1

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

Givensee Group of Industries Ltd.

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INTRODUCTION

By achieving practical knowledge it is possible to apply the theoretical knowledge

in the practical field. For any technical education, practical experience is almost

equality necessary in association with the theoretical knowledge.

The industrial attachment is the most effective process of achieving practical

experience. University education provides us vast theoretical knowledge as well

more practical knowledge, despite of all these Industrial Attachment helps us to

be familiar with technical support of modern technology, suitability about various

processing/operation stages.

It also provides us sufficient practical knowledge about production management,

productivity evaluation, work study, efficiency, industrial management,

production planning and control, production cost analysis, inventory

management, purchasing, utility and maintenance of machinery and their

operation technique etc. The above mentioned cannot be achieved successfully

by means of theoretical knowledge only. Industrial attachment makes us reliable

and improves courage and inspiration to take self-responsibility.

We had the opportunity to perform the industrial attachment with Givensee

Group of Industries Ltd. During 42days (6-Weaks) long attachment, We studies the

man, Machine, material expects of the Batching, Dyeing section (Knit fabric),

Finishing section, Quality Control, Lab, Knitting section, store & inventory control

of the mill. According to my studies there we have prepared the following report

and would like to present.

We have prepared this report according to the guideline given by the University

authority, which will lead to a strong guideline and milestone for our future

career.

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Object of Industrial Attachment

B. Sc. in Textile Technology is the combination of Theoretical knowledge along

with the practical experience. We as the Graduates of Textile Technology must

acquire adequate practical knowledge to combat with the challenge that we will

face in future. This is why 'the mid-course' industrial training has been included in

our academic curriculum.

The main objective of this training is to comprehend our theoretical knowledge

along with the practical knowledge. It also enables us to orient ourselves with the

practical environment that we will work in future. We systematically learned

about various steps of wet processing.

Moreover we know about the man management technique. We also learned

about dyeing techniques and quality assurance system.

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CHAPTER-1

PROJECT

DESCRIPTION

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Company Profile

Introduction:

Hotapara Garments LTD.was established in late 2005 and is currently one of the largest

knitwear manufacturing factories in Bangladesh. It has been exporting automatic circular

knitted items to North American and European retailers. Its operations are spread over a floor

space of more than 180000 sq. Ft. With a net export of over USD 12 Million in 2011, we are

ready to support our customer with their new knitwear collections for the upcoming seasons.

Hotapara Garments LTD. can produce various types of fabrication such as Single Jersey, Rib,

Interlock, Pique, and Drop Needle, 2-Thread / 3-Thread Fleece and feeder stripe repeats.

Ourdyeing section has capabilities of dyeing under atmospheric pressure in case of cotton fabric

andalso it can dye viscose, nylon and polyester fabrics under pressure dyeing conditions. Some

ofour common product lines are T-shirt, Polo shirt, Knitted Jackets and bottoms.

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Hotapara Garments LTD. has a successful record of customer satisfaction. It is also a highly

Compliant unit in terms of social standard. It has a very strong quality management team,

whoare continually reporting their finding to the board of directors. This ensures our

commitment tothe customers on their quality requirement.

Hotapara Garments LTD. has a daily production capacity of 40,000 pieces of T-shirts, Polo shirts

and other knitted items and its major raw materials such as yarn and accessories are sourced

fromother group sister concerns such as Givensee Spinning Mills LTD. and GivenseeGarment,

Accessories LTD.

Our Spirit:

Our Market base experience, research techniques and razor- sharp analytical skills have

enabled us to leverage opportunities in our existing and emerging markets.

Our Vision:

To become the largest multinational embellishment corporate in garments Industry

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Infrastructure:

Being one of the earliest composite units in Bangladesh, HGL has a very robust infrastructure in

Terms of machinery, floor layout and space distribution. The factory is well equipped with top

of.The line machinery along with adequate a pares in order to ensure smooth operation and

efficient performance

COMPANY NAME HOTAPARA GARMENTS LTD. Factory Address BOKRAN, MONIPUR GAZIPUR. Head Office Givensee Group of Industries

House # 06, Road # 13

Sector # 03, Uttara Model Town

Uttara, Dhaka, Bangladesh.

Tel: 8932813, 8913802

8961936jkj

Mail: rubel@givenseegroup.com Establishment Year 2005 Banker MERCHANTILE BANK LTD Production Capacity 1.2 MILLIONE PER MONTH Dyeing capacity 12000KGS PER DAY Knitting Capacity 8000KGS PER DAY Sewing Capacity

Basic T- Shirt 40000 Polo shirt 32000 Fancy Item 25000 Floor space 120000 SFT. Yearly Turnover US$14.50 MILLIONE PER ANNUM(APRX) Total Workers 1850

Minimum Order Quantity 5000 PCS

Shipment lead time

associated with 60 DAYS

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Different Departments:

To ensuring smooth running of various activities, some departments are available they are

given below:

Knitting Section:

Knitting

Grey Fabric Inspection

Batch Section

Knit Dyeing Section:

Store house for Dyeing & Chemicals

Dyeing Section

Lab & QC

Finishing

Single Jersey(S/J) S/J with Lycra Alt/Full Feeder Heavy Jersey Honeycomb Pique Diamond Pique Lycra Pique Single Lacoste Double Lacoste Interlock 1x1 Rib 2x2 Rib 1x1 Rib 2x2 Rib with Lycra with Lycra French Terry Yarn Dyed

Polo Shirt (Basic/Fancy) T-Shirt(Basic/Fancy) Sweat Shirt Tank- tops Skirts & Dresses Ladies Wear Children’s Wear Sports Wear Under Garments

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Garments Section:

Merchandising

Sample

Production

Packaging

Maintenance

Electrical

Mechanical

Utility Section

Accounts & Commercial Departments

Planning Department

HR Section

Admin Section

Product Mix:

YARN-

100% Carded; count 20, 22 24, 26, 28, 30, 32, 34, and 40

100% Combed: count 2-. 22, 24, 24, 28, 30, 32, 34, 40

100% O.E Yarn: count 10, 12, 14, 16, 18, and 20

CVC (65% Cotton + 25% Polyester)

Lycra (40d, 80d)

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FABRIC:

1.Single jersey with or without Lycra 2.Ribs -1x1; 2x1; 2x2; plain or with Lycra

3.Polo Pique with or without Lycra 4.Interlock- plain or with needle drop

5.Single or Double Lacoste with or

without Lycra

6.Waffle or Thermal Fabric

7.Terry Fabrics - blended or 100%

Cotton

8.Four track fancy design fabric

Strip fabric

9.Three thread fleece 10.Heavy Jersey

Annual Raw Materials Requirement:

Dyes chemical Yarn Fabric

69600 kg 100000 kg 2640000 kg 2400000 kg

Production Capacity:

GARMENTS

Woven Items : 300,000 pcs per month

Knit Items : 800.000 pcs per month

Sweaters : 1,400,000 pcs permonth

TEXTILE

Yarn : 900,000 lbs.

Knitting : 240,000 kg

Dyeing : 300,000 kg

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Joint Venture:

ZAHINTEX INDUSTRIES 1 Soydana, Board Bazar Gazipur. 3. ZAHINTEX INDUSTRIES 3 ZAHINTEX INDUSTRIES 4 Bokran, Monipur, Gazipur. 5. ZAHINTEX INDUSTRIES 7 ZAHINTEX INDUSTRIES 8 Araishaprashad, Kaultia, Gazipur. 7. MASUMA KHATUN TEXTILE Bokran, Monipur,Gazipur. 9. GIVENSEE GARMENTS LIMITED Hotapara,Gazipur. 11. GIVENSEE GARMENTS ACCESSORIES LTD Araishaprshad, Kaualtia, Vaoul, Mirzapur,Gazipur.

2. ZAHINTEX INDUSTRIES 2 74/A ,Konabari, Gazipur. 4. ZAHINTEX INDUSTRIES 5 ZAHINTEX INDUSTRIES 6 Araishaprashad, Kaultia, Gazipur. 6. ZAHINTEX INDUSTRIES 9 Bishia, Kuribari, Gazipur. 8. HOTAPARA GARMENTS LIMITED Bokran, Monipur, Gazipur. 10. GIVENSEE WASHING LIMITED Bokran, Monipur, Gazipur.

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CHAPTER-2

MANPOWER

MANAGEMENT

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MANPOWER MANAGEMENT

Management System:

Buyer sample is send to Responsible Management.

Matching is done by lab in charge.

Sample is prepared by Ass. Dyeing Manager.

Sample is send to the buyer for approval.

Approved sample is returned and taken as std. Sampleforbulk production.

Asst. Dyeing Manager gives responsibilities to production officer.

Then production officer, with the supervisors start bulk production.

On line and off line quality check is dome by Lab in charge and A. D.M.

After dyeing finishing in charge controls the finishing process with the supervision of

production officer.

After finishing the material is checked by Ass. Dyeing Manager.

Finally D.M checks the results with A.D.M and decision is taken for delivery.

Shift Schedule:

Per shift is 12 hrs.

1st shifts 8 am -8 pm

2nd

shifts 8pm -8am

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DEPERTMENT NO.OF EMPLOYEE

G.M (PRODUCTION) 01

P.M 01

QC. Manager 02

H.R officer 01

Trainer 10

Senior H.R officer 01

Mercendiser 03

Well fair officer 01

Flore in charge 01

Line chef 05

Production reporter 01

pion 01

supervisor 15

input man 18

Line quality 08

Sewing operator 490

cutting 06

Sewing helper 320

Sewing mechanical 10

15

security 13

Office stuff 02

Line quality 10

sample 15

Finishing 260

Quality 63

utility 28

Designation

No of employee

director 01

Group fire officer 01

Side engineer 01

Assistant officer 01

Mechanical engineer/dyeing 01

Store assistant 04

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DYEING SECTION No of employee

Dyeing manager 01

Dyeing assistant manager 01

Assistant production officer 04

Shift in charge 03

supervisor 02

Assistant supervisor 04

Dyeing operator 52

Dyeing helper 21

fitter 01

total 88

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LAB SECTION

:

LAB in charge 01

Assistant in charge 01

LAB technician 04

LAB assistant 03

TOTAL 09

BATCH SECTION

Batch in charge 01

Batch supervisor 02

Batch supervisor 13

TOTAL 16

Finishing manager

01

Q.C. in charge 01

Assistant q.c. in charge 01

Compactor technician 01

supervisor 08

Q.C. 07

Q.I. 05

18

Operator 20

helper 47

Sample man 05

Total 96

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KNITTING SECTION:

Knitting manager 01

Mechanical engineer 01

Shift in charge 02

Q.C. in charge 01

Filter 05

mechanics 03

Q.C. 06

Operator 40

Helper 12

TOTAL 78

OTHERS

WORKSHOP 01

Ometer 01

Leath supervisor 01

Security guard 10

Drive 06

Office pion 12

loader 14

Stuff 08

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CHAPTER-3

LAY OUT PLAN

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CHAPTER-4

MACHINE

DESCRIPTION

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DYEING SECTION

• Total Dyeing Machine: 27

• No. of sample Dyeing Machine: 12

• No. of Bulk Production Dyeing Machine: 15

Dyeing Machine:

AIR TURNING MACHINE No. of machine Machine Name (Functional) Manufacturer Manufacturing Country Model Brand Capacity Function

:02 : AIR TURNING MACHINE : DONG NUM INDUSTRIAL CO.LTD. :KOREA : DNAT-400 : DONG NUM : 20000 : To reverse the fabric front side to back side.

Machine Name Brand Model Origin Capacity /

M/c

No.of

kg M/C

ED-8-250 2000 1

ED-4-250 1000 1

Overflow winch Tungshing ED-8-250 Honkong 600 4

(Soft Flow) ED-2-250 400 5

ED-1-250 200 2

ED-5-100 70 2

High Pressure Tungshing ERD-2-250 Honkong 400 1

Sample (High

Pressure)

Tungshing ERD-5-15 Honkong 15 1

30 2

Sample Local Bangladesh

50 1

20 2

10 5

Total M/C 27

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Benefits of overflow winch machine:

1. Efficient washing effect.

2. Less water consumption.

3. Less temperature shocks when filling with cold water.

4. Precise calculation of water consumption.

Fully automatic function:

1. Automatic salt & soda dosing system

2. Automatic chemical injection system

3. Automatic heat exchanging process

Components of M/c:

1. Mixing tank:There is a tank in this machine. Every chemical are used to put here. Here all

the chemicals, dyes & salt are mixing for delivery into machine.

2. Unloading reel: The fabric is used to unload from the machine by this part. The number

of unloading reel is equal to the number of nozzle in the machine. It is rubber coated which

helps to unload fabric easily.

3.Monitor:It is situated at the right side of the machine. The commands are shown in the

monitor & the operators can work from these commands. There are also some buttons for

working properly & to obey these commands.

4. Alarm Box: There is an alarm box on the upper side of the machine. There are also some

buttons to operate the machine & to stop the alarm.

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5. Three detectors:There are 3 detectors on the above of the nozzle are as follows:

a. Temperature detector: It is at the left side between these 3 detectors which can detect

the temperature of the main tank.

b. Fabric turning pressure detector: It is at the middle of these 3 detectors. It can detect

the pressure at which the fabric turning.

c. Atmospheric pressure detector: It can detect the atmospheric pressure of the main

tank.

6. Plain board:It is situated at the right side of the machine.

7. Waterlevel:There is a water level to know the amount of water in the main tank.

It does not give correct result but it can give an approximate result.

Process Requirement:

Software used:

In this factory for total dyeing management usedSETEX – GERMANY.

Key accessories used in this factory for pretreatment to complete dyeing are:

-Salt tank.

-Mixing tank.

-Machine tank.

-PH meter.

-Eye protecting glass.

-Hand gloves.

-Sewing machine.

-Gum boot.

-Hand lifter for carrying the batch.

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N.B:Fixing process is done during dark or deep shade.

N.B: SAS: If shade% is more than salt is added before dyes add. Sometimes salt is adding two

times in deep shade.

DAS:If shade% is less then salt is added after dyes adding

Work instruction of Bulk dyeing Machine:

At first should to clean the machine.

Should to check electrical connection of the machine.

Should to take the working description of daily work from shift operator,

Senior production officer or production officer.

To take the fabric from supervisor of batch section according to

Production plan +Batch lot No. for coloration.

By observing the indicated program of the machine described abovethe fabric dyeing

program sheet, should to set the program no. kept @ computer memory attached with

the dyeing machine.

Should to be kept/write down the batch no./program no./party

Name/order ref./color name/into dyeing m/c/ comp memory.

Should to use the color into m/c.

M/c should to run /set by program no.

Dyes/chemical should to mix from the given chart /chart got from m/c

During the running of program.

Coloration running according to the computer program of m/c.

Sample should to collect from the coloring processed fabric into m/c

When computer panel program show sample.

To check shade, collected sample is sent to the lab,

Water inside m/c is drained out if the sample is "ok" by lab.

