields of yarn manufacturing, ribbon production,
knitting, dyeing, sales and product development and quality control.
14
Vision:
To establish as a one stop source for the Global Knit Apparel market
and to satisfy and meet customer's expectation by developing and
providing products and services on time, which offer value in terms
of Quality, Price, Safety & Environmental impact. Assuring complete
compliance with the international quality standards and also
providing the employees internationally acceptable working
condition and standards. To promote the development and to use
human talent & equal opportunity of employment NRG Composite
Yarn Dyeing Ltd. procure the most advanced & sophisticated
technology suitable for producing desired product and attain highest
level of competence through continuous development of the
professional management system and to ensure complete
transparency in all aspect of business.
Mission:
N.R GROUP realizes the need to stake out a competitive segment in
the changing global market of today through technological
excellence and human expertise. N.R Group is committed to
transpose its local success to the world scene.
15
Chapter-2
Project Description
16
Name of the Factory:

NRG Composite Yarn Dyeing Limited
Type:
Knit fabric manufacturing for 100% export oriented readymade Garments Industry.
Year of Establishment:
2001, Commencement of Production in June 2002
Address:
It is situated in Jamirdia, Master Bari, Valuka, Mymensingh, Bangladesh.
History of Project Development:

In 1997, N.R Group entered the textile sector with its manufacturing facilities of cotton yarn.
Combining modern technology with skilled manpower under N.R Group's unique inspiring,
atmosphere, this new N.R Group venture soon rose to the top of the local textile industry.
Today it has one of the most sophisticated vertically integrated set-ups.
In 1998: Second unit of N.R Group established.
In 2000: N.R Group Spinning Ltd. started its journey.
In 2001: N.R Group Knit Fabrics ltd. and NRG Composite Yarn Dyeing Ltd.
established.
In 2002: N.R Group Knit Fabrics commenced with its production.
Textile Mills of N.R Group Group:

N.R Group Knit Fabrics Ltd.
N.R Group Spinning Ltd.
N.R Group Textiles Ltd.
N.R Group Multi Fabrics Ltd.
Physical Infrastructure:
N.R Group at Valuka have two shades. They are N.R Group Knit Fabrics Limited, NRG
Composite Yarn Dyeing
Total factory area is 165,000 ft Production space is 135,000 ft, single storied.
There are four dormitories for worker, two dormitories for officials.
17
NRG Composite Yarn Dyeing Ltd. maintains its telecommunication with VOIP
connection to its different corporate zones, PABX connections and LAN connections.
Its others facilities areOwn Network Server,
Own power management;
Own utility management,
Free transport facility,
24 hour medical center,
Fire service facility and
ETP (Effluent Treatment Plant)
Different Departments:
NRG Composite Yarn Dyeing Ltd has the following departments approximately:
18
Product Type:
Piece Dyed fabric,

Mercerized & Dyed fabric,
Yarn dyed fabric,
Mercerized yarn dyed fabric (double mercerized).
Product Mix:
Cotton: Carded, Combed, Compact, & Organic.

Viscose: Modal, Mlange,
Polyester,
Lycra,
Polyester-cotton blend,
CVC
Product Range:
Engineering stripe and semi jacquard,

Plain (100% cotton single jersey, slub single jersey, lycra single jersey.
Pique (100% cotton, 100% Lycra),
Four Needle structure,
Wofel rib,
1X1 Rib (cotton), 1X1 Rib (lycra), 1X1 Rib (slub),
2X2 Rib (100% cotton), 2X2 Rib (100% Lycra),
2X1 Rib,
4X4 Rib,
Interlock,
Pique interlock (pima cotton),
Interlock (double mercerized),
Locust,
Jacquard,
Fleece & Terry fleece, etc.
19
Capacity:
Around 15,000-17,000 Kg. of Knit fabric processed per day (Open width &
tubular finish).
Production Capacity in knitting:
10000-12000 kg. Of Greige fabric and 25000 pieces of cuff & collar set per
day (depends on design i.e. if design is more than production will be less).
Production Capacity in yarn dyeing:
4000 kg. Per day
Production Capacity in knit dyeing:
30,000 Kg. Per day
Investment Cost:
Investment cost is US$ 7.50 million.
Remarks:
N.R.G. Knit Fabric Ltd. is greatest concerned with the quality of its product.
For this reason it do not look for the production volume rather the quality of
product, this increase its overhead cost. But better quality has welcome buyers
with satisfaction. The infrastructure and land asset has the greatest possibility
to extension and to create social contributions.
20
Chapter-3
Manpower Management
21
Organogram of Administration:
22
Organogram of Operation:
23
An overall Organogram:
24
Shift Change:
There are three shifts for operation personnel in this industry. So the shifts are
changed at every 8 hours. The shift timings are as below:
6:00 am to 2:00 pm (A Shift)
2:00 pm to 10:00 pm (B Shift)
10:00 pm to 6:00am (C Shift)
Administration i.e. Management personnel work on General (G) shift of
duration 8:00 am to 5:00 pm and 6 days per week.
Responsibilities of Production Executive:
To follow and execute the daily production plan accordingly.
To give the right decision for the minor troubleshooting.
To match the shade with the approved lab dip and take necessary help from
Spectrophotometer.
To prepare dye line correctly and maintain logbook.
To convey the proper information to the next shift.
To maintain target productivity of every section in his shift
To give job card to maintenance department whenever machine is not
working or any other problem with the machine.
Job description of Production Executive:
Report to:
Senior production officer
Job Summary:
To plan, execute & follow up the production activities & control the quality.
25
Duties & Responsibilities:

Overall supervision of dyeing, finishing production.
Batch preparation & PH check.
Dyes & chemical requisition issue & check.
Write fabrics loading & unloading time from m/c.
Program making, sample checking, color measurement.
Control the supervisors, operators asst. operator & helpers of dyeing
m/c.
And also any other work as & when required by the management.
Job Responsibilities of Production officer and senior Production Officer:
To keep workers attendance

Distribute the workers to various machines
To distribute yarn according to order No. and Lot.
To prepare production register after every shift
To maintain log book
To report shift wise floor production to Sr. Executives/ Executives
To monitor product quality
To take all types of initiatives to increase production
To take all types of initiatives to reduce wastage
Management System:
Corporate management system.
Remarks:
NRG Composite Yarn Dyeing Ltd. has manpower more than 6000 in around
a single fence & N.R.G Multi Fabrics Ltd. Has around 200s manpower. N.R
Group pay a great attention for providing food and transport, medical,
schooling of personnels children, their utility and maintain a safe, secured and
calm environment. The working condition here is also standardized. These
opportunities for the personnel of the industry have a direct positive impact on
the production and also motivate the personnel for better and greater efficiency.
26
Chapter-4
Raw Materials
27
NRG Composite Yarn Dyeing Ltd. is a knit composite textile industry. In the industry raw
materials for different section is different. As for example knitting uses the raw material
Yarn, Fabric processing department uses the knit fabrics, dyes and chemicals again yarn
processing uses the grey yarn and dyes chemicals. Following we describe the raw materials
used in NRG Composite Yarn Dyeing Ltd.
Yarn
Grey fabrics
Dyes
Chemicals
Auxiliaries
Yarn:
Following types of yarns are used to knit fabrics:
28
Grey Fabrics:
Following types of grey fabrics are dyed:
29
Sources: The required yarns are supplied from:
N.R Group Spinning Mills Ltd. (Bangladesh)

Thermax (Bangladesh)
NRG (Bangladesh)
Badsha Spinning Mills Ltd. (Bangladesh)
Ginni (India)
Nahar (India)
And special yarns are from:

Bardhaman (India),
Aarti (India),
Organic cotton Indonesia.
The required grey fabrics are produced in this industry
Price:
Not provided.
Dyes:
The following dyes are usedReactive dyes.
Disperse dyes.
The list of dyes for different substrate is as below:
30
For Cotton Group (Reactive Dyes)
31
32
33
34
35
Chemicals:
Basic Chemicals
Acid Buffer:
Sodium Acetate
Ammonium Sulphate
36
Bleaching Agent
Salt/Electrolyte
Caustic Soda
37
Detergent and Scouring Agent
Antifoam/ Penetrating Agent
Anti-Creasing Agent
38
Peroxide Stabilizer
Peroxide Killer
Sequesterent & Dispersent for Bleaching
Mercerizing Wetting Agent
39
Leveling Agent for Heat Setting
Reactive Fixing Agent
Cotton Leveling & Prof-Colloid
Oxidizing Agent for Polyester
40
Dispersing Leveling Agent for Polyester
Acid PH Buffer (For Polyamide)
Setavin PAS
After Soaping Agent
Gliding Agent for Cotton Yarn
Reducing Agent
41
Enzyme Finishing Agent
Optical Brightener for Cotton
PES-Dyeing PH Buffer
Rubbing Fastness Improver
42
De-Colorant for Effluent Treatment
Ultra violet protection Agent
Anti-murobiol Hygiene Protection Agent
Silicon Stripper Agent
Knitting Oil Removing Agent
43
Special Finishing Agent
44
Softener
45
Chapter-5
Literature Review
46
Cotton Fiber and its Chemical Structure

