beximco textile limited

7/24/2019 Beximco Textile Limited

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Internee ReportOnBeximco Textile Limited

(Course code: TE-410)

Supervisor

Rabiul Islam Khan

Lecturer

Department of Textile Engineering

Facult of !cience " #nformation Tec$nolog

Prepared ByMainul Morshed

ID : 091-23-1194

%rogram: &'!c' in Textile Engineering

Facult of !cience " #nformation Tec$nolog

Department o !e"tile #n$ineerin$

1 Dafodil International University Library


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%c&no'led$ementt t$e er *eginning # ac+no,ledge t$e infinite *lessing " profound +indness of%lmi$ht( %llah)-T$e supreme aut$orit of t$e unierse' # also ac+no,ledge t$eloing support of m parents " famil mem*ers'

Mr* Rabiul Islam Khan .ecturer/ Department of Textile Engineering/ Daffodil#nternational niersit/ m superisor/ to ,$om # am extremel grateful for $istremendous support " guidance t$roug$out m internee'

&eing ,or+ing ,it$ $im # $ae not onl earned alua*le +no,ledge *ut ,as alsoinspired * $is innoatieness ,$ic$ $elped to enric$ m experience to a greaterextent' is ideas " ,a of ,or+ing ,as trul remar+a*le' # *eliee t$is internee

report could not *e finis$ed if $e did not $elp me continuousl'

# ,ould li+e to t$an+ %rofessor DR* Md* Mahbubul +a,ue ead of t$eDepartment of Textile Engineering/ Daffodil #nternational niersit/ ,$o $asinspired me to ta+e " continue t$is report'

# ,ould li+e to t$an+ t$e management of t$e 2.e"imco !e"tile Limited3 for

giing me t$e opportunit to do t$e industrial training successfull " also t$eiralua*le suggestions' deepest appreciation goes to Mr* Khairu//aman Khan,it$out $is permission to conduct m industrial training' # ,ould also li+e to t$an+executies/ senior executies " ot$er officials of &eximco Textile .td' for $elpingme to complete industrial training successfull' gratitude also goes to all t$eemploees of &eximco Textile .td' for t$eir sincere co-operation/ support "alua*le adices'

.ast *ut not t$e least/ t$an+s go to all t$e people ,$o $ae assisted/ $elped "inspired me to complete t$is tas+ at arious stages' # reali5e t$at ,it$out t$eircontinuous support # ,ould not *e a person # am rig$t no,'



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Introduction

T$e term textile means originall a ,oen fa*ric/ *ut textile " t$e plural textiles

are no, also applied to fi*re/ filament " arn' 6atural " manufactured fi*re "most products for ,$ic$ t$ese are ra, materials are called textiles'

T$is definition em*races/ for example fi*re *ased products in t$e follo,ingcategories: t$reads/ cords/ ropes " *raids/ ,oen/ +nitted " non-,oen fa*rics/lace/ nets " em*roider/ $osier +nit,ear " made up apparels/ $ouse$old textiles/soft furnis$ing " up$olster/ carpets " ot$er floor coerings/ tec$nical/ industrial" engineering textiles include geo textiles " medical textiles'

Textile education is *ased on industrial ground' T$eoretical *ac+ground is notsufficient enoug$/ for ,$ industrial training is an essential part of stud to ma+e atec$nologist tec$nicall sound in t$is field' #ndustrial training proides me t$atopportunit to gat$er practical +no,ledge'

&eximco Textile .td' $as t$e capa*ilit to offer a complete product range for t$e

export textile mar+ets' T$e goal of &eximco Textile .td' is to *ecome t$e preferredpartner for sourcing $ig$ 7ualit fa*rics " clot$ing from &anglades$ ,it$ $ig$ladanced tec$nolog " an emp$asis on deeloping local $uman resources'&eximco Textile .td' $as t$e potential to ma+e an important contri*ution to t$enation8s gro,ing readmade garments export sector'

T$e rationale *e$ind t$e existing structure " future expansion of &eximco Textile.td' is to capture alue added at eac$ stage of t$e textile manufacturing process'Despite &anglades$8s lac+ of indigenous cotton production capa*ilit/ &eximcoTextile .td' $as leeraged &anglades$8s la*or cost adantage " exportcompetitieness to t$e maximum leel'



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!able o ontent

ame o contents a$e o*

hapter-1: eneral inormation o .e"imco !e"tile Ltd* -21Compan profile 9

istor of &eximco

ission of &eximco -11

;ision of &eximco 11

Commitment of &E=

Deelopment of .a* Dip >>

Color measurement of standard sample >4

ac$ineries for .a* Dip >4->A

%arameter s$eet for .a* >A->B

as$ing se7uence of .a* >B

.ig$t sources for different *uers >?hapter-4: retreatment o .e"imco !e"tile Ltd* 38-44

Desi5ing mac$ine >

&leac$ing mac$ine 40-41

#nformation of merceri5ing mac$ine 4=-4>Flo,-c$art of merceri5ing process 4>

hapter-: D(ein$ section o .e"imco !e"tile Ltd* 4-0

T$ermosol ac$ine 4B-4?

Deing recipe 4?

igger mac$ine 4?-49



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ater pumps AB

ater softening 9?

Flo, c$art of ,ater treatment plant 9?hapter-12: #luent treatment plant o .e"imco !e"tile Ltd* 88-91

#ntroduction 9a@or effluent sources 9

C$emical used in ET% 9

C$aracteristics of ,aste ,ater 9

%rocess se7uence of ET% 0

ualit of treated ,ater 1

hapter-13: In6entor( o .e"imco !e"tile Ltd* 92-94

#nentor control >

!cope of #nentor control >

#nentor sstem for ra, materials >-4hapter-14: ompliance o .e"imco !e"tile Ltd* 9-98

Definition B

Compliance issues B-9hapter-1: onclusion 99-101

ac$ieement 100

!uggestions 100-101

.imitations of t$e report 101

.astl 101



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1st hapter

eneral inormation of

.#>IM? !#>!IL# LIMI!#D



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ompan( roile:

ame &eximco &extex .imited

In6estor !alman F' Ga$man " '!'F Ga$man

?R?R%!# +#%D/000 illion Ta+a%ID = %I!%L I .D! 1/99='A0 illion Ta+a=M.#R ?; 7+%R#+?LD#R7 >?/=

=M.#R ?; 5?B# L??M7I7!%LL#D

=>

=M.#R ?; 7IDL#7

I7!%LL#D11/A=0

=M.#R ?; D#IM L??M7

I7!%LL#DAB

=M.#R ?; IIR=L%R KI!

M%+I# I7!%LL#D>0

R?D=!I? %%I!@ =9 illion .inear eters

=M.#R ?; #ML?@##7 A/191



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+istor( o .#>IM?:

&extex .td' (t$e Compan) ,as incorporated in &anglades$ as a %u*lic .imited

Compan ,it$ limited lia*ilit on 9 arc$ 14 and commenced commercialoperation in 1A and also ,ent into t$e pu*lic issue of s$ares and de*entures int$e same ear' T$e s$ares of t$e Compan are listed in t$e D$a+a and C$ittagong!toc+ Exc$anges of &anglades$'

&extex .td' is t$e most modern composite mill in t$e region' &extex .td' $as aninstalled capacit of =99 $ig$-speed air-@et looms in its ,eaing section and a$ig$-tec$ deing and finis$ing section ,it$ a capacit of 100/000 ards of finis$edfa*ric per da' T$is compan is located at t$e &eximco #ndustrial %ar+ '

&extex .td' $as a state of t$e art composite +nit fa*ric production mill/ ,$ic$seres t$e gro,ing needs of $ig$-7ualit +nit garments exporters in &anglades$'T$e pro@ect ,as set up as a state of t$e art +nit fa*ric +nitting/ deing and finis$ingfacilit' During t$e ear t$e Compan produced and sold $ig$ 7ualit of +nitfa*rics and *ringing fort$ all t$e latest in $ard and soft tec$nologies in +nitting/deing " finis$ing of +nit fa*ric'

&extex .td' also $as a cotton and polester *lended arn-spinning mill/ ,it$1==/000 spindles is one of t$e largest spinning mills of t$e countr' T$e mill ,as

set up to feed t$e countrLs export oriented industries'

&extex .td' produces speciali5ed finis$es of denim clot$ for export in finis$ed as,ell as clot$ onl form'

Mission o.#>IM?:

&E


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das/ t$e roup $as eoled from *eing primaril a commodities trading companto a leading/ diersified group ,it$ a presence in industr sectors t$at account fornearl ?AM of &anglades$8s D%' &E


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C$eron/ Calin Jlein/ "/ C %enne/ acs/ Para/ 6#CEF/ Goal Doultonand ;illero " &oc$'

&E


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ommitment o .#>IM? to the #n6ironment:

Our compan is er committed to presere a $ealt$ and pollution-freeenironment' #t $as a er efficient ,aste collection and disposal sstem' #n orderto reduce air pollution * ex$aust of gas from engine-generators/ it maintains acostl plant t$at uses t$e ex$aust gas to generate steam for c$illing unit' *oemeasures not onl $elp +eep t$e ,ater " air free from pollution *ut also $elp saecost of ,ater treatment " air conditioning' Kour compan uses onl PO-free des

and is dedicated to ensure a $ealt$ and eco-friendl enironment'