Hot wash is done by filling the water inside m/c of the colored fabric.

After the drain out of water soft wash of the fabric is done using soft

Wash chemical by filling water into m/c.

Then dyed /colored fabric is dropped from the m/c if s sent to the

Dewatering section with batch card by trolley.

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Checklist before operation:

Checking the program

Machine set-up.

Fabric weight.

Fabric quality.

Yarn quality.

Collar design (Tipping/ solid).

Rib designs (Normal/Lycra).

Chemical availability,

Power availability.

Steam availability.

Water availability.

Compressed air.

Manpower availability.

Fabric stitch is done properly.

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Finishing Section

Finishing Machine:

Machine

Name

Brand Model Origin Serial

No.

No.

of

Machine

Capacity

(kg) M/C

Ball

owningSqueeze

r

Corino Italy 1 7000

Ball

owningSqueeze

r

Dongnam DNBS-1600 Korea DN-053, DN-

054

2 8000

Tensionless

Dryer

Dongnam DNTD-2400 Korea 0527, 0653 2 1200

0

Soft Setting Dongnam 1400 Korea 0553, 0830 2 1200

0

Tube Tex

Compactor

Tube Tex BM-

10043(SP)

USA 10043, 10187 2 1400

0

Tumble Dryer GuangzhouPa

yne

China 3 30

Air Turning Dongnam DNAT-400 Korea DN-0829,

DN-0532

2 2400

0

Wet Calendar Dongnam DNW - 1400 Korea DN - 0531 1 6000

Fabric

Inspection

SAFOT JD 6A- 40S China JD 1 A - 40 1

Total = 16

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Lab Section

Wet Lab Machine

Machine name Brand Origin Model Serial no. Test Name

Capacity

(pot)

Qty

.

Spectrophotometer

DATA

COLOR USA 600TM Recipe Analysis 1

Light Box VERIVIDE UK CAC-120 Lab Dip Shade Check 1

Electronic Balance

Meter SHIMADZU JAPAN AUY-120 Weight Measuring 1

Lab Dip Dyeing

M/C-1 Taiwan IR 12SM 8102 12 1

Lab Dip Dyeing

M/C-2 IRDYER IR 12SM 8085 12 1

Lab Dip Dyeing

M/C-3 IR 24SM 6337 Lab Dip Dyeing 24 1

Lab Dip Dyeing

M/C-4 China HB-12SF 11163 12 1

Lab Dip Dyeing

M/C-5 RAPID L-24C 5620 24 1

Dryer Taiwan R-3 92706 Lab Dip Drying 1

Total = 9

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Physical & Chemical Lab Machine

Machine

name Brand Origin Model Serial no. Test Name

Test

method

Qty

.

Crock meter

CROCK

MASTER UK

67

0 670/07/2060 Color Fastness to Rubbing

ISO 105-

X12 1

Q-SUN XENON USA

0SU11B0

2

09.3815.32.

B02 Color Fastness to Light

ISO 105-

B05 1

Wascator ELETROLUX Sweden

FOM71-

CLS

98670116

3 Dimensional Stability ISO 6330 1

Tumble Dryer SIEMENS Poland WDT 2 Shrinkage Test 1

Tumble Dryer WDT 45 1

Rotter wash RAPID China HB 125F Dimensional wash

ISO 105-

C06 1

Pilling Test M/C FYICHINA

YG511-

IV ..0106 Pilling Test ISO 12945-1 1

Precision Woven Y902 ..0906

Color Fastness to

Perspiration

ISO 105-

E04 1

pH meter HANNA

HI.98129,

30 pH & EC/TDS test ISO-3071 2

Total = 10

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Knitting Machine Profile

S/L

No. Brand Origin M/C Grade Dia. Gauge Capacity Qty.

1 17 24 250 1

2 18 24 250 1

3 19 24 250 2

4 20 24 250 2

5 21 24 250 2

6 22 24 250 3

7 23 24 250 4

8 FUKAHAMA TIWAN S/J-SH-2BFA 24 24 250 4

9 25 24 250 3

10 26 24 250 3

11 27 24 250 1

12 S/J-SH-2XFA 28 24 250 2

13 30 24 233 1

14 RIB-SH-2BIR-2 30 18 233 1

15 32 18 200 1

16 34 18 200 2

17 36 18 235235 22

18 30 24 200 1

19 Interlock SH-BIR-2 32 24 200 1

20 34 24 233 1

21

SHIMA

SEIKI GERMANY

FLAT KNIT SFF-

152T 60 14 1200 PCS 2

22 LOCAL

BANGLADES

H

FABRIC

INSPECTION M/C 2

Total = 42

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Utility Section

Utilities & Supporting Equipment

Machine Name Origin Capacity Unit

Gas generator Austria 1064 Kw 3

Diesel generator UK 400 Kw 3

Gas boiler LC - 11

Taiwan

8.4 Ton 4

Air compressor USA 13 m3/hrs 11

Air dryer USA 13 m3/hrs 15

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CHAPTER- 5

RAW MATERIALS

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RAW MATERIAL

Raw material is a unique substance in any production oriented textile industry. It plays a vital

role in case of continuous production & for high quality fabric. The EKCL always try to use high

quality raw material to export high quality and world class product.

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Types of Raw material:

1. Yarn

2. Fabric

3. Dyes

4. Chemical & Auxiliaries

1. Yarn:

• Cotton

• Polyester

• Lycra

• Viscose

2. Fabric:

• Single Jersey(S/J)

• Heavy Jersey

• Honeycomb Pique

• Diamond Pique

• Single Lacoste

• Double Lacoste

• Interlock

• 1x1 Rib

• 2x2 Rib

• 2x2 Rib with Lycra with Lycra

• French Terry

• Terry Fleece

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3.Dyes:

Serial No.

Trade Name

Type of Dyestuffs

Origin

1 COLVAZOL YELLOW-3RS Reactive

China

2 COLVAZOL YELLOW 4GL (150%)

3 COLVAZOL.RED 3BSN

4 COLVAZOL BLACK-B

5 COLVAZOL YELLOW-4GL

6 COLVAZOLYELLOW-RR

7 COLVAZOL RED-RR

8 COLVAZOL BLUE-RR

1 Shulofix Yellow 3RS(Y 145) Reactive

China 2 Shulofix Red 3BS (R 195)

3 Shulofix Black B

1 Sumifix Brilliant Blue R special gran. Reactive

Singapore

2 Sumifix Supra Blue BRF 150% gran.

1 STARFIX YELLOW 3RFN 150%

2 STARFIX YELLOW 4GL 150%

3 STARFIX RED 3BFN 150%

4 STARFIX BLACK B 150%

5 STARFIX BRILL BLUE R(SPL) 150%

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6 STARFIX T.BLUE G 150%

7 STARFIX BLUE BRN 150%

1 NOVACRON® YELLOW FN-2R Reactive

Switzerland

2 NOVACRON® BRILLIANT RED FN-3GL

3 NOVACRON® YELLOW S-3R

4 NOVACRON® RED FN-R

5 NOVACRON® BLUE FN-R

6 NOVACRON® TURQUISE H-GN

7 NOVACRON® SUPER BLACK G

8 NOVACRON® BRILLIANT BLUE FN-G

1 TERASIL® GOLDEN YELLOW W-3R Disperse

Switzerland

2 TERASIL® YELLOW W-6GS

3 TERASIL® RED FBN CONC

4 TERASIL® RED WW-FS

5 TERASIL® RED W-RS

6 TERASIL® RED W-4BS/W-4BS-01 150%

7 TERASIL® NAVY W-RS

8 TERASIL® BLUE W-BLS

9 TERASIL® BLACK W-NS

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Chemicals& Auxiliaries

S/L Trade Name Technical Name Origin

1 CETATEX PC H2O2 killer England

2 Avosperse AD Sequestering Agent

3 STABILISER A pdr Stabilizer for H2O2

4 CETALUBE NFL Anti-creasing Agent

5 CETAFIX R Fixing Agent

6 Texsanscour CS Detergent Korea

7 Texsantifoam AF Antifoaming Agent

8 ALBAFIX® ECO Fixing Agent Switzerland

9 ERIOPON® R LIQ. Washing Agent

10 UNIVADINE® DP Leveling& Dispersing Agent

11 ALBATEX® AB-45 pH-Regulating Agent

12 Alba fixFRD

13 Optifix EC Liq Fixing Agent Thailand

14 HostapalDTC Detergent

15 Leucophor BBU 300 powder

Optical Brightening Agent

16 Ultrafab ARW Plus Optical Brightening Agent

Thailand

17 Flake Super TLF Softener

18 ASTROLEVEL CO Levelling Agent Italy

19 Sunhite - 4 B K Optical Brightening Agent

Taiwan

20 Rossacid N liquid Acid India

21 Hydrogen Per-Oxide (H2O2)50%

Bleaching agent Bangladesh

22 IogenFibrilase® HDL 350

Enzyme

23 IogenFibrilase® GXM Ultra

Enzyme Canada

24 KAPPATEX R 98 Strong Reducing Agent

25 HK J218 Alkali China

26 Acetic Acid Acid Taiwan

27 Caustic Soda Strong Alkali China

28 Soda ASH Light Mild Alkali China

39

29 Glauber Salt Electrolytes Singapore

30 Bleaching Powder Reducing Agent

31 Hydrose Reducing Agent

40

CHAPTER-6

PRODUCTION PLANNING &

SEQUENCE & OPERATION

41

PRODUCTION PLANNING, SEQUENCES & OPERATION

Introduction and Basic Procedure of Planning and Control:

A planned work brings success. Without planning nothing is completed within the required

time. So planning has its own importance which is intolerable. "Planning" gives a scheduled task

and 'control' completes it successfully. But production planning and control is not an easy task.

So Esquire Knit Composite Limited’s has a high-performance department called "Production

Planning & Control". Its Basic working procedure is as follows –

Taking orders from marketing division.

Analyzing the orders.

Planning for knitting the fabric.

Planning for dyeing the fabric.

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. Then some steps are

omitted for planning procedure.

Taking orders from marketing division:

EKCL marking division supplies Fabric Orders to the EKCL Planning and control division by a

special format.

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 for required quantity of fabric to be

knitted

42

(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.

Planning for knitting:

This section plans for knitting production. It selects machine for knit the fabric for specific type

of fabric, type of yarn used, required GSM, width etc. It also gives delivery data for knitted

fabric. It also places orders for buying of yarn from spinning mills by a specific schedule.

Planning for dyeing the fabric:

Production planning for dyeing is called 'Batch Plan'. According to the batch no. And color,

width, style and construction the batch plan is made. For easy understand this section gives

some 'ROUTE CARD.' cards. "ROUTE CARD' cards are serialized according to the priority of

delivery. The batches and "ROUTE CARD ' cards also serialized as to dye light shade at first and

lastly the dark shades, since faulty shades can be converted to dark color later.

Planning for finishing the fabric:

Finishing schedule is same as the dyeing. After dyeing the material goes to the finishing section

with the batch plan. Finished data is written to the batch card and is informed to the planning

section.

However, this section always enforces to all the departments to finish all the works within 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 role in the success of the

company.

43

44

KNITTING

SECTION

45

PROCESS FLOW CHART OF KNITTING

Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tape positive feeding arrangement and

Tension devices

Knitting

46

PRODUCTION FLOW CHART OF KNITTING SECTION

Sample fabric

Design analysis

Machine selection

Setting the Machine forthe Specific Design

Sample Knitting

Sample approval

Bulk Production

Grey fabric inspection

47

DESCRIPTION OF PRODUCTION PROCESS:

1. Firstly, knitting manager gets a production shit from the merchandiser as accordance

as consumer requirements then he informs or orders production officer about it.

2. Production officer informs technical in charge and knows about machine in which the

production will be running.

3. Technical in charge calls for leader of mechanical fitter troops, they two take decision

about machine for production considering machine condition, production capacity,

maintenance complexity, etc.

4. Production officer with experienced mechanical fitter adjusts required stitch length

and grey GSM for required final GSM.

5. Supervisor checks daily production regularity and make operator conscious about

finishing tin due time.

6. Operators operate machine in high attention as if there were no faults in the fabrics. If

he thinks or sure about any fabric fault, then he calls for the mechanical fitters in duty.

Mechanical fitter then fixes it if he can or he informs technical in charge. Then he

comes in spot.

7. After required production and final inspection in 4-point system, they sent in dyeing

section.

PRODUCTION PARAMETER:

Machine Diameter;

Machine rpm (revolution per minute);

No. of feeds or feeders in use;

Machine Gauge;

Count of yarn;

Required time (M/C running time);

Machine running efficiency

48

YARN PATH OF CIRCULAR KNITTING M/C

Creel

Tube

Knot Catcher

Tension Disc

Senser Ceramic Eye pot

Yarn Wheel

Guide

Senser

Guide

Ceramic Eye pot (Feeder

Ring)

Feeder

Needle

49

Method of Increasing Production

1. By increasing m/c speed:

Higher the m/c speed faster the movement of needle and ultimately production will be

increased.

2. By increasing the number of feeder:

If the number of feeder is increased in the circumference of cylinder, then the number of

courses will be increased in one revolution at a time.

3. By using machine of higher gauge:

The more the machine gauge, the more the production is. So by using machine of higher gauge

production can be increased.

4. By imposing automation in the m/c:

a) Quick starting & stopping for efficient driving system.

b) Automatic m/c lubrication system for smoother operation.

c) Photo electric fabric fault detector.

5. By imposing other developments:

• Using creel-feeding system.

• Applying yarn supply through plastic tube that eliminates the possibilities of yarn

damage.

• Using yarn feed control device.

• Using auto lint removal.

50

Description of Knitting Parts With Figure:

Name of the

parts

Picture Function

Creel

Creel is a part of knitting machine. Here yarn

packages are stored for yarn feeding in the

machine.

MPF Wheel

Its control the speed of the MPF. Pulley belt

gives motion to the wheel.

MPF

It’s mean Mamminger positive feed. It gives

equal length yarn distribution in the knitting

cycle.

VDQ Pulley

It is a very important part of the machine. It

controls the quality of the product. Altering the

position of the tension pulley changes the G.S.M

of the fabric. If pulley moves towards the

positive directive then G.S.M decreases and

reverse direction G.S.M will increase

Pulley belt

It controls the rotation of the MPF wheel.

51

Yarn guide

pipe

It helps the yarn to feed in the feeder & also

reduce ply.

Inlet & outlet

stop motion

It is an important part of the machine. It stops

the machine instantly when a yarn breaks.

Feeder ring

It is a ring where all feeders are place together.

Feeder

Feeder is a device where yarn passes through the

knitting section.

Brush

It cleans the pulley belt.

Sinker

It is most important element of the machine. It

helps to loop formation, hold down the loop,

knocking over the loop.

52

Sinker ring

It is a ring where all sinkers are placed together.

Cam

Cam is a device which converts rotary machine

drive into a suitable reciprocating action for the

needles and other elements. The cams are

carefully profiled to produce precisely-time

movement and dwell periods and are two types,

engineering and knitting cams.

Cam box

Where cam are placed horizontally in the box.

Needle

Needle is a primary knitting elements. It gives

movement according to the cam arrangement.

Cylinder

Needle track are situated here.

53

Needle trick

Where all needles are placed in a decent design.

Lycra

attachment

Lycra is placed here and feeding to the machine.

Lycra stop

motion

When lycra is broken it stops the machine.

Screen

It is a digital screen. Which show the all machine

information and we can get command to the

machine.

Automatic

oiler

It gives the machine oil all the time properly and

automatically.

54

Production Calculation:

Production per hour = kgyarncount

EMmmLSNNFNMPR

2046.28403654.210

60.)(.....

Here,

R.P.M = Machine speed (Revolution per minute)

N.F = Number of feeder

N.N = Number of needle

S.L = Stitch length

M.E = Efficiency of machine

55

Cam Arrangement of some Design

Single Jersey Single Pique ▲ ▲ ▲ ▲ ▲

▲ ▲ ▲ ▲ ▲

▲ T

T ▲

Double Pique

Single Lacoste

▲ ▲ T T

T T ▲ ▲

▲ ▲ T ▲

T ▲ ▲ ▲

Two Thread Fleece / F. Terry

Twill Fleece

▲ T ▲ M

▲ M ▲ M

▲ M ▲ T

▲ ▲ ▲ M ▲ M

▲ M ▲ ▲ ▲ M

▲ M ▲ M ▲ ▲

Single Jersey woffle

Thermal / Miss Woffle

T T ▲ ▲

▲ ▲ ▲ ▲

D ▲ ▲ ▲ M M

C M M ▲ ▲ ▲

Woffle mini

Flat Back Rib

D ▲ ▲ T T

C ▲ ▲ ▲ ▲

▲ M M

D ▲ ▲ M

C M T ▲

Separation Rib ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M ▲

D ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M ▲

C T ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M

M ▲ M ▲ ▲ M ▲ M ▲ M ▲ M ▲ M

Small Mash ▲ M ▲ M ▲ M ▲ M ▲ M

D ▲ M ▲ M ▲ M ▲ M ▲ M

C T ▲ T ▲ T ▲ M ▲ M ▲

M ▲ M ▲ M ▲ T ▲ T ▲

1 × 1 Rib

Interlock

▲ ▲

D ▲ ▲

C ▲ ▲

▲ ▲

▲ M

D M ▲

C ▲ M

M ▲

56

No. Faults Response

1. Wrong ply Reject

2. Hole Reject

3. Needle line Reject

4. Slubs Reject

5. Wrong design Reject

6. Wrong tripping Reject

7. Fly & contamination Acceptable for color but not for white

8. First round problem Reject

9. Uneven tension Discuss with manager

10. Missing yarn Reject

11. Crease line Reject

12. Rust line Reject

13. Oil stripe Reject

14. Thick-thin Reject

15. Wrong tube Reject

57

Faults and response taken by grey inspection section:

Rejection criteria for body & Rib:

No. Faults Response

1. Needle marks Major needle line is rejected.

2. Stripe Major needle line is rejected.

3. Barre marks Rejected

4. Slubs 1 point

5. Wrong design Rejected

6. Pin holes 1 point

7. Fly &contamination Acceptable for color but not for white

8. Sinker marks Do

9. Uneven tension Discuss with manager

10. Missing yarn Use 4 point

11. Crease line Do

12. Uneven tension Discuss with manager

13. Oil stripe/line Do

14. Thick-thin place Rejected

15. Mixed yarn Discuss with manager

58

DYEING SECTION

59

Production parameters for dyeing

a.pH-

During H2O2bleaching pH - 9-11

During reactive dyeing pH - 10.5-12

Durinng ebzime pH – 4.5-5

During salt pH – 4.5-6

During fixing pH – 6

Softener using pH – 6-6.5

During acid wash – 2-3

b. Temperature-

For cotton scouring - (90-95)0c

For enzyme wash 55-0c

For cotton cold wash –( 30-40) 0c

For cotton hot wash –(70-80) 0c

For cotton acid wash –(60-70) 0c

For cotton dyeing with reactive dye –

(80-90) 0c for hot brand.

(40-60) 0c for cold brand.

c. Time -

For scouring 60-70 mins.

For cotton with reactive dyeing 60-90 mins

For Enzyme wash 60 mins.

For hot wash 20 mins.

For acid wash 20 mins.

d. M: L -

For reactive dyeing M:L ratio maintain between – 1:9

60

Function of different process:

a. Pre-bleaching – To remove impurities, oil, wax from fiber, fabric / yarn. Also to make fabric

bleached white by removing natural color.

b. Anti-pilling – To remove protruding fiber from fabric.

c. Dyeing – To get desire shade by applying requires chemical.

d. Soaping – To remove unfix color.

e. Fixing – To fix the color strictly.

f. Softening – To make the fabric soft.

Description of production process:

Washing for colored fabrics:

The colored fabrics to be washed are loaded in the machine.

Required amount of water is taken.

PCLF (detergents) added & washing continued at 80°C for 20 min.

Cold washing.

Scouring-bleaching:

Fabric to be scoured is loaded in the machine.

Required amount of water is loaded

Washing agent/ detergent is added.

Steam pipes are on & scouring agents (i.e. Caustic soda/ Soda ash) added when

the temperature reaches at 50 C.

When the temperature reaches at 60°C then stabilizer is added.

Then H2O2 is added.

Temperature is then raised to 90°C and the process is then carried out for 60-90

min. depending on the requirements.

The liquors are then drained. Then cold wash at 30°-40°C, hot wash at 70°-80°C

and acid wash at 60°-70°C is done.

61

Dyeing:

After acid wash all liquors are drained out

Required amount of water is taken

Then leveling agents, anti-creasing agents, de-foaming agents are added according to

the requirement

Steam pipes are on & after 10-15 min. dyes are added Salts are added after another 30

min.

Then soda ash after another 30 min.

Then the temperature is raised slowly up to the mark

The process is carried on and samples are taken after every 30-40 min. to match with

the target shade. It continues until shade matching.

If the sample is matched, then the liquors drained out

Then cold wash at 30°-40°C, hot wash at 70°-80°C, acid wash at 60°-70°C is done

Then softener is added at 40°C for 20-30 min.

Fixer is applied for deep shade only before adding softener

Re-dyeing:

When shade is not matched then fabric is treated again in dyeing machine for shade matching

is known as re-dyeing.

Generally, re-dyeing is done if the shade is deeper than the target shade. It may occur when the

fabrics absorb one or two colors more or less. One re-dyeing process is described below.

Drain the let off solution.

Hotwashat70°-80°C.

Acid wash at 60°-70°C(600 for light shade & 70° for deep shade).

Soda ash washes at 90°-100°C for 60mins to reduce the depth of shade.

Acid wash at 60°C.

Addition to required dyestuffs.

Salt addition.

Soda ash addition.

Other operations are same as previous described dyeing operations.

62

LAB SECTION

63

Process flow chart of Lab:

Swatch from merchandiser or Buyer

Storage

Selection swatch by priority

Recipe Formulation

Spectrophotometer Previous Lab Dip

Record

Carefully Fabric Dyeing

Matching Visually

Recipe correction

Exact matching with swatch

Two or more option of Lab dip sends to buyer

Approved Not Approved

Go for Production Matching Re-Lab dip

64

Procedure for Lab Dip:

Fabric weight measured by electric balance

Calculate the recipe

Keep the fabric in the pot

Then required amount of water, salt, soda and other chemicals are taken to the pot by

pipetting.

Start the program for dyeing. The dyeing time and temperature depend on types of dyes

& color being used.

Example:

Process For Reactive Dye Temperature Time

Turquoise , Green& Hospital

color

60°C then migrate it

80°C

30min.

30min.

Any Light & Deep Color 60°C 60min.

After finished the dyeing time then cold wash two times.

Acid wash for neutralization.

Then soaping by required soap solution for 10 min. at 900C.

Cold wash then drying the lab dip and compare with the standard.

65

Calculation:

Usually following calculations are followed –

Recipe% × Sample Weight

Dye Solution = (cc)

Stock Solution %

Total liquor × g/l×100

Salt, Soda, Chemicals = (cc)

Stock Solution ×1000

Samples send to Buyer:

Now for every separate sample dyeing with separate recipe are send to buyer for approval. The

buyer approves one sample and the recipe of that approved sample is now sending to dyeing

section.

66

BULK

PRODUCTION

67

Bulk Production:

Batching:

Batching means the preparation of the fabric for dyeing according to the capacity of the dyeing

machine. It has done under instruction of planning department and time Schedule of the

dyeing department.

Function or purpose of batch section:

a. To receive the grey fabric roll from knitting section or other source.

b. Turn the grey fabric if require.

c. To prepare the batch of fabric for dyeing according to the following criteria -

• Order sheet (Received from buyer)

• Dyeing shade (color or white, light or dark)

• M/C capacity

• M/C available

• Type of fabrics (100% cotton, PC, CVC)

• Emergency

d. Send the grey fabric to the dyeing floor with batch card.

e. To keep records for every previous dyeing.

68

Batching of a product depends on some factors such as:

Fabric type

Yarn count

Fabric width & GSM

Machine load capacity etc.

Ratio of collar cuff with body fabric.

Preparation of batch:

Make the priority as per dyeing plan

•

Check the availability of fabric

•

Take required quantity of body fabric from the store

•

Take collar/cuff as per size

•

Distribution of collar/cuff or rib in each rope equally to ensure equal length

• Stitch the fabric to make equal weight

•

Prepare batch card

•

Send fabric to the dyeing floor.

69

Production flowchart:

Production flow chart for 100% cotton

Grey fabric loading

Scouring & bleaching at 980C for 1 hour

H2O2 Killer

Acetic Acid

Enzyme [pH 4-4.5, temp.550C, Time 50’-60’]

Hot Wash

Leveling

Dyeing Salt

Acetic Acid

Hot Wash

70

Fixing

Softener

Unload

71

White Dyeing Recipe for (100% Cotton)

Fabric Type: S/J Color: White

Process Chemical, Dyes Name Dosing (g/l

or %)

Consumption (kg)

Pretreatment Texsanscour CS (PCLF) 0.8 1.842

Pretreatment CETALUBE NFL 0.8 1.842

Pretreatment Lianeg– 710 0.2 0.461

Pretreatment STABILIZER A pdr. 0.7 1.612

Pretreatment Caustic Soda 3 6.909

Pretreatment Hydrogen Per-Oxide (H2O2)50% 6 13.818

Pretreatment Texsantifoam AF (JET) 0.2 0.461

Pretreatment Rossacid N Liquid (Green Acid) 1 2.303

Enzyme GXM Ultra 0.28 0.645

Enzyme Rossacid N Liquid (Green Acid) 0.5 1.152

Leveling Lianeg– 710 0.3 0.691

Dyeing .

DYES Leucophorr BBU 300 powder 0.167 0.392450

DYES Sun white - 4 BK 0.05 0.117500

After treatment Lianeg– 710 0.1 0.230

After treatment Ultra Fab Con 4 2 4.606

pH Control Ross acid N Liquid (Green Acid) 0.1 0.230

M : L Scouring Dyeing Enzyme + Softener

Fabric Weight 235 235 235

Liquored Ratio 9.8 9.8 9.8

TOTAL LIQURE 2303 2303 2303

72

Sequence:

At first Scouring bleaching chemicals are added to the bath & they are treated at 980C for 60

min.

Temperature is lowered at 800C, Leucophorr BBU 300 powder&4BK is added Run time is 1hr.

Temp. Is raised to980C & Run time is 20min.

Then Enzyme treatment is applied & then softening

Pretreatment Curve: °

73

Normal Hot:

Dyeing Curve:

74

After treatment Curve:

Sample:

75

Scouring & bleaching process:

Process flow chart:

Machine filling with water at normal Temperature

Fabric loaded at normal temperature (35-40°c)

Scouring & Bleaching chemical is added.

First liq. Chemical &then solid chemical.

Run time 98°C×60'

Absorbency test is done

Rinse & Drain

Per oxide killer is added at 90°C × 20'

Rinse & Drain

Acetic acid is added at 60°×20'

PH is Checked (pH=4.5-5.5)

Rinse & Drain

76

Ant pilling:

Fill Water

Enzyme (Cell soft Combi9800L) at 55°C×55'

PH is Checked (pH=4.5-5)

Rinse & Drain

77

Turquoise Color Dyeing Recipe(100% Cotton)

With Reactive Dye

Fabric Type: S/J

Color: Turquoise

G.S.M: 145

Pretreatment Process: Scouring, Bleaching & Enzyme

Process Chemical, Dyes Name Dosing

(g/l or %)

Consumption

(kg)

Pretreatment Texsanscour CS (PCLF) 0.8 2.074

Pretreatment CETALUBE NFL 0.8 2.074

Pretreatment Lianeg– 710 0.2 0.518

Pretreatment Caustic Soda 2.5 6.480

Pretreatment Hydrogen Per-Oxide (H2O2)50% 2.5 6.480

Pretreatment Texsantifoam AF (JET) 0.2 0.518

Pretreatment CETATEX PC 0.5 1.296

Pretreatment Rossacid N Liquid (Green Acid) 1 2.592

Enzyme GXM ULTRA 0.5 1.134

M : L Scouring Dyeing Enzyme +

Softener

Fabric Weight 324 324 324

Liquor Ratio 8 9 7

TOTAL LIQURE 2592 2916 2268

78

Dyeing Process:

Chemical ASTROLEVEL CO 1.5 4.374

Anti-Creasing CETALUBE NFL 0.8 2.333

Leveling Lianeg - 710 0.3 0.875

DYES DYCHUFIX YELLOW 3R-XF (150%) 0.0012 0.003888

DYES DYCHUFIX TURQUISE BLUE G (H/C) 0.954 3.090960

DYES Sum fixes Supra Blue BRF 150% gram.

0.036 0.116640

Salt & Soda Glauber’s salt 40 116.640

Salt & Soda Soda Ash Light 10 29.160

After Treatment Process:

Wash Off Rossacid N Liquid (Green Acid) 1 2.916

Wash Off Avorseperse AD 0.5 1.458

Leveling Lianeg– 710 0.1 0.227

Fixing Texsanfix FX 0.5 1.458

Softener Ultra Fab Con 4 1 2.268

pH Control Rossacid N Liquid (Green Acid) 0.1 0.227

Dyeing Curve:

79

Sample:

Again Dyeing MACHINE WASH RECIPE

Sequence:

Bleaching Deter. +Soda add into the machine

At room temp, for 20 min

Increase temp, at 98°for 40 min Drain water

Add PCLF+Castic+Hydross at 98°for 1 hr.

Drain Total m/c cleaning

Serial No Name Dosing (g/1)

01 Bleaching powder 0.5

02 Detergent 0.1

03 Soda ash 1.0

04 Caustic 1.0

05 Hydrous 1.0

80

81

FINISHING

82

Finishing Section:

83

Objective of finishing:

Improving the appearance, luster, whiteness etc.

Improving the feel, which depends on the handle of the material & its softness,

Suppleness, fullness etc.

Wearing qualities, non- soiling, antic ease, ant shrink, comfort etc.

Special properties required for particular uses -water -proofing flame proofing etc.

Covering of the faults in the original cloth.

Increasing the weight of the cloth.

Finishing effects:

Easy care.

Crease recovery.

Dimensional stability

Good abrasion resistance.

Unproved tear strength.

Good sew ability.

Soft or stiff handle.

Shine or luster.

84

CHAPTER –07

QUALITY ASSURANCE

SYSTEM

85

Q. C. Department

Machines:

Wash Fastness Tester

Light fastness tester

Rubbing fastness tester

Electronic balance

G.S.M. cutter

Fabric inspection table

Light box

Shrinkage (%) meter

Inspection area:

Shade match of fabric

G.S.M.

Fabric diameter

Shrinkage (%)

S Lengthwise S Width wise

Fiber type

Wash fastness

Light fastness

Rubbing fastness

Faults

86

Faults are found in Q.C department:

a. Dyeing faults

b. Knitting faults

Knitting faults:

Hole

Needle Mark

Sinker Mark

Patta

Slub

Thick place

Thin place

Naps

Stripe

Missing yarn

Contamination

Light

Medium

Deep

Dyeing faults:

Uneven shade

Running shade

In fastness property

Finishing faults:

GSM variation

Spirality

Shrinkage control

87

Quality assurance sysstem

Quality assurance procedure:

The Delta Composite Knitting Industries Ltd. assures the quality of their products in the

following three steps:

In laboratory

In Dyeing section &

In finishing section Procedures are described below:

In laboratory:

Swatch card from buyer according to their requirement

Recipe prediction for sample dyeing

Sample dyeing until matching with swatch card

If matching is OK, then it is sent to the buyer for approval.

If buyer approves the sample then bulk production.

In dyeing section:

After approval from the buyer, sample dyeing is done in dyeing m/c in dyeing shed &

again matched with the approved sample

If result is OK. Then balk production,

During dyeing, samples are taken until accurate shade matching. The interval may be

30-40 minutes

After dyeing sample is collected after softening matching is done

Last of all, sample is collected after fixation & matched

Then allowed the fabrics to be finished in finishing section

Correctly dyed, after treated & matched fabrics are allowed for finishing

By using a series of finishing machines correct width, softness & appearance are

maintained according to requirements

Then sampling is done for several times to test GSM, Shrinkage & fastness properties.

Finally fabric is inspected & prepared for delivery

88

List of Equipment’s:

Machineries & equipment used-

• Spectrophotometer with software (Data color)

• Color light box

• Sample dyeing machine (2)

• Lab. Dip

• Iron

• Electric Balance

• Crock meter

• Washing m/c

• GSM Tester

• PH meter

Quality Standard:

Textile Testing Methods of HGL

1. Dimensional Stability : ISO - 6330

2. Color Fastness to Rubbing : ISO-105X12

3. Color Fastness to Wash : ISO-105C06

4. Color Fastness to

Perspiration

: ISO-105E04

5. Color Fastness to Light : ISO-105B02

6. Pilling Resistance : ISO-12945-1

7. pH test : ISO-3071

89

Problemencountered in dyeing

Uneven Dyeing

a) It can be caused due to rapid addition of dyes and chemicals. For this purpose the

dosing of soda ash should be maintained properly.

b) Pressure difference.

c) Over loading in the m/c.

d) Yarn lot mixing.

e) Improper control of temperature.

f) Less amount of leveling agent.

g) Improper pretreatment.

Uneven Shade in Rope to Rope:

a) Improper rope length in each chamber.

b) Improper fabric flow speed in each nozzle.

Off Shades:

a) Improper M: L ratio.

b) Lower amount of auxiliaries.

c) Improper mixing of dyestuffs.

Dye Spots:

This is most common fault caused by operator not correctly mixing and thoroughly dissolving

dyestuffs in the right amount of water.

90

Batch to batch shade variation:

If any of parameters of dyeing are changed then it will produce problems in batch to batch

consistency. In order to avoid this defect the following steps should be followed-

a) Maintain the same liquor ratio.

b) 2. Check that the fabric has the same dye affinity.

c) Use the same standard program procedures for each batch.

d) Making sure that the operators add the right Bach of chemicals at the same time &

temperature in the process.

e) Check the water supply daily especially ph, hardness & Na2COs content.

Crease Mark:

Crease marks are produced due to the lower concentration of anti-creasing agent and improper

cooling rate (defective cooling gradient). This is encountered by increasing the concentration of

anti-creasing agent and proper adjustment of cooling rate.

Patchy Dyeing:

It is caused, if dye solution is not correct and also scouring is improper.

Process of Shade Matching:

The required shade provided by the buyer is reproduced in the lab in lab dyeing machine after

the recipe prediction. The lab in-charge first uses the Computer Color Matching System, to

obtain the closest shade match recipe. Then he consults the shade card and Pantone book to

verify the obtained recipe. If he thinks that certain changes in the recipe are necessary, he then

alters the recipe according to his experience. This recipe is used to dye a sample of 5 gm fabric

in the lab dyeing machine with following parameters.

91

a) Temperature and time

Cold Brand Reactive Dye - 65° c temp; 60 min

Hot Brand Reactive Dye - 98° c temp; 60 min

Turquoise Color (Cotton) - 80° c temp; 60 min

Polyester -130° c temp; 30 min

b) M: L ratio

The samples are usually dyed using 1:9 ratio.

Pantone Book:

Pantone Textile Color Selector

Total shade-1701

Color numbering system - 6 digit + suffix

First two digits 11 to 19 (range of lightness)

Middle two digits 01 to 64 (range of hue)

Last two digits01 to 64 (range of Chroma)

92

CHAPTER -08

MAINTENANCE

93

Maintenance

94

Maintenance procedure

During maintenance procedure following points should be checked.

Checklist of different parts:

Maintenance: Mechanical

Machine:Dyeing Machines

Item need to be checked & Serviced

Crease the winch bearing.

Complete cleaning of machine

Cleaning of drain valves, replace seals if required

Check air supply filter, regulators, and auto drain seals

Clean filters element and blow out

Greasing of Unloading Roller Bearings.

Checking of oil level and bolts of Unloading Roller Gearbox.

Checking of unloading roller coupling and packing.

Checking and cleaning (if required) of Min Vessel Level Indicator

Check the oil level of pump bearing and refill if required.

Check the function of heat and cool modulating valves

Check all belts and belt tension

Check all door seals

Maintenance:Mechanical

95

Machine: Lab dyeing m/c.

SI. No. Item need to be checked & Serviced

1 Check rotating main shaft bearing.

2 Check cooling water inlet and outlet nose and nose clips.

3 Check cooling fans

4 Check driving belts and pulleys.

SL No. Item needed to be checked & Serviced

1. Checking of Steam pipe lines

2. Checking of pneumatic pressure valves

3. Checking of belt conveyor system

4. Checking of plaiting device

5. Checking of speed regulating unit

96

CHAPTER-09

97

Utility service

Production and profit are closely related. In order to get quality final product it needs fresh raw

materials as well as effective manpower and machinery in good condition. Utility in conjugation

with the three M's plays an important role to maximize the production as well as the profit.

Utility ensures the followings:

1. Power supply (By Generator)

2. Soft Water supply (By Pump)

3. Steam supply (By Boiler)

4. Compressed air (By A/C plant)

5. Exhaust air handling (By vacuum planning system)

6. Fuel & gas supply

7. Effluent Treatment plant (ETP).

Power supply:

Hotapara Garments Ltd. has two generators for power supply to ensure continuous knitting,

dyeing & GMT operation and help to fulfill their target production. Gas generator is widely used

because of lower production cost.

Electricity:The main electricity is supplied by generator & REB

No. of Gas Generator: O2

Capacity: Generator 1-SSOKW

Generator 2-ssoKw

Own Power: Capacity: 4 Mw

REB Power: Capacity: 1 Mw

98

Specification of Gas generator: Synchronous Alternator

Types: Gas generator

Company: GE Jenbacher

Made In: Germany

Model: JGS-320

Capacity: 850 kw.

KW: 1064

PF: 0.8

Volts: 415/240

Rotation: CCW

Frequency: 50Hz

RPM: 1500.

Pressure of gas: s-20Pa

Year Built: 2009, Temp rise: 105°C, Weight: 4763Kg.

Total power is then distributed as per requirements of different section like Knitting,

Dyeing (Yarn/Fabric), Finishing, Maintenance, WTP, ETP etc.

Gas: Gas is mainly supplied from TITAS. It is mainly used for steam production.

Water supply:

There are two deep tubes well for supplying water in the factory. This unit collects water from

the underground and here for hardness testing common test i.e. shop testis followed. For

dyeing section 5-10 ppm is maintain. This collecting water is reserve in reserve tank and then

supply everywhere in the factory. On the other hand, there is water treatment plant use to

oxidize water before supply .Soft water is supplied in different section continuously by using

submersible & centrifugal pumps

Source of water: Underground water

No. Of Submersible Pump: 02

99

Steam:

Pure steam with required temperature must be produced to meet the continuous demand of

steam in different sections. There are four running boilers & one is remaining to be run used for

steam generation, to meet the requirement of different sections.

Main parts of the boiler:

1. Gas Chamber

2. Blower

3. Gauge glass

4. Safely valve

5. Burner

Boiler 1:

Company: long chuan

Made In: Taiwan

Fuel: Natural Gas

Capacity: 10ton

Connected Load: 20 Kw

Function: To Produce Steam

Compressed Air:

The requirement of compressed air is fulfilled by air compressor m/c. In this m/c, natural gas is

drawn by pipe through the filter above the compressor & the air is compressed. In such a case

the air becomes slightly hot. Hence cold water is drawn to reduce the temperature of

compressed air. While doing so, the cold water becomes slightly hot & it is transferred through

outlet pipe to the overhead reservoir. There the vapors are condensed and outlets drop by

drop. Then the water is set to fall slowly through the reservoir to the compressed air to obtain

moist compressed air.

100

Source of Utility:

Electricity: Generator & REB Power

Gas: TITAS

Water: Pumps

Compressed Air: Compressor

Steam: Boiler

Function of different ingredients used in E.T.P plant:

Lime:

Lime is used to change the color of effluent & to increase the transparency of color

Ferrous Sulphate:

Ferrous Sulphate is used for the agglomeration of the colloidal matters present in the

effluentPoly Electrolyte:

Poly electrolyte is used to flocculate the precipitation for easy deposition at the

bottomHydrochloric Acid:

Hydrochloric acid is used to sustain the required PH of the biological

101

Experimental procedure of ETP:

102

CHAPTER-10

MARKETING

ACTIVITIES

103

Marketing activities

Hotapara Garments LTD. (HGL) is a 100% export oriented industry. All the goods produced in

this industry are expected into various foreign countries.

Name of the buyers of the products of the industry are-

1) TERRANOVA

2) TAG Int.

3) COLLEZIONE

4) OBS

5) WAVES

6) TURNKEY

7) SATURN Textile.

8) Unitex Knit (Bangladesh)

9) C & A

10) Defecto

11) Style tex.

12) TEX-EBO

a) TEX-EBO J.S

b) TEX-EBO Donny

c) TEX-EBO Raia

d) TEX-EBO Descimas

e) TEX-EBO Lee cooper

13.TEX-EBO Teddy smith

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Buyers of Givensee Group:

Price Quotation

There are some systems for price quotation as given below -

1. FOB (Free on board)

2. C&F (Cost& Freight)

3. GIF (Cost, Insurance & Freight)

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The factory is full compliance with ILO and Bangladesh Labor Law.

Their company policy is as follows:

No child labor.

No forced labor.

Transport facilities for worker.

Hours of work.

Voluntary over time.

Intervals for rest.

Weekly holidays.

Annual leave.

Festival holidays & leaves with bonus.

Maternity protection.

Worker's welfare committee.

Mineral drinking water.

Sanitary facilities.

First aid box.

Canteen services.

Day care center.

Health care activities for the worker & employ company doctor.

Fire extinguisher each & every floor & conduct fire drill at least 12 times a year. We are

giving a top priority on prevention of fire and eventual evacuation.

Other safety department (no discrimination).

Compensation cases department.

The development of compliance programmer.

Environmental developer.

Smoking free zone.

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CHAPTER-11

107

Recommendation

The working condition of HGL Garments Ltd is much better than most of the textile

manufacturing industry in Bangladesh. But there are few points that might be considered for

improving the current quality and productivity.

Dyeing

i. Operators should be warned to be careful about maintaining proper time of dyeing.

ii. Wastage of water should be reduced.

iii. During the transportation of the fabric in the dyeing floor & also during the loading of

the machine, fabrics are soiled for the contact with floor. This makes the fabric/part of

the fabric dirty. It may require more scouring/bleaching agent or may create stain.

Finishing

I. Use of vacuum cleaner to reduce dust during cleaning machines.

II. Online quality control system should be introduced for greater performance.

III. Removing of unused machine or machine part from finishing and inspection floor.

IV. Workers and staffs of finishing and inspection should be compelled to wear mask during work.

Common suggestions:

I. Drainage system should be improved to displace the rain water efficiently in front of dyeing

floor.

II. Color of ribbon of ID card must be different for executives, interns, staffs & operators so that

everyone can identify themselves easily.

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CONCLUSION:

Industrial training is an essential part for textile education because it minimizes the gap

between theoretical and practical knowledge. Undoubtedly, this industrial training helped us a

lot about textile technology, production process, machineries, and industrial management and

made us comfortable with industrial life. Besides it hive is the first opportunity to work in

industry.

During our two month long industrial training at HGL We got the impression that this factory is

a modern export oriented composite knit including industry. Though it was established9 years

ago, it has earned a very good reputation in foreign market for its best quality product over

many other export oriented textile mills. They are very much concerned about the quality

control of each product. They have well equipped & modern textile testing laboratory. They do

all the chemical & physical tests of dyed good and the results are very good and within the

buyer’s acceptance limit. Moreover they use good quality yarn, dyes, & chemicals in

production. The administration, management and chain of command are well organized.

Mill is settled with utility to give all convenient supports to the productions for twenty- four

hours. It had self-power generator system to satisfy total power consumptions of the mill.

We are enough fortunate that we have got an opportunity of having a training in this mill. This

mill owner home district in Pabna & here 85% workers & officer’s home district also in Pabna.

We got many help from workers& officers.Md. Ibrahim H0ssain, Assistant Dyeing Manager of

Hotapara Garments LTD. always helped us very sincerely and carefully, So many thanks for

him.During the training period we received co-operation and association from the authority full

& found all man, machines & materials on appreciable working condition. All worker & officers

were very sincere & denoted their duties to achieve their goal.