The chemical composition of cotton, when picked, is about 94 percent cellulose; in finished
fabrics is it 99 percent cellulose. Cotton contains carbon, hydrogen, and oxygen with
reactive hydroxyl groups. Glucose is the basic unit of the cellulose molecule. Cotton may
have as many as 10,000 glucose monomers per molecule. The molecular chains are arranged
in long spiral linear chains within the fiber. The strength of a fiber is directly related to chain
length. Hydrogen bonding occurs between cellulose chains in a cotton fiber. There are three
hydroxyl groups that protrude from the ring formed by one oxygen and five carbon atoms.
These groups are polar meaning the electrons surrounding the atoms are not evenly
distributed. The hydrogen atoms of the hydroxyl group are attracted to many of the oxygen
atoms of the cellulose. This attraction is called hydrogen bonding. The bonding of
hydrogen's within the ordered regions of the fibrils causes the molecules to draw closer to
each other which increases the strength of the fiber. Hydrogen bonding also aids in moisture
absorption. Cotton ranks among the most absorbent fibers because of Hydrogen bonding
which contributes to cotton's comfort. The chemical reactivity of cellulose is related to the
hydroxyl groups of the glucose unit. Moisture, dyes, and many finishes cause these groups
to readily react. Chemicals like chlorine bleaches attack the oxygen atom between or within
the two ring units breaking the molecular chain of the cellulose.
Chemical structure of Cotton Fiber
Bleaching
Bleach is a chemical that removes colors or whitens, often via oxidation. Common chemical
bleaches include household "chlorine bleach", a solution of approximately 36% sodium
hypochlorite (NaClO), and "oxygen bleach", which contains hydrogen peroxide or a
peroxide-releasing compound such as sodium per-borate, sodium per-carbonate, sodium
persulfate, sodium per-phosphate, or urea peroxide together with catalysts and activators,
e.g. tetraacetylethylenediamine and/or sodium nonanoyloxybenzenesulfonate. To bleach
something is to apply bleach, sometimes
47
as a preliminary step in the process of dyeing. The bleaching of textiles appears to have been
known as early as 300 B.C. when soda ash was prepared from burned seaweed and used to
clean cloth. Then the cloth was treated with soured milk to reduce its alkalinity. The
bleaching process was completed when the cloth was exposed to the Sun. This type of sun
bleaching typically took several weeks. A Swedish chemist discovered chlorine gas in 1784
and succeeded in demonstrating its use for decolorizing vegetable dyes. Fifteen years later a
patent was awarded for a bleaching powder formed by the absorption of chlorine gas into
dry hydrate of lime. Following World War I the technology for shipping liquid chlorine was
developed. This allowed for on-site production of sodium hypochlorite in textile mills and
led to the development of other chlorine-based bleaches. In 1928, the first dry calcium
hypochlorite bleach containing 70% available chlorine was produced in the United States.
This material largely replaced bleaching powder in commercial bleaching.
Hydrogen peroxide was prepared as early as 1818 but did not find use in the bleaching of
textiles until much later. By 1930, the prices of peroxides had dropped sufficiently to allow
the use of hydrogen peroxide in the bleaching of cotton, wool, and silk. By 1940, 65% of all
cotton bleaching was done with hydrogen peroxide.
Textile bleaching is one of the stages in the manufacture of textiles. All raw textile materials,
when they are in natural form, are known as 'greige' material. This greige material will be
with its natural color, odor and impurities that are not suitable for clothing materials. Not
only the natural impurities will remain on the greige material but also the add-ons that were
made during its cultivation, growth and manufacture in the form of pesticides, fungicides,
worm killers, sizes, lubricants, etc.
The removal of these natural coloring matters and add-ons during the previous state of
manufacturing is called scouring and bleaching.
48
Bleaching Chemistry
The process of bleaching can be summarized in the following set of chemical reactions:
Cl2 (aq) + H2O (l) H (aq) + Cl (aq) + HClO (aq)
+
The H+ ion of the hypochlorous acid then dissolves into solution, and so the final result is
effectively:
Cl2 (aq) + H2O (l) 2H (aq) + Cl (aq) + ClO (aq)
+
Hypochlorite tends to decompose into chloride and a highly reactive form of oxygen:
ClO Cl + O
-
This oxygen then reacts with organic substances to produce bleaching or antiseptic effects.
Reactive Dyes
The best dyes, by far, to use for cotton and other cellulose fibers are the fiber reactive dyes.
They are much brighter, longer-lasting, and easier-to-use than all-purpose dyes. Reactive
dyes first appeared commercially in 1956, after their invention in 1954 by Rattee and
Stephens at the Imperial Chemical Industries Dyestuffs Division site in Blackley,
Manchester, United Kingdom. Reactive dyes are used to dye cellulosic fibres. The dyes
contain a reactive group, either a haloheterocycle or an activated double bond, that, when
applied to a fibre in an alkaline dye bath, forms a chemical bond with a hydroxyl group on
the cellulosic fiber. Reactive dyeing is now the most important method for the coloration of
cellulosic fibres. Reactive dyes can also be applied on wool and nylon; in the latter case they
are applied under weakly acidic conditions. Reactive dyes have a low utilization degree
compared to other types of dyestuff, since the functional group balso bonds to water,
creating hydrolysis.
49
Reactive dyes are categorized by functional group:
Dyestuffs with only one functional group sometimes have a low degree of fixation. To
overcome these dyestuffs containing two different reactive groups (i.e. one
monochlorotriazin and one vinyl sulfone) were created.
Bifunctional Dyestuffs containing two groups are also known as bifunctional dyestuffs,
though some still refers to the original combination. Other type of bifunctional dyes has
been introduced. The first bifunctional dye made where more tolerant to temperature
deviations (better process). Other bifunctionals are created, some with fastness (better
quality) or only fixation degree (better environment/economy) in mind.
Reactive dyes have good fastness properties owing to the bonding that occurs during dyeing.
Cotton is made of cellulose molecules which react with the dye .During reactive dyeing the
H atom in the cellulose molecule combines with the cl atom in the dyeing process and
results in a bond. Trifunctional dyestuffs also exist. Procion MX. Many people feel quite
strongly that the best dye choice for the beginner, as well as for many experienced dyers, is
Procion MX, because this dye is very easy to work with.because this dye is very easy to
work with.
50
The dyes are relatively non-toxic. Other advantages include the remarkable wash fastness
found in all fiber-reactive dyes.
Optimum reaction temperatures for Procion MX dyes are between 95 and 105F = 35 to
41C (except for turquoise, which prefers up to 130F = 55C)
Cibacron F. Another very good fiber reactive dye for artists and crafters to use is the
Cibacron F line. (Don't confuse Cibacron F with just plain Cibacron! They can be
completely different types of dyes; be sure you get the type with the "F" suffix.) Like
Procion MX dyes, Cibacron F dyes can be used in warm water, instead of extremely hot
water like some dyes. Its advantages over Procion MX dyes are that it 'keeps' better in
solution, so you can store and possibly even buy it already in solution (liquid form),
avoiding the safety hazard of breathing dye powder; it is also much easier to wash the excess
dye out of the fabric when using Cibacron F dyes than when using Procion MX. However,
the Cibacron F line has one major drawback when compared to the Procion MX line: there
is not as wide a choice of colors.
Cibacron F dyes can be used according to the exact same recipe as Procion MX dyes, and
even mixed freely with them. However, Cibacron F dyes are slightly less quick to react than
Procion MX type, which is why they can be stored so much longer after dissolving them in
water than the Procion MX type dyes; this also means that slightly higher temperatures are
needed.
Optimum temperatures for Cibacron F dyes are slightly higher than for Procion MX dyes.
Ciba says 55 to 65C (130 to 150F); ProChem (Sabracron F) says 45 to 55C. (113 to
130F) Drimarene K. This is the remaining popular "cool water" fiber reactive dye. It
requires higher temperatures still than Cibacron F, but does not require steaming.
Instructions for Drimarene K dyes can be found at Batik Oetoro; they are very similar in
action to MX type dyes, except for requiring a minimum temperature of 35C or 95F. The
greatest drawback, besides the need to find a warm place for the dye reaction to occur, is the
lack of a truly rich red.
Drimarene K has optimum temperatures around 60C (140F) for most colors, 80C (176F)
for turquoise and a couple of others.
Procion H dyes are usually used for silk painting; they require steaming or simmering to fix
to cotton or silk. They are chemically similar to Procion MX dyes, being
monochlorotriazines, but they are far less reactive, and will not work at all well at room
temperature.
51
Procion H dyes, may be fixed to cotton using a high-pH solution such as sodium silicate at
room temperature, or by moderate heating. Vinyl sulfone dyes are particularly useful for
chemical resist dyeing, in which two different types of fiber reactive dyes are used to print
foreground and background in different colors. Remazol dyes are more suitable for dyeing
for later discharge (bleaching) than are other fiber reactive dyes.
Levafix. made by Dystar, for small-scale users. Their temperature optimum is around 50C
(122F). This is lower than the optimum temperature of 60 to 80 C. for the Drimarene K
dyes, which can be used in "cold" dyeing, but higher than the optimum temperature of about
35 to 40C (95 to 105F) for Procion MX. It is not necessary to get quite as high as the
optimal temperature in order to have acceptable results.
Dissolving the Dyes

The dyes are in most cases readily water-soluble. They are dissolved either by passing with
cold water to which is then added hot water or by strewing the dye powder into hot water
which is stirred at high speed. Usually a temperature not greater than 80C is used for
dissolution. In the case of highly reactive dyes such as Procion MX (ICI) warm (50-60C)
water is used. Since the dyes are prone to hydrolysis stock solutions should not be stored for
long periods.
Reaction with Cellulosic fiber
Reactive dyes formed covalent bond with cellulosic fiber by Nucleophilic substitution and
addition reaction. The reactions are as follows ----Substitution reaction:
D R Cl + HO - Cell D R O Cell + HCl
52
Addition reaction:
D F CH2 = CH2 + HO Cell D F CH2 CH2 O Cell
Reaction with water:
The cold brand reactive dyes are highly reactive in nature. They react also with water and
get hydrolyzed. The reaction is as follows ---D R Cl + HOH D R OH + HCl
The hydrolyzed dye is also colored substances and has very low substantivity for the
cellulosic fiber. So they are attached with fiber surface after dyeing. If they do not washed
away from the fiber surface the fastness property of the fiber must be very low.
Salts used for Reactive Dyeing
Depends on the substantivity, salts like common salt (NaCl) or Glaubers salt (Na2SO4) is
used.
Alkalis for Reactive Dyeing
The common alkalis used for reactive dyeing are sodium bi-carbonate (NaHCO3), sodium
carbonate (Na2CO3), sodium hydroxide (NaOH), sodium silicate (Na2SiO3) and sodium
phosphate (Na3PO4). Sodium silicate is very strong alkali and only used for deep dyeing.
Sodium carbonate is mostly used alkali in reactive dyeing.
Eliminating the hydrolyzed dye
The hydrolyzed dye is also colored substances and has very low substantivity for the
cellulosic fiber. They tend to stay on the fiber surface after dyeing for sometimes although
there is no bond between the dye and the fiber. These unfixed dyes come of the fibers when
washed or rubbed subsequently. If they do not washed away from the fiber surface the
rubbing and wash fastness property of the fiber must be very low. The presence of
electrolytes in the washing water causes an increase in the hydrolyzed dye affinity making it
difficult to extract, therefore very saline water must be avoided even if this water
conditioned.
53
Optical Brightener
Optical brighteners, optical brightening agents (OBAs), fluorescent brightening agents
(FBAs) or fluorescent whitening agents (FWAs) are dyes that absorb light in the ultraviolet
and violet region (usually 340-370nm) of the electromagnetic spectrum, and re-emit light in
the blue region (typically 420-470nm). Fluorescent activity is a short term or rapid emission
response, unlike phosphorescence, which is a delayed emission. These additives are often
used to enhance the appearance of color of fabric and paper, causing a perceived
"whitening" effect, making materials look less yellow by increasing the overall amount of
blue light reflected.
Properties
The most common classes of chemicals with this property are the stilbenes and older,
noncommercial fluorescent dyes such as umbelliferone, which absorb energy in the UV
portion of the spectrum and re-emit it in the blue portion of the visible spectrum. A white
surface treated with an optical brightener can emit more visible light than that which shines
on it, making it appear brighter. The blue light emitted by the brightener compensates for the
diminishing blue of the treated material and changes the hue away from yellow or brown
and toward white.
There are approximately 400 brightener types listed in the Color Index, but less than 90 are
actually produced commercially and only a handful are commercially important.
Generically, the C.I. FBA number can be assigned to a specific molecule, however, some are
duplicated, since manufacturers apply for the index number when they produce it. The
global OBA production for paper, textiles and detergents is dominated by just a few di- and
tetrasulfonated triazole-stilbenes and a di-sulfonated stilbene-biphenyl. These are subject to
fading when exposed long term to UV, due to the formation of optically inactive stilbene
cisisomers found at the center of the molecule. All brighteners have extended conjungation
and/or aromaticity, allowing for electron movement. Some non-stilbene brighteners are used
in more permanent applications such as whitening synthetic fiber.
Basic class types of brighteners include:
Triazine-stilbenes (di-, tetra- or hexa-sulfonated)

Coumarins
Imidazolines
Diazoles
Triazoles
Benzoxazolines
Biphenyl-stilbenes
54
Brighteners can be "boosted" by the addition of certain polyols like high molecular weight
polyethylene glycol or polyvinyl alcohol. These additives increase the visible blue light
emissions significantly. Brighteners can also be "quenched". Too much use of brightener
will often cause a greening effect as emissions start to show above the blue region in the
visible spectrum. Besides the formation of cis isomer in stilbene-containing brighteners
(only the trans isomer is optically active), continued exposure to UV-containing light will
actually cleave the molecule and start the process of degradation.
Common uses
Brighteners are commonly added to laundry detergents to replace whitening agents removed
during washing and to make the clothes appear cleaner. Optical brighteners have replaced
bluing which was formerly used to produce the same effect. Some brighteners can cause
allergic reactions when in contact with skin, depending on the individual.
Brighteners are used in many papers, especially high brightness papers, resulting in their
strongly fluorescent appearance under UV illumination. Paper brightness is typically
measured at 457nm, well within the fluorescent activity range of brighteners. Paper used for
banknotes does not contain optical brighteners, so a common method for detecting
counterfeit notes is to check for fluorescence.
A side effect of optical whitening is to make the treated fabrics more visible with Night
Vision Devices than non-treated ones. This may or may not be desirable for military or other
applications. Optically brightened paper is often not useful in exacting photographic or art
applications, since the whiteness decreases with time.
Endues of optical brighteners include:
Detergent whitener (instead of blueing agents)