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Location o .#>IM?:



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Gazipur Highway

Nabinagar,Savar

B!I"#

$IndustrialPar%

roducts o .#>IM?:



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Yarn Products:

Count: Ganging from B N 1=0/

Fi*er - Cotton ( super N com*ed/ com*ed/ carded)/

C;C - B0M cotton/ 40M polester/ TC - BAM polester->AM cottonR 100M polester *ot$ regular and se,ing

t$read/ .ocell/ Tencel/ odal/ Gaon/ ;iscose etc'

Fabric Products:

7olid D(ed

%oplins

T,ills

Do**ies

Oxfords

!eersuc+ers

Canas

Gi*stops in 100M Com*ed Cotton

C;C and C;!HTC

!tretc$

!ateen

@arn D(ed

ing$ams

!tripes



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Fill-a-fillsHEnd-on-ends

C$am*ras

!eersuc+ers

%inpoint

Oxfords

Do**ies

%laids in 100M Com*ed Cotton

C;C and C;!HTC

!tretc$

!atin

;inishin$

rin+le Free

Eas Care

%eac$

C$int5

%aper Touc$

Teflon Coated

ater Gepellent

ater Gesistance

Gu**eri5ed



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Dobb( Desi$ns

erring*ones/

&edford CordsHCoteles/

affles and arious structures in 100M Com*ed Cotton/

C;C and C;!HTC'

@arn ount

Ganging from ? to 1=0'

Knit Products:

erse : #n 100M Com*ed Cotton/ C;C/ C;!HTC/ and .cra mix/

%olo %i7ue : #n 100M Com*ed Cotton/ C;C and C;!HTC/

&ac+ %i7ue : #n 100M Com*ed Cotton/ C;C and C;!HTC/

erring*one : #n 100M Com*ed Cotton and C;!HTC/

%opcorn : #n 100M Com*ed Cotton and C;!HTC/

&u**le Jnit : #n 100M Com*ed Cotton/ C;C and C;!HTC/

Crepe : #n 100M Com*ed Cotton and C;!HTC/ Engineering !tripe : #n 100M Com*ed Cotton and C;!HTC/

Feeder !tripe : #n 100M Com*ed Cotton and C;!HTC/

uto !tripe : #n 100M Com*ed Cotton and C;!HTC/

Gi* : #n 100M Com*ed Cotton and C;!HTC/

ac7uard : #n 100M Com*ed Cotton and C;!HTC'

Denim Products:

C$am*ra : #n classic indigo colours ranging from 4o5 to A'Ao5HKd=

Denim (*lue) : #n classic indigo colours ranging from 4o5 to 1Ao5H Kd=

Denim (*lac+) : #n sulfur *lac+ colour ranging from 4o5 to 1Ao5H Kd=

Coloured Denim : #n a ariet of colours - *ot$ in sulfur " reactie

des(,arp ded) Oerded Denim : #n a ariet of colours on indigo *lue " sulfur *lac+



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&ull Denim : #n a ariet of reactie colours ranging from 10o5 to 1>o5H Kd=

(piece ded) !tretc$ Denim : #n classic indigo colours ranging from 4'A o5 to 1>'?A

o5HKd='

Special Yarn Products:

%lied Karn/ Fanc Karn/ !lu* Karn (?Ls to =0Ls)/ !tretc$ *ot$ .cra (10Ls to 40Ls) and

!pandex and ot$er Core !pun/ ulti count/ ulti T,ist etc'

Unique rin!le"Free product:

?R!#K-2000

m*edded filament core/ ,$ic$ ma+es it permanentl ,rin+le-free' no resins orc$emicals are used ma+ing t$e fa*ric ecologicall friendl as ,ell as $ig$ldura*le'T$e tec$nolog proides t$e soft/ natural comfort of cotton and t$e ,rin+le-freeconenience and strengt$ of snt$etic fi*re' &eximco is t$e manufacturer and

exclusie licensee in *anglades$ of Cortex-=000/ !'

?!R% D 3* C

T$is is a 100M cotton fa*ric/ ,$ic$ is c$emicall/ treated in a $i-tec$ precureprocess ,$ic$ is safe/ clean and ecologicall friendl' T$e result ac$ieed meets adura*le press rating of dp >'AS (aatcc - 1=4)'%reiousl/ t$is result could onl *e ac$ieed * ammonia processing ,$ic$ is

rapidl *ecoming o*solete/ as it is $a5ardous to $ealt$ and enironment'&eximco is t$e manufacturer and exclusie licensee in &anglades$ of Cotra dp >'AS/ !'



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roduction o .#>IM?:

&E


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7er6ices o .#>IM?:

Speed to #ar!et $pportunities:

!uppl c$ain model *ased on a relations$ip of trust and simple/ s$ort

procedures/

ar+eting model *ased on afforda*le/ 7uic+ c$ange fas$ion/

Clear pro@ection or commitment and firm *oo+ing of capacit/

aximi5e design/ product deelopment capa*ilit of manufacturer/ incolla*oratie design process/

On-spot placement of order after reie,ing of designs/

Focused product deelopment' ig$er adoption rate from collection/

;ertical facilit ena*ling 7uic+ response/ ,$ic$ allo, us to produce from

Karn to arment in fift das and repeate orders in t$irt das/ leading to

reduced mar+do,ns'

Desi%n Studio & #ission:

To proide design and product deelopment support from fi*er to garments

to leading retailers and *rands using integrated manufacturing resources/

po,erful CD tools/ tec$nolog colla*oration ,it$ ma@or suppliers (li+e

C#&/ Du%ont etc') and interface ,it$ fas$ion for,ard customers/ rapidl

deelop and *ring trend/ innoatie differentiated products to our strategic

partners eer season' Our Design !tudio ,or+s to produce entire

collections ,it$ #nditex including ,omens and mens clot$ing/ ,oen and

+nit tops/ casual and denim *ottoms and @ac+ets' e $ae no, introduced a

catalogue ,$ic$ ,ill $ig$lig$t our concept of complete ne, loo+s/ products



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and fa*ric s,atc$es and ,e ,ill *e sending one of t$ese to all our +e

customers almost eer eig$t ,ee+s'

Resources emplo'ed to (ul(ill t)e mission:

=A $ig$l 7ualified designers ,$o trael t$e ,orld isiting fairs/ interfacing

,it$ t$e designers of fas$ion for,ard customers and competitie *uing

from ,ell +no,n fas$ion outlets/ 1A0 people ,or+ing in se,ing room dedicated to design team/

Dedicated arn deing/ ,arping and ,as$ing facilities for design team/

Cooperman adanced erman net,or+ed CD sstem'



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ustomers o .#>IM?:

Springfield VAN Heusen Calvin Klein

DKNY Zara J.C. Penny

Next IZD Ari!"na

H # $ %e"ff"ry &eene St. J"'ns &ay

$"t'er Care Arr"( J. )errar



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&ers'*a Kennet' C"le +ea,ti"n De,ree

-SPI+I CHAPS /evis



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2nd hapter

5o6en 7ectionof




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Deinition:

oen fa*ric composed of t,o sets of arns " formed * ,eaing/ ,$ic$ is t$einterlacing of t$ese sets' One set of arns t$e ,arp/ ,$ic$ runs along t$e lengt$ oft$e fa*ric' T$e ot$er set of arns t$e ,eft/ ,$ic$ is perpendicular to t$e ,arp'oen fa*rics are $eld toget$er * ,eaing t$e ,arp " t$e ,eft arns oer "

under eac$ ot$er' & using arious com*inations of t$e t$ree *asic ,eaes (plain/t,ill " satin)/ it is possi*le to produce an almost unlimited ariet ofconstructions'

#n addition to ariations in ,eae/ man noelt effects ma *e o*tained * suc$met$od as:

sing different filament or spun arn/

Karn made of different fi*res/

Karns ,it$ different amounts of t,ist'

et$ods of ma+ing fa*rics ot$er t$an * ,eaing include +nitting/ felting/ needlepunc$ing/ netting/ croc$eting/ lace ma+ing/ tatting " * *onding toget$er fi*re,e*s as in non-,oen fa*rics'

Manpo'er o 'o6en section:

7ection Manpo'er

re-treatment 9



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D(ein$ 10?

