industrial attachment of beximco knitting ltd

BEXIMCO KNITTING LTD. 2013

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INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUTRY NAME: BEXTEX


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ACKNOWLEDGEMENT

Industrial Attachment Course is an academic function of the Southeast University. Like allother years our teacher Prof. Syed Fakhrul Hasan, Chairman, Department of TextileEngineering, gave us an opportunity to choose preferable mills for Industrial AttachmentCourse. We, the three students of 04th batch choose BEXIMCO Knitting Ltd. Joyfully withthe supervision of our teacher Md. Fazley Elahi.

During the attachment with BEXIMCO Knitting Limited we worked in all thedepartments related with the Wet Processing Section. We not only gave priority to the WetProcessing but also worked sincerely in the Knitting Section, Utilities, Maintenance andEffluent Treatment Plant. Beside these, we learned about Quality Control Section andFinished Fabric Inspection Section, warehouse & Store & Inventory, finishing speciallydyeing.

We owe a particular debt of gratitude to MD. Lat Mia, Asst. Manager, DyeingSection, BKL. He gave away some of his valuable time regularly in helping us to achieve ourintended goal.We also express our gratitude to all the executives of BKL knitting, batching,store & inventory control.

Of course, we wish to pay our special thanks to the persons guided us, inspired us &cared us during these days-Md. Khairul Islam, Manager, Dyeing Section & Mr. RafikulIslam Raju, GM, BKL.

Lastly we express our gratitude to our supervising teacher, the name that should bementioned first, Md. Fazley Elahi, Lecturer of the Dept. Textile Engineering, SEU, for hisvaluable direction & supervision.

However, we have prepared our Industrial Attachment report overcoming all thedifficulties & also the shortage of time. Here we would like to present the report.

Date: ……../……../2010 (Rahat Bin Rahman)

(Md. Yeasin Arafat)


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(Md. Abu Hurayra

Chapter- 01

ProjectDescription


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Company Information

Name : BEXIMCO KNITTING LIMITED (Dyeing section)

Type : KNIT DYEING.

Year of establishment : 1996 Location : Beximco industrial park, Sarabo, Kashimpur, Gazipur.

(5 km north from DEPZ).

Address:Corporate Headquarter:

17, Dhanmondi, R/A,Road no. 2, Dhaka- 1205

Operational Headquarter & Factory:

Beximco Knitting Limited,Beximco Industrial park.Sarabo, Kashimpur, Gazipur.

Sponsors : World Bank, Marubeni.


YRS SEU Figure- Location of BEXTEX

DEPZ

DEPZBipile

Nobinagar

Chakraborti

BeximcoIndustrial

Park

Abdullahpur

Savar Ashulia

National Assembly

Mirp

ur R

oad

Farmgate

J. U.

Asad gate

Mirpur

Gabtoli

Tongi

Uttara

New Air port

Old Air portPrimeMinister’sHouse

Dha

ka M

ymen

sing

Roa

dMohakhali

Sat Rasta


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HISTORY OF BEXIMCO GROUP1965-1973: Beximco was born.

1965 New Dacca Industries Ltd

1973 Beximco UK branch.

1976-1989: Beximco diversifies

1978 Beximco foods Ltd.

1979 Beximco pharmaceuticals ltd.

1982 Shinepukur Jute Spinners Ltd.

1985 Beximco apparels Ltd.

1987 Recognised as export house for contribution to country’s export.

1990-1995: Beximco expands

1990 Padma Textile Mills Ltd.(plant -1)

1992 Beximco Synthetics Ltd.

1996-1999: Beximco preparing for the new millennium.

1996 Beximco Textiles Ltd (Phase 1).

Beximco Knitting Ltd.

Beximco Denims Ltd .

1997: Padma Textiles Mills Ltd (Plant -2).

1998: Beximco Textiles Mills Ltd (Phase 2).

Beximco Fashions Ltd .

Physical Infrastructure Single storied building (only dye warehouse is double storied ) Concrete structure (about 30 ft high)


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Different Department

A) Production oriented departmentProduction Planning and controlKnittingBatch preparationDyeingFinishingLab& Quality assuranceDye warehouseMaintenanceUtilityFinished warehouse

B) Supporting department- Personnel administration- Procurement- Marketing- IT- HRD- Finance & accounting.

Remarks:- Available data on physical infrastructure was not available.- Production per day ranges from 8-12 tons.


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Chapter- 02

ManpowerManagement


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2.1 Shift change:Per shift is 8hrs

1st shift : 6:00 AM - 2:00 PM2nd shift : 2:00 PM - 10:00 PM3rd shift : 10:00 PM - 6:00 AMGeneral shift : 9:00 AM - 5:00 PM

Chief executive officer (CEO)

Head of manufacturing Chief operating officer

DGM (Production)

Maintenance Manager Knitting Manager Dyeing Manager Finishing Manager Q.C Manager

Asst. Manager Deputy Manager Shift officer Shift officer

Shift officer Shift officer

Electrical incharge Mechanical Incharge

ORGANOGRAM OF MANPOWER


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2.2 Responsibility of a production officer: Overall supervision of dyeing, finishing production. Batch preparation & pH check. Dyes & chemical requisition issue & check. Write Fabrics loading &loading time from m/c. Program making, sample checking, colour measurement. Control the supervisor, operator, asst. operator and

helper of dyeing m/c. And also any other work as & when required by the

management.

2.3 Job description:Title : Production OfficerDept/Section : DyeingReport to : Sr. Production OfficerJob summary : To plan, execute & follows up

the production activities&control the quality production

with related activities.

Title : Sr. Production OfficerDept/Section : DyeingReport to : Asst manager (production)Job summary : To plan, execute & follow up

the production activities.


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Chapter- 03

MachineDescription


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3.1 Dyeing Machines:BKL is an integrated computerized company. It has total 19 dyeing machines among

of them 10 machines are fully computerized. The machines are centrally controlled byBeacon Controller.

3.1.1 Dyeing Machine Specifications:Machine No. : 1, 2, 3, 7, 8

Machine Name : Eco-soft

Company Name : Thies, Germany

No. of Nozzle : 4


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Capacity : 500-600 kg.

Diff. Pressure : 500-600 m.bar.

Rope speed : 200-250 m/min.

Machine No. : 5Machine Name : Mini-soft


No. of Nozzle : 1

Capacity : 75 kg.Diff. Pressure : 500-600 m.bar.



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Machine No. : 6Machine Name : Eco-soft


No. of Nozzle : 2

Capacity : 350 kg.



Machine No. : 9Machine Name : Luft-roto


No. of Nozzle : 2




Machine No. : 10Machine Name : Luft-roto


No. of Nozzle : 3




Machine No. : 11Machine Name : Local

Company Name : Beximco, Bangladesh

Capacity : 70 kg.

Pressure : 500-600 m.bar.


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Capacity : 5-10 kg.


Rope speed : 100-150m/min.


Company Name : Beximco, BangladeshCapacity : 120-150 kg.

No. of Nozzle : 1



Machine No. : 15Company Name : Thies, Germany


No. of Nozzle : 2



Machine No. : 16, 17Company Name : Thies, Germany


No. of Nozzle : 3

Machine No. : 18,19Machine Name : Local


Capacity : 8-15 kg.


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3.2 Finishing Machines:

3.2.1 Finishing Machine Specifications:

Hydro-extractorManufacturer : Nazar Corporation (Pakistan).Function : To remove water from fabric by

centrifugal extractionYear : 1980Capacity : 120 kg.

Extraction % : 65%.Speed : 1400 rpm.

Extraction Time : 5-7 min.

.

Dewatering M/C:

Manufacturer: CALATOR BORAS (SWEDEN)

Function:1. Reduce water content.2. Apply chemicals.3. Open the fabric from the rope form.

Controlling Parameters:

Padder pressure : 4-7 bar Fig: De-watering m/cPick up % : 85%GSM : 20-35%Speed at m/c : 8.5 m/min-60 m/minStretch : 8 to 12% minimum than the

requirement of customers.


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Chemical application:Softener:

To soften the fabric.

Recipe:Baso soft (Fatty acid condensation) : 4 g/LAcetice acid : 0.25 g/LpH : 7.5

Dryer:

Drying:Drying is defined as a process where the liquid portion of the solution is evaporatedfrom the fabric.

Curing:Curing can be defined as a process following addition of a finish to textile fabrics inwhich materials are heated for a short time in elevated temperature to effect achemical reaction.

Controlling parameters:GSM : 15-35%Shrinkage : 12-15%


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Equipment Used:Following equipment are used for relax

drying process:

a) Ruckh relax dryer (Germany):* Gas burner heated.* Blower motor- 8* Conveyor net- 2* Over feed roller- 1* 4 chamber, 1 burner/ 2 chamber* Maximum temperature- 150 °C* Capacity- 2.5 to 3.0 ton* Cyclon- 2 (for hot air remove)* Tube or open fabric can be dried.

b) Santex Relax Dryer (SWITZERLAND):* Model- CH 9555 Tobel* Steam heated.* Blower motor- 2* Conveyor net- 2* Expander roller- 1* Over feed roller- 1* Variable speed- 10 to 15 m/min

Machine Setup: Fig: Drying m/c

a) M/C set up for Ruckh relax dryer:M/C parameter Set-up valueTemperature setting 1000c- 1200c for white shade

1200c-1300c for light shade1300c-1400c for Dark shade1500c-1700c for curing

Blower fan setting AutoExhaust fan setting Auto

M/C Speed 3-35 m/min. Depends on quality of fabric.Over feed 0-40% depends on fabric construction.


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Width of expreader setting 45-114 cm: Depends on the required width offabric.

b) M/C set up for Santex Relax Dryer:M/C parameter Set-up valueTemperature 1000c- 1100c for white shade

1100c-1200c for light shade1200c-1300c for Dark shade

Blower fan setting Push button switch onExhaust fan setting Push button switch onM/C Speed 1-12 m/min. Depends on quality of fabric.