Paper brightening (internal or in a coating)
Fiber whitening (internal, added to polymer melts)
Textile whitening (external, added to fabric finishes)
55
Mercerization
Mercerized cotton is cotton which has been treated with sodium hydroxide to bring
out certain properties first discovered by John Mercer in 1851. In 1890, Horace Lowe
added an additional step to the process, and the British cotton industry began to take
an interest in mercerized cotton, which is available today in a wide range of
incarnations from thread to completed garments. When treated properly, mercerized
cotton is stronger, smoother, and shinier than regular cotton. In addition, it takes dye
more readily so that manufacturers can create rich color saturation in their cottons.
The brilliant, lustrous hues of Mercerized cotton can be found in fabric stores, yarn
shops, and department stores all over the world.
John Mercer discovered that immersing fibers such as cotton and linen in a caustic
soda bath would increase their strength and also allow them to take dye more readily.
He patented his fiber work, but the cotton industry did not express very much interest
in it. It was Horace Lowe who popularized the process, by discovering that keeping
the fibers under tension while they were soaked yielded a more lustrous thread.
Mercer's name is presumably given to the process to recognize his important initial
discovery, which paved the way to Lowe's refinement of the treatment. Mercerization
starts with gathering the cotton and spinning it normally. Because cottons with long
fibers take better to mercerization, Pima, Egyptian, and Sea Island cotton are usually
chosen for the process. The cotton thread is held under tension and submerged in a
highly alkaline bath of sodium hydroxide in a percentage which ranges, but usually
hovers around 22%. After treatment, the mercerized cotton is placed into an acidic
bath to neutralize it. Once this process is complete, the cotton can be dyed and
knitted, woven, or packed as standalone spools of thread.
The terms "pearl cotton" and "pearle cotton" are also used to refer to Mercerized
cotton, because of the deeply lustrous appearance of the finished cotton thread. In
addition to having rich color saturation and a shimmering appearance, mercerized
cotton is also much stronger than conventional cotton thread. The process shrinks the
cotton fibers, tightening and smoothing the grain of the thread. Because the cotton is
preshrunk, mercerized cotton also tends not to shrink as much as regular cotton, so
consumers can be more confident about the fit of mercerized garments.
56
Mercerization Process
Single Mercerization is a process in which the yarn used to make a shirt is run
through the middle of an open flame at a very high speed. It passes through so
quickly that the yarn itself doesn't burn but the millions of fuzzies and slubs on the
yarn are eliminated instantly. This makes the yarn stronger. Since there is no fuzz on
the yarn, it is held together better and can no longer unravel by it-self. The yarn is
also less prone to shrinking because the mercerization process literally pre-shrinks
the fabric. Mercerization also cleans the yarn and gives it a strong affinity for dye.
While normal cotton yarn has no clarity or depth to it's color, Mercerized yarn
accepts the dye much better and the colors come out deeper, sharper and have a very
clean look. The fabric now looks and feels ten times better. Single Mercerization is a
huge step up from the quality of regular cotton shirts but Double Mercerization takes
it even a step further. During the knitting process some fuzzies will ultimately
resurface. In Double Mercerization the knitted fabric undergoes a second
Mercerization process to remove these. The fabric is placed in a chemical bath using
caustic soda to once again remove any additional fuzzies or slubs and is then washed
clean. This makes the fabric even stronger and makes it look and feel even better. It
has a luster and sheen that is unmatched. Double mercerized fabric feels so soft and
smooth its look and feel can easily be mistaken for silk.
57
Chapter-6
Chemical Laboratory
58
Chemical Lab Lay-Out
59
Description of the Chemical Lab Layout
60
Introductory instruments of Chemical Lab:
These following equipment are used in chemical lab:

Conical Flux
Glass Beaker
Glass Cylinder
Pipette Werrtlab
Glass Rod
Dyes Pot
Dyes or Caustic measurement steel spoon
Hand Gloves
Mask and Googles
Pipette Filter
Burrette
PH Meter
Balance
Plastic Beaker
Scotch Tape, Maskin Tape, Both side tape
Scotch Tape Holder
Volumetric Flask
PH Paper
Peroxide Paper
Thermometer
Caustic Boume Meter
Firsape Beaker wash brush
EDP
Scussor
Burrette stand
61
Chemical Lab Organogram:
Senior Manager
Deputy Manager
Executive -i
Executive-ii
Senior Lab assistant
Lab assistant
Junior lab assistant
62
Working Procedure for Chemical Laboratory:
Requisition receive from buyer/ merchandiser

Standard receive from buyer/merchandiser
Recipe open by visually/data color
Combination select by lab/floor responsible person
Fabric record list by PO/APO
Fabric requisition to knitting according to buyer requirement
Coming fabric from knitting and dyeing floor checking
Checking issues:
Buyer
Style Number
NRG Number
Yarn Lot
Yarn count
Fabric composition
Fabric type
Fabric absorbency
63
Fabric whiteness
Bio kill/Remove H2O2
Lab Machineries:
1. Machine Name: Auto Dispenser
Company Name: TLOS
Country Name: Greece
Function: At a time 24 solutions are done
Capacity: Accuracy .0001
Description: - Auto dispensing system is used.
- Robolab software is used.
- Powder Beaker
- EDP is not possible 2 unit maximum but possible at Robolab
- Glass beaker number is 84.
2. Machine Name: Ahiba IR (Pro)
Company Name: Data Color

Country Name: USA
64
Fiber Type: All

Minimum Liquor Ratio: For natural 1:5, For Synthetic 1:4
Temperature Ratio: 20-1400 Celcius
Infrared Lamp: 3 KW
Speed: 5-50 (Selectable)
Program Storage: Up to 99 programs
Languages: 7 Languages
3. Machine Name: Top Speed II
Company Name: Ahiba

Nuance
Country: USA
Function: Dyeing is done with
program setting.
65
4. Instrument Name: Sink
Nomenclature: Washing Chamber

Function:
- Here, some soaping chemicals are used. For example: ADW
and Ladiquest can be mentioned.
- Hot and cold wash is done.
5. Machine Name: Washing Machine

Nomenclature: Rapid washing machine
Country: USA
Conical Flux Number: 24
Functions: - Hot wash is done at 950 Celcius

- 1st wash is done at 15 minutes
- 2nd wash is done at 15 minutes, i.e, 30 minutes is required
66
6. Machine Name: Quick Wash

Company Name: SDL ATLAS
Country: China
Functions: - Yarn and fabric is washed by spin

- Water is out from fabric or yarn
- Required time 20 seconds
7. Machine Name: Microprocessor PH meter

Company Name: Hanna
67
Country: USA
Nomenclature: Memorizing Reading
Functions: - Memorizing reading
- Memory recall
- Select PH
8. Machine Name: Spectrophoto Meter
Brand Name: Data Color

Country: USA
Rating: 100-240V, 47-263 Hz, 100V A
Functions: - Software recipe formulation
-R value input
-Color fastness assessment
68
9. Machine Name: Light Box

Model: CAC 120-5
Serial Number: E883806
Type of tests: All color fastness
Used Methods: C01, C08, E01, E04, X12 or EOS
Lights Used: CWF, D65, TL 84, UV
10. Machine Name: EDP (Electronic Digital Pipette)

Country: USA
Function: This device complies with 15-j fec rules.

Capacity: 10 ml
11. Machine Name: Electronic Digital Balance
Company Name: OHAOS Crop, Usl
Country: USA
69
Maximum Capacity: 110 grams

Functions: Measurement of salt, soda and different types of fabric samples.
Working Procedure of dyeing in chemical Lab:

The following flowchart is strictly maintained throughout the chemical lab procedures. And
is compulsory to maintain it if we are to ensure maximum quality product with highest
efficiency. The flowchart is given below---
70
Stock solution preparation

Pipetting preparation
Bleached fabric loading
Salt dosing
Machine loading and running
Soda, Alkali dosing and running
Unload
Dryer
Keeping record
71
Process Flowchart Description:
Data Color and PH Meter Calibration System:

Data color should be calibrated 3 times a day between 5.0 AM to
6.0 AM, 1.0 PM to 2.0 PM and 9.0 PM to 10.0 PM.
PH meter should be calibrated 3 times a day.
PH buffer should be replaced once per week.
Fabric preparation for Lab dip and Bulk Checking:

Find the correct fabric for dyeing.
Take accurate measurement as possible and try not to hurry. The fabric weight should
be written on the right corner of the top of worksheet.
Do the quick wash process completely and load the fabric immediately after quick
wash. After Quick wash amount of water inside fabric vary each and every minute.
For bulk checking, order number, yarn lot, GSM could be 100% maintained as per
worksheet information.
Stock Solution Preparation:
Prepare the stock solution daily morning.

Use cold water to dissolve dyes.
Take accurate measurement of solid powder dyes keeping all air condition off.
Prepare stock solution of 0.001%, 0.1%, 0.5%, 1.0%, 2.0%, and 4.0% only for dark
and navy shades.
Worksheet Preparation: While preparing worksheet, we have to write properly fabric

construction, Buyer name, Color code, Recipe number, Liquor ratio, Program number,
Fabric code and Style number very carefully.
72
Salt Measurement System:

Take accurate measurement of Glauber or Refined salt.
Make sure that Glauber or Refined salt is used.
Measure the entire salt amount within 15 minutes.
Loading System:
Sensor water change.

Correct program and follow the monitor graph.
Follow the machine temperature.
Dont open the door after temperature exceeding 800 Celcius.
If the rubber cap gets broken then it must be changed.
Follow the program.
Follow the full time during dyeing.
Soda dosing in due time.
Dont left pipettes pot open for more than half an hour.
Load the batch within half an hour after pipetting.
Wash Off: For washing off samples after dyeing following flowchart is followed on
Chemical Lab:
73
Unload
Cold wash
Neutralization with Sirrix NE (0.50 g/l)

PH =6.0-6.50 adjusted at 500 Celcius temperature
Soaping (Eriopon OS)
Hot Wash (Rapid Machine)
Drying
Dry the sample:
After washing, the samples are kept in quick wash machine for 0.5-1.0 minutes. Also
carefully maintain the fact that counting the sample correctly to put in and out for
avoiding the outline problem.
Fabrics samples are lye on, on the dryer and yarn keep spreading.
Cotton fabrics sample should be dry on Tumble dryer and polyester, yarn dry on the
line dryer as per setting temperature,
After drying, the sample is kept out and relaxed then attached to the worksheet for
evaluation.
74
Data Color Report:

Measure the standard swatch and save.
Measure the sample with actual standard or swatch.
Different types of data value write on the worksheet properly according to the
sample number.
Visual Assessment:
Buyer wise light source selection before shade checking.
Malting the shade with actual standard and data value reports.
If the shade is 95%+ matching visually and data value report could be selected.
Final Shade Selection: For final shade selection, lab employees have to follow buyer
selected light source, requirement tolerance, direction etc.
Shade Submission for Approval:

Selected samples are submitted according to the buyer requirements, date, style,
order number.
The submitted samples and writing out looking must be fine without overwriting.
Table Work: Here in NRG Composite Yarn Dyeing Ltd. chemical lab, some processes are
maintained carefully. Such as
Buyer list
Production card making (Yarn)
Production card making (Fabric)
Lab Dip submission.
75
Lab dyeing Program and Procedure: For Cellulosic Material
Sample+Color+Salt+Levelling agent (Albatex 1 g/l)
600 x 20 min
Machine halt for dosing
Dosing soda ash and caustic soda
600 x 20 min
Machine stop
Rinse
Neutralization with Acetic Acid
Soaping using rapid soaping machine
Washing
Drying
76
Program for Polyester:
Sample + Color + Underdin DIF (1 g/l) + Albatex AB 45 (1 g/l)
30x45
Lowering temperature at 600 Celcius
Machine Stop
Reduction clearing by Rapid soaping machine [Hydrose (1 g/l)+NaOH (1 g/l)]
Neutralization
Washing
Drying
77
Program: Turquoise Color
Sample+Colo+Salt+Leveling [Albatex DBC (1 g/l)]
80 x 20
Cooling at 700 Celcius [
40C/min]
Machine halt for dosing
Dosing soda ash and caustic soda
800 x 40
Machine Stop
Rinse
Neutralization with Acetic Acid
Soaping using Rapid soaping machine
Washing
Drying
78
Dyes Name
Supplier Name
Novacron Navy FN-BN
Huntsman
Novacron Dark Blue W-R
Huntsman
Novacron Red FN-2BL
Huntsman
Novacron Ruby S-3B
Huntsman
Novacron Yellow NP
Huntsman
Novacron Blue FNR
Huntsman
Novacron Blue TS 3G
Huntsman
Novacron TS-GC
Huntsman
Novacron Ocean SR
Huntsman
Novacron Deep Orange S-4R
Huntsman
Novacron Deep Cherry S-D
Huntsman
Novacron Deep Night SR
Huntsman
Novacron SScarlet FN-6G/C-6G
Huntsman
Novacron Brill Red FN-3G
Huntsman
Cibacron Super Black G/Novacron
Huntsman
Cibacron Super Black R/Novacron
Huntsman
Corafix Violet GDB
Hi-Tech color-chemicals
Moderzol Black F-C-N
TMA Corporation
Moderzol Turquoise Blue G-133%
TMA Corporation
Moderzol Turquoise Blue G-266%
TMA Corporation
Drimaren Navy CL-R
Clariant Export AG
Drimaren Navy K3R
Clariant Export AG
Kimsoline Red KLL
Kimsoy
Kimsoline Yellow KLL
Kimsoy
Kimsoline Blue KLL
Kimsoy
79
Kimsoline Br. Blue DBR
Kimsoy
Kimsoline Red KED
Kimsoy
Vivizol Red DBR
Kimsoy
Blue Shade BL
Kimsoy
Yellow Shade SL
Kimsoy
Red Shade 3B
Kimsoy
Parafix Turquoise Blue G266%
Celustar Dye-Chemicals
Liyuansol Turq Blue-266%
Liyuansol Blue RSPL 150%
Levafix Blue CA Gran
Dystar
Levafix Brill Red E-4BA
Dystar
Levafix Brill Red E-BA
Dystar
Levafix Brill Red F-6BA
Dystar
Levafix Amber CA/CA-N
Dystar
Levafix Brill Blue E-FFN
Dystar
Levafix Fast Red CA
Dystar
Levafix Orange CA
Dystar
Levafix Brill Yellow CA
Dystar
Remazol Luminous Yellow FL
Dystar
Remazol Dark Blue SLT
Dystar
Remazol Red RR
Dystar
Remazol Blue RR
Dystar
Remazol Brill Blue BB New GM 133
Dystar
Remazol Brilliant Yellow 3GL
Dystar
Remazol Yellow RR
Dystar
Remazol Deep Red RGB
Dystar
Remazol Red RGB Gran
Dystar
Remazol Golden Yellow RGB Gran
Dystar
80
Remazol Brill Red F-3B
Dystar
Remazol Ultra Carmine RGB
Dystar
Remazol Ultra Yellow RGB
Dystar
Remazol Navy Blue RGB
Dystar
Remazol Green 6B-T
Dystar
Remazol Turquoise GN 266%
Dystar
Remazol Turquoise Blue G133%
Dystar
Setazol Blue R Special
Satas Kimya
Setazol Brilliant Red SB
Satas Kimya
Sunzol Ultra Yellow RGBN/GRBN
Huntsman
Solophenyl Yellow ARLE-154%
Huntsman
Solophenyl Red 7BE
Huntsman
Solophenyl Blue FGLE
Huntsman
Everzol Yellow 3GL
Everlight
Everzol Turquoise Blue G
Everlight
Everzol Navy Blue GG
Everlight
Everzol Blue ED-G
Everlight
Everzol Brill Blue RSPL
Everlight
Everzol Black GR
Everlight
Eibazol Black HG/ Superb Black
Well Prospering
Avitera Yellow SE
Huntsman
Avitera Deep Sea SE
Taha Colors
Avitera Light Red SE
Taha Colors
Avitera Light Blue SE
Taha Colors
Avitera Blue SE
Taha Colors
Avitera Orange SE
Taha Colors
81
Avitera Red SE
Taha Colors
Avitera Deep Blue SE
Taha Colors
Jinjipai Red SNE
Taixing Jinyun Dye
Jinjipai Turquoise HFG (266%)
Taixing Jinyun Dye
Argazol Brilliant Blue RSPL/ R Conc
Argus
Bezaktiv Navy SBL
Bezema
Bezaktiv Blue V RSPL
Bezema
Bezaktiv Red S-2B
Bezema
Bezaktiv S-3B
Bezema
Bezaktiv Yellow S-3R
Bezema
Bezaktiv Violet V-5R
Bezema
Capacity of the Lab:

Total Sample Dyeing machine: 07
Total Pot/ Beaker: 95 pieces
Per day sample delivery: 30 shades
Per month Sample delivery: 900 shades
82
Buyers of N.R GROUP Fashios Ltd. are named below:
Tema
Beratta
S. Olivier
Leross
M and S
E. Straws
Esprit
Malfini
Puma
MPL
Mexx
Casamoda
C. House
Creasion
Mothercare
Police
Ashcity
Grey Stone
H&M
83
Chapter-7
Production Planning Sequence
Operations
Knitting:
Knitting is a method by which yarn is manipulated to create a
textile or fabric .Knitting creates multiple loops of yarn, called
stitches, in a line or tube. Knitting has multiple active stitches
on the needle at one time. Knitted fabric consists of a number
of consecutive rows of interlocking loops. As each row
progresses, a newly created loop is pulled through one or more
loops from the prior row, placed on the gaining needle, and the
loops from the prior row are then pulled off the other needle.
Types of Knitting:
Warp Knitting
Weft Knitting
Knitting Floor Lay- Out:
84
Specification of Knitting Machine:
Different circular knitting m/c:
PAILUNG S/J CERCULAR KNITTING M/C

Knitting M/C
85
MAYER & CIE S/J Circular
Important components of Knitting M/C:
\
Standing Creel
Feeder
Needle
Cam
86
Positive
Yarn Guide
Cylinder
87
VDQ Pulley
Fabric Spreader
Function of different parts of the machine:
88
Yarn Package Career: Yarn package career contains the

yarn.
Needle: An element which forms loops and wales.
Tricks: Slots which guide needles during knitting.
Cylinder: A cylinder drum which contains slots, needles and
sinkers.
Dial: A horizontal plate which contains slots and horizontal
needles.
Yarn Guide: Its guide the yarns from package to Dial/Cylinder
Dial Cams: It helps in the movement of dial needle.
Cylinder Cams: Its helps in the movement of cylinder needle.
Oiling: Oiling needs in knitting m/c because of abrasion free
movement of needles cams.
Sensors: Sensors used in knitting m/c find out the yarns
breakage during knitting process.
Motor: Motor is the top most important parts of knitting m/c.
Motor is used to transfer the motion to cylinder and Dial.
Roller: Rollers are used to take up the fabric.
Belts: Belts are used to connect the pulley to each other.
Yarn Path diagram:
89
Raw Materials:
Cotton yarn
Carded yarn
Combed yarn
Organic cotton
Viscose Yarn
Modal yarn
Mlange yarn
Ecru Mlange
Synthetic
Polyester
Nylon
90
Acrylic
Elastomeric
Blend
PC
Mlange
CVC
91
PRODUCTION PLANNING, SEQUENCE AND OPERATIONS:
PRODUCTION PARAMETERS:
a. pH:
During H2O2 bleaching pH 9.2 12
During reactive dyeing pH 10.5 12.5
During disperse dyeing pH 4.5 6.0
b. Temperature:
For cotton scouring 900-950C

For cotton cold wash 300 400C
For cotton hot wash 700-800C
For cotton acid wash 600-700C
For cotton dyeing
800-900C (For hot brand)
600C (For cold brand)

Polyester dyeing: 1000-1300C
c. Time:
For scouring 60-90 mins

For reactive dyeing 60-90 mins
For disperse dyeing 60-90 mins
92
d. M:L ratio:
For reactive dyeing M:L ration maintained beween 1 : 7.5 to 1 :

10
DESCRIPTION OF PRODUCTION PROCESS:
Washing for colored fabrics:
The colored fabrics to be washed is loaded in the machine

Required amount of water is taken
PCLF (detergents) added & washing continued at 800C for 20
mins
Cold washing
Scouring-bleaching:
Fabric to be scoured is loaded in the machine
Required amount of water is loaded
Washing agent/ detergent is added
Steam pipes are on & scouring agents (i.e. Caustic soda/ Soda
ash) added when the temperature reaches at 500C
When the temperature reaches at 600C then stabilizer is added
Then H2O2 is added
93
Temperature is then raised to 900C and the process is then

carried out for 60-90 mins depending on the requirements
The liquors are then drained
Then cold wash at 300-400C, hot wash at 700-800C and acid
wash at 600-700C is done
Dyeing:
After acid wash all liquors are drained out
Required amount of water is taken
Then leveling agents, anti-creasing agents, de-foaming agents
are added according to the requirement
Steam pipes are on & after 10-15 mins dyes are added
Salts are added after another 30 mins
Then soda ash after another 30 mins
Then the temperature is raised slowly up to the mark
The process is carried on and samples are taken after every
30-40 mins to match with the target shade. It continues until
shade matching.
If the sample is matched, then the liquors drained out
Then cold wash at 300-400C, hot wash at 700-800C, acid wash at
600-700C is done
Then softener is added at 400C for 20-30 mins
Fixer is applied for deep shade only before adding softener
94
Re-dyeing:
When shade is not matched then fabric is treated again in
dyeing machine for shade matching is known as re-dyeing.
Generally, re-dyeing is done if the shade is deeper than the
target shade. It may occur when the fabrics absorb one or two
colors more or less. One re-dyeing process is described below.
Drain the let off solution

Hot wash at 700-800C
Acid wash at 600-700C(600 for light shade & 700 for deep
shade).
Soda ash washes at 900-1000C for 60mins to reduce the depth
of shade.
Acid wash at 600C.
Addition to required dyestuffs.
Salt addition.
Soda ash addition.
Other operations are same as previous described dyeing
operations.
95
PRODUCTION FLOW CHART:

Production flow chart for 100% cotton
Grey fabric loading
Scouring & Bleaching at 95oC for 1 hour
Scou g HO + (95oC x 15)
H2O2 killer [invotex PC or gazyme PC]
A.Acid
Enzyme [pH 4 4.5, temp 60oC for 40-60]
Hot wash
Levelling [Ladiquest 1097]
Dyeing
Salt
Color
Soda
A. Acid
Hot wash [Decol SN, RSK, RFL]
Fixing [VNF, ECO]
Softener [LCF, Non ionic]
Unload
96
Scouring
Scouring H2O2
& bleaching
hot
killer A. acid
950C
1 hr
15 m
leveling
salt
dye
700C
600C
enzyme Hot wash agent
45 60 min
4 0 min
matl
cold wash
400C
Dyeing curve of 100% cotton fabric with reactive dye
CVC DYEING SEQUENCE:
97
soda
98
DYEING SEQUENCE FOR WHITE:

Scouring + bleaching, 950
Blutton 50'
15' Sample test
Water drain
Hot (without chem.: at 800C for 20')
A.cAcid
If OKIf not oK
SequesterSoftener
Softener
Unload
Unload
dye
Detergent +
800C
20
material
1300C 50
scourig
950C
Leveling &
Cold wash buffering agent
A. Acid
salt
R. dye
Soda
600C 50
600C
400C
Cold wash &
DYEING CURVE OF PC / CVC FABRIC WITH REACTIVE / DISPERSE DYES
99
Procedure for white colour:
Fill water and fabric loading
Addition of auxiliaries (Leveling agent, Sequestering agent,

Anti-creasing agent, Antifoaming agent)and runtime 10 min
Raise the temp at 60 degree
Alkali dosing (70% progressive dosing)and runtime 10 min
Addition of Hydrogen peroxide and no runtime
Dosing of optical brightening agent at 70 degree and runtime

20 min
Raise the temp at 98 degree and runtime 60 min
Cooling at 80 degree
Drain out and fill water
Addition of soaping agent

100

Raise the temp at 98 degree and runtime 10 min
Cooling at 80 degree and drain out
Fill water again
Neutralisation with Acetic acid at 40 degree and runtime 10

min
Rinse 5 min and Drain out
Fill water again
Softening with softener with normal water and runtime 30 min
Rinse 5 min and drain out
Unload fabric
Blend dyeing:
Polyester part dyeing procedure:

101

Fill water and Load fabric in machine
Addition of Buffer solution
Addition of dispersing agent
Dosing of Disperse Dye (Linear dosing)
Runtime 40 min for light shade/60 min for dark shade
Hydrose +Caustic at 80 degree and runtime 20 min
Neutralization with Acetic acid at 50 degree and runtime 10

min
Rinse 5 min and fill water
102

Addition of soaping agent and raise the temp at 98 degree and
runtime 10 min
Rinse temp 5 min and Fill water again
Addition of fixing agent and runtime 10 min
Rinse 5 min and fill water again
Unload fabric
103
Cotton part dyeing procedure:
Fill water in machine
Fabric load in machine
Raise the temp of 60 degree
Auxiliaries addition (Leveling agent, Sequestering agent,