;inishin$ A


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6o' of mac$ines: 0=

&rand name: onforts onfortex

Origin: erman

%roduction capacit: 0000-100000 mHda

Merceri/in$ machine

6o' of mac$ines: 01


Origin: erman

%roduction capacit: A0000-?0000 mHda

D'ein% section:

!hermosol machine

6o' of mac$ines: 0=


Origin: erman

%roduction capacit: 1A00 mHda

i$$er

6o' of mac$ines: 01

&rand name: oller

Origin: erman

%roduction capacit: >000 mHda

old-pad

6o' of mac$ines: 01 &rand name: onforts onfortex

Origin: erman

%roduction capacit: >000 mHda

ad-steam



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6o' of mac$ines: 01

&rand name: oller

Origin: erman

%roduction capacit: 10000-=A000 mHda

5ashin$

6o' of mac$ines: 01

&rand name: Gamisc$ Jleine,efers

Origin: erman

%roduction capacit: 1>000 mHda

Finis)in% section:

7tanter machine

6o' of mac$ines: 0=


Origin: erman

%roduction capacit: =B000-=9000 mHda

7anori/in$ machine

6o' of mac$ines: 0=


Origin: erman

%roduction capacit: ?A000-100000 mHda

#mari/in$ machine

6o' of mac$ines: 0= &rand name: onforts onfortex

Origin: erman

%roduction capacit: =4000 mHda

urin$ machine



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6o' of mac$ines: 01


Origin: erman

%roduction capacit: =0000-=9000 mHda

alendarin$ machine

6o' of mac$ines: 01


Origin: erman

%roduction capacit: >000-4000 mHda

%R? inish

6o' of mac$ines: 01


Origin: erman

%roduction capacit: >000-4000 mHda

*ualit' +ontrol lab:

Different tpes of fastness tests of t$e ded fa*ric are done in 7ualit controldepartment of t$e &eximco Textiles .td' Different tpes of met$od are follo,edfor different tpes of tests'

T$ere are t,o tpes of 7ualit assurances' T$e are -----

?n line test

! of t$e fa*ric/

Exact diameter " ,idt$/ re fa*ric inspection (4 point)/

!$ade c$ec+/

&ias " *o,ing/

;isual appearance/

!tripe'



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? line test

ll t$e off line tests for finis$ed fa*rics can *e grouped as foll,s-----

%$sical tests "

C$emical tests'

h(sical tests

T%#/

Fa*ric ,eig$t/

idt$ test/

Tensile strengt$/

Tear strengt$/

!eam slippage/

*rasion resistance/

T$ermal sta*ilit/

Crease resistance/

!tretc$a*ilit " ro,t$ recoer/

!moot$ness appearance'

hemical tests

Fastness tests to ,as$/

Fastness tests to ,ater/

Fastness tests to perspiration/

Fastness to lig$t/

Fastness to ru**ing/

Fastness to $eat/

Fastness to ironing/

Fastness to dr cleaning/ Fastness to sea ,ater/

Fastness to c$lorinated ,ater/

Fastness to ,ater spotting/

as$ing sta*ilit/

Fa*ric p'



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Inspection section:

T$e inspection of fa*ric is a procedure * ,$ic$ t$e defects of fa*ric are identified" fa*ric is classified according to degree or intensit of defects' T$e fa*ricinspection is done for *ot$ gre " finis$ed fa*ric'

re( abric inspection

re fa*ric inspection is performed according to 4-point sstem'

;inished abric inspection

4-ponit num*ering sstem is follo,ed for finis$ed fa*ric inspection' Defects foundin t$e final inspection'

neen s$ade/

Oil spot/

6eps/

Crease mar+/ ac$ine stoppage mar+/

.isting/

.ine mar+/

%ic+ missing/

Dou*le arn/

Dead cotton/

&o,ing/

Fl arn contamination'



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?r$an $ram o 'o6en section:



33/108

hairman

!ir"#$or%&'"#u$iv" (ir"#$or

G"n"ra) manag"r

!"pu$* G"n"ra) manag"r

+ro(, -ua)i$* .ain$, /$i)i$* S$or" ##oun$s (min, .

+,.ngr -,.ngr .,.ngr /,.ngr S,.ngr ,.ngr (,.ngr .

ss$, .ngr,S"nior o#"r.ain$, &ngr,/$i)i$* &ngr,S"nior o#"r##o$s, o#"r (, o#"r.$g,

#"r or"man #"r ashi"rSub as$, &ngr, s$, (, o#"r S

+ro(n, o#"r ab assis$an$i$$"r or"r ")p"r

or"r

or"r

")p"rss$, pro(, o#"r

Snr,+ro(,o#"r

ab bo*

.% op"ra$or

")p"r

or"r



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3rd hapter

Lab Dip De6elopmentof


Deinition:



35/108

.a* Dip Deelopment means t$e sample ,$ic$ is ded according to *uer8sre7uirements' Depending on .a* Dip Deelopment sample deing " *ul+

production deing planning done'

?bEecti6es:

ain o*@ecties of la* dip are as follo,s-----

Calculate t$e recipe for sample deing/

Compare ded sample ,it$ s,atc$ * lig$t *ox or spectroflas$/

Calculate reise recipe for sample deing/

Totall approed .a* Dip'

De6elopment o Lab Dip:



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"#"iving s$an(ar( sa$#h

Sp"#$ropho$om"$"r r"a(ing

"#ip" s$ar$ up so$ar"

S$ar$ up r"#ip" giv"n

.anua) (isp"rsion

+a( (*"ing ; #uring

/n)oa(

Norma) ash

#i( ash

o)( ash

!r*ing

o$ ash

olor measurement o standard sample:



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Color measurement is mainl done for t$e purpose of s$ade matc$ing as perfectlas possi*le' !$ade matc$ing of t$e produced sample ,it$ t$e standard one iscompulsor' Color measurement can *e done * follo,ing t,o met$ods-----

1) anual met$od/

=) #nstrumental met$od'

#anual met)od:

#n manual met$od t$e standard sample8s color is measured * comparing it ,it$preiousl produced samples of different tric$romatic color com*ination' T$esample ,it$ ,$ic$ t$e color of t$e standard matc$ed/ t$at sample8s color recipe is

*eing ta+en for s$ade matc$ing' T$is met$od8s accurac completel depends on

t$e ision of t$e person related to it *ut person must *e needed gat$er experiencea*out color matc$ing'

Instrumental met)od:

T$is met$od is more relia*le if it is operated accuratel to do t$e ,or+ of colormeasurement' !pectrop$otometer interfaced ,it$ a %C is used for s$ade matc$ing'T$is instrument ,or+s ,it$ t$e principle of reflectance measurement of lig$t atdifferent ,ae lengt$' $en t$e standard sample is *eing su*@ected underspectrop$otometer/ t$en t$e instrument suggest a recipe ,it$ re7uired tric$romaticcolors ,it$in t$e tolerance limit of color difference' #n t$is ,a/ colormeasurement of t$e standard sample is carried out for t$e purpose of s$adematc$ing'

Machineries or Lab Dip:

adder d(ein$ machine

6o' of mac$ines: 0=

&rand name: at$is

Origin: !,it5erland



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Dr(in$ machine

6o' of mac$ines: 01

&rand name: Gapid

Origin: !,it5erland

7teamer

6o' of mac$ines: 01

&rand name: at$is

Origin: !,it5erland

arameter sheet or Lab:

For li%)t ,ei%)t (abric:

Gange of .: 100-=00

%adder pressure: 1'A +gHcm=

!peed of padder: > rpm

%rocess: %D& Dring time: = min'

Curing time: 1 min'

!teaming time: ?0 sec'

Gange of temperature: as per parameter s$eet

For medium ,ei%)t (abric:

Gange of .: =00->00



%rocess: %D&

Dring time: = min'



39/108

Curing time: 1 min'

!teaming time: ?0 sec'

For )ea-' ,ei%)t (abric:

Gange of .: >00 " more



%rocess: %D&

Dring time: = min'

Curing time: 1 min'

!teaming time: 110sec'

5ashin$ se,uence o Lab:

5ashin$ parameter

Li$ht 'tFshade

5ash !ime

Medium 'tFshade

5ash !ime

+ea6( 'tFshade

5ash !ime

!tep-1 Cold ,as$ at >00

C 1 >0 sec 1 >0 sec 1 >0 sec!tep-= ot ,as$ at00C 1 >0 sec 1 >0 sec = 1 min'

!tep-> 1 >0 sec 1 >0 sec 1 >0 sec

!tep-4 = 1 min' > 1'A min' > 1'Amin'

!tep-A 1 >0 sec 1 >0 sec 1 >0 sec

:. 1:10 1:1A 1:=0

!oaping amount(gH.) = = >



40/108

Li$ht sources or dierent bu(ers:

ame o .u(ers

Li$ht sources re,uired

rimar( 7econdar( !ertiar(**##@ . >00 DBA 10

+GM T. 9> DBA 10B+ CF DBA -

A%R% T. 94 DBA -

.#R7+K% T. 94 DBA -ull G .ear T. 94 DBA -

5#%R M# DBA DBA -

!I;;I@7

5#%R

DBA - -

7%L5% DBA - -



41/108

4th hapter

re-treatmentof




42/108

Machineries or retreatment:

Desi.in% mac)ine:Machine name !ingeing " Desi5ing.rand name onforts onfortex

?ri$in ermanManpo'er 19roduction ran$e 90000-100000 mHda

MF speed ran$e A0-1A0 mHmin'!emperature 00Co* o padder =

adder pressure G-1'9 " .-1'o* o burner 1=sed utilities as

Recipe or desi/in$

ature o ;abric hemicalsFMaterial used

ll cotton color fa*ric Desi5ing agent

ll cotton color peac$ finis$ fa*ricetting agent/ se7uestering agent/

dearating agent'

