Documente Academic
Documente Profesional
Documente Cultură
INDUSTRIAL ATTACHMENT
FAKIR KNITWEARS LTD
Acknowledgement
At first I would like to thank almighty Allah for giving me the opportunity to complete
my internship. I have taken an opportunity to express my deepest since of gratitude and
sincere thanks to my reverend teacher Prof. Syed FakhrulHasan,Chairman, Department of
Textile Engineering, Southeast University, Banani, Dhaka.I also thank toA.N. M. Ahmad
Ullah , Co-ordinator, Departmentof Textile Engineering, Southeast University, Banani,
Dhaka,for giving me the chance internship in Fakir Knitwears Ltd.
I would like to thank Mr.Sultan Mahmud Hosseinee,GM (HR & Compliance) of Fakir
Knitwears Ltd.
I would like to thank Mr. Md. Kashem Ali Khan, Manager (IE & Planning) of Fakir
Knitwears Ltd. for his valuable direction and special attention.
I would like to thank Mr. Md. Toriqul Islam, Manager (Dyeing) of Fakir Knitwears
Ltd.
I also thank to Mr. Mohammad Din Islam, Asst. Manager (IE & Planning) of Fakir
Knitwears Ltd. for his real advice.
I am also grateful to Mr. Abul Basher Muhammad Suhas, Management Trainee & Mr.
Md. TanvirHossainMazumdar ,PO (Knitting) of Fakir Knitwears Ltd. for giving me their
proper guideline and continuous support.
I want to offer my deepest thanks and complements to my parents and brother for their
unselfish and stimulating influence in my any education life.
Fakir KnitwearsLtd, started in the year 1988 in knit garment exporter, Fakir
Knitwears Ltd. Crossed over a long way and found us as one of the best
knitwear manufacturer-exporter of Bangladesh.
Fakir Knitwears Ltd. certified with OKEO-TEX, ISO 9001-2000 &SRM and
also getting by WRAP and ISO-14001
Fakir Knitwears Ltd. strive to provide the best quality garment to the buyers.
Factory provided advanced technology in all aspects of operation to attain
excellence concerning quality, dependability and commitment for apparel
industry and society. Product quality is ensured with the practice of advanced
technology and our inclination toward meeting with the buyer's satisfaction with
competitive price.
Fig: Location map of the FKL
Chapter One:
Project Description
COMPANY PROFILE
Phone:88-02-7641379-80
7643242,7643271
Fax:88-02-7634611
Dhaka-1000,Bangladesh.
Dyeing-42 tons/day
Dyeing Finishing-42tons/day
Garments-200000 pcs/day
Garments Washing-20000pcs/day
Printing-100000 pcs/day
Embroidery-200 Head
Contact(Marketing) : 1)F.A.Zaman(neaz),(Director)
Email: neaz@fakirgroup.com
2)Mr.MahmudulHasan, DGM
Email: hasan@fakirgroup.com
3)Mr.BiswajitSaha,AGM
Email: biswajit@fakirgroup.com
Buyers :H&M
TEMA
PRIMARK
PEACOCKS
PENNYES
BERSHKA
ZERA
Type of Factory& Concern Department
The factory is a Knit composite industry. The factory has the following departments-
Knitting:
o Knitting
o Inspection
o Quality control
Dyeing:
o Batch section
o Dye house
o Dyeing laboratory
o Quality control
o Finishing
Garments:
o Merchandising
o Sample
o Cutting Section
o Sewing Section
o Finishing Section
Maintenance:
o Electrical
o Mechanical
Administration
Security
Marketing
Production Planning & Control
Human Resource & Development
Remarks
The factory has outstanding quality of producing and exporting goods. The infrastructure is
the fabric is well enough to be a very good composite factory in Bangladesh. The
informations are given according to source of Management department.
Organogram
Chapter Two:
Management System
FAKIR KNITWEARS LTD
Managing Director
Reporting to Chairperson
Responsible to board of director/s
Monitor factory operation and make sure orders are delivered on time, with
customer's required quality at a minimum cost
Take the total charge of all human resource activities and make sure FKL. To have
professional and cheerful work force
Director
Reporting to Managing Director
Product analyzing and providing technical guidance for optimum benefit of the
company.
Co-ordinate with the entire departmental in charges and all the workers in the
factory
Responsible to monitor,
Directly reporting to the MD Sir about the over all situation of the factory
Maintain and process information received from buyers and buying offices and
process and transfers them between head office and factory.
Make sure the quality is maintained at buyer's required standard and maintained
company quality system.
Responsible to monitor system management, health & safety and all other
compliance affairs.
HROfficer
Co-ordinate with the entire department in charges and all the workers in the
factory.
Responsible to monitor,
Responsible to maintain all the books and paperwork with regards to company
accounts.
Should conduct regular security inspections in the premises both day and night
Maintain records of all incomings and out going goods, personal and vehicles.
Conduct security activities and make sure the total premise is completely safe and
secured.
Motivate subordinates.
Chapter Three:
Machineries
Garments Machineries
Boiler Machineries
SI no. Model No of m/c Origin Brand
01 DDHI 5.0-10 02 Germany Omnica
02 UL-S-1000 02 Germany Loos
Manpower
FAKIR KNITWEARS LTD
Total Manpower and Section Wise Manpower:
Administration Department:
13 Peon 13
14 Cleaning Supervisor 08
15 Cleaner & Sweeper 240
16 Cook 07
17 Medical Assistant 02
Total = 310
Accounts Department
Total=1 26
Maintenance Department
Sample Department
SL.NO Designation No of Manpower
01 Manager 01
02 Pattern Master 04
03 Sample Cutter 08
04 Sample Man 06
05 CAD Manager 01
06 CAD Designer 09
07 Q.C (Sewing) 06
08 Operator (Sewing) 27
Total = 61
Security Department
03 Security Officer 02
04 Security Supervisor 04
05 Fire Man 08
06 Security Guard 87
07 Driver 20
Total = 123
Inventory Department
SL.NO Designation No of Manpower
01 General Manager 01
02 Asst. Store Manager 03
03 Inventory Officer 02
04 Asst. Inventory Officer 05
05 Sr. Store Keeper 05
06 Store Officer 11
07 Store Keeper 21
08 Store Assistant 19
09 Tally Man Incharge 01
10 Tally Man 14
Total = 82
Cutting Department
Production Department
SL.NO Designation No of Manpower
01 General Manager 01
02 Production Manager 05
03 Floor In-charge 15
04 Production Co-ordinator 02
05 Supervisor 48
06 Input Man 15
07 Operator 1056
08 Helper 864
09 Count Man 48
Total = 2390
Printing Department
SL.No Designation No of Manpower
01 Printing Manager 01
02 In-charge 02
03 Color Muster 01
04 Invigilator 08
05 Supervisor 04
06 QC 21
07 Check Man 73
08 Printer 74
10 Cleaner 22
11 Helper 428
12 Expose Man 2
13 Loader 11
Total = 671
Quality Department
SL.NO Designation No of Manpower
01 Deputy Manager 01
02 Manager 01
03 Asst. manager 01
04 In-charge 04
05 Quality Controller 26
06 Check Supervisor 39
Total = 72
Finishing Department
SL.No Designation No of Manpower
01 Finishing Manager 01
02 Finishing In-charge 06
03 Finishing Supervisor 34
07 Packer man 40
08 Helper 60
Total = 527
Chapter Four:
Raw Materials
Yarn
The raw material for knitting is the yarn. Different types of yarn of wide range of different
count areused. Both carded and combed yarn is used for knitting.
Fabric:
Fakir Knitwears Ltd.is a knit composite textile industry. In the industry fabric is used as raw
material in dyeing-
Grey Fabrics:
Single jersey
Single jersey with lycra
Polo pique
Single lacoste
Fleece
Interlock
Interlock with lycra
Rib
Rib with lycra
11 rib
22 rib
6X2 rib
Sugar rib
Regular drop needle
Irregular drop needle
Different types of collar & cuff
Chemicals:
Basic Chemicals:
1. Acetic Acid
2. Hydrochloric Acid
3. Sulphuric Acid
4. Caustic soda
5. Formic acid
6. Bleaching powder
1. SUNMORL CK-2
2. AssistB26f/SL2F(CK)
Levelling Agent
1. Neocrystal-200BF
2. LevagalDLP
Sequestering Agent
1. Neocristal 150
2. Neocristal-DMBF
3. NOBLEACH N(Multi-function)
Salt
1. Glauber Salt
2. Common Salt
Whitening Agent
1. Sapamine FPG
2. Aleamine-CWS
3. Necipole PR 99
4. Gramazin-E2R
Fixing Agent
1. NeofixRP70
2. Neofix-R-250
3. Albafix ECO
Reducing Agent
1. Hydrose
2. Caustic
3. Visco Color
4. ViscoBleah
Bleaching Agent
1. (50%)H2O2
Enzyme
1. Retrocell PLX
2. BIO-C35
Stabilizer
1. Nobleach N(Multi-function)
2. Neorate PH 55 NF
3. Neorate PH 150
Anticreasing Agent
1. Texport GL 500
2. Texport D-600
3. AC-200
PH Controller
1. Acetic Acid
2. Formic Acid
3. Soda Ash
4. Caustic
5. Invatex AC
Per-oxide Killer
1.Croaks NF
Antifoaming agent
1. Albatex FFC
Dyes
1.Sumifix
2.Boductive
3.Ciba
4.Livafix
5.Terafix
Remarks
As quality is the prime concern of the factory, qualitative raw materials are always
bought by the management of the factory. Besides, there is enough space to keep those
raw materials in the factory.
Chapter Five:
Knitting section
Process Flow chart of Knitting:
Yarn in cone form
Feeding the yarn in the feeder via trip-tape positive feeding arrangement and Tension device.
Knitting
Inspection
Numbering
Tensioning device: Tensioning device is used to give proper tension to the yarn.
VDQ pulley: VDQ pulley is used to control the GSM by controlling the stitch length.
Sensor: Sensor is used to seen & the machine stops when any problem occurs.
Spreader: Spreader is used to spread the knitted fabric before take up roller.
Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machine
to feed the yarn at specific finger.
Rethom: These devise are used in Electrical Auto Striper Knitting machine
The type of fabric to produce depends on the setting of the Cam of Knitting machine. The
different types of fabric can be produced by only changing the cam setting. The cam settings
to produce different fabric are given below:
Single jersey:
Only knit cams are used to produce single jersey fabric. So the setting would be-
K K K
K K K
K K K
Inter lock:
Inter lock fabric is produced by using knit and miss cam. So the setting would be-
K M K
M K M
Lacost:
K K T K K
T K K K T
French terry:
K M K M K M
K T K M K T
K M K T K M
Considered pointof Knitting:
When a buyer orders for fabric then they mention some points related to
production and quality. Before production of knitted fabric, these factors are needed to
consider. Those are as follows-
Finished G.S.M.
Type of Fabric or design of Fabric.
Yarn count
Types of yarn (combed or carded)
Diameter of the fabric.
Stitch length
Color depth.
c) Honeycomb
b) Cuff
Production Calculation:
A. Production/shift in kg at 100% efficiency
B. Production/shift in meter
Course / min .
Course / cm
RPM No. of Feeder 60 12 Efficiency
Course / cm 100
Wales / cm 100
Total no. of Needles used in knitting
Wales / cm 100
D. Needle calculation
For example: Diameter of the machine is 18 and Gauge of the machine is 24. Then the
number of Needles on the machine would be-
18 X 24 X 3.14 = 1356
For example: Length of the machine needle bed is 56 and Gauge of the machine is 14. Then
the number of Needles on the machine would be-
56 X 14 = 1568
Faults of Knitting:
1. Hole Mark
Causes:
2. Needle Mark
Causes:
When a needle breaks down then needle mark comes along the fabrics.
If a needle or needle hook is slightly bends then needle mark comes on the
fabrics.
Remedies:
3. Sinker Mark
Causes:
When sinker corrode due to abrasion then some times can not hold a new
loop as a result sinker mark comes.
If sinker head bend then sinker mark comes.
Remedies:
5. Drop Stitches
Causes:
Defective needle.
If yarn is not properly fed during loop formation i.e. not properly laid on to
the needle hook.
Take-down mechanism too loose.
Insufficient yarn tension.
Badly set yarn feeder.
Remedies:
6. Oil stain
Causes:
When oil lick through the needle trick then it pass on the fabrics and make
a line.
Remedies:
7. Rust stain
Causes:
8. Pin hole
Causes:
Due to break down or bend of the latch, pin hole may come in the fabric.
Remedies:
9. Grease stain
Causes:
Improper greasing
Excess greasing
Remedies:
Cloth fall- out can occur after a drop stitch especially when an empty
needle with an empty needle with closed latch runs into the yarn feeder
and remove the yarn out of the hook of the following needles.
Remedies:
Make sure all the latches of needle are closed with feeding yarn after a
drop stitch.
11. Barre:
A fault in weft knitted fabric appearing as light or dark course wise (width wise)
Stripe.
Causes:
In knitting section too much lint is flying to and fro that are created from
yarn due to low twist as well as yarn friction. This lint may adhere or
attaches to the fabric surface tightly during knit fabric production.
Remedies:
Blowing air for cleaning and different parts after a certain period of time.
By cleaning the floor continuously.
By using ducting system for cleaning too much lint in the floor.
Over all ensure that lint does not attach to the fabric.
Causes:
If yarn contains foreign fiber then it remains in the fabric even after
finishing,
If lot, count mixing occurs.
Remedies:
Causes:
Needle Break,
High Tension on Tensioner,
Excess cotton with yarn on needle.
2. Missing Needle:
Causes:
Faulty Needle,
Faulty Cam setting.
3. Oil mark:
Causes:
4. Loop Miss:
Causes:
Fabric Received
Inspection
Fabric Divided according to Diameter
Supervisor batches the fabric according to quantity by Calculation
Sent for Dyeing
Knitting Hole
Oil Spot
Tara
Shade UP
Star Mark
Patta
Lack out
Batch Calculation:
= Batch Quantity (M/C Quantity) / Total Quantity X Diameter quantity
=Diameter Quantity (Weight of Fabric in a roll) X 39.37 X1000 / Finished GSM / Finished
open Diameter
Batch management:
Primarily batching is done by dyeing manager taking the above criteria under
consideration. Batch section in charge receives this primary batch plan from dyeing manager.
Some time planning is adjusted according to m/c condition or emergency.
Remarks:
The batch section of the factory is well equipped but it lacks in a quality controller.
Chapter Seven:
Lab section
Lab dip:
Lab dip is a process by which buyers supplied swatch is matched with the varying dyes
percentage in the laboratory with or without help of DATA COLOR
Lab dip plays an important role in shade matching & and detaching the characteristics of the
dyes and chemicals are to be used in the large scale of production so this is an important task
before bulk production.
Objective of Lab dip
Crocking
Sample Received
Standard is checked with the Reference from the inventory
If matched then sample prepared from that recipe
If not matched than the color percentage is calculated by using Data Color
Recipe Prepared
Sample prepared according to recipe
Standard (From Buyer) and Sample prepared is Compared
If Okay then the sample is sent to Buyer
Buyer approves the sample and order for the bulk production.
Sample Received:
Buyer sends a sample which is considered as standard in whole process. Buyer also
gives some requirements about the properties of the standard fabric. For example, Buyer
wants good wash fastness, light fastness, rubbing fastness, pilling formation etc. The lab
receives this standard to make this fabric according to buyer requirements.
Standard is checked with the Reference from the inventory:
The factory dyed a lot of fabric in its running years. It also stores a lot of sample in its
inventory. The standard is first checked with the samples kept in the inventory.
If matched then sample prepared from that recipe:
If the standard is matched with the sample of inventory then the next process becomes
easier. Because after matching the sample with standard previously maintained recipe is
followed. If the sample does not match with the standard then the process goes to data color.
If not matched than the color percentage is calculated by using Data Color:
If the standard does not match with the samples of inventory, then the standard
percentage of color is found out from the data color machine.
Recipe Prepared:
According to the results of data color machine the recipe is prepared to get the desired
sample of that standard.
Sample prepared according to recipe:
Following the procedure the sample is prepared.
Standard (From Buyer) and Sample prepared is Compared:
After getting the sample is compared with the standard. And several tests are done to
meet the buyer requirement.
If Okay then the sample is sent to Buyer:
Sample is then sent to the buyer for the final approval.
Buyer approves the sample and order for the bulk production:
When buyer gives the final approval the fabric is sent to production floor for the bulk
production.
Properties test
Procedure:
Firstly a sample of size (14 5) cm is taken at Wales & Course wise. The crocking cloth is
put on to the finger &is staged by finger clip & run 10 times in 10 seconds manually &
assesses the crocking cloth with gray scale.
The crocking cloth is placed on the water, it will suck some water and crocking cloth is then
squeezed. Then place the wet rubbing cloth on to the finger and stag with finger clip and run
10 times in 10 seconds manually. The crocking is then assessed cloth by gray scale for wet
rubbing. Wet and dry rubbing are checked according to buyers requirement.
The fabric 12.5 x 12.5cm is cut & balanced mark should be 10cm by using template. Then
the fabric is sewn so that it can be firmly fit in the tube a moulded polyurethane tubes.Then
four tubes are placed in a box & started 602 rev/min for 5 hrs or according to buyer
requirement. Then the fabric is assessed by putting tested specimen on the cabinet &
compared with standard photographs.
Buyers requirements:
Template size: 50cm & 35cm, 25.5cm &18cm (use after quick wash).
Width wise----5%
Right -------- 5%
Procedure:
Firstly two ply of fabric is taken & put the template (50cm) on to the fabric. The template has
8 holes. Both length & width wise the template holes can measure 35cm at 3 places. Then 8
holes are marked by permanent marker & also at the edges of the template.
The fabric is sewn & it is given to the washing m/c for run at 60C for 60minutes with water.
After that the sample is dried & then fabric is measured.
Calculation:
Shrinkage Test:
Lengthwise:After wash Before wash
= ----------------------------------100
Before wash
Width wise: After wash Before wash
= ----------------------------------100
Before wash
Spirality test:
Left side Right side
= 2 100 %
Length(wid th for H & M)
A dye comes to industry then a sample fabric is dyed first to make it a reference. When that
dye is used and finished from inventory, new dye is ordered. But it is not sure the dye that
reached newly, will make a fabric as much dyed as before. That is why after arriving of dye
to the factory it is used to make a sample. Then this newly made sample is checked in respect
of previously dyed sample. If the two samples match with each other, it is resulted that the
strength is okay. But if not match then the amount to be given (less or more) is determined.
Remarks:
The laboratory of the factory is well enough to make quality products. But more attention to
laboratory is required to make it more efficient. The informations that lacks about laboratory
in this report is just the result of the unavailability of time of the depart
Chapter Eight:
Dyeing section
Cellulose:
When all impurities have been removed from the natural cotton fiber, cellulose remains.
Cellulose has an empirical formula of (C6H10O5) n. pure cellulose is a white substance with a specific
gravity of 1.5. It burns freely in air with a luminous smokeless flame. Cellulose is insoluble in water
and alkalis but dissolves in cold concentrated sulfuric acid. Like other carbohydrates, when heated
with concentrated sulfuric acid it swells up, forming a mass of carbon. It is also attack by hydrochloric
acid nitric acids.
When hydrolyzed with dilute acids an almost theoretical yield of glucose is obtained. This indicates
that cellulose is a long-chain polymer produced by linking together a large number of glucose units.
Starch and glycogen are also polymers of glucose but they have no fiber forming attributes.
From the foregoing it will be apparent that cellulose is a polymer of glucose, and it must contain a
large number of CH2OH and CHOH groups.
The repeating unit in the cotton polymer is cellobiose, which consists of two glucose units. Cellobiose
is hydrolyzed by the enzyme emulsion, which it is known, will only break down links between beta
glucose molecules. cellobiose consists of two beta glucose molecules linked together at the 1:4 carbon
atoms.
The most important chemical grouping on the cotton polymer is the hydroxyl groups or -OH groups.
These are also present as methylol groups or CH2OH. Their polarity gives rise to hydrogen bonds
between the OH groups of adjacent cotton polymers. Van der Waals forces also occur but
compared with the hydrogen bonds, the Vander Waals forces are of little significance.
Chemical composition of raw cotton:
Others 2.0 %
02 Basic dyes Nylon, Acrylic, Acetate Rayon, Silk, Wool and Jute
03 Direct dyes Cotton, Viscose Rayon, Linen, Nylon, Wool and Silk
08 Disperse dyes Polyester, Nylon, Acrylic, Acetate Rayon and Triacetate Rayon.
Reactive dyes are colored compounds and the only class of dyes that form covalent
bonds between the dye molecules and the fibers. The dye contain reactive group which react
with the fiber and make covalent bond with the fibers in the alkaline condition and act as an
integral part of the fiber is called reactive dye. Reactive dyes may be used for coloration of
cellulose and protein fibers and this is the most important class of dyes for dyeing and
printing of cellulosic fiber.
D B R - X
Where,
D = Dye part
B = Bridging group
X = Reactive group.
Fixation: fixation of dye means the reaction of reactive group of dye with the
terminal -OH group of fiber& thus forming strong covalent bond with fiber.
Controlled by maintaining ph by adding alkali properly.
Wash off:as the dyeing is completed a good wash must be applied to remove extra
or unfixed dye from surface of fabric & for level dyeing it is important.
Substitution reaction:
Addition reaction:
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.
Dyes: The molecules of the organic compounds called dyes are responsible for the color of
dyed and printed lest tile fabric materials. Dye molecules are colored became they are
selectively able to absorbed and reflect incident light. Dyes molecules contain at least one of
each of the radicals called chromophores and auxochromes.
Pretreatment:
Pretreatment is the preparation period of fabric fro dyeing. For getting proper fastness of
fabric and proper dyeing pretreatment is a mandatory process.
Demineralization:
It is a process of removing mineral materials from the water. It is done in water treatment
plant. Water from natural sources contains many mineral materials which may hamper the
dyeing process. If the mineral materials are present in water then it may lead to uneven shade
in dyeing. Besides it may also damage the fabric and the machine.
Scorning:The process to remove fats, oil, waxy substances and added the impurities by
certain percentage of alkali treatment and which increase the absorbing power of the textile
units, is called scouring.
Bleaching:The process by which the natural color of a fiber can be removed and make the
textile this pure white and bright is called Bleaching.
Wetting agent:The chemical which is used for quickly moisten or watering the textile
units is called wetting agent.
Detergent:Detergent are nothing but a chemical which is used for clearing the textile units
or to remove fats, oil and wash. It is know as surface active agent.
Labeling agent:The chemical which are used for dyeing just to give level shade or even
dyeing is called leveling agent.
Exhaust:The absorption of dye moleules from the dye liquor by the fibers being dyed.
(1) Sulostrate
(2) PH
(3) Dyeing Assistant
(4) Temperature
Dyeing AssistanceThese are added in dyeing bath for which dyeing affinity is increased
is called dyeing asst.
(1) Electrolyte
(2) Leveling agent
(3) Carriers
(4) Solvents
(1) Hue
(2) Shade
(3) Brightness
(4) Cost
Topping:The application of further colorant not necessarily of the same hue/class to a dyed
substance in order to adjust the lather to the denied final color is called topping.
Dyeing Process:
Fabric loading
Demineralization
(Wetting /Detergent +Antricreasing+Deminaralizing agent)
[Dosing time 5min temp 400C ]
Temp raised at 550C 20 min
Draining (10-min)
Deteront /wetting agent +Andricreasing agent + Caustic
[Dosing time 20 min temp-500Cmin (Run time]
Temp raised 700C
H2O2(50%) added [700Cmin]
Temp raised at 980C60 min
M/C Cooled (temp drop 800C
Brightening agent added
[Dosing time 30 min 800C min]
Temp raised 980C
Sample check
Drain wash
normal hot wash
PH control at 4.5 (acetic acid leveling agent)
enzyme wash (550C60 min)
0
Temp raised 80 10 min [enzyme killing]
after treatment with acid, leveling agent and softener
unload
Note:
(2) The required temp for enzyme wash in 550- 600C. At high temp (800-820C) the
enzyme destroyed or can ................ during the enzyme wash PH must be 4.5 cause in
alkaline condition enzyme wash can not get well.
(3) At high temperature caustic must be not use, otherwise create hates on fabric surface.
(4) Demineralization have done for remove water hardness and also remove grey fabric
hardness.
(5) Draining have not done directly at 800C to protect crease mark.
Process flow chart for100% Cotton (Black Color):
Fabric loading
0
Demineralization (60 C10) (cracking agent +Diminaralizing agent)
Temp raised 980C 20min
M/C cooled at 800C
Drain wash/ Rising 5min
Added acetic acid for PH control at 4.5
Enzyme wash
EnzymeDosing time 10 min temp550C
Run( 10 min)
PH Ckeck (6.9-7)
Leveling with No bleach N (Dosing 600C 10 min)
Salt dosing (dosing time 30 min 600C 5 min
color dosing (with no. bleach N) , Dosing time 30 min 600C 10 min
Caustic added (PH= 10.5) (Dosing time -30 min 600C 10 min )
Color steam (600C60 min)
Sample check
Drain wash, 60 min
Acetic acid, PH -4.5 300C 20 min
Normal wash
0
Ultram 350 (90 C20 min) (Unfixed dye remove)
Disusing 20 min
Softener (Dosing time= 10 min 400C 20 min)
Unload the fabric
Note:-
(1) This dyeing process for any deep color such as Navy, Red etc.
(2) Black or any deep color dyeing there is no need scouring & bleaching.
(3) No bleach N or leveling agent mixed with dyes for better dye figure or get best
solution of dye figure and happened dye mixing tem not in dye bath.
(4) It the caustic is not use in this process them the common salt and soda ratio will be
80/20 where 20 means amount of soda.
Process flow chart S/J Lycra (Cotton 65%+Polyester 35%) For Blue
Color:
Fabric load
Demineralization (Liqonr1:8{500C1D}
Caustic {Dosing time = 1D min} 500C 10 min
Temp raised 700C
H2O2 (50 %) added {d,T= 1D min 700C 10 min
0
Temp raised 980C10min
Dye bath cool, 800C
Sample check
Drain wash
Hot rinsing
Acid, added, PH- 4.5
Enzyme wash
{dosing 55010min}
0
Temp raised 80 C10 min ,ThenDraining
0
Butter solution added {60 C10 min} (PH Check at 4.5)
Dispersing /leveling agent with sequestering. (600C10 min)
Temp raised 800Cmin
20 grace (20c/ min) temp raised at 1300C 40 min
20 grade temp drop at 800C check
Drainin, 30 min
Normal wash with only water (800C 10 min)Added acetic acid 1%
Cotton dyeing(Previous Dyeing Process)
Unload
Note:-
(1) Polyester fiber or fabric can be dyeing with disperse dye and applied at hight
temperature is, 1300 -1400C.
(2) Disperse dyes have as conic groups and are insoluble in water.
(3) With the help of a dispersing agent dyes can be dispersed in the dye bath.
(4) Reduction clearing is done in case of medium and deep shade only to improve the
wash fastness.
(5) This high temperature process in non loxic and hygienic process.
(6) At high temp like 1300C acid getting weaker so for getting PH 4.5 Butter solution is used in
polyester dyeing process and it is strong acidic along with dispersing agent.
(1) Polyester is a man made, synthetic polyester, polyester filament or staple fiber . The
most common polyester apparel filament or fiber is usually composed of polyester
lerephthalate polyester.
Fabric loading
Demineralization {Dosing time= 15 min 400C5min}
0
Temp raised at 50 C 20 then Draining
Detergent {Dosing time= 5 min 500C5}
+multifunction agent (Nobleach N) SDT=5 500C5
Caustic { Dosing time= 15min 500C5 min
Temp raised at 700C
Added H2O2 (50%) { Dosing time= 10 min 700C5}
Temp raised at 980Cmin
Sample check
Draining & wash (cold wash)
0
cat (80 C 20 min)
(H2O2 Killer)
Draining wash
Acetic acid {Dosing time 400C 5 min}
enzyme wash {550C 60min}
Run 60020min
after PH Check added leveling agent
(anticilConz +Sarabid MIP) {Dosing time=10} 600C10}
Color dosing {Dosing time = 30min 600C10 min
Temp raised at 750C 20 grade
Salt added {Dosing time 20 min 750C10 min}
Temp dropped at 600C
Sample check
Soda ash added {Dosing time= 30 min 600C10
Color steam {600C40min}
(Shade check)
Temp raised at 800C 20 min
Drain wash
Hot wash (Ultraw 350/RBR)
Unload fabric
Process flow chart for R(SPL) 100% Cotton :-
Fabric load
Wetting agent multi function agent (50 0C 15)
Caustic +H2O2{D.T= 10 500C}
(bleaching) (Sousing)
Tem raised 980C60
Drain wash
normal hot 90C 20
Naturalization
Acetic acid (90C 20)
Drain wash
Check PH- 6.8
Leveling with (Dosing time=- 10 330C10
Enzyme dosing (330C10)
Salt added {D,T =30 (330C10) }
Dyes dosing {D,T =30 (330C10) }
Soda added {1 step 20% 2 step 80% }(D,T=10 min) (R.J =5 min)
st nd
Temp raised 550C5
color steam 550C30 min
Drain Wash
Soaping 1%
(800C20medium shade 90020dark shade steam 10
Neutralization for 20 min with acetic acid
Drain wahs
0.5% Ck for Hot wash
(60 C 20 Medium shade 80010 dark shade) steam 10
0
Drain wash
Check PH, 5.2
Softening with CWS {D,T =10 400C 20}
Unload
Uneven dyeing:
Causes:
Uneven Pretreatment
Improper addition of color
Improper addition of chemical
Using dyes of high fixation properties
Less control of dyeing machine
Less circulation time
Remedies:
Remedies:
Remedies:
Causes:
Remedies:
Crease mark:
Causes:
Remedies:
Causes:
Remedies:
Use standard dyes and chemicals
Proper machine speed.
Using soft waste.
Remarks
The dyeing process of Cotton Club (BD) ltd. is very much satisfactory. Cotton Club only
cares for quality. It is heard from the management of the company, after establishing the
factory till now, a single order is not cancelled. Thats why it is sure that the company is well
enough to produce quality fabric.
Chapter Nine:
Finishing section
Introduction of Finishing:
Textile finishing involves treating a textile material in such a way that the product has the
desired properties required for its intended useand therefore has great market value. The
desired properties may include the fabric dimensions and their stability, its weight, drape,
appearance, softness and handle, as well as any required functional properties such as
resistance to creasing, flame, water, oil, dirt or bacteria. Textile finishing is therefore an
extremely diverse field involving an extensive range of chemicals.
The degree of permanency of a particular finish for a fabric depends on its intended use. The
chemicals used may weigh the fabric to make it easy to slide and handle, or allow smooth
penetration of a sewing needle to minimize needle breakage.
Anyone involved in textile coloration must be aware of the influence of preparation process
on the dyeing behavior of the fabrics as well as the finishing chemicals on the final color of
the goods and on their color fastness properties. Without this knowledge, nobody can ensure
the ultimate color and its fastness properties
After dyeing, knit fabric is required to finish. During dyeing all knit fabric are dyed in tubular
form. According to buyer's requirement knit fabric are finished in Open form or tubular form.
The tubular and open finishing sequences of Fakir KnitwearsLTD .Bangladesh Ltd are given
bellow
Flow Chart of finishing for tube fabric:
Dyed Fabric
Tube Dryer
Tube Compactor
Final Inspection
Delivery to Garments
Flow Chart of finishing for Open Width fabric:
Dyed Fabric
Open Squeezer
Stenter
Compactor
Final Inspection
Delivery to Garments
Objective of finishing:
Improving the feel,this depends on the handle of the material and its softness,
suppleness, fullness, etc.
Wearing qualities, none soiling, anticrease, antishrink, comfort, etc.
Special properties required for particular uses water proofing,flame proofing, etc.
2) Mechanical finishing:
Finishing effects:
Easy - care
Crease recovery.
Dimensional stability.
Good abrasion resistance.
Improved tear strength.
Good sew ability
Soft or stiff handle.
Shine or luster
After dyeing process from the dyeing machine then the fabrics arc ready for dc-watering.
This is the process to remove the water from the fabric partially by squeezing. This is the
main function of the squeezing machine. But here also control the some important factor of
the fabric quality.
Squeezer:-
Turntable (Basket)
Detwister
Ring Guide Speeder
Feed R/R
Dancing R/r
Water Pander
Ballon former
Extracting Squeezer
Dancin roller
Softener padder
Ballon Former
Padding squeezer
Main squeezer
Conveyors Blanket
Paliter
Delivery basket
Important parts
Twist detector
Expander
Padder
The basic function of the squeezing m/c:
To remove the water from the fabric.
To control the width of the fabric.
To control the length of the fabric.
To control the spirality of the fabric.
To control the over feeding system.
To increase the softness of the fabric.
To remove the crease mark of the fabric.
Controlling points:
Diameter setting must be accurate.
Excess padder pressure may cause fabric damage. Padder pressure depends on
fabric construction.
Overfeed.
Dryer
Drying is defined as a process where the liquid portion is evaporated from the fabric.
Important Parts:
o Conveyor net
o Chamber
o Burner
o Exhaust air fan
o Over feed roller
o Filter net
o Fan
o Nozzle
Controlling Points
o Overfeed (%): It depends on fabric structure
o Temperature: It depends on color.
o Speed: It depends on fabric construction and color. For higher GSM lower the
speed.
Compactor:-
Basket
Spindle R/r
Centering R/r
Under feed R/r
Over feed R/r
Tension control R/r
Bowing Control R/r
Brush R/r
Endless Clip /Pin
Steam box
Heated Conveyor Blanket
Coaling Fan
Take-Up-r/r
Plaiter
Delivering Basket
TUBE COMPACTOR
Important parts
Overfeed roller
Expander
Blanket
Steam sprayers
Cylinder
Teflon covers
Controlling Points
a. Temperature : It depends on construction and composition &color of the fabric.
d. Over feed : Over feed should be optimum. It increases GSM but higher over feed
leads to the formation of crease mark.
Observation of tube compacter setting for different fabric
Fabric
parameter
Compector 30 30 N/A
Overfeed 5 12 N/A
OPEN COMPACTOR
Important parts
Over-feed roller
Blanket
Steam sprayers
Cylinder
Tell on covers
The basic functions of the Open compactor machine
To control the GSM. (Increase& decrease).
Controlling Points
d. Over feed :Over feed should be optimum. It increases GSM but higher over
feed leads to the formation of crease mark.
Fabric
parameter
Slitting Machine
Slitter:
Basket (M/C)
J. Box (Padder)
Retested
SlitteringRevice (Shape &Knife)
Spindle R/r
Cantering R/r
Spindle R/r
Squeezer
Take-up-roller
Pleiter
Delivery Basket
Important parts
Twist detector
Cutting knife/device
Padder
Controlling Points
Stenter:-
Basket
Spindle R/r
Centering R/r
Spindle R/r
Water Padder
Squeezer (1) (4 PS1)
Dancing R/r
Spindle R/r
SofternerPadder
Squeezer-2 (3PSI)
Dancing R/r
Bowing control R/r
Under feed R/r
Over feed R/r
Brush wheel
Endless Pin Chain
Steam BOx
Burner Chemicals
Cooling Fan
Take-up R/r
Planter
Delivering Basket
Important parts
Burner
Exhaust air fan (4 )
Suction fan (8 )
Overfeed roller
Nozzle
Chain arrangement
To control GSM.
To control shrinkage.
To control spirality.
Drying of fabric.
Controlling Points
Fabric
parameter
Required Dia 88 80 54 80
Machine speed 20 18 18 16
Fabric Inspection :
The finished fabric may have different kinds of faults. This may occur during Knitting,
dyeing or finishing. If the fabric delivered then the quality of the fabric may not be good and
the buyer will reject the finished garments. For this reason careful inspection of this finished
fabric is so important. In finished fabric the following faults are generally found:
Here, 4- point system is used for inspecting goods. Spining knitting and processing
faults are inspected and enlisted here, commons fauls that are found here are yarn,
cont............... slub, neps hole, needle mark, niuker mark lyera miss/out, oil stain , crease
mark, softener mark, color spot mark, Bowing mark etc.
() 4 Point system:
Fault size Points
0-3 1
>3 -62
>6 -93
>94
Hole 4
Acceptance
Up to 40 Points =A
41-60 Points =B
61-80 Points =C
80 above = Rejected
Calculation:
This report is prepared according to buyer name order no. It can be done both for
finished fabric /T-shirts. Amount of shrinkage is expressed both in percentage (%) and in can.
This report contain information about roll no, M/C dia Required dia, Finished dia,
Finished GSM, Shrinkage (Length &widith wise) etc.
GSM Board
GSM of finished fabrics from different rolls of a Batch is around here with sample.
GSM of 50% acceptable from required.
Chapter Ten:
Quality Assurance System
The quality assurance department is assigned to maintain consistently uniform quality of the
material; in process and various stages of its manufacturing.
The focus of the quality policy of Fakir Knitwear Ltd has been to provide products at a
price and service advantage through direct response mechanism. In order to sustain the
investments in the key technology area concerning our business, Fakir Knitwear have made
significant investment testing and quality assurance equipment from the best in the world in
each of our production bases and also ensured a Company-wide standardization discipline
through implementation of OEKO-TEX & ISO 9001:2000. These are reinforced periodically
through personal interactions between their filed representatives and consumer of their
products. Fakir Knitwear Ltd advance management team along with well-trained Quality
Assurance team ensures the best quality of products to meet the international standard.
The quality team follows some standardized international rules which are as
follows:
Moreover the quality team creates various types of report for maintaining the best quality.
They always create GSM check report, Light box system report. The process of the quality
teams are:
Pattern test
Trial Inspection
In line Process
Pre-final process
Final Process
Fakir Knitwears Ltd is the only factory in Bangladesh that got the nomination from the world
renowned buyer H&Ms skip process. The In house quality team maintains the quality and
inspection of the H&Ms product and finishes the final inspection. They have also a GPQ
team to ensure the work process of quality team. This is for why they always maintaining the
best quality for their friends (buyers) products.
Quality Control:
Quality control is concerned with the evaluation of test data and its application to control of
the textile process, raw materials, intermediate products and final products. It is concerned
not only with quality level and cost of maintaining this quality level but also concerned with
the presentation of tangible values to measure quality and changes in quality. In order to
control quality one must know about the consumers expectations.
Quality assurance:
Quality assurance is defined as all those possible planned and systematic actions necessary to
provide adequate confidence than a product or service will satisfy given requirements for
quality. The Quality Assurance Department is assigned to maintain consistently uniform
quality of the material in process and various stages of its manufacturing
Yarn receiving
Sample Knitting
Batching
Compacting
Final inspection
On-Line
Off-Line
Process control:
The method chosen for process must be provided with necessary
parameters.
During knitting, samples are taken and G.S.M checks with the reference
samples.
If not properly reset the machine parameter.
Sample is collected after fixation & matched.
During finishing, temperature, speed, padder pressure, overfeed should be
controlled as per requirement.
GSM, width, spirality, shrinkage (both length & width) should be
maintaining as per buyer requirement.
Finish fabric inspection:
Purpose:
To ensure that only an acceptable quality fabric is used for producing garments and
proper quantity of shipment is received from the supplier.
Scope:
All produced and incoming fabrics of Fakir Knitwears Ltd.
Procedure:
Store in charge will check the received fabric with the reported length,
color and type of fabric with the stated shipment document quantity and
the actual order quantity.
The finding will be recorded in inventory report and discrepancy regarding
fabric type, color and length will be notified to the Factory
Manager/Manager (Dyeing & Finishing).
For in-house products quality control officer will guide all over inspection.
- PH test.