Anti*creasing agent, Anti-foaming agent)
Alkali dosing( 70% progressive dosing)in 10 min
Addition of hydrogen peroxide at 70 degree, no run time
Raise the temp at 98 degree , runtime 60 min
104
Drain out
Filing water in the machine again
Addition of soaping agent
Raise the temp at 98 degree, runtime 10 min
Drain out
Fill water again
Neutralization with Acetic acid
Rinse temp at 50 degree and run time 10 min
Check pH (should be 5.5)
Drain out
Fill water in machine again

105

Addition of auxiliaries (Leveling agent, Sequestering agent,
Anti-creasing agent, Antifoaming agent) and runtime 10 min
Salt dosing for 10 min (salt circulation) and runtime 20 min
Dye dosing for 30 min (linear dosing) and runtime 30 min
Alkali dosing for 40 min at 70% progressive dosing
Raise the temp at 65 degree with temp gradient 1.5degree/

min and runtime 60 min
Bath drain
Rinse 1 or 2 times depend upon dye shade and runtime 10 min
Neutralisation with Acetic acid at 50 degree and runtime 10

min
Rinse 5 min and fill water
106
Addition of soaping agent and raise the temp at 98 degree and

runtime 10 min
Rinse temp 5 min and Fill water again
Addition of fixing agent and runtime 10 min
Rinse 5 min and fill water again
Unload fabric
Dyeing faults:
Dyeing faults are given as below:
Patchy effect :
Reasons:
107
1.
Entanglement of fabric.
2.
Faulty injection of alkali.
3.
Faulty color addition.
4.
Due to hardness of water.
5.
Due to impure salt addition.
Remedies:
By partial or full stripping of dyed fabric.
Roll to Roll variation / Meter to Meter variation :

Reasons:
1.
Yarn lot mix
2.
Faulty heat setting
3.
Hardness of water.
4.
Faulty m/c speed.
Dye-stain :
Reasons:
1.
Un-dissolved dye particle in bath.
2.
Un-dissolved caustic particle in bath.
Remedies:
By partial or full stripping
108
Crease mark :
Reasons:
1.
If pump pressure & reel speed is not equal.
2.
Due to high speed m/c running.
4.Rub mark:
Reason :
1.
Due to reel cranking .
2.
Due to sharp point of nozzle.
3.
Due to sharp delivery roller.
5.Nozzle to Nozzle variation :

Reason :
Pump pressure & reel speed is not equal.
109
STANDARD RECIPE OF SCOURING

& BLEACHING OF UKDL
SCOURING & BLEACHING:
DEEP SHADE
01. ALBATEX FFC
: 0.15 G/L
02. LADIQUEST 1097
LIGHT SHADE
: 0.15 G/L
: 0.25 G/L
: 0.25 G/L
03. CIBAFUUIDE C : 0.50 G/L
: 0.50 G/L
04. HOSTAPOL JU
: 2.00 G/L
: 2.00 G/L
05. CAUSTIC SODA : 2.50 G/L
: 2.00 G/L
06. SODA ASH
: 2.50 G/L
: 2.00 G/L
07. STABILIZER SF. : 0.35 G/L
: 0.30 G/L
08. H2O2 (50%)
: 3.50 G/L
: 3.00 G/L
09. ACETIC ACID
: 1.00 G/L
: 1.00 G/L
10. INVATEX PC
: 0.30 G/L
: 0.25 G/L
: 0.50 G/L
: 0.50 G/L
LEVELLING:
01. CIVAFLUDIE c
02. LADIQUEST 1097
(FOR LYCRA S/J
: 0.80 G/L
CIBAFLUIDE C
: 0.60 G/L
: 0.70 G/L)
LEVELLING: FOR TURQUISE BLUE, R-BLACK, ROYEL COLOUR
110
01. CIBAFLUIDE C
: 0.70 G/L
02. LADIQUEST 1097

03. E2R
: 1.00 G/L
: 0.50 G/L
[ FOR WHITE SHADE ]

H2O2 ( 50% )
: ( 4.00 G/L - 7.00 G/L)
111
White Dyeing Recipe For (100% Cotton)

Buyer Name :
Farnoorr M : L
Order No
Cross line
Batch No
19100
1:8
Mtl wt.
Water
100 kg
800 Liter
Fabric Type :
(1 * 1) Rib
G. S. M.
200 210 Colour
Serial No
Name
Dosing
(g/l)
Quantity
01
Hostapol JU
0.20
160 gm
02
Cibafluide-C
0.20
160 gm
03
Albatex FFC
0.20
160 gm
04
Cibafluide C
0.73
584 gm
05
Hostapol JU
1.20
960 gm
06
Sequester K
1.00
800 gm
07
Caustec Soada
2.25
1.80 Kg
08
Soda Ash
1.00
800 gm
09
Stabilizer SF
.30
240 gm
10
H2O2
4.00
3.20 Kg
11
BLUETONE BVB
0.21 %
210 gm
12
Acetic Acid
0.60
480 gm
13
Sequester K
0.40
320 gm
14
Softener (Non Ionic)
1.50
1.20 Kg
Fab dia. =
42 inch
White
112
Remarks
950 C , 60
min
Prepared by :
Checked by : ..
Dyeing Incharge : .
Production Manager : ..
113
Colour Dyeing Recipe (100% Cotton)

With Reactive Dye
Buyer Name :
D. S. L
Order No
Cross line
Batch No
19100
Water
Fabric Type :
S/J
Fab dia. =
G. S. M.
160 170 Colour
M:L
1:8
Mtl wt.
100 kg
800 Liter
42 inch
Navy
Serial No
Name
Dosing
(g/l)
Quantity
01
Hostapol JU
2.00
1.60 kg
02
Ladiquest 1097
0.40
320 gm
03
Albatex FFC
0.15
120 gm
04
Cibafluide C
0.50
400 gm
05
Stabilizer SF
0.50
400 gm
06
Soda Ash
2.50
3.60 kg
07
Caustec Soada
3.00
2.40 Kg
08
H2O2
4.00
3.20 Kg
09
Acetic Acid
1.00
800 gm
10
Invatex PC
0.15
120 gm
11
Cibafluider C
0.50
400 gm
12
Ladiquest 1097
0.80
640 gm
13
Reactive S
Yellow F3R
0.33 %
330 gm
14
Reactive S Red
F3B
0.79 %
790 gm
114
Remarks
15
Reactive Black
5
4.20 %
4.20 kg
16
Salt
62.00
49.60 kg
17
Soda Ash
20.00
16 kg
18
RFL
0.80
640 gm
19
A. Acid
1.00
800 gm
20
Softner (Non
Ionic)
1.00
800 gm
Scouring
Scouring H2O2
& bleaching
hot
killer A. acid
950C
1 hr
15 m
leveling
salt
dye
700C
600C
enzyme Hot wash agent
45 60 min
4 0 min
matl
cold wash
400C
Dyeing curve of 100% cotton fabric with reactive dye
115
soda
REMARKS:
NRG strictly follow the production parameters like the time,
temperature, M:L ratio pH etc. As they do some difficult shade,
it takes more time for the production of the batch. Because of
the trolley shortage and generator failure, the production
process is sometime hampered. Considering these limitations,
the production officer and the Sr. Production Officer try their
best to reduce the production time.
116
Chapter-8
Quality Assurance Department (QAD)
117
NRG Composite Yarn Dyeing Ltd. is more concern about quality. In this factory quality
assurance is more preferred than quality control, but both are in advancement. The Quality
Assurance Department is assigned to maintain consistently uniform quality of the material in
process and various stages of its manufacturing.
Objective of Quality Control:
Research
Selection of raw materials
Process control
Process development
Product testing
Specification test
Scope of Quality Control, Quality Assurance and Testing:
Testing Lab
Machine auditing system
A good training system
Excellent analytical backup
Technical expertise
Quality Control Procedure:
On line quality control
Off line quality control
Off-Line Tests:
118
Quality Control Flow Chart:
119
List of Equipments:
Machineries & equipment used:
Spectrophotometer with Software (Data Color)

Martindale Abrasion Tester
Day Light Box
Sample Dyeing Machine (5)
ROBO Lab
Iron
Electric Balance
Crock Meter
Washing Machine (Electrolux Wascator/Siemens)
GSM Cutter
PH Meter
ICI Pilling Box
Martindale Pilling Machine
Bursting Strength Tester
SDL ATLAS Rotawash
Perspirometer
Xenon Test Chamber
Mechanical Shaker Machine
Fabric Inspection:
The inspection of fabric is a procedure by which the defects of fabric are identified and
fabric is classified according to degree or intensity of defects. The fabric inspection is done
for both grey and finished fabric.
Grey Fabric Inspection:
In NRG Composite Yarn Dyeing Ltd. grey fabric inspection is performed according to 4
point system.
Four-Point System:
Size of Defect
Penalty
0 inches to 3 inches
1 point
2 point
3 point
More than 9 inches
4 point
120
Acceptance Calculation:
Any Hole 4 Point

Up to 20P/100m = Class A
Upto 20-30P/100m = Class B
Upto 30-40P/100m = Class C
More than 40P/100m = Reject.
Faults found during Grey Fabric Inspection:
Wrong Design:
Causes:
Wrong insertion of yarn during knitting.

Wrong setting of fabric design in knitting machine.
Lycra out:
Causes:
Lycra tears out during running the machine for production.
Barrie Mark/Patta:
Causes:
Yarn package is either hard or soft.
Lot mixing of yarn.
Improper yarn tension.
Uneven yarn dyeing.
121
Thick & Thin:

Causes:
Diameter of yarn is uneven i.e. yarn irregularity.
Variation of yarn tension in course wise direction.
Sinker Mark:
Causes:
Defective sinker.
Dust in sinker.
Improper servicing time of knitting machine.
Needle Line:
Causes:
Needle mixing.
Dust in needle group.
Improper servicing time of knitting machine.
Oil Stain:
Causes:
D
ust in cylinder & Dial group.
D
ust in needle group.
I mproper oil flow.
Pin Hole:
Causes:
Breakage of needle tail.
If needle tail bends.
Loop:
Causes:
Dust in yarn during running the machine for production.
Yarn knot thicker.
Breakage of needle.
Fly Yarn:
Causes:
Fly fiber during knitting.
One colors dirt is knitted with another color during running the machine.
Slub:
Causes:
Excessive ply during yarn production.
Improper machine setting (Blow Room, Carding, Ring Frame).
122
Finished Fabric Inspection:

4 point numbering system is followed for finished fabric inspection.
Four-Point System:
Acceptance Calculation (Classification):
< 40 PTS = A
41 60 PTS = B
61 80 PTS = C
80 ABOVE = REJECT
Faults found during Finished Fabric Inspection:

Chemical Stain:
Causes:
Padder contains dust during silicon finish.
Improper mixing of silicon softener.
Improper PH of softener mixing.
Too much m/c stoppage within short time.
Dirt Stain:
Causes:
Fabric is stored in floor.
Trolley is not properly cleaned.
Finishing m/c is not properly cleaned.
Oil Stain:
Causes:
Dust in cylinder & Dial group.
Dust in needle group.
123
Improper oil flow.
124
Dye Stain:
Causes:
Appearance of the darker spots of the same color caused by incomplete dissolution
of the dye.
Improper dyes quality & dyes dosing.
Insect Spot:
Causes:
Fabric is finished with insect when insect is in surface area of the fabric.
Fabric is stored for long time.
Barrie Mark/Patta:
Causes:
Yarn package is either hard or soft.
Lot Mixing of yarn.
Improper yarn tension.
Uneven yarn dyeing.
Slub:
Causes:
Excessive ply during yarn production.
Improper machine setting (Blow Room, Carding, Ring Frame).
Wrong Design:
Causes:
Wrong insertion of yarn during knitting.
Wrong setting of fabric design in knitting machine.
Lycra out:
Causes:
Lycra tears out during running the machine for production.
Thick & Thin:

Causes:
Diameter of yarn is uneven i.e. yarn irregularity.
Variation of yarn tension in course wise direction.
White Specks/ Dead Cotton:

Causes:
If fiber is immature.
Fabric construction contains dead fiber/ damage fiber.
125
Crease mark:
Causes:
More cycle time.