Karn ded " %CHC;C fa*ric6atural gas for *urner steam "

compressed air'

$ite cotton fa*ric " special arn ded

fa*ric6atural gas/ ,ater " compressed air'

%CHC;C fa*ric

=O=/ 6aO/ !ta*ili5er/ etting agent/

Detergent/ se7uestering agent "

dearating agent

6atural gas/ ,ater " compressed air'

%CHC;CHKarn ded peac$ finis$ fa*ric

!ta*ili5er/ etting agent/ Detergent/

se7uestering agent " dearating agent


&ull-t,ill e'g' ea fa*ric =O=/ 6aO/ !ta*ili5er/ etting agent/

Detergent/ se7uestering agent "



43/108

dearating agent


Bleac)in% mac)ine:Machine name &leac$ing mac$ine

.rand name onforts onfortex?ri$in ermanManpo'er 1

roduction ran$e 0000-100000 mHda

MF speed ran$e A0-B0 mHmin'!emperature B00C

o* o chamber 9

=sed utilities as

7teamin$ time

!couring " *leac$ing U == min'

Ge-*leac$ U =B min'

!couring U =0 min'5ashin$ temperature 00C

7teamer temperature 1040C

adder pressure =->&ar7,uee/er pressure ='=A-='A &ar

ompensator pressure =-> &ar

Doctor blade position = &ar;abric position Face

hemical le6el p-to t$e leel indicator

5ater le6el *oe t$e rollerDosin$ pump &ased on t$e recipe %.C is programmed

;unction !couring/ &leac$ing/ as$ing

7courin$ recipe or FB:

hemicalshemical compositionHmF&$ o abric

'ith con6e(or

Li$ht abrics:

6aO

etting agentHdetergent

B0-90

=->



44/108

+ea6( abrics:

6aO


90-0

>

%ter cold bleach recipe or all 'hite abrics:

hemicalshemical compositionH$mF&$ o

abric 'ith con6e(or

Li$ht abrics:

=O=(A0M)

6aO

!ta*ili5er etting agentHdetergent

!e7uestering agent

Dearating agent

1A-=A

1A-=0

A-B>-4

1-=

0'A

Medium G +ea6( abrics:

=O=(A0M)

6aO

!ta*ili5er


!e7uestering agent

Dearating agent

=0-=A

1A-=0

B-?

>-41-=

1'A

Recipe or all 'hite abrics:

hemicalshemical compositionHmF&$ o abric

'ith con6e(or

Li$ht Medium G +ea6( abrics:

=O=(A0M) 6aO

!ta*ili5er


!e7uestering agent

Dearating agent

A0

>0

9-1=

B-9

=->

0'A



45/108

as)in% recipe:

as$ing is done ,it$ $ot ,ater " detergent ma *e used for medium " $eacolor fa*rics mac$ines speed'

roduction ,ualit( chec&:

During production t$e operator ,ill c$ec+ for cosmetic defects suc$ as spots/ tears" ,ears an ot$er a*normalities t$at can *e detected * ees'


46/108

;abric 'idth ?9-9

%ir pressure =-> &ar7team pressure =-='A &aradder pressure =->&ar

7,uee/er pressure ='=A-='A &aro* o air /oon roller =1;abric position Face

hemical le6el p-to t$e leel indicator5ater le6el *oe t$e rollerDosin$ pump &ased on t$e recipe %.C is programmed

;unction Onl merceri5ing

Flo,"c)art o( merceri.in% process:



47/108

"#ov"r* #hamb"r .i'ing $an #oo)ing #h

#he&i'al preparation

@a$#h"r inh"mi#a) #hamb"rh"mi#a) #hamb"rS$abi

@a$#h"r ou$*)in("r (r*"r #hamb"r B4 B3


48/108


49/108

th hapter

D(ein$ sectionof


!hermosol Machine:

Machine name T$ermosol.rand name onforts onfortex

?ri$in erman



50/108

Manpo'er 19

roduction ran$e 1A000 mHda

MF speed ran$e=0-=A mHmin' for $ea fa*ric

>A-40 mHmin' for lig$t fa*ric

!emperature 190-100

C for $ea fa*ric1A0-1B00C for lig$t fa*ric

o* o no//le =9

Le6el o d(ein$ bath (0-A00M)for %-T-# " manual %-T-##rocess selector s'itch %ad *atc$Hcontinuous7peed 6ariable &nob or B!-1G2 (0-100M)/ M " M

IR section-1:

7peed

Intensit(

(0-100)mHmin'M

(=0-100)%M

IR section-2: 7peed

Intensit(

(0-100)mHmin'M

(=0-100)%M

adder pressure 0-4 &ar

7peedHrpm (0-1=0)mHmin'!emp* o therme"H1-3 0-=A00C

.lo'er an settin$ or therme" o* 3 .o,H$ig$

osition o main damper therme"H1-

3(0-B)diision

osition o e"haust dampertherme"H1-3

(0-B)diision

osition o air lo' &nob o

thermo"H1-3V 9 diision

neumatic pressure o $uiders 0-10 &arneumatic pressure o compensators 0-B &ar

as pressure or IR-section 0-40 mH&ar or max' =0mH&ar

as pressure or burners 0-=A0 mH&arosition o IB $ear bo" or traction

dri6e G 'indo's 0-B &ar%ir pressure 0-10 &ar=sed utilities as

roduct ,ualit( chec&!$ade c$ec+/ cosmetic defects/ s$ade

ariation


51/108

duration operation' C also c$ec+ t$e

parameters'

D'ein% recipe:

D(esD(estus

In$redients H0*1- H*01-10 H10-0 0

$Fl $Fl $Fl $Fl

Reacti6eHD.

rea A0 ?A 100 1A0

%rima5ol 6F = = = =

%rima5ol ; 10 10 10 10lau*er salt 10 10 10 10

!oda as$ 10 1A =0 =A

Reacti6eHDD

steam

%rima5ol 6F = = = =

%rima5ol ; 10 10 10 10

lau*er salt 10 10 10 10

7

lau*er salt =00 =00 =A0 =A0

!oda as$ 10 10 1A 1A

Caustic flac+s A A 9 10

Disperse

%rima5ol ; 10 10 10 10

!etamol &. = = 1 1

cetic acid 0'A 0'A 0'A 0'A

i$ment

%rima5ol ; 10 10 10 10

!iligen F 10 10 10 10

;itexol %FF A A A A

Jerolin et & = = = =

&inder 10 =A 40 ?0

i$$er machine:

Machine name igger



52/108

.rand name oller

?ri$in ermanManpo'er Broduction ran$e >000 mHda

MF speed ran$e 40-90 mHmin' or as re7uired!emperature A0-00CLi,uor le6el A=0 .

;abric position Face%-rame position !et propert%6ailabilit( o se'in$ thread =-> cones

=sed utilities as

roduct ,ualit( chec&

C$ec+ for cosmetic defects suc$ as

spots on t$e fa*ric/ crease mar+ on t$e

fa*ric/ fa*ric position/ fa*ric se,ing/seledge torn or an ot$er a*normalities

t$at can *e detected isuall'

000 mHdaMF speed ran$e =9->A mHmin' or as re7uired

!emperature B0-?00Co* o padder 4;abric position Face

%-rame position !et propert

%6ailabilit( o se'in$ thread =-> cones=sed utilities as

roduct ,ualit( chec& C$ec+ for cosmetic defects suc$ as



53/108


fa*ric/ fa*ric position/ fa*ric se,ing/

seledge torn or an ot$er a*normalities

t$at can *e detected isuall'

A mHmin' or as re7uired

!emperature ?0-1000C

o* o padder =o* o chamber 9

;abric position Face%6ailabilit( o se'in$ thread =-> cones=sed utilities as

roduct ,ualit( chec&!$ade c$ec+/ cosmetic defects/ s$ade

ariation


54/108

?ri$in erman

Manpo'er roduction ran$e 1>000 mHdaMF speed ran$e =A mHmin' or as re7uired

!emperature 0-A0

C;abric position FaceH*ac+5ater le6el l,as full

ressure or s,uee/er 1-= &arompensator pressure ='A-> &ar=sed utilities gas


C$ec+ for cosmetic defects suc$ as


fa*ric/ fa*ric position/ fa*ric se,ing/

seledge torn or an ot$er a*normalitiest$at can *e detected isuall'


55/108

th hapter

;inishin$ 7ectionof




56/108

7tanter machine:

Machine name !tanter.rand name onforts onfortex?ri$in erman

Manpo'er >0roduction ran$e =B000-=9000 mHda

MF speed ran$e40-A0 mHmin' for $ea fa*ric

B0-90 mHmin' for lig$t fa*ric

!emperature190-100C for $ea fa*ric

1A0-1B00C for lig$t fa*ric

o* o chamber 9o* o .urner 9o* o .lo'er 1B

=sed utilities as

;unctions

eat setting

!oft finis$

ater repellant

$ite fa*ric finis$(soft/ ,rin+le

free)

Colored fa*ric finis$(soft/ ,rin+lefree)

Toping

Top finis$

idt$ control

.oop control

oisture control

! control

Dring

!$rin+age controlroduct ,ualit( chec& !$ade c$ec+/ fault c$ec+/ ,idt$ c$ec+


57/108

p$sical tests/ c$emical tests/ " analsis

t$e tests " notes t$e results in fa*ric test

results'

7anori/in$ machine:

Machine name !anfori5ing

.rand name onforts onfortex?ri$in erman

Manpo'er =4

roduction ran$e ?A000-100000 mHda

MF speed ran$e40 mHmin' for $ea fa*ric

?0 mHmin' for lig$t fa*ric

7team pressure or dampin$ ='A *ar5ater pressure 4'A *ar

?6er eed AM

Rubber belt pressure 9-1= *ar7team pressure or rubber belt 0-= *ar

Rubber belt tension Depends on *elt t$ic+ness

%ir pressure or belt 4'A *ar7team pressure or belt =-> *ar

ressure or 'indin$ batcher 0-4 *ar

;unctions

!$rin+age control/ ,idt$ control/increase softness/ increase smoot$ness

" luster'

roduct ,ualit( chec& Fault c$ec+ " ,idt$ c$ec+


58/108

#mari/in$ machine:

Machine name Emari5ing

.rand name .afer

?ri$in %a+istanManpo'er

roduction ran$e =4000 mHda#mer( stic&s roller settin$ 1-> for lig$t fa*ric

A- for $ea fa*ric

#mer( stic&s roller One B0

T,o =4

#"haust an settin$ anual

MF speed =0 mHmin'

=sed utilities ir pressureo* o belt B

.elt pressure = *aro* o dram roller =4

Dram pressure = *ar

Dram speed 0mHmin'o* o padder roller 4

Roller pressure s re7uired

#mer( paper $au$e 190-=40m for lig$t fa*ric

1=0 for $ea fa*ric#mer( paper chan$e c(cle 4A000m for lig$t fa*ric

>0000m for $ea fa*ric

;unctions

Gemoe t$e neps/ peac$ finis$ can *e

done/ surface smoot$ness " softness

can *e done'


a' Fault c$ec+*' T$ic+ness of fa*ricc' !moot$ness of fa*ric

d' and feel ,it$ standarde' Fa*ric design " structure


59/108

urin$ machine:

Machine name Curing

.rand name onforts onfortex?ri$in erman

Manpo'er Broduction ran$e =0000-=9000 mHda

MF speed ran$e>0->A mHmin' for $ea fa*ric

=A-=9 mHmin' for lig$t fa*ric

!emperature190-==00C for $ea fa*ric

1A0-1?00C for lig$t fa*ric

o* o roller ?0

o* o .urner 1=sed utilities as

;unctions

c$emical reaction causing cross

lin+ing of a t$ermoset resin in a fi*re

composite

roduct ,ualit( chec& !$ade c$ec+/ fault c$ec+/ ,idt$ c$ec+


60/108

!emperature=A00C for $ea fa*ric

1A00C for lig$t fa*rico* o roller ARoller pressure ran$e 190-=00 *ar

=sed utilities draulic pressure

;unctions

a' To upgrade t$e fa*ric $and*' To impart a smoot$ " sil+ touc$c' To compress t$e fa*ricd' To reduce fa*ric t$ic+nesse' To improe opacit of fa*ricf' To reduce arn slippageg' To impart different degree of

luster of t$e fa*ric$' To reduce t$e air permea*ilit of

t$e fa*ric'


a' Fault c$ec+*' T$ic+ness of fa*ricc' !moot$ness of fa*ricd' and feel ,it$ standard'


61/108


a' Fault c$ec+*' !moot$ness of fa*ricc' and feel ,it$ standard'


62/108


63/108

In laborator':

!,atc$ card from *uer according to t$eir re7uirement/

Gecipe prediction for sample deing/ !ample deing until matc$ing ,it$ s,atc$ card/

Fastness " ot$er tests of t$e fa*ric or arn are done $ere'

In d'ein% section:

ccording to t$e *uer8s sample/ sample deing is done in sample deing

mac$ine in deing s$ed " again matc$ed ,it$ t$e approed sample/

#f result is OJ t$en *ul+ production/ During deing/ samples are ta+en until accurate s$ade matc$ing' T$e

interal ma *e >0-40 min' fter deing sample is collected after softening matc$ing is done/

T$en sample is collected after fixation " matc$ed/

T$en allo,ed t$e fa*rics to *e finis$ed'

In (inis)in% section: & using a series of finis$ing mac$ines correct ,idt$/ softness " appearance

are maintained according to re7uirements/ T$en sampling is done for seeral times to test !/ s$rin+age " fastness

properties/ Finall fa*ric is inspected " prepared for delier'


64/108

T$ere are t,o tpes of 7ualit assurances' T$e are -----

1' On line test/=' Off line test'

Lab Machineries:

T)reads per Inc):

MF used:T$read counter

Manuacturer:ames ' eal " compan/ alifax/ England

erson responsible:.a* assistant ;re,uenc(:Eer order

erormance standard: VAM

Incase o non- conormit(: Gefinis$

rocedure:1 s7uare inc$ samples are ta+en from a fa*ric/ t$ese samples are

ta+en one from t$e left / one from t$e rig$t " ot$er from t$e center t$readsof eac$ samples are counted *ot$ ,eft " ,arp ,ise'

DocumentsF;orms used:Tests results for 100M cotton finis$ed fa*ric/

Tests results for %C/C;C finis$ed fa*ric/

Tests results of ot$er customer8s finis$ed fa*rics'

Fabric ,ei%)t:

MF used: ! cutter


erson responsible:.a* assistant

;re,uenc(:Eer order

erormance standard:ccording to *uer8s standard' Incase o non- conormit(: To increase ! U Geduce ,idt$ mec$anicall

To decrease ! U increase ,idt$ mec$anicall rocedure: > samples are cut ,it$ ! cutter' Find t$eir aerage !'

DocumentsF;orms used: Tests results for 100M cotton finis$ed fa*ric/

Tests results for %C/C;C finis$ed fa*ric/ Tests results of ot$er customer8s finis$ed fa*rics'



65/108

idt) test:

MF used: easuring tape

Manuacturer:ames ' eal " compan/ alifax/ England erson responsible:.a* assistant

;re,uenc(:Eer order

erormance standard:1A0 cm V = or as specified * customer

Incase o non- conormit(: Gefinis$

rocedure: anual measurement * tape



Tensile stren%t):

MF used: lp$atens Tensile Tester " Titan uniersal !trengt$ Tester'



;re,uenc(:Eer order'

erormance standard: ccording to &T. ualit standard "

specification'

Incase o non- conormit(: To increase Tensile strengt$R remercerise "refinis$'

rocedure: ccording to customer8s re7uirements " or as specified in t$e

&T. ualit standard specification' DocumentsF;orms used: Tests results for 100M cotton finis$ed fa*ric/


Tear stren%t):

MF used: Elmendorf Tearing Tester 1BA>'

Manuacturer:essmer #nstrument .td'


;re,uenc(:Eer order (onl for 100M cotton fa*ric)



66/108

erormance standard:For *ot$ ,arp " ,eft ?000m6 m or ?1> gm

minimum or as per t$e customer8s re7uirement' Incase o non- conormit(: To increase Tensile strengt$R remercerise "

refinis$'

rocedure: ccording to customer8s re7uirements " or as specified in t$e&T. ualit standard specification'



Seam slippa%e:

MF used: lp$atens Tensile Tester " Titan uniersal !trengt$ Tester'




erormance standard:For *ot$ ,arp " ,eft 906 minimum for Bmm

opening or as per t$e customer8s re7uirement' Incase o non- conormit(: Gesin finis$ or finis$ ,it$ special softener

,$ic$ increases seam slippage propert' rocedure: ccording to customer8s re7uirements " or as specified in t$e

&T. ualit standard specification' DocumentsF;orms used: Tests results for 100M cotton finis$ed fa*ric/


0brasion resistance:

MF used:6u-artindale *rasion " pilling Tester'



;re,uenc(:$eneer re7uired'

erormance standard:rade-4/ rade-> (for peac$ fa*ric)

Incase o non- conormit(: Gesingeing follo,ed * Gesin finis$'

rocedure: ccording to customer8s re7uirements'




67/108


T)ermal stabilit'1S)rin!a%e2: MF used: Contact eat Test nit'

Manuacturer:Goac$es Engineering .td'


;re,uenc(:Eer *lend fa*ric order'

erormance standard:arp U 1'AM " eft U 1'AM

Incase o non- conormit(: eat set

rocedure: &! 100B/ #!O 10A:%01

DocumentsF;orms used: Tests results for 100M cotton finis$ed fa*ric/ Tests results for %C/C;C finis$ed fa*ric/ Tests results of ot$er customer8s finis$ed fa*rics'

+rease resistance:

MF used: Crease recoer tester'

Manuacturer:!$irel/ England'



erormance standard:ccording to *uer8s standard'

Incase o non- conormit(: oist cross/ finis$Hresin finis$'

rocedure: &! E6 ==>1>/TCC BB/ #!O =>1>'

DocumentsF;orms used: Tests results finis$ed fa*rics'

Stretc)abilit' 3 %ro,t) reco-er':

MF used: !tatic extension *oard " Titan uniersal !trengt$ Tester'

Manuacturer: #ndia " ames ' eal " compan/ alifax/ England'


;re,uenc(:For eer stretc$ fa*ric " after eer su*se7uent processing

stage'



68/108

erormance standard:!tretc$a*ilit U =0MR ro,t$ recoer U BM " as

per customer8s re7uirements' Incase o non- conormit(: Consult ,it$ t$e section inc$arge'

rocedure: !T D>10? " D%O6T .cra met$od'

DocumentsF;orms used: !tretc$ fa*ric process record'

Smoot)ness appearance:

MF used: Electrolux ascator " Tum*le drer'

Manuacturer: & ascomst'


;re,uenc(:Eer ,rin+le free order'

erormance standard:s per customer8s re7uirements' Incase o non- conormit(: oist cross/ finis$Hresin finis$'

rocedure: TCC 1=4 or as per customer8s specification'

DocumentsF;orms used: &T. ualit standard specification

ualit standardof ot$er customers'

;astness tests:

Fastness to ,as):

MF used: ro,as$'

Manuacturer: ames ' eal " compan/ alifax/ England'

erson responsible:.a* assistant'


rocedure: &! 100B ref:C0B C=A/ TCC B1 " according to customer8s

re7uirements' erormance standard: For color c$ange 4C/ for color staining 4! "

according to customer8s re7uirements' Incase o non- conormit(: Ge,as$ for reactie ded fa*ric/ GC for

disperse ded fa*ric' DocumentsF;orms used:

a' Tests results for 100M cotton finis$ed fa*ric/*' Tests results for %C/C;C finis$ed fa*ric/c' Color fastness assessment/



69/108

d' &T. ualit standard specification/e' ualit standardof ot$er customers'

;abric si/e: 10cm W 4 cm

!emperature: B00C

!ime: >0 min'

hemical: !oap or detergent " soda'

?peration procedure:

a' d@ust t$e mac$ine to maintain t$e re7uiredtemperature " time as test re7uired/

*' %re $eat t$e canister " steel *all to set t$e temp' oft$e mac$ine/

c' C$ec+ t$e temp' * using t$ermometer/d' %our t$e container ,it$ t$e detergent/e' %lace t$e sample ,it$ ad@acent fa*ric/f' Clamp on t$e coer " fasten t$e canister erticall

into t$e color of t$e mac$ine/g' !tart t$e mac$ine/$' !top t$e mac$ine ,$en t$e *u55er on after

completion of t$e test/i' Gemoe t$e sample from t$e can/ ,as$ properl "

dr it'

Fastness to ,ater:

MF used: %erspirometer c$emical +it " car*olite incu*ator'




rocedure: &! 100B ref: E01/ TCC 10? " according to *uer8s

re7uirements' erormance standard: For color c$ange 4C/ for color staining 4! "

according to *uer8s re7uirements' Incase o non- conormit(: Ge,as$ " refinis$ ,it$ fixing agent'

DocumentsF;orms used:

a' Tests results for 100M cotton finis$edfa*ric/

*' Tests results for %C/C;C finis$edfa*ric/

c' Color fastness assessment/



70/108



!emperature: >?0C

!ime: 4 $rs'

hemical:6o c$emical used'

Fastness to perspiration:




;re,uenc(:$eneer re7uired' rocedure: &! 100B ref: E04/ TCC 10A " according to *uer8s

re7uirements' erormance standard:

.!L std* olor chan$e olor std*

cid s,eat 4C >-4!

l+ali s,eat 4C >-4!

Incase o non- conormit(: Ge,as$ " refinis$ ,it$ fixing agent'


a' Tests results for 100M cotton finis$edfa*ric/

*' Tests results for %C/C;C finis$edfa*ric/

c' Color fastness assessment/d' &T. ualit standard specification/e' ualit standardof ot$er customers'


!emperature: >?0C

!ime: 4 $rs'

hemical:

a' cid: 6a Di-$drogen ort$op$osp$ate(6a=%o4==O)*' l+ali: Di-sodium $drogen ort$op$osp$ate =-

drate(6a=%o4==O)



71/108

Fastness to li%)t:

MF used: .ig$t fastness tester'


erson responsible:.a* assistant' ;re,uenc(:$eneer re7uired'

rocedure: &! 100B & 0='

erormance standard: For dar+ s$ade 4C/ for lig$t " pale s$ade >C "

according to *uer8s re7uirements' Incase o non- conormit(: !elect destuffs ,it$ *etter lig$t fastness

propert' DocumentsF;orms used:

a' Tests results for 100M cotton finis$ed fa*ric/

*' Tests results for %C/C;C finis$ed fa*ric/c' Color fastness assessment/d' &T. ualit standard specification/e' ualit standardof ot$er customers'

!emperature: ==0-=400C

!ime: 90-100 $rs'


Fastness to rubbin%:

MF used: Croc+ meter'




rocedure: &! 100B ref: W1=/ TCC 9 " according to *uer8s

re7uirements'

erormance standard:

.!L std* on peach each

Dr ru* 4! >!

et ru* >! =!

Incase o non- conormit(: Ge,as$ " refinis$ ,it$ fixing agent'



72/108


a' Tests results for 100M cotton finis$ed fa*ric/*' Tests results for %C/C;C finis$ed fa*ric/c' Color fastness assessment/


Fastness to 4eat:

MF used: Contact $eat test unit'

Manuacturer: Goac$es Engineering .td'



rocedure: #!O 10A: %01 " &! 100B: W 11

erormance standard: ccording to *uer8s re7uirements'

Incase o non- conormit(: !elect destuffs ,it$ *etter lig$t fastness to

$eat' DocumentsF;orms used:Tests results for finis$ed fa*ric/

;abric si/e:10cm W 4 cm

!emperature: =000C

!ime: 1A sec'


Fastness to actual launderin%:

MF used: Electrolux ascator " Tum*le Drer'

Manuacturer: ascomat'



rocedure: TCC 1>A/ after >rd,as$'


Incase o non- conormit(: Ge,as$ " !elect destuffs ,it$ *etter fastness

to $eat' DocumentsF;orms used:



73/108

a' &T. ualit standard specification/*' ualit standardof ot$er customers'

Fastness to dr' cleanin%: MF used: ro,as$'




rocedure: #!O 10A E0=: 19


Incase o non- conormit(: For color c$ange 4C/ for color staining 4!'

DocumentsF;orms used:a' &T. ualit standard specification/

*' ualit standardof ot$er customers'

Fastness to sea ,ater:





rocedure: #!O 10A E0=: 19


Incase o non- conormit(: For color c$ange 4C/ for color staining 4!'



Fastness to +)lorinated ,ater:

MF used: ro,as$'






74/108

rocedure: TCC 1B='


Incase o non- conormit(: For color c$ange >C'



Fastness to ,ater spottin%:

MF used: %ipette'



;re,uenc(:$eneer re7uired' rocedure: TCC 104: 14


Incase o non- conormit(: Consult ,it$ section $ead'

DocumentsF;orms used: Tests results finis$ed fa*rics'

as)in% stabilit':

MF used: Electrolux ascator " Tum*le Drer' Manuacturer: ascomat'


;re,uenc(: Eer order " *atc$er'

rocedure: &! 4=> ref: =/ TCC 1>A " #!O B>>0

erormance standard:

;abric 5arp 5et

6on-elastane V >M V >M

!pandexHelastane

0-B M 0-B M

Incase o non- conormit(: Gefinis$ " resanfori5e/


a' Tests results for 100M cotton finis$ed fa*ric/*' Tests results for %C/C;C finis$ed fa*ric/c' ualit standardof ot$er customers'



75/108

d' !$rin+age result register'

Fabric P415xtract met)od2:

MF used: etler Toledo'

Manuacturer: etler Toledo '


;re,uenc(: $eneer re7uired'

rocedure: TCC 91-1B


Incase o non- conormit(: Ge,as$H finis$ ,it$ acid'

DocumentsF;orms used: Tests results for finis$ed fa*rics of ot$er

customers'



76/108

8th hapter

Inspection 7ectionof


;abric inspection 7ection:



77/108

T$ere are ? mac$ines in clot$ inspection section' !pecification of t$is mac$ines aregien *elo,-----

&rand name OFF FG#EG#O !G.

Tpe Fa*ric inspection mac$ine

Countr #talodel no' T6 >0= 94H9A

HC speed A0 mHmin

Function Fa*ric inspection

!(pes o inspection:

1) re inspection/=) Final inspection'

6re' inspection:

#nspection " grading of fa*ric 7ualit is one of t$e important functions of 7ualitcontrol is t$e gre or finis$ed state' T$e grading of fa*ric is difficult tas+/ ta+ingt,o primar considerations: as t$e fre7uenc of effects " t$e seriousness of

defects'

rading $as t,o primar functions: 1st to classif fa*rics according to standard7ualities *ased on t$e end use " customer demands " =ndis to suppl informationas to t$e 7ualities actuall *eing produced'

Final inspection:

ll pieces ,ill *e graded on t$e *ase of 4 points per 100 linear ards

mapping ,ill *e done on eac$ piece to ensure proper grading' Do not countmore t$an 4 points per one ard'

ll defects must *e recorded " mar+ed in final inspection " an accurate

account of points made to ensure proper grading/ ll fa*rics must meet specifications/



78/108

t t$e end of eac$ piece of fa*ric/ t$e inspector ,ill add up total points "

decide ,$et$er t$e piece can *e s$ipped as first 7ualit or not/ re,or+ed /placed in lo,er 7ualit/ or cut " upgraded for s$ipment' Fifteen ards ormore can *e s$ipped as first 7ualit/

ualit control superisor must approe t$e grading of all 7ualit leels "c$ec+ t$e lo,er 7ualit/

a@or or unsig$tl defects in t$e first " last ard of a roll or piece ,ill *e

cut' ll defects of one ard lengt$ or more ,ill *e cut of t$e piece' Defects,it$in t$e first = inc$es or t$e last = inc$es of a piece ,ill not *e cut out orcounted in t$e grading/

Open defects on t$e *ac+ of fa*ric suc$ as drops/ runs " $anging pic+s are

to *e included in t$e grading of t$e fa*ric/ %ieces can *e connected toget$er/ once eac$ piece must *e t$e same s$ade/

ll defects suc$ as runs t$at extend more t$an a ard in lengt$ ,ill *e cut

out'

?peration procedureJ

1) !$ade sorting process/=) !$ade sorting process in t$e data color spectrop$otometer/

>) ;isual s$ade sorting process/4) Off s$ade fa*ric inspection process'

Inspection o ;abric b( 4-point s(stem:

#nspection of Fa*ric is a procedure * ,$ic$ t$e defects of fa*rics are identified "

fa*rics are classified according to degree or intensit of defects'

#n &eximco Textiles .td' fa*ric inspection is done * 4-point inspection sstem'T$e details of it is gien *elo,-----

;ault oint

.andF startin$ mar&Fshade bar 4-point



79/108

Lost end 4-point

?il spots

1' p to A mm dia U 1point=' p to 10 mm dia U = point>' ore t$an 10 mm dia U 4point

7labs 1point#mbedded l( 4-pointMa"* penalt( point or an( runnin$

(dsH3 abric 'idth4-point

%ll hole 1-4-point(according to fault si5e);aults in both 'arp G 'et recei6e

e,ual points1-4-point(according to fault si5e)

Missin$ pic&Fdouble pic&1' p to 0'0A3 U 1 point=' Oer 0'A03 U = point

@arn contamination accordin$ to thesi/e

1point

Knot 1point

eps

1' Fa*ric dar+ crease ma *e

re@ected/=' .ig$t crease ma *e considered

rease mar&


5ater drops


D(e resist


D(e stain


Dirt( mar&

1' p to A mm dia U 1point

=' p to 10 mm dia U = point>' ore t$an 10 mm dia U 4point

7ote (or 8"point s'stem:

13->3 U 1 point



80/108

Points per ()) s*+ yards ,-otal points . ()) ./0

-otal length in yards . useable width in in

>3-B3 U = point

B3-3 U > point

ore t$an 3 U 4 point

;abric la$$in$ 'ith stic&er:

.arge B point ma@or fault in eit$er ,arp " ,eft s$ould *e fagged ,it$ arro,

mar+ed stic+er in t$e rig$t $and side of t$e fa*ric/ oles/ stains " soils s$ould *e flagged/

Flags s$ould *e clearl isi*le ,$en fa*ric is spread face up or face do,n/

Flags s$ould not *e detac$ed from t$e fa*ric during transportation "

$andling * an means'

7plicin$:

!(pe o abric Ma"imum roll si/e

%oplin =A0 m

Karn ded =A0 m

TC fa*ric >00 m

T,ill 1A0 m



81/108

9th hapter

=tilit( 7ectionof




82/108

7ource o utilit( ser6ices:

ere t$e follo,ing utilit serices are aaila*le-----

1' ater : %umps=' Electricit : %D& " enerator>' !team : &oiler4' as : TitasA' Compress air : Compressor

5ater:

ater is supplied continuousl in different sections * using su*mersi*le "centrifugal pumps'

entriu$al pump or 'ater suppl( or d(ein$ G other

sectionsapacit(

=0 '% %edrollo pump (eac$ pump: 1000.Hmin') 4 units 4000.Hmin'

10 '% %edrollo pump(flo, rate: B00.Hmin') 1 unit B00 .Hmin'

A'A '% %edrollo pump(pump flo, rate: A0.Hmin') 1 unit >A0 .Hmin'

!pare pump motor pedrollo =0 '% 1unit " A'A '% 1 unit 1 .Hmin'

$onson pump(>0 '%) = unit 100 m>H$r

J!& pump(>0 '%) 1 unit 100 m>H$r

!u*mersi*le pump J!& 4B +, 1A0 m>H$r

#lectricit(:Machine description ori$in o* o machine apacit(

Caterpillar gas generator ! 1 6o' 114A J

arsila gas generator France 1 6o' A= J

%rime po,er generator !pain 1 6o' B>B J

!u*-station/ %D& &anglades$ 1 6o' 1000 J;



83/108

Prime po,er %enerator:

.rand name:uascor

?ri$in:!pain

Model:F.D 490

7tandb( 6olta$e:>90;/ ?A J

rime 6olta$e:B>B J/ 1=09 J

hase:0>

5ei$ht:194A Jg

Diesel %enerator:

.rand name:JOT!

?ri$in:!ingapore

Model:E! B>0->

7erial o:>011=

7tandb( 6olta$e:440J/ AA0 J

rime 6olta$e:440 J/ A00 J

hase:0>

;re,uenc(:A0 5

5ei$ht:>900 Jg

.oiler:

&oiler is mainl used to produce " delier steam to different sections as re7uired'#n &eximco Textiles .td' four *oilers are used to produce " delier steam todifferent sections'

Boiler speci(ications:



84/108

.rand name:COIM? !#>!IL# LIMI!#D



90/108

Introduction:

ater for a textile plant ma come from arious sources' &ut t$is ,ater cannot *eused directl in textile processing *ecause it contains arious salts' T$ese salts aremainl t$e car*onates(CO>

=-)/ $drogen car*onatesH*i car*onates( CO>=-)/

sulp$ates(!O4=-) " c$lorides(Cl-) of calcium " magnesium' T$ese are called

$ardness in t$e ,ater' t$ese must *e remoed t$oug$ ,ater treatment plant'

atural 'ater ,ualit(:

ater for a textile plant ma come from arious sources' T$ese include surface,ater from riers/ la+es " su*terranean ,ater from ,ells' #n %%C t$e collect,ater from underground' 6atural " pre-treated ,ater ma contain a ariet ofc$emical species t$at can influence textile ,et processing in general " deing in

particular'

T$e arious salts present in ,ater depend on t$e geological formations t$roug$,$ic$ t$e ,ater $as fio,ed' T$ese salts are mainl t$e car*onates(CO>

=-)/$drogen car*onatesH*i car*onates(CO>

=-)/ sulp$ates(!O4=-) " c$lorides(Cl-) of

calcium " magnesium' lt$oug$ calcium " magnesium car*onates in limestones



91/108

are relatiel insolu*le in ,ater' !o in t$is reasons/ ,ater $ardness can *e diidedinto t,o ,as-----

!emporar( hardness: Ca(CO>)=/ g(CO>)=/ Fe(CO>)=

ermanent hardness:CaCl=/ Ca!O4/ Ca(6CO>)=/ gCl=/ g!O4/ g(6CO>)=

T$is ,ater $ardness causes some serious conse7uences in a textile deing "finis$ing industries " t$ese are-----

%recipitation of soaps/

Gedeposit ion of dirt " insolu*le soaps on t$e fa*ric *eing ,as$ed/ t$is can

cause ello,is$ " lead to uneen deing " poor $andle/ %recipitation of some des as calcium " magnesium salts/

!cale formation on e7uipment " in *oilers " pipelines/

Geduction of t$e actiit of t$e en5mes used in ,as$ing/

#ncompati*ilit ,it$ t$e c$emicals in finis$ing recipes " so on'

ardness expressed * parts per million of CaCO>/ ,$ic$ is standard $ardnessscale " it is also called merican $ardness' T$e $ardness of ra, ,ater is 100 ppmor more' To use it in deing " in *oiler t$is ,ater must need to soft " foreignmaterials needs to remoe'

7tandard 'ater ,ualit(:

arameter ermissible concentration

olor Color less7mell 6o *ad smell

5ater hardness A ppm

+ 6alue ?-9 (neutral)Dissol6ed solid A ppm

Inor$anic salt A00 ppm

Iron 0'1 ppmMa$nesium 0'01 ppm

opper 0'oo A ppm

itrite A0 ppm



92/108

itrate A ppm

5ater pumps:ater is supplied continuousl in different sections * using su*mersi*le "centrifugal pumps'

entriu$al pump or 'ater suppl( or d(ein$ G other

sectionsapacit(

=0 '% %edrollo pump (eac$ pump: 1000.Hmin') 4 units 4000.Hmin'