On-Line Tests:
FKL have all the facility for off-line quality control of the materials used and processed
materials. There are two types of materials are tested in GKL laboratory for the purpose of
quality control. This are
A. Fabric testing.
B. Raw materials testing.
A. Fabric testing:
All the Off-line tests for finished fabrics can be grouped as follows:
1. Physical Tests.
2. Chemical Tests.
Physical tests:
Fabric inspection by 4-point system.
G.S.M test.
Width of the fabric measure.
Rubbing test.
Pilling and Snagging test.
Shrinkage test
Twisting test
Chemical tests:
Color fastness to water.
Color fastness to wash.
Color fastness to perspiration.
Oxidative test damage.
Saliva test.
B. Raw material testing:
Yarn count test.
Yarn strength test.
Yarn TPI test.
Lycra count test.
List of Equipments:
Sl. No. Machine Name Model Serial Manufacturer Built Year Origin
No. No.
Measurement direction:
Assessment:
Rating Remark
5 Excellent
4-5 Good
4 Good
Grey scale value for 3-4 Average
staining 3 Average
2-3 Average
2 Poor
1 Very poor
Rating Remark
5 Excellent
4-5 Good
4 Good
Grey scale value for 3-4 Average
change value & 3 Average
staining 2-3 Average
2 Poor
1 Very poor
Dimensional stability:
It is now quite common to measure the Grey Scale change in color instrumentally. This is
made using a suitable reflectance spectrophotometer according to the test method
procedure, EN ISO 105-A05.
Grey scale for assessing staining:
This Grey Scale is for assessing the degree of staining caused by a dyed Textile / yarn in
color fastness tests. For example, the staining of wool and cotton fabrics in the wash fastness,
perspiration fastness, etc.
The scale consists of nine pairs of gray color chips each representing a visual difference and
contrast.
Chapter Eleven
Garment Section
Sample Section
Responsibilities:
Speed- 3000-3600
Volts-220 V
- Cycle-50/60
Sewing machine
2-Necdle Lockstitch
Steam ironing
Machine Brand:
1. BROTHER (Japan)
2. Pl-GASUS (Japan)
1.Quotation sample:
At first they make a sample of medium size as per buyer requirements is called quotation
sample. If the sample is not ok they make another sample called revised quotation sample.
If the quotation sample is ok then they make the samples of all size which are call size set
sample. If it is not ok the make revised size set sample.
3.Production sample:
Finally they make the sample for production called production sample
Working procedure:
Inspect the sample after finishing.
The sample is then provided to merchandizing dept.
If it is ok they are called to make size set sample or if it is not ok they have to make
revised quotation sample
They make grading pattern by the CAD department
Make sample of all size as the same procedure and provide to merchandizing
department. If it is ok they make production samples or not they have to make revised
size set samples.
CAD (Computer Aided Design) Section
Responsibilities:
Make basic pallern and production pattern.
Make fabric consumption with allowance %, shrinkage% and total process loss %.
Usage equipments:
1. Misfires software for pattern making.
MARCHANDISING
All 95/5% cotton single jersey fabric 3cm for body length & 2cm for biceps
two side.
All 100% cotton single jersey fabric 3cm for body length & 2cm for biceps
two side.
2.Shrinkage percentage
3.Process loss
For making actual fabric consumption the CAD section consider following process losses.
V. H& M and Tema consumption for all type of yarn dyed fabrics with
bio finish.
losses losses
Formula:
Totlal area of the market
Fabric consumption in Kg no. of required garments
member of garments in the market
Note:
In the CAD section normally they calculate the fabric consumption for a large size sample.
For this, the amount of required fabrics is more. So fabric wastages are more. If it is possible
to evaluate the fabric consumption for each then some fabrics may be save. And it will be
beneficial for the Company.
Cutting section
Spread the fabric in the cutting table with required diameter required amount.
Make the fabric according to the si/.e, lot, amount of pieces and etc
Store the fabric into input area and deliver the cut fabrics to the sewing department.
Working procedure:
File collect from planning department
Fabric collects from store
Marker come from CAD
Fabric folding by auto folding machine
Fabric spreading (Lay)
Marker setting on the lay
Cutting (By using Straight knife, and automatic cutter)
Sticker attaches & hand check
Reject part change
Bundling
If required Print / Embroidery
Store on input rack
Equipments usage:
1. Cutting table
Unit 1-6
Unit 2- 7
Unit 3- 4
Number- 4
Brand-KONSAN .
Number- 4
Brand- fly
4. Auto cutter 1
Brand- I.cctra
5. Auto cutter 2
Brand- Takatori
Model- UN
Fabric diameter- upto 73"
Brand- KM
Speed- 3000-3600
Volts- 220 V
Cycle- 50\60
8. Inspection table
9. Input rack
Brand- I.cctra
5. Auto culler 2
Brand- Takatori
Model- UN
Brand- KM
Speed- 3000-3600
Volts- 220 V
Cycle- 50\60
8. Inspection table
9. Inpm1 rack
Process loss:
Fabric loss is a major contribution to material utilization. Minimizing fabric loss during
spreading can reduce the total production costs for garment manufacturing. This is the key
point which has been highlighted in this report. Today garment industry is facing very tough
scenario because of more competitors and less buyers, buyers have many options but
suppliers have very limited choices, the time has gone when there was quota system and
garment industry didn't need to be very many efficient but today suppliers are fighting for
price and quality; on fewer prices better quality is expected. Orders are given to the suppliers
who offer better quality and less prices. So within such scenario, only the things which can
increase profit and minimize loss of a company is fabric saving. Fabric loss in cutting section
may be for following reason.
Inefficient marker
Variation of fabric diameter
Higher GSM than required
More fabric faults
More dyeing faults.
Note:Strife fabrics and low GSM fabrics arc cut by hand cutting
Communication module of Sample, CAD and Cutting Section:
Sample
Merchandising
CAD
Printing/
Embroidery Cutting
Sewing
ChapterTwelve:
Cost Analysis
Cost analysis
The costing of the product is most secret matter of the Industry. They are not interested
to flash the cost related data. So we could not collect the Costing process of the products.
Calculation:
For dyeing total process lost: 12% to 15%.
Say, Process lost: 12% for given sample.
From given sample, we find out
Yarn count: 30/1 Ne.
S L: 3.07 mm. or Finish GSM/S.L =? (When color yarn used for knitting)
Gray GSM =?
M/C gauge =? (1 inch = No of loops (sample) = No of needles)
No of feeder & No of active feeder =?
M/C Dia =?
Note:
1. If yarn count change then yarn purchased cost change.
2. If yarn color change then dyeing cost increase / decrease.
3. If washing & finishing process change then washing & finishing cost change.
Remarks:
The costing of the product is most secret matter of the Industry. They are not interested to flash the
cost related data. So we could not collect the Costing process of the products.