Faulty plaiting device.
Slack on tight selvedge causes crease at an angle to each selvedge.
Incorrectly set bowed-expander.
Compacting is done when fabric is in folded condition.
Variation of heating and cooling rate.
Improper fabric movement.
Physical Laboratory Tests

Color Fastness to wash Test: This test measures the resistance of fading of dyed textiles
when exposed to daylight.
A Typical recipe to measure the color fastness to wash:
Sodium Perborate-1 g/l

Tetra Acetyl ethylene Diamine-0.15 g/l
ECE Phosphate-4 g/l
M:L-1:50
Temperature- 600 Celcius for ISO-105-C06
Temperature-400 Celcius for ISO-105-C08
Machineries Specification:
Name: Rota Wash Machine
Model: M228
No. of steel balls: 25
126
Picture of Rota Wash M228

Required Instruments of color fastness to wash Test Procedure:
There are instruments which are required to determine color fastness to wash. They are-
Rota Wash machine

Stainless steel ball
Multifibre Fabric
Grey Scale
Sewing Machine
Color Mtching Cabinet
Working Procedure of color fastness to wash Test
127
Sample collection and conditioning

Making a specimen of 10x4 cm
Sewing the specimen with multifibre fabric
Making solution of 4 g/l ECE detergent anmd 1 gg/l Sodium Perborate (0.15 g/l
TAED when required)
Put the specimen with multifibre fabric on Rotawash
Set the temperature to 600 celcius and time 30 minutes
Rinsing with hot water
Squeezing with cold water
Drying at around 600 celcius
Stiching isd broken except one end
Measuring of staining and color change in Grey scale
Assessment of Color Fastness to Wash:
Grading
Color Fastness
Grade-5
Excellent
Grade-4
Good
Grade-3
Fair
Grade-2
Poor
Grade-1
Very Poor
128
Color Fastness to Perspiration Test: This test measures the resistance of fading of dyed
textile when exposed to human sweat.
A Typical recipe to measure the color fastness to perspiration:
Sodium Di-Hydrogen Phosphate (Acid)-2.2 g/l

Di-Sodium Hydrogen Phosphate (Alkali)-2.5 g/l
Sodium Chlorite-5 g/l (Used in both acid and alkali pot)
L Histidine Monohydro Chloride-0.5 g/l (Used in both acid and alkali pot)
Distill water
Lactic acid
Machineries Required:
Machine Name: Binder
Working Procedure of Color Fastness to Perspiration:
129
Collect the sample from bulk
Conditioning at least 4 hours
Cut a specimen in size 10 x 4 cm
Attach same size multifibre with specimen
Prepare acid and alkali solution an d check PH (Acid 5.50 and alkali 8.00)
Immerse the sample in acid (Alkali glass rod (1:50) for 30 minutes
Place the sample with multifibre in preheated perspirometer glass plates
with pressure of 12.5 KPa
Place the perspirometer in woven for 4 hours (Temp-370 celcius)
Remove the perspirometer from woven and remove the sample from
perspirometer
Dry at temperature not exceeding 600 Celcius
Assessment with grey scale and test report making
130
Personal Safety:
Use Hand Gloves
Use Eye Protector
Color Fastness to Rubbing:
Definition: This test is designed to determine the degree of color which may be transferred
from the surface of a colored textile to a specific Crockmeter test cloth for rubbing. (Dry and
Wet state).
Rubbing Machine Features:
Name: Crockmaster 680

Manufacturer: James Heal
Origin: UK
Press 4 and 6 together for calibration.
Complies with ISO-105-F09
ISO Crocking Cloth Features:

Length x Width: 5x5 cm
Fabric Type: 100% Cotton
131
Picture: ISO Crocking Cloth
Picture: Crockmaster
132
Working Procedure of Color Fastness to Rubbing:

Tense the fabric to its limit
Put Newton weight on fabric sample
Calibrate the machine
Then stary rubbing according to buyer requirements
GSM: GSM is the term that determines the weight in grams of fabric for each N.R Group
meter. In N.R Group knit fabric the following machine is used to determine the GSM.
Machine Features:
Machine Name: GSM Cutter

Manufacturer: Antonio Brustio
Criteria: GSM Measurement
Origin: Italy
Working Procedure of determining GSM:
Put the fabric sample under the GSM cutter.

Move the circular handle by putting and applying pressure.
This will make the fabric get cut in a circular shape.
Now, measure the weight of fabric sample.
133
Fabric Analysis via Burnout: Here in NRG Composite Yarn Dyeing Ltd., fiber analysis is
done via burnout. Lets have a deep see at the process:
Take a fabric weighing 1 gram (Here, 60% cotton and 40% polyester combination was taken.
Prepare a solution of 80% Sulphuric acid
Dissolve the fabric sample into the solution
After 5 minutes, the cotton part will be eliminated
Now, the fabric is weighed up again
Thus, the the weight of cotton and Sulphuric sample was determined.
Resistance to Pilling Test: This test determines the formation of pills and other related
surface changes of textile fabrics. In, SMFL three types of machines are available to
determine resistance to pilling. They are1. Maxi-Martindale Pilling Machine
2. Impulse Pilling Machine
3. ICI Pilling Machine
Now, The Maxi-Martindale machine is mostly used due to its easy application method and
accuracy.
134
1. Maxi-Martindale Pilling machine Specification:

Dimension: 670 x 320 x 890 (Depth x Height x Width)
Electrical Requirements (Single Phase): 85-264 Volts

No. of specimen: 09
RPM: 47.5+-2.5
Working pressure on test specimen: 2.5 CN/cm2
Origin: UK
Weight: 80 Kg
Woven Felt Diameter: 140 mm/ 90 mm
ISO: 12945:2
135
Picture: Maxi-Martindale Pilling Tester
Different Parts of Maxi-Martindale Pilling Test machine:
Woven Felt Fabric

Weight
Table
Spindle
Campaign Mechanism
2. Impulse Pilling Machine Technical Specification:
Picture: Impulse Pilling Tester
Standard: ASTM D3512

Dimension: 300 x 520 x 500 mm (Width x Depth x Height)
Weight: 35 Kg
Power: 85-204 Volts
136
Air Supply: 2 Cubic feet/minutes

Template size: 105 x 105
Running Time: 30 Minutes
ICI Pilling Machine Technical Features:
Weight: 39 Kg
No. of boxes: 4
Rotation Speed: 30/60 rpm
Power: 220 volts
Template size: 125 x 125 mm
Origin: UK
Body: Steel, Box Surface: Rough
Polyurethane Pipe: 140 x 31.5 x 3.2 mm (Length x Diameter x Thickness)
Working Procedure of Pilling Test (All Three in One Flow chart):
137
Cut the sample according to test procedure
Sample size ICI: 125 x 125 mm, Maxi-Martindale: 140 mm Impulse: 105 x 105 mm
Place the sample in machine with required tube/felt/abradent/foam or filament
Set the machine according to buyer rerquirements
Remove the sample and assessment with pilling standard
Test report making
Assessment of Pilling Test:

Grading
Resistance against Pilling
Grade-5
Excellent
138
Grade-4
Good
Grade-3
Fair
Grade-2
Poor
Grade-1
Very Poor
Color Fastness to Water
Color Fastness to Water: Color fastness to water is designed to measure the resistance to
water of dyed, printed, or otherwise colored textile yarns and fabrics. This method is to
assess the degree of cross staining which may occur when garments are left in contact when
damp. This test measures the resistance to water of any colored textiles.
Apparatus:
Perspiration Tester
Oven
Multi-Fiber Fabric
Grey Scale
Color matching cabinet
Glass plate or Acrylic resin plate
Glass beaker and stirring rod
Weight applied: 5 kg
Temperature: 370 Celcius
Reagent: Distilled water or de-ionized water is used in this test method because natural
water is variable in composition.
Working Procedure:
139
Collect the sample freom bulk

Cut the specimen in size 10x4 cm
Attach same size multi-fiber with specimen
Immense the sample in distill water with glass rod (1:50) at room temperature
Place the sample with multi-fiber in pre heated perspirometer glass plates with pressure of 12.5 KPa
Place the perspirometer in oven for 4 hours
Remove the perspirometer from oven and remove sample from perspirometer
Dry at temperature not exceeding 600 Celcius
Assessment with grey scale and report making
Assessment:
Grading
Fastness Rating
Grade-5
Excellent
Grade-4
Good
Grade-3
Fair
Grade-2
Poor
140
Grade-1
Very Poor
Color Fastness to Dry Cleaning
Color Fastness to Dry Cleaning: This test measures the resistance of fading of dyed textiles
when exposed to dry cleaning processes.
Apparatus and Conditioning:
200 ml Perchloroethylene
Undyed Cotton Twill Bag
Rota Wash Machine without steel balls
Working Procedure:
141

Cut a specimen size of 100 x 40 mm
Prepare 100 x 100 mm cotton bag with three sides sewing
Place the specimen with 12 steel disks in undyed cotton bag and shut the bag
Place the bags with disks in the container and add 200 ml Perchloroethylene
Start the machine and set 30'x300 Celcius
Remove the sample from cotton bag and absorbent paper of cloth
Drt at temperature not exceeding 600 Celcius
Assessment with Grey scale
Assessment of Dry Cleaning Result:

Grading
Fastness Rating
Grade-5
Excellent
Grade-4
Good
Grade-3
Fair
Grade-2
Poor
142
Grade-1
Very Poor
Color Fastness to Light
Color Fastness to Light: This test measures the resistance of fading of dyed textiles when
exposed to sunlight.
Apparatus:
Distill Water
Light Box
Conditioning Room
Blue Wool
Xenon Test chamber
Working Conditions:
Temp-630 Celcius
Humidity-30%
Time-20 hours
Working Procedure:
143

Cut the specimen in size of 10 x 4.5 cm
Set the test sample into a cardboard
Set the Blue Wool into another cardboard
Place the specimen with blue wool in Xenon test chamber
M/C configuration: Temp-630 Celcius, Humidity-30%, Time-20 hours
Remove the sample from Xenon Chamber
Assessment with grey scale and test report making
Assessment of Color fastness to Light Procedure
144
Grading
Light Fastness
Grade-8
Outstanding
Grade-7
Excellent
Grade-6
Very Good
Grade-5
Good
Grade-4
Moderate
Grade-3
Fair
Grade-2
Poor
Grade-1
Very poor
Phenolic Yellowing
Phenolic Yellowing: It determines the resistance of textile from getting yellowed because of
many reasons.
Tools for Phenolic Yellowing:
BHT free polythene

Adhesive tape
Conditioning room
Perspirometer
145
Picture: Control Fabric
Picture: Control Paper
Working Procedure of Phenolic Yellowing:

Cut a specimen in size 100 x 30 mm
Each specimen and control fabric individually placed between a test paper in half folded
Prepare a sandwich with one control fabric, 05 sample, 06 test paper and 3 glass plates
Wrap up with 03 layers BHT free polythene and sealed with adhesive tape
Place the sandwich in perspirometer with pressure of 12.5 KPa
Place the perspirometer from woven and remove sample from perspirometer
Assessment without conditioning and immediately with Grey scale
Yest reporty making
146
Assessment of Phenolic Yellowing Result:

Grading
Rating
Grade-5
Excellent
Grade-4
Good
Grade-3
Fair
Grade-2
Poor
Grade-1
Very Poor
Brusting Strength
Brusting Strength: Brusting Strength defines the ability of a textile fabric to withstand
pressure. Here in SMFL, for measuring the brusting strength of a fabric, TruBrust2 machine
is used.
Machine Introduction and Specification:
Picture: TruBrust2 Machine
147
Name: TruBrust2
Origin: UK
Area: 7.3 cm2 and 50 cm2
Maximum applied force: 1100 KPa/ 160 PSI
Working Procedure:

Cut 05 specimen perfectly
Sample size not less than 500 mm
Place the samle on the machine with required diameter
Start the machine and record figure
Start the machine for correction (Without sample)
Record figure and test report making
PH Test of Fabric:
148
Instruments and Apparatus and Technical data:
Machine Name: Wise Shake

RPM:70
Specimen: 2 grams
Time: 2 hours
100 ml distilled water
5 mm sample size
Buffer solution (4.0, 7.0, 10.0)
Test Procedure:
Collect sample from bulk
Cut 20 grams specimen in size 0.5 mm and 0.05 grams
Place the specimen into glass stopper flask
add 100 ml distill water (1:50) and check PH
Place the specimens into the mechanical shaker for 2 hours
Remove the flask from mechanical shaker and calibrate PH meter

Assessment with PH meter and test report making
149
Lab Dip Preparation

While training in N.R Group Knit Fabrics Ltd. we prepared the several lab dip and match
with the standards by the spectrophotometer. The preparation and matching with the
standards is described below:
150
Washing Procedure:
151
For Dark Shade (above 3.0)
152
153
Test for Mercerizing:

Necessary Equipment:
Volumetric flask
Beaker
Burette
Pipette
Measuring flask
Electric balance
Shaker
Scissors
Necessary Chemicals:
Barium hydroxide, Ba(OH)2 0.25(N)
Hydrochloric acid, HCl, 0.1(N)
Water
Methyl Orange
Sample:
Yarn sample 58/2 s singed and mercerized
Single mercerized fabric Grey mercerized, Yarn count 58/2s , Speed 10m/min.
Double mercerized fabric Grey mercerized, Yarn count 58/2s, Speed -10m/min.
Stock solution preparation:
To prepare 0.25(N) Ba(OH)2 Solution from a hydride barium hydroxide powder following
formula should be applied:
154
155
N
ow dissolve this Ba(OH)2 in to 250 ml distilled water.
K
eep the solution overnight in a safe position in a volumetric flask
Procedure:
2 gm of mercerized sample (fabric or Yarn) has to taken
The sample has to immerse in 30 ml 0.25(N) Ba(OH)2 solution.
The sample in immersion under Ba(OH)2 solution should keep 4 hrs
After 4 hrs the sample mercerized cotton should remove from the solution and
shaken carefully and well by a shaker.
From the left out solution 10 ml has to take for titration.
The solution is titrated with 0.1 (N) HCl in presence of methyl orange indicator.
The volume of HCl required to titrate the Ba(OH)2 solution has been recorded.
Now the mother/stock solution of Ba(OH)2 also titrated with same HCl and the
amount has been recorded.
Then can be calculated by the following formula,
Ba(OH)2% absorbed by the mercerized sample =
156
Chart:
Result:
Ba(OH)2 % absorbed by the mercerized Yarn sample = 20.319%
Ba(OH)2 % absorbed by the single mercerized fabric sample = 23.904%
Ba(OH)2 % absorbed by the double mercerized fabric sample = 25.5%
Evaluation:
Below 15% Unmercerized
Above 15% Mercerized
70% Fully mercerized
So the samples are mercerized.
Remarks:
The easy test done is not a standardize test. It is generally practiced in mills and factories for
quicker evolution of mercerization. In this test accuracy is maintained as much as possible.
Titration is done manually. Moreover the concentration of HCl and Barium Hydroxide also
measured by the same titration procedure. As the test result comes in a percentage basis the
initial concentration variation does not hamper the test result. For this reason the test result
is claimed accurate and satisfactory.
157
Chapter-09
Effluent Treatment Plant (ETP) &
Caustic Recovery Plant (CRP)
158
NRG Composite Yarn Dyeing Ltd. is very much concern about its
effluent, for this reason they established two effluent treatment plant and
they are ETP-I (capacity1200 m3 per day) & ETP-II (capacity 3000m3 per
day). The ETP in NRG is a biological one. Here bacterial and protozoa are
the catalyst of biochemical reaction to convert the toxic material into
environmental friendly gases and substances. The initial cost of biological
ETP is more but it has a low running cost if control is greater.
Reaction Time:
8-12 hr for secondary treatment
50 m3/ hr for secondary treatment
3-4 ppm/30-35 c (for proper bacterial action)
Quantity of micro-organism 1:4
Total capacity of ETP plant: 1200 m3 /day + 3000 m3/day = 4200 m3/day.
Sludge removes level: 800 MI/ 1/2hr f
Effluent Analyzing Report:
159
Reference:
USPEA (United States Environment Protection Agencies)
IWRA (International Water Resources Association)
GOB (Government of Bangladesh)
Typical flow diagram of a Physical-Chemical and Biological

treatment Plant in N.R Group Knit fabric Ltd :
160
Equipments for ETP Laboratory:
HACH method (for measuring BOD & COD)

BOD Incubator
Electric Shaker
Reflex Condensat for COD measuring
PH meter
TDS meter
Inhoff con for measuring sludge quantity
Desiccators
Separating funnel
Electric Balance
COD Reactor
Parameters of ETP:
Waste water outlet - 3000 m3/day

Treatment capacity - 1500 m3/day
Running cost - 2 4 Tk./m3
Plant capacity - 1200 m3/day
Bacterial: Protozoa - 60:1
Sludge collection at - 60 70 %
Screen allowance - 1 in2
PH - 6.5 8
Dissolved oxygen (DO) - 2 3 ppm
Outlet water temperature - 30 - 35C
Dwell time for effluent discharge - 48 hrs. (For oxidation tank)
Bacteria in oxidation tank
Protozoa
Bacilli
Paramecium caudatum
Cocehi
Euplotes
Beggiatoa
Vorticella dutrina
Spirillum
Colpidium
161
Biochemical Reaction:
Bacteria decompose the organic matter and other matters are related with
oxygen by microbial action i.e. biochemical reaction and produce gases and free
radicals. Metals are bio-chemically reacting with the enzyme and produces
gases.
Mn + O2
Enzyme
MnO2
Process Water Test Report:
Note: Sample Collection from Hanks Dyeing Area
162
Caustic Recovery Plant (CRP)

NRG Composite Yarn Dyeing Ltd. is very much concern about the
environmental issues. Here a large volume of caustic both liquid and solid
used in different wet processes as a basic chemical. In case of Yarn and
Fabric Mercerization most of the liquid caustic produced and effluent
containing caustic produced. The recovery of these caustic of 2 to 5 Be
concentration is beneficial for cost minimization and reduction of effluent
which may cause environmental hazard.
Few Parameters:
Inlet steam pressure 7 8 bar
Vacuum condenser pressure 0.3 0.4 bar
Condenser temperature 70C - 75C, Pressure 2 bar, Flow
60lit/80sec
Weak lye temperature 35 - 37C, Concentration 5-6Be
Strong lye temperature 75 C - 85C, concentration 28 30Be
1st stage:
o Shell side steam pressure 1.2 1.6 bar
o Shell side temperature 120 130C
o Pipe temperature 110 115 C
2nd stage:
o Shell side temperature 110 C
o Pipe temperature 90 100 C
3 rd stage:
O Shell side temperature 85 -100C
oPipe temperature 70 - 85C
163
164
Shhematic diagram of Caustic Recovery Plant
165
Recovery Process:
166
Rain Water Harvesting:
Rain water is collected here.
Remarks:
NRG Composite Yarn Dyeing Ltd. is using 0-5deg (total) hardness water which is suitable
very for dyeing. The underground water is free from hardness creating metals and eliminates
the need for water treatment plant. The electricity supply system is very good and fluent. It
is fully equipped to produce its necessary power. Its capacity of power generation is
increasing with another two generators to be established. The constant pressure of water also
eliminates the need for high rise water tank and maintains flow speed in different machines.
167
Chapter-10
Maintenance
168
MACHINE MAINTENANCE PROGRAM OF NRG

Maintenance of Machinery:
Maintenance of machinery is very essential mechanical effort for achieving
smooth running of different machines. Maintenance is a process by which equipment
is looked after in such a way that trouble free. Services and increased machine life
can be ensured and specific product quality required by the customers is sustained.
On time maintenance increase m/c lifetime & ensures trouble free services.
In N.R Group Fashion Ltd. following two types of maintenance are done.
Break down maintenance
Preventive maintenance
Maintenance System used in NRG:
YEARLY MAINTENANCE CHECK LIST

Demag monorail hoist
Grease all the moving parts and bearings

Check all the nut and bolts
Check oil level
Check each sprocket, chain and chain collector are ok
Check the thickness of the lines
Check visually the damage of main girders
Pressing machine
Check rotating table balls and lubricate.
Lubricate the axial bearings
169
Yarn singeing machine

Clean control cabinet using a vacuum cleaner.
Do not touch the circuit card and soldering joints.
Every 4 year change the battery on the RAM card.
Santex compactor machine
Check the machine for visual damages.
Replace the worm reduction gear oils.
Check the compacting shoes for wearing.
Check the blankets for wearing.
Check the foundation bolts of the machine
Fabric dyeing machine

Drain & replace the main pump bearing oil.
Drain & replace the oil of gearboxes.
Check and if necessary replace all plaiter bearings balls.
Check the platter/ J-box center alignment
Check the manhole O-ring.
Check and grease all greasing points.
Check and tight all plaiter, catch basket, reel and other support
bolts from theinside of the machine.
Check all the PTFE carbon supports and sleeves in the plaiting
device systeminside the machine
Replace the worm reduction gear oils.
Check the compacting shoes for wearing. Replace if necessary.
Check the blankets for wearing.
Check the foundation bolts of the machine.
Dornier mercerizing machine
Grease all the bearings and moving parts.
Check the bearing bolts and replace them if necessary.
Change the gear oil of the gear boxes
Check the rubber coating of the fixation & drive rollers
Complete check of the cooling plant
Check the spray rings, piping and armatures
170
Check the pneumatic piping for proper connection

Check and retighten the electric connections of machine
Replace the chains and the chain wheels of the drives
HALF YEARLY MAINTENANCE

Alea hank dryer machine
Adjust the chain tension and lubricate it
Check the oil level of the gear box
Change the gear oil once a year
Lubricate the bearings with grease
Calatorruckh inspection machine
Lubricate chain and adjust the tension.
Grease all the bearings.
Change gear oil once a year.
Precision winding machine
Clean the cable channels and electric cabinet
Clean the flyer set and displacement unit
Check certain
Every 5 year replace buffer batteries on the control cabinet
Loris Bellini hank dyeing machine
Clean and check the compressed air filter.

Check the pneumatic cylinders.
Tightening of every bolt.
Tightening of foundation bolts.
Check and replace the roller bearings if necessary.
Maintenance for piston pneumatic valves.
Tightening of terminals of electric motors.
Tightening of terminals of electric boards.

Check condition of variator, remove any wound on thread.
Check automatic contrails of all sensors.
171
172
MONTHLY MAINTENANCE CHECK LIST

Assembly winding machine
Check the cone holder's looseness
Clean the inverters
Clean the yarn path properly
Check the package diameter sensor
Jaeggli yarn mercerizing machine
Grease hooks draught bearings. (B)
Grease function bearings of the squeegee roller (H)
Grease fulcrum bushes of the lifting cylinder(L)
Check the hydraulic oil pressure
Loris Bellini hank dyeing
Inspection of wear and tear of lid gasket
Lubricate the electric motors.
Check the mechanical seals of add pumps
Inspect the serviceability of safety valves.
Maintenance of stuffing box
Check spindle motor supply
Check function of the vacuum monitor of the suction off switch.
Check function of the compressed air monitor on the gas mix section
Scholl package dyeing
Check main pump v- belt connection
Check the safety, steam and water valves
Hydro extractor machine
Lubricate the spindle bearings at the end of the shaft and greasing nipple on
the rotary treble behind the front part of removable casing.
Lubricate the guide pulley behind the front part of removable casing.
Mahlo setter and compactor
Check, Grease if necessary:
Nuts of width adjustment spindles for wear
Check all spindle bearings for free running
Free running of guide rollers, deflection rollers and contact rollers.
Pressure springs of chain pensioner
Perform visual inspection: Gear box oil level
Belts, pulleys
Move width adjustment motor to the end position & check counters
173
Corino slitting machine

Grease the squeeze for the rope fabric part
Grease the dewatering bearings
Grease the bearings of water slitting device & driving screw for
basket opening
Grease the bearings of open width squeezer
Change gear oil once a year
Sclavos fabric dyeing machine
Check the main pump oil level.
Check all bearings, seals, gaskets.
Check all mechanical seal flush pipes.
Discharge the water from air filter.
Check all m/c flange & platform bolts.
Grease RCR rotary joints every 2 weekly
Clean & check the control panel.
Check the adjustment of catch basket mechanism and plaiter system
FABRIC DYEING MACHINE

Check the machine for visual damages. Check the main pump
bearing oil level.
Replace the oil. Check the operation of all alarms.