10 '% %edrollo pump(flo, rate: B00.Hmin') 1 unit B00 .Hmin'

A'A '% %edrollo pump(pump flo, rate: A0.Hmin') 1 unit >A0 .Hmin'

!pare pump motor pedrollo =0 '% 1unit " A'A '% 1 unit 1 .Hmin'$onson pump(>0 '%) = unit 100 m>H$r

J!& pump(>0 '%) 1 unit 100 m>H$r

!u*mersi*le pump J!& 4B +, 1A0 m>H$r

5ater sotenin$:

T$ere is an ion exc$ange met$od * ,$ic$ $ardness of ,ater is remoed'

;lo' chart o 'ater treatment plant:



93/108

ar( a$"r s$on" $an

S$on" D)$"r

arbon D)$"r

"sin D)$"r

!")iv"r* pump

So$ a$"r s$or" $an



94/108

12th hapter

#luent !reatment lantof


Introduction:

Effluents are generated from different sections of a textile industr must *e treated

*efore t$e disc$arged to t$e enironment' ;arious c$emicals " p$sical meansare introduced for t$is purpose'

MaEor eluent sources:



95/108

!couring c$emicals/

&leac$ing c$emicals/

as$ing c$emicals/

Deing c$emicals'

hemical used in #!:

Ferrous sulp$ate/

droc$loric acid/

.ime/

%olmer/ !odium $po-c$loride/

rea fertili5er'

haracteristics o 'aste 'ater:

&iological oxgen demand(&OD) U >00 mgH.

C$emical oxgen demand(COD) U =00 mgH.

!uspended solid(!!) U =00 mgH.

Color U Dar+

% U 9-11'A

rocess se,uence o #!:

rocess:&iological apacit(:1A00 m>Hda



96/108

S'reening


97/108

&OD U >0 mgH.

COD U 1B0 mgH.

!uspended solid U >0 mgH.

Color U Colorless

6o-ernment o( Ban%lades) required:

% U B-

&OD U A0 mgH.

COD U =00 mgH.

!uspended solid U 1A0 mgH.

Color U .ig$t *ro,nis$



98/108

13th hapter

In6entor(of.#>IM? !#>!IL# LIMI!#D

In6entor( control:



99/108

!tore is t$e place ,$ere eer tpes of ra, materials/ spares finis$ed goods are+ept in proper sstem' #nentor control means t$e accurate calculation " data ofeer tpe of ra, materials/ spares " finis$ed goods in time to time' #nentorcontrols are necessar/ *ecause-----

To +no, a*out t$e re7uired amount of ra, materials/ To *e continued t$e production process/

To find out t$e profit or loss of a compan/

!toc+ " stoc+ alue for consumption measuring'

7cope o In6entor( control:

Des store/

Ga, material/

Ot$er c$emicals/

re fa*rics/

!pare parts/

eneral store/

Capital e7uipments/

ccessories/

!tationar' aintenance parts'

In6entor( s(stem or ra' materials:

#nentor is t$e stoc+ of goods' #t is a ital part of *usiness' #t protects against

stoc+ outs' Tpes of inentor carried in t$is factor as follo,s----- re fa*ric : O,n ,eaing or imported

Des " c$emicals : .ocal or imported

%ac+ing materials : .ocal or imported

!pare parts : .ocal or imported



100/108

6re' (abric store:

ll t$e gre fa*rics are stored near t$e fa*ric8s *atc$ section' Different tpes offa*rics are listed in t$e s$eet according to fa*ric tpes/ 7uantit " consumer8sre7uirement'

D'es 3 c)emicals:

T$ere are different stores for des " c$emicals' ;arious tpes of des " c$emicalsare stored $ere according to des " c$emicals companies' Different tpes of des" c$emicals are listed in a s$eet' #n t$e s$eet t$e stored 7uantit of des "c$emicals are also included' Eer mont$ t$e s$eet is updated " a cop of t$iss$eet is supplied to t$e deing manager/ de $ouse " la* section'

Spares:

#n &eximco Textiles .td' re7uired amount of spares of different mac$ines arestored in t$e mec$anical store room' ll t$e spares are listed in a s$eet ,$ic$ iscontrolled * t$e mec$anical " maintenance personnel' !pares are arranged in t$estore room according to t$eir si5e/ 7uantit " re7uirements' T$ere are s$elf in t$estore room to +eep t$e small spare parts'

Finis)ed %oods:

&eximco Textiles .td' supplies its finis$ed ded fa*rics to its garments section' !ofinis$ed fa*rics are stored for s$ort time in t$e finis$ing section' ll t$e delieredfa*rics are noted on t$e tall +$ata according to t$e lot no' 7uantit/ fa*ricsdiameter/ *uer8s name/ color " considering ot$er tec$nical parameters'

Remar!s:

&eximco Textiles .td' $as indiidual stores for ra, materials/ finis$ed goods etc'T$ere are not enoug$ space to store t$e finis$ed goods' #t re7uires increasing t$estore area' #n &eximco Textiles .td' t$e store for inentor control is satisfactor'



101/108

14th hapter

omplianceof




102/108

Deinition:

Compliance means conformit of certain standard' &T. maintain a moderate,or+ing condition for t$eir emploees' T$oug$ it is ,ell esta*lis$ed pro@ect' T$ere

are some lac+ing of proper compliance issues'

ompliance issues:

Compensation for $olida/

.eae ,it$ ,ages/

ealt$ register/

Time care/

ccident register/

or+man register/

E7ual remuneration/

6ational festial $olida/

Oertime register/

.a*or ,elfare/

ee+l $olida fund/

!exual $arassment polic/

C$ild la*or a*olition polic/

nti-discrimination polic/

Pero a*asement polic/

or+ing $our polic/

iringHrecruitment polic/

Enironment polic/

!ecurit polic/

&uer8s code of conduct/

ealt$ " safet committee/ Canteen'

4ealt):



103/108

Drin+ing ,ater at least 4'A.HdaHemploee/

Cup aaila*ilit/

Drin+ing ,ater suppl/

ater cooler/ $eater aaila*le in canteen/

Drin+ing ,ater essel clean at once in a ,ee+/ ater resere at least once a ,ee+/

ater center in c$arge person ,it$ cleanliness/

!uggestion *ox register'

Toilet:

!eparate toilet for ,omen " men/

seat ,it$ proper priac " loc+ facilit/ rinal accommodation/

Effectie ,ater se,age sstem/

!oap toilet/

ater tap/

Dust *ins/

$ite ,as$ed one in eer four mont$s/

Dail cleaning log s$eet/

6o-smo+ing signs/

.adiesHgents toilet signs *ot$ in &engali " Englis$/ Disposal of ,astes " effluent'

Fire:

!ufficient fire extinguis$er/

ccess area ,it$out $indrance/

Fire signs in *ot$ &engali " Englis$/

Fire certified personal p$oto/

Emergenc exit'

Sa(et' %uard:



104/108

etal glo,s on good conditions/

Gu**er mats " ironers/

First aid *ox one/

#roners ,earing sleepers/

First trained emploees/ otorHneedle guard/

Ee guard/

6urse/

Doctor/

edicine/

edicine issuing register/

elfare officer'

$t)ers:

Goom temperatures/

.ig$ting facilities'



105/108

1th hapter

onclusion



106/108

&eximco Textiles .td' is a ,ell planned ersatile pro@ect' T$e administrations/management/ c$ain of command all are ,ell organi5ed' T$e are deoted to satisft$e customer * t$eir actiities' o,eer/ some of t$e point ,e ,ant to mentionfor t$e good of &eximco Textiles .td'

M( achie6ement:

# got t$e general information of suc$ a large factor t$at gies me t$e clear

idea a*out t$e re7uirements of a composite industr set up ,it$ all necessarmanpo,er " mac$ineries/

# $ae earned some +no,ledge a*out t$e 7ualit management sstem of

different sections of t$e industr/ # $ae identified t$e process se7uence of different units t$at gies me t$e

*etter idea a*out running of a program/ # got t$e information a*out related to t$e amount of ,astage of different

units t$at $elped me to calculate t$e *enefit " loss of an pro@ect t$at can*e run/

Communication of different *uers " merc$andisers $elped me to deelop

m personal s+ills " self confidence/ # $ae $armoni5ed mself ,it$ t$e industrial enironment/ ,or+ "

administration t$at ,ill $elp me to do @o* in an industr/ Furt$ermore # ac$ieed some practical +no,ledge a*out eer steps related

to t$e production of a ,oen fa*ric t$at ,ill facilitate me to deelop mexperience more in t$is field'

7u$$estions:



107/108


108/108

# am luc+ enoug$ t$at # got an opportunit to get industrial training at &eximcoTextiles .td' During t$is training period # $ae isited different sections of t$e mill" receied enoug$ co-operation " " support from t$e aut$orit " all t$e

personnel of different sections' ere/ all t$e officers " t$e stuffs are er cordial "er muc$ deoted to t$eir duties/ ,$ic$ ,as also learning for me'

----->-----