Over feed 0-45% depends on fabric construction.

c) Recommended Temperature for Various Types of Fabric Rukh Dryer:Fabric Type GSM Color/ Shade Temperature °C

TC Single jersey, Pique,Fleece 100-160

White 100-110Light 110-120Dark 120-130

TC Single jersey, Pique,Fleece 180-220

White 110-120Light 120-130Dark 130-140

CVC, Single jersey,Pique/ Fleece 100-160

White 110-120Light 110-120Dark 120-130


White 120-130Light 130-135Dark 135-140


White 130-140Light 140-150Dark 150-160


White 140-150Light 140-150Dark 155-165

100% Cotton, Singlejersey, Pique, Fleece 100-160

White 110-120Light 115-125Dark 120-130

100% Cotton, Single White 120-130


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jersey, Pique, Fleece 180-220 Light 130-140Dark 140-150


White 130-140Light 140-150Dark 150-160


White 140-150Light 145-155Dark 160-165

Checking parameters:1. Shade Check

2. Width check3. Weight check4. Compaction check5. Fault check:

Operator checks -a) Knitting faultsb) Spinning faults

c) Dyeing faults

d) Other faults6. Bow and Slant check for Ruckh Relax Dryer only.

Slitter M/C:

Slitting:

Slitting is a process that is applied for cutting the tubular fabric through the intendedbreak wales line on lengthwise direction prior to stenter processing.

Equipment used :

Airtex Slitter Machine (Sweden)

Speed: 20-25 m/min.

M/C parts:a) Rotary blade b) Ringc) Guide Roller d) Plaiting


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Checking parameters:1) Cutting line check2) Bow & slant check3) Fault check

Operator checks –a) Knitting faultsb) Spinning faults

c) Dyeing faultsd) Other faults

Stenter M/C:

Fig: Slitter m/c

Equipment used:Name : Krantz Stenter Machine (Germany)No of chamber : 7No of Burner : 14No of Padding through : 2No of exhaust fan : 7Type : Pin stenterPick up% : 80%Total length : 22 mWidth control range : 1 to 2.6 mCapacity : 9-10 ton/24 hrs.

Parts of the Stenter:a) Chamber:

Each chamber contain- 4 air duck nozzle 2 hot air fan 1 hot blower motor 2 burner

b) Chemical mixing tank 2 chamber Fig: Stenter m/c 2 motor

c) Chemical bath


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3 roller (1 free, 2 expander) Padder

2 roller1 motor

d) Controller To control spirality 2 motor 2 roller (1 blowing)

e) Loading section 1 motor 2 expender roller 2 free roller 1 over feed roller 2 sensor

f) Connecting device To centre the fabric Expender (to expand

the fabric) 2 motor 5 roller

g) J- box To store the fabric

h) Chain 2 chains 120 m length Moves horizontally 2 feeding motor/ wheel 4 pin push

i) End side Fig: Chain Guider Cooling chamber 2 cooling fan 4 air duck nozzle

j) Selvedge cutting device To cut the selvedge of the fabric.

k) Delivery section Platting 4 free roller 1 over feed roller


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Function:1. Apply chemicals.2. To dart set the T/C fabric.3. Drying of fabric.4. To control width.5. Curing of fabric.6. Apply pigment dyeing.7. To control GSM.8. To control shrinkage.

Machine Setup:

M/C parameters Set up valuePadder pressure 2 to 8 barTemperature setting 90- 1800 cBlower fan setting Lower to high

Exhaust fan setting ManualWidth of m/c chain setting 110 cm up to 260 cmOver feed 0-60%Burner gas pressure 30-50 m/ barMachine speed 6 to 60 m/ min

Light wt (100-140 GSM)Medium wt (150-180 GSM)Heavy wt (190-250)

20-30 m/min14-18 m/min10-15 m/min


2. Width check3. Weight check4. Compaction check5. Fault check

Operator check:a) Knitting faultsb) Spinning faults

c) Dyeing faults


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Tubular Compactor:

Equipment used :Ruckh Tubular Compactor m/c (Germany).

Function:1. To control shrinkage.2. To control width.3. To control GSM.4. To smooth fabric. Fig: Tubular Compactor

M/C set up:M/C parameters Set up value

Steam pressure 4-6 barsAir pressure 5 barTemperature 90-1000c

Cooling fan Motor AutoWidth control 48 to 114 cmSpeed setting 5- 35 m/min





6. Edge line checking


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Open Compactor:

Manufacturer: Feraro (Italy)

Function:1. To control shrinkage.2. To control width3. To control GSM.4. To smooth the fabric.

Fig: Open compactor

M/C set up:

M/C parameters Set up value

Steam pressure 4-6 bars

Air pressure 5 bar

Temperature 700-1000c

Width 36”-100”

Speed 5-25 m/min.






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Beacon Controlling System

In BKL Beacon Controller 2800 is used. It contains programs of pretreatment,washing, rinsing, unloading, dyeing. It shows graphs for every program.

Where,Yellow line = Indicates theoretical required temperature.Red line = Indicates practical temperature.Blue line = Indicates theoretical chemical dosing to vessel from tank.Pink line = Indicates practical chemical dosing to vessel from tank.Green line = Liquor level in vessel.

In BKL from m/c no. 1-10 is controlled by this Beacon Controller.

Advantages:1. One officer can control 10 m/cs at a time.2. Production is high.3. Show programs with graphs.

Dye Kitchen:Dyeing m/c no. 1-10 require 4 tanks.

Tanks no. 1, 2, 3 are present in dye kitchen and tank

no. 4 is present with dye vessel. In dye kitchen operator

measures dye & soda according to requirement. Then

operator dissolves dye with water in tank no. 1. Accordingto program dye passes to tank no. 4 and then to dye vessel.After required time operator dissolves soda with water intank no.1 which pass to tank no. 4 and to dye vessel.

Fig: Dye Kitchen House


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CHAPTER - 04

RAWMATERIALS


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4.1 Introduction:Raw material is a unique substance in any production oriented textile industry. Itplays a vital role in case of continuous production & for high quality fabric.

4.2 Types of raw materialThe basic raw materials used are:

fabricdyestuffsChemicals & auxiliaries.

Names & source

Fabric:Different types of fabric treated in BKL dyeing section are namely

- Single Jersey- Single jersey with lycra attachment- Polo pique- Back pique- Rib Fabric- Lycra fleece- Jacquard- Cross –rib- STB Pique- Thermal- Fleece

Dyestuffs:

Dye Brand name Origin/sourceReactive dye Bezactive Bezema , Switzerland

Ciba Ciba , SwitzerlandDychufix Hubei Hwalle dyestuff

Ind.co.Kemafix Jaychem,IndiaLevafix Dystar , GermanyProcion Dystar, germanyJackazol IndiaKemazol Jaychem,IndiaRemazol Dyestar , GermanySolazol Solarfine , TaiwanSolacion Solarfine , Taiwan


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Brand name Type SourceNovolube Jet Anti creasing agent Techna, ItalyBluton BVB1 Violet tone brightener CHT, GermanyCibacel DBC Sequestering agent Ciba, India.Cibafix ECO Fixing agent Ciba, Switz.Cibafluid C Anticreasing agent Ciba, Switz.SandocleanPCLF Detergent Clarient, GermanyPermacol FA Stabilizer Techna, ItalyNovostone CR Enzyme Techna, ItalyCotton white T Redder tone brightener CHT, GermanyCyclanon E Fixing agent BASF, GermanyCyclanon ECO Reduction cleaning agent BASF, GermanyJinlev RLF349 Dispersing agent Geigy, TaiwanEulysin S pH buffer in PET dyeing BASF, GermanyFelosan NOF Detergent CHT, GermanyUvitex EBF Whitening agent Ciba , Switz.Jinlev CL-225 Leveling agent for reactive dye Geigy, TaiwanOxalic caid Iron remover -Palegal FA-8 Leveling agent for disperse dye BASF, GermanyRespumit BU Antifoaming agent BASF, GermanyPermacol SQ Sequestering agent Techna, ItalyNa thiosulphate Peroxide killer -Uniperol O Washing agent for PET dyeing BASF, GermanyUvitex EVF PET brightener Ciba, Switz.Uvitex 2B Yellow tone brightener Ciba, Switz.Mollan129 Soapenging agent Rota, dystarAcetic acid pH controller -Reduction HCS Reduction cleaning agent Geigy, TaiwanMollan130 Sequestering agent Rota, dystarBluton 2B Whitening agent Ciba, India

Remarks- The list is for the time of our industrial attachment. It varies according

to the availability of the material & their price.

Disperse dyeTerasil Ciba , SwitzerlandDianix Dystar, germanyDispersol Dystar, germanyBoron Zenith chemicals,Taiwan


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CHAPTER -05

PRODUCTIONPLANNING & SEQUENCE

OFOPERATION


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Final Inspectioninspection

Finished Store

Delivery to Garment industry

SEQUENCE OF OPERATION

Knitting

Grey inspection

Batch preparation

Pretreatment White Processing

Polyester dyeing Cotton dyeing

Hydro extracting

Dewatering

Drying

Compacting


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5.1 Introduction and Basic Procedure of Planning andControl:

A planned work brings success. Without planning nothing is completed within therequired time. So planning has its own importance which is intolerable. "Planning"gives a scheduled task and 'control' completes it successfully. But production planningand control is not an easy task. So BEXIMCO has a self-sufficient and high-performance department called "Production Planning & Control". Its Basic workingprocedure is as follows –

1. Taking orders from marketing division.2. Analyzing the orders.

3. Planning for knitting the fabric.4. Planning for dyeing the fabric.5. Planning for finishing the fabric.

It is only a basic procedure. It may change according to the type of order. Sometimes,order is places only for finishing the material or only for dyeing the white goods. Thensome steps are omitted for planning procedure.

1. Taking orders from marketing division:BEXIMCO marking division supplies Fabric Orders to the BKL Planning and controldivision by a special format.

2. Analyzing the orders:This section analyzes the orders according to buyers, Order Quantity, type of orders(i.e. type of fabric, color to be dyed etc.), delivery date etc. Then it selects which M/C.to use, no of M/C. to use, time required for production etc. This section plans forrequired quantity of fabric to be knitted (Order quantity + 6% of Order Quantity),knitting balance, fabric need to be dyed. Dyeing balance, RFD (Ready for delivery),RFD balance, delivered fabric and delivery balance.

3. Planning for knitting:This section plans for knitting production. It selects machine for knit the fabric forspecific type of fabric, type of yarn used, required GSM, width etc. It also givesdelivery data for knitted fabric. It also places orders for buying of yarn from spinningmills by a specific schedule.

4. Planning for dyeing the fabric:Production planning for dyeing is called 'Batch Plan'. According to the batch no. Andcolor, width, style and construction the batch plan is made. For easy understand this


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section gives some 'T.' cards. 'T' cards are serialized according to the priority ofdelivery. The batches and 'T' cards also serialized as to dye light shade at first andlastly the dark shades, since faulty shades can be converted to dark color later.

5. Planning for finishing the fabric:Finishing schedule is same us the dyeing. After dyeing the material goes to thefinishing section with the batch plan. Finished data is written to the batch card and isinformed to the planning section.

However, this section always enforces to all the departments to finish all the workswithin the delivery time given by the buyers. This section delivers materials by truck,micro, air etc to the customer within the meantime. Thus it plays a very important rolein the success of the company.


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CHAPTER- 06

KNITTING SECTION


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6. Introduction:The BEXIMCO Knitting Limited is a self-sufficient modern company. Its knittingsection is divided into two sections –

1. Flat knitting section &2. Circular knitting section.

6.1. Flat Knitting Section:Flat knitting section consists of Flat Knitting Machines. Its main production is Collarand Cuff. Different types of designed collar & cuff is produced here with relation to thebody of the garments.

6.1.1 Production Equipment

Table: The following equipment are used for production-Name Fabric type Manu. Model Gauge Length No. of m/c.

STOLL semi-jacquard Germany -------- 14 84 inch 2

MATSUYA Plain Japan M-100 14 100 cm 26

MATSUYA Plain Japan M-70 14 70 cm 22

KAUO HENG Semi-jacquard Taiwan KH-313 14 54 inch 17

MATSUYA Semi-jacquard Japan 14 64 inch 2

Total machines = 69

Note: Collar & cuff prepared is mainly rib fabric.

Tipping is also used in the collar & cuff. ‘Tipping’ is stripe design mainly knittedby Polyester yarn.


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Plain flat bed knitting. m/c. (M-70)Semi- Jacquard (KH-313)

MATSUYA Semi Jacquard Semi- Jacquard


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6.2. Circular Knitting Section:Circular Knitting section consists of Circular Knitting Machines. Different types ofbody fabric are produced in this section.

6.2.1 Production Equipment

BEXIMCO Knitting Limited (BKL) is capable to knit Weft Knitted fabrics only.Following types of machines are available with BEXIMCO Knitting Ltd. for CircularKnitting.

Gauge Model No. Origin No. of Cylinder Existing Set-up18 1995 CAMBER, UK 05 020 1995 CAMBER, UK 10 0824 1995 CAMBER, UK 14 1428 1995 CAMBER, UK 26 06

16 (RIB) 1995 CAMBER, UK 01 0118 (RIB) 1995 CAMBER, UK 01 0120 (RIB) 1995 CAMBER, UK 01 0

Total 58

Note: There are 7 (Seven) machines with lycra facilities.

Single Jersey Stripe Single Jersey (Lycra facilities)


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Double Jersey Circular kng. m/c. Single Jersey Circular kng. m/c.

6.3 Knitting Faults: Barre or stripe Press off Miss stitch/ drop stitch Needle mark Sinker mark Oil stain Crease mark/Edge mark Holes Excessive slubs Spirility Broken needle Pin hole Tight course Missing Yarn etc.


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CHAPTER- 07

GRIEGE BODY&

RIB INSPECTIONS


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7. Inspection:To detect and identify the knitting fault in fabric by visual assessment on Inspection m/c.

7.1 Collar & cuff inspection:Collar & cuff inspection is a process of identifying quality fault in knitted collar& cuff from flat knit m/c.

Equipment used:

a) Inspection m/c (Calator Sweden)

b) Inspection Table.

M/C Set up (Inspection m/c):

M/C set up Parameter range Set value

Roller speed 0-40 m/min 25-30 m/min

light Not applicable Artificial day light

Length measuringunit

Not applicable Attached with m/c.

7.2 Faults:

H = Hole OS = Oil stain

DS = Drop stitch. WD = Wrong Design

NL = Needle line. S = Stripe

TT = Thick & Thin yarn. S = Slubs

SM = Sinker Mark. WP = Wrong Ply,etc.

7.2.1 Four Point System:

Size of defect Penalty

3 inches or less 1 points

over 3 but not over 6 2 points

Over 6 but nor over 9 3 points

Over 9 inches 4 points


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Acceptance calculation:Total point per 100 square yards

= 100widthActual

36lengthRollActualcountedpointsActual

= Points/100 square yards.

Classification of Inspection Fabric :< 40 points = A

41-60 points = B

61-80 points = C

80 above = Reject.

Acceptance:Generally any piece of fabric with 40 points or less faults per 100sq. yard isallowed to pass however for a roll, the average value should not exceed 18pointper 100sq.yard.More than 40points faults per 100sq yard is recorded as“REJECT”.


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CHAPTER- 08

BATCHPREPARATION


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Batch Preparation Sequence

Process sequence of Batch preparation receive batch card from Grey In-charge

Make the priority as per dyeing plan

Take one specific Batch card.

Read the Batch Card for own understanding

Check the availability of fabric

Take required quantity of body fabric from ware-house.

Make required no. of Rope maintaining equal length.

Take collar/cuff as per size, keep the total weight.

Distribute the collar /cuff or Rib in each rope equally unsure equal length

Stitch the fabric

Write down the weight against roll no. in the back side of the Batch Card.

Write the total weight in Batch Card.

Put signature & date.

Fill up the production report form.

M/c for Batch preparation:Two types of m/c’s :

a) Turning m/c b) Plaiting m/c.


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CHAPTER- 09

SINGEING


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9. Singeing:Singeing is the process of burning of the fibre hairs projecting through the fabricsurface. In a gas-singeing machine this burning is carried out by passing fabricagainst hot flames under specified conditions.

Objects: To obtain a uniform & smooth fabric surface by removing hairiness.

To ensure uniform optical reflectance throughout the fabric surface insubsequent fabric wet process.

Equipment-used:Machine : Sando Gas Singing m/c.

Manufactures : Sando Iron Works, Japan.

Required Parameters:a) Steam: Steam is supplied to the steam box of the machine.

b) Compressed air: The standard air supply pressure requirement is 4 kg/cm2.

c) Water: The standard water supply pressure requirement is 1-1.2 kg/cm2.

d) Natural gas: The standard gas supply pressure requirement is 3 kg/cm2.


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M/C Setup:Setup parameters Range Set value

Speed(m/min) 0-120 55-60 for cotton.70 for PC/CVC.

Potentiometer Setting (rpm) 0-150 80-90 for cotton fabric60-70 for CVC/PC.

Burner in use 1 or 2 2

Burner operation mode. Auto/Manual Auto

Flame height (cm) 1-8 6 for white & light shade fabric.6.5 for medium & dark shade

fabric

Flame angle with the direction offabric.

450 to 900 450 for blends900 for cotton

Flame intensity Low/normal/high

Low – not usedMedium – for white & light shadeHigh – for medium & dark shadefabric

Singeing Faults:a. Singeing line:

Due to ununiform joint of bricks by cement, there become gaps between flame

and thus singeing line is formed.

b. Uneven singeing:

One to uneven flame height uneven singeing is occurred.


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CHAPTER- 10

MERCERIZING

PROCESS


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10. Mercerizing:Mercerizing is a physio-chemical process in which cotton fabric is treated with

concentrated solution of caustic alkali & subsequently stretched & washed under

specified conditions.

Objects: To increase lusture of fabric.

To increase the strength of fabric.

To improve dimensional stability.

To increase dye absorbency.

Equipment used:

Dornier mercerizing m/c (Germany).

Required parameters:Parameters Value

Squeeze pressure 1.5-2 bar (by compressed air)

Temperature of washing 800-900c

PH after mercerizing 7-7.5

Caustic solution temperature In mixing tank : 80-900cIn caustic stroage tank : 70-800cIn chiller : 140cIn Mercerizing bath : 160-200c

1st sigar diameter Set with fabric dia +3

2nd sigar diameter Set with fabric dia +5

Caustic strength 280 Be


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Function of m/c parts:

Sigar:

1. To stretch the tubular knit fabric.

2. To prevent shrinkage.

3. To retain dimensional stability of fabric.

4. To wash off mercerizing chemicals from the fabric byspraying water on it.

Padder Pressure:

To squeeze and drive the fabric to a little extent otherwise there is a risk offorming edge line at two sides of fabric.

Water valves:

Supply water to washing tank.

Steam values:

Steam value supply steam to washing chamber.

Mercerizing process faults: PH variation

Crease

Water drop mark

Spot

Problem from sigar

Holes

Distortion of dimensional stability


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CHAPTER- 11

PRE-TREATMENT


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11. SCOURING:

Objects: To remove fats, wax, impurities from fabric.

To increase absorbency of fabric.

To remove natural nitrogenous coloring materials, dirt, dust, husk, brokenseed, protein, leaf etc. by oxidizing on chemical treatment.

To obtain pure & permanent white color.:

11.1 Single Stage Scouring-Bleaching:

Process steps:

Take water in bath at required level.

Load fabric.

Circulate fabric & raise temp. at 60oc

Add Anti-creasing agent, Detergent, sequestering agent, stabilizer.

Add Caustic soda

Circulate fabric.

Add H2O2.

Continue circulation fabric 25 min. at 100oc

Decrease temp. at 800c

Rinse & Drain.

Add Detergent & H2O2 killer and raise temp 80oc

Continue circulation for 10’ at 60oc

Rinse & Drain.

Hot wash for T/C

To remove waxes, fats.

Increase absorbency for T/C & TTC for dark shades.


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Curve:

600

00c

Recipe:1. Anti-creasing Agent : 1 g/L2. Detergent : 1.5 g/L

Steps: Take water in bath at required level. Load fabric. Circulate fabric & raise temp. at 60oc Add Anti-creasing agent, Detergent. Circulate fabric and raise temp.

11.2 Enzyme Treatment:If dead fibre or hairiness present in fabric then enzyme treatment is done.

Function:

It attacks surface cellulose fibre and removes it from surface.

Precaution:Excess enzyme is harmful for cellulose fabric.

Application of enzyme is done by two ways:a) Before Dyeing Enzyme treatment Dyeingb) After Dyeing Dyeing Enzyme treatment

2

1

900c15

Tem

pera

ture

Time


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Curve:

550c

Recipe:1. Acetic Acid : 0.1g/L (pH 4.5-5)2. Novostone CR : 0.5~1 %3. Novolube JET : 0.3~0.5 g/L

Steps: Take water bath at required level. Load fabric. Circulate fabric and raise temp. at 55oc Add acetic acid, Novostone CR& Novolube JET Drain. Hot fill for 10 min. at 75oc Novolube JET. Rinse & Drain.

00c

2+3

1

30

Drain 3 Drain

750c

10Tem

pera

ture

Time


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CHAPTER- 12

DYEINGPROCESS


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12. Reactive Dyeing:

Properties:Anionic in nature.Soluble in water.Form strong covalent bondBetter wet & light fastness.Have better substantibity.Dyeing is carried out at alkaline condition.

Influencing factors:1. pH2. Temperature.3. Conc. of electrolyte.4. Time.5. Liquor ratio.

Amount of salt, soda, caustic for Cibacron dye at 60oC:

Shade % G. salt g/L Soda g/L Caustic Soda g/L<0.25 10 5 _

026-0.5 20 5 _0.51-1 30 7.5 _

1.01-2 40 10 _2.01-3 50 5 0.3

Above 3 60 5 0.7


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12.1 REACTIVE DYEING FOR SENSITIVESHADE AT 60oC

Dyeing steps: Take water required level. Load fabric Raise temp. at 60oc Add anti-creasing agent (1), sequestering agent (2). Add color (3) by injecting for 30 min & circulate fabric (4) Injection of G. salt (5) & circulate fabric. Add soda ash by injecting 40 min. Rinse & Drain Wash at 60oc by circulating fabric for 10 min. Hot fill & circulate fabric for 10 at 90oc with soap. Wash at 50c by circulating fabric for 7 min. Rinse & Drain Unload fabric.

Dyeing curve:

90˚c

60˚c

Drain

0˚c

1 2 3 4 5

12.2 REACTIVE DYEING FOR DARK SHADE AT 60oC:

Process steps:1. Take water (1) required level.

Tem

pera

ture

Time


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2. Load fabric (2).3. Raise temp. at 60oc & circulate fabric4. Add anti-creasing agent (3), sequestering agent m (4).5. Add G. salt (5).6. Circulate fabric for 5 min.7. Continue circulate color inject for 30 min.8. Circulate fabric & Add soda ash & caustic soda for 60 min.9. Rinse & Drain.10. Hot fill & circulate fabric for 10 min & Drain.11. Add acetic acid & raise temp 600c for 10 min.12. Hot fill & circulate fabric for 15’ with soap.13. Rinse & Drain.14. Hot fill & circulate fabric for 10 min & Drain.15. Hot fill & circulate fabric for 10 min.16. Rinse & Drain.17. Unload fabric.

Dyeing curve:

60˚c

Drain

1 2 3 4 5

12.3 Hot Brand Reactive Dyeing:

Dyeing at 92oC:

Tem

pera

ture

Time


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Required Salt, Soda ash :

Shade % Glauber salt g/L Soda ash g/L

up to 0.5% 70 10

0.51-1.2% 80 15

1.21-2% 90 15

above 2% 90 20

Dyeing curve:

60c

Recipe :1. Anti-creasing agent (Ciba fluid C): 0.5 g/L2. Sequestering agent (Ciba cel DBC): 1.5 g/L3. Glauber salt : 90 g/L4. Procion Flavine HEXL: 0.0942 %

Procion Yellow HEXL: 1.633 %Procion Sapphire HEXL: 2.061 %

5. Soda ash : 20 g/L6. Acetic acid: 0.75 g/L7. Soap (Albatex S): 1 g/L

920c

Rinse

600c

Rinse

600c

Rinse

600c

Rinse

600c

Rinse

600c

Rinse

600c

Rinse

600c

60 Shadecheck

1

600c

00c2

3

20

Rinse

800c

4

5 10

5 10

Tem

pera

ture

Time


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Process steps : Take water at required level. Load fabric. Raise temp at 60oc & circulate fabric Add anti-creasing , sequest agent & Glauber salt.&check ph. Circulation fabric for 5 at 60oc. Color inject for 25 min. Continue fabric and raise temp. at 92oc and continue 20 min. Continue circulation & add soda ash for 60 min. Decrease temp at 80oc. Check shade. Rinse & Drain. Hot fill & raise temp at 80oc & continue circulation for 10 min. & Drain. Cold fill & raise temp at 60oc add acetic acid and continue 10 min. Raise & Drain. Hot fill & raise temp at 90oc Add soda & continue for 10 min. Rinse & Drain. Cold fill & raise temp at 60oc for continue circulation for 10 min. Rinse & Drain. Unload fabric.

12.4 Polyester Dyeing:Disperse dye:

Disperse dye is one kind of organic coloring substances which is free of ionizinggroup, less soluble in water & used on hydrophobic Textile material .

Properties of Disperse dye:1. Non ionic in nature.2. Insoluble in water.3. Wet & light fastness is good.4. They are used in acidic condition.

Influencing factors for dyeing:

a) pH of bath (4.5~5.5)

b) Temp. of bath.c) Concentration of dispersing agent.d) Time of dyeing cycle.


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Dyeing curve:

5+6

Recipe :1. Acid Buffer (Eulusin FAS) : 1.8 g/L2. Dispersing agent (Jinlev RLF349) : 1.8 g/L3. Antcreasing agent (Ciba fluid C) : 0.5 g/L4. Dianix Red : 0.106 %

Dianix Yellow : 0.07%Dianix Black : 0.78 %

5. Reduction clearing (Reduction HCS) : 1-3 g/L6. Acetic Acid:1g/l.7. Detergent (Albatex S) : 0.5 g/L

Process steps for Polyester part : Take water at required level. Load fabric. Raise temp. at 40oc & circulate fabric Add Acid Buffer, Dispersing agent, Anticreasing agent Raise temp at 50oc Continue circulation of fabric & inject color. Raise temp. to 90oc by 1.5oc/ min. Then raise temp at 130oc, 1oc/ min. and

continue 30 min. Decrease temp. at 90oc,, 0.750c/min. Thus decrease temp. at 78oc, 1oc/min. Rinse & Drain. Mixed fill, add reduction clearing agent. Rinse temp. at 80oc and continue 15 min. & Drain Cold fill & raise temp at 80oc & rinse & Drain. Cold fill, add detergent & raise temp. at 80oc & continue 10 min. Rinse & Drain.

400c

800c

10

00c

Rinse

1

301300c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

32780c

Shade Check

500

c

4

7 Rinse400c

800cRinseTem

pera

ture

Time


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12.5 STRIPPINGStripping is carried out to remove uneven of shade or to reduce dark shade. In BKL

Stripping is done for 100% cotton, T/C, CVC & TTC.

12.5.1 Full Stripping For 100% Cotton:.

Curve:

100CX60min

CR 60°CX15``

80°C

3

1 2

Recipe:1. Anticreasing agent: 1 g/L

Sequestering agent-1g/l2. Caustic soda: 5 g/L3. Hydrose : 5 g/L4. Stabilizer: 0.5 g/L5. Caustic: 2 g/L6. H2O2: 2 g/L7. Acetic acid: 0.5 g/L

Process steps: Take water at required level. Load fabric. Raise temp. at 50oc & circulate fabric. Add Anti-creasing agent, caustic & Hydrous. Circulate fabric & raise temp at 1000c & continue 60min. Decrease temp at 800c & rinse for 10 min. & Drain Hot fill & raise temp at 600c, & continue for 15 min. & Drain

50°C

80°C

80°CX10``

Time

Tem

pera

tur

e


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12.5.2 Polyester striping

Process curve:

3°C/min

Recipe:1. Anti-creasing agent : 1 g/L

Sequestering agent : 1g/l2. Caustic soda : 5 g/L3. Hydrose : 5 g/L4. Carrier DTE : 3g/L5. Acetic Acid : 1 g/l6. Bleaching agent : 2 g/L

Process steps: Take water in bath. Raise temp. at 40oc & circulate fabric. Add Anti-creasing agent, seq agent, caustic soda, Hydrose, Carrier. Continue 5 min. Raise temp. at 1350c & continue 30 min. Cool rinse & check shade. Drain. Hot fill & raise temp at 700c Drain Cold fill & add Bleaching agent. Raise temp. at 900c. Rinse & Drain.

0°C1

Rinse2

3

30

60°C

610

135°C

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

5

10

470°C

90°C

30

Cold rinseCheck shade

Time

Tem

pera

tur

e


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12.6 Whitening :Whitening Is A Chemical treatment, fabric white at a desried level by bleaching &

OBA treatment.Factors Influencing Whitening:

1. PH

2. Temp.3. Time

12.6.1 Whitening Process for 100% cotton:

Process curve:

Recipe:1. Detergent (Sando clean PCLF) : 0.7 g/L2. Anticreasing agent (Novolube JET) : 0.4 g/L3. Stabilizer (Permacol FA) : 0.7 g/L4. Caustic soda : 2.25 g/L5. Hydrogenperoxide 50% :6.5 g/L6. Bluton 2B : 0.8%

Bluton BVB1:.06%7. Glauber salt : 5 g/L8. Acetic acid : 0.8 g/L

Process steps: Take water at required level. Load fabric. Raise temp. at 600c & circulate fabric.

60°C4

1

Rinse6

3 5

30

80°C

10

2 7

100°C

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse

5

10

Time

Tem

pera

ture


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Add Detergent, Anti-creasing agent stabilizer. Add caustic & circulate fabric. Continue circulation & add Hydrogenperoxide Add Uvitex 2b & circulate fabric. Add Glauber salt & continue 5 min. Raise temp. at 1000c & continue 60 min. Decrease temp. at 800c. Rinse for 10 min. & Drain. Hot fill & raise temp at 800c and continue 10 min. & Drain. Drain. Mixed water fill, add acetic acid & raise temp at 600c & continue 10 min. Rinse & Drain.

12.6.2 T/C whitening process:

Process curve:

Recipe:1. Detergent : 5 g/L2. Anti-creasing agent : 0.1 g/L3. Stabilizer : 0.5 g/L4. Sequestering agents : 1 g/L5. Caustic soda : 1.5 g/L6. Hydrogenperoxide 50% : 1.5 g/L7. Blankophor ER-T330% : 0.066 %8. Uvitex 2B : 0.363 %9. Glauber salt : 5 g/L10. Acetic acid : 0.5 g/L

Process steps: Take water at required level. Load fabric. Raise temp. at 600c & circulate fabric

110 °C

0°C4

1

Rinse5

3 6

30

80°C

10

2 8

7 9

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

90°C

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

70°C

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse

Tem

pera

tur

e


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Add detergent, anti-creasing agent, stabilizer, sequestering agent. Continue circulation of fabric & add caustic soda. Continue circulation of fabric & add Hydrogen peroxide. Add PES brightener & cotton brightener. Continue circulation of fabric & add Glauber salt. Raise temp. at 1100c & continue 30 min. Decrease temp. slow at 900c. Decrease temp. quickly at 800c. Rinse for 10 min. & Drain. Hot fill & raise temp. at 800c & continue. Drain. Mixed fill & add Acetic acid and raise temp. at 600c & continue 10 min. Rinse & Drain.

12.7 Dyeing faults:Dyeing faults are given as below:

12.7.1 Patchy effect:

Reasons:1. Entanglement of fabric.2. Faulty injection of alkali.3. Faulty color addition.4. Due to hardness of water.5. Due to impure salt addition.

Remedies:By partial or full stripping of dyed fabric.

Roll to Roll variation / Meter to Meter variation:

Reasons:1. Yarn lot mix2. Faulty heat setting3. Hardness of water.4. Faulty m/c speed.


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12.7.2 Dye-stain:

Reasons:1. Undissolved dye particle in bath.2. Undissolved caustic particle in bath.

Remedies:By patrial or full sripping

12.7.3 Crease mark:

Reasons:1. If pump pressure & reel speed is not equal.2. Due to high speed m/c running .

12.7.4 Rub mark:

Reason:1. Due to reel cranking .2. Due to sharp point of nozzle.3. Due to sharp delivery roller.

12.7.5 Nozzle to Nozzle variation:

Reason:Pump pressure & reel speed is not equal.


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Chapter- 13

Finishing


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13. Introduction: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 ortubular form.

13.1 For Tubular form following m/c is required:

Hydro-extractor

De-watering

Dryer

Tubular Compactor

13.2 For open form following m/c are required:

Hydro-extractor

De-watering

Dryer

Slitter

Stenter

Open compactor


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13.3 For collar & Cuff Finishing Following m/c are Required :

Hydro-extractor

Softening Machine

Dryer

13.4 Chemicals Used :

TC collars & cuffs:1. Softener (cationic & nonionic)2. Additive3. Stiffener4. Acetic Acid to adjust pH

100% cotton fabric (soft):1. Softener2. Additive3. Acetic acid to adjust PH

100% cotton collar & cuffs (cross-linking):

1. Softener (cationic /nonionic)2. Additive3. Resin4. Catalyst.5. Acetic acid to maintain PH


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CVC collar & cuffs:1. Softener (cationic & nonionic)2. Additive3. Stiffener4. Acetice acid to maintain PH

CVC collar cuffs (soft) :1. Softener2. Additive3. Acetic acid to maintain PH

M/C set up :

M/C parameters Set up valuePadder pressure 2-7 bar

M/C speed As standard speed set bymanufacturer.

13.5. Inspection:Inspection refers to an investigation process of accepting or rejecting the final finished

fabric from the bulk. It is an observation process of finding. Out each and everyvisible fault in the fabric.

Responsibilities:

1. 100 Fabric Inspection2. Joint Inspection with buyer.3. Problem rectification.4. Fabric transfer to store.

Equipment used :

a) Nazer Inspection m/c, Pakistan.b) Verivide Day Light box.


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13.5.1. Faults:Following faults are detected & identified in final inspection for body :

a) Penalty points legend:H = HoleOS = Oil stainCS = Chemical stain.W = Water spots.FY = Fly yarn.YC = Yarn contamination.WX = White speaks.IS = Insect spots.R = Rub mark.DS = Dye stain.D = Dirt stain.Rs = Rust stain.

b) Faulty appearance:US = Uneven shade.N = NepsCR = Crease MarkP = Patches.HR = HairyMS = Machine stoppage.N = Needle line.BR = Barre mark.CM = Crumple mark.DC = Dead cotton.BW = Bowing.

Beside these, role to role and meter to meter variation is checked.

Four – Points system

Size of defect Penalty

3 inches on less 1 point

over 3, but not over 6 2 point


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Over 6, but not over 9 3 point

Over 9 inches 4 point

13.5.2 Acceptance Calculation:

Total point per 100 square yards

= 100widthActual

36lengthRollActualcountedpointsActual

= Points/100 square yards.

Classification of Inspection Fabric:< 40 points = A41-60 points = B61-80 points = C80 above = Reject.

13.5.3. Collar & cuff inspection:After dyeing & finishing operation measure collar & cuff size and width and

compare with buyer requirements.

Following faults also detect and identify

Faults Decision

1. Rub mark Reject

2. Cutting Reject

3. Hole Reject

4. Crumple Reprocess

5. Tipping bleed Reprocess

6. Uneven shade Reprocess

7. Neps Enzyme wash

8. Oil spot Reject


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9. Role to role variation Reprocess

10. Yarn contamination Reject

11. Barre mark Reject

13.5.4. Some definition of yarn faults:

Neps: Neps may be termed as small light balls of tangled fibers. Contamination: When yarn contains hair, foreign matter, other fibre andspeed pot etc along with fibre, it is called yarn contamination.

Dead cotton and hairiness: Hairiness arises from the fibres that protrudeoutside the fabric surface, it causes pilling. Cotton which is dead cannot absorbdye.

White speaks: Undyed area due to unwanted fiber mixed with cotton.

13.5.5. Some definition of knitting faults: Oil mark: When excess lubricant use for knitting m/c then Oil mark ariseson fabric. Hole: faulty or damage yarn creates hole in fabric. Needle mark: Due to faulty needle this fault caused along wales direction. Sinker mark: Due to faulty sinker this fault caused. Barre mark: Different lot mixing causes this problem.

13.5.6. Some definition processing fault: Crease mark: Uneven heat control during process. Unlevelness: If dyestuffs are not fixed with fabric uniformly causes thisproblem. Patches: This problem causes due to different color on some portion offabric. Crumple mark: This problem is as like crease mark but looks meeting effectover PC fabric. Dye stain: Marks of color on fabric surface cause this problem. Dirty mark: This mark can appear any where in fabric. Rub mark: Caused by friction with metallic component of m/c: Water sports: One to accumulation of water. Chemical stain:Stain caused by chemical during dyeing or finishing.


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. Rust strain:If m/c is affected by rust then rust stain appears on fabric.

Bowing:Bowing means ratio of bow depth at highest point of arc to fabric width. It isexpressed in percentage.


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Chapter- 14

QualityAssurance System


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LabBefore bulk production buyer give a sample to lab. Lab produces similar or nearer

shade of it. If buyer approves this shade then this sample is gone for bulk production. Ifbuyer doesn’t approve that shade, Lab again produces similar or nearer shade of standard andgive it to buyer for approval.

14.1 Equipments used in Lab:

Ahiba Nuance dyeing m/c:Manufacturer: Data color International

Capacity: 12 beakers per m/c

Purpose: Sample dyeing.

Ahiba Spectra dye:Manufacturer: Data color International

Capacity: 24 beakers per m/c.

Purpose: Sample dyeing.

Incubator:Purpose: Pre-drying, Water fastness.

Electrolux Washcator:Manufacture: James H. Heal & Co. Ltd. Halifax.

Country: England.

Purpose: Washing & Hydro-extraction.

Tumble dryer:Country: UK (Electra).

Purpose: Drying.


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Pilling Tester:Manufacturer: James H. Heal & Co. Ltd. Halifax.

Speed: 30-60rpm.

Electronic Balance:Manufacturer: Ohaus corp. USA

Readability: 0.001gm

Maxm Capacity: 210gm

14.2 Some Fabrics used in BKL Lab:1. Single jersey.

2. Polo Pique.

3. Back Pique.

4. Normal Rib.

5. Interlock.

14.2.1 Fabric composition:In BKL, 100% cotton, CVC, T/C, TTC fabric is used. A chemical test is applied to

find out cotton & polyester percentage that is present in fabric.

The chemical test is followed by :

1. At first weight of a sample is taken

2. Then put it 70% H2SO4.

3. Stir for 10 min.

4. Then wash the sample.

5. Then dry the sample.

6. At last weight of this sample is taken.

Some CVC fabric compositions:

a) 80% cotton + 20% Polyester.

b) 70% cotton + 30% Polyester.


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c) 65% cotton + 35% Polyester.

T/C fabric composition :

65% Polyester + 35% cotton.

TTC fabric composition:

80% polyester + 20% cotton.

14.3 Chemicals & Auxiliaries Used:14.3.1For reactive Dyeing:

For Cibacron Dyes:L: R = 1: 8600C Dyeing:

CibaF/w

% <0.3 0.3-0.5 0.5-1.0 1.0-2.0 2.0-3.0 >3.0

Salt G/L 10 20 30 40 50 60

Soda ash G/L 5 5 7.5 10 5 5

NaOH(50%) G/L Nil Nil Nil Nil 0.3 0.5

Cibacel DBC G/L 1-1.5 1-1.5 1 1 1 1

Anti-Crease G/L 1 1 1 1 1 1

For Levafix Dyes:L: R = 1: 8

600c Dyeing:


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Levafix % <0.2 0.2-1 1-2 2-3 3-5 >5

Salt G/L 10 20 30 40 50 60Soda ash G/L 2 5 8 10 10 12NaOH(50%) G/L Nil 0.3 0.7 0.9 1.2 1.4Cibacel DBC G/L 1-1.5 1-1.5 1 1 1 1

Anti-creasingagent

G/L 1 1 1 1 1 1

For Remazol Dyes:L: R = 1: 8600C Dyeing:Remazol % <0.2 0.2-0.5 0.5-1 1-2 2-3 3-5 >5

Salt G/L 10 20 30 40 50 60 80

Soda ash G/L 5 5 7.5 10 5 5 5

NaOH(50%) G/L Nil Nil Nil Nil 0.5 0.5 0.7

Decol SN G/L 1 1 1 1 1 1 1

Anti-Crease G/L 1 1 1 1 1 1 1

For Procion Dyes:L: R = 1: 8

820C Dyeing:Procion % <0.5 05-1 1-1.5 1.5-2 2-2.5 >2.5

Salt G/L 30 60 60 70 80 90

Soda ash G/L 5 10 15 15 15 20

Dekol SN G/L 1 1 1 1 1 1


L: R = 1: 8

920C Dyeing:


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Procion % <0.5 .5-1 1-1.5 1.5-2 2-2.5 >2.5

Salt G/L 40 60 70 80 90 90

Soda ash G/L 10 10 15 15 15 20

Dekol SN G/L 1 1 1 1 1 1


14.3.2 For Disperse Dyeing :i) Temp. : 1300c

ii) Dispersing agent : 0.8-1 g/L

iii) Acetic acid : 0.5-1 cc/L

iv) PH : 4.5-5

For medium and dark shades reduction clearing is required after dyeing :

Chemicals % Medium shade Dark shade

Detergent G/L 0.5 0.5

Caustic Soda G/L 1 2

Sodium hydrose G/L 2 4

Acetic acid G/L 0.5 0.5

14.4 Lab line:a) Standard Sample:

At first Recipe % of standard sample is measured by CCM (Computer Color

Matching) system.

b) Lab trial:

Then by taking that recipe lab officer produces lab trial and match with standardaccording to buyer requirements.


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c) Approved sample:

Then sample swatch which is matched with the standard & send to buyer for approval.

After approving to this sample this sample is send for bulk production with the recipe.

Program Number in Ahiba Dyeing Machine:

Program no. Temperature Time

1 1000c 68

2 800c 90

3 400c 20

4 600c 50

5 500c 37

6 620c 60

7 900c 96

8 600c 40

9 800c 40

10 600c 45

11 600c 70

12 700c 30

13 950c 30

14 950c 10

15 950c 60

16 1300c 76

17 1100c 30

18 1000c 40


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14.5.1 Reactive dyeing procedure for cotton fabric:Stock solution of Dyes is prepared.

Scouring & Bleaching sample is weight for light shade. But for dark shadeonly scouring.

Sample is weight m/c beaker is washed. Then pipetting of dye solution iscompleted into beaker according to requirement.

Water is taken according to requirement into that beaker.

Then Glauber salt is weighted and put it into beaker in solid form.

Scouring & bleaching or only scouring weighed sample is wet with coldclear water and squeeze then put it into the beaker.

Then beaker is closed with its cover and set it in Ahiba dyeing m/c.

8. Set program no. 8.

9. After complete this program cover of m/c beaker is opened and put Soda ash orSoda ash + caustic according to requirement.

10. Then cover the beaker & again put it in Ahiba dyeing m/c.

11. Set program no. according to dye types.

12. After completion of that program dyed sample is taken out from beaker.

13. Then wash the sample with cold water.

14. Then wash with hot soap water.

15. Then again washed with cold water.

16. Then dried.

14.5.2 CVC or T/C Dyeing procedure:At first polyester part is dyed with disperse dye. Then cotton part is dyed with reactivedye.

14.5.2.1 Disperse dyeing procedure:

Stock solution of disperse dyes is prepared.

Scouring & Bleaching Sample is weight for light shade. But for darkshade only scouring sample is weighted.


YRS SEU

M/C beaker is washed and pipetted the dye solution, dispersing agent &acetic acid into the beakers.

Water is taken according to requirement into the beaker.

Then sample is wet with cold clear water & squeezed, then put it into thebeaker.


Set program no. 16.

After complete of the program cover of beaker is opened and sample iswashed but if it is medium on dark shade then reduction clearing is carriedout.

Stock solution of reactive days is prepared.

M/C beaker is washed and pipetting of dye solution is completed intobeaker.

Water is taken according to requirement into that beaker.

Then Glauber salt is weighted and put it into beaker in solid from.

Then disperse dyed sample is wet with cold clear water and squeeze thenput it into the beaker.


Set program no. 8.

After complete this program cover of m/c beaker is open and put soda ashor soda ash + caustic according to requirements.

Then covered the beaker and again put it in Ahiba dyeing m/c.

Set program no. according to dye types.

After complete of that program dyed sample is taken out from beaker.

Then wash the sample with cold water.

Then wash with hot soap water.

Then dried.


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Quality Control

Quality control department is divided into two sections-

Online quality control

Offline quality control

a) Online quality control-On line Knit quality is the process of evaluating the greige, finishing and

checking the knit circular & flat machine parameter, in order to ensure conformity withthe fabric specifications required by the customer.

Working Area of Online Quality Control:

On line circular knit:

Function:

Design & shade approval.

Yarn & m/c evaluation.

QC parameter checking.

Body & Rib Inspection.

On line flat knit:

Function:

Design & shade approval.

Yarn & m/c evaluation.

QC parameter checking.

Collar & cuff. Inspection.

Greige inspection:

Function:

100% Fabric Inspection.


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Fabric transfer to store.

Area cleaning.

Co-ordinating & reporting.

On line finishing:

Function:

100% Fabric Inspection

Problem Identification.

Problem Rectification.

Fabric Transfer for reprocesses.

Response to faults:

Following response are to be taken:

Faults Response

Greige inspection Inform yarn supplier & knittingdepartment.

Knitting fault Inform knitting Department

Finishing fault Inform Finishing Department

b) Offline Quality Control-All quality control tests relates to Finished fabric (body, collar/cuff & rib) testingas per customer's required quality standard or international standard.

Typical Quality control in BKL: Shade Check.

Gram per square meter (GSM) test

Width on dia check.

Shrinkage test

Spirility test

Crocking/Rubbing Fastness test.

Pilling resistance test.


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Wash fastness test.

Water fastness.

Color fastness to perspiration.

a) Shade check:

Shade check after finishing of fabric is done according to customer'srecommended light source.

Equipment used : Verivide Light box.

Manufacturer : James H. Heal & Company, Halifax,England.

Light sources:

Artificial day light D65

TL 84

F(Filament)

UV (Ultra violet) light etc.

b) Gram per square Meter:After finishing of fabric gram per square meter is check by GSM cutter.

Equipment used : GSM cutter.Manufacturer : James H. Heal & Company, Halifax,

England.

c) Width on Dia Check:

After finishing of fabric width on dia of the fabric is check by measuring tape.

d) Shrinkage test:After finishing of fabric shrinkage is tested.Equipment used : Electrolux washcatorManufacturer : James H. Heal & Co. Ltd. Halifax,

England.

Procedure:

Two layer of 1212 sample is cut.

Then stitch the layers.


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Then wash the sample by –Test MethodBS 26330 3A 60 +/- 30c Prog – 13BS 26330 4A 50 +/- 30c Prog – 14BS 26330 5A 40 +/- 30c Prog – 15

Then dried the sample according to customer requirements :

Tumble drying or, Line drying

Then measured the dried sample.

Standard Shrinkage %:

Length (max) : 5% after domestic washing

Width (max) : 5% after domestic washing.

e) Spirility test:

After finishing of fabric spirilily is tested.

Equipment used : Electrolux wascator.

Manufacturer : James H Heal & Co. Ltd. Halifax, England.

Procedure:

Two layers of 21 & 21 sample is cut.

Then stitch the layers.

Then wash the sample by :

Test Method

BS 26330 3A 60+/-30c Prog – 13

BS 26330 4A 50+ /-30c Prog – 14

BS 26330 5A 40+/-30c Prog – 15

Then dried sample according to customer requirements :

Tumble drying or,


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Line drying

5. Then measured the sample following way :

Where,

L= Length of Sample.

D1, D2 = Distance of seam movement.

Calculation:

Spirility % =

L

DD

221 100

Standard spirility %:

Maximum: 5% after domestic washing.

f) Rubbing / crocking fastness:After finishing of fabric rubbing fastness is measured.

Equipment used : Crock meter.Manufacturer : James H. Heal & company, Hali fax,

England.Method : AATCC 8Standard result :

Dry rub : 4s

Wet rub : 2s

g) Pilling resistance test:After finishing of fabric pilling resistance test is carried out.

Equipment used : ICI pilling box

LL

D1

D2

1st Side 2nd Side


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Manufacturer : James H. Heal & Company, Halifax, England.Method : BS 5811 or according to customer requirement.

Revolutions for BS 5811 method:

7000 cycle for low pilling 9000 cycle for Medium pilling 11000 cycle for High Pilling.

Procedure:

A marker of 55 with two hole line at required distance is put on fabric.

Mark the fabric around the marker & draw line through the hole line.

Then cut the sample at mark.

Then join the draw lines by stitching and put it around rubber tube. 4Rubber tube is prepared this way.

Then put rubber tube in ICI pilling box. Take similar no. of rubber tube inboth box.

Then put cycle no and start the m/c.

After complete cycle rubber tube bearing the sample is taken out frombox.

Then sample which is pilled compare with –

Double Jersey std. Pilling

Photograph Nos. 1-5

Stock code 766-464

Standard result: Grade : ¾

h) Wash fastness test:

After finish of fabric wash fastness is checked:

Equipment used:

AG machine.


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Manufacturer: Quyyum textile Engineering, Pakistan

Ahiba Nuance.

Manufacturer : Data Color International, U.K.

Method : ISO 105-C06

Procedure:Take multi fabric and take also same size of dyed sample and stitch themat one end.Then multi fabric sample put in a m/c beaker and take 20 balls into thebeaker..Then take 50 cc solutions of following recipe :

4 g/l detergent 1 g/l Na-perborate 600c temp 30 min.

Then dried the sample & Measured fastness with staining scale.Standard result:

Shade Light shade Dark shade

Staining scale 4 3/4

i) Water fastness:

After finishing of fabric water fastness is checked.

Equipment used: Perspirometer Carbolite (Thermostat Oven)

Manufacturer : James H. Heal & Company, Halifax,England.

Method : ISO 105-E01/BS 1006 EO1

Procedure:

Take multi fabric & take same size of dyed sample & stitch at one end.Dip the sample in distilled water for 20-30 min.


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Then wet sample is put in perspirometer and kept it in carbolite thermostatoven for 4 hrs. at 370c.Then dried the sample not more than 600c and measured with stainingscale.

Standard result:

Light shade Dark shade

Staining 4 ¾

j) Color fastness to perspiration:

After finishing of fabric color fastness to perspiration is checked

Equipment used: Perspirometer Carbolite

Manufacturer : James H. Heal & Company, Halifax, England.

Method : AATCC 15.

Procedure:

A test solution is prepared with :Sodium chloride : 10g/lLactic acid, USP 85 : 1g/lDi-sodium hydrogen phosphate : 1g/lHistidine mono hydrochlorite : 0.25g/lpH : 4.3 0.2

Take multi fabric and sample of same size & stitch at one end.

Immerse the test specimen for 15-30 min.Then put the test specimen in perspirometer with 8 lbs load.Then put the perspiromenter in carbolite thermostat over for 6 hrs at 380 10c temperature.Then dry not more than 600c and measure with staining scale.

Standard result:

Light shade Dark shade

Staining scale 4 3/4


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Chapter- 15

MMaaiinntteennaannccee


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15.1 Maintenance:Maintenance is a process by which equipment is looked after in such a way thattrouble free. Services and increased machine life can be ensured and specificproduct quality required by the customers is sustained.

On time maintenance increase m/c lifetime & ensures trouble free services.

15.2 Types of maintenance:

Preventive Maintenance :

Preventive Maintenance is a predetermined routine activity to ensure on timeinspections / checking of facilities to uncover conditions that may lead to productionbreak downs or harmful depreciation.

Corrective Maintenance / Break down Maintenance:

In this case, repairs are made after the equipment is out of order and it can notperform its normal functions.

Maintenance

Preventive Maintenance Corrective Maintenance

MechanicalMaintenance

ElectricalMaintenance

MechanicalMaintenance

ElectricalMaintenance


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PM Tasks listMaintenance : MechanicalMachine : Thies Dyeing Machine

Sl. No. Item need to be checked & Serviced1. Crease the winch bearing (Grease Staburag NBU-12)2. Complete cleaning of machine3. Cleaning of drain valves, replace seals if required4. Check air supply filters, regulators, and auto drain seals5. Clean filters element and blow out6. Greasing of Unloading Roller Bearings by BP Energrease LS-27. Checking of Oil level and bolts of Unloading Roller Gearbox.8. Checking of unloading roller coupling and packing9. Checking and cleaning (if required) of Main Vessel Level Indicator10. Check the oil level of pump bearing and refill if required by BP Energol

THB-10011. Check the function of heat and cool modulating valves12. Check all belts and belt tension13. Check all door seals

Maintenance : ElectricalMachine : Thies Dyeing m/c

Sl. No. Items need to be checked & Serviced1. Check & clean fluff and dirt at all motor fan covers2. Check all motor's terminals3. Check main panels (by using compressed air)4. Check panel cooling fan & clean it filter5. Clean main pump inverter and its cooling fan6. Check all on/off switches7. Check current setting of all circuit breaker & motor over loads.8. Visual checking of all power & control cables9. Check all emergency Switches10. Check DC drive of neel motors11. Check all pressure switches12. Check calibration of main vessel & all additional tank13. Check all pneumatic solenoids14. Check calibration of heating/cooling. Modulating value.


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15. Check all indicating lamps

Maintenance tools & equipments :

PliersInside CalipersOutside CalipersDigital Multi MeterHeating ShoulderHammerPhilesetc.

Remarks :

Maintenance of machine’s are very essential to prolong the m/c life and goodmaintenance is important for economical consideration.In this industry maintenance program is done by expert maintenance team .So very few times production are stopped due to m/c problem .


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CCHHAAPPTTEERR-- 1166

UUTTIILLIITTYYSSEERRVVIICCEESS


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Available facilities of utility:ElectricityGasWaterCompressed airSteam.

Electricity:The main utility electricity is supplied from PDB and also by Generator.

Specification:

Equipment used: Gas generator.No. of generator: 8 (1 self start able & other 7 are air+CH4 start able).Manufacturer : Wartsila-Frank.Gas engine used.16 cylinders per engine.Overall efficiency : 80%.Heat recovery possible from 4 engines.Stroke of engine : 176mm.Cylinder capacity : 71.6dm3Ignition pressure : 90bar.Piston speed : 9m/sec.Air flow of full load : 1.65kg/hour.Exhaust flow at full load : 1.7kg/hour.Exhaust gas temp : 500 C.Pressure of gas : 60-62 milibar.Air pressure : 7 bar.Electricity take up from PDB : 1.5MW/sec.

Total power is then distributed as per requirements of different section of Beximcoindustrial park.

Gas:Gas is mainly used for steam production.The gas is used from TITAS.Generally 36 m3 gas is required to produce 1 ton steam.

Water:Continuous supply of water for BTL,BDL&BKL must be ensured by pump.Mainly two pumps are used for water pick up.

PUMP CAPACITY SETUPSubmersible pump-I 260 m3/hr Discharge value 100% openSubmersible pump-II 204 m3/hr Discharge value 100% open

Depth of pump: 140ft.


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Also pumps for chemical dosing & Centrifugal pump for yarn dyeing.Steam:

Pure steam with required temperature must be produced to meet thecontinuous demand of steam in different sections.

Fire tube type boiler is used.

No. of boiler: (4+1) twine boiler.

1 boiler is operated by using burn gas. 4 boiler is operated by Titas gas.

3 pass heating system.Measuring meter for water supply.4" depth greasol insulation so no heat at outside of drum.The lower drum is 100% water filled & the top drum is 60% water &40% steam filled.Proper supply of air for gas burnings.Boiler capacity; 10ton.Steam pressure; 8.2bar.Steam flow = 7 ton(approximately)Manufacturer: Thermax;India.Model: TD-100-10-54/6AS/E.Fuel: Natural gas.Water pressure: 10.3bar.Evaporation= 1000*3 kg/hr.Output: 6.28x3 MW.Steam Temperature: 185 CBoiler Temp(inner) =224 C-275 C.

Every result is recorded for 4 hours.Chemicals used for boiler feed water:

NaCl solution for regeneration. NALCO-4654(scale remover).

Compressor:

Natural gas is drawn by pipe through the filters above the compressor & the air iscompressed. In such a case the air becomes slightly hot. Hence cold water is drawn toreduce the temperature of compressed air. Thus the cold water becomes slightly hot &goes through outlet pipe to the overhead reservoir. Then the water falls slowlythrough a sieve and becomes cool & again feed to the compressor. At the other handthe cooled compressed air along with some vapors are transferred to the reservoirwhere the vapors are condensed and outlets drop by drop.The moist compressed air is transferred to the dryer & a slight warm compressed airis delivered to required sections of Beximco Industrial Park.

Parameters Set value


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Unloading pressure 7.5 barPressure difference 0.6 barOil pressure 1.2 bar

Motor running time 15 sec

Total no. of compressor : 3+3 =6Capacity : 774 lt air/compressor/sec.Manu : Atlas capco.Country : Belgium.Oil free air is prepared : By Electronikon.

Chemicals used:-Shell Turbo-T-68.-Grease.-Nalco 7328 & 7330.

Chiller:Manufacturer : Thermax.Country : India.To start a chiller electricity & steam is required.Capacity :[(21083)+(500*1)] ton = 1130 ton water cooling.Absorption type Chiller is used.

Settings:L-cut set point CHWSP : 8 C.Cooling water inlet temp set point : 20 C.HTG temperature set point for AC drive : 140 C.L-cut hysterics : 2 C.Std. continuous flow : 12.2 C - 6.7 C

Chemicals used:LiBr (Lithium bromide):-

Components: Li=7,99%;Br=92.01%.S.G = 3.464 at 25 C.MP = 549 C.BP = 1265 C.

Lythium Molybodate.Octyl Alcohol (2-Ethyl-1 feanol).Nalco 7328 & 7330.Refrigerant.

Source of Utility:

Electrically : PDB & Generator.Steam : Boiler.


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Water : Pump.Compressed ai r : Compressor.Temperature control : Chiller.Gas : TITAS.

Cost:36 cubic meter gas required for 1 ton steam generation.Required steam/day = 9500 ton.

PDB:Pick hour : 4.22 Tk/unitOff pick hour : 3.70 Tk/unit.

Generator:Electricity : 2.25 Tk/unit of.

The Effluent Treatment Plant

The effluent generated from different sections of a textile mill must be treated beforethey are discharged to environment. Various chemicals & physical means areintroduced for this purpose. The effluent treatment plant in beximco is chemical-bio9logical combination process developed by India.

Objects:This process is provided for treating the effluents of dyeing, printing, finishing,weaving & thus allow to discharge it as per norms given by world bank dept ofenvironment of Bangladesh. This process comprises of collecting, pumping,clarification, filtering, setting, aeration, pH correction, discharging, etc.

Characteristics of raw effluents:

Volume : 3600 cubic meter/dayPeak flow : 225 cub met/hrpH : 10-12.5BOD : 500-800 PPMCOD : 1300-2000 PPMTDS : 2000-5000 PPMSS : 100-400 PPMColour : Black/ Blue

Requirement of dischargeable effluent as per World Bank:

pH : 6-8BOD : <50


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COD : <250SS : <100TDS : Not statedColour : Clear

Chemicals used & their colors:

Chemicals used : AppearanceFerrous sulphate : Granular solid, greenish colorLime : White bulk formPolyacrylate : White granular solidSulphuric acid : Clear liquidAlum : White bulk formNa-hypochlorite : Clear liquidHydrochloric acid : Clear liquid

Flow chart of effluent treatment:

Raw effluent

Skin chamber

Collection Sump

Pump station

Dissolved Air Floatation Tank

Clarifier

Aeartion tank

Setting tank

Clear water, pH check

Sand filter

Carbon filter

Drain

Sludge separation:Sludge of DAF


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Sludge thickening plant

Sludge drying be

Product quality check:Following chemical tests are carried out to check the quality:

BODCODTotal suspended solidsTotal dissolved solidsColourpH

Typical output of the plant:

Raw effluent treated : 15000 LPHRaw effluent color : BlackRaw effluent pH : :11Treated effluent color : Light greenishTreated effluent pH : 8.5Treated effluent temp : 38 CTo0tal suspended solids : 35 PPM

Iron Removal Plant

For Textile dyeing Iron free water is required. This plant removes Iron and makeswater 0.03-mg/l iron content.

Procedure:

Raw water is collected in raw water tank (1) from deep tubewell.

Alkali dosing by flow meter (f) to maintain PH 8.Then raw water is passed through MnO2 bed (2) here ferrous ironformed insoluble ferric iron oxide and coagulated.Then water is passed through nozzle (3).Water then passed through sand & stone filter (4).Then filtered water (5) is collected to store tank (6).


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For back wash of MnO2 water in through nozzle (3) and back washwater is drain (7)For back wash of sand & stone filter water passes through the endof 5 and out let of is done at 4 and drain at 8..Excess water of MnO2 or filter is drain out by 9 and 10.


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Chapter-17

Store &Inventory Control


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Frequency of inventory control:Monthly inventory controlAnnual inventory control

Scope of inventory controlRaw materials

Dyes store Others chemicals store Grey fabrics

Finished fabricSpare partsGeneral store

Capital equipment Accessories Stationary Maintenance parts.

Inventory system for raw materialsRaw materials partially received from production planning & directlyfrom head office.Material Receiving & Inspection Report (MRIR) is prepared. Receivedquantity is mentioned & noted down.Submitted to QC department. Some are OK & few rejected.Entry of data of goods in DATATEX .Goods are arranged according to OK or rejected group.Department gives store requisition to warehouse.As per requisition materials supplied & this record is noted down.

Stages of grey fabric inventory controlAfter knitting productionGrey inspectionWarehouseBatch preparationDye house.

Stages of finished fabric inventory controlFinishing sectionAfter final inspectionWarehouse.

Store capacity


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Dyes : 6-7tonsChemical : 33-35tonsGrey fabric : 20-25 tonsYarn storage : 50 tonsRFD : 50 tonsSet range of dyes: 80-100kg/daySet range of Chemicals: 2-2.5ton/day

RemarkThe inventory system of BKL covers both knitting & dyeinginventories.The space is noticed to be insufficient considerably.An expansion of space is thus desired for sound inventory.

The department is computer oriented & connected by ERP.


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CHAPTER-18

COSTANALYSIS


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Costing of the product:Costing system mainly describes how the cost of the final product is fixed by thecompany/benificiar. According to buyers/customers requirement at first the fabric iscollected from local and foreign suppliers. Then it is calculated how much dyestuffand chemical is required till the end of the processing of that specific fabric. Afterthat, the final cost is fixed including some profit. Then the unit price is offered to thebuyer for approval. If the buyer approves it, all the transaction of money is carried outby bank.

Costing of the product is done by the consideration of the following factors:1. Amount of raw materials consumed.2. Direct labor.3. Indirect labor.4. Factory cost.5. Office and administrative cost.6. Sales and distribution cost.7. Profit, etc.

Remarks:The costing of product is a secret matter of the industry. They are not interested toflash up the cost related data. So, we could not collect the price of the product andcosting of the product.


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Chapter- 19

MarketingActivities


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Consumer of the products:Beximco knitting LTD. is a100% export oriented industry. All the goods produced inthis industry are exported into various foreign countries. Name of the main buyers ofthe products of the industry are given below:

Ash city. B&C. Wall mart. Haddad. Pimkie. Zara. Charter House. H&M.

Product label:Product label differs from buyer to buyer. The product labels are prepared according

to fabric criteria and the buyer requirements.

Package size and label:Package size and label differs from buyer to buyer. The package size and labels areprepared according to fabric criteria and the buyer requirements.

Local Market:Beximco knitting LTD. is a100% export oriented industry. All the goods produced inthis industry are exported into various foreigncountries. So, goods are not supplied into local markets.

Importing countries:The countries which are importing goods from Beximco knitting Ltd are given below:

USA. Canada. Germany. Europian countries.

Marketing Strategy:Marketing strategy is a very important factors to sale the products to the buyer.Beximco knitting Ltd mainly senior marketing officers, merchandiser and higher dealwith buyer. There are some fixed buyers of the industry. The buyers give their orderscontinuously all over the year. The marketing officers and by both side understandingthe rate and the order quantity are fixed.Duties& responsibilities of marketing officer:The main duties and responsibilities of a marketing officer are given bellow:

To prepare cost sheet by dealing with the buyer.


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To take different steps by discussing with the high officials andmerchandiser.To maintain a regular & good relationship between commercial officer& merchandiser.To maintain a regular communication with the buyers & buyinghouses.Communicate with the new buyer.Display the criteria of the products.

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

Remarks:Beximco knitting Ltd has a well learned marketing & merchandising team. Theyalways communicate with the buyers. The marketing section also looks for the quality& quantity buyers.


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CHAPTER- 20

CONCLUSION


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Industrial attachment program send us to the expected destiny of practical life. Thecompletion of tow month industrial attachment at Beximco knitting Ltd I have got theimpression that the factory is one of the most modern knit dyeing project inBangladesh. This company has earned very good reputation for its best performanceover any other knit dyeing project.

During my industrial attachment program I had tried to my best to done my duty. Mysupervising officer also satisfied to me & offer co-operation in every steps. It iscompletely a new experience in my life, which will be very very effective in myservice life. During my training period I realized that practical experience is morevaluable for service life.

In our industrial attachment program contents some secret subject of factory isincluded. To collect this information like history of project development, costing ofproducts, marketing strategy etc every student face a great problem as it is a secret. sowe proposed our college authority to exclude these topics from the contents.

Limitation of The Report:

Because of the secrecy act, the data on costing and marketing activitieshas not been supplied and hence this report excludes these chapters.

We had a very limited time. In spite of our willing to study moredetails it was not possible to do so.

Some of the points in different chapters are not described as these werenot available.

These whole process is not possible to bind in such a small frame asthis report, hence our effort spent on summarizing them.

Lastly:What special is this report is that the information, data and description is very muchsubjective and practical. So, one can easily have an idea about the whole dyeing unitof BKL at a single look on it.

The new comer can use this report for further details study or can know Beximcoknitting Ltd without much work. But what should be remembered the chemicals,some process steps may be modified within the period this paper goes to the reader.