Check and clean the sedo master controller.
Clean the inlet filter of magnet level indicator.
Check the pressure & temperature gauges.
Check and grease all greasing points.
Check all mechanical seal flush pipes. Specially check the plaiter
water nozzle.
Grease rotary joints.
Grease heated rollers supports bearings.
Grease all the bearings.
Grease all the transmission chains.
174
WEEKLY MAINTENANCE CHECK LIST

Stalam yarn dryer
Clean the dryer by compressed air
Clean the foreign matters in the inductor and between electrode
Clean the filter of asplirator air intake
Hydro-extractor
Remove all the centrifugal heads & check
Clean the entire machine
Lift the c over & clean the drain cannel.
Lubricate the rotary table behind the front part removable casing.
Yarn pressing machine
Check the joints for tightness.
Check the foundation bolts
Check pneumatic oiler oil level
Scholl package dyeing machine
Flange connections checked for tightness.

Open outlet of V68 valves and clean.
Open outlet pipe after V, 38 valve and clean.
Check lip seal & clean grease with PROBA 270( kluber)
Upper side of cams on lid ring treated with lubricant. Use molykote
graphitegrease.
Checked oil level in atomizer
Monfortspadder, stretcher & dryer machine

Perform visual inspection & clean
In feed roller control unite cylinders
Guide rod. guide roller & bearings
Lifting device cylinders bearings
Under liquor squeeze roller adjustment
Teflon coated bearings, immersed rollers
175
Belt tension, gear unit

Universal joint shaft coupling
Width adjustment functional wheels
Selvedge sensor uncovers. Pinning shoes. brush
Never grease graphite chain guide rails
Brushes after pinning
Clean & oil
Filter housing & replace.
Sprockets. Clamps with E
Sliding guides cylinders
Dryer removable screens
Air suction control butterfly valves
Oil level of pneumatic oiler filter

Cleaning the burner rings.
Cleaning the root blower suction air filter.
Clean the traveling blower.
Dornier mercerizing machine
Visually check the motors and pumps
Check the chain drives and tension of chains
Check that all the expanders are properly adjusted Check the
& readability of the expander rollers.
Clean the machine from fluffs, dirt, chemicals
Check the function of the solenoid valve
Check the function of the cooling plant,
Check the spraying nozzles and clean them if blocked
Check the rubber coating of the drive rolls
surface
Corino slitting machine

Check turntable tire pump & spring pressure.
Grease the turntable.
Check de twister speed reducer, transmission belts pneumatic brake.
Check oiler oil level of the fabric expander.
Check movable reel plaiter driving system.
176
Fabric dyeing machine

Check the main pump oil level.
Check all bearings, seals, and gaskets.
Check all mechanical seal flush. pipes.
Discharge the water from air filter.
Check all m/c flang& platform bolts.
Grease RCR rotary joints every 2 weekly
Clean & check the control panel.
Check the adjustment of catch basket mechanism and plaiter system.
Corino squeezer machine

Clean the machine rollers with wet cloth..
Check visually all bearings & drive chains.
Check all air and water hose joints.
Clean compressor filter.
Check tyre pump bellow the turntable.
Check and clean fabric spreader.
Check tension of trapezoidal belts.
Grease turntable- bearing balls
Clean the machine properly.

Check all bearings & chains.
Check all mechanical joints.
Check all the machine alignments.
Top up the compressed air lubricant.
Clean the panel A/C properly.
Check tension and wear of the spreader belt pulleys.
177
DAILY MAINTENANCE CHECK LIST

DORNIER MERCERIZING MACHINE
Check the quantity of fresh caustic soda in the caustic soda storage tank.
Check the complete machine and the auxiliary equipment visually.
Check whether all chains, chain wheels and drives are properly running.
Check the soda temperature to ensure that the cooling plant works
properly
Check that all rollers are easily relatable.
ETP
WEEKLY
Clean the glass electrode of pH meter.
Check the filter net of dosing pump.
Check the current of air pressure.
Clean air filter of blower (monthly).
EVERY 4 MONTH
Calibrate the PH meter with buffer solution, 7 & 4.
Calibrate the blower meter,
Grease the oxygen meter.
Grease the scraping, bridge, bridge wheel of ball bearing.
EVERY 2 YEAR
Grease the spring ball bearing.

Change the oil of sludge transfer pump.
Change the oil of feed pump.
Change the oil of lifting pump.
Change the oil of sludge blower.
Change the sensor of oxygen blower (if necessary).
Change the electrode of pH meter (if necessary).
Change the oil of dosing pump.
178
Chapter-11
Utility Services
179
180
Utility Facilities Available:

The following utility facilities are available at NRG Water.
- Steam.
- Electricity.
- Gas.
- Compressed air.
Description of the Utilities

Water:
Raw water hardness: 18-20 0 (Generally 30 ppm)
Boiler water hardness: 0 0

M/c used: Water conditioner
Submergible pump : 2 (For NRG) & 1 (For Dormitories)
o Process water: 200m3/hr and 150 m3/hr
o Domestic use: 150 m3/hr

Company: Cleaver Brooks

Country of origin: USA.

Water consumption: 4500-5000m3/day

Water pressure: 6-6.5 bar
Steam:
oiler Steam: 10.2 tons/hr. & 2.3 tons/hr.

B
Steam pressure: 7.5-8 bar
Steam temp: 150-160 0 C
M/c used: Fire tube type Gas Boiler & Exhaust Gas Boiler
Piece: 02 (Fire tube type Gas Boiler) & 01 (Exhaust Gas Boiler).
Capacity: 10.2 tons/hr. & 2.3 tons/hr.
Power Supply:

Supply: Self

M/c used: Electricity Gas Generator

Brand: Cater Pillar

Origin: USA

Piece: 05
Total Capacity: 5.6 MW (1 MW+1 MW +1 MW +1 MW+1.6 MW).
181
Chiller:
Air Compressor:
Piece: 07
Brand: BOGE (No. of machine 6) & ROLL AIR (No. of machine 1).
Country of origin: Germany
Capacity: 6 m3 /hr.
Cooling Tower:
Use in: Generator
Country of origin: Thailand
Piece: 12
Source of Utility:
1. Water- Own supply (Pump)
2. Steam-Own supply (Boiler)
3. Electricity-Generator & PDB
4. Gas- Titas Gas Transmission & Distribution Co. Ltd.
5. Compressed air- Own supply (Air compressor)
Remarks: NRG Composite Yarn Dyeing Ltd is using 0-5deg (total) hardness water
which is suitable very for dyeing. The underground water is free from hardness creating
metals and eliminates the need for water treatment plant. The electricity supply system is
very good and fluently. It is fully equipped to produce its necessary power. Its capacity of
power generation is increasing with another two generators to be established. The constant
pressure of water also eliminates the need for high rise water tank and maintains flow speed
in different machines.
182
Chapter-12
Store & Inventory Control
183
Inventory System for Raw material:

In NRG Composite Yarn Dyeing Ltd there are different inventory systems for different
raw materials.
Grey Fabric Store:
All the grey fabrics are stored in the fabric store near the batch section. Different types of
fabric are listed in the sheet according to fabric types, quantity and consumer's requirement.
Dyes and Chemicals:
There is a different store for dyes and chemicals. Vanes types of dyes and chemicals are
stored here according to dyes and chemicals companies. Different types of dyes and
chemicals are listed in a sheet. In the sheet the stored quantity of dyes and chemicals are also
included. Every day the sheet is updated and a copy of this sheet is supplied to the dyeing
manager, dye house and lab section.
Spares:
In NRG Composite Yarn Dyeing Ltd required amount of spears of different machines are
stored in the mechanical store room. All the spares are listed in a sheet which is controlled
by the mechanical & maintenance personnel. Spares are arranged in the store room
according to their size, quantity & requirements. There are shelves in the store room to keep
the small spare parts.
Finished Goods:
NRG Composite Yarn Dyeing Ltd supplies its finished dyed fabrics to its garments
section. So, dyed finished fabrics are stored for short time in the finishing section. All the
delivered fabrics are noted on the tally khata according to the lot no, quantity, fabrics
diameter, buyer's name, Color & considering other technical parameters.
Remarks:
NRG Composite Yarn Dyeing Ltd has individual stores for raw materials, finished goods
etc. the store of dyestuff & chemicals are not so clean. There is no enough space to store the
finished goods. It requires increasing the store area.
184
Chapter-12
Conclusion
I have completed our industrial attachment successfully by the grace
of Allah. Industrial attachment sends us to the expected destiny of practical life. The
completion of the two months Industrial attachment at N.R.G. Composite Yarn Dyeing
Ltd. we have got the impression that factory is one of the most modern export oriented
composite complex in Bangladesh. Though it was established only a few years ago, it has
earned very good reputations for its best performance over many other export
oriented textile mills. During our training period, talking with the clients of this mill we
knew that the mill is fulfilling the countrys best export oriented white finished
fabric as well as very good colored fabric due to its modern machinery & good
management system. Mill is settled with utility to give all convenient supports to the
productions for twenty-four hours. It had self-power generator system to satisfy total power
consumptions of the mill. We are enough fortunate that we have got an opportunity of
having a training in this mill. During the training period we are received co-operation and
association from the authority full & found all man, machines & materials on appreciable
working condition. All stuffs & officers were very sincere & devoted their duties to achieve
their goal. Finally we would like to wish N.R.G. Composite Yarn Dyeing Ltd. to have a
blast & thanks to administration of NR GROUP Ltd. for their cordial attitude to us.
185

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Knowledge for Innovation and Change

Department of Textile Engineering

MD. Tauhidul Islam

Supervisor: Prof. Dr. M. A. Jalil

In the name of GOD

Knowledge for Innovation and Change

Department of Textile Engineering

Name & Designation of Supervising Teacher

Northern University Bangladesh

Name & Designation of Supervising Officer of

Subject: Submission of the Industrial attachment Report.

Md. Tauhidul Islam

Department of Textile Engineering

Supervising Facultys Approval

Prof. Dr. M. A. Jalil

Supervising Mill Authoritys

Textile technology education is based on

All the praises are for the almighty, Allah who

Man Power Management

Production Planning Sequence

Effluent Treatment Plant

Store & Inventory Control

Name of the Factory:

History of Project Development:

Textile Mills of N.R Group Group:

Piece Dyed fabric,

Cotton: Carded, Combed, Compact, & Organic.

Engineering stripe and semi jacquard,

Duties & Responsibilities:

To keep workers attendance

Sources: The required yarns are supplied from:

N.R Group Spinning Mills Ltd. (Bangladesh)

And special yarns are from:

For Cotton Group (Reactive Dyes)

Detergent and Scouring Agent

Antifoam/ Penetrating Agent

Sequesterent & Dispersent for Bleaching

Mercerizing Wetting Agent

Leveling Agent for Heat Setting

Reactive Fixing Agent

Cotton Leveling & Prof-Colloid

Oxidizing Agent for Polyester

Dispersing Leveling Agent for Polyester

Acid PH Buffer (For Polyamide)

After Soaping Agent

Gliding Agent for Cotton Yarn

Enzyme Finishing Agent

Optical Brightener for Cotton

Rubbing Fastness Improver

De-Colorant for Effluent Treatment

Ultra violet protection Agent

Anti-murobiol Hygiene Protection Agent

Silicon Stripper Agent

Knitting Oil Removing Agent

Special Finishing Agent

Cotton Fiber and its Chemical Structure

Chemical structure of Cotton Fiber

Reactive dyes are categorized by functional group:

Dissolving the Dyes

Triazine-stilbenes (di-, tetra- or hexa-sulfonated)

Detergent whitener (instead of blueing agents)

Chemical Lab Lay-Out

Description of the Chemical Lab Layout

Introductory instruments of Chemical Lab: