industrial attachment of square knits fabrics limited (skfl)

INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTSquare Knits fabrics Limited (SKFL)

TEXTILE ENGINEERING DEPARTMENT

Square Knits fabrics Limited (SKFL)

Abstract

Textile technology education is based on industrial ground. Theoretical background is not

sufficient so, industrial training is an essential part of study to make a technologist

technically sound in this field. Industrial training provides us that opportunity to gather

practical knowledge. Square Knits fabrics Limited (SKFL) is a truly integrated

undertaking. The textile division has the capability to offer a complete product range for

the export & domestic textile markets. The goal of this textile factory is to become the

preferred partner for sourcing high quality fabrics & clothing from Bangladesh. With high

advanced technology & an emphasis on developing local human resources, the textile

division has the potential to make an important contribution to the nation’s growing

readymade garments export sector. The rationale behind the existing structure & future

expansion of the textile division is to capture value added at each stage of the textile

manufacturing process. Despite Bangladesh’s lack of indigenous cotton production

capability, Square Knits fabrics Limited (SKFL)has leveraged Bangladesh’s labor cost

advantage & export competitiveness to maximum level.


Declaration

We hereby declare that the submitted work was completed using only the mentionedliterature and without any Unalloyed assistance.


ACKNOWLEDGEMENT

All the praises are for the almighty, Allah who bestowed me with the ability and potential tocomplete this Internship. I also pay my gratitude to the Al-mighty for enabling me tocomplete this Internship Report within due course of time.

Project paper is an academic function of the Southeast University. We are highly delighted toexpress our regards & gratitude to honorable Professor supervising teacher Prof. SyedFakhrul Hassan for providing us the chance to complete our internship and completion ourproject work in Squre knit fabrics limited

We take this opportunity to record my deep sense of gratitude and appreciation to our ProjectAdvisor “Mr. Fazley Elahi” (Asst. proff.) Department of Textile engineering, SoutheastUniversity for his constant encouragement and inspiring guidance with his Wisdom.We alsotake the opportunity to express our sincerest gratitude to the management, administration &personnel of Squre knit fabrics limited for their kind assistance.Cordial thanks goes toMahamuddun Nabi General Manager & Md.Habibuzzman (Shameem)Senior ManagerYarn

Processing & Mercerizing Square Knit Fabrics limited for their excellent co-operation during theperiod of our training. We would also like to thank Mofizur Rahman Senior Manager knitFabrics dyeing section for their sincere support.Above all, we would like to acknowledge ourdeep debt to all teachers of our university & particularly of Wet Processing Department fortheir kind inspiration & help, which remain as the backdrop of all our efforts.

Finally, we would like to acknowledge that we remain responsible for the in-adequacies &errors, which doubtless remain in the following report.


Contents

CHAPTER – I .................................................................... Error! Bookmark not defined.

Organizational Over view.................................................... Error! Bookmark not defined.

CHAPTER –II........................................................................ Error! Bookmark not defined.

Project description .............................................................. Error! Bookmark not defined.

CHAPTER – III ................................................................. Error! Bookmark not defined.

Man power Management ..................................................... Error! Bookmark not defined.

CHAPTER -IV ....................................................................... Error! Bookmark not defined.

Raw materials ..................................................................... Error! Bookmark not defined.

CHAPTER -V..................................................................... Error! Bookmark not defined.

Literature Review ............................................................... Error! Bookmark not defined.

CHAPTER -VI .................................................................. Error! Bookmark not defined.

Chemical Laboratory .......................................................... Error! Bookmark not defined.

CHAPTER -VII ................................................................ Error! Bookmark not defined.

Yarn processing ................................................................... Error! Bookmark not defined.

CHAPTER –VIII ......................................................... 102Error! Bookmark not defined.

Knitting ................................................................................ Error! Bookmark not defined.

CHAPTER -IX ................................................................... Error! Bookmark not defined.

Fabric Processing:................................................................ Error! Bookmark not defined.

CHAPTER -X .................................................................... Error! Bookmark not defined.

Fabric singeing & Mercerizing ......................................... 1Error! Bookmark not defined.

CHAPTER -XI ................................................................. 1Error! Bookmark not defined.

Fabric finishing ................................................................. 1Error! Bookmark not defined.

CHAPTER -XII ........................................................... 158Error! Bookmark not defined.

Quality Assurance Department (QAD) ............................... Error! Bookmark not defined.

CHAPTER -XIII ............................................................... Error! Bookmark not defined.

Effluent treatment plant (ETP)& Custic recovery plant (CRP)Error! Bookmark not defined.


CHAPTER -XIV ............................................................... Error! Bookmark not defined.

Maintenance......................................................................... Error! Bookmark not defined.

CHAPTER -XV ................................................................. Error! Bookmark not defined.

Utility Services .................................................................... Error! Bookmark not defined.

CHAPTER -XVI ............................................................... Error! Bookmark not defined.

Store & Inventory Control ................................................... Error! Bookmark not defined.

CHAPTER -XVII .............................................................. Error! Bookmark not defined.

Socil & Invironmantal Information ..................................... Error! Bookmark not defined.

CONCLUSION .................................................................. Error! Bookmark not defined.


Organizational Overview


Introduction:From fiber to fabric, the Textile division of Square group is a truly integrated undertaking.

The Textile Division has the capability to offer a complete product range for the export

textile markets. The goal of the Textile Division is to become the preferred partner for

sourcing high quality fabrics and clothing from Bangladesh. With this goal Square Knit

Fabrics Ltd. is advancement of this journey. With highly advanced technology and an

emphasis on developing local human resources, the Textile Division has the potential to

make an important contribution to the nation's growing ready made garments export sector

keeping green environment into close consideration.

The rational behind the existing structure and future expansion of the Textile Division is to

capture value-added at each stage of the textile manufacturing process. Despite lack of

indigenous cotton production capability of Bangladesh, Square has leveraged labor of

Bangladesh cost advantage and export competitiveness to the maximum.

Vision:To establish as a one stop source for the Global Knit Apparel market and to satisfy and

meet customer's expectation by developing and providing products and services on time,

which offer value in terms of Quality, Price, Safety & Environmental impact.

Assuring complete compliance with the international quality standards and also providing

the employees internationally acceptable working condition and standards.

To promote the development and to use human talent & equal opportunity of employment

Square Knit Fabrics Ltd. procure the most advanced & sophisticated technology suitable for

producing desired product and attain highest level of competence through continuous

development of the professional management system and to ensure complete transparency

in all aspect of business.

Mission:Square realizes the need to stake out a competitive segment in the changing global market

of today through technological excellence and human expertise. Square is committed to

transpose its local success to the world scene.


Dhaka CantonmentGulshan KakoliChourasta

SOUTHEASTUNIVERSITY

Joydevpur Chandra

Master -Bari Bus Stand

GazipurChourasta

Bhawal GorNational Park

Square knitfabrics Ltd.

Nasir Glass

R.A.K Pharmaceuticals

MaonaBazarMaona

Bazar

Valuka Thana

MYMENSINGH

HIGH

WAY

Mohakhali

Ashulia

Rajendrapur Cantonment

Location Map of Square Knit Fabrics Limited.


Project Description


Name of the Factory:Square Knit Fabrics Limited (SKFL).

Type:Knit fabric manufacturing for 100% export oriented ready made Garments Industry.

Year of Establishment:2001, Commencement of Production in June 2002

Address:It is situated in Jamirdia, Master Bari, Valuka, Mymensingh, Bangladesh.

History of Project Development:In 1997, Square entered the textile sector with its manufacturing facilities of cotton yarn.

Combining modern technology with skilled manpower under Square's unique inspiring,

atmosphere, this new Square venture soon rose to the top of the local textile industry.

Today it has one of the most sophisticated vertically integrated set-ups.

In 1998: Second unit of Square Textile established.

In 2000: Square Spinnings Ltd. started its journey.

In 2001: Square Knit Fabrics ltd. and Square Fashions Ltd. established.

In 2002: Square Knit Fabrics commenced with its production.

In 2009: Square Multi Fabrics Ltd. Commenced with its production.

Textile Mills of Square Group:Square Knit Fabrics Ltd.

Square Spinnings Ltd.

Square Textiles Ltd.

Square Fashions Ltd.

Square Multi Fabrics Ltd.

Physical Infrastructure: Square at Valuka have three shades. They are Square Knit Fabrics Limited, Square

Fashions Limited & Square Multi Fabrics Limited.

Total factory area is 165,000 ft2. Production space is 135,000 ft2, single storied.

There are four dormitories for worker, two dormitories for officials.


Square Knit Fabrics Ltd. maintains its telecommunication with VOIP connection to its

different corporate zones, PABX connections and LAN connections.

It’s others facilities are

Own Network Server,

Own power management;

Own utility management,

Free transport facility,

24 – hour medical center,

Free meals,

Fire service facility and

ETP.

Different Departments:Square Knit Fabrics Ltd has the following departments approximately:

Different Departments

Personnel and Administration

Knitting

Wet Processing

Yarn Processing

Mercerizing

Quality Assurance

Finishing

Laboratory

R & D

Fabric InspectionMaintenance

Electrical

Mechanical

Utility

ETP

Fabric Processing

Package and Hank


Product Type: Piece Dyed fabric,

Mercerized & Dyed fabric ,

Yarn dyed fabric,

Mercerized yarn dyed fabric (double mercerized).

Product Mix: Cotton: - Carded, Combed, Compact, & Organic.

Viscose: - Modal, Mélange,

Polyester,

Lycra,

Polyester-cotton blend,

CVC.

Product Range: Engineering stripe and semi jacquard,

Plain (100% cotton single jersey, slub single jersey, lycra single jersey, double

mercerized single jersey),

Pique (100% cotton,100% lycra),

Four Needle structure,

Wofel rib,

1X1 Rib (cotton), 1X1 Rib (lycra), 1X1 Rib (slub),

2X2 Rib (100% cotton), 2X2 Rib (100% lycra),

2X1 Rib,

4X4 Rib,

Interlock,

Pique interlock (pima cotton),

Interlock (double mercerized),

Locust,

Jacquard,

Fleece & Terry fleece, etc.


Capacity:30,000-31,000 Kg. of Knit fabric processed per day (Open width & tubular finish).

Production Capacity in knitting:

15,000 kg. Of greige fabric and 25000 pieces of cuff & collar set per day (depends on

design i.e. if design is more then production will be less).

Production Capacity in yarn dyeing:

4000 kg. Per day

Production Capacity in knit dyeing:

30,000 Kg. Per day

Investment Cost:Investment cost is US$ 11.11 million.

Remarks:Square Knit Fabric Ltd. is greatest concerned with the quality of its product. For this reason

it do not look for the production volume rather the quality of product, this increase its

overhead cost. But better quality has welcome buyers with satisfaction. The infrastructure

and land asset has the greatest possibility to extension and to create social contributions.


Manpower Management


Organogram of Administration:

Organogram of Operation:

Managing Director

Executive Director

General Manager

Deputy General Manager

Assistant General Manager

Senior Manager

Manager(Of QAD, YP, FP, Maintenance etc.)

Deputy Manager

Assistant Manager


Shift Change:There are three shifts for operation personnel in this industry. So the shifts are changed at

every 8 hours.

The shift timings are as below:

6:00 am to 2:00 pm (“A” Shift)

2:00 pm to 10:00 pm (“B” Shift)

10:00 pm to 6:00am (“C” Shift)

Administration i.e. Management personnel work on General (G) shift of duration 8:00 am

to 5:00 pm and 6 days per week.

Responsibilities of Production Executive: To follow and execute the daily production plan accordingly.

To give the right decision for the minor troubleshooting.

To match the shade with the approved lab dip and take necessary help from

Spectrophotometer.

To prepare dye line correctly and maintain logbook.

To convey the proper information to the next shift.

To maintain target productivity of every section in his shift

To give job card to maintenance department whenever machine is not working or any

other problem with the machine.

Senior Executive II

Executive I

Executive II

Executive III

Production Officer

Assistant Production Officer

Supervisor

Senior Operator

Senior Executive I


Job description of Production Executive:Report to:

Senior production officer

Job Summary:

To plan, execute & follow up the production activities & control the quality.

Duties & Responsibilities:Overall supervision of dyeing, finishing production.

Batch preparation & PH check.

Dyes & chemical requisition issue & check.

Write fabrics loading & unloading time from m/c.

Program making, sample checking, color measurement.

Control the supervisors, operators’ asst. operator & helpers of dyeing m/c.

And also any other work as & when required by the management.

Management System:Corporate Management System.

Remarks:Though Square Knit Fabric Ltd. has more than 1100 manpower but Square Fashions Ltd.

has manpower more than 6000 in around a single fence & Square Multi Fabrics Ltd. has

around 200 manpower. Square pay a great attention for providing food and transport,

medical, schooling of personnel’s children, their utility and maintain a safe, secured and calm

environment. The working condition here is also standardized. These opportunities for the

personnel of the industry have a direct positive impact on the production and also motivate

the personnel for better and greater efficiency.


Raw Materials


Square Knit Fabrics Ltd. is a knit composite textile industry. In the industry raw materials for

different section is different. As for example knitting uses the raw material Yarn, Fabric

processing department uses the knit fabrics, dyes and chemicals again yarn processing uses

the grey yarn and dyes chemicals. Following we describe the raw materials used in Square

Knit Fabrics Ltd.

Yarn

Grey fabrics

Dyes

Chemicals

Auxiliaries

Yarn:Following types of yarns are used to knit fabrics:

SyntheticPolyester

ViscoseModal Yarn

Mélange Yarn

Ecru mélange

Cotton yarnCard Yarn

Combed Yarn

Compact Yarn

Organic cotton


Grey Fabrics:Following types of grey fabrics are dyed:

Sources:The required yarns are supplied from

Square Spinning Mills Ltd. (Bangladesh) ,

Thermax (Bangladesh),

NRG (Bangladesh),

Badsha Spinning Mills Ltd. (Bangladesh)

Ginni (India),

Nahar (India),

Flat bed Simple Collarand Cuff

Jacquard Collarand Cuff

Double jersey1x1 and 2x2 rib

Interlock

Flat back

Single jersey Single anddouble lacoste

Polo pique

Terry fleece

Engineering stripe

Jacquard etc.

BlendPC

CVC

Mélange


And special yarns are from

Bardhaman (India),

Aarti (India),

Organic cotton – Indonesia.

The required grey fabrics are produced in this industry.

Price:Not provided.

Dyes:The following dyes are used-

Reactive dyes.

Disperse dyes.

The list of dyes for different substrate is as below:

For Cotton Group (Reactive Dyes)

Shade Name of Dyes Country ofOrigin

SupplierName

Golden YellowType

Novacron Yellow FN -2R Singapore CibaNovacron Yellow NC Singapore Ciba

Drimarene Yellow CL-2R Switzerland ClariantIndofix Yellow WHR India Indo ColchemImcozin Yellow E3R German Impocolor

Kimsoline Yellow KLL Turkiye Cida-TexKimsoline G.Yellow HF-2GR Turkiye Cida-Tex

Kimsoline Yellow KED Turkiye Cida-Tex

KimsolineYellow Shade SL Turkiye Cida-Tex

Levafix Yellow CA Gran Singapore DystarLevafix Amber CA Singapore Dystar

Remazol Luminus Yellow FL Singapore DystarRemazol Yellow RR Singapore Dystar

Remazol Golden Yellow RGBGran

Singapore Dystar

Remazol Ultra Yellow RGB Singapore Dystar

Bezaktiv Yellow SLF Switzerland Bezema

Bezaktiv Yellow S-3R Switzerland BezemaCibacron Yellow H-R Singapore Ciba



SupplierName

Lemon YellowType

Cibacron Brilliant Yellow H-4GN

Singapore Ciba

Kimsoline Yellow HF -3GN Turkiye Cida-Tex

Kimsoline Yellow HF4GL150%

Turkiye Cida-Tex

Everzol Yellow 3GL Taiwan Everlight

Levafix Brill Yellow CA Singapore Dystar

Remazol Brilliant Yellow 4GL Singapore DystarImcozin Brill. Yellow V4GL German Impocolor

Blue Type

Bezaktiv Blue SLF Switzerland Bezema

Bezaktiv Blue S-FR Switzerland Bezema

Bezaktiv Blue S-GLD Switzerland BezemaBezaktiv Blue V-2B Switzerland BezemaCibacron Blue H-GN Singapore DystarCibacron Blue F-GFN Singapore Dystar

Cibacron Brilliant Blue FNG Singapore Dystar

Novacron Blue FNR Singapore Dystar

Novacron Ocean SR Singapore Dystar

Drimarene Blue CLBR Singapore Dystar

Remazol Blue RR Singapore Dystar

Remazol Dark Blue SLT Singapore Dystar

Remazol Br. Blue BB New Singapore Dystar

Levafix Blue CA Singapore Dystar

Levafix Brill. Blue E-FFN Singapore Dystar

Imcozin Blue E-NR German Impocolor

Kimsoline B. Blue SHF-RL Turkiye Cida-Tex

Kimsoline Blue Shade BL Turkiye Cida-TexKimsoline Blue KLL Turkiye Cida-Tex

Kimsoline Blue BRF Turkiye Cida-Tex

Shade Name of Dyes Country of Origin Supplier NameNovacron Red FNR Singapore Ciba


Red Type

Novacron Brill Red FN-3GL Singapore Ciba

Novacron Brown NC Singapore CibaNovacron Scarlet FN-6G Singapore Ciba

Cibacron Red H-D Singapore CibaIndofix Red WHR India Indo Colchem

Imcozin Red E-3BF German Impocolor

Kimsoline Red KLL Turkiye Cida-Tex

Kimsoline Red HF- 6BN Turkiye Cida-Tex

Kimsoline Red KED Turkiye Cida-TexKimsoline Red Shade 3B Turkiye Cida-Tex

Levafix Red CA Gran German Dystar

Levafix Brill Red E-4BA German Dystar

Levafix Brill Red E-BA German Dystar

Levafix Brill Red E-6BA German DystarLevafix Fast Red CA German Dystar

Levafix Scarlet CA Singapore DystarLevafix Rubine CA Singapore Dystar

Remazol Red RR Singapore DystarRemazol Deep Red RGB

GranSingapore Dystar

Remazol Red RGB Gran Singapore DystarRemazol Ultra Red RGB Singapore DystarRemazol Brill Red F-3B Singapore Dystar

Remazol Ultra Carmine RGB Singapore DystarBezaktiv Red SLF Switzerland BezemaBezaktiv Red S-2B Switzerland BezemaBezaktiv Red S-3B Switzerland BezemaSunfix Red MFD Korea OH Young Ind. Ltd.


Supplier Name

Navy Type

Drimarene Navy CL-R Switzerland Clariant Export AG

Kimsoline Navy Blue HF-RN Turkiye Cida-Tex

Kimsoline Navy Blue SHF-GFN Turkiye Cida-Tex

Remazol Navy Blue GG Singapore Dystar

Everzol Navy Blue GG Taiwan EverlightBezaktiv Navy -S MAX German Bezema

Bezaktiv Navy SBL Switzerland Bezema


Bezaktiv Navy SLF Switzerland BezemaCibacron Navy FN-B Singapore CibaCibacron Navy H-2G Singapore Ciba

Sunfix Navy Blue MFD Korea OH Young Ind.Ltd.

Black Type

Cibacron Super BlackG/Novacron

Singapore Ciba

Cibacron Super BlackR/Novacron

Singapore Ciba

Indofix Black B India Indo ColchemKimsoline Black B Turkiye Cida-Tex

Remazol Black B Gran Singapore DystarRemazol Deep Black GWF Singapore Dystar

Reafon Deep Black NS Singapore Kappa International

Bezaktiv Black -S MAX German Bezema

Bezaktiv Black S -BUDGET German Bezema

Sunzol Black EP Korea OH Young Ind.Ltd.

TurquoiseType

Cibacron Turquoise H-GN Singapore Ciba

Everzol Turquise Blue G Taiwan Everlight

Imcozin Turquiss Blue VG German Impocolor

Remazol Tuerkis Blue G Singapore Dystar

Remazol Brill Green 6B Singapore Dystar

Kimsoline Turquise Shade 2G Turkiye Cida-Tex

Kimsoline Turquise Blue HFG Turkiye Cida-Tex

RSPL TypeBezaktiv Blue VR SPCL German Bezema

Everzol Blue R SPCL Taiwan Everlight

Shade Name of Dyes Country of Origin Supplier Name

Orange Type

Cibacron Orange FN-R Singapore CibaNovacron Orange FBR Singapore Ciba

Levafix Orange CA Singapore DystarKimsoline B. Orange 3R Turkiye Cida-Tex

Sunfix Orange MFD Korea OH Young Ind. Ltd.

Violet TypeRemazol Brilliant Violet 5R Singapore Dystar

Bezaktiv Violet V-5R Switzerland BezemaBezaktiv Gray SLF Switzerland Bezema


Grey Type Novacron Gray NC Switzerland Bezema

Olive TypeLevafix Olive CA Singapore Dystar

Novacron Olive NC Singapore Dystar

For Polyester Group (Disperse Dyes)

Sl. No. Name of Dyes Country of Origin Supplier Name1. Dianix Blue XF Singapore Dystar2. Dianix Blue CC Singapore Dystar3. Dianix Rubine CC Singapore Dystar4. Dianix Crimson S-F Singapore Dystar5. Dianix Yellow Brown SE-R Singapore Dystar6. Dianix Terquise C-C Singapore Dystar7. Dianix Navy X-F Singapore Dystar8. Dianix Green C-C Singapore Dystar9. Dianix Scarlet C-C Singapore Dystar10. Dianix Scarlet X-F Singapore Dystar11. Dianix Flavine XF Singapore Dystar12. Dianix Luminus Yellow 10 G Singapore Dystar13. Dianix Luminus Red G Singapore Dystar14. Dianix Luminus Pink 5G Singapore Dystar15. Dianix Luminus Red 3B Singapore Dystar16. Dianix Brill Orange G Singapore Dystar17. Dianix Turquise XF Singapore Dystar18. Dianix Yellow CC Singapore Dystar19. Dianix Blue AC-E Singapore Dystar20. Dianix Red AC-E German Dystar21. Dianix Yellow AC-E Singapore Dystar22. Dianix Yellow S-4G Singapore Dystar23. Dianix Navy S-2G Singapore Dystar24. Dianix Black S-R Singapore Dystar25. Dianix Deep Red SF Singapore Dystar26. Dianix Blue S-BB Singapore Dystar27. Dianix Violet S4R Singapore Dystar28. Dianix Black XF Singapore Dystar29. Dianix Yellow Brown SE-R Singapore Dystar30. Terasil Black SRL Singapore Ciba31. Terasil Violet BL Singapore Ciba32. Terasil Blue BGE-01 Singapore Ciba33. Terasil Blue W-BLS Singapore Ciba34. Terasil Blue WW2GS Singapore Ciba35. Terasil Blue W-RBS/W-BLS Singapore Ciba36. Terasil Gold Yellow W-3R Singapore Ciba37. Terasil Red W-BF Singapore Ciba38. Terasil Red W-RS Singapore Ciba39. Terasil Red FBN German Ciba


40. Terasil Red W-FS Singapore Ciba41. Terasil Red W-4BS Singapore Ciba42. Terasil Red WWFS Singapore Ciba43. Terasil Red WWBFS Singapore Ciba44. Terasil Red 3BL Singapore Ciba45. Terasil Red WW-3BS Singapore Ciba46. Terasil Navy GRLC Singapore Ciba47. Terasil Navy W-RS Singapore Ciba48. Terasil Flabine 8GFN Singapore Ciba49. Terasil Yellow W-4G Switzerland Ciba50. Terasil Yellow W-6GS Switzerland Ciba

Chemicals:Basic Chemicals

Name of Item Country of Origin Supplier NameAcetic Acid (Glacial) India Jubilant Organosys LTD.

Acetic Acid 30% India Jubilant Organosys LTD.Sirrix NE Switzerland Clariant

Hydro Chloric Acid Singapore Swiss ColourOxalic Acid

Soda Ash Australia/India Penrice sodaproduct/Nirma

Sulphuric Acid Indonesia Ptlautan Iuas Tbk

Acid Buffer Sodium Acetate Ammonium Sulphate

Bleaching AgentName of Item Country of Origin Supplier Name

Polyclean SPViscoclor Turkiye Cida-Tex

Viscobleach Turkiye Cida-TexNo Bleach 200% Turkiye Eksoy Kimyevi

Cottobleach Turkiye Eksoy KimyeviHydrozen Peroxide 50% China Gaungdong Zhong

Salt/ElectrolyteName of Item Country of Origin Supplier Name

Sodium Sulphite(GlubarSalt)

Taiwan FCFC

Sodium Sulphite(Refined Salt)

Thailand KC Salt

Caustic SodaName of Item Country of Origin Supplier Name

Caustic Soda Pearl Saudi Arabia Arabian Alkali Co.


Detergent & Scouring AgentName of Item Country of Origin Supplier NameKappawet Bos Germany KaAP-ChemieKieralon Jet-B Germany BASF

Diwet PlusTannex Noveco India Lanxess

Lenaryl RK Germany ACIForyl BGL India Pulcra Chemicals

Feloson NOF Germany CHT R-BeitechKSN NOF

Antifoam/Dearreting & Penetrating AgentName of Item Country of Origin Supplier NameAlbaflow JET Singapore Swiss ColourContripon S Germany Harris & MenukPrimasol NF Germany BASF

Anti Creasing AgentName of Item Country of Origin Supplier Name

Cibafluid C Singapore Swiss ColourPersoftal L India Lanxess

Base Ledesan SVE Span Global Chemicals

Peroxide StabilizerName of Item Country of Origin Supplier NameStabilizer S0F Thailand Clariant

Peroxide KillerName of Item Country of Origin Supplier Name

Bio Kill Turkey Eksoy Kimyevi

Sequesterent & Dispersent for BleachingName of Item Country of Origin Supplier NameLadiquest 1097 Thailand ClariantOptavon 4UD Germany Harris & Menuk

Kappaquest A-41 Germany Hi-Tech Auxi ChemLufibrol MSD Germany BASF

Mercerizing Wetting AgentName of Item Country of Origin Supplier NameUniverdin MR Singapore Swiss Colour


Levelling Agent for Heat SettingName of Item Country of Origin Supplier NameDepicol RC 9 Germany Zachimmer

Reactive Fixing AgentName of Item Country of Origin Supplier Name

Cibafix Eco/AlbafixECO

Singapore Swiss Colour

Rewin ACP German R.H. CorporationPermafix RD Thailand Total quality

Tinofix FRD/AlbafixFRD


Cot. Levelling & Prof-ColloidName of Item Country of Origin Supplier Name

Irgasol Co New/AlbatexCO


Levagol RL India LanxessDrimagen E-2R Switzerland ClariantDrimagen E-3R Switzerland Clariant

Oxidizing Agent for PolyesterName of Item Country of Origin Supplier Name

Ludigol AR Singapore BASF

Albatex AR Singapore Swiss Colour

Dispersing Levelling Agent for PolyesterName of Item Country of Origin Supplier NameUnivadine DIF Singapore Swiss Colour

Acid PH Buffer (For Polyamide) Setavin PAS

After Soaping AgentName of Item Country of Origin Supplier NameMatexil ADW India

Avolan IS India LanxessCyclanon XC-W Germany BASF

Eriopon OS Singapore Swiss Colour

Gliding Agent for Cotton YarnName of Item Country of Origin Supplier Name

Katamin BW Germany Zachimmer & Schwar


Reducing AgentName of Item Country of Origin Supplier Name

Hydrosulphite (Hydrose) Singapore BASF

Enzyme Finishing AgentName of Item Country of Origin Supplier Name

Nuvosoft / Ecosoft X750 Thailand Vrintex LTD.Biotuch C-39

Biopolish B-500Primafast Luna CLMega EH-S /EH-3 China Total quality

Fabrilage HDL

Optical Brightener for CottonName of Item Country of Origin Supplier Name

Uvitex BHV SingaporeUvitex BAM India Diamond dye

Skywhite BVB India

PES-Dyeing PH -BufferName of Item Country of Origin Supplier NameCibatex AB-45 Singapore Swiss Colour

Rubbing Fastness ImproverName of Item Country of Origin Supplier Name

Geitex WRN Taiwan Geigy Ent.

De-Colorant for Effluent TreatmentName of Item Country of Origin Supplier Name

Water Decolorint Agent. Local

Ultra violet protection AgentName of Item Country of Origin Supplier NameTanofast CEL Singapore Ciba

Antimurobiol Hygiene Protection AgentName of Item Country of Origin Supplier NameOleophobol ZSR Singapore Ciba

Silicon Stripper AgentName of Item Country of Origin Supplier NameSilicon Stripper

Knitting Oil Removing AgentName of Item Country of Origin Supplier Name

Silvatol FLN Singapore Ciba


Special Finishing Agent

Softener

Type ofSoftener

Name of Item Country ofOrigin

SupplierName

CationicSapamine CWS

Tissocyl RC9 (Used for heatsetting)

WeakCationic/Non-

ionic

Basosoft F-Euk Conc Singapore BASFJinsofter CWSSoulbio SSK China Global

ChemicalsAlcamine CWS /Sapamine CWS Singapore Swiss Colour

Non-ionicSoulbio FC China Global

ChemicalsBelsoft 200 Conc. P I German Cognis

Silicon

Adasil SM German Cognis

Albafix ECOLaxsof Taiwan Geigy Ent.

Silizen PEP

Unisil 2ST Turkey Eksoy Kimyevi

Unisil NBI Turkey Eksoy Kimyevi

Unisil NLPW Turkey Eksoy Kimyevi

Microsillc EG Super

Name of Item Country of Origin Supplier NameUltraphil HCT Singapore Swiss ColourTubingal MSQ German R.H. Corporation

Siligen PEPUltra-Fresh Silphure Canada Thomson

Unidal APY.THSanitized T9919

(Anti Bacterial Agent)Hydroperm RPU

(Anti Bacterial Agent)Dilasoft JWN-CN

(Anti Bacterial Agent)Umidol (Anti Bacterial

Agent)


Literature Review


Cotton Fiber and its Chemical Structure:

The chemical composition of cotton, when picked, is about 94 percent cellulose; in finishedfabrics is it 99 percent cellulose. Cotton contains carbon, hydrogen, and oxygen with reactivehydroxyl groups. Glucose is the basic unit of the cellulose molecule. Cotton may have asmany as 10,000 glucose monomers per molecule. The molecular chains are arranged in longspiral linear chains within the fiber. The strength of a fiber is directly related to chain length.

Hydrogen bonding occurs between cellulose chains in a cotton fiber. There are three hydroxylgroups that protrude from the ring formed by one oxygen and five carbon atoms. Thesegroups are polar meaning the electrons surrounding the atoms are not evenly distributed. Thehydrogen atoms of the hydroxyl group are attracted to many of the oxygen atoms of thecellulose. This attraction is called hydrogen bonding. The bonding of hydrogen's within theordered regions of the fibrils causes the molecules to draw closer to each other whichincreases the strength of the fiber. Hydrogen bonding also aids in moisture absorption. Cottonranks among the most absorbent fibers because of Hydrogen bonding which contributes tocotton's comfort.

The chemical reactivity of cellulose is related to the hydroxyl groups of the glucose unit.Moisture, dyes, and many finishes cause these groups to readily react. Chemicals likechlorine bleaches attack the oxygen atom between or within the two ring units breaking themolecular chain of the cellulose.

Chemical Structure of CottonBleaching:

Bleach is a chemical that removes colors or whitens, often via oxidation. Common chemicalbleaches include household "chlorine bleach", a solution of approximately 3–6% sodiumhypochlorite (NaClO), and "oxygen bleach", which contains hydrogen peroxide or aperoxide-releasing compound such as sodium per-borate, sodium per-carbonate, sodium per-sulfate, sodium per-phosphate, or urea peroxide together with catalysts and activators, e.g.tetraacetylethylenediamine and/or sodium nonanoyloxybenzenesulfonate. To bleachsomething is to apply bleach, sometimes as a preliminary step in the process of dyeing.

The bleaching of textiles appears to have been known as early as 300 B.C. when soda ashwas prepared from burned seaweed and used to clean cloth. Then the cloth was treated withsoured milk to reduce its alkalinity. The bleaching process was completed when the cloth wasexposed to the Sun. This type of sun bleaching typically took several weeks.A Swedish chemist discovered chlorine gas in 1784 and succeeded in demonstrating its usefor decolorizing vegetable dyes. Fifteen years later a patent was awarded for a bleachingpowder formed by the absorption of chlorine gas into dry hydrate of lime. Following World


War I the technology for shipping liquid chlorine was developed. This allowed for on-siteproduction of sodium hypochlorite in textile mills and led to the development of otherchlorine-based bleaches. In 1928, the first dry calcium hypochlorite bleach containing 70%available chlorine was produced in the United States. This material largely replacedbleaching powder in commercial bleaching.

Hydrogen peroxide was prepared as early as 1818 but did not find use in the bleaching oftextiles until much later. By 1930, the prices of peroxides had dropped sufficiently to allowthe use of hydrogen peroxide in the bleaching of cotton, wool, and silk. By 1940, 65% of allcotton bleaching was done with hydrogen peroxide.

Textile bleaching is one of the stages in the manufacture of textiles. All raw textile materials,when they are in natural form, are known as 'greige' material. This greige material will bewith its natural color, odour and impurities that are not suitable for clothing materials. Notonly the natural impurities will remain on the greige material but also the add-ons that weremade during its cultivation, growth and manufacture in the form of pesticides, fungicides,worm killers, sizes, lubricants, etc.

The removal of these natural coloring matters and add-ons during the previous state ofmanufacturing is called scouring and bleaching.

Bleaching Chemistry

The process of bleaching can be summarized in the following set of chemical reactions:

Cl2(aq) + H2O(l) H+(aq) + Cl-(aq) + HClO(aq)

The H+ ion of the hypochlorous acid then dissolves into solution, and so the final result iseffectively:

Cl2(aq) + H2O(l) 2H+(aq) + Cl-(aq) + ClO-(aq)

Hypochlorite tends to decompose into chloride and a highly reactive form of oxygen:

ClO- Cl- + O

This oxygen then reacts with organic substances to produce bleaching or antiseptic effects.

Reactive Dye:

The best dyes, by far, to use for cotton and other cellulose fibers are the fiber reactive dyes.They are much brighter, longer-lasting, and easier-to-use than all-purpose dyes.Reactive dyes first appeared commercially in 1956, after their invention in 1954 by Ratteeand Stephens at the Imperial Chemical Industries Dyestuffs Division site in Blackley,Manchester, United Kingdom.

Reactive dyes are used to dye cellulosic fibres. The dyes contain a reactive group, either ahaloheterocycle or an activated double bond, that, when applied to a fibre in an alkaline dyebath, forms a chemical bond with an hydroxyl group on the cellulosic fibre. Reactive dyeingis now the most important method for the coloration of cellulosic fibres. Reactive dyes canalso be applied on wool and nylon; in the latter case they are applied under weakly acidicconditions. Reactive dyes have a low utilization degree compared to other types of dyestuff,since the functional group also bonds to water, creating hydrolysis.


Reactive dyes are categorized by functional group

Functional group Fixation Temperature Included in BrandsMonochlorotriazine Haloheterocycle 80o Basilen E & P

Cibacron EProcion H,HE

Monofluorochlorotriazine Haloheterocycle 40o Cibacron F & CDichlorotriazine Haloheterocycle 30o Basilen M

Procion MXDifluorochloropyrimidine Haloheterocycle 40o Levafix EA

Drimarene K & RDichloroquinoxaline Haloheterocycle 40o Levafix ETrichloropyrimidine Haloheterocycle 80-98o Drimarene X & Z

Cibacron TVinyl sulfone activated double bond 40o RemazolVinyl amide activated double bond 40o Remazol

Dyestuffs with only one functional group sometimes have a low degree of fixation. Toovercome these dyestuffs containing two different reactive groups (i.e. one monochlorotriazinand one vinyl sulfone) were created.

Bifunctional Dyestuffs containing two groups are also known as bifunctional dyestuffs,though some still refers to the original combination. Other type of bifunctional dyes has beenintroduced. The first bifunctional dye made where more tolerant to temperature deviations(better process). Other bifunctionals are created, some with fastness (better quality) or onlyfixation degree (better environment/economy) in mind.

Reactive dyes have good fastness properties owing to the bonding that occurs during dyeing.Cotton is made of cellulose molecules which react with the dye .During reactive dyeing the Hatom in the cellulose molecule combines with the cl atom in the dyeing process and results ina bond. Trifunctional dyestuffs also exist.Procion MX. Many people feel quite strongly thatthe best dye choice for the beginner, as well as for many experienced dyers, is Procion MX,because this dye is very easy to work with. The dyes are relatively non-toxic. Otheradvantages include the remarkable wash fastness found in all fiber-reactive dyes.

Optimum reaction temperatures for Procion MX dyes are between 95° and 105°F = 35° to41°C (except for turquoise, which prefers up to 130°F = 55°C)

Cibacron F. Another very good fiber reactive dye for artists and crafters to use is theCibacron F line. (Don't confuse Cibacron F with just plain Cibacron! They can be completelydifferent types of dyes; be sure you get the type with the "F" suffix.) Like Procion MX dyes,Cibacron F dyes can be used in warm water, instead of extremely hot water like some dyes.Its advantages over Procion MX dyes are that it 'keeps' better in solution, so you can storeand possibly even buy it already in solution (liquid form), avoiding the safety hazard ofbreathing dye powder; it is also much easier to wash the excess dye out of the fabric whenusing Cibacron F dyes than when using Procion MX. However, the Cibacron F line has onemajor drawback when compared to the Procion MX line: there is not as wide a choice ofcolors.


Cibacron F dyes can be used according to the exact same recipe as Procion MX dyes, andeven mixed freely with them. However, Cibacron F dyes are slightly less quick to react thanProcion MX type, which is why they can be stored so much longer after dissolving them inwater than the Procion MX type dyes; this also means that slightly higher temperatures areneeded.

Optimum temperatures for Cibacron F dyes are slightly higher than for Procion MX dyes.Ciba says 55° to 65°C (130° to 150°F); ProChem (Sabracron F) says 45 to 55°C. (113° to130°F) Drimarene K. This is the remaining popular "cool water" fiber reactive dye. Itrequires higher temperatures still than Cibacron F, but does not require steaming.

Instructions for Drimarene K dyes can be found at Batik Oetoro; they are very similar inaction to MX type dyes, except for requiring a minimum temperature of 35°C or 95°F. Thegreatest drawback, besides the need to find a warm place for the dye reaction to occur, is thelack of a truly rich red.

Drimarene K has optimum temperatures around 60°C (140°F) for most colors, 80°C (176°F)for turquoise and a couple of others.

Procion H dyes are usually used for silk painting; they require steaming or simmering to fixto cotton or silk. They are chemically similar to Procion MX dyes, beingmonochlorotriazines, but they are far less reactive, and will not work at all well at roomtemperature.

Procion H dyes, may be fixed to cotton using a high-pH solution such as sodium silicate atroom temperature, or by moderate heating. Vinyl sulfone dyes are particularly useful forchemical resist dyeing , in which two different types of fiber reactive dyes are used to printforeground and background in different colors. Remazol dyes are more suitable for dyeing forlater discharge (bleaching) than are other fiber reactive dyes.

Levafix. made by Dystar, for small-scale users. Their temperature optimum is around 50°C(122°F). This is lower than the optimum temperature of 60° to 80° C. for the Drimarene Kdyes, which can be used in "cold" dyeing, but higher than the optimum temperature of about35° to 40°C (95° to 105°F) for Procion MX. It is not necessary to get quite as high as theoptimal temperature in order to have acceptable results.

Dissolving the DyesThe dyes are in most cases readily water-soluble. They are dissolved either by passing withcold water to which is then added hot water or by strewing the dye powder into hot waterwhich is stirred at high speed. Usually a temperature not greater than 80ºC is used fordissolution. In the case of highly reactive dyes such as Procion MX (ICI) warm (50-60ºC)water is used.Since the dyes are prone to hydrolysis stock solutions should not be stored for long periods.

Reaction with Cellulosic fiberReactive dyes formed covalent bond with cellulosic fiber by Nucleophilic substitution andaddition reaction. The reactions are as follows -----

Substitution reaction:

D – R – Cl + HO - Cell D – R – O – Cell + HCl


Addition reaction:

D – F – CH2 = CH2 + HO – Cell D – F – CH2 – CH2 – O – Cell

Reaction with water:The cold brand reactive dyes are highly reactive in nature. They react also with water and gethydrolyzed. The reaction is as follows ----

D – R – Cl + HOH D – R – OH + HCl

The hydrolyzed dye is also colored substances and has very low substantivity for thecellulosic fiber. So they are attached with fiber surface after dyeing. If they do not washedaway from the fiber surface the fastness property of the fiber must be very low.

Salts used for Reactive DyeingDepends on the substantivity to increase the exhaustion, salt like common salt (NaCl) orGlouber’s salt (Na2SO4) is used.

Alkalis for Reactive DyeingThe common alkalis used for reactive dyeing are sodium bi-carbonate (NaHCO3), sodiumcarbonate (Na2CO3), sodium hydroxide (NaOH), sodium silicate (Na2SiO3) and sodiumphosphate (Na3PO4). Sodium silicate is very strong alkali and only used for deep dyeing.Sodium carbonate is mostly used alkali in reactive dyeing.

Eliminating the hydrolyzed dyeThe hydrolyzed dye is also colored substances and has very low substantivity for thecellulosic fiber. They tend to stay on the fiber surface after dyeing for sometimes althoughthere is no bond between the dye and the fiber. These unfixed dyes come of the fibers whenwashed or rubbed subsequently.

If they do not washed away from the fiber surface the rubbing and wash fastness property ofthe fiber must be very low.

The presence of electrolytes in the washing water causes an increase in the hydrolyzed dyeaffinity making it difficult to extract, therefore very saline water must be avoided even if thiswater conditioned.

Optical BrightenerOptical brighteners, optical brightening agents (OBAs), fluorescent brightening agents(FBAs) or fluorescent whitening agents (FWAs) are dyes that absorb light in the ultravioletand violet region (usually 340-370nm) of the electromagnetic spectrum, and re-emit light inthe blue region (typically 420-470nm). Fluorescent activity is a short term or rapid emissionresponse, unlike phosphorescence, which is a delayed emission. These additives are oftenused to enhance the appearance of color of fabric and paper, causing a perceived "whitening"effect, making materials look less yellow by increasing the overall amount of blue lightreflected.

PropertiesThe most common classes of chemicals with this property are the stilbenes and older, non-commercial fluorescent dyes such as umbelliferone, which absorb energy in the UV portionof the spectrum and re-emit it in the blue portion of the visible spectrum. A white surfacetreated with an optical brightener can emit more visible light than that which shines on it,making it appear brighter. The blue light emitted by the brightener compensates for the


diminishing blue of the treated material and changes the hue away from yellow or brown andtoward white.

There are approximately 400 brightener types listed in the Color Index, but less than 90 areactually produced commercially and only a handful are commercially important. Generically,the C.I. FBA number can be assigned to a specific molecule, however, some are duplicated,since manufacturers apply for the index number when they produce it. The global OBAproduction for paper, textiles and detergents is dominated by just a few di- and tetra-sulfonated triazole-stilbenes and a di-sulfonated stilbene-biphenyl. These are subject tofading when exposed long term to UV, due to the formation of optically inactive stilbene cis-isomers found at the center of the molecule. All brighteners have extended conjungationand/or aromaticity, allowing for electron movement. Some non-stilbene brighteners are usedin more permanent applications such as whitening synthetic fiber.

Basic class types of brighteners include:- Triazine-stilbenes (di-, tetra- or hexa-sulfonated)- Coumarins- Imidazolines- Diazoles- Triazoles- Benzoxazolines- Biphenyl-stilbenes

Brighteners can be "boosted" by the addition of certain polyols like high molecular weightpolyethylene glycol or polyvinyl alcohol. These additives increase the visible blue lightemissions significantly. Brighteners can also be "quenched". Too much use of brightener willoften cause a greening effect as emissions start to show above the blue region in the visiblespectrum. Besides the formation of cis isomer in stilbene-containing brighteners (only thetrans isomer is optically active), continued exposure to UV-containing light will actuallycleave the molecule and start the process of degradation.Common uses

Brighteners are commonly added to laundry detergents to replace whitening agents removedduring washing and to make the clothes appear cleaner. Optical brighteners have replacedbluing which was formerly used to produce the same effect. Some brighteners can causeallergic reactions when in contact with skin, depending on the individual.

Brighteners are used in many papers, especially high brightness papers, resulting in theirstrongly fluorescent appearance under UV illumination. Paper brightness is typicallymeasured at 457nm, well within the fluorescent activity range of brighteners. Paper used forbanknotes does not contain optical brighteners, so a common method for detecting counterfeitnotes is to check for fluorescence.

A side effect of optical whitening is to make the treated fabrics more visible with NightVision Devices than non-treated ones. This may or may not be desirable for military or otherapplications. Optically brightened paper is often not useful in exacting photographic or artapplications, since the whiteness decreases with time.Endues of optical brighteners include:

- Detergent whitener (instead of blueing agents)- Paper brightening (internal or in a coating)- Fiber whitening (internal, added to polymer melts)-Textile whitening (external, added to fabric finishes)


MercerizationMercerized cotton is cotton which has been treated with sodium hydroxide to bring outcertain properties first discovered by John Mercer in 1851. In 1890, Horace Lowe added anadditional step to the process, and the British cotton industry began to take an interest inmercerized cotton, which is available today in a wide range of incarnations from thread tocompleted garments. When treated properly, mercerized cotton is stronger, smoother, andshinier than regular cotton. In addition, it takes dye more readily so that manufacturers cancreate rich color saturation in their cottons. The brilliant, lustrous hues of Mercerized cottoncan be found in fabric stores, yarn shops, and department stores all over the world.John Mercer discovered that immersing fibers such as cotton and linen in a caustic soda bathwould increase their strength and also allow them to take dye more readily. He patented hisfiber work, but the cotton industry did not express very much interest in it. It was HoraceLowe who popularized the process, by discovering that keeping the fibers under tensionwhile they were soaked yielded a more lustrous thread. Mercer's name is presumably given tothe process to recognize his important initial discovery, which paved the way to Lowe'srefinement of the treatment.Mercerization starts with gathering the cotton and spinning it normally. Because cottons withlong fibers take better to mercerization, Pima, Egyptian, and Sea Island cotton are usuallychosen for the process. The cotton thread is held under tension and submerged in a highlyalkaline bath of sodium hydroxide in a percentage which ranges, but usually hovers around22%. After treatment, the mercerized cotton is placed into an acidic bath to neutralize it.Once this process is complete, the cotton can be dyed and knitted, woven, or packed as stand-alone spools of thread.The terms "pearl cotton" and "pearle cotton" are also used to refer to Mercerized cotton,because of the deeply lustrous appearance of the finished cotton thread. In addition to havingrich color saturation and a shimmering appearance, mercerized cotton is also much strongerthan conventional cotton thread. The process shrinks the cotton fibers, tightening andsmoothing the grain of the thread. Because the cotton is preshrunk, mercerized cotton alsotends not to shrink as much as regular cotton, so consumers can be more confident about thefit of mercerized garments.

Mercerization ProcessSingle Mercerization is a process in which the yarn used to make a shirt is run through themiddle of an open flame at a very high speed. It passes through so quickly that the yarn itselfdoesn't burn but the millions of fuzzies and slubs on the yarn are eliminated instantly. Thismakes the yarn stronger. Since there is no fuzz on the yarn, it is held together better and canno longer unravel by itself. The yarn is also less prone to shrinking because the mercerizationprocess literally pre-shrinks the fabric. Mercerization also cleans the yarn and gives it astrong affinity for dye. While normal cotton yarn has no clarity or depth to it's color,Mercerized yarn accepts the dye much better and the colors come out deeper, sharper andhave a very clean look. The fabric now looks and feels ten times better. Single Mercerizationis a huge step up from the quality of regular cotton shirts but Double Mercerization takes iteven a step further. During the knitting process some fuzzies will ultimately resurface. InDouble Mercerization the knitted fabric undergoes a second Mercerization process to removethese. The fabric is placed in a chemical bath using caustic soda to once again remove anyadditional fuzzies or slubs and is then washed clean. This makes the fabric even stronger andmakes it look and feel even better. It has a luster and sheen that is unmatched. Doublemercerized fabric feels so soft and smooth its look and feel can easily be mistaken for silk.


Chemical Laboratory


Chemical Lab Layout

Way ofphysical lab& samplesection ofbleachedfabrics

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Description of the Chemical Lab Layout

Sl. No. Equipment Manufacturer1 Light box UK

2 Robo lab Greece

3 Ahiba Nuance sample Dyeing machine (5 piece) U.S. A.

4 Bath tab & Rack to keep apparatus, chemicals etc.

5 Rapid Washer /Quick Wash Plus Rapid6 Electrolux Wascator SDL

7 Soaping (AH2-Y) Locally made8 Rota wash SDL

9 Quick wash SDL10 Washing machine (Siemens) Germany

11 Rota wash M228 SDL

12 Electrolux Washing machine (especially forH&M)

UK

13 Washing M/C WASCATOR FOM 71 CLS (allbuyer)

UK

14 Washing machine Whirlpool USA15 Spectrophotometer (Data color 600) USA16 Q-SUN Xenon test chamber Bangkok

17 Lab attendant area + pipetting

18 Senior manager desk of QAD

19 Fabric inspection or approval room

20 Table for executive task21 Iron on the stand

22 & 23 Senior Executive desk


LIGHT BOX:

Brand name: VeriVideCompany name: James. H. HealOrigin: UKPurpose: Sample is examined under different lighting media.

With today’s complex color requirements, a shade cannot always be assessed under one lightsource. Several may be needed so that the shade is viewed in applicable conditions

LightSource

Name Description C.R.I

Length Watts

D65 VeriVideD65"ArtificialDaylight

VeriVide D65 “Artificial Daylight”.Correlated colour temperature 6500K. Withinthe tolerances prescribed in BS 950: Part 1;and all international specifications for D65illuminant. Specified for most applicationswhere there is a need to maintain colourconsistency and quality. Conforming highly tothe CIE specifications, for accurate colourmatching.

98 600mm1200mm1500mm

20w40w65w

F TungstenFilament

Tungsten Filament Lighting. Approximatecolour temperature of 2800K. Required by BS950: Part 1 as a test for metamerism(approximating CIE Illuminant ‘A’). Typicallight source used within domesticenvironments

100 GlobeGlobeRoundClear-284mmOpal-284

40w60w150w60w60w

A

TungstenHalogen

Tungsten Halogen Lighting (CIE Illuminant‘A’). This represents incandescent A (inc-A)with a color temperature of 2856K. Typicallight source used within domesticenvironments. Used to check for metamerism.

100 --------- 35w

840P15

Narrow Band Triphosphor FluorescentLamps. Correlated colour temperature of4000K. CIE Illuminant F11. Often chosen as

85 600mm1200mm1500mm

18w36w58w

Figure: Light box & viewed angle


SAMPLE DYEING MACHINE

Machine name: Top Speed IIBrand name: Ahiba NuanceCompany name: Data colorOrigin: America.

UsesA rotary dyeing machine yielding the highest production in the laboratory.Process: Exhaust Fibers: Synthetic, Natural, Blends Substrate: Piece, Skein, Loose Stock,Top Testing: Fastness TestingBenefits- Laboratory recipes correlate with production recipes- Uniform temperature inside each dyeing beaker- Level dyeing

a European “Point of Sale” light source, withgood colour rendering and manufactured to atighter tolerance specification as prescribed byMarks & Spencer. (Formerly TL84)

CWF CoolWhite

Cool White Broad Band Fluorescent Lamps.Correlated colour temperature of 4000K. Usedas an American “Point of Sale” light source.Moderate colour rendering.

62 600m1200mm1500mm

20w40w65/80w

830 Narrow Band Triphosphor FluorescentLamp. Correlated colour temperature 3000K.Often chosen as a European “Point of Sale”light source with good colourrendering.(Formerly TL83)

85 600mm1200mm1500mm

18w40w65/80w

UV UltraViolet

Ultra-Violet Black light. Used to detect thepresence of Optical Brightening Agents and/orFluorescent dyes. Therefore it is useful whenassessing white and Fluorescent shades tocheck the level present and its evenness.

N/A Clear-450mmBlacklight-600mm

15w18w

Figure: Sample dyeing Machine


- Unlimited program storage and easy program editing

Dyeing Positions & Beaker Size20 x 150cc beakers (Two machine)15 x 300cc beakers (Three machine)

Features- Infrared heating; Water Cooling- Easy to program controller with memory card- Precision control and constant monitoring of dyeing parameters- Programmable speed and constant movement of the dye bath and substrate- Manual auxiliary additions- Machine standard rpm is 35- Each M/C contains one sensor beakers.

ROBO LAB

Manufacturer: SclavosCountry of Origin: GreeceManufacturing Year: 2001Total Weight: 800kgStroke force: 7kwElectric consumption: 220vDimension: Length = 200 cm, Width = 170cm, Height = 200cm.Purpose: -Uniform mixing of dyes.

- Mixing up to 24 hours.- To ensure uniform solubility.- Automatic pipetting.

Features Fully automated dyestuff solution preparation. Fully automated dispensing of dyeing recipes. High dispensing accuracy +/- 0.003 g

Figure: ROBOLAB 240 (Auto dispenser)


High dyestuff solution accuracy +/- 0.0001% Fast solution preparation (4 min.) & fast recipe dispensing (2 min. with 3 ingredients) Patented gravimetric dispensing system Direct dispensing into the beaker. Compatibility with beakers of many lab machinery manufacturers.Windows operating system. Available in various languages Data transfer via floppy disk or network.Rapid washing machine Soaping is done after neutralization to remove unfixed dyes. Dyeing is also possible except polyester. Temperature: 95c (Max). Speed: 60 rpm. At a time 24 samples would be washing.

Washing Machine

Place of Origin: FinlandUsed but excellent: Year approx 2006Model Number: Wascator FOM71MP-LabBrand Name: ElectroluxStandard reference washing machine Wascator FOM71MP-Lab is manufactured byElectrolux AB, Sweden. The machine is used to determine the stability of fabrics andgarments to washing and to investigate the effects of detergents and chemicals. The machineis in very good condition and fully operational. It is robustly constructed and the drum andexternal panels are manufactured in stainless steel and are rigidly fixed to a galvanizedinternal frame. This Wascator is microprocessor controlled and accepts up to 99 programswhich can be entered or modified by the user, either manually at the keypad or electronicallyfrom a cassette. The Liquid crystal display shows up to four lines of text. The unit isprogrammed with BS, ISO, IWS and M&S test programs.

Figure: Electrolux lab washing machine


Machine physically:

Width 660 mm Depth 630 mm Height 1070 mm Weight approx 120 kgRota wash

Brand name: Rota washCompany name: SDL ATLASCountry of origin: UK

Feature Using this machine for test color fastness to wash This machine contains some jar Also contains 25 steel ball (5mm diameter)Machine running time accordingly test method used.Machine run rotationally.

Quick Wash Plus

Figure: Color fastness test machine

Figure: Quick wash machine


Machine name: Quick wash plusCompany name: SDL ATLASOrigin: UK

Features Less than 20 minute wash and dry time. 5 chamber bins handles multiple samples and weights. Handles from 1-20 samples per bin depending on fabric weight.Microprocessor controlled wash & dry sequences. Prolonged programs for AATCC & other testing method.\Table top maintaining. Electronic air & water control & display.Optional fully automatic four liquid dispensing systems.Utilize operator time more efficiently.Utilize space not taken by traditional washer & dryer more efficiently.Quality control-testing dimensional stability, spirality and finish durability.

SpecificationAccessories: Sample tongs

Fabric making templates (2)Direct reading shrinkage rulerMarker pens (yellow & black)

Sample size: 20*20 cm to 25*25 cmCycle time: 12-45 minutes, Pre-programmed cycles up to 10.Number of specimens: 1 to 20 per cycle depending on sample weight.Water temperature: up to 70CAir temperature: Up to 90CAir pressure: 2.4 to 4.8 barWater volume: 2.0 to 4.5 liter

Siemens Washing Machine


Product name: Washing MachinesBrand: SiemensOrigin: Germany

Feature

Label: A / A / CCapacity: 5 kgSpin speed: 1000/600 rpmButtons: Rinse Hold, Spin speed reduction, StartEasy-care program: 30°C, 40°C, 60°CWash optimization: Spin off, Spin speed reduction, StartMultiple water protection LED program progress indicators Aquatronic wash system Automatic load adjustment system Unbalanced load detection Foam detection system 30 cm porthole with 140 degree opening door can be built-underWhites and colored program: 30°C, 40°C, 60°C, 60°C Pre-washing, 60° Stains Intensive,

90°CWater protection system Fully electronic control dials for wash programs, temperature and special programs

Special programs: stains, pre-wash, hand-wash wool and delicates

Figure: Washing machine especially for Puma


Rota wash M228

Machine name: Rota washCompany name: SDL ATLASOrigin: UK

Feature Increased capacity is capable of holding the same amount of 550 ml or 1200 ml containers No extra hardware tools or adaptors are required for 1200 ml containers. Graphical display panel equipped with multi function controller frequency operation. Built in testing programs for various international standards including ISO. Communication part for routine updating.

The redesigned Rota wash color fastness tester offers many feature upgrades that make itmore efficient & easier for the lab technician to operate. The new graphical display &integrated controller provide an easy operating interface. All functions of the Rota wash arepreciously controlled.

Water temperature. Test duration Rate of temperature rise.Water level adjustment (Drain & Filling). Rotation of container for loading & unloading. Test method selection.

Figure: Color fastness to wash test machine


Electrolux Wascator Machine

Machine name: Electrolux WascatorCompany name: Healink James H. HealOrigin: UK

WASCATOR FOM 71 CLS

Machine name: WASCATOR FOM 71 CCompany name: Healink, James H. HealOrigin: UKCode: 310BModel: Wascator FOM 71 CLSWeight: 195 kg

DESCRIPTIONHigh precision washing machine acknowledge as a standard reference for washing tests onfabrics. WASCATOR is suitable for checking dimension stability during washing and forchecking the effects of washing detergent and chemical products on textile. Equipped with

Fig.: Garments washing machine especially for H&M

Fig.: Washing machine for all buyers


microprocessor for the control of the functioning cycle of the machine. Included are 9 pre-programmed washing cycles, programmable washing cycles are available as optional.OPTIONALScode 310 2 polyester make-weight code 310.4 ECE reference detergent code 310.8 sodiumper borate code 310.14 Stability template and percentage rule for checking dimensionalstability

Whirlpool Washing Machine

Machine name: WhirlpoolCompany name: SDL ATLASOrigin: Made in USAModal: Heavy duty series 8

SpecificationDry load capacity: 8.2 kgWeight approximate: 143 kgWater supply: Hot & ColdMinimum water pressure: 1 barMinimum water temperature: 603 C

Fig.: Fabric/Gts. Washing machine for American


Spectrophotometer

Machine name: SpectrophotometerModel: Data color 600Origin: USA

Purposes: To collect recipe from Data Color. To measure CMC difference. (Pass/Fail decision).To give staining, wash fastness, light fastness result.To know the metameric value & dye concentration.To give topping recipe.

Figure: Spectrophotometer and different parts


Specifications:

Feature DescriptionInstrument Type Dual-beam spectrophotometer

Measurement Geometry Diffuse illumination and 8° viewing

Illumination Source Pulsed xenon filtered to approximate D65

Sphere Diameter 152 mm / 6.0 in

Specular Port Automated included or excluded

Spectral Analyzer Proprietary SP2000 analyzer with dual 256 diode arrayand high resolution holographic grating

Transmittance Measurements No

Wavelength Range 360 nm to 700 nm

Reporting Interval 5 nm or 10 nm(1)

Effective Bandwidth 5 nm or 10 nm

Photometric Range 0 to 200%

Black Trap High performance

20 Read Repeatability On TheWhite Tile Using Dual Flash(CIELAB)

0.01 (max)

Inter-instrument Agreement(2) forReflectance (CIELAB)

0.15 (max) , 0.08 (avg.)

Lens 4 position auto zoom

Aperture plates for reflectionmeasurements

3 standard (LAV, SAV, USAV)

2 optional (XUSAV)

LAV 30 mm illuminated

26 mm measured

MAV 20 mm illuminated

16 mm measured

SAV 9 mm illuminated

5 mm measured

USAV 6.6 mm illuminated

2.5 mm measured

XUSAV(3) 3.0 mm illuminated

2.5 mm measured

Reflection Aperture PlateDetection

Yes

UV Calibration Yes


Automatic UV Control Automatic UV calibration for the measurement offluorescent Specimens with UV cutoff filters at 400 nm,420 nm and 460 nm

Q-Sun Xenon Test Chamber

Machine name: Q-Sun Xenon test chamberCompany name: Color Global Co. Ltd.Origin: Bangkok

Purpose:- To measure color fastness to light.- To measure color fastness to light perspiration.

Total Table Work

Buyer swatch

Work sheet open

Lab dip submission card send to buyer

Sample approved

Yes No

Production card

Re Submission


TOTAL LAB PROCEDURE

Swatch/standard/pantone number from buyer

Swatch input in spectrophotometer to get color combination

A/C to standard prepare recipe for lab dyeing with the help ofdatabase and spectrophotometer, fabrication is important issue.

Sample taken a/c to buyer requirements for dyeing

Prepare dye solution a/c to recipe with the help of electronicdigital pipette (EDP) or hand Pipetting.

Dyeing this sample according to recipe in lab dyeing machine.

After treatment is done

Drying and pressing

Shade match with the swatch/standard in the light boxaccording to the recommended light source of buyer

Comparison of sample with swatch/standard

If Pass If Fail

Prepare lab deep submissioncard for buyer approval

Color difference analysis

RecipeCorrection(Add / less)more than

one.

NO YES Production card preparedfor lab to bulk


Sample Dyeing Procedure

Recipe Calculation

Shade % × Weight of the fabric in gmDyes (gm) =

Stock solution %

Salt (gm) =

Auxiliaries & chemicals (cc/ml) =

For Caustic soda (38 Be.)

Dye line (Recipe) form lab executive

Making stock solution (1% & 0.1%) for pipetting if necessary

Add salt & soda according to shade percentage

Take sample 10 gm and emerged in the solution

Dyeing according to sample & dyes properties

After treatment is done according to dyeing method.

Drying & Ironing

Required amount (g/l) × Liquor ratio × sample weight

1000

Required amount (g/l) × Liquor ratio × sample weight1000 × concentration (%) of stock solution


Required alkali solution in (cc/ml) =

Conversion formula from percentage to g/l is asg/l = Required amount (%)× 10 .

Stock Solution Making Procedure

For solid,X gm chemicals/dyes/auxiliaries in the 100 ml water is called x% stock solution.

For liquid,X ml/cc chemicals/dyes/auxiliaries in the (100 - x ml/cc) water is called x% stock

solution.

Caustic soda: The amounts of alkali recommended for the respective procedures refer tocaustic soda 30%, 66Tw (36Be). For other concentrations, the amounts can be calculatedwith the aid of the following table: Density and conc. of caustic soda at 15C

Baume(Be)

Twaddle(Tw)

Densityg/ml

g NaOH 100%per 1 Kg

NaOH soln.

g NaOH 100% per 1Lit NaOH soln

15 23.2 1.116 103.0 114.916 25.0 1.125 110.6 124.417 26.8 1.134 119.0 134.918 28.4 1.142 126.9 145.019 30.4 1.152 135.0 155.520 32.4 1.162 143.5 166.721 34.2 1.171 151.5 177.422 36.0 1.180 160.0 188.823 38.0 1.190 169.1 201.224 40.0 1.200 178.1 213.725 42.0 1.210 187.1 226.426 44.0 1.220 196.5 239.727 46.2 1.231 206.0 253.628 48.2 1.241 215.5 267.429 50.4 1.252 225.0 281.730 52.6 1.263 235.0 296.831 54.8 1.274 244.8 311.932 57.0 1.285 255.0 327.733 59.4 1.279 265.8 344.734 61.6 1.308 276.5 361.735 64.0 1.320 288.3 380.636 66.4 1.332 300.0 399.637 69.0 1.345 312.0 419.638 71.4 1.357 325.0 441.039 74.0 1.370 337.3 462.140 76.6 1.383 350.0 484.141 79.4 1.397 363.6 507.9

Required amount (%) × wt of substrate × LR

Conversion value from Be. to g/l of alkali


42 82.0 1.410 376.5 530.943 84.8 1.424 390.6 556.244 87.6 1.438 404.7 582.045 90.6 1.453 420.2 610.646 93.6 1.468 435.8 639.847 96.6 1.483 451.6 669.748 99.6 1.498 467.3 700.049 102.8 1.514 484.1 732.950 106.0 1.530 501.0 766.5

For Light – Medium Shade (Cotton Fabric) with Cold Brand DyestuffSample Weight = 10 gmM: L = 1:8FabricationBuyer Name: XRecipe:Leva Blue CA = 0.034%Remazol yellow RGB = 0.447%Remazol Red RGB = 1.051 %Glauber Salt = 45 gm/lSoda Ash (20%) = 16 gm/lLeveling Agent = 1 g/lSequestering agent = 1 g/lCalculation:Leva Blue CA = 0.034 × 10 = 0.34 ccRemazol yellow RGB = 0.447 × 10 = 4.47 ccRemazol Red RGB = 1.051 × 10 = 10.51 ccGlauber Salt = (45 ×80)/1000 = 3.6 gmSoda Ash (20%) = (16 × 80)/ (1000×20%) = 6.4 ccSequestering agent = (1× 80)/ (1000×10%) = 0.8 ccLeveling agent = (1× 80)/ (1000×10%) = 0.8 cc

Total Required Water = [80 – (0.34 +4.47 +10.51 +6.4 +0.8+0.8)]= 56.68 cc


Dyeing Curve

.

38

Dyeing Procedure:

(1) At first, take required Dyes & leveling agent by pipetting in a beaker.

(2) Then add glauber salt into the beaker. After that we put the sample fabric into thebeaker.

(3) Then place the beaker into the sample dyeing machine and dye bath set at 38oc.

(4) Raise the temperature up to 60o c (3oc gradient or 3o/min )

(5) Run the machine for 30 minutes at 60oc.

(6) At 30oc hold the machine and dosing soda/alkali solution according to dyeline.

(7) Then run the machine 60 minutes at 60oc.(8) After that we drop the temperature of the sample dyeing machine and get the

Sample from the machine and the sample is ready for after treatment. After thatgive soaping at 85oc for 10 minutes. We soaped again at 90oc for 10 minutes. Thenwe again give cold wash.

(10)After that dried the sample and ironing it.

Tem

po C

Fig: Dyeing Curve for Light Shade

H60

Time (min)308 90

B.D

Dosing alkali/soda


After Treatment:

For Dark to Extra Dark Shade (Cotton Fabric) with Cold Brand DyestuffSample Weight = 10 gmM: L = 1:7Yarn quality: 40/1 (100% cotton)Buyer Name: X

Recipe:Levafix Blue- CA = 0.600400%Levafix Amber-CA = 0.6780%Levafix fast red-CA = 0.5650 %Glauber Salt = 45 gm/lSoda Ash (20%) = 16 gm/lLeveling Agent = 1 g/lSequestering agent = 1 g/l

Calculation:Levafix Blue- CA = 0.06004 × 10 = 6.004 ccLevafix Amber-CA = 0.6780 × 10 = 6.780 ccLevafix fast red-CA = 0.5650 × 10 = 5.650 ccGlauber Salt = (45 ×70)/1000 = 3.15 gmSoda Ash (20%) = (16 × 70)/ (1000×20%) = 5.6 cc

Unload the sample from dyeing machine

Neutralization with acetic acid (1 gm with 1 liter water for 4-5 min)

Soaping with Sandphore RSK 1g/l at 85 o C for 15 min

Soaping with Sandphore RSK 1g/l at 90 o C for 15 min.

Hot wash

Cold wash

Drying & pressing

Cold wash


Sequestering agent = (1× 70)/ (1000×10%) = 0.7 ccLeveling agent = (1×70)/ (1000×10%) = 0.7 cc

Total Required Water = [70 – (6.004 +6.780 +5.650 +5.6 +0.7+0.7)]= 44.53 cc

Dyeing Curve:

Dyeing Procedure:


(2) Then add glauber salt into the beaker. After that put the sample fabric/yarn into thebeaker.

(3) Then place the beaker into the sample dyeing machine and dye bath set at 30oc.

(4) Raise the temperature up to 60o c (3oC gradient or 3oC/min)

(5) Run the machine for 30 minutes at 60oc.

(6) After 40 min run at 60oc hold the machine and dosing soda/alkali solutionaccording to dyeline.

(7) Then run the machine 70 minutes at 60oc.(8) After that drop the temperature of the sample dyeing machine and getthe sample from the machine and the sample is ready for after treatment(9) After that give soaping at 95oc for 10 minutes. We soaped again at 90oc for 10minutes. Then again give cold wash.(10)After that dried the sample and ironing it.

Tem

po C

Fig: Dyeing Curve for light shade

H60

Time (min)4010 110

B.D

Dosing alkali/soda


After Treatment:

Dark Shade for Mercerized Yarn

Sample Weight =10 gmM: L = 1:12Yarn quality = 60/2 (100% cotton double mercerized)

Recipe:Levafix Blue CA = 0.07300 %Kimsoline red KED =1.5217 %Kimsoline yellow KED = 0.71199 %Leveling agent (Ludigol) & Sequestering agent (10%) =1 gm/lSoda Ash (20%) =12 gm/lGlauber Salt = 50gm/l

Calculation:Levafix Blue CA = 0.07300 ×10=0.735ccKimsoline red KED =1.5217 ×10=15.21ccKimsoline yellow KED = 0.71199 ×10=7.11ccLeveling agent (Ludigol 10 %) = (1×120) / (1000×10%) = 1.2 ccSequestering agent (10%) = (1×120) / (1000×10%) = 1.2 cc


Neutralization with acetic acid (1 gm with 1 lt water for 4-5 min)


Soaping with Sandphore RSK 1g/l at 90 o C for 15 min.

Hot wash

Cold wash

Drying & pressing

Cold wash


Soda Ash (20%) = (12×120) / (1000×20%) =7.2ccGlauber Salt = (50×120) / 1000 = 6 gmTotal Required Water = [120 – (0.735+15.21+7.11+1.2+1.2+7.2)]

= 87.345 cc

Dyeing Curve:

H

Working Procedure:


(2) Then add glauber salt into the beaker. After that put the sample fabric into thebeaker.

(3) Then place the beaker & Dye bath set at room temperature(30 oc)

(4) Raise the temperature at 60 oc (3 oc per minute) and run for 20 minutes.

(5) Again raise the temperature at 80 oc (2 oc per minute) and run for 20 minutes.

(6) Now temperature migration from 80 oc to 60 oc (4 oc per minute). Then hold themachine for soda dosing according to dyeline.

(7) After Soda dosing we run the machine for 65 minutes and finally drop the bathfor after treatment.

30

80

60

10 30 40 60 1250Time (min)

Tem

po C

Fig: Dyeing curve for Mercerized 100% cotton fabric or yarn

Dosing soda/alkali

B.D


(8) Now should need cold wash of the sample.

(9) Then neutralize the sample fabric by giving a wash with 1 gm CH3COOH in1litre cold water for 4-5 minutes.

(10)After that we give soaping at 90oc for 15 minutes.

(11)After that we dried the sample and ironing it.

After Treatment:

Dyeing of polyester with disperses dyes:

Dark Shade for Mercerized Yarn

Sample Weight =10 gmM: L = 1:8Fabrication = S/J (100% polyester)

Recipe:Terasil blue WBLS = 0.006 %Terasil red FBN Conc. =0.6742 %Leveling agent & Sequestering agent (10%) =1.5 gm/lAcid buffer (Cibatex AB) = 2 g/l

Calculation:Terasil blue WBLS = 0.006 x 10=0.06ccTerasil red FBN Conc. =0.6742 x10=6.74cc



Hot wash

Cold wash

Drying & pressing

Cold wash

Neutralization with acetic acid (1 gm with 1 lt water for 4-5 min)


Leveling agent (10 %) = (1.5 x 80) / (1000 x10%) = 1.2 ccSequestering agent (10%) = (1.5 x 80) / (1000 x 10%) = 1.2 ccAcid buffer (Cibatex AB 10%) = (2 x 80) / (1000 x 10%) = 1.6 cc

Total Required Water = [80 – (0.06+6.74+1.2+1.2+1.6)] = 69.2 cc

Dyeing Curve:

Working Procedure:

(1) At first, take required Dyes, leveling, sequestering, agent and acid buffer bypipetting in a beaker.

(2) Then put the sample fabric into the beaker.

(3) Then place the beaker & Dye bath set at room temperature (30 oc)

(4) Raise the temperature at 130 oc (2 oc per minute) and run for 70 minutes.

(5) Now cooling temperature at 60 oc (2 oc per minute) and drop dyeing bath for aftertreatment.

50 140120

30

130

B.D

Time (min)

Tem

po C

Fig: Dyeing curve for 100% Polyester fabric or yarn


(6) Now should need cold wash of the sample.

(7) Then need reduction clearing the sample fabric by giving a wash with caustic andHydrose in 1 g/liter for 10 minutes at 80-90 oc

(8) Again cold wash and neutralizing with acetic acid 1 g/l

(9) Cold wash after that drying and pressing

After Treatment:

Dyeing of Cotton goods with Hot brand (Turquoise) Reactive dyes

Dyeing Curve


Cold wash

Neutralize with acetic acid 1 g/l

Cold wash

Drying & pressing

Cold wash

Reduction clearing with Hydrose & Caustic (1 g/l) @ 80-90 oC for 10 min.

H

30

60

80

Tem

po C


Dyeing Procedure

1) At first, we took required Dyes, leveling& sequestering agent by pipetting in a beaker.2) Then we add glauber salt into the beaker. After that we put the sample fabric into the

beaker.3) Then place the beaker & Dye bath set at room temperature (30 oc)4) Raise the temperature at 60 oc (3 oc per minute) and run for 20 minutes.5) Again raise the temperature at 80 oc (5 oc per minute) and run for 6-8 minutes.6) Now temperature migration from 80 oc to 60 oc.7) Then hold the machine for soda dosing according to dyeline.8) After Soda dosing we run the machine for 45 at 80 oc minutes and finally drop the

bath for after treatment.9) Now we should need cold wash of the sample.10) Then we neutralize the sample fabric by giving a wash with 1 gm CH3COOH in 1 liter

cold water for 4-5 minutes.11) After that we give soaping at 95oc for 10 minutes two times.12) After that we dried the sample and ironing it.

After Treatment:


Neutralization with acetic acid (1 gm with 1 liter water for 4-5 min)

Soaping with Sandphore RSK & Ladiquiest1.5 g/l at 95 o C for 10 min

Soaping with Sandphore RSK & Ladiquiest1.5 g/l at 95 o C for 10 min.

Hot wash

Cold wash

Drying & pressing

Cold wash


Introducing with Buyer Requirements

Some buyers of square knit fabrics Ltd.

PUMA , G.STAR, H & M, S.Oliver, ESPRIT, ELCORTE, TEMA, Mexx, Strauss, ChaterHouse, Promod, M & S, Ashcity, Kitaro, Mustang, Matalan etc.

Buyer requirements receive by mail or hard copy or hand to hand. Maximum requirementsare same for all buyers but particular buyers may have exceptional requirements. Somecommon requirements are given below-

Metameric free. Shrinkage. Spirality. Color Fastness to washing. Color fastness to rubbing. Color fastness to light. Color fastness to light perspiration. (Acid/Alkali) Color fastness to perspiration. Pilling properties. Fabric strength etc.

Metal free dyes must be used for Tema kids dress (Exceptional requirements) some tests aredone as a special requirement.

Right First Time (RFT)

RFT is very much important for dyeing plant. Said that whose RFT good his production isgood. It means lab to bulk trial. When lab dip approved then it is ready for bulk production atfirst batch of bulk for one particular batch to be considered as a trial batch If trial batch isokay at first trial without addition, topping as less as time as possible then we can say RFT isgood then next batches run as follow as trial batch. But if does not match first trial batch thensecond trial is run for that some time become delay. But you have to remember it timeconsuming is very much important issue for profit as well as meet the buyer requirements andmaintain schedule delivery time as per dead. If RFT increase simultaneously dyeingproduction efficiency increases. If we can save one hour per shift then we can save 3 hoursper day that means 90 hours per month so it is huge profit if we right use this time.


Yarn Processing


The demand of dyed yarn now a days increasing for the production of export quality knit

fabrics. Yarn dyed fabrics add value to the garments and if the yarn is singed and mercerized

then quality of garments improve remarkably. The Square Knit Fabrics Ltd. specializes in

yarn dyeing both in hank form and package form. Here singeing and mercerizing of yarn is

done in modern machineries and quality of processed yarn is maintained strictly which

suffice the buyer demand. Variety of shade and yarn type has been processed for producing

sophisticated extra qualified – double mercerized fabrics.

In this report we will discuss the flow of process of yarn processing, layout, machine studies,different faults occurring at the different stages of production, recipe preparation and qualitycheck.

Flow Process Chart of Yarn Dyeing (Package Section):

Yarn receive by store from spinning mill according to buyer requirement

Grey yarn receive from yarn storage by SR (Store Requisition)

Soft winding / Precession winding on spring holder package

Batch preparation for dyeing on the basis of yarn quantity at spindle

Scouring & Bleaching

Dyeing according to Dye line

Washing & Finishing

Hydro extracting

Drying by RF dryer

Random or hard winding at paper cone

Packaging & delivery to yarn storage


Layout of Package Dyeing Section:


Description of the Layout of Package Dyeing Section:

Sl.No.

Equipment Name Sl.No.

Equipment Name

1. Sample Dryer Machine 12. BERTA T.E. Hydro extractor Machine2. SCHOLL Sample Dyeing

Machine-01113. SCHOLL Hydro extractor Machine

3. Fong’s Sample DyeingMachine-009

14. STALAM RF Dryer Machine-001

4. SCHOLL Yarn DyeingMachine-001

15. STALAM RF Dryer Machine-002


16. SSM (SCHARER SCHWEITER METTLERAG) Soft Winding Machine-001







9. SCHOLL Yarn DyeingMachine-006 & 007

20. SSM (SCHARER SCHWEITER METTLERAG) Random (Hard) Winding Machine-001

10. Fong’s Yarn DyeingMachine-008


11. Fong’s Sample DyeingMachine-010


Specification & Description of Package Dyeing Machine:Soft Winding (Precession Winding) Machine:Grey Yarn is wound on stainless steel dye springs on precession winders from SSM ofSwitzerland under controlled humidity to give uniform density package for best Dyeing. Here60 Spindles Winding Machine, each Spindle is individually motor driven clubbed with SSMPropeller Yarn Guiding System which ensures most gentle treatment of yarn material. Yarntensioning device by permanently rotating bar of disks adjustable by weights, with automaticyarn tension reduction with increase in package diameter. Thread guiding system ensuresuniform winding density and no patterning. This machine has traveling blower to suck fliesand fluff so that it does not go into soft package.


Machine Name: SCHARER SCHWEITER METTLER AG (SSM)Machine No.: 883.0109/01

883.0110/01883.0108/01883.0491/07

Type: PS6 – W/FU: 415 VI Max: 32 AF: 50 HZNo. of Spindles: 60RPM: 1000 (Max)Origin: SwitzerlandCapacity: 60 Packages.

Various Parts of Soft Winding Machine:

01) Push button or lock using package in or out.02) Opening bar using for package out from spindle.03) Tube holder- Spring tube.04) Support roller.05) Yarn bar.06) In flyer use for proper wind of the yarn on the package.07) Sensor yarn bar.08) Yarn clear guide.09) Tension bar (guide + spring).10) Feeder.11) Finger.12) Anti-balloon.13) Anti-balloon yarn bar.14) Package holder15) Motor16) Overhead blower17) Auto splicer.18) Locking device.

Check Points:

o Clean over head blower.o Water level in splicer.o Clean the yarn cleaner.

Factors Considered / Controlling Parameters in Soft Winding:

Winding on tension of the machine should be optimum and constant though the different

heads of the machine.

Length of packages should be constant.

Package density should be optimum and constant.

Twist of yarn should be constant


Yarn count mixing or lot mixing should be avoided.

All cones should be wound to a definite length of yarn.

Parameters of Soft Winding Machine:

Yarn Count Speed (m/min) Tension Length(meter)

Feeder

Initial Final24/1 1000 45% 35% 46000 18%26/1 1000 45% 35% 49000 18%30/1 1000 45% 35% 58000 18%34/1 1000 40% 30% 66000 18%40/1 1000 35% 25% 77000 18%20/2 1000 55% 45% 19000 18%40/2 1000 45% 35% 39000 18%

58/2 (mercerized) 900 50% 40% 52500 18%60/2 (mercerized) 900 50% 40% 54000 18%100/2 (mercerized) 800 35% 25% 103000 18%

Length Calculation in Package:

To maintain the constant package density same length of yarn should be wound to all the

packages of a batch or lot. The dyeing machine capacity is calculated on weight, so it is

necessary to maintain the uniform weight throughout the packages. To do this for a definite

count of yarn following calculation is followed,

Count (Ne) =)()()()(

WWeightlunitLengthwunitWeightLLength

L =w

WlNe =6.453

840 WNe yds. =1006.453

54.236840

WNe meter

= Ne × W in Kg × 1.693 m.

In this machine length is pre selected. For different count of yarn different length of yarn is

pre selected. This is due to maintain the constant package weight and package density.

Production Calculation:

Production =

= ………X……… Kg/day.

Production = Count (Ne) x Weight (lb)

M/c rpm x No. of m/c x No. of head x Eff. x 60 x 8 x 3 x 1.0936 x 0.453

Yarn count (Ne) x 840


= Count (Ne) x Weight (lb) x 2.2046 x 840= Count (Ne) x Weight (lb) x 2.2046 x 840 x 0.914 (yard to meter)

== ………X…….. m/min=……… X…… m/min x 60 x 8 x 3 x No. of head x No. of M/c x Eff.= ………X……..m/day.

Batching:

Machine name: TelemechaniqueType: XCK-JModel: ZCK-EOOrigin: France

This is the second step of yarn processing, done by a pneumatic pressure unit. The soft

wound packages of similar count are batched in a package carrier. The no of packages that

will process is defined by the machine manufacturer for a definite machine with a definite

carrier. The recommended no of package for carrier is as below:

Type of Carrier No. of Packages in each Carrier Standard Height

Full carrier 11 1524 mm

Middle Carrier 8 1108 mm

Half carrier 5 700 mm

Count (Ne) x Weight (lb) x 2.2046 x 840 x 0.914 (yard to meter)M/c speed (rpm)


It should be mentioned that length of 11 packages is not 1524 mm yet. First 11 packages are

creel in the spindle then pneumatic pressure is applied from up above the spindle. When 1524

mm reached then a screwed cover is screwed on the top of the spindle. The reason to press

the soft wound package is to make uniform density of the packages by pressing all alone. The

ratio of compression is recommended by the machine manufacturer.

Note: Squeeze packages up to 13% from relax condition (It is depend upon dye bath depth).Exceptional only Fong’s bulk dyeing machine which contains 14 packages in each carrier andonly full carrier is used.

Package Density Calculation:Formula

Total diameter of package = D1Diameter of spring = D2Diameter of the package = D (D1 – D2)Height of the package = HWeight of the total package = W1Weight of the spring = W2Weight of the package (W) = (W1-W2)

We know,

Package density () = Package weight / Package volume

And volume of cylinder, V = π r2 H= π (D/2)2 H

So package volume (V) = π (D1/2)2 H - π (D2/2)2 H= π /4 x H {(D1)2

– (D2)2}=…X… cm3

Now package density () =

=..........X……gm/cm3

= …….X……gm/cm3 x 1000

=……..X…….gm/dm3.

π /4 x H {(D1)2– (D2)2}

W (gm)

H

D1

D2


Density Calculation for Several Counts:1**Before PressingYarn Quality: 30/1 ccPackage Height (H) = 162mm = 16.2cmTotal Package Dia (D1) = 162mm = 16.2cmTotal Package Weight (W1) = 1.38kg = 1380gmSpring Weight (W2) = 0.185kg = 185gmSpring Dia (D2) = 65 mm = 6.5cm

Now Package density () =

= 426 gm/dm3

2**After PressingYarn Quality: 30/1 ccPackage Height (H) = 145mm = 14.5cmTotal Package Dia (D1) = 165mm = 16.5cmTotal Package Weight (W1) = 1.38kg = 1380gmSpring Weight (W2) = 0.185kg = 185gmSpring Dia (D2) = 65 mm = 6.5cm

Now package density () =

= 456 gm/dm3

**So we can sure that after pressing for every count, yarn package density will be increase.

Causes of Variation of Package Density:

Package density may vary due to the following reason:

Head to head tension variation

High yarn irregularity

Differing yarn length among packages

Stoppage of head due to end breakage

Mechanical problem in flyer, tensioner, sensor etc

1.195 x 4π x (16.22 – 6.52) x 16.2

1.195 x 4

π x (16.52 – 6.52) x 14.5


Sample Dyeing Machines:

1. Machine Name : SchollManufacturer : Switzerland AG, CH: 5745, Safenwill.Capacity : 2.5 kgSpindle no : 1Package : 2Temperature : 140oCPressure : 3-4 Bar

2. Machine Name : Fong’sManufacturer : Fongs national EngineeringSerial no : 29015894Capacity : 14 kgSpindle no : 2Package : 14Design Temperature : 140oCDesign Pressure: 660 Kpa

3. Machine Name: Fong’sManufacturer : Fongs national EngineeringMachine no : LABWIN -12Serial no : 32022483Capacity : 12 kgSpindle no : 2Package : 12Design Temperature : 170oCDesign Pressure: 700 Kpa


Bulk Dyeing Machines:

1. Machine Name: SchollManufacturer: Switzerland AG, CH: 5745, Safenwill.Capacity : 50 kgSpindle No. : 4 [1 Spindle = 11 Packages]Temperature : 140OCPressure : 3-4 Bar

2 Machine Name: SchollManufacturer: Switzerland AG, CH: 5745, Safenwill.Capacity : 100 kgSpindle No. : 7Temperature : 140OCPressure : 3-4 Bar

3. Machine Name: SchollManufacturer: Switzerland AG, CH: 5745, Safenwill.Capacity : 100 kgSpindle No. : 7Temperature : 140OCPressure : 3-4 Bar

4. Machine Name: SchollManufacturer: Switzerland AG, CH: 5745, Safenwill.Capacity : 200 kgSpindle No. : 15Temperature : 140OCPressure : 3-4 Bar

5. Machine Name: Scholl


Manufacturer: Switzerland AG, CH: 5745, Safenwill.Capacity : 200 kgSpindle No. : 15Temperature : 140OCPressure : 3-4 Bar

6. Machine Name : SchollManufacturer : Switzerland AG, CH: 5745, Safenwill.Capacity : 300 kgSpindle No. : 23Temperature : 140OCPressure : 3-4 Bar

7. Machine Name : SchollManufacturer : Switzerland AG, CH: 5745, Safenwill.Capacity : 400 kgSpindle No. : 32Temperature : 140OCPressure : 3-4 Bar

8. Machine Name : FongsManufacturer : Fongs National EngineeringMachine No. : FCT ILSerial no : 612091-1Capacity : 520 kgSpindle No. : 32Temperature : 140OCDesign Pressure: N/A


DYE LINE YARN PROCESSING UNIT

Clients Name TEMA Lot No. 46 Work order no SFL-1531Yarn quality 26/1 cc Shade Pink Y/P No. 04Batch No. 4979/09 Total liquor(Lt.) 525 Recipe No. 9y366211Batch Wt. 48.0 No. of package 48 Dyeing prog. No. 3500Plan date 02-Nov-09 Shift B M/C No. YP-DY-02

Auxilaliary name Amount (g/l) Amount (%) Total amount (Kg) AdditionMachine washHydrose 0.00 0.000Caustic soda 0.00 0.000NeutralizationAcetic acid 0.00 0.000DemineralizationKSN NOF 0.50 0.263 60C – 10 MINOptavon 4UD 1.00 0525BleachingKSN NOF 1.00 0.525Optavon 4UD 0.50 0.263Caustic soda 2.50 1.313Hydrogen peroxide 3.00 1.575Stabilizer SOF 0.00 0.000Albaflow jet 0.50 0.263Hot wash (without chemical)

80C- 20 min.Neutralization (Bleaching)Acetic acid 1.00 0.525 50C – 20 MINHot wash (with chemical)Bio kill 0.22 0.116 Check PH

45C- 20 min.Dyeing (Dyes & Chemicals)Leva red CA 0.3729 179 gmLeva fast red CA 0.00035 0.17 gmG. Salt 16.00 8400Soda Ash 6.40 3360Caustic Soda (India) 0.000 0.000Irgasol Co NEW 1.50 0.788Kappaquest A-41 1.00 0.525Albaflow Jet 0.50 0.263 Std. PH= 10.0-11.0Neutralization (Dyeing)Sirrix NE 0.50 0.263Soaping 1Cyclanon XCW 0.50 0.263Kappaquest A-41 0.50 0.263Soaping 2Cyclanon XCW 0.00 0.000Kappaquest A-41 0.00 0.000FinishingKatamine BW 2.00 2.00 0.960Tinofix FRD 0.00 0.000Unisil NBI 0.00 0.000Acetic acid 0.10 0.053 Std. PH= 4.5-5.0

Dye weight by Machine loading time 11.40Cost per Kg Machine unloading time 23.30

Dye line for Light-Medium Shade


Process Flow Chart Dyeing (Package Section)

For Light Shade (Cellulosic Fiber)

Hot wash (8020)

Bleaching (10020)

Neutralization (5020)

Peroxide killing (4520)


Hot wash (5010)

Dyeing (6045)

Soaping (8520)

Hot wash (7010)

Finishing (4520)

Machine wash (10020)

Demineralization (6010)

Machine neutralization (6015)

Running 10 minutes withauxiliaries & chemicals thendyestuff dosing (linear) 6020& run 20 after that Soda dosing(progressive-3) 6045 & run45 also need check PH of thedye bath it should maintain(10.0 to 11.0)

Dosing 10 & run 20 @ 45 Calso check PH & maintainstandard level (4.5 to 5.0)

Check PH (6.0 to 7.0)

Caustic add at 70C

Dyeing sample

Soaping sample

Finishing sample

If shade match then

Unload


For Medium Shade (Cellulosic Fiber)

Hot wash (8020)

Bleaching (10020)




Hot wash (5010)

Dyeing (6045)

Soaping 1 (9015)

Hot wash (7010)

Soaping 2 (8510)


Running 10 minutes with Dyes,auxiliaries & chemicals 6020than Soda dosing (progressive-3)6045 & run 45 also needcheck PH of the dye bath itshould maintain (10.0 to 11.0)



Caustic add at 70C

Dyeing sample

Soaping sample

Finishing sample

Hot wash (6010)

Finishing (4520)

If shade match then

Unload


For Dark-Extra Dark Shade (Cellulosic Fiber)

Hot wash (8020)

Bleaching (10020)




Hot wash (5010)

Dyeing (6045)

Soaping 1 (9515)

Hot wash (8010)

Soaping 2 (9010)


Running 10 minutes with Dyes,auxiliaries & chemicals 6020than Soda dosing (progressive-3)6045 & run 45 also needcheck PH of the dye bath itshould maintain (10.0 to 11.0)



Caustic add at 70C

Dyeing sample

Finishing sample Finishing (4520)

If shade match then

Unload

Hot wash (7010)

Hot wash (6010)


For White Shade of Cellulosic Fiber

Hot wash (8020)

Bleaching & Dyeing (12020)


Hot wash (9015)





Sample taken

Finishing (4520)

If shade match then

Unload

Drain @ 60 C


For Black Shade (Cellulosic Fiber)

Hot wash (8020)

Rinsing (3010)

Rinsing (3010)

Dyeing (6045)

Neutral (5020) withSodium acetate

Soaping (9520)

Rinsing (3010)


Running 20 minutes with Dyes,auxiliaries & chemicals 6020than alkali dosing (progressive-3) 6045 & run 45 also needcheck PH of the dye bath itshould maintain (10.0 to 11.0)



If shade match then

Unload

Wash with NaCl (3010)

Rinsing (3010)

Soaping (9520)

Rinsing (3010)Soaping sample

Dyeing sample


For Light-Medium Shade (Mercerized Cellulosic Fiber)

Hot wash (8020)

Bleaching (10020)




Hot wash (5010)

Dyeing (6045)

Soaping (8520)

Hot wash (7010)

Finishing (4520)




Running 10 minutes withauxiliaries & chemicals thendyestuff dosing (linear) 6020& raise temperature at 80 andrun 20 min after that migration at60 & soda dosing (progressive-3) 6045 & run 45 also needcheck PH of the dye bath it shouldmaintain (10.0 to 11.0)



Caustic add at 70C

Dyeing sample

Soaping sample

Finishing sample

If shade match then

Unload


For Dark-Extra Dark Shade (Mercerized Cellulosic Fiber)

Hot wash (8020)

Bleaching (10020)




Hot wash (5010)

Dyeing (6045)

Soaping 1 (9515)

Hot wash (8010)

Soaping 2 (9010)


Running 10 minutes with Dyes,auxiliaries & chemicals at 60 thenraise temperature at 80 then runfor 20 minutes after that migrationat 60 & Soda dosing (progressive-3) 6045 & run 45 also needcheck PH of the dye bath it shouldmaintain (10.0 to 11.0)



Caustic add at 70C

Dyeing sample


If shade match then

Unload

Hot wash (7010)

Hot wash (6010)


CVC/PC Dyeing Flow Chart

** In CVC/PC dyeing after bleaching process at first need to dyeing polyester part at hightemperature & pressure then cotton part dyeing. It is known as double part dyeing or doubledyeing.

Hot wash (8020)

Bleaching (10020)



Drain

Cooling at 90C

Dyeing Polyester part (13045) for dark shade & 30 for light shade

If light shade then hot wash (8015) without chemical & rinse for 10 minutes

If dark shed need reduction clearing with Hydrose & Caustic (8020)

Neutral by Acid (5015)



Check PH (4.5-5.0)

Caustic add at 70C

If shade match then

Unload



Hydro Extractor

01.Machine name: Frauchiger TechnikA member of SCHOLL groupMan. Country: SwitzerlandYear of Manufacture: 2001Spindle: 8RPM: 3500Package frame (1-10 rpm most greaterthen 5 time 5minutes)

02.DETTIN S.P.A SCHIO ITLAYCENTRIFUGA BERTA 24VELOCITA ROTAZ Max 1500 giri/minCarico Max 60 kgOrigin: ItalyRPM: 1700 (but run at1500)No. of package each basket: 16No. of basket: 4 (Spare 2 & active 2)Time: Around 5 minutes

Function:To remove excess water from package after yarn dyeing by centrifugal force.

Calculation for water extraction by Hydro extractor:

For 40/1 Cotton CountWeight of the package before hydro = 2.385 kgWeight of the package after hydro = 1.60 kgWater released = (2.385 – 1.60) Kg

= 0.78 Kg

Water released at percentage =

= 32.778 %

For 30/1 Cotton CountWeight of the package before hydro = 2.55 kgWeight of the package after hydro = 1.60 kgWater released = (2.55 – 1.60) Kg

= 0.95 Kg

Water released at percentage =

0.78 100

2.38

0.95 100

2.55


= 37.254 %RF Dryer:

STALAM 36055NOVY ITALYVIA Dell Olmo 7 (Zona Industriale)Voltage – 400 VCurrent – 220 AInstall Power – 140 KWFASI PHASES – 3Frequency – 50 HzNormally Rated Power – 85 KWNormal CEN ELEC EN 6024-1 CEI – 44-5IEC 204-1 According to Std.No. of package per meter: 36 (New) & 32 (Old)Function:To dry-up the yarn package after de watering process.

Technical Data of R.F Dryer

Parameter Old Dryer New DryerSupply voltage 400V 400V

Phases 3 3Maximum power 85KW 85KW

Thermal protection 250A 250AMagnetic protection 2300A 2400AShort circuit current 65KA 100KA

Belt width 1750 mm 1780mmBelt length 18100 mm 18250 mm

New Dryer Speed for various Shed & Count

Yarn Count Shade Speed (m/min.)26/1,16/1,24/1,30/1,40/1

(100% cotton)Dark 7.5-8

Medium 6.5-6.8Light 5.4-5.5Black 8-8.5white 5.6

60/2, 58/2 mercerizedyarn

Dark 5.6Medium 5.4

Light 5.0Black 5.8white 4.2-4.8

CVC/PC yarn Dark 7.8-8medium 6.6-7

Light 5.6-5.8Black 8.6white 5.8


100/2 singeing 100%cotton yarn

Dark & black 6-6.2Medium, light & white 5.6-5.8

Hard Winding/Random Winding

1.SCHARER SCHWEITER METTLER AG (SSM)Type: CW1 – WU: 415 VI Max: 40 AF: 50 HZNo. of Spindles: 108RPM: 1000 (Max)

2.SCHARER SCHWEITER METTLER AG (SSM)Type: CW1 – WU: 415 VI Max: 40 AF: 50 HZNo. of Spindles: 108RPM: 1000 (Max)

3.SCHARER SCHWEITER METTLER AG (SSM)M/C No. : 863.0033/07Type: CW2 – WU: 400 VI Max: 28 AF: 50 HZNo. of Spindles: 96RPM: 1000 (Max)

Function:To wind the yarn on the paper cone (from spring to cone) after drying.

Various Parts of the Hard Winding Machine:

01) Drum02) Spindle03) Handle of spindle04) Sensor05) Wax motor & wax device06) Tensioned box07) Antiballon08) Motor09) Overhead cleaner (blower)10) Auto splicer11) Package holder12) Yarn guide etc.


Various Speed of Random Winding

Yarn count Shade Speed (rpm)All White 500

New machine All count & shade 80040/1,60/2,100/2 Any 500

30/1,34/1,24/1,16/1,26/1,20/1 Any shed 600

Production Calculation of Hard Winding Machine:

Production =

= ………X……… Kg/day.

Hank Dyeing Section

Flow Chart of Hank Dyeing

M/c rpm No. of m/c No. of spindle Eff. 60 8 3 1.0936 * 0.453

Yarn count (Ne) 840

Doubling or Twisting

Singeing

Reeling

Mercerizing

Dyeing

Drying

Hank to cone

Delivery to yarn store


Yarn Dyeing (Hank Section) Layout

12 3 4

5

16

15 T

6

7

8

910

11

12

13

14

T

Exit & Entrance

Exit & Entrance

Exit & Entrance

Finishingfloor

Washing room

Yarn & ChemicalStore


Description of the Yarn Processing (Hank section) Floor Layout

Serial No. Equipment Name

1 Sample dyeing machine by LORIS BELLINI (5 kg)Liquor required = 90 Liter.

2 & 3 Bulk Dyeing m/c by LORIS BELLINI (250 kg)Liquor required = 90 Liter.

4 Bulk Dyeing m/c by LORIS BELLINI (500 kg)Liquor required = 90 Liter.

5 Dryer by ALEA, Italy.

6,7 & 8 Hank to cone machine by SSM, Switzerland.

9 & 10 Yarn/Gas singeing machine by SSM, Switzerland.

11, 12 , 13 & 14 Reeling machine by ZERBO, Italy.

15 Panel board of yarn mercerizing machine.

16 Yarn Mercerizing machine byJAEGGLI-MCCANOTESSILE, Italia.

T Supervisor table.


Yarn Singeing Machine

Machine name: SSMManufacturer: Scharer Schweiter Mettler.Origin: SwitzerlandType: COMBIW.GSXMachine No. 877.0130/01&02I (max): 40AF: 50 HzU: 415VMade in EUEngineered in Switzerland

Various parts of singeing machine

01) Package holder cone form02) Handle of spindle03) Drum or roller04) Roller or drum plate05) Yarn guide06) Gas burner07) Feed Package holder08) Overhead cleaner09) Every m/c contains 40 package10) Each package weight is 2.5 kg11) Spindle plate (Tension box + sensor + yarn guide)

Machine Parameter

Yarn quality Speed (rpm)58/2, 60/2 100040/2, 20/2, 30/2, 24/1 850-900Air pressure 15 barGas pressure 17 bar

Production Calculation of Yarn singeing machine:

Production =

= ..X… Kg/day.

Length = Count * Weight= Count * Weight * 840 yards= (Count * Weight * 840) / rpm yards per minute= (Count * Weight * 840) / rpm * 60 * 8 * 3 yards per day= (Count * Weight * 840) / rpm * 60 * 8 * 3 * 0.914=……X…meter/day.

M/c rpm × No. of m/c ×No. of head ×Eff. ×60 × 8 × 3 × 1.0936 ×2

Yarn count (Ne) × 840 ×2.2046


Reeling Machine

Machine name: ZERBO O.M.P. BODEGAManufacturer: AspatriceM/c No.: 5522, 5523, 5524, &5525Year: 2001Origin: Italy

Machine Parameter01) No of m/c: 402) No. of creel: 16 (2 set for one head)03) No. of stand (3 set for one head)04) Yarn support roller/stick05) Spindle/arm with yarn guide06) Roller (movable by motor)07) Circumference of the roller:137cm08) Hank weight: 750 gm09) Sensor (Each head contains one sensor)

Production Calculation of reeling machine:

= ..X… Kg/day.

Yarn Mercerizing Machine

Machine name: Jaeggli-MeccanotessileManufacturer: COMO-ItaliaMachine type: HD-2000 / HL-2000Serial no.: 0008/021Years of manufacture: 2001

Machine Parameter01) Eco block: cooling caustic (17.5 to 19.5)C02) Hydraulic pump: up& down cylinder,

Cover & roller03) Panel board: CPU04) Rill holding roller05) Inside of Caustic, dia of roller: 136.5cm06) First wash & second wash,dia of roller:141cm07) Squeezing/pressure roller(Rubber coated)08) Capacity: at a time 10.5 kg09) Concentration of caustic: 30.0 – 30.5 baume10) Mercerizing oil mixing 90ml/doff (Invadin MR)11) Caustic recycling.12) Yarn 3.5 minutes run in caustic solution at (17.5-19.5)C13) Hot wash at 80C for 40-45 seconds.14) Second hot wash at 60C for 1.15-1.30 minute.

M/c rpm × Circumference of swift (d) × No. of m/c × no. of head × Eff. × 24 ×60× 1.0936*2Yarn count (Ne) × 840 × 2.2046 × 0.9136

Production =


15) Normal washes 50-60 seconds.16) Total process needs 6 to 7 minutes.

Flowchart of Hank Mercerization Process:

Feed the hank

Caustic impregnation for 3 min 45 sec(With no stretch)

Hot wash at 80ºC for 60 sec

(With stretch)

Hot wash at 60ºC for 45 sec(With stretch)

Cold wash for 60 sec

(With stretch)

Pull up

Dyeing Machine

Machine Name: Loris BelliniMade in ItalyHighest temperature: 110C

Machine Parameter

One Sample dyeing machine (capacity 5kg) liquor required 90 liter. Three bulk dyeing machine. Two machines (capacity 250 kg full & half 100kg) required liquor for full 2400 & half

1200 liter. One bulk dyeing machine (capacity 500 kg) required liquor 4800 liter Liquor circulate front to back side 3 min. & back side to front side 3 minute. No. of spindle required for full carrier 92 (23×2×2)Machine no.3 contains two full carrier chambers.Machine no. 1&2 used for half carrier dyeing but 3 is not used.


Flow Chart for Hank Dyeing Process

For Light Shade (100% Cotton) With Moderate Brand Reactive Dyes.

Bleaching (10020)


Hot wash (8020)


Hot wash (6010)

Dyeing (6040)

Bio kill (4520)

Hot wash (7010)

Dye bath neutral (5020)

Soaping (8018)



Hot wash for mercerized cotton (6020)

At first chemicals inject & run(6012) then color dosinglinearly (6040) & run(6020) now salt dosing(6025) & run (6012)Migration temperature at (60 to80C) @ 1.5 gradient. Run(8030) & cooling @ 60, run10 & finally soda dosing(6045) check PH (10.0-11.0) &run for (6040), take dye bathsample



Dyeing sample

Soaping sampleFinishing sample

Hot wash (7010)

Hot wash (6010)

Finishing (4520)

If shade match then

Unload


For Medium Shade (100% Cotton) with Moderate Brand Reactive Dyes.

Bleaching (10020)


Hot wash (8020)


Hot wash (6010)

Dyeing (6040)

Bio kill (4520)

Hot wash (7010)


Soaping (9020)




At first chemicals inject & run(6012) then salt transfer runfor (6010). Now color dosinglinearly (6030) & run(6012). Migration temperatureat (60 to 80C) @ 1.5 gradient.Run (8020) & cooling @ 60at2 gradient, & finally soda dosing(6045) check PH (10.0-11.0)and run for (6040), take dyebath sample

With acetic acid run 6 min @ roomtemperature. Then Katamine dosing10 min. & run 10 minute @ 45C &transfer Tinofix FRD & run 10@45 C also check PH & maintainstandard level (5.0 to 5.0)


Dyeing sample


Hot wash (7010)

Hot wash (6010)

Finishing (4520)

If shade match then

Unload

Hot wash (8010)


For Dark Shade (100% Cotton) with Moderate Brand Reactive Dyes.

Bleaching (10020)


Hot wash (8020)


Hot wash (6010)

Dyeing (6040)

Bio kill (4520)

Hot wash (7010)


Soaping (7020)




At first chemicals inject & run(6012) then salt transfer runfor (6010). Now color dosinglinearly (6030) & run(6012). Migration temperatureat (60 to 80C) @ 1.5 gradient.Run (8020) & cooling @ 60at2 gradient, & finally soda dosing(6045) check PH (10.0-11.0)and run for (6040), take dyebath sample



Dyeing sample

Soaping sample

Finishing sample

Hot wash (7010)

Hot wash (6010)

Finishing (4520)

If shade match then

Unload

Hot wash (8010)

Hot wash (7010)

Hot wash (6010)

Hot wash (8010)

Soaping (9020)


For Light Shade (100% Cotton) with Hot (Turquoise) Brand Reactive dyes.

Bleaching (10020)


Hot wash (8020)


Hot wash (6010)

Dyeing (8060)

Bio kill (4520)

Hot wash (7010)


Soaping (8018)




At first chemicals inject & run(6012) then color dosinglinearly (6040) & run(6020) now salt dosing(6025) & run (6012)Migration temperature at (60 to80C) 1.5 gradient. Run (8030)& cooling @ 60, run 10 &finally soda dosing (6045)check PH (10.0-11.0) & againraise temperature & 80C (2gradient) run for (8060), &cooling at 60C to take dye bathsample



Dyeing sample


Hot wash (7010)

Hot wash (6010)

Finishing (4520)

If shade match then

Unload


For Medium Shade (100% Cotton) with Hot (Turquoise) Brand Reactive dyes.

Bleaching (10020)


Hot wash (8020)


Hot wash (6010)

Dyeing (8060)

Bio kill (4520)

Hot wash (7010)


Soaping (9020)






Dyeing sample


Hot wash (7010)

Hot wash (6010)

Finishing (4520)

If shade match then

Unload

Hot wash (8010)



Dark Shade (100% Cotton) with Moderate Brand Reactive dyes.

Bleaching (10020)


Hot wash (8020)


Hot wash (6010)

Dyeing (8060)

Bio kill (4520)

Hot wash (7010)


Soaping (7020)






Dyeing sample

Soaping sample

Finishing sample

Hot wash (7010)

Hot wash (6010)

Finishing (4520)

If shade match then

Unload

Hot wash (8010)

Hot wash (7010)

Hot wash (6010)

Hot wash (8010)

Soaping (9020)



Dryer Machine

Machine name: ALEAManufacturer: Cinsello (Milano)Origin: Italy

Machine Parameter

01) 23 sticks at a time dry.02) No. of Chamber:203) M/C speed 11.9 mm/min.03) Belt speed (100 mm/min.)04) Heat produce by steam.05) Machine speed (11.9 mm/min.)06) Blower fan use for heat control.07) Padder use for dewatering.08) 1.20 hour required to complete 23 sticks at 100 mm/min.09) Temperature of first chamber (Hydro extraction) 135C & second chamber (Drying)

130C for dark shade.10) Temperature of first chamber (Hydro extraction) 130C & second chamber (Drying)

125C for light-medium shade.11) Revolving zone (stick alter surface of the yarn).

Hank to Cone Winding Machine

Machine name: SSMManufacturer: Scharer Schweiter Mettler AGOrigin: SwitzerlandMade in EUEngineered in Switzerland

Various Parts of hank to cone winding machine

01) Drum.02) Yarn guide from roller.03) Support roller.04) Tensioner.05) Sensor06) Waxing device.07) Spindle (package holder)08) Yarn guide.09) Roller surface contact.10) Reel drum.11) Spindle drum.12) No. of head: 6013) Package weight: 750 gm.14) No. of machine: 03


Machine Parameter

Yarn quality Speed (rpm)

58/2, 60/2 450

All single count 500 to 550

Production Calculation of hank to cone winding machine:

Production =

= ..X… Kg/day.

Length = Count Weight= Count * Weight 840 yards= (Count Weight 840) / rpm yards per minute= (Count Weight 840) / rpm 60 8 3 yards per day= (Count Weight 840) / rpm 60 8 3 0.914=……X…meter/day.

Packaging Section:

Flow chart

M/c rpm No. of m/c No. of head Eff. 60 8 3 1.0936 2

Yarn count (Ne) 840 2.2046

Making package or guide with 60 packs(If package weight 750 gm)

Making package or guide with 40 packs(If package weight 1.1 kg)

Package rapping with poly bag

Add sticker in side the hole of cone

Sticker contain Buyer name, yarn quality, Batchno. etc


Knitting


Layout of Flat Bed Knitting Section:


Machine Specification (Flat Bed Knitting Section):

Machine No. 001 & 004

Machine Type Jacquard

Country of Origin Japan

Brand Name SHIMA SEIKI

No. of Needle 1120 X 2

Gauge 14

No. of Feeder 6

Machine No. 002, 003, 005, 006, 015, 016,

017, 018, & 019

Machine Type Semi Jacquard

Country of Origin Japan

Brand Name SHIMA SEIKI


Gauge 14

No. of Feeder 4

Machine No. 007 to 014

Machine Type Semi Jacquard

Country of Origin Germany

Brand Name STOLL


Gauge 14

No. of Feeder 6


Layout of Circular Knitting Section:


Machine Specification (Circular Knitting Section):

Machine No. 02

Machine Type Single Jersey


Brand Name Mayer & Cie

No. of Needle 2268

Gauge 24E

Cylinder Diameter 30 inch

No. of Feeder 96

Pitch 1.06 mm

Machine No. 04




No. of Needle 2112

Gauge 24E


No. of Feeder 90

Pitch 1.06 mm

Machine No. 06

Machine Type Fleece Fabric

Country of Origin Taiwan

Brand Name PAI LUNG

No. of Needle 2256

Gauge 24E


No. of Feeder 90

Machine No. 01




No. of Needle 2268

Gauge 24E


No. of Feeder 96

Pitch 1.06 mm

Machine No. 03




No. of Needle 2268

Gauge 24E


No. of Feeder 96

Pitch 1.06 mm

Machine No. 05



Brand Name PAI LUNG

No. of Needle 2256

Gauge 24E


No. of Feeder 90


Machine No. 08

Machine Type Engineered Stripe



No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 10




No. of Needle 2712

Gauge 24E


No. of Feeder 144

Pitch 1.06 mm

Machine No. 12




No. of Needle 2268

Gauge 24E


No. of Feeder 120

Pitch 1.06 mm

Machine No. 07



Brand Name PAI LUNG

No. of Needle 2256

Gauge 24E


No. of Feeder 90

Machine No. 09




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 11




No. of Needle 2712

Gauge 24E


No. of Feeder 144

Pitch 1.06 mm


Machine No. 14




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 16




No. of Needle 2208

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 18




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 13




No. of Needle 1944

Gauge 24E


No. of Feeder 84

Pitch 1.06 mm

Machine No. 15




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 17




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm


Machine No. 20




No. of Needle 2088

Gauge 22E


No. of Feeder 72

Pitch 1.15 mm

Machine No. 22




No. of Needle 1944

Gauge 24E


No. of Feeder 84

Pitch 1.06 mm

Machine No. 24




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 19




No. of Needle 2268

Gauge 24E


No. of Feeder 96

Pitch 1.06 mm

Machine No. 21




No. of Needle 2088

Gauge 22E


No. of Feeder 72

Pitch 1.15 mm

Machine No. 23




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm


Machine No. 26




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 28




No. of Needle 2712

Gauge 24E


No. of Feeder 144

Pitch 1.06 mm

Machine No. 30

Machine Type Interlock




Gauge 20E


No. of Feeder 96

Pitch 1.27 mm

Machine No. 25

Machine Type Engineered Jacquard



No. of Needle 2208

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 27




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 29




No. of Needle 2712

Gauge 24E


No. of Feeder 144

Pitch 1.06 mm


Machine No. 32




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 34




No. of Needle 2544

Gauge 24E


No. of Feeder 54

Pitch 1.06 mm

Machine No. 36





Gauge 20E


No. of Feeder 96

Pitch 1.27 mm

Machine No. 31




No. of Needle 2088

Gauge 22E


No. of Feeder 72

Pitch 1.15 mm

Machine No. 33




No. of Needle 2376

Gauge 22E


No. of Feeder 54

Pitch 1.15 mm

Machine No. 35

Machine Type Rib Fabric




Gauge 18E


No. of Feeder 74

Pitch 1.41 mm


Machine No. 38




No. of Needle 2376

Gauge 22E


No. of Feeder 54

Pitch 1.15 mm

Machine No. 40





Gauge 18E


No. of Feeder 74

Pitch 1.41 mm

Machine No. 42





Gauge 16E


No. of Feeder 63

Pitch 1.59 mm

Machine No. 37




No. of Needle 2268

Gauge 24E


No. of Feeder 48

Pitch 1.06 mm

Machine No. 39




No. of Needle 2544

Gauge 24E


No. of Feeder 54

Pitch 1.06 mm

Machine No. 41





Gauge 20E


No. of Feeder 96

Pitch 1.27 mm


Machine No. 44





Gauge 18E


No. of Feeder 70

Pitch 1.41 mm

Machine No. 46





Gauge 18E


No. of Feeder 62

Pitch 1.41 mm

Machine No. 43





Gauge 16E


No. of Feeder 74

Pitch 1.59 mm

Machine No. 45





Gauge 18E


No. of Feeder 72

Pitch 1.41 mm

Machine No. 47





Gauge 20E


No. of Feeder 96

Pitch 1.27 mm


Machineries of Knitting Section


Production Parameters of Knitting: Stitch Length (SL) GSM Dia Gauge RPM Yarn Count

Production Flow Chart of Knitting Section:

The knitting section in Square Knit fabrics Ltd. is well decorated with modern machineries,

state-of-the-art technology, well established process sequence, quality assurance with an

ergonomic environment. This section is capable of producing versatile circular weft knitted

structures especially on engineering stripes and semi jacquard designs. The rib based collar

and cuff has also been produced in flat knitting at a different shade equipped with semi

jacquard and jacquard V- bed flat knitting machines. This section is capable of meeting the

production demand of Square Knit Fabrics Ltd. fully. In this purpose we supposed to include

the production stages, parameters, resources, quality assessments machinery specification

alone with the machinery layout in a short time span primarily.

Process Flow Diagram:

Work order received

Design developed

Requisition of raw material (yarn)

Machine parameter setup

Grey fabric inspection

Fabric delivery


Fabric Design Produced:Square Knit Fabrics Ltd. is capable of producing stripes of any width and enormous colors.

The engineering stripes machines are used for producing such fabrics. Except this feeder

stripes are also produced. Single jersey fabrics and its derivatives like lacoste, polo-pique,

terry fleece etc are produced. Rib and interlock fabrics and their different derivatives such as

2x2, 6x3 etc. are also produced. Different figured fabrics can be produced by semi jacquard

machined by varying the tucking lengths and looping sequences.

Collar and cuffs of any designs are produced here in the semi jacquard and jacquard

machines. The jacquard design can be computerized and easily transferred to the knitting

machine by Floppy disks. The yarn that used in the body fabric is also used in producing

collar and cuff.

GSM:

It is the crucial parameter that is checked and controlled at different staged of processing the

fabric after knitting to finishing. Fabric GSM in knitting can be controlled by the following

ways:

By varying the loop length by VDQ pulley

By varying the no. of loops by needle gauge setting

By using different count of yarn

The yarn count, in all cases, has prescribed by the buyers. So machine setting is the only way

to control the grey GSM. The final GSM in the finished fabric depends on the finishing

treatments and parameters of finishing machineries.

Fabric width:

Fabric width can be controlled by changing cylinder diameter or by changing machine

RPM:

Machine rpm is adjusted with the lead time for production. When lead time is very short then

RPM may increase at a certain level for a definite count and strength of yarn. So it also

depends on the yarn parameter and also with structure to be produced.

Loop length:

Loop length determines the fabric GSM. It can be controlled by changing the Dia of VDQ

pulley. In Mayer and Cie machine it can be controlled digitally.

No. of feeder or No. of cone:

It depends on the urgency of production, available cone packages, color to be knit and

structure of the fabric.


Gauge:

Needle gauge determines the number of loops in a course which in terms determine the GSMof the fabric.

Production Calculation:For Machine No. 02:

No. of Needle = π × Machine Diameter (D) × Machine Gauge (N)= 3.1416 × 30 × 24= 2262

Yarn Count = 30/1 Ne No. of Feeder = 96Machine RPM = 28Stitch length = 3 mmEfficiency = 85% = 0.85Shift = 8 hr. = 8 × 60 = 480 min

No. of Needle × No. of Feeder × Stitch length (mm) × RPM × Shift × EfficiencyProduction/Shift =

10 × 2.54 × 36 × 30 × 840 × 2.206

2262 × 96 × 3 × 28 × 480 × 0.85=

10 × 2.54 × 36 × 30 × 840 × 2.206

= 146.407 Kg

Production of the machine is 146.407 Kg/Shift.

Note: If any parameter in this calculation is changed then production capacity per shift willbe changed.

GSM Calculation:

WPI × CPI × Stitch length (mm) × (39.37)2 × 453.6 WPI = 32GSM = CPI = 45

1000 × 840 × Ne × 0.9144 Stitch length = 3 mmYarn Count = 20’S Ne

32 × 45 × 3 × (39.37)2 × 453.6=

1000 × 840 × 20 × 0.9144

= 197.72


Fabric Processing


Fabric Dyeing

Batching Section

Name: Turning Machine

Brand Name: Dong A

Sr. No: 0110055

Manufacturing Year: 2001

Manufacturing Country: Korea

Capacity: 23 m/min

Speed: 2930 rpm

Power: 7.5 kW

Voltage: 400

Hertz: 50

Steel bar capacity: 50-60 kg

Purpose: Turn the fabric surface to avoid dyeing unevenness on face side of the fabric.

Flow Chart of the Batching Section

Fabrics receive by machine operator.

Fabric put in trolley

Separate fabric according to nozzle

Fabric from grey store according to requisition.

Prepare batch card according to machine capacity


Product Mix

S/J

Lacoste

Rib

Finished fabric

Yarn dyed fabric

Collar & cuff

Allowance consider for further process in batching section

Fabric type White (%) Average (%) Black (%)

S/J 10 8 8

Rib (11) 10 8 8

Rib (22) 10 8 6

Lycra cotton 14 12 10

Lycra viscose 14 14 12

Calculation

8% = 0.92

10% = 0.90

12% = 0.88

14% = 0.86

** Extra 2% allowance is also adding for the enzyme treated fabrics and for collar, cuff &Tape allowance will be 5-6 %.


Fabric Dyeing Floor Layout

1 2 3 4 65

109T

OfficeRoom

D

7

8

T

12

13

14

15

16

17

18

19 20

21

11

DW

Finishing floor

Finishing

floor

Hank

Dyeing

&

Mercerizing

Enter/Exit

Enter/Exit of Yarn storeEnter/Exit in the plantEnter/Exit in finished fabric

store

L

Singein

g

Mercerizing


Description of the Fabric Dyeing Floor Layout

Serial No. Equipment Name Serial No. Equipment Name

01 FONG’S - 10 15 FONG’S - 60

02 SCLAVOS - 01 16 THIES

03 SCLAVOS - 02 17 SCLAVOS - 06

04 SCLAVOS - 03 18 SCLAVOS - 07

05 SCLAVOS - 04 19 FONG’S - 3

06 SCLAVOS - 05 20 FONG’S - 2

07 FONG’S - 20 21 FONG’S – 60N

08 FONG’S - 30 T Supervisor table

09 FONG’S - 01 D Sample Dryer machine

10 AK DYEING MACHINE - 1 DW Sample Dewatering machine

11 AK DYEING MACHINE -35

L Light Box

12 AK DYEING MACHINE - 2

13 SCLAVOS S.A - 08

14 FONG’S - 120


Machineries of Fabric Dyeing Section

Specification of Fabric Dyeing Machineries:


Machine No – 03SCLAVOSSer. No : 03-2A-2402Origin : Athens, GreeceCapacity : 540 KgTemperature : 135 0C (max.)Pressure : 3.5 bar (max.)M/C V : 3400 ACCurrent : 52 A (max.)Winch Speed : 280 m/min (max.)Total Horse Power: 31 HP

Machine No – 04SCLAVOSSer. No : 03-2A-2400Origin : Athens, GreeceCapacity : 360 KgTemperature : 135 0C (max.)Pressure : 3.5 bar (max.)M/C V : 3400 ACCurrent : 44 A (max.)Winch Speed : 280 m/min (max.)Total Horse Power: 24.5 HP

Machine No – 05SCLAVOSSer. No : 03-2A-2403Origin : Athens, GreeceCapacity : 720 KgTemperature : 135 0C (max.)Pressure : 3.5 bar (max.)M/C V : 3400 ACCurrent : 68 A (max.)Winch Speed : 280 m/min (max.)Total Horse Power: 40 HP


Machine No – 01Fong’s (Sample Dyeing m/c)Ser. No : 27013232M/C. No. : ALLFIT-60Origin : ChinaCapacity : 10 Kg – 12 KgTemperature : 135 0C (max.)Pressure : 440 Kpa (max.)Frequency : 50 HzM/C V : 415M: L : 1: 6-10Current : 17 A (max.)Winch Speed : 50 m/min (max.)



Machine No – 07Fong’s (Sample Dyeing m/c)Ser. No : 29015893M/C. No. : ALLFIT-30Origin : ChinaCapacity : 30 KgTemperature : 135 0C (max.)Pressure : 400 Kpa (max.)Frequency : 50 HzM/C V : 415Current : 14 A (max.)Winch Speed : 150 m/min (max.)

Machine No – 08Fong’s (Sample Dyeing m/c)Ser. No : 27013233M/C. No. : ALLFIT-30Origin : ChinaCapacity : 30 KgTemperature : 135 0C (max.)Pressure : 440 Kpa (max.)Frequency : 50 HzM/C V : 415Current : 25 A (max.)Winch Speed : 172 m/min (max.)

Machine No – 09FONG’SSer. No : 29015895M/C. No. : ECO-38-4TOrigin : ChinaCapacity : 1000 KgTemperature : 100 0C (max.)Pressure : 350 Kpa (max.)Frequency : 50 HzM/C V : 415Current : 79 A (max.)Winch Speed : 280 m/min (max.)

Machine No – 10AK (Asian Kingdom) Dyeing M/CSer. No : 03378 MModel : AK – RED 4TOrigin : TaiwanCapacity : 800 KgTemperature : 100 0C (max.)Pressure : 3 bar (max.)M : L : 1 : 5-7Winch Speed : 350 yd/min (max.)

Machine No – 11AK Dyeing M/C (Sample Dyeing)Ser. No : 03378 MModel : AK – MSL 25Origin : TaiwanCapacity : 35 KgTemperature : 135 0C (max.)Pressure : 3 bar (max.)M : L : 1 : 6-10Winch Speed : 450 yd/min (max.)

Machine No – 12AK Dyeing M/CSer. No : 03378 MModel : AK – RED 3TOrigin : TaiwanCapacity : 600 KgTemperature : 100 0C (max.)Pressure : 3 bar (max.)M : L : 1 : 5-7Winch Speed : 350 yd/min (max.)


Machine No – 13SCLAVOSSer. No : 04-2A-2741Origin : Athens, GreeceCapacity : 360 KgTemperature : 135 0C (max.)Pressure : 2.6 bar (max.)M/C V : 3400 ACCurrent : 53 A (max.)Winch Speed : 350 m/min (max.)Total Horse Power: 32HP

Machine No – 14FONG’S (Sample Dyeing m/c)Ser. No : 31020644M/C. No. : ALLFIT-120Origin : ChinaCapacity : 120 KgTemperature : 135 0C (max.)Pressure : 350 Kpa (max.)Frequency : 50 HzM/C V : 380Current : 21 A (max.)Winch Speed : 175 m/min (max.)


Machine No – 16THIESManufacturers No. : 04-2A-2741M/C Type: Heizschalange f AG 7.10 m2/4 LagenOrigin : GermanyCapacity : 500 KgTemperature : 174 0C (max.)Pressure : 0.9 barWinch Speed : 350 m/min (max.)

Machine No – 17SCLAVOS (Sample Dyeing m/c)Ser. No : 03-1A-2504Origin : Athens, GreeceCapacity : 180 KgTemperature : 135 0C (max.)Pressure : 3.5 bar (max.)M/C V : 3400 ACCurrent : 26 A (max.)Winch Speed : 250 m/min (max.)Total Horse Power: 14 HP

Machine No – 18SCLAVOS (Sample Dyeing m/c)Ser. No : 01-1B-2396Origin : Athens, GreeceCapacity : 50 KgTemperature : 135 0C (max.)Pressure : 3.5 bar (max.)M/C V : 3400 ACCurrent : 14 A (max.)Winch Speed : 135 m/min (max.)Total Horse Power: 7.5 HP


Machine No – 19FONG’SSer. No : 32022611M/C. No. : HSJ-1TOrigin : ChinaCapacity : 250 KgTemperature : 135 0C (max.)Pressure : 350 Kpa (max.)Frequency : 50 HzM/C V : 400Current : 51 A (max.)Winch Speed : 456 m/min (max.)

Machine No – 20FONG’SSer. No : 32022613M/C. No. : ECO-38-4TOrigin : ChinaCapacity : 1000 KgTemperature : 135 0C (max.)Pressure : 350 Kpa (max.)Frequency : 50 HzM/C V : 400Current : 112 A (max.)Winch Speed : 400 m/min (max.)



Flow Chart of Fabric Dyeing Procedure

For Light-Medium Shade (100% Cotton) with Moderate Brand Reactive dyes.


Aquachron (955) & (703)

Bio kill (5015)

Bio polishing (6260)

Dyeing (6060)

Aquachron (4020)

Rinsing (250 L/min10)


Soaping (8010)


Bleaching (9830)

At first chemicals & auxiliariesinject & run (405) then salttransfer & run for (405). Nowcolor dosing linearly (4030) &run (4020). Now soda dosing(1 gm/L) progressive-3, (4020)& run (406) Again soda dosing(progressive-3) for (6035) &run (6060) check PH maintain(10.0-11.0) and run for (6040),take dye bath sample


Dyeing sample

Washing (4020)

Finishing (405 dosing & 10 run)

If shade match then

Unload

Aquachron (802), (702) & (604)



Soaping sample

Check sample

Check sample

Auxiliaries & caustic transfer at60C raise the temperature at70C & dosing peroxide for 5minutes. Finally raise temperatureat 98C (4C/min.) & run for 30min.

Finishing agent dosing 5min. & run 10 min. at 40C

Digressive dosing Enzyme


For Dark-Extra dark Shade (100% Cotton) with Moderate Brand Reactive dyes.


Aquachron (955) & (703)

Bio kill (5015)


Dyeing (6060)

Aquachron (4020)



Soaping (9520)


Bleaching (9830)

At first chemicals & auxiliariesinject & run (605) then salttransfer & run for (605). Nowcolor dosing linearly (6020) &run (6020). Now soda dosing(1 gm/L) progreesive-3, (6020)& run (606) Caustic dosing(linear) for (6020) & run(6060) check PH maintain(10.0-11.0), take dye bath sample.


Dyeing sample

Washing (4020)


If shade match then

Unload

Aquachron (802), (702) & (604)



Soaping sample

Check sample

Check sample





For White Shade (100% Cotton).

Hydrogen-per-oxide transfer @70C

Caustic transfer @ 60C & run for 5

Temperature up to 80C

Skywhite BVB dosing 10(linear) +Univerden BAM

Check sample

Temperature up to 98C & run for 10

Normal wash


Enzyme transfer & run for (6260)


Run for (603)

Fabric load & chemicals transfer @ 80C

Sample check

If shade match then

Unload

Rinse for 10



For Light - Medium Shade (100% Cotton) with Hot Brand (Turquoise) Reactive dyes.

`


Aquachron (955) & (703)

Bio kill (5515)


Dyeing (8020)

Aquachron (4020)



Soaping (9010)


Bleaching (9830)

At first chemicals & auxiliariestransfer & run (406) then colordosing linearly (4030) & raisetemperature @ 80C (1/min.) & run(8015).Now salt dosing 10 (linear)& run for (805). Again salt dosing15 (linear) & run for (805). Finallysalt dosing 20 (linear) & run for(8020). Now migration temperature@ 60C (1/min.) & run for 10. Sodadosing progressive-3, (6040) & run(605) Caustic dosing (linear) for(6020) & run (6010) check PH

maintain (10.0-11.0), & take dye bathsample.


Dyeing sample

Washing (4020)


If shade match then

Unload

Aquachron (802), (702) & (604)



Soaping sample

Check sample

Check sample

Auxiliaries & chemicals inject@50C then caustic transfer at60C. Per-oxide dosing (linear)(706) raise the temperature at98C (3/min.) & run for (9830)



Machine neutral (5010)


For Dark - Extra Dark Shade (100% Cotton) with Hot Brand (Turquoise) reactive dyes.


Aquachron (955) & (703)

Bio kill (5515)


Dyeing (8020)

Aquachron (4020)



Soaping (9010)


Bleaching (9830)

At first chemicals & auxiliariestransfer & run (606) then colordosing linearly (6030) & raisetemperature @ 80C (1/min.) & run(8015).Now salt dosing 10 (linear)& run for (805). Again salt dosing15 (linear) & run for (805). Finallysalt dosing 20 (linear) & run for(8020). Now migration temperature@ 60C (1/min.) & run for 10. Sodadosing progreesive-3, (6040) & run(605) Caustic dosing (linear) for(6020) & run (6010) check PH

maintain (10.0-11.0), & take dye bathsample.


Dyeing sample

Washing (4020)


If shade match then

Unload

Aquachron (802), (702) & (604)



Soaping sample

Check sample

Check sample

Auxiliaries & chemicals inject@50C then caustic transfer at60C. Per-oxide dosing (linear)(706) raise the temperature at98C (3/min.) & run for (9830)



Machine neutral (5010)


Flow Chart of Fabric Dyeing for CVC/PC

Polyester Part

Color dosing (6010) linearly


Temperature up 60 to 80C

Again temperature up 80 to 135C (1/min.)

Cooling @ 85C (1/min.)

Run for 60 minutes @ 135C

Take sample

If ok

Then bath drop

Bleaching

Transfer chemicals & auxiliaries

Fill water @ 60C

Sample check (carbonizing)

If shade match then

Unload

Soaping or RC (For PC) @ (8515)



N.B.: For CVC dyeing don’t need RC (Reduction Clearing) & for cotton part dyeingfollowed by previous method mentioned above.

Flow Chart of Fabric Dyeing for Black Shade

Chemical 60xT


Run 60x5 min

Bleaching

Transfer chemicals & auxiliaries

Fill water @ 60C


Run 6010

Salt -60xT

Color dosing 60 x20min(linear)

Run 60x20 min

Soda dosing 60x20 min1g/l(progress-3)

All soda dosing 6030P#3

Run -60x3

pH check(10-10.8)

Hold time 45 min

Sample check

Batch Drop

Aq 60x20 min


Drain

A Acid (60x5min)

Filling water x60

pH check(5.5-6.5)

Soaping 95x20 min

Wash (60x5min)

Aq.40x10

Water clean

Sample check

Ok/not ok

Fixing 40x10

Unload


Fabric Singeing & Mercerizing


Fabric Singeing

Brand Name: DornierOrigin: GermanyNo. of Burners: 8Angle of Burners: TangentialMaximum Cigar Diameter: 220-230 cmBurner Distance from Fabric: 37 cmGas Pressure: 10 PSIFlame Pressure for Compaction: 1.5-2 Bar


Fabric Passing Speed:

Fabric Type Speed (m/min)Single Jersey 50Rib/Interlock 45Terry Fleece 45

Faults in Singeing:

o Crease Marko Line Marko Bowing mark

Fabric Mercerizing


Brand Name: Dornier

Origin: Germany

Type: CM B/2

Serial No.: 100625

Year: 1999

Maximum Width: 36 inch

Process Flow Chart:Grey / Yarn dyed fabric received from the store

Batch making

Stitching and checking for knitting defects and holes

Yarn dyed fabric mercerized and Grey fabric singed & mercerized

Yarn dyed transferred to the finishing department

Grey fabric turning and transfer to the dyeing department

Process Control Parameter:Caustic soda concentration 30 - 32 ºBe

Caustic soda temperature 16 - 18ºC

Concentration of wetting agent 5 gm/lt.

Initial width of the fabric increase to 10cm

Final width of the fabric as per requirement

Dwell time 22 - 25 sec in caustic soda

Nip pressure:

Cigar setting 35 to 45 % as per fabric quality and stretching, for solid grey 35%

Position For yarn dyed fabric in Bar For gray fabric in Bar

After NaOH bath 1.5 1.5

Before acid bath 1.0 1.0

After acid bath 1.0 1.0

After washing 1.0 1.0


Washing water temperature for yarn dyed fabric all 50ºC and for grey fabric 90ºC,

80ºC, 70ºC, 60ºC.

Inlet fresh water velocity 7 m3/hr

Fabric PH after mercerization 5 – 6

Neutralization at 60oC with Sirrix NE @ 10 gm/lt.

Fabric Passing Speed:

Fabric Type Speed (m/min)Grey Fabric Single Mercerizing 12Grey Fabric Double Mercerizing 15Yarn Dyed Double Mercerizing 15

Total Time Needed for Mercerization: 4.50 minute @ 15 m/min (Fabric Passing

Speed).

25 second submerged in caustic soda solution @ 15 m/min.


Fabric Finishing


Layout of Fabric Finishing Section:


Specification of Fabric Finishing Machines:

MachineType

Brand Model Year Origin

Slitting Corino APRICORDA 2001 ItalySlitting Corino APRICORDA TAGLIERIDA 2005 Italy

Dewatering Corino ST-4 2001 ItalyDryer Monforts 4F-DYNAIR 2001 GermanyDryer Santex Santa Shrink 2003 SwitzerlandStenter Monforts MONTEX-50002F 2001 GermanyStenter Sun Super SST-6GP 2004 South KoreaStenter Sun Super SST-7GP 2007 South Korea

Compactor Ferrraro Comptex/RC-2800 2004 ItalyCompactor Monforts DOGAL-04 2001 GermanyCompactor Navis Array Tex (TM-100) USACompactor Santex Santa Spread-TS 2001 Switzerland

Description of Fabric Finishing Machines:

1.) Corino Slitting & Dewatering Machine (For Open Width Fabric):

No. of Machine: 2No. of Padder: 1 PairCapacity: 20 kg/min.Maximum Fabric Passing Speed: 60 m/minMaximum Fabric Dia Capacity: 225 cmMinimum Fabric Dia Capacity: 65 cmMaximum Over feed (%): 40%Minimum Over feed (%): 25%Maximum Padder Pressure: 4 Bar (Depends on Shade)Minimum Padder Pressure: 1 Bar (Depends on Shade)



Tube Fabrics

Detwisting

Slitting

Dewatering

Open Fabric

Trolley

Standard Operating Procedure:

To check the machine to keep it cleans.

To check the blade.

To check the padded pressure.

To check the sensor.

To check the proper movement of basket.

To check the amount of overfeed.

To check the activities of auto sensor.

To check the movement of turning table.

To check the activities of dewatering device.

Work Instruction:

Fabric Type Padder pressure (Bar) Machine Speed (m/min) Over feed (%)

Single Jersey 2.50 - 3 40 – 50 40

PK 3 40 – 50 40

11 Rib 3- 3.50 50 – 60 25

22 Rib 3- 3.50 60 40

Plain Interlock 3- 3.50 40-50 35-40


Mercerized:-

Single Jersey 2 40 40PK 2.50 40 40

11 Rib 2.50 – 3 50 2522 Rib 2.50 – 3 60 40

Plain Interlock 2.50

2.) Corino Dewatering Machine/Squeezer Machine (For Tube Fabric):

No. of Machine: 1No. of Padder: 2 PairMaximum Padder Pressure: 1.5 BarMinimum Padder Pressure: 1.5 BarMaximum Speed for Fabric: 30 m/minMaximum Speed for Cuff/Collar: 20 m/minMaximum Fabric Dia Capacity: 128 cmMinimum Fabric Dia Capacity: 50 cmMaximum Over feed (%): 30%Minimum Over feed (%): 0% (For Collar No Overfeed)


Tube Fabrics

Detwisting

Dewatering

Trolley


To check the machine to keep it cleans

To check the padded pressure

To check the proper movement of basket

To check the amount of overfeed

To check the activities of dewatering device

To check the activities of auto sensor


Work Instruction: If Fabric Dia is 70 cm

Fabric Type Stretch (%) Machine Speed (m/min) Over feed (%)

Single Jersey 85 40 30

PK 92 40 30

11 Rib 20 40 30

Plain Interlock 92 40 30

Mercerized 80-85 40 30

11 Lycra Rib 100 40 30

3.) Monforts Dryer (Dynair 5000):

No. of Chamber: 4No. of Burner: 4No. of Padder: 1No. of Expander Roller: 5 (Motor Controlled)No. of Free Roller: 13 (Easy Controlled)No. of Blower: 4No. of Finger Roller: 4Capacity: 6 tons/dayMaximum Temperature: 180oCMinimum Temperature: 100oCFabric Passing Speed: 8 m/min to 50 m/min (Depends on fabric type, temperature & dry

requirement i.e. half dry/full dry)

Maximum Over feed (%): 60%Minimum Over feed (%): -10%Maximum Fabric Dia Capacity: 260 cmMinimum Fabric Dia Capacity: 85 cm



Machine should be cleaned

Padder should be cleaned

Stenter pin should be checked

Tray of each chamber should be cleaned

Function of auto chamber should be checked

Padder pressure should be adjusted

Function of burner should be checked

Overfeeding speed should be checked

Conveyor belt should be checked

Dancing roller should be checked.

Work Instruction:

Type of Fabric Over feed (%) Temperature (oC) Stretch (%)

S/J

Non-Mercerized -10/60 100-180 35

Mercerized -10/60 100-180 45

Dyed (Yarn) -10/60 160-180 35

Dyed Mercerized -10/60 160-180 45

PKWhite -10/60 100-150 50

Dyed -10/60 160 50

1X1 RibWhite -10/60 100-150 20

Dyed -10/60 160-180 Maximum

P.I.L.White -10/60 100-150 50

Dyed -10/60 160 50


4.) Santex Dryer Machine:

No. of Chamber: 6No. of Burner: 3No. of Padder: 0No. of Blower: 3No. of Exhaust Fan: 1No. of Expander Roller: 1No. of Motor Controlled Roller: 3

No. of Conveyor Belt: 2Maximum Fabric Dia Capacity: 222 cmMaximum Fabric Passing Speed: 35 m/minMinimum Fabric Passing Speed: 2 m/minMaximum Over feed (%): 35%Minimum Over feed (%): 0%Maximum Temperature: 180oCMinimum Temperature: 90oC


Open & Tube Fabric

Drying

Trolley


To clean the machine properly.

To clean the trey for every chamber.

To check the proper activity of burner.

To check over feeding and vibrating.


To check the conveyor belt.

Work Instruction:

Fabric Type Temp.

(oC)

Over feed

(%)

Vibration Ext. Temp.

(oC)

Speed

S/J White 110 25-30 750 65 30

Color 100-165 10-35 500-750 70 10-45

PK White 130-140 35 750 65 20-30

Color 140-150 30-35 700-750 70 20-30

1X1 Rib Tube 140-150 10-20 700-750 65-70 25

Open 140-150 20-35 700-750 65-70 25

P. Interlock 120-140 35 750 65-70 25

Mercerized Grey

Fabric

165 - - 80 5-10

1X1 L. Rib 120-150 20-35 700-750 65-70 20-30

s

5.) Monforts Stenter (Montex 5000):

Maximum Fabric Passing Speed: 40 m/minMinimum Fabric Passing Speed: 5 m/minMaximum Over feed (%): 50%Minimum Over feed (%): -10%Maximum Under feed (%): -3%Minimum Under feed (%): -5%Maximum Temperature: 190oCMinimum Temperature: 120oCMaximum Fabric Dia Capacity: 240 cmMinimum Fabric Dia Capacity: 60 cm


No. of Burner: 2No. of Steaming Chamber: 2No. of Temperature Chamber: 2No. of Cooling Chamber: 1No. of Expander Roller: 2+2 = 4No. of Finger Roller: 4No. of Bianco Roller: 1

Process Flow Diagram:Open Fabric (Dried)

Mahlo (Bowing control only yarn dyed fabrics)

Stentering

Trolley



Function of auto chamber should be checked

Machine net should be cleaned

Steam line should be checked

Function of burner should be checked

Function of Mahlo should be checked

Bowing control should be checked

Tray of each chamber should be cleaned

Conveyor belt should be checked

Work Instruction:

Type of Fabric Over feed

(%)

Temperature

(oC)

Stretch

(%)

S/J

Non-Mercerized 50 120 5

Mercerized 50 120 15

Dyed (Yarn) 40-50 120-160 5-7

Dyed Mercerized 40-50 120-160 15

White 50 120 15


PK Dyed 40-50 120-160 15

1X1 RibWhite 50 120 2-3

Dyed 40-50 120-160 2-3

P.I.L.White 50 120 10

Dyed 40-50 120-160 10

D/N Interlock

Mercerized 50 120 8-10

Non-Mercerized 50 120 7

Dyed (Yarn) 45-50 120-160 10

6.) Sun Super Stenter Machine:

No. of Machine: 2 (6 Chamber & 7 Chamber)

For 6 Chamber Machine

No. of Padder: 2 PairNo. of Burner: 12Maximum Fabric Dia Capacity: 290 cmMinimum Fabric Dia Capacity: 90 cmMaximum Fabric Passing Speed: 28 m/minMinimum Fabric Passing Speed: 10 m/minMaximum Over feed (%): 40%Minimum Over feed (%): -19%Pinning Maximum: 19%Pinning Minimum: 0%Maximum Temperature: 190oCMinimum Temperature: 120oCMaximum Temperature for Heat Setting: 190oC (For Lycra, CVC, PC, Viscose) & 180oC

(For Model Fabric)No. of Blower: 12 (0-1800 r.p.m.)


No. of Exhaust Fan: 3Maximum Padder Pressure: 2.5 kgf /cm2

Minimum Padder Pressure: 1 kgf/cm2

For 7 Chamber MachineNo. of Burner: 14


Open Fabric (Dried)

Chemical with padding

Mahlo (Bowing control only yarn dyed fabrics)

Stentering

Trolley


To check the machine to keep it cleans.

To check the activity of burner.

To keep the padded clean.

To check the amount of overfeed.

To check the control for bowing.

To check the machine for auto moisture control.

To check the movement of densing roller.

To clean the tray for every chamber.

To adjust the padded pressure perfectly.

To check the gas pressure.

Work Instruction:

Type of Fabric Padder

Pressure

Over feed

(%)

Temperature

(oC)

Stretch

(%)

P1 P2

Non- 2.5 2.5 25 120 8-10


S/J

Mercerized

Mercerized 2.5 2.5 35 120 12

Dyed 2.5 2.5 30 120-130 8-12

PKWhite 2.5 2.5 30 120 10-12

Dyed 2.5 2.5 30 120-130 10-12

1X1

Rib

White 2.5 2.5 35 120 5

Dyed 2.5 2.5 35 130 5

2X2

Rib

White 2.5 2.5 35 120 8-10

Dyed 2.5 2.5 35 130 8-10

Note: Softener is used in padder pressure (P2).

Standard R.P.M.:-

Fabric Type RPM

S/J up to 160 GSM 22-24

S/J up to 200 GSM 21-22

Fleece up to 280 GSM 16

Fleece up to 320 GSM 12

PK up to 200 GSM 18-20

PK up to 220 GSM 13

Rib up to 250 GSM 12

2X2 Rib up to 220 GSM 12-13

Lycra S/J Heat Set 21

Lycra S/J Finished 16-18

7.) Monforts Compactor Machine:


Maximum Speed: 40 m/minMinimum Speed: 7 m/minSteam Pressure: 4 - 4.5Maximum Over feed (%): 22%Minimum Over feed (%): 18%Pressure Type: Cylinder + Rubber Belt



Machine cylinder should be cleaned

Machine rubber belt and blanket should be checked

Machine dumping should be checked

Machine cylinder temperature should be checked

Machine overfeed should be checked

Machine padder pressure should be checked

Water and air line should be checked

Machine out line steam should be checked.

Shrinkage Tolerance of Different Fabric:

Fabric Type Length (%) Width (%)

S/J -5.50 -5.50

Lycra S/J -6.00 -6.00

Single Lacoste -7.00 -7.00

Lycra Single Lacoste -7.00 -7.00


1X1 Rib -7.00 -7.00

Lycra 1X1 Rib -7.00 -7.00

2X2 Rib -8.00 -8.00

Lycra 2X2 Rib -8.00 -8.00

Interlock -7.00 -7.00

Terry Fleece -5.00 -5.00

8.) Navis Compactor Machine:

Type: Blade Compactor Machine

Types of Roller: 4 (Anti Roll, Expander Roll, Retard Roll, Pad Roll)

Compaction depends on Retard Roller.

Shade depends on Shoe Depth.

Feed Roll Temperature is automatically set by the machine.

Shoe Pressure: 2.5 - 3

Maximum Fabric Passing Speed: 40 m/min

Minimum Fabric Passing Speed: 20 m/min

Maximum Over feed (Bilateral Slat) %: 98%

Minimum Over feed (Bilateral Slat) %: 90%

Maximum Temperature: 80oC

9.) Ferraro Compactor Machine:


Type: Blanket Compactor Machine

No. of Steam Chamber: 2

Steam Temperature: 100oC

Maximum Fabric Dia Capacity: 225-228 cm

Minimum Fabric Dia Capacity: 100 cm

GSM Control: 7-8

Maximum Fabric Passing Speed: 20 m/min

Minimum Fabric Passing Speed: 10 m/min

Maximum Over feed (%): 35%Minimum Over feed (%): 0%

10.) Santex Compactor Machine (Tubular Knitted Fabric Compactor):

Type: Blanket Compactor Machine

Minimum Fabric Dia Capacity: 126 cm

Maximum Fabric Dia Capacity: 28 cm

Steam Temperature: 120oC


Maximum Overfeed (%): 40%

Minimum Overfeed (%): -10%

No. of Cylinder: 2

Padder Pressure: 6-7

Flow Process of Finishing Range:

Working Steps at a Glance:Collect the work order from marketing dept., merchandising dept or from local buyer

or from other production dept of SKFL/ SFL.

Make a production plan according to work order & style.

Collect/ received dyed yarn or washed fabric from fabrics dyeing section.

Collect/ receive greige fabrics from batching section.

Commence production.

Send product to QAD (final inspection).

Collect daily production info & prepare a report.

Faults in Finishing:

o Shade Change o Softener Mark

Finishing Range

Open fabric Tubular fabric

Slitting,dewatering and

detwisting

Open width line 1Padder with dryer

Open width line 26 & 7 chamber

Stenter with padder

2 chamber stenter

CompactorCompactor

Dewatering anddetwisting

Dryer

Tube compactor


o Crease Mark o Shrinkage Problem

o Water Spot o Pinning Problem

o Diameter Variation o Spreader roller does not work properly

o Slitting Uneven


Quality Assurance Department (QAD)


Square Knit Fabrics Ltd. is more concern about quality. In this factory quality assurance is

more preferred than quality control, but both are in advancement. The Quality Assurance

Department is assigned to maintain consistently uniform quality of the material in process

and various stages of its manufacturing.

Objective of Quality Control: Research. Selection of raw materials. Process control. Process development. Product testing. Specification test

Scope of Quality Control, Quality Assurance and Testing: Testing Lab Machine auditing system A good training system. Excellent analytical backup. Technical expertise.

Quality Control Procedure: On line quality control

Off line quality control

Off-Line Tests:

Physical Tests: Chemical Tests:

Threads per inch Fastness to washing

Fabric weight (GSM) Fastness to light

Fabric Width test (Dia) Fastness to heat

Tensile strength Fastness to actual laundering

Tear strength Fastness to sea water

Seam slippage Fastness to Chlorinated water

Abrasion resistance Fastness to water spotting

Pilling resistance Fastness to perspiration

Thermal stability Fastness to light perspiration

Crease resistance Fastness to rubbing

Stretch ability & growth recovery

Smoothness appearance


Bursting Strength

Quality Control Flow Chart:

Yarn Processing(Yarn test)

Pass Fail

Knitting

Send to spinning millGrey fabric inspection

Pass Fail

Send to store as rejectGrey store

Batch making

Dyeing

Finishing

Fabric checkingPhysical Lab Inspection Shade

Pass Fail

Delivery RejectReprocess

Send to store as reject

Shade check

Pass

FailRedyeing

Quality Control

On Line Off line


List of Equipments:Machineries & equipment used:

Spectrophotometer with Software (Data Color)

Martindale Abrasion Tester

Day Light Box

Sample Dyeing Machine (5)

ROBO Lab

Iron

Electric Balance

Crock Meter

Washing Machine (Electrolux Wascator/Siemens)

GSM Cutter

PH Meter

ICI Pilling Box

Martindale Pilling Machine

Bursting Strength Tester

SDL ATLAS Rotawash

Perspirometer

Xenon Test Chamber

Mechanical Shaker Machine

Fabric Inspection:The inspection of fabric is a procedure by which the defects of fabric are identified and fabric

is classified according to degree or intensity of defects. The fabric inspection is done for both

grey and finished fabric.

Grey Fabric Inspection:In SKFL grey fabric inspection is performed according to 4 point system.

Four-Point System:

Size of Defect Penalty

0 inches to 3 inches 1 Point




More than 9 inches 4 Point

Acceptance Calculation:o Any Hole – 4 Point

o Upto 20P/100m = Class “A”

o Upto 20-30P/100m = Class “B”

o Upto 30-40P/100m = Class “C”

o More than 40P/100m = Reject.

Faults found during Grey Fabric Inspection:

Wrong Design:Causes: Wrong insertion of yarn during knitting. Wrong setting of fabric design in knitting machine.

Lycra out:Causes: Lycra tears out during running the machine for production.

Barrie Mark/Patta:Causes: Yarn package is either hard or soft. Lot Mixing of yarn.


Improper yarn tension. Uneven yarn dyeing.

Thick & Thin:Causes: Diameter of yarn is uneven i.e. yarn irregularity. Variation of yarn tension in course wise direction.


Sinker Mark:Causes: Defective sinker. Dust in sinker. Improper servicing time of knitting machine.

Needle Line:Causes: Needle mixing. Dust in needle group.


Improper servicing time of knitting machine.

Oil Stain:Causes: Dust in cylinder & Dial group. Dust in needle group. Improper oil flow.

Pin Hole:Causes: Breakage of needle tail. If needle tail bends.

Loop:Causes: Dust in yarn during running the machine for production. Yarn knot thicker. Breakage of needle.

Fly Yarn:Causes: Fly fiber during knitting. One colors dirt is knitted with another color during running the machine.

Slub:Causes: Excessive ply during yarn production. Improper machine setting (Blow Room, Carding, Ring Frame).

Uneven Loop Loose tension/Tight tension Over looping

Finished Fabric Inspection:4 point numbering system is followed for finished fabric inspection.

Four-Point System:

Size of Defect Penalty

3 inches or less 1 Point

Over 3, but not over 6 2 Point

Over 6, but not over 9 3 Point

Over 9 inches 4 Point


Acceptance Calculation (Classification): < 40 PTS = A

41 – 60 PTS = B

61 – 80 PTS = C

80 ABOVE = REJECT.

Faults found during Finished Fabric Inspection:

Chemical Stain:Causes: Padder contains dust during silicon finish. Improper mixing of silicon softener. Improper PH of softener mixing. Too much m/c stoppage within short time.

Dirt Stain:Causes: Fabric is stored in floor. Trolley is not properly cleaned. Finishing m/c is not properly cleaned.

Oil Stain:Causes: Dust in cylinder & Dial group. Dust in needle group. Improper oil flow.

Dye Stain:Causes: Appearance of the darker spots of the same colour caused by incomplete dissolution

of the dye. Improper dyes quality & dyes dosing.

Insect Spot:Causes: Fabric is finished with insect when insect is in surface area of the fabric. Fabric is stored for long time.

Barrie Mark/Patta:Causes: Yarn package is either hard or soft. Lot Mixing of yarn. Improper yarn tension. Uneven yarn dyeing.


Slub:Causes: Excessive ply during yarn production. Improper machine setting (Blow Room, Carding, Ring Frame).

Wrong Design:Causes: Wrong insertion of yarn during knitting. Wrong setting of fabric design in knitting machine.

Lycra out:Causes: Lycra tears out during running the machine for production.

Thick & Thin:Causes: Diameter of yarn is uneven i.e. yarn irregularity. Variation of yarn tension in course wise direction.

White Specks/ Dead Cotton:Causes: If fibre is immature. Fabric construction contains dead fibre/ damage fibre.

Crease mark:Causes: More cycle time. Faulty plaiting device. Slack on tight selvedge causes crease at an angle to each selvedge. Incorrectly set bowed-expander. Compacting is done when fabric is in folded condition. Variation of heating and cooling rate. Improper fabric movement.

Physical Laboratory TestsDetermination of Dimensional Stability (Shrinkage):Method Followed: ISO: 6330/ 3759/ 5077, AATCC: 150

Required Equipment: Electrolux Wascator/ Siemens, Loading cloth, Detergent (Light,

Persil, ECE, Sodium Perborate)


Working Procedure:

Taking the sample fabric (1.5 m) from the bulk.

↓

Put it into the conditioning for test for 04.30 to 06 hours.

↓

Take measurement of 50 cm 50 cm and mark 35 cm 35 cm and cut according to

taken measurement.

↓

Overlock three edges & One edge (Length wise) open.

↓

Put into the Washing m/c (Wascator/ Siemens) with loading cloth & Detergent Loading

cloth 02 to 03 kg, Detergent 02 to 04 gm/lt.

↓

Start the programme & Wash according to the programme

Electrolux Wascator- Prog. 5A 60OC Temp. 60 min

Siemens Washing m/c- Prog. Cotton Manual Temp. 90 min

↓

Put into the Dryer (Tumble Dryer) for 60oC Temp/ 40oC Temp with 60 min

If required Line/Flat dry, generally hang with line dry &lay down with flat dry

↓

After drying conditioning the fabric for 4.30 hours.

↓

Take the measurement and make a test report.

Determination of Spirality (Twisting):Method Followed: Inhouse system, AATCC: 179

Required Equipment: Electrolux Wascator/ Siemens, Loading cloth, Detergent (Light,

Persil, ECE, Sodium Perborate)

Working Procedure:

Taking the sample fabric (1.5 m) from the bulk.

↓

Put it into the conditioning for test for 04.30 to 06 hours.

↓


Take measurement of 50 cm 50 cm and mark 35 cm 35 cm and cut according to

taken measurement.

↓

Overlock three edges & One edge (Length wise) open.

↓

Put into the Washing m/c (Wascator/ Siemens) with loading cloth & Detergent Loading

cloth 02 to 03 kg, Detergent 02 to 04 gm/lt.

↓

Start the programme & Wash according to the programme

Electrolux Wascator- Prog. 5A 60OC Temp. 60 min

Siemens Washing m/c- Prog. Cotton Manual Temp. 90 min

↓

Put into the Dryer (Tumble Dryer) for 60oC Temp/ 40oC Temp with 60 min

If required Line/Flat dry, generally hang with line dry &lay down with flat dry

↓

After drying conditioning the fabric for 01 hours.

↓

Take the measurement according to the following diagram and make a test report.

Before washing

After Washing

After Washing

A B

C D

A B

C1 D1

A B

C1 D1

Here the Spirality% = (CC1 / AC1 X 100 + DD1/BD1 X 100)/2


Determination of Fabric Weight (GSM):

Method Followed: ISO: 3801, ASTM: D3776

Required Equipment: G.S.M. cutter, Balance.

Working Procedure:

Taking the sample of fabric from bulk and conditioning for 4.30 to 06 hours

↓

Taking the conditioning fabric for test on the G.S.M. cutter pad so that no crease or crinkle is

formed.

↓

Cutting the fabric with G.S.M. cutter (GSM Cutter Diameter 11.2 cm)

↓

Taking the weight of the cut fabric (Length & Width 11.2 cm) in balance and multiply with

100.

↓

Make a test report

Determination of Fabric Width (Dia):Method Followed: ISO: 3932, ASTM: D3774

Required Equipment: Measurement Tape, Scale.

Working Procedure:


↓

Taking the conditioning fabric for test on the table so that no crease or crinkle is formed.

↓


Measuring the fabric width with Measurement tape or scale

↓

Taking the result of the test fabric

↓

Make a test report

Determination of Pilling (Martindale):

Method Followed: ISO: 12945-1/2, ASTM: 3512

Required Equipment: ICI Pilling Box, Martindale Pilling m/c, Fales fabric, Cotton

fabric, Grey Scale.

Working Procedure:

Taking the fabric from bulk and then conditioning for 04.30 to 06 hours

↓

Cut the sample for test as per pilling cutter size (Dia meter 13.8 cm)

↓

Make two round shaped samples (13.8 cm) for testing by cutter.

↓

There are two portions in the Martindale abrasion machine, Upper part and lower part. Upper

part can be taken out from the lower part which is attached with the lower part with screws.

Loose the screws and take the upper part detached from the lower part.

↓

There are some parts in the lower part on which there are kept some felts. One piece of cut

sample is placed on a felt and then a tensioning weight is placed on the sample fabric so that

an even tension is created on the sample fabric.

↓

Start the program (At a time SKFL have 06 test facilities in that m/c)

↓ SKFL use 2000 Revolution, Time 3600 sec


Measuring the sample with grey scale & make a test report.

Determination of Crocking (Rubbing):

Method Followed: ISO: 105 X12, AATCC: 8

Required Equipment: Crockometer, Crocking cloth, Grey scale, Distill water.

Working Procedure:


↓

Select the sample fabric for test and cut 50 cm x 40 cm (02 Pcs)

↓ for Dry & Wet Rubbing

Dry rubbing:-

Put in tract of the crockometer for dry rubbing.

↓

Mount the crocking cloth on the head of the finger.

↓

Lower the finger on the test specimen and turn for 10 times within 10 sec so that it will cover

all the dyed area of the specimen, do the same way two specimens.

↓

Evaluate with grey scale.

Wet rubbing:-

Put in tract of the crockometer for wet rubbing.

↓

Wet the crocking cloth in distilled water with pick up 100%, remove excess water with

blotting paper.


↓

Mount the crocking cloth on the head of the finger.

↓

Lower the finger on the test specimen and turn for 10 times within 10 sec so that it will cover

all the dyed area of the specimen, do the same way two specimens.

↓

Dry the white fabric and evaluate with grey scale.

↓

Measurement & make test report

Determination of Color Fastness to Washing:Method Followed: ISO 105 C06/C08, AATCC: 61

Required Equipment: Rotawash, Stainless Still Ball, ECE Detergent, Multi-fibre fabric,

Grey scale, Sodium Perborate, TAED.

Working Procedure:

Collecting the sample from bulk and then conditioning for 04.30 to 06 hours

↓

Making a specimen of 04 cm10 cm in size.

↓

Sewing the specimen with multi-fibre fabric of same size at one corner.

↓

Making the solution of 4gm/litre ECE detergent & 1 gm/litre sodium perborate, (If required

SKFL use 0.15 gm/litre TAED).

↓

Putting the specimen with multi-fibre fabric into the solution in Rotawash m/c

Prog.: C2S Temp.: 60OC/ 40OC Time: 30 min Still ball: 25 pcs

↓

Rinsing with hot water respectively.

↓

Squeezing with cold water of the sample is done (Hand Wash).

↓

Then drying is done at a temperature in the air not exceeding 60 0 C

↓


The stitching is then broken out except on one of the shorter end.

↓

Measuring the staining and color change by grey scale & make a test report.

Determination of Color Fastness to Perspiration:Method Followed: ISO 105 E04, AATCC: 15

Required Equipment: Perspirometer, Woven Dryer, Multifibre, Below mentioned

Chemicals, Distilled water and Grey scale.

Working Procedure:

Taking the sample fabric from bulk and then conditioning for 04.30 to 06 hours

↓

Select the sample for test and cut the specimen in 04cm10 cm.

↓

Attach with multi-fibre fabric of same size.

↓

Make-up solution with below chemicals:

For Acid:

L-histadine monohydrochloride: 0.5 gm/litre

Sodium Chloride: 5 gm/litre

Sodium dihydrogen orthophosphate dihydride: 2.2 gm/litre

For Alkali:

L-histadine monohydrochloride: 0.5 gm/litre

Sodium Chloride: 5 gm/litre

Di Sodium hydrogen orthophosphate 2-hydrate: 2.5 gm/litre

Water: 1000 cc

↓

Immerge the sample and Multifibre fabric into solution for 01 hours

↓01 sample 50 ml, Solution 1:50

Place in between the perspirometer plate and fix with proper weight.

Put into the perspirometer with 100% pick up

↓

Set the perspirometer in woven dryer at 37oC temp for 4 hours

↓


Out the perspirometer in woven dryer & set it another dryer

↓

Dry the sample at 60oC temp for 60 min

↓

Measurement with grey scale for shade change and staining & make a test report.

Determination of Color Fastness to Water:Method Followed: ISO 105 E01, AATCC: 107

Required Equipment: Perspirometer, Woven Dryer, Multifibre, Distilled water and

Grey scale.

Working Procedure:


↓

Select the sample for test and cut the specimen in 04cm10 cm.

↓

Attach with multi-fibre fabric of same size.

↓

Put into the distilled water for 01 hours

↓ 01 sample 50 ml, Solution 1:50

Put into the perspirometer with 100% pick-up.

↓

Set the perspirometer in woven dryer at 37oC temp for 4 hours

↓

Out the perspirometer in woven dryer & set it another dryer

↓

Dry the sample at 60oC temp for 60 min

↓

Measurement with grey scale for shade change and staining & make a test report.


Determination of Bursting Strength:

Method Followed: ISO: 13938-2, ASTM: D3786

Required Equipment: Bursting Strength Tester.

Working Procedure:

Taking the sample fabric from the bulk and conditioning for 04.30 to 06 hours.

↓

Make reading of F1 and F2 zero by presenting them for 3 seconds respectively.

↓

Loose the handle by moving it anticlockwise.

↓

Put the fabric in the middle of the pressure (glycerin container) and the envil.

↓

Tighten the handle by moving it clockwise.

↓

In switch on condition take the switch at first in off mode and then in forward mode.

↓

After bursting, the switch is needed to move at first in offside and then in reverse mode.

↓

When the pressure comes in neutral condition there will be no sound. In this condition by

pressing F1 and F2 we can get the result of pressure created to get the strength. The

measurement is counted in kPa (Kilopascal).

↓

Received the measurement & make a test report.


Determination of Color Fastness to Light:Method Followed: ISO 105 B02, AATCC: 16

Required Equipment: Xenon Test Chamber, Sample stand, Test Paper, and Blue Wool

Std.

Working Procedure:


↓

Select the sample for test and cut the specimen in 05cm10.5 cm.

↓

Attached with Test Paper (same as sample fabric)

↓

SSeett iinnttoo tthhee SSaammppllee wwiitthh ssaammppllee ssttaanndd

↓

Put into the Xenon Test Chamber Disk & start the program

Light- Day, Wave Length- 35W/m2, Temp- Black Panel 50oC, Chamber Air 39oC

Relative Humidity- 40%, Test Time- 24 hours.

↓

Position change- 04 times for 24 hours test

↓

After test collect the sample & measurement with Grey Scale

↓

Make a test report

Determination of PH Value:

Method Followed: ISO: 3071, AATCC: 81

Required Equipment: Mechanical Shaker m/c, PH Meter, Distill Water.

Working Procedure:


Taking the sample fabric from bulk and conditioning for 4.30 to 06 hours

↓

Taking the sample for test weight 2 gm & make it very small pieces

↓

Collect the 100 ml distill water & boiled it 05 min (Temp 40oC to 100oC)

The sample placed into the beaker (100 ml) with deionized water (PH 5.0-6.5)

↓

The beaker placed into the mechanical shaker at 40oC temp for one hour.

↓

Measure the PH value of the solution by inserting the PH meter into the glass flask.

↓

Wait until the reading has settled before taking and recording the result.

↓

Make a test report

LLaabb DDiipp PPrreeppaarraattiioonn

While training in Square Knit Fabrics Ltd. we prepared the several lab dip and match with the

standards by the spectrophotometer. The preparation and matching with the standards is

described below:

Sequence of Lab dip Preparation:STD receive from Merchandiser

(Physical swatch/R. Value)

Scan / Input in spectrophotometer } Color Tools

Save / Store

DCI Match – Recipe

Substrate (S/J, 1 * 1 rib, 26/1, 30/1 etc)

STD

Dye Set

Combination → as per buyer Requirements

Then recipe

Salt/ Soda/ Caustic as per Recipe

Dyeing Program Selection


Pipe ting

Salt + Sample + Aux

Dyeing

Alkali Inject

Unload after dyeing

Wash → as per program

Dry → 60ºC * 20' – 30'

Finish (Iron)

Shade matching

Washing Procedure:

For Light Shade (<1.0%):

Rinse

Cold Wash

Neutralization with 0.5 gm/l Acetic Acid

Soaping with RSK 1 gm/l at 85ºC * 10' – m/c wash

Cold Wash

Dry

For medium Shade (1.0 – 3.0):Rinse

Cold Wash


Soaping with RSK1) 1.5gm/l at 85ºC * 10' – m/c wash2) 1.0gm/l at 90ºC * 10' – m/c wash

Hot wash

Cold Wash

Dry


For Dark Shade (3.0 above):Rinse

Cold Wash


Soaping with RSK1) 1gm/l at 90ºC * 10' – m/c wash

2) 1.5gm/l at 85ºC * 10' – m/c wash

Hot wash

Cold Wash

Dry

Recipe no : Yarn Fabric: L:R =Shade: Quality: Sample weight:

Dyes / Auxiliaries % / g/lit dE Trial SampleTrial – 1

Rema Blue RR 1.979% 2.1Rema Yellow RGB 3.598%Rema Red RGB 1.587%Salt 95g/lSoda ash 20% 5g/lCaustic 38º Be 2ml/l

Trial – 2Rema Blue RR 1.999% 1.02Rema Yellow RGB 3.633%Rema Red RGB 1.587%Salt 95g/lSoda ash 20% 5g/lCaustic 38º Be 2ml/l

Trial – 3Rema Blue RR 1.941% 0.551Rema Yellow RGB 3.528%Rema Red RGB 1.512%Salt 95g/lSoda ash 20% 5g/lCaustic 38º Be 2ml/l

Trial – 4Rema Blue RR 1.999% 0.38Rema Yellow RGB 3.598%Rema Red RGB 1.557%Salt 95g/lSoda ash 20% 5g/l


Caustic 38º Be 2ml/l

Test for Mercerizing:Necessary Equipment:

Volumetric flask

Beaker

Burette

Pipette

Measuring flask

Electric balance

Shaker

Scissors

Necessary Chemicals:

Barium hydroxide, Ba(OH)2 0.25(N)

Hydrochloric acid, HCl, 0.1(N)

Water

Methyl Orange

Sample:

Yarn sample→ 58/2 s singed and mercerized

Single mercerized fabric→ Grey mercerized, Yarn count – 58/2s , Speed – 10m/min.

Double mercerized fabric→ Grey mercerized, Yarn count – 58/2s, Speed – 10m/min.

Stock solution preparation:

To prepare 0.25(N) Ba(OH)2 Solution from a hydride barium hydroxide powder following

formula should be applied

N =VM

W 1000 where, N = Normality

W = Weight of Ba(OH)2

M = Molecular mass equivalent of hydride Ba(OH)2 i.e. Ba(OH)2 .

8H2O,

V = Volume of Ba(OH)2 solution,

For 250 ml solution of 0.25(N) Ba(OH)2 following parameters should maintained,


W =1000

VMN

=21000

25048.31525.0 = 9.8587gm

Now dissolve this Ba(OH)2 in to 250 ml distilled water.

Keep the solution overnight in a safe position in a volumetric flask

Procedure:

2 gm of mercerized sample (fabric or Yarn) has to taken

The sample has to immerse in 30 ml 0.25(N) Ba(OH)2 solution.

The sample in immersion under Ba(OH)2 solution should keep 4 hrs

After 4 hrs the sample mercerized cotton should remove from the solution and shaken

carefully and well by a shaker.

From the left out solution 10 ml has to take for titration.

The solution is titrated with 0.1 (N) HCl in presence of methyl orange indicator.

The volume of HCl required to titrate the Ba(OH)2 solution has been recorded.

Now the mother/stock solution of Ba(OH)2 also titrated with same HCl and the amount

has been recorded.

Then can be calculated by the following formula,

Ba(OH)2% absorbed by the mercerized sample =

stockoftitrationforrequiredHClsolutionoutleftoftotrationforrequiredHClstockoftotrationforrequiredHCl

× 100%

Chart:

Sample

noSample type

Impregnation Required ml of

HCl to titrate

Ba(OH)2

Ba(OH)2 %

absorbed by the

mercerized

sampleStart time End time

1Mercerized

Yarn10:50 am 2:50 pm 20 20.319%

2Single

mercerized11:00 am 3:00 pm 19.1 23.904%

3Double

mercerized11:10 am 3:10 pm 18.7 25.5%

Result:


Ba(OH)2 % absorbed by the mercerized Yarn sample = 20.319%

Ba(OH)2 % absorbed by the single mercerized fabric sample = 23.904%

Ba(OH)2 % absorbed by the double mercerized fabric sample = 25.5%

Evaluation:

Below 15%→ Unmercerized

Above 15%→Mercerized

70%→ Fully mercerized

So the samples are mercerized.

Remarks:The easy test done is not a standardize test. It is generally practiced in mills and factories forquicker evolution of mercerization. In this test accuracy is maintained as much as possible.Titration is done manually. More over the concentration of HCl and Barium Hydroxide alsomeasured by the same titration procedure. As the test result comes in a percentage basis theinitial concentration variation does not hamper the test result. For this reason the test result isclaimed accurate and satisfactory.


Effluent Treatment Plant (ETP) &Caustic Recovery Plant (CRP)


Effluent Treatment Plant (ETP)Square Knit Fabrics Ltd. is very much concern about its effluent, for this reason they

established two effluent treatment plant and they are ETP-I (capacity1200 m3 per day) &

ETP-II (capacity 3000m3 per day). The ETP in SKFL is a biological one. Here bacterial and

protozoa are the catalyst of biochemical reaction to convert the toxic material into

environmental friendly gases and substances. The initial cost of biological ETP is more but it

has a low running cost if control is greater.

Reaction Time: 8-12 hr for secondary treatment

50 m3/ hr for secondary treatment

3-4 ppm/30-35c(for proper bacterial action)

Quantity of micro-organism 1:4

Total capacity of ETP plant: 1200 m3 /day + 3000 m3/day = 4200 m3/day.

Sludge removes level: 800 MI/ 1/2hr f

Effluent Analyzing Report:Parameter Unit Quantity Std. Value

PH 7.5 6-8

COD mg/lt 39 150-200

BOD5 mg/lt 23 29-50

Color APHA/Pt.Co 335 220-250

Phosphate mg/lt 3.2 5-15

Sulphate mg/lt 560 1000

Ammonia mg/lt 2.50 5-10

Chloride mg/lt 120 500-600

Nitrate mg/lt 6.16 08-10

TSS mg/lt 80 60-80

TDS mg/lt 2075 2100

Chlorine mg/lt 0.1 1

Nitrite mg/lt 0.21 >1

Sludge (wet) ml / ½ hr 800-820 700-800


1. Collection Sump

2. Screen Filter3. H

omozeniging Tank

4. Neutralization Tank

5. Distribution Tank

6. Oxidaiton Tank

7. Sedimentation tank

8. Sludge return9. Sludge thikener10. Filter press11. A

ir blower

12. Acid tank

13. Anti foam

ing tank14. D

ecolorent tank15. Polyelectrolyte tank15. N

aHO

Cl tank16. Treated effluent.

Ref: USPEA (United States Environment Protection Agencies)IWRA (International Water Resources Association)GOB (Government of Bangladesh)

13

45

6

7

17

89

10

1516

1213

142

11


Equipments for ETP Laboratory: HACH method (for measuring BOD & COD) BOD Incubator Electric Shaker Reflex Condensat for COD measuring PH meter TDS meter Inhoff con for measuring sludge quantity Desiccators Separating funnel Electric Balance COD Reactor Farness; Portable Spectrophotometer-Meter

Parameters of ETP: Waste water outlet 3000 m3/day

Treatment capacity 1500 m3/day

Running cost 2 – 4 Tk./m3

Plant capacity 1200 m3/day

Bacterial: Protozoa 60:1

Sludge collection at 60 – 70 %

Screen allowance 1 in2

PH 6.5 – 8

Dissolved oxygen (DO) 2 – 3 ppm

Outlet water temperature 30 - 35ºC

Dwell time for effluent discharge 48 hrs. (For oxidation tank)

Bacteria in oxidation tank: Protozoa:Bacilli Paramecium caudatumCocehi Euplotes

Beggiatoa Vorticella dutrinaSpirillum Colpidium

Vitreoscilla


Biochemical Reaction:Bacteria decompose the organic matter and other matters are related with oxygen by

microbial action i.e. biochemical reaction and produce gases and free radicals.

Metals are bio-chemically reacting with the enzyme and produces gases.

Mn + O2 Enzyme MnO2

Organicradicals Gases and free radicals

C

+ O2 ORGANISMMICRO

CO2H H20N NO3S SO4

2-

P PO43-

Process Water Test Report:

Sl.No.

Water quality parameters Unit Dye house standard Testresult

1. PH - 6 to 8 6.232. Color Pt.Co 5 2.03. Turbidity NTU 2 1.04. Total Alkalinity as CaCO3 mg/lt 150 465. Chloride mg/lt 100 8.76. Total Hardness as CaCO3

(TH)mg/lt 2o Gh = (2X17.85) = 35.7

ppm16.45

7. Manganese (Mn) mg/lt 0.1 Nil8. Iron (Fe) mg/lt 0.1 0.029. Total Dissolved Solid (TDS) mg/lt 100 to 180 14510. Sulphate mg/lt 100 111. Oil & Grease mg/lt Nil -12. Arsenic (As) ppb 0.005 -13. Dissolved Silica mg/lt - 42.6

Note: Sample Collection from Hanks Dyeing Area.


Weak lyetank

Pre Heater

Pre Heater

Heat Exchanger

Heat Exchanger

EvapuratorEvapurator

Heat Exchanger

Evapurator

Condenser

Sedimentation

tankStronglye tank

Heating Steam

inlet

Steam inlet

Fig: Shhematic diagram

of Caustic R

ecovery Plant

Caustic Recovery Plant (CRP)Square Knit Fabrics Ltd is very much concern about the environmental issues. Here a large

volume of caustic both liquid and solid used in different wet processes as a basic chemical. In

case of Yarn and Fabric Mercerization most of the liquid caustic produced and effluent

containing caustic produced. The recovery of these caustic of 2º to 5º Be concentration is

beneficial for cost minimization and reduction of effluent which may cause environmental

hazard.


Recovery Process:Effluent reached to weak lye tank

Concentration is 2º - 5º Be

Pre heating done in pre heaterTemperature 60ºC - 65ºC

Boiling occurs in 1st Heat exchanger

Temperature 120ºC

Evaporation of water in 1st evaporatorConcentration 10ºBe

2nd Heat exchanger

Temperature 114ºC

2nd EvaporatorConcentration 20º Be

3rd Heat exchanger

Temperature 84ºC

3rd EvaporatorConcentration 30º Be

VaporCondensation at condenser (Condense flow rate)

Strong lye tank / sedimentation tank

Dosing H2O2

Strong lye tank

Mixing tankMixing with pre stored caustic (1litre 30o Be Caustic + 25 gm Solid Caustic)

Concentration 40ºBe Few Parameters:

Inlet steam pressure 7 – 8 bar

Vacuum condenser pressure 0.3 – 0.4 bar

Condenser temperature 70ºC - 75ºC, Pressure 2 bar, Flow 60lit/80sec

Weak lye temperature 35 - 37ºC, Concentration 5-6ºBe

Strong lye temperature 75 ºC - 85ºC, concentration 28 - 30ºBe

1st stage:

Shell side steam pressure 1.2 – 1.6 bar

Shell side temperature 120 – 130ºC

Pipe temperature110 – 115 ºC

2nd stage:

Shell side temperature110 ºC

Pipe temperature90 – 100 ºC

3rd stage:

Shell side temperature 85 -100ºC

Pipe temperature 70 - 85ºC


Maintenance


MACHINE MAINTENANCE PROGRAM OF SKFL

Maintenance of Machinery:Maintenance of machinery is very essential mechanical effort for achieving smooth running

of different machines. Maintenance is a process by which equipment is looked after in such a

way that trouble free. Services and increased machine life can be ensured and specific

product quality required by the customers is sustained. On time maintenance increase m/c

lifetime & ensures trouble free services.

In Square Knit Fabrics Ltd. following two types of maintenance are done.

Break down maintenance

Preventive maintenance

Maintenance System used in SKFL:

YEARLY MAINTENANCE CHECK LIST

Demag monorail hoist

Grease all the moving parts and bearings

Check all the nut and bolts

Check oil level

Check each sprocket, chain and chain collector are ok

Check the thickness of the lines

Check visually the damage of main girders

Pressing machine

Check rotating table balls and lubricate.

Lubricate the axial bearings

Yarn singeing machine

Maintenance

Preventive Maintenance Breakdown Maintenance

MechanicalMaintenance

ElectricalMaintenance

MechanicalMaintenance

ElectricalMaintenance


Clean control cabinet using a vacuum cleaner.

Do not touch the circuit card and soldering joints.

Every 4 year change the battery on the RAM card.

Santex compactor machine

Check the machine for visual damages.

Replace the worm reduction gear oils.

Check the compacting shoes for wearing.

Check the blankets for wearing.

Check the foundation bolts of the machine.

Fabric dyeing machine


Drain & replace the main pump bearing oil.

Drain & replace the oil of gearboxes.

Check and if necessary replace all plaiter bearings balls.

Check the platter/ J-box center alignment

Check the manhole O-ring.

Check and grease all greasing points.

Check and tight all plaiter, catch basket, reel and other support bolts from the

inside of the machine.

Check all the PTFE carbon supports and sleeves in the plaiting device system

inside the machine



Replace the worm reduction gear oils.

Check the compacting shoes for wearing. Replace if necessary.

Check the blankets for wearing.

Check the foundation bolts of the machine.

Dornier mercerizing machine

Grease all the bearings and moving parts.

Check the bearing bolts and replace them if necessary.

Change the gear oil of the gear boxes

Check the rubber coating of the fixation & drive rollers

Complete check of the cooling plant

Check the spray rings, piping and armatures


Check the pneumatic piping for proper connection

Check and retighten the electric connections of machine

Replace the chains and the chain wheels of the drives

HALF YEARLY MAINTENANCE Alea hank dryer machine

Adjust the chain tension and lubricate it

Check the oil level of the gear box

Change the gear oil once a year

Lubricate the bearings with grease

Calator ruckh inspection machine

Lubricate chain and adjust the tension.

Grease all the bearings.

Change gear oil once a year.

Precision winding machine

Clean the cable channels and electric cabinet

Clean the flyer set and displacement unit

Check certain

Every 5 year replace buffer batteries on the control cabinet

Loris Bellini hank dyeing machine

Clean and check the compressed air filter.

Check the pneumatic cylinders.

Tightening of every bolt.

Tightening of foundation bolts.

Check and replace the roller bearings if necessary.

Maintenance for piston pneumatic valves.

Tightening of terminals of electric motors.

Tightening of terminals of electric boards.


Check condition of variator, remove any wound on thread.

Check automatic contrails of all sensors.

TWO MONTHLY Stalam yarn dryer

Check inside of the panel

Check the nut, bolts and belts of dryer


Grease the roller support every 4 month

MONTHLY MAINTENANCE CHECK LIST Assembly winding machine

Check the cone holder's looseness

Clean the inverters

Clean the yarn path properly

Check the package diameter sensor

Jaeggli yarn mercerizing machine

Grease hooks draught bearings. (B)

Grease function bearings of the squeegee roller (H)

Grease fulcrum bushes of the lifting cylinder(L)

Check the hydraulic oil pressure

Loris Bellini hank dyeing.

Inspection of wear and tear of lid gasket

Lubricate the electric motors.

Check the mechanical seals of add pumps

Inspect the serviceability of safety valves.

Maintenance of stuffing box.

Pressing machine

Check the function of rotating table moving arm

Check thoroughly the sliding pneumatic parts.


Check spindle motor supply

Check function of the vacuum monitor of the suction off switch.

Check function of the compressed air monitor on the gas mix section

Scholl package dyeing

Check main pump v- belt connection

Check the safety, steam and water valves


Clean and lubricate the motors the motors

Clean and lubricate the pumps and check the impellers

Clean the switch board and the switching elements visually


Check the bearings of all rollers

Check the bearings of the chain reversing sprockets

Check the magnetic attachment

Clean the entire plant

Hydro extractor machine

Lubricate the spindle bearings at the end of the shaft and greasing nipple on the

rotary treble behind the front part of removable casing.

Lubricate the guide pulley behind the front part of removable casing.

Monforts Padder, Stretcher & Dryer Machine Lubricate:

Bearings of padder rolls with "N"

Sprockets and chains with "E"

Hand wheel, idle rollers with "B"

Check, Grease If necessary.-

Nuts of width adjustment spindles for wear

Check all spindle bearings for free running

Free running of guide rollers, deflection rollers & contact rollers

Pressure springs of chain pensioner

Perform visual inspection:

Gear box oil level

Belts, pulleys

Move width adjustment motor to the end position & check counters

Mahlo setter and compactor

Check, Grease if necessary:



Free running of guide rollers, deflection rollers and contact rollers.

Pressure springs of chain pensioner

Perform visual inspection:-

Gear box oil level

Belts, pulleys


Corino slitting machine


Grease the squeeze for the rope fabric part

Grease the dewatering bearings

Grease the bearings of water slitting device & driving screw for basket opening

Grease the bearings of open width squeezer

Change gear oil once a year

Sclavos fabric dyeing machine

Check the main pump oil level.

Check all bearings, seals, gaskets.

Check all mechanical seal flush pipes.

Discharge the water from air filter.

Check all m/c flange & platform bolts.

Grease RCR rotary joints every 2 weekly

Clean & check the control panel.

Check the adjustment of catch basket mechanism and plaiter system.

FABRIC DYEING MACHINE Check the machine for visual damages. Check the main pump bearing oil level.

Replace the oil. Check the operation of all alarms.

Check and clean the sedo master controller.

Clean the inlet filter of magnet level indicator.

Check the pressure & temperature gauges.

Check and grease all greasing points.

Check all mechanical seal flush pipes. Specially check the plaiter water nozzle.


Grease rotary joints.

Grease heated rollers supports bearings.

Grease all the bearings.

Grease all the transmission chains.

Grease centering device guide and bearings.

Check driving belts tension and wear.

WEEKLY MAINTENANCE CHECK LIST

Stalam yarn dryer

Clean the dryer by compressed air

Clean the foreign matters in the inductor and between electrode


Clean the filter of asplirator air intake

Hydro-extractor

Remove all the centrifugal heads & check

Clean the entire machine

Lift the c over & clean the drain cannel.

Lubricate the rotary table behind the front part removable casing.

Yarn pressing machine

Check the joints for tightness.

Check the foundation bolts

Check pneumatic oiler oil level

Scholl package dyeing machine.

Flange connections checked for tightness.

Open outlet of V68 valves and clean.

Open outlet pipe after V, 38 valve and clean.

Check lip seal & clean grease with PROBA 270( kluber)

Upper side of cams on lid ring treated with lubricant. Use molykote graphite

grease.

Checked oil level in atomizer

Jaeggli yarn mercerizing machine

Ease bearings of stretching rollers. (A, E)

Ease sleeves of stretching rollers. (F)

Ease bearings of squeezer rollers. (G)

Ease bushes candle. (I)

Check hydraulic oil level and leakages.

Check hydraulic -oil cooling system Is ok

Loris bellini hank dyeing machine

Clean the grid filter of the electric board

Clean the protective grid of the electric motor

Tighting all the bolts and nuts

Maintenance of safety device with program test

Monforts padder, stretcher & dryer machine

Perform visual inspection & clean

In feed roller control unite cylinders


Guide rod. guide roller & bearings

Lifting device cylinders bearings

Under liquor squeeze roller adjustment

Teflon coated bearings, immersed rollers

Belt tension, gear unit

Universal joint shaft coupling

Width adjustment functional wheels

Selvedge sensor uncovers. Pinning shoes. brush

Never grease graphite chain guide rails

Brushes after pinning

Clean & oil

Filter housing & replace.

Sprockets. Clamps with E

Sliding guides cylinders

Dryer removable screens

Air suction control butterfly valves

Oil level of pneumatic oiler filter

Monforts padder, stretcher & dryer machine

Lubricate:-

Bearings of padder rolls with "N"

Sprockets and chains with "E"

Hand wheel idle rollers with "B"

Check, Grease if necessary: -



Free running of guide rollers, deflection rollers & contact rollers.

Pressure springs of chain tensioner

Perform visual inspection:

Gear box oil level

Belts, pulleys


Calator ruckh inspection machine

Clean the reflector for the edge guiding photocell

Check drive belt and chain


Check the inspection table with a cloth


Cleaning the burner rings.

Cleaning the root blower suction air filter.

Clean the traveling blower.


Visually check the motors and pumps

Check the chain drives and tension of chains

Check that all the expanders are properly adjusted Check the surface & readability

of the expander rollers.

Clean the machine from fluffs, dirt, chemicals

Check the function of the solenoid valve

Check the function of the cooling plant,

Check the spraying nozzles and clean them if blocked

Check the rubber coating of the drive rolls

Corino slitting machine

Check turntable tire pump & spring pressure.

Grease the turntable.

Check de twister speed reducer, transmission belts pneumatic brake.

Check oiler oil level of the fabric expander.

Check movable reel plaiter driving system.

Fabric dyeing machine

Check the main pump oil level.

Check all bearings, seals, and gaskets.

Check all mechanical seal flush. pipes.

Discharge the water from air filter.

Check all m/c flang & platform bolts.

Grease RCR rotary joints every 2 weekly

Clean & check the control panel.

Check the adjustment of catch basket mechanism and plaiter system.

Corino squeezer machine

Clean the machine rollers with wet cloth..

Check visually all bearings & drive chains.

Check all air and water hose joints.


Clean compressor filter.

Check tyre pump bellow the turntable.

Check and clean fabric spreader.

Check tension of trapezoidal belts.

Grease turntable- bearing balls.


Clean the machine properly.

Check all bearings & chains.

Check all mechanical joints.

Check all the machine alignments.

Top up the compressed air lubricant.

Clean the panel A/C properly.

Check tension and wear of the spreader belt pulleys.

DAILY MAINTENANCE CHECK LIST.

.DORNIER MERCERIZING MACHINE

Check the quantity of fresh caustic soda in the caustic soda storage tank.

Check the complete machine and the auxiliary equipment visually.

Check whether all chains, chain wheels and drives are properly running.

Check the soda temperature to ensure that the cooling plant works properly

Check that all rollers are easily relatable.

ETPWEEKLY

Clean the glass electrode of pH meter.

Check the filter net of dosing pump.

Check the current of air pressure.

Clean air filter of blower (monthly).

EVERY 4 MONTH

Calibrate the PH meter with buffer solution, 7 & 4.

Calibrate the blower meter,

Grease the oxygen meter.

Grease the scraping, bridge, bridge wheel of ball bearing.


EVERY 2 YEAR

Grease the spring ball bearing.

Change the oil of sludge transfer pump.

Change the oil of feed pump.

Change the oil of lifting pump.

Change the oil of sludge blower.

Change the sensor of oxygen blower (if necessary).

Change the electrode of pH meter (if necessary).

Change the oil of dosing pump.

Change the oil of scraping grease motor


Utility Services


Utility Facilities Available:

The following utility facilities are available at SKFL Water.

- Steam.

- Electricity.

- Gas.

- Compressed air.

Description of the Utilities

Water:

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

Boiler water hardness: 0 0

M/c used: Water conditioner

Submergible pump : 2 (For SKFL) & 1 (For Dormitories)

Process water: 200m3/hr and 150 m3/hr

Domestic use: 150 m3/hr

Company: Cleaver Brooks

Country of origin: USA.

Water consumption: 4500-5000m3/day

Water pressure: 6-6.5 bar

Steam: Boiler Steam: 10.2 tons/hr. & 2.3 tons/hr.

Steam pressure: 7.5-8 bar

Steam temp: 150-160 0 C

M/c used: Fire tube type Gas Boiler & Exhaust Gas Boiler

Piece: 02 (Fire tube type Gas Boiler) & 01 (Exhaust Gas Boiler).

Capacity: 10.2 tons/hr. & 2.3 tons/hr.

Power Supply: Supply: Self

M/c used: Electricity Gas Generator

Brand: Cater Pillar

Origin: USA


Piece: 05

Total Capacity: 5.6 MW (1 MW+1 MW +1 MW +1 MW+1.6 MW).

Chiller:Hotwaterchiller

Vapourabsorbentchiller

Vapour compressionchiller (CentrifugalChiller)

Flue gas with steamabsorption Chiller (Dualcore chiller)

Brand:

Prochill

Thermax

Brand:

Prochill

Thermax

Brand: Mc Quay Brand: Shuang Liang

Capacity:

400 rt/hr.

Capacity: 400

rt/hr.

Capacity: 400 rt/hr Capacity: 661 rt/hr.

Origin:

India

Origin: India Origin: USA Origin: China

Air Compressor:Piece: 07

Brand: BOGE (No. of machine 6) & ROLL AIR (No. of machine 1).

Country of origin: Germany

Capacity: 6 m3 /hr.

Cooling Tower:Use in: Generator

Country of origin: Thailand

Piece: 12

Source of Utility:1. Water- Own supply (Pump)

2. Steam-Own supply (Boiler)

3. Electricity-Generator & PDB

4. Gas- Titas Gas Transmission & Distribution Co. Ltd.

5. Compressed air- Own supply (Air compressor)

Remarks:SKFL is using 0-5deg (total) hardness water which is suitable very for dyeing. The under

ground water is free from hardness creating metals and eliminates the need for watertreatment plant. The electricity supply system is very good and fluently. It is fully equippedto produce its necessary power. Its capacity of power generation is increasing with anothertwo generators to be established. The constant pressure of water also eliminates the need forhigh rise water tank and maintains flow speed in different machines.


Store & Inventory Control


Inventory System for Raw material:In SKFL there are different inventory systems for different raw materials.

Grey Fabric Store:All the grey fabrics are stored in the fabric store near the batch section. Different types

of fabric are listed in the sheet according to fabric types, quantity and consumer's

requirement.

Dyes and Chemicals:There is a different store for dyes and chemicals. Vanes types of dyes and chemicals are

stored here according to dyes and chemicals companies. Different types of dyes and

chemicals are listed in a sheet. In the sheet the stored quantity of dyes and chemicals are

also included. Every day the sheet is updated and a copy of this sheet is supplied to the

dyeing manager, dye house and lab section.

Spares:In SKFL required amount of spears of different machines are stored in the mechanical

store room. All the spares are listed in a sheet which is controlled by the mechanical &

maintenance personnel. Spares are arranged in the store room according to there size,

quantity & requirements. There are shelves in the store room to keep the small spare

parts.

Finished Goods:SKFL supplies its finished dyed fabrics to its garments section. So, dyed finished fabrics

are stored for short time in the finishing section. All the delivered fabrics are noted on

the tally khata according to the lot no, quantity, fabrics diameter, buyer's name, Color &

considering other technical parameters.

Remarks:SKFL has individual stores for raw materials, finished goods etc. the store of dyestuff &

chemicals are not so clean. There is no enough space to store the finished goods. It

requires increasing the store area.


Social & Environmental Information


Scope of Employment Opportunity:As SKFL is continuously expanding with new innovation and advanced modernization in

a diversified manner it creates ample opportunity for employment in our country. Here in

SKFL people have the opportunity of intensively learning about worldwide textile

technology.

Internship Program:SKFL offers a very promising internship program to post graduate and under graduate

students across Bangladesh. Every year SKFL gives opportunity internees to join with

them and they provide as much help as an internees needs during the internee periods. All

the renowned educational institution in Bangladesh highly prefer their students to attend

internship program in SQUARE because of its modem art of state, high profile of

manpower, recognition of superb management.

Environmental Pollution Control:SQUARE is still an example to the industries in the country of a conscientious and civil

and socially responsible manufacturer. Their commitment to improve the environment to

provide their workers with a health and friendly workspace and their neighbours with a

pollution free clean area continues to be strong as ever. All their chemically contaminated

water is treated, neutralized, cleared and given to neighbouring farmers. They provide

Ecotex label to their customer which is a proof of free from carcinogenic dyes and are

accepted as a very environment friendly production unit.

Environmental Policy (For ISO 14001: 2004):SKFL is committed to the protection of the environment and the conservation of natural

resources

SKFL will comply with environmental laws and regulations and will closely monitor its

service, manufacturing, storage, treatment and disposition processes to ensure that the

company’s operations do not create any adverse impact on environment, health and safety

of communities.

SKFL is committed to continual improvement of environmental management system and

environmental performance.


Noise, Dust Pollution Control and Air Emission:Proper administrative and engineering control is deployed in rectifying, reducing and

controlling noise and dust pollution. Air emission is another major concern in the factory

area. Periodic monitoring is conducted to rectify contamination on the air and the air

quality of the area.

Health, Safety and Hygiene Awareness:SKFL believes that all employees are to work in a safe, healthy and hygienic work

atmosphere. In each and every unit, First Aid and Hygiene team along with appropriate

training to care for its people. In all our industrial units SUL have both male and female

physicians with necessary aid and medical facilities.

In order to increase the awareness level of the employees the management also takes great

initiative to take part in ergonomics area such as child care, Family Planning, Pure

drinking water, Arsenic, Diarrhea, Sanitation, HIV, Dengue and general health and

hygiene. This has been practiced in order to aware them and their families.

Conclusion:

Square Knit Fabrics Ltd. has now established in the world as a manufacturer of reputed fabric

and capable of producing value added products and executing difficult orders at very short

lead time. The planning, organizing, controlling, designing, creativity, the technical skill and

above all the quality conscious have cemented the base of this leading textile industry. With

highly advanced technology and an emphasis on developing local human resources, its

seems to be clear that Square Knit Fabrics Ltd. has the potential to make an important

contribution to the nation's growing ready made, garments export sector and makes a example

for others. Industrial training is an important and essential part of education as through this

training I learn all the implementations of the processes which I have studied theoretically. It

gives me an opportunity to compare the theoretical knowledge with practical facts and thus

develop my knowledge and skills. This industrial training also gives me an opportunity to

enlarge my knowledge of textile administration, production planning, procurement system,

production process, and machineries and teach me to adjust with the industrial life.

I have found myself fortunate to have my industrial training at SKFL. It has a hugeproduction capacity with a very efficient production team. SKFL has a very good, well


equipped and modern laboratories and producing a wide range of color. During my trainingperiod I have noticed that SKFL is very concern about their quality and they rarely have anyquality complain. The management of SKFL is very organized, pre-active and co-operative.

At the end of the day I realized that industrial training make my knowledge’s applicationpractically and make me confident to face any problem of my job sector.

Bibliography: www.square-bd.com

www.swicofil.com

www.pburch.net

Basic Principles of Textile Coloration – Arthur D Broadbent

Mr. Md. Habibuzzaman (Shameem)

Senior Manager

Yarn Processing & Mercerizing

Square Knit Fabrics Limited.

industrial attachment of square knits fabrics limited (skfl)

Engineering

sandphore

total horse

sdl atlas

textile engineering

origin japan

origin germany

good colour

optical brightening