ChapterThirteen:
Maintenance
Maintenance
Maintenance;
Maintenance is the 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 customer is sustained. Maintenance can increased machine life and ensured trouble
free service
Maintenance of Machinery:
Maintenance
Preventive Maintenance:
Preventive Maintenance is a predetermined routine actively to ensure on time
inspection or checking of facilities to uncover conditions that may lead to production
break downs or harmful description.
Routine Maintenance:
Maintenance of different machines is prepared by expert engineers of the maintenance
department. Normally in case of dyeing machine maintenance after 30 days complete
checking if different important parts are done.
Corrective Maintenance:
Corrective Maintenance is done after a failure has occurred. Fakir KnitwearsLTD. has an
expert team for maintenance. When problem occurs they actively solve the problems.
Maintenance Procedure:
As a part of maintenance normally Fakir KnitwearsLTD. follows preventive
maintenance. During maintenance procedure following points has to be checked.
Maintenance: Mechanical
Machine : Dyeing
S/l No. Items need to be checked and serviced
8 Checking exhauster
Maintenance: Electrical
Machine : Dyeing
Utility Services
Utility Services
Boiler:
Boiler is mainly used to produce and deliver steam to different section as required.
3. Corrosion of boiler:
Type Total
Model Serial no Brand Country
nos
DDHI 5.0-10 188/9 Omnica Germany 2
Fire tube
UL-S-1000 103730 Loos Germany 3
Power plant:
Our Countrys most important issue is power sector. The government faces lots of problem
for supplying the power for industrial sector. Considering all these, at the very beginning of
establishment of Fakir Knit wears Ltd; Fakir Knitwears Ltd. using their own power generator.
They have vast setup for the own power source and generating 24 hour power system to
successfully running our whole project. They have:
Electricity:
The main utility electricity is supplied by generator.
Gas Generator:
04 Waukesh 415/ 1000 50 1565 1125 900 3.6 Mw 2.8 Conti USA
a Power 24 MW nuous
Systems hr
Total power is then distributed as per requirements of different section like knitting,
Dyeing (yarn/ fabric), Finishing, Maintenance, WTP, ETP etc.
Compressor:
Compressor is mainly used to deliver compressed air to different section as
required. In FakirKnitwears Ltd. they usedcompressors to produce and deliver
compressed air to different section.
In Fakir Knitwears Ltd. follow the base Exchange water softening process for softening the
hard water.
In where Z is the abbreviation for the Al2O3 SiO2 H2O part of Zeolite.
Regeneration:
1 kg resin required = 200 gm salt
Salt : water = 1 kg : 4.5 L
Used water = 6500000 Ltr/Day
Chapter Fifteen
Waste Management system:
ETP:
Effluent is the stream of excess chemical liquor extracted from an industry after using in original
operation. In the case of dyeing industry, the excess dye liquor extracted from textile industry
after dyeing is an effluent of that industry.
Fakir Knitwears Ltd commitment to the environment can be gauged from the fact they seek to
meet all the legal norms. Taking for instance the establishment of ETP & WTP because they
have, nothing is more important than the maintenance of pollution-free environment. Fakir
Knitwears Ltd. Establish a ETP plant which is the biggest and no.1 ETP plant in Bangladesh.
Fig: ETP Plant
Process sequence:
Screen brush
Storage tank
Neutralization tank
Distributor tank
Sedimentation curve
Sludge return pump slump
Sludge thickener
Filter press
Used chemicals:
Sodium hypochlorite
Nutrient salt
Anti foam
Sulphuric acid
Poly electrolyte
decolorant
Testing lab instrument:
microscope
BOD sensor system
Thermo reactor
Spectrophotometer
Digital muffle furnace
Portable DO meter
Portable DO meter
Micro-processor PH meter
Electrical balance
BOD 281 23 50
COD 730 56 200
TDS 2730 1811 2100
TSS 204 31 150
EC 5210 3403 1200
DO 0.1 4.6 4.5 8
Chloride - >200 600
Phosphate 2.6 2.2 8
Nitrite PPM 0.15 0.08 50
Nitrate 0.9 0.6 10
Ammonium 0.09 .07 5
Sulphate - 27 -
Arsenic - - 0.2
Cobalt - - -
Cynanide - - -
PH - 10.2 7.8 67
Tepm. C 41 37 40
Cadmium PPM - - 0.05
chromiun PPM - - 0.5
Chapter Sixteen
Conclusion
Conclusion
There is large difference between the theoretical knowledge and practical experiences.
This is truer in case of the study of Textile Technology. Industrial attachment or,
Industrial training is an essential part for textile education because it minimizes the gap
between theoretical and practical knowledge. The Industrial training increase our
though a lot about textile technology. It also helps us to know a lot about industrial
production process, machineries, and industrial management and made us suitable for
industrial life. Besides it gives us the first opportunity to work in industry. So we can say
industrial attachment prepare us for the expected destiny of practical life.
My Achievements:
We have got a lot of knowledge about the laboratory work and the steps
that should be maintained before bulk production.
We have identified the process sequence dyeing and gathered adequate
knowledge about each process sequence.
We have earned some mechanical knowledge about dyeing machine.
We have found some special points that should be considered during
dyeing production.
We have understood about industrial environment and administration .
Some suggestion:
Industrial salt should not be used because it corrodes the inner parts of
dyeing machine.
Dyeing production needs to increase as well as technical persons need to
be employed there?
More skilled labor should be used in a project and the overall efficiency
will have to be increased.
Dyeing machine must keep dust free.
There need proper handling of the machine.
Check all production parameter regularly.
Dyeing floor should keep always net and clean. It kept wet after unloading
the fabric from the dyeing machine specially, for Athena. Water must be
swept time to time.
During the transport of the fabric and during the loading of the m/c,
fabrics get soiled due to their drawing over the floor. This makes the
fabric/part of the fabric dirty. It may require more scouring/bleaching
agent or may create stain.
Due to the pressure of higher production sometimes machine operators
do not maintain accurate time according to the actual process so that less
quality product is produced and may reject. So need to be increased
machine and reduce the pressure on the operator.
Should increase understanding between the top level personal and floor
level personal.
Finishing section need to be enlarged well as more technical persons need
to be employed there?
The m/c stoppage time should be analyzed and minimized. The
maintenance should be carried out when the m/c is out of action
(Wherever possible) and routine maintenance should be carried out
regularly.
In the Laboratory there is no technical person, a textile engineer may be
employed here.
There is shortage of proper light in the dyeing and finishing floor,
specially, when smoke is produced from dryer and stenter. Proper
lighting should be provided in the floor.
The person at the top level of a department must take good care of the
trainees & he should provide all kinds of support to them.
Limitations of the report:
Because of secrecy act, the data on costing and marketing activities have
not been supplied.
We had a very limited time. In spite of our willing to study more it was not
possible to do so.
Some information in different sections are not included as these were not
available.
It is not possible to hold the whole thing of a textile industry in such a
small frame as this report. So, try our hard to summarize all the
information that we are provided.