report on industrial trainning at mtl
TRANSCRIPT
Shyamoli Textile Engineering College (Affiliated By University Of Dhaka)
Report On Industrial Training
At
Mashriquee Textiles Limited
Submitted To
Engr. Md Faridul Hasan
General Manager
Submitted By
Name: B. M. Tanimul Islam
University Roll : 700
University Reg. No. : 4578
Name: Md Naim Hasan Towhid
University Roll: 707
University Reg. No. : 4592
Name: Khandokar Hasanuzzaman
University Roll: 704
University Reg. No. : 4589
Name: MD. Shariful Huda
University Roll: 711
University Reg. No. : 4602
Report On Industrial Training
At
Mashriquee Textiles Limited
Foreword
At first we would like to express our heart full off thanks to Almighty Allah for his kind
blessing for completion of the “Industrial Training” successfully.
Industrial training is a sole part of academic function of any engineering education. Textile
is the most demanded product after food. The higher study of textile engineering needs the
experience of industrial knowledge is gathered academically.
We the students of Shyamoli Textile Engineering College affiliated by University of Dhaka
were assigned to perform our “Industrial Training” in Mashriquee Textiles Limited for
months. This is one of the renowned knit composite factory in Bangladesh. After getting
permitted through the proper authorities we got the chance to experience the industry.
In our training in Mashriquee Textiles Limited we worked in all departments related with
the textile manufacturing. We worked sincerely in knitting section, utilities, maintenance,
dyeing, finishing & garments, quality assurance department and ETP.
We also learned about inspection section, warehouse, store and inventory. As we majored
wet processing so our emphasis of this report is on dyeing & finishing.
Finally we would like to thank our supervising teachers of our institution. Especially our
respected principal Prof .Dr. Engr. Md. Mufazzal Hossain and our supervising teacher Avik
Kumar Dhar for his sincere time, valuable guidance, suggestion and encouragement.
This report would be incomplete if we don’t mention the heart warming friendliness of
Mashriquee Textiles Limited executives and workers. Especially
1. Hasan Hafizur Rahman (MD)
2. Engr. MD. Faridul Hasan (GM)
3. Md. Atiqur Rahman Sazib (Co-ordinator, Quality Assurance Department)
4. Md. Humayan Kabir (Dyeing Manager)
Contents 1. Project Description 05 – 09
Pages
2. Man Power Management 10 – 15
Pages
3. Machine Description 16 – 54
Pages
4. Raw Material 55 – 57
Pages
5. Production Planning Sequences & Operations 58 – 85
Pages
6. Quality Assurance System 86 – 99
Pages
7. Maintenance 100 – 108
Pages
8. Utility Services 109 – 120
Pages
9. Store & Inventory Control 121 – 124
Pages
11. Marketing Activities 125 – 128
Pages
12. Conclusion 129
Page
Chapter – 1
Project Description
1.1 Company Profile
Mashriquee Textiles Limited is a 100% export oriented knit composite factory. It is well
equipped with most modern & sophisticated European textile finishing equipment &
Japanese vastly experienced management. Mashriquee Textiles Limited committed to render
best services on timely shipment of garments to the valued customers all over the world.
Mashriquee Textiles Limited is a knit composite mill consists off fabric manufacturing
(Knitting), knit dyeing, finishing & garments manufacturing department with an area of
24,375 square feet. Mashriquee Textiles Limited is located in Konabari BSCIC Estate,
Gazipur, Dhaka. Mashriquee Textiles Limited is very much distinctive about the quality as
in the knitting & dyeing section varieties of product is produced. All of the machineries
used in this company are branded, modern & sophisticated machineries. All of the manpower
of this company are highly trained and consists of skillful knowledge.
This company deals with various foreign buyers those are very much renowned worldwide
for their supremacy. Among those buyers we may include EFRA, Al-hasan, Nework, Gulf,
Unigear, Southern, Next, Comfit, Unique, Ayesha, Knitzone, S&P, Lazim, Steadfast, Avg Party,
Danys, Mukul etc.
1.1 General Information About the Factory:
Name of the Mill : Mashriquee Textiles Limited
Type : 100% Export Oriented knit Composite Mill
Company Number : C – 54858
Status : Resgistered
Jurisdiction : Bangladesh
Year of Establishment : 2006
Head Office : Sector 13, Uttara, Dhaka
Corporate Office : Basic Estate Konabari, Gazipur, Dhaka
Address : Konabari Basic Estate Plot # S – 33, S – 34, A – 105 (part), A – 108 (part),
Gazipur, 1711, Banglacesh.
Space Available : 24,375 sft/Floor
Environment : RCC Constructed and steel building
Web : www.mashriqueetex.com
Fax : +88 02-9298705
Phone : +88 02-9298705
Name of Contact Person : Enge. Md. Faridul Hasan
Md. Atiqur Rahman Sazib
Email : [email protected]
Name of Bank :
Investor : Hasan Hafizur Rahman, Managing Director
Access to Sourcing : Capable of importing yarn, fabric & accessories from any
country.
Raw Materials : Cotton, (100%), polyester, CVC, PC, viscose, nylon, lycra as well as
Blended fabric.
Different Department:
(a) Knitting Section: 1 Knitting section inspection
(b) Dyeing Section: Batch section.
Dyeing lab.
Dyeing section
Quality control.
Finishing
(c) Garments Section: Cutting
Sewing
R.N.D./ Sample
Quality control
L.E.N & planning
Store.
(d) Merchandising & Marketing
(e) Maintenance Section: Electrical.
Mechanical
(f) Store Section
(g) Supporting Department:Security department
HRD
Marketing
Procurement
Finance and accounting
Personnel administration.
Total Manpower: Over 2000
Project Cost: 40 Cores (approx)
Production Capacity: (i) Knitting section: 8-10 tons perday.
(ii) 10-12 ton per day.
(iii) 17,000-18,000 pcs/day (Average)
Major Customer : # EFRA # Comfit
# Al-hasan # Mukul
# Network. # Unique
# Gulf # Ayesha
# Unigear # S&P
# Southern # Lazim
# Next # Stead fast
1.3 Mill Location:
1.4. History of Mashriquee Textiles Limited:
Mashriquee Textiles Limited was established in the year 2006 and is engaged in
manufacturing of all kinds of knitted garments. When it first started it had only a few
conventional knit dyeing machine. But under the guidance of managing director Hasan
Hafizur Rahman, the company has gained immense success. He is guiding his team with
his wide experience and skill. Now the company has all kinds of modern machine &
in house infrastructure. They also make use of simple hand tools that helps in producing
high quality fabric in large volumes & varieties. Their products are made using top
quality yarn that is produced from reliable sources across world. They are dedicated to
offer timely delivery of goods and services at affordable prices.
1.5. Product Mix:
(a) Knitted Grey Fabrics: Plain single jersey, heavy jersey, polo pique, lacoste, rib &
interlock double jersey, drop needle, 2/3 thread fleece (brushed/un-brushed), collar &
cuff etc.
- 100% cotton
- 100% polyester
Grey mélange (15% viscose+ 85% cotton
30% viscose+ 70% cotton
10% viscose+ 90% cotton
1% viscose+ 99% cotton)
- Polyester-cotton blends
(b) Knit Garments: T-shirts, polo shirt, sweat shirt, golf shirt, cardigan, jogging suit,
short/trouser, legging, fashion dress % children wears etc.
1.6. Final Products Name:
- T-shirts
- Polo shirts
- Ladies wear
- Sports wear
- Tank tops
- Kids wear
- Jog suits
- Reversible garments.
1.7. Physical Infrastructure:
The mill is built in such a way that there is possibility for further expansion of the
mill. The structure such as mill, office buildings, record rooms, guardrooms & dining
room etc. are made of solid hard concrete & brick. The main set up for m/c’s are built
of corrugated iron & iron sheet, transparent hard plastics with enough ventilation &
scope of passing light & air.
Total area of the industry : 30,000 sq.ft
Factory land area : 28,000 sq.ft
Building : 4 storey
Floor space (Knitting) : 8,000 sq.ft
Floor space (Dyeing & Finishing) : 24,375 sq.ft
1.8. Mission:
Mashriquee Textiles Limited is a full service vendor with strong vertically integrated
production facilities as well as creative & analytical capabilities which clearly set us
apart from most other vendors in Bangladesh. Each of their activities must benefit and
add value to the common wealth of our society. We firmly believe that, in the final
analysis we are accountable to each of the constituents with whom we interact; namely
our employees, our valued customers, our suppliers, our business associates, our
shareholders and our fellow citizens.
1.9 . Vision:
Gain market leadership in high value added composite in Bangladesh.
Use “Innovation” & “Speed” as prime drives, rather than cotton & cheap labor.
Dominate these markets in high quality.
Men’s, women’s, children’s dresses.
Knitted tops & bottoms.
Sport wear, jog suits, t-shirt, polo shirts, reversible garments etc.
Chapter – 2
Manpower Management
The company has skilled administration, management and marketing team guided by
proficient, dexterous & experienced leaders of offer right solution for the consumers
with the right eminence & with the shortest lead time for the export market in
Bangladesh. The best use of continuous development of human resources by providing
them standard equal comprehensive competence in al level of the organizational
hierarchy.
Mashriquee Textiles Limited the MD who controls the entire factory. And the others
who controls the department chief controls their department in this factory.
2.1. Organogram of Mashriquee Textiles Limited:
Managing Director (MD)
Director
General Manager (GM)
Deputy General Manager
(DGM)
AGM
(Garments)
Manager
(Dyeing)
Manager
(knitting)
Manager
(Maintenance)
Manager
(Finishing)
Manager
(Merchandising)
Cutting/
Sewing
Asst.
Manager
Asst.
Manager
Asst.
Manager
Asst.
Manager
Senior
Merchandiser
In charge P.O. Knitting
Master
Maintenance
Officer
Maintenance
Officer
Junior
Merchandiser
Supervisor In Charge In Charge In Charge In Charge
In Charge
Operator Supervisor
Supervisor
Supervisor
Supervisor
Supervisor
Helper Operator
Operator
Operator
Operator
Operator
Helper
Helper
Helper
Helper
Helper
2.2. Management System:
Internal Communication System:-
o Intercom telephone
o Fax
o E-mail
o Written letters & papers
o Oral
Shift Change:
There are three shifts in this factory and each shift is of eight hours. Its is changed after
a week on Monday.
Shift timetable for workers & security personel:
Shift (A) ---------- 7:00 am ---------- 3:00 pm
Shift (B) ---------- 3:00 pm ---------- 11:00 pm
Shift (C) ---------- 11:00pm ---------- 7:00 am
General shift ----- 9:00 am ---------- 6:00 pm
2.3. Duties and Responsibilities of Different Working Personnel:
Designation: Managing Director
Responsibilities:
o Make policy and ensure effective implementation.
o Check and approve company budget & ensure proper utilization.
o Arrange all resources as necessary & ensure proper utilization.
o Monitor & audit of all ongoing functions.
o Check, analyze & review reports & data for continual improvement plan.
o Make plan for sales, marketing & procurement and monitor all respective issues.
Designation: Director.
Responsibilities:
o Provide policy & strategy of sales & marketing & ensure available work orders as
per the requirement of the company policy.
o Provide updated information of both local and global commercial functions to all
member of the merchandising team so that they can make procurement plan
accordingly.
o Monitor both merchandising and commercial activities.
o Analyze, review and update of customer requirements.
o Proper raw materials procurement plan & production schedule.
o Ensure sending of complete order file before 7 days of bulk production.
o Monitor production status, ensure in time pre-shipment inspection and in time
delivery.
o Reports to MD & Chairman.
Designation: General Manager.
Responsibilities:
o Making decision about implementation of planning.
o Making decision for purchasing raw materials, machines and equipment, spare parts.
o Observing the production rate and giving necessary instruction to increase
production.
o Employing skilled & efficient personnel in different section.
o Monitor both merchandising and commercial activities.
o Monitor production status, ensure in time pre-shipment inspection and in time
delivery.
Designation: Deputy General Manager.
Responsibilities:
- Making decision about production amount, style, process machines and
equipment used.
- Monitoring the time schedule of order and shipment.
- Giving direction to the junior officers.
- Reporting to GM.
Designation: Manager.
Responsibilities:
o L/C Import Operation.
- Identification of gaps & getting clarification
- Ensuring necessary amendments.
- Operate all other function regarding L/C as per necessity of customer,
company and supplier.
o Export operation & preparation of relevant documents.
o Custom and other relevant activities.
o C & F operation.
o Accountable to chairman.
Designation: Assistant Manager (Production).
Responsibilities:
Monitor daily in line operation & take following steps to ensure balanced production.
Re-adjustment of production / operation layout.
Re-adjustment of working time.
Inter section linking with proper feedback.
Waste control.
Abide by the company’s social compliance.
Accountable to manager.
Designation: Production Officer.
Responsibilities:
To collect the necessary information and instruction from the preview shift for
the smooth running of the section.
To make the junior officer understand how to operate the whole production
process.
To match the production sample with the target shade.
To identify the faults of production and making a report to the PM/GM for
necessary action.
To execute the overall floor work.
Designation: In Charge.
Responsibilities:
- Support marketing & sales section with following activities:
- Develop new design with decent make up.
- Relevant technical information.
- Consumption of raw material.
- Support procurement section with the following:
Details analysis of PI/Contact sheet, determination of order requirement,
identification, classification of gaps.
Preparation of approval sample & detail check list with relevant technical
information (consumption, measurement, sketch & critical qua;ity point of raw
material).
Preparation of photo sample & swatch card.
- Distribution complete order (along with following) files before 7 days of bulk
production:
Contract or order sheet.
Quality breakdown.
Makeup/style detail.
Measurement chart.
Sketch/placement of accessories.
Stitching detail.
Garment sample (Approved by customer).
Washing and embroiding instruction.
Fabric & accessories swatch card (Mentioning fabric face – back).
Master pattern set.
- Report to merchandising & commercial department.
Designation: Supervisor.
Responsibilities:
- Ensure sewing of every cut panel and to assemble all part to make complete
garments as per customer specification.
- Manage and motivate members of the team.
- Maintain/monitor all required reports.
- Make decisions for the problem which cannot solve by operators and need to be a
living example in the floor.
- Ensure maximum utilization of time table.
- Abide by the company’s social compliances.
- Accountable to assistant manager (production)
2.4. Section – Wise Manpower:
Department Manpower
Knitting 100
Dyeing & Finishing, Lab & QC 200
ETP 10
Garments 1500
Power, Boiler, Utility & Maintenance 50
Inventory 10
Administration 50
Security 50
Others 40
Total 2010
Chapter – 3
Machine Description
3.1. List of Machine
Department Machine Type No. of Machines
Grey Fabric Store &
Inspection
Fabric Inspection m/c 1
Batching Turning m/c 2
Overlock m/c 5
Dyeing Floor Winch Dyeing m/c 7
Sample Dyeing m/c 4
Lab Dip Machine 2
Electrical Pipet 2
Spectrophotometer (Data
color)
1
Computer 1
Printer 1
Lab Washing m/c 1
Tumble Dryer 3
GSM Cutter 3
Crock Meter (Wet & dry
rub)
1
PH Meter 1
Dryer 1
Electric Balance 2
Washing Section Slitting m/c 1
Hydro Extractor 1
Finishing Section Stenter m/c 1
Computer 1
Circular Knitting m/c 5
Knitting Section Rib/Interlock Knitting m/c 12
Single Jersey 15
Flat Knitting m/c 3
Auto Trimmer Plain m/c 220
Button Hole Plain m/c 10
Button Stitch Plain m/c 20
Sewing, Cutting & Finishing Bar Tuck Plain m/c 5
Snap Button Plain m/c 10
Over Lock m/c 185
Flat Lock Machine 120
Auto CAD 1
Rib Cutting m/c 9
Metal Detector m/c 10
Strapping Machine 5
Cloth Inspection m/c 10
Cutting Inspection m/c 15
Cutting m/c RM 15
Stem Iron 5
Precutting m/c 80
Embroidery Machinery -
Barudan
5
Feiya 3
Profit 2
Printing Machinery – Single
plate Fleat Press machine
2
Printing Section Conveyer dryer 3
Vacuum Expose m/c 1
Mest Tension m/c 1
Oven m/c 1
Compressor 22v/1.1KW 2
Fluck m/c 4
Double Station Heat Press
m/c
2
Generator 3
Power / Utility Boiler 2
Compressor 3
3.2. Specification, Features and Functions of Different Machines:
3.2.1. Machines in Grey Fabric Store & Inspection
Specification:
Name: Fabric inspection & rolling machine
Model: Ai-204
Country: India
Brand: Techmech Warp.
Working Width: 1150 to 4000mm
Max Dia of Inspection Roll: 400mm
Working Width: 0 to 50 meters/min
Electric Power: 2HP (2 motors)
Power Supply: 220W, 1 phase, 50 HZ
Salient Features:
Fabric inlet from roll, flat fold or big batch rolls.
Fabric outlet from roll, flat fold or big batch rolls.
Laminated inspection table with opaque glass.
Fabric edge guider for straight edged fabric rolls.
Two sets of geared motors driven by inverter (multik drive).
Dancing roller mechanical length counter meter.
Standard mechanical length counter meter.
Adjustable roll hardness.
Variable illumination inside & over the table.
Wooden platform.
Variable speed from 0 to 50 meters/min.
Full length revering and linching.
Powder coated external touch.
Function:
Defects and incorrect sizes are easily & rapidly discovered.
Reduces fabric waste to minimum and guarantees only high quality fabric is
delivered.
Tensionless handling got fabric focuses on fabric care.
Work fast, efficient and easily handled requires only one operator.
Produces straight and presentable fabric rolls.
3.2.2. Machines in Batch Section:
Turning m/c.
Specification:
Name: KD-300 type tubular air type cloth turning m/c.
Type: Turning m/c.
Brand Name: KD
Model Number: KD300
Country: China
Certification: CE Mark
Technical Parameters:
Diameter of air-duct: 200mm
Height of center: 1.0-1.2m
Length: 3.5-4m
Speed of cloth turning: 35-60m/min.
Application:
This m/c is used for cloth turning of tubular knitted fabric
Overlock m/c 1,2
Specification:
Name: Four thread overlock JACK JK-804D-M2-24
Type: Overlock m/c.
Manufacturer Name: TROJAN SEWING.
Model Name: JK-804D-M2-24
Brand Name: JACK
Mfg. Country: Australia
Product Description:
Needle: B27 size 11/14 number of needles 2
Direct Drive Motor: 70% saving on standard clutch motor.
Stitch Length: 4.2
Stitch Width: 4mm (Nice and wide).
Pressure Foot Height: 5.5mm
Sewing Speed: Adjustable up to 6000 S.P.M
Differential Feed Ratio: 0.7-2
Fully Lubricated: High speed overlock, complete on formica table and unit stand.
Features:
Direct drive 4 thread high speed overlock integrated power saving motor.
Adjustable speed; Ease of use, ease of threading built into this modern designed
overlock has become the machine of choice for all stretch fabric.
Oil supply optimization: Fully enclosed needle bar mechanism & oil return
mechanism, improve thee condition of needle bar abrasion & oil leaking.
Push-button: Stitch length control
Differential feed control allowing flat pucker free seams on difficult fabrics.
Built in LED light: No more struggling with problematic machines. The JACK JK-
804D is a pleasure to use. Silent motor & reliable machine.
3.2.3. Machines in Dyeing Floor:
Dyeing Machine-01
Specification:
Name: SCLAVOS Athena 3A™ 150H
Type: Winch dyeing machine
Country: Greece
Model: Athena 3A™ 150H
Brand: SCLAVOS
Year of Manufacturing: 2016
Serial No.: 16-1A-3499
Temperature Range: 0°-142°C
Max Work Pressure (MPa): 0.28 [2.8 bar]
Testing Pressure (MPa): 0.40 [4 bar]
Volume: 6760 L
No. of Nozzle: 1
No. of Motor: 4
Production Capacity: 150kg
Design Code: ASME VIII DIV 1
Patent No: 5:624.937
Dyeing Machine – 02
Model: Athena 3A™ 1250H
Serial No.: 14-5A-3442
Volume: 30208L
No. of Nozzle: 5
No. of Motor: 5
Production Capacity: 1250kg
Dyeing machine – 03
Model: Athena 3A™ 750H
Serial No.: 14-3A-3441
Volume: 19202L
No. of Nozzle: 3
N. of Motor: 8
Production Capacity: 750kg
Dyeing machine – 04
Model: Athena 3A™ 500H
Serial No.: 14-2A-3430
Volume: 13655L
No. of Nozzle: 2
No. of Motor: 6
Production Capacity: 500kg
Dyeing Machine – 05
Model No.: Athena 3A™ 250H
Serial No.: 14-1A-3498
Nozzle: 1
Motor: 4
Volume: 8360L
Production Capacity: 250kg
Dyeing Machine – 06
Name: Vatansever
Production capacity: 400kg
Product Id: P60321036
Manufacturing Country: Turkey
Manufacturing Year: 2006
No. of Nozzle: 2
No. of Motor: 6
Volume: 12208L
Code: Mr-02279
Dyeing machine – 07
Name: Overflow dyeing machine
Production Capacity: 100kg
RF.: 1489628-1
Brand: Mcs
Year: 2006
Country: Europe western and northern.
No. of Nozzle: 1
No. of Motor: 4
Sample Dyeing Machine – 01
Name: SCLAVOS Athena S20H
Type: Sample dyeing machine.
Country: Greece
Model: Athena S20H
No. of Nozzle: 1
No. of Motor: 4
Dead Weight: 550kg
Serial No.: 04-1C-3487
Volume: 1500L
Sample Dyeing Machine – 02
Model: Athena S50H
Volume: 1500L
Dead Weight: 600kg
Serial No.: 04-1B-3482
No. of Nozzle: 1
No. of Motor: 4
Sample Dyeing Machine – 3,4
Name: Jet dyeing machine
Manufacturer Name: FONG’s
Country: Hong Kong
Temp. Range: 0°-140°c
Used Utilities: Water, steam, electricity, compressed air
No. of Nozzle: 1
No. of Motor: 4
Production Capacity: 10kg
Winch Speed: 240-300m/min
SCLAVOS Athena 3A™ machines used in this factory have the same unique features except
their production capacity. Athena 3A is the newest development of SCLAVOS in the field
of knitted and a range of knitted fabric dyeing m/c.
Athena 3A incorporates some unique features such as:
Double soft floating dyeing system (DSF)
Open plaiter system with liquor by pass
Aquachorn 3GA continuous washing system for non stop rinsing operation.
Double Rope operating system for increased capacity of light weight fabrics.
Automatic setting Adjustment
Advance Automation system for total Interactive control
Full monitoring of utilities consuptions
Variable loading system
Integrated Control of Liquor Ratio
Low power pump built in house
Benefits that Sclavos can guarantee to users of Athena 3A are;
Fabric Quality
No surface pilling due to mechanical abrasion
Low tension and shrinkage
Minimum fiber loss
Gentile treatment of delicate fabrics
Performance:
Fast process time
Low energy consumption
Minimum water consumption
Ease of operation
Batch to batch repeatability
Tangle free operation
High capacity for light weight fabrics with no tangles
“Automatic” washing cycle
Data for costing calculation
Main Parts of the Machine :
Main tank
Reel
Emergency rod
Nozzle
Panel board
Heat exchange
Heat recover box
Filter tube
Chemical tank-1,2(Injecting)
Salt dosing tank
Monitor
Drain line
Winch
Viewing light
Valves
Main motor
J-box
Additional motor
Main Tank: Main tank is the largest plant of the dyeing machine. This is the main
dye bath which contains the dye liquor and the fabric. The size of the tank depends
on the capacity of the machine. Liquor and fabric circulates in the main tank during
dyeing process.There may have different number of nozzle connected to main tank
according to the machine capacity.
Reel
Nozzle
Panel Board
Main Tank
Heat Exchanger
Monitor
Main Motor
Chemical Tank-2
Chemical Tank-1
Reel: Fabric is loaded in the main tank using real. There is a motor attached to the
reel. It makes the loading process easy. Reel also used to unload the fabric from
tank after dyeing..
Nozzle: Nozzle is the part of winch dyeing machine where dye pick up of the
fabric is maximum. After the winch the fabric is passed through the nozzle. Main
motor is connected to the nozzle and continuously circulate dyeing liquor to the
machine via nozzle. Fabric passed with the pressure of water and used for controlling
the speed of dye liquor. There is opening in the nozzle which can be controlled as
required.
Panel Board: Panel board is attached to the main tank. By this board is used to
control the rpm, temperature, on-off of the machine.
Monitor: Monitor is used to observe the process. Such as cheek water level,
temperature, pressure, dosing time etc. According to each bath data, machine sets all
the operation adjustment automatically by advanced Automation and Autosettings.
Thus, dye house supervisor is not involved to prepare any adjustments. As a result
machine always operates at optimum conditions, ensuring full batch to batch
repeatability
Chemical Tank-1, 2: Chemicals are directly passed to the main tank by injecting
process. Injecting means to directly pass the liquor from dosing tank to main tank
without any time required i.e. to inject the liquor from dosing tank to main tank.
Heat Exchanger: Heat exchanger is used for heating & cooling the dye bath liquor.
Heat exchange process is achieved by passing steam or water through the coiled
pipe line present in the heat exchanger. When heat is increased then steam valve is
opened and passed through the coiled pipe line and dyeing liquor is passed through
the heat exchanger. During the passage, heat increase of dyeing liquor. For reducing
heat, water valve is opened and heat will reduce.
Heat Recover Box: A heat recover system is used here. This system uses temperature
of the waste water to heat up the fresh water. LAB-PRO is able to provide an overall
solution for the optimization of hot and cold water supply.
Main Motor: Centrifugal pump is used for circulating the liquor through the
dyeing machine. Its capacity will depend on the capacity of the motor.
Emergency Rod: Pulling the emergency rod stops the machine.
Emergency
Rod
Filter Tube: Filter tube is used inside the circulating line and drain line through
which dyeing liquor is passed to filter impurities. If the filter is jammed then remove
from line cleaned.
Filter Tube
Salt Dosing Tank: Salt is closed in this factory by linear process. Linear dosing
means to pass the liquor from dosing tank to main tank in a time equally. As for
example, if we want to pass 60g/l liquor in 30 minutes in linear dosing then we
will have to pass 2g/l per minutes.
Salt Dosing
Tank
Drain Line: Drain line is used for extracting the liquor out of the dyeing
automatically.
Drain Line
Winch: Winch is an important part of dyeing machine and used fir moving the
fabric through the whole dyeing machine. Winch is rotated with the help of motor.
Fabric is passed over the winch and fabric dwell time depends on the winch speed.
Winch speed will depend on the rope length and gsm of the fabric to be dyed.
There is opening on the machine for winch to removed tangled fabric from winch.
No. of nozzle per winch is normally 1 or 2 and total no. of winch per machine will
depend on machine capacity .
Viewing Light: Viewing light is given in the dyeing machine to see how the dyeing
of the fabric is advancing in the dyeing machine from outside of the dyeing machine
as it is impossible to look in to the dyeing machine due to high steam temperature.
Valves: Different types of valves are used in dyeing machine .Such as steam
valve, water valve, pneumatic valve etc.
J-box: J-box of the machine is where fabric will stored after falling from the
nozzle. J-shape helps the smooth passage of fabric. This box contains a deposition
tube line attached to the fabric guide. This box is perforated and ensure easy
circulation of dyeing liquor to the machine.
Additional Motor: Additional motor is used to dissolve salt, soda dye and other
chemicals. This motor is used in the dosing tank and there is an agitator
connected to the motor for additional power.
Athena S 50H:
Athena S 50H is a high temperature Fabric Dyeing Machine for batches between 30 and
50 kgs of fabric. Machine can operate with low liquor ratio 1: 5.5
Athena S 50H is equipped with one soft flow nozzle with liquor by pass ensuring gentle
treatment of knitted fabrics.
Thus achieved equality of fabric is as good as in bulk capacity SCLAVOS machines.
Machines operation is fully automates.
Athena S 20H:
Athena S 20H is a high temperature Fabric Dyeing Machine for batches between 15 and
20 kgs of fabric machine can operate with low Liquor Ratio 1: 5.5
Athena S 20H is equipped with one soft flow nozzle with liquor by pass ensuring gentle
treatment of knitted fabrics
Thus achieved quality of fabric is as good as in bulk capacity SCLAVOS machines.
Machines operation is fully automated .
Machine Setup on the Basis of Fabric Type and GSM:
Fabric type GSM Pump Speed (%) Reel Speed (RPM)
Up to 140 80 250
Single Jersey 140-180 85 230
180-above 90 210
Polo pique, Back Up to 160 85 280
Pique & Bubble 160-200 90 260
knit 220-above 90 240
Up to 180 85 260
Interlock 180-220 90 240
220-above 90 220
3.2.5. Machines in Lab section:
Spectrophotometer
Name: 650™ BENCH-TOP SPECTROPHOTOMETERS
Part No.: 1200-1473
Serial No.: 8809277
Ratings: 100-240 VAC, 47-63HZ, 100VA
Made In: Design USA, Assemble China
Instrument Type: Dual – beam d/8° spectrophotometer.
Illumination Source: Pilsed xenon filtered to approximate D65.
Sphere Diameter: 152mm/6.0inch.
Specular Analyzer: Proprietary SP2000 analyzer with dual 256 diode array and high
resulation holographic grating.
Transmittance: Yes
Wavelength Range: 260nm to 700nm, reporting at 10nm intervals.
Photometric Range: 0 to 200%
20 Read Repeatability: 0.01 (max DE CIELAB)
Inter-Instrument Agreement-Reflectance: 0.15 (max DE CIELAB)
0.08 (max DE CIELAB)
Inter-Instrument Agreement-Regular Transmittance at 550nm: ±0.20% at 85%T
±0.10% at 32%T
Inter-Instrument Agreement-Transmission Haze Measurements: ±15% at 10%TH
Transmission Sampling Aperture Size: 22mm
Features:
No profiting required – the industry’s best inter-instrument agreement right out of
the box.
Superior dark end stability.
State of the art SP2000 spectral technology
Automated zoom lens and specular port (SCI/SCE)
Automated UV control for measuring florescent material.
Multiple viewing aperatus with automatic aperature recognition.
LED status lights.
Transmission measurement - total, direct and maze (650).
Spectrum: color
Mounting: benchtop
Wavelength: Min: 360nm, max: 700nm
Technical applications: for color measurement
Other characteristics: reflectance, transmission.
Description:
The data color 650™ is the ultimate flexible spectrophotometer, featuring unparalleled
accuracy for both reflection and transmission the perfect solution for plastics and dye
manufacturers requiring the best results for color matching a wide variety of materials.
Designed for: Precise color matching and color quality control for dyes, plastics and
transparent materials.
Light box – 1
Specification:
Name: TRU-VUE® 4 Light Booth
Type: Color matching cabinet
Brand: Datacolor
Country: USA
Model: TRU-VUE® 4D
Dimensions:
Height Width Depth
19 inch 26.5 inch 19 inch
48 cm 67 cm 50.6 cm
Viewing Area:
Height Width Depth
14.25 inch 24 inch 16 inch
36.2 cm 61 cm 40.6 cm
Shipping Weight: 38lbs (17kg)
Electrical: 214W (120 or 220VAC)
Light Sources Model
120V Models:
Light
1 Daylight
Fluorescent
Daylight (6500K)
1 Store light
Cool white fluorescent
1 home light Incandescent (2800K)
1 Ultra violet A 315-400nm black light blue
1 Optional fluorescent TL83 fluorescent
220V Models:
1 Daylight Fluorescent
Daylight (6500K)
1 store light
TL84 Fluorescent
1 home light Incandescent (2800K)
1 Ultraviolet A 315-400nm Black light blue
1 Optional fluorescent TL83 fluorescent
Features:
ASTM D1729 compliant
Compact size
4 different light sources
Dimming on the three primary sources (Day – store and Home – light)
Illuminated push button control
Programmable one touch automatic light source sequencing.
Optically neutral diffuser for aging of primary light source.
Munsell N7 gray surround.
Optional 45° viewing table.
Tumble Dryer - 1, 2, 3
Specification (Technical):
Name: Ramsons Tumble Dryer
Brand: Ramsons.
Country: India.
Model: RTD 75
Capacity: 75kgs
Basket volume (ltrs): 1495
Basket Depth (mm): 1000
Basket Diameter (mm): 1380
Door Opening (mm): 750
Drive Motor (HP): 3
Blower Motor (HP): 2
Steam Inlet (inch): 1.25
Steam Outlet (inch): 1.25
Air Outlet (mm): 200×250
Heater (Optional) (HP): 27
Dimension (W×D×H) (mm): 1560×2010×2330
Approximate Weight (KG): 1050
Technical features:
The Ramsons tumble dryers come with an inner stainless steel basket. All the dryers
have a programmable controller capable of storing up to 5 programs. Features such as
auto reverse, digital temperature indicator/controller, forward timer with pause timing and
total time come standard with this controller.
All machines come with an auto PH (residual humidity) meter thereby ensuring that
maximum energy is saved (optional). The drive of the Ramsons dryers is via balanced
closed grained cast ironed pulleys with matching V belts and pedigreed bearings. This
enables the equipment’s to sustain radial and axial loads.
The inner basket is double insulated with a high quality mineral wool held in place by
fine aluminum shed backing on loaded spring hooked ties. The inner stainless steel basket
is a fitted with CVC manufactured stainless steel paddles to ensure a smooth tumbling
effect.
The high load capacity ratings self, self cleaning lint screen and other designed features
make this dryer a space and energy saver and guarantees faster drying time.
As an option, dryers are also available in all stainless steel construction, direct gas fired
heating option is also available.
Lab Dyeing Machine 1
Specification:
Name: Datacolor AHIBA IR™
Brand: Datacolor
Model: AHIBA IR™
Country: USA
Applications:
Features Description
Fibers All
Substrates Piece, Skein, loose, tops
Minimum Liquor ratio 1:5 Natural fibers
1:3 Synthetic fibers
Heating/Cooling:
Features Description
Heating system Infra-red
Max-heating power 3KW
Temperature range 20°-140°c
Cooling Forced air
Dyeing capacities:
Feature Description
Beaker sizes & maximum 150cc×20
Number of dyeing positions 300cc×15
500cc×8
1000cc×8
5 liter drum×1
Dosing:
Manual dosing injector
Controller:
Feature Description
Controller type Icon/Button driver.
Program capacity 99 dyeing programs
Program name User selectable number
Programmable steps 15 steps
Language N/A
Display size 114mm×64mm
Controller Parameters:
Features Description
Time In minutes
Temperature 0.1°c or °F
Temp. fradient 0.1°c or °F/min
Rotation speed 5 to 50 rpm
Reversing Automatic every 1 minute
Program halt Selectable on/off for each step
Physical/Electrical:
Features Description
Dimension 864×594×648mm
Weight 34×23.5×25.5inch
Weight 73kg
Voltage 230V AC 50/60HZ single phase
Insulation Fiberglass
Features:
Multiple beaker configurations ( 150cc, 300cc, 500cc, 1000cc, 5L )
Dosing options available High – grade precision stainless steel construction.
New Microprocessor Controller
New controller interface uses symbols to relay programming information, eliminating
the need for language translations
New see – through Door
High temperature glass protected by a heat shield allows the user to visibly see the
beaker motion in action
New temperature sensor
New design is durable and accurate and gives years of reliable results.
Low Environmental Impact
High efficiency infra-red lamps and high output air cooling system reduce energy
consumption
Increased productivity in the laboratory
Up to 20 dyeing positions available, many beaker sizes available, adaptable as the
needs of the dye lab changes
Low liquor ratio capable
Beaker agitation options that offer smooth or aggressive agitation given the specific
substrate requirement.
Increased program storage capability
Up to 99 programs of 15 steps available to be stored locally for easy recall
Stored 99 multistep programs
Easy to use language free microprocessor controller
Dye bath temperature measured inside the beaker.
Lab Dyeing machine - 2
Specification:
Name: ECO DYER
Brand: Rapid
Model: ECO-24
Serial No: F-751
Country: FUJIAN CHINA
220V 1 Phase 50HZ 45 kw
Special Features:
1. Lowest power consumption: 4.5KW required only. Comparing to glycerine type dyeing
machine 9KW or IR type dyeing machine 6KW, ECO DYER not only saving
electricity cost, but also cut off the expense of glycerin.
2. No more sensor pot is needed: No sensor pot is required in the ECO DYER, so
comparing to traditional IR type dyeing machine, no more temperature sensor`s
problem.
3. Ready to use: No water piping is required. Using dual air cooling system for faster
cooling.
4. Friendly design: Not only dye pot but also pot position is numbered in order to
avoid operating errors. Dye pot can easily be loaded and unloaded from the rotary
drum. Futhermore, Complete with sight glass for easy observation of pot motion.
5. Modernize laboratory by installing ECO DYER: ECO DYER with modernized
appearance, no fume pollution and glycerin free, pleasent working environments and
attractive laboratory are assured.
6. Simple and easy operation: ECO DYER`S operating habit same as glycerin type
dyeing machine, simple and easy to running process, individual dye post can be
loaded or unloaded without interruption of temperature.Different amount off dye
liquor can be performed in one lot of dyeing process etc.
7. S.S. 316L made dye pot: Dye pots are made of stainless steel 316L,and are produced
by pressing, no welding spots or creates exist, chemical resistance and perfect dyeing
are guaranteed
8. Even dyeing: The rotary drum has an infinitely variable drive, also provide rotation
360 degree, allows users to achieve even and crease- mark- free dyeing results, even
for high density polyester.
9. Unique design for chemical addition system ECO DYER use “ONE TOUCH”
injection system, to replace traditional syringe injection system. All syringe troubles
such as glass easier break, chemical block in the injection nozzle etc. Are now
history.
10. Application: The most versatile and ECO laboratory dyeing machine, suitable for
general laboratory purpose under high temperature condition, such as recipe dyeing
test, washing fastness test and other laboratory R & D applications etc. now with
modern temperature control system and wide range of dye pots sizes available
ensure safe and level dyeing results.
Specification:
Working temperature: Max 140°C
Rate of temperature rise: Max 3.5°C/min
Heating source: Electric heat-conduct
Volume of dye pot: 300cc, 420cc
No. of pot position: (ECO-24) 24*300cc pot
(ECO-18) 18*420ccpot
Control panel :LCD graphic display microprocessor (50 programs,50 steps)
Cooling system: Dual air cooling design
Power consumption: 4.5 Kw
Electric connection : 220V * single phase
Machine dimention:69 * 73 * 75 cm (L*W*H)
Machine weight: About 150 Kg
Model of Designation: ECO- 24
No. of POT POSITION
24: 24*300cc pot
18: 18*420cc pot
3.2.6. Machine in Washing Section
Slitting Machine
Specification:
Commercial Name: Super SLITT A.T
Brand: Corino
Country: Italy
Machine: Rope detwisting, turning and slitting machines
Process Brief Description: The machine treats the fabric after dyeing process and prepares
it for drying
The Main Operations on the Fabric are: Rope Squeezing- Slitting- Squeezing- Folding
Material Processed: All kinds of fabric in tubular and open width form.
Energy/ Environmental Performance:
Installed Power: 27KW
Power Consumption: 0.00036 Nm^3/kg material processed
Plant Location Country: European Union
27 Up- to- Data Collection (year): 2015
Alternzione (Working): For your personal safety observe the fabric passage wrong passage
causes accidents.
Anno 2015 Year
Tipo Super slit Type
Makicola 260/15 Serial no.
Tensone 400V 50HZ Voltaze
P. Max 27KW P.max
Detwister break
Pressure max 2.5 bar
Warning: Set to 0 bedore activating pulley mororization massima pressure 2.5 bar
Components of Slitting m/c:
Hydrotable
Rope squeezer
Corino De-twister
LT-07
Quadratex
Antipilling tank
Foulard-FC Due
Spreading solution
Alignment solution
Dry cleaning
Hydro extractors and foulard
Rope openers
Hydrotable:
Turntable with hydraulic control. The hydraulic system is positioned externally.
Rope Squeezer:
To continuously reduce the excess fabric liquid after rope dyeing and washing process.
Constantly feeding the rope openers it reduces the fabric weight and avoids water spills
during the opening process.
Corino De-Twister:
Intelligent element of every Corino opening systems keeps rope twists at the front and can
control a turntable for the elimination of the twists. Matchless sensitivity, the stainless steel
construction reduces the maintenance to the minimum.
LT07:
Rotating basket with rollers, ever since the best tubular guiding system, the only one anle
to create a suction attaching the tube to the guiding rollers.
Quadratex:
System for the detection and the control of the wales of knitted fabrics
Antipilling Tank:
Fabric cleaning system after bio-polish enzyme treatment. Two compartments tank with high
cleaning effect the cleaning is achieved by the continuously circulating bath and the use
of spraying hazzles.
Foulard-FC Due:
Two roller foulard for squeezing or application of chemical products with high-tech rubber
coverings guarantee the lowest possible residual moisture> Made entirely of stainless steel
and equipped with the most advanced fabric spreading devices placed on the nip entry.
Over Feed and Padder Pressure of Slitting Machine
Fabric Type Speed Padder Feed Padder Pressure 1 Padde Pressure 2
S/J 60 m/min
80 m/min
2.5 % - 3 %
1.5 Bar (chemical)
2 Bar (normal)
3 Bar (Chemical)
4 Bar (Normal)
1×1 Rib 30 m/min
40 m/min
2.5 % - 3 % 1.25 bar (chemical
3 bar (normal)
2.5 bar (chemical)
3 bar (Normal)
2×2 Rib 20 m/min
30 m/min
2.5 % - 3 % 1.25 bar (chemical)
3 bar (normal)
2.5 bar (chemical
3 bar (normal)
Loop Back 20 m/min
30 m/min
2.5 % - 3 % 1.5 bar (chemical)
2 bar (normal)
3 bar (chemical)
4 bar (normal)
3.2.7. Machine in Finishing section
Stenter Machine
Specification:
Name: TEXTINNO
Type: Stenter machine
Model: TEXTINNO
Brand: Ehwha Glotech
Year of Manufacturing: 2016
Total Length of Machine (mm): 47,525
Length of Chamber (mm): 30,000
Electricity Consumption (kw): 260
Hot Air Circulation: 15 kw Turbo fan 1 set/chamber
Maximum 40,000 m3/hr. chamber
Exhaust: 7.5 kw Turbo fan 1 set (Eco Flow Exhaust)
Maximum 24,000 m3/ hr. Stenter
Gas Pressure: below 3600 mm. aq
0.1~0.36 bar
Heating Source: 1 burner/chamber (Gas)
Fabric Speed: Maximum 70 m/min (Cotton, Knit fabric)
Maximum 120 m/min (Synthetic fabric)
Application of Stenter:
Stabilizing of Fabric Form:Heat setting of fabric
Drying of Fabric: Implemented after the washing and dyeing process
Fixation of Dye: Color development processing etc.
Curing of Fabric: Implemented after resin treatment processing for stiffening the
fabric
Main sections:
Fabric Entry Section
Over-feeding Device
Inlet Rail And Pinning Device
Drying & Heat Setting Chamber And Eco Flow Exhaust System
Outlet Rail And Main Driver
Plaiting Device
Compactor Machine:
Specification:
Name: Lafer SPA
Type: Compactor Machine
Model: KSA 500
Brand: Lafer SPA
Cylinder Width: 2600 – 2800 mm
Minimum Fabric: 950 mm
Maximum Fabric: 2400 mm
Conical Unit Maximum Closing: 1400 mm
Mechanical Speed: 5 – 60 m/min
Electric Power : 25 – 31 kW
Chapter – 4
Raw Materials
4.1 Raw Materials for Dyeing:
Mashriquee Textiles Limited is a knit composite textile industry. In this industry the raw
materials used for production of colored or white finished fabrics which are ready for
the preparation of garments are:
Grey fabrics
Dyes
Chemicals
4.2 Grey Fabrics
According to Fibers:
100% cotton fabric
CVC fabric
PC fabric
Lycra twill fabric
Grey mélange
According to Fabric Structure:
Single jersey
Single jersey with lycra
Polo pique
Single & double Lacoste
Fleece
Interlock with lycra
Rib & its derivatives (1*1 Rib, 2*2 Rib)
Rib with lycra
Different types of collar & cuff
Piping, Twill tape & other decorative accessories
Grey Fabric Source: Mashriquee Textiles Limited dyeing department of receive grey
fabric from knitting department of this company. According to buyer order, store officer
receive the grey fabric and he maintains the delivery of finished fabric.
Annual Requirements of Grey Fabric: Determination of annual requirements is very
tough. It mainly depends on the buyer order and subcontract order when the buyer order
is large then the consumption is high and vice-versa. The annual requirements of grey
fabric depend on the buyer order and the requirements of dyes and chemicals depend on
the color depth.
4.3 Dyes:
Brand Trade Name
Reactive
Reactobond Yellow SPX
Reactobond Red SPX
Reactobond Blue SPX
Reactobond Yellow SDS
Reactobond Red SDS
Reactobond Navy SDS
Reactobond Yellow 3 GL
Reactobond Yellow RR
Reactobond Red RR
Reactobond Blue RR
Reactobond Deep Yellow LW
Reactobond Deep Red LW
Reactobond Deep Blue LW
Reactobond Red 3 GX
Reactobond Black-KGD
Reactobond Black-DX
Reactobond T. Blue G 133%
Reactobond T. Blue G 266%
Reactobond Blue BRX
Reactobond Red XL
Reactobond Orange 2 RX
Reactobond Orange RR
Reactobond Blue BB
Reactobond Navy Blue RGB
Reactobond Blue RSPL
Novacron Blue FN. R
Novacron Blue FNR-0
Syno White 4 BK
Bri Red F3BS
Forneon Prink E-11V
Disperse
Disperse Yellow MD
Disperse Yellow 2GD
Disperse Yellow MD
Disperse Yellow 10GN
Disperse Rubine MD
Disperse Orange FCR
Disperse Orange 3RI 150%
Disperse Red G
Disperse Scarlit MD
Disperse R. Blue MD
Disperse T. Blue BG 200%
Disperse Navy MD
Disperse Black MD
4.4 Chemicals:
Brand Trade Name
Detergent SYT
Sequestering Agent 2UD
Wetting Agent Wetting Agent
Levelling Agent CL-S
Anti-creasing Agent L t F
Acetic Acid Acetic Acid
H2O2 H2O2
Glauber Salt (Anhydrous) Glauber Salt (Anhydrous)
Soda Ash Soda Ash
Soda LS Soda LS
Caustic Caustic
Enzyme Enzyme JQ 400
Fixing Agent ECO NURLX
Softener S.V.N
Hydrose Hydrose
Bleaching Powder Bleaching Powder
Oil Remover O.S.R
Carrier Alvagol set
Polyester Levelling Polyester Levelling
Polyester Buffer Polyester Buffer
Polyester Levelling Polyester Levelling
Polyester Levelling Polyester Levelling
Fixing Color A.B.S.
Silicon Silicon
Hydrophilic Softener Silicon Hydrophilic Softener Silicon
Soaping Agent R.S.K.
Stabilizer YML
Enzyme LERZYME 2000
Enzyme Enzyme JQ Scour
Levelling Agent K.83
Order Receive
Planning
Sampling
PP Sample
ApprovalCosting
Material
Sourcing
Trims &
Accessories
Knitting Dyeing
Storing
PP
Meeting
CuttingSewing
Section
Finishing
Section
Inspection
Shipment
Chapter – 5
Production Planning Sequences & Operations
5.1 Production Planning Sequence in Mashriquee Textiles Limited:
5.1.1 Order Receive: For production any kind of Garment. At first we have to receive
order to execute production for any kind of RMG factory. After receiving orders, knit
composite factory plan how to execute order, which method they follow to execute order
and they also make for buyer approval as well as they also involve in material sourcing
process.
5.1.2 Planning: Here factory makes time and action plan based on man, machine, materials
availability or their capacity to accomplish order. In this stage, authority decides how to
accomplish the order, how much man, machine, material requires accomplishing order, how
to they control overall process etc.
5.1.3 Sampling: Here factory makes sample according to buyer requirements and send the
sample to the buyer for the buyer’s comments so that they can rectify the fault in the
sample.
5.1.4 PP Sample Approval: After getting the buyer comments, the factory rectify the
faults and send sample to the buyer again before going to the bulk production. That’s
why it is called pre-production sample.
5.1.5 Material Sourcing: In the mean time, factory will be involved in Material sourcing
process. At first they booked yarn to produce fabric in their knitting section. After
making fabric, the grey fabric sends to the dyeing section for dyeing according to the
requirements. After dyeing fabric & booking trims and accessories, stock up the fabric &
trims and accessories in the store and inspection the product.
5.1.6 Trims and Accessories: Factory must have to ensure trim and accessories are in
house before going to bulk production as per required quality and quantity.
5.1.7 Knitting: Here several steps are followed. Very First, yarn received from the
spinning mill, then dyed the yarn if required. After that, place the yarn cone in the creel
and feeding the yarn and knitting the fabric. After knitting fabric, withdraw fabric roll
from the machine and inspect the roll and give the roll number. So that, we can identify
the specific roll by the number.
5.1.8 Dyeing: After grey fabric knitting. Knitting section sends it to the dyeing section for
dyeing fabric roll according to required color. Before dyeing several stages have to be
maintained such as desizing, scouring, bleaching, mechanizing etc.
5.1.9 Storing: Before going to the bulk production, the factory have to ensure all the
equipment are available in store and store department inspect all the materials and makes
a summery about shade segregation, issuing product amount, sustaining balance and
closing the summery.
5.1.10 PP Meeting: Based on the planning, sample approval and material sourcing and
store department inspection report pp meeting are held to decide how to finally execute
the bulk production depends on what necessary step should be taken, how works will be
divided, section wise responsibility will be distributed through this meeting.
5.1.11 Cutting: As per PP meeting decision, cutting section received pattern as per style,
cutting ratio and then cutting master making the marker. After that fabric receive from
the store, fabric checking to see if it’s okay for cutting or not, then spread the fabric on
the cutting table and create lay, then marker on the lay and start cutting. After cutting
check the parts to see if there is any cutting fault or not, then numbering the cutting
pieces to avoid shade variations, then sorting & bundling the parts and send to the
printing and embroidery section if required or send to the sewing section for further
process.
5.1.12 Sewing Section: At this junction at first PP sample analysis is done, setup line
target, distribute process to the workers. Then cutting parts received from cutting or
printing/embroidery section and distribute the parts to workers in the same way as
process distribution and workers sewing the parts. In the mean time, line Q.C. check and
Q.C. audit has been occurred so that we can accomplish required quality. After that
finally counting output according to target and full garment quality ensuring is done and
garments are send to the finishing section.
5.1.13 Finishing Section: It is one of the most important part of this factory. After
inputing garments, first initial quality check is done to dind out the faults of the
garments. Here, spot removing, ironing/pressing, inspection, hang tag attach, get up change,
folding the garments as per requirements, poly the garments, metal checking etc are done
to give product aesthetic value. After that goods cartooning or packing to box is done
for buyer’s inspection.
5.1.14 Inspection: Buyer’s representatives or buyer inspect the cartoon randomly to find
out if the product produces according to requirements. If they find satisfactory result then
the goods will be accepted otherwise the entire shipment will be rejected.
5.1.15 Shipment: After inspect the goods as per predetermined condition, if buyer find
satisfactory result then the goods will be accepted for shipment otherwise the entire
shipement will be rejected.
5.2 Section A : Lab
5.2.1 Lab Dip Procedure:
Color standard receive
Storing color on spectrophotometer
Recipe prediction by software
Prepare dye solution with the help of robolab machine
Sample measurement by digital balance
The sample is pre-rinsed, spinning & drying
Add salt & leveling to the dye bath
Dyeing at infra-red dyeing machine (AhibaIR)
Alkali addition by digital pipette
Run time 65 min
20 min for cooling
Unload & wash in cold water
Neutralization by acetic acid
Wash off &
Again spinning & drying
Shade match spectrophotometer and visual assessment
5.2.2 Recipe Formulation :
Buyer can give fabric sample or color code, pantone number or spectral value (R%Value).
So at first the color is to identify if the buyer gives color code or pantone number. It is
easier to formulate recipe by spectrophotometer from spectral value because they are very
specific. But if it is a fabric sample then with the help of spectrophotometer several
number of recipes are to formulate.
5.2.3 Lab Dip Dyeing:
With these recipes several number of samples are to be dyed. We can dye 19 samples at
a time by a single dyeing machine (AHIBA IR Data Color machine).
5.2.4 Lab Dips Send to Buyer :
Now for every separate sample dyeing with separate recipe are send to buyer for approval.
The buyer approves one sample and the recipe of that approved sample is now send to
dyeing section.
5.3 Available Stock Solution:
Any concentrated dye solution (from 0.05% - 5.0%) can be obtained from ROBOLAB
machine. Because with the help of ROBOLAB machine up to 0.0001ml solution can be
obtained.
5.4 Calculation:
Usually following calculations are followed
Recipe Amount (gm/L) x Total Liquor
Soda = cc
1000 x Stock Solution %
Recipe Amount (gm/L) x Total Liquor
Salt= gm
1000
5.5 Recommended Salt, Soda Concentration for R special –Turquoise only
(100%Cotton)
Liq.ratio&
Sample
weight
Shade
% salt,
soda
<0.1
>0.1-
0.5
>0.5-
1.0
>1.0-
1.5
>1.5-
2.0
>2.0-
2.5
>2.5-
3.0
>3.0-
4.0
>4.0-
5.0
>5.0
1.6
10gm
Salt
(g/l)
15 20 25 27 40 45 50 55 65 70
Soda
(20%)
6 6 8 10 13 14 16 18 5 50
Caustic
(50Be)
0 1.3 1.5
1.7
10gm
Salt
(g/l)
0.9 1.2 1.5 2.1 2.4 2.7 3 3.3 3.9 4.2
Soda
(20%)
1.8 1.8 2.4 3 3.9 4.2 4.8 5.4 1.5 1.5
Caustic
(50Be)
0.0 0.36 0.41
1.8
10gm
Salt
(g/l)
1.2 1.6 2 2.8 3.2 3.6 4 4.4 5.2 5.6
Soda
(20%)
2.4 2.4 3.2 4 5.2 5.6 6.4 7.2 2 2
Caustic
(50Be)
0.0 0.48 0.55
1.10
10gm
Salt
(g/l)
1.5 2 2.5 3.5 4 4.5 5 5.5 6.5 7
Soda
(20%)
3 3 4 5 6.5 7 8 9 2.5 2.5
Caustic
(50Be)
0.0 0.60 0.69
1.12
10gm
Salt
(g/l)
1.8 2.4 3 4.2 4.8 5.4 6 6.6 7.8 8.4
Soda
(20%)
3.6 3.6 4.8 6 7.8 8.4 9.6 10.8 3 3
Caustic
(50Be)
0.0 0.72 1.15
5.6 Recommended Salt, Soda Concentration for 100% Viscose, Modal, Bamboo, 95%
Viscose + 5% Lycra-R.sp Turquoise
Liq.ratio
&
Sample
weight
Shade%
, Salt &
Soda
<0.
1
>0.1
-0.5
>0.5
-1.0
>1.0
-1.5
>1.5
-2.0
>2.0
-2.5
>2.5
-3.0
>3.0
-
4.0
>4.0
-5.0
>5.
0
Salt 12 16 20 27 35 38 42 47 18 6
Soda 5 6 7 10 12 13 14 16 18 20
1.6
10gm
Salt
(g/l)
0.72 0.96 1.2 1.62 2.1 2.28 2.52 2.82 5.3 3.6
Soda
(20%)
1.5 1.8 2.1 3 3.6 3.9 4.2 4.8 5.4 6
Caustic
(50Be)
0.00 0.00 0.00
1.7
10gm
Salt
(g/l)
0.48 1.12 1.4 1.89 2.45 2.66 2.94 3.29 3.85 4.2
Soda
(20%)
1.75 2.1 2.45 3.5 4.2 4.55 4.9 5.6 6.3 7
Caustic
(50Be)
1.8
10gm
Salt
(g/l)
0.96 1.28 1.6 2.16 2.8 3.04 3.36 3.74 4.4 4.8
Soda
(20%)
2 2.4 2.8 4 4.8 5.2 5.6 6.4 7.2 8
Caustic
(50Be)
1.10
10gm
Salt
(g/l)
1.2 1.6 2 2.7 3.5 3.8 4.2 4.7 5.5 6
Soda
(20%)
2.5 3 3.5 5 6 6.5 7 8 9 10
Caustic
(50Be)
1.12
10gm
Salt
(g/l)
1.44 1.92 2.4 3.24 4.2 4.56 5.04 5.64 6.6 7.2
Soda
(20%)
3 3.6 4.2 6 7.2 7.8 8.4 9.6 10.8 12
Caustic
(50Be)
5.7 Recommended Salt, Soda Concentration for 100% Cotton-All Dyestuff Except,
Terquiose and R-special
Liq.ratio&
Sample
weight
Shade% <0.1
>0.1-
<0.5
>0.5-
<0.7
>0.7-
<1.0
>1.0-
<2.0
>2.0-
<3.0
>3-
<4.0
>4.0-
<5.0
>5.0
Salt (g/l) 15 20 25 35 45 55 65 75 85
Soda (20%) 6 8 10 12 16 18 5 5 5
Caustic
(50Be) 1.3 1.5 1.7
1.6
10gm
Salt (g/l) 0.9 1.2 1.5 2.1 2.7 3.3 3.9 4.5 5.1
Soda (20%) 1.8 2.4 3 3.6 4.8 5.4 1.5 1.5 1.5
Caustic
(50Be) 0.36 0.41 0.47
1.7
10gm
Salt (g/l) 1.05 1.4 1.75 2.45 3.15 3.85 4.55 5.25 5.95
Soda (20%) 2.1 2.8 3.5 4.2 5.6 6.3 1.75 1.75 1.75
Caustic
(50Be)
1.8
10gm
Salt (g/l) 1.2 1.6 2 2.8 3.6 4.4 5.2 6 6.8
Soda (20%) 2.4 3.2 4 4.8 6.4 7.2 2 2 2
Caustic
(50Be) 0.48 0.55 0.63
1.10
10gm
Salt (g/l) 1.5 2 2.5 3.5 4.5 5.5 6.5 7.5 8.5
Soda (20%) 3 4 5 6 8 9 2.5 2.5 2.5
Caustic
(50Be) 0.60 0.69 0.78
1.12
10gm
Salt (g/l) 1.8 2.4 3 4.2 5.4 6.6 7.8 9 10.2
Soda (20%) 3.6 4.8 6 7.2 9.6 10.8 3 3 3
Caustic
(50Be) 0.72 0.83 0.94
5.8 Section : Dyeing
5.8.1 Dyeing Program:
Program No.01
Program no.02
Super Critical (40O-60OC )
25
60*C 10 30
2*C/Min Shade
20 10 10 20 Residual check
10 20 6 soda & caustic
P-3 dose
0.3 liquor
Dyes ½ salt soda(2g/l)
Linear dose Linear dose P-3 dose
0.3 liquor 0.2 liquor 0.3 liquor
½ salt
Linear dose
0.2 liquor
Shade
check
15
Levelling Color
Linear dose
Salt
Linear dose
Soda
P-3 dose
60*C
20 15
20
40 30
Very Light Color (<0.5 %) Dyeing:
Program: 03
Program no.04
Polyester Dyeing
130⁰CX30min
60⁰C 115⁰C 1.5⁰C/m 80⁰C
80⁰CX15min
60⁰C
Shade check
Color dos reduction clear
Check ph check ph
Leveling dos
Shade check
6
Levelling Salt
Transfer 100%
Speed
Color
Linear dose
0.3 Liquor
Soda
P-3 dose
0.3 Liquor
60*C
20
20
40
30/50
Extra Dark color ( > 5 % ) Dyeing:
6
Program no.05
(40-60*C Dose with Enzyme):
60
60*C 10 30
3*C/Min Shade
20 10
10 10 1/3Salt + Alkali
P-3 dose
Dyes +Auxi+Enzyme
Linear dose
2/3 salt
Linear dose
0.2 liquor
Program no.06
Turquise Dyeing (60*C-80*C).>1.5%:
40
80*C 30
3*C/Min Shade
20 20 Residual
6 20 soda & caustic
P-3 dose
0.4 liquor
Leveling
dos Salt Transfer color
( 50%Speed) Linear dose
Program no.07
Super Critical (40O-60OC):
25
60*C 10 30
2*C/Min Shade
20 10 10 20 Residual check
10 20 6 soda & caustic
P-3 dose
0.3 liquor
Dyes ½ salt soda(2g/l)
Linear dose Linear dose P-3 dose
0.3 liquor 0.2 liquor 0.3 liquor
½ salt
Linear dose
0.2 liquor
Soaping Program
Dyeing program Temperature Time(min) Chemical
01 90 10 ̃ 12 1 g/l
02 90 & 90 (dark) 10&10 “
03 85 (light) 10 “
04 85 (polyester) 10 “
Drying / finishing
Hot air drying
Hot pressing / Ironing
Shad matching :
Spectrophotometer
Visual assessment if correction needed then again pipetting.
5.9 Section : Batching :
Process Sequence:
Fabric booking sheet
Follow order date
Planning
Send batch to dyeing section
5.10 Planning:
During planning the following factors are considered.
1.Order priority
2.Yarn type
3.Yarn dyed / colour ( light / medium / deep)
4.Fabric quantity
5.Capacity of available machines
6.Capacity per nozzle
7.Length of the fabric in per nozzle
8.Lot numb
Fabric weight in Kg x1000 x 39.37
Rope Length : = meter.
Fabric GSM X Fabric diameter in inch
Sequence of Operation:
Batching
Pre- heat set(if-necessary)
Pretreatment
Enzyme wash (if necessary)
Dyeing
Soaping & neutralizing
Fixing (if necessary)
Softening
5.10.1 Production Parameters:
1.PH:
Parameter PH
Scouring 11 - 12.5 Bleaching 11 - 12.5
Enzyme 5.5
Before Dyeing 6.5
During Dyeing 11- 11.78
Neutralizing 6.5 - 7
Soaping 6.5 - 7
Fixing 6
Softening 5.5 - 6
Unload 6 - 7
2.M:L Ratio: In Mashriquee Textiles Limited, M:L ratio is maintained 1:5. When the
machine is filled with for the first time the M:L ratio is kept 1:5.6, but it is kept to 1:5
for further processing.
3.Temperature & Time:
Yarn Dyed Wash 950C 20 min
Scouring & Bleaching
Below 130 GSM
Above 130 GSM
950C
1050C
30 min
20 min
Enzyme Wash 550C 50 min
Colour dyeing
Light shade
Medium / Dark
600C
600C
45 min
60 min
Cotton Neutralization 550C 8-10 min
Polyester Dyeing 120-1300 C 45 min
Hot Wash 800C 7-8 min
Cold Wash 550C 5-6 min
4. Reel Speed of the Machine:
Fabric weight in kg X 1000
Reel speed= meter/min
Fabric GSM X fabric dia ( in meter) X no of chamber X cycle time
Here cycle time = 2.5 - 3.5
5.10.2 Description of Production Process:
Process Flow Chart for Scouring, Bleaching & Enzyme Treatment:
Filling soft water
Heat 500C + fabric loading + chemical transfer
At 500C runtime 5 min
Transfer H2O2 Save L:R
Heat 800C + Caustic transfer
Heat 950C
Heat 1050C
Run time 20 min
Temp reduce to 950C
Aquachron 800C
Aquachron 550C
Transfer green acid
Runtime 8 min
pH check
transfer peroxide killer
run time 8 min
check peroxide
enzyme transfer
run time 50 min
sample check
heat 750C
aquachron 600C
draining 1 min
Process Curve: Bleaching
Fig: process curve of single stage cotton scouring & bleaching process.
Process of Cotton Whitening (White Dyeing):
Process Curve:
110cx40 min
98oC
Steam 80oC(Hot wash)
70oC 55oC(Acetic acid)
Brightener dosing 60 min
Check Enzyme Check
Caustic pH dosing sample Bath
Steam dosing Peroxide dosing(10 min) (5 min) drop
60oC Det (10 min)
+Sequestering
Process Sequence:
Fill water
↓
Material loading
↓
Detergent + Anticreasing + Sequestering
Run time-5 min
Caustic dosing (10 min)
Run time-5 min
↓
At 60 ˚C Hydrogen Peroxide dosing 10 min
70˚C
↓
Brightener dosing for 15 min
↓
Steam 98˚C
↓
90 min BD
↓
Cold wash
↓
Hot wash at 80˚C
↓
Cold wash 15 min
↓
Cold wash 15 min
↓
New water(1:6)
↓
Acetic acid at 55˚C
↓
pH check
↓
Enzyme dosing 5 min
Run time 40 min
↓
Sample check.
Process Flow Chart for Light Colour Dyeing:
Filling soft water
Hold time 3 min
Recall L:R
Temp 600C+ sequesterant transfer
Ph check
Run time 3 min
Dye dozing linear(20 min)
Run time 10 min
½ salt dozing linear(10 min)
Runtime 10 min
½ salt dozing linear(10 min)
Run time 20 min
Alkali dozing( progress 3)(45 min)
Run time 40 min
Sample check
Draining 2 min
Filling soft water
Ttemp raise to 600C(aquachron)
Transfer green acid
Run time 10 min
Ph check
Soaping agent transfer
Heat 950C
Run time 10 min
Aguachronn (850C) 5L/kg
Aquachron( 700C) 4L/kg
Aquachron( 600C ) 4L/kg
Sample check
Aquachron 500C
Filling soft water
Unload
Bath drain(1 min)
Process Sequence of Super Critical Colour Dyeing(40oC-60oC):
Filling soft water
Hold time 3 min
Temp 40oC
Leveling transfer(3 min)
Dye dozing (20 min)
Run time 10 min
½ salt dozing
½ salt dozing
Runtime 20 min
½ soda dozing 6 min
Runtime 10 min
½ soda dozing 25 min
Run time 30 min
pH check(after 5 min)
Sample check
Bath drain
Filling soft water
Heat 60oC
Aquachron
Green acid transfer
Run time 10 min
pH check(6.58)
Draining 2 min
Filling soft water
Add soaping agent at 90oC
Run time 10 min
Aquachron at 85oC
Aquahron at 75oC
Aquachron at 60oC
Sample check
Add green acid at 40oC
pH check(5.5)
Softener dozing 10 min
Run time 20 min
Bath drain
Process of CVC Dyeing:
Polyester Part Dyeing:
Filling soft water & heat at 50oC
Save liquor
Increase temperature 60oC
Transfer sequesterants
Check pH & then colour dozing
Increase temperature 120oC
Run 20 minute
Cooling at 80oC
Check sample
Bleaching without Enzyme:
Aquachron at 80o C
Aquachron at 60o C
Detergent transfer
Run time 5 min
Peroxide transfer
Save liquor
Temperature raise to 80oC & transfer caustic
Temperature raise to 105oC
Run time 20 min
Cooling at 95oC
Cotton part Dyeing:
Aquachron at 80oC
Aquachron at 55 oC
Check pH & peroxide transfer
Run time 8 min
Check peroxide
Aquachron at 55oC
Draining 1 min
Filling soft water
Hold time 3 min
Re-call liquor
Heat at 40oC
Transfer sequesterant
Run time 3 min
Colour dozing 20 min
Run time 10 min
½ salt dosing 10 min
Hold time 6 min
½ salt dosing 10 min
Run time 20 min
½ Soda dosing 20 min
Hold time 6 min
Heat at 60oC
Run time 10 min
½ soda dosing 30 min
Run time 30 min
Check sample
Drain
Softening Process
Filling soft water
Heat at 60⁰C
Aquachron at 60⁰C
Acid transfer
Run time 10 min
Aquachron at 60⁰C
Softener transfer
Hold time 10 min
Aquachron at 80⁰C
Aquachron at 70⁰C
Aquachron at 50⁰C
Check sample
Aquachron at 50⁰C
Filling soft water
Sample check
Unload
Draining
Fixer Process
+ Softener
Acid
50 0C 10′ 30′
Time in min
Fig: Softening Process
5.10.3 Checking Points:
Checking Instruments/ type Checking Points Requirements
PH: Measured by digital pH
meter & pH paper
1. Enzyme/bio polishing
2. Cotton leveling
3. Salt in side tank
4. Dye bath
5. Fixing
6. Softening
7. Soaping
8. Unload
5.5
6.5
7.0
As per alkali
6.0
5.5-6.0
6.0-7.0
6.5-7.0
Tem
per
atu
re i
n
0 C
Residual Peroxide:
Measured by Peroxide
measurement strip
After adding peroxide killer 0-1.00mg/L
Hardness:
Measured by hardness
measurement strip & titration
process
1. Line water
2. Dye bath
3. Salt/soda
Less than 20 ppm
Specific Gravity: Measured
by Hydrometer
1. Salt in side tank
2. Dye bath
As per SG graph
Sample Check 1. Before load
2. Bleaching
3. Enzyme/bio polishing
4. Dyeing shade check
5. Hot wash
6. Fixing
7. Unload & attached in
folder
Information 1. Batch parameter in dye line
2. Operator name
3. Load/unload
date/time/shift, total duration
4. Information attached in
unload folder.
Before start dyeing 1. Condition of m/cs
2. Cressure of air, steam,
water line etc.
3. Machine OK from
maintenance
4. Batch ready for dyeing
5. Lab dip, colour, batch
information etc. ready for
dyeing
During dyeing 1. Program and process for
that particular batch & colour
2. Liquor ratio, chemical &
colour amount, time &
temperature of specific
process steps.
3. Cycle time, fabric
absorbency, bleaching
whiteness, fabric running
inside the machine.
4. Colour & chemical
dissolving, transferring &
dozing , filtrationof
colour,checking monitor
information during
processing whatever
necessary to maintain.
5. Responsible operators,
helping must be present in
front of machine during
processing specially for
dyeing.
Chapter-6
Quality Assurance System
Introduction: The Quality Assurance Department is assigned to maintain consistently
uniform quality of the material in process and various stages of its manufacturing.
Mashriquee Textiles Limited is more about concern about quality. In this factory quality
assurance is more preferred than quality control, but both are in advancement.
After collecting fabric rolls from different machines, they are needed to be inspected or
assured required quality by the quality inspectors as if there were no big production
hampered and no complain from the buyers. Here are the details about it.
6.1 Objects And Scope of Quality Control:
Objects of Quality Control:
1. Research
2. Selection of raw materials
3. Process control
4. Process development
5. Product testing
6. Specification
Scope for Quality Control, Quality Assurance And Testing:
1. Testing Lab
2. Machine auditing system
3. A good training system
4. Excellent analytical back up Technical expertise.
6.2 Quality Control Flow Chart:
Yarn Receiving
Sample Knitting
Batching
Dyeing (Check Shade & Faults
of dyeing)
Dewatering &
Untwisting
Drying (Check Diameter, Pretreatment, Shrinkage
Spriality and GSM)
Compacting
Final Inspection
If sample OK go for bulk production.
Quality Control in Grey Fabric Inspection:
Some points are needed to maintain for high quality:
1. Brought good quality yarn.
2. Machines are oiled and greased accordingly.
3. GSM stitch length, tension are controlled accurately.
4. Machines are cleaned every shift and servicing is done after a month.
5. Grey fabrics are checked by 4 point grading.
List of Equipment:
In this factory this is the list of equipments to assure quality:
1. Inspection m/c #1
2. Scissors
3. Electric balance
4. GSM cutter
5. Indication sticker
6. Measuring tape.
6.3 Quality Assurance Procedure:
1. Body & Rib Inspection: All rolls are kept in front of the inspection m/c time and
are inspected over the inspection m/c visually in a pre-set speed against light. For
any major minor faults like thick-thin, bare mark, fall out, contamination, fly, holes,
oil lines, needle line, slubs etc. are recorded in inspection report to classify the
fabric based on the four point system.
2. Collar & Cuff Inspection: Collar & cuff are inspected visually under the light box,
any major or minor faulty collar/cuff like having wrong ply, hole, needle line,
slubs, wrong design, first round problems etc. properly counted and recorded.
Quality Standard:
Mashriquee textiles Limited maintains the full ISO:9002 standard incase of quality. They
also posses SGS and oekotex certificate therefore, the 4 point system is followed to inspect
the body and rib fabric, the defects found and points given against are recorded in the
inspection sheet, following table shows the 4 point grading system followed by inspection
at Mashriquee Textiles Limited
Four Point Grading System
Size of defects Penalty
3 inches or less 1 point
Over 3 inch but not over 6 inch 2 point
Over 6 inch but not over 9 inch 3 point
Over 9 inch 4 point
Hole < 1 inch 2 point
Hole > 1 inch 4 point
The following formula is used for determining points 100sq.yds. in a roll of a fabric:
Points/100 Sq.yds. = (0.08*Roll points*A.GSM) / Roll wt. in Kg
Grading Calculation Based on Points:
Points Grade
Up to 10 points A
10-20 B
20-30 C
30-40 D
Above 40 Reject
Following table shows common body and rib faults and response by inspection section at
Mashriquee Textiles Limited:
Rejection Criteria for Body & Rib
Faults Response
Needle mark Major needle line is rejected
Stripe Major needle line is rejected
Barre mark Rejected
Contamination & fly Approved for color but for white shed 1
point is assigned.
Slubs 1 point
Thick thin place Rejected
Pin holes 1 point
Wrong design Rejected
Mixed yarn Discuss with manager
Sinker mark Major sinker mark is rejected
Missing yarn Use 4 point
Holes DO
Oil line/stain DO
Chemical DO
Dirt stain DO
Grease line DO
Uneven tension Discuss with manager
Following table shows common collar and cuff faults and response taken by inspection
section at Mashriquee Textiles Limited:
Rejection Criteria for Collar & Cuff
Faults Response
Wrong ply Reject
Hole Reject
Needle line Reject
Slubs Reject
Wrong design Reject
Fly & contamination Acceptable for color but not for white
First round problem Reject
Uneven tension Discuss with manager
Missing yarn Reject
Crease line Reject
Rust line Reject
Oil stripe Reject
Thick-thin Reject
Wrong hole Reject
6.4 Quality Control in Dyeing and Finishing:
The Mashriquee Textiles Limited assures the quality of the products of dyeing section in
the following three steps:
1. In laboratory
2. In dyeing section &
3. In finishing section.
Procedures are described below:
In Laboratory:
1. Swatch card from buyer according to requirement
2. Recipe prediction for sample dyeing
3. Sample dyeing until matching with swatch card.
4. Fastness & other tests of the fabric or yarn are done here.
In Dyeing Section:
1. According to the buyer’s sample, sample dyeing machine in dyeing shed & again
matched with the approved sample.
2. If result is OK, then bulk production.
3. During dyeing, samples are taken until accurate shade matching. The interval may
be 30-40 minutes.
4. After dyeing sample is collected after softening is done.
5. Last off all, sample is collected after fixaton & matched.
6. Then allowed the fabric to be finished.
In Finishing Section:
1. By using a series of finishing machines correct width, softness & appearance are
maintained according to requirements.
2. Then sampling is done for several times to test GSM, Shrinkage & fastness properties
3. Finally fabric is inspected & prepared for delivery.
Quality Standard:
Mashriquee Textiles Limited follows the quality standard: ISO-9002:2000. It also
possess SGS and Tex certificate. So it maintains and Oeko Tex requirements.
List of Equipment’s:
1. KERN Electronic Balance.
2. Iron
3. AHIBA Nuance Lab. Dip Dyeing Machine.
4. Digital pipette.
5. Creda Dryer
6. Rota wash
7. Crock meter
8. Incubator
9. Spectrophotometer with software (Data Color)
10. pH meter
11. GSM cutter
12. Fly yarn contamination
Inspection Checking Points:
1. Enzyme on fabric surface
2. Hand feel on fabric surface
3. Uneven on fabric surface
4. Running shade on fold to fold
5. Color spot on fabric surface
6. Softener spot on fabric surface
7. Oil spot on fabric surface
8. Bowing line
9. Bias on grid line
10. Line mark on fabric surfaces
11. Dia variation in one roll fabric surface
12. GSM of fabric against required GSM
13. Needle mark or slit mark
14. Pin mark or fabric surface
15. Sinker mark
16. Crease mark
17. Dia mark
18. Neps, contamination, thick & thin place
19. Patta problem
20. Stripe bowing
21. Fabric elasticity
22. Fabric strength
23. Brush quality
24. Suided/piece finish quality
25. Color fastness to wash and water
26. Rubbing fastness to dry and wet
27. Shrinkage and Spirality.
Procedure of the Different Tests:
Different types of fastness tests of the dyed fabric are done in quality control
department of the Mashriquee Textiles Limited. Different types of method ( Standard or
buyer’s recommended ) are followed for different types of tests. The process of the different
tests of fabric & lab. Dip dyeing is described in the following section:
Color Fastness Test Procedure:
Color Fastness: The ‘color fastness’ of a colored textile defined as its resistance to this
changes when subjected to particulates of conditions. It follows that color fastness must be
specified in terms of this changes and expressed in terms of magnitude.
Color Fastness to Wash Test:
Required Materials:
Sample size 10 × 4 cm
Multifiber at 10 × 4 cm
ECE detergent (WOB) – 4g/L
Sodium Perborate (Na2BO3.H202.3H202-1g/L) – 1g/L
Distilled water
Normal cold water
Steel balls.
Required Instruments:
1. Rota wash
2. Scissor
3. Stitch machine
Procedure:
Cut sample & multifiber at 100 × 40 mm and then stitch.
1. 50 ml ECE detergent (WOB) & 50 ml Sodium perborate is taken with the sample.
2. The sample is kept in 60°C for 30 minutes in Rota Wash machine.
3. Rinse the sample twice with cold water.
4. Dry at 60°C by hanging or by flat iron pressing but temperature sjould not be
more than 105°C.
Report:
Dry the specimen and the change of shade & degree of staining is measured by Grey
Scale & staining scale.
Color Fastness to Perspiration Test:
Test Specimen:
1. Sample fabric – 10 cm × 4 cm
2. Multifiber fabric – 10 cm × 4 cm
3. Same fabric – 10 cm × 4 cm
4. Cut the multifiber into two piece
5. Sandwich the test specimen between two piece of fabric.
Testing Solution:
1. Alkaline Solution: Histidinemonhydro chloride (C6H10CIN3O2.H2O) - .05 g/L
Nacl – 5.00g/L
Disodium hydrogen orthophosphate (Na2HPO4.2H2O0 – 2.5 g/L
PH – 8 (Adjust by 0.1 N Naoh)
2. Acidic Solution: Histidinemonohydro chloride monohydrate (C6H10CINO2.H2O) – 0.5
g/L
NaCl – 5.00 g/L
Sodium di-hydrogen orthophosphate (NaH2PO4.2H2O) – 2.2 g/L
PH – 5.5 (Adjust by 0.1 N NaoH)
Method:
1. The composite specimen is put in a biquor (2 specimen of a sample).
2. Solution (Alkaline & acidic) is taken in the two liquor. Here M:L is taken 1:5.
3. The Specimen is put for 30 minutes at room temperature
4. Then the liquor is poured off without removing the sample. So that sample remains
wetted.
5. Then specimen placed between 2 glass plate.
6. Then specimen and glass plate is placed into the incubator at (37 ± 2)°C for 4 hours
7. The specimen is dried (Temp. ≤ 60°C)
Report: Change of shade and degree of staining is measured by the grey scale and staining
scale
Color Fastness to Water Test:
Color Water:
Test Specimen:
1. Sample fabric – 10 cm × 4 cm
2. Multifiber fabric – 10 cm × 4 cm
3. Same fabric – 10 cm ×4 cm
4. Sandwich the test specimen between two piece of multifiber.
Testing Solution:
Method:
1. The composite specimen is put in a liquor (2 specimen of a sample).
2. Water is taken in the liquor as required.
3. The specimen is put for 30 minutes at room temperature.
4. Excess water is poured off and specimen is placed between two glass plate.
5. Then composite specimen & glass plate is placed between two glass plate.
6. Then composite specimen & glass plate is placed into the incubator at (37 ± 2)°C
for 4 hours.
7. The specimen is dried (Temp ≤ 60°C).
Report:
Change of shade & degree of staining is measured by the Grey scale & staining scale.
Hot Water:
Test Specimen:
1. Sample fabric – 10 cm × 4cm
2. Mutifiber fabric - 10 cm × 4cm
3. Same fabric - 10 cm × 4cm
4. Sandwich the test specimen between two piece of multifiber
Testing Solution:
1. Distilled water of slightly acidic is taken as required
Method:
1. At first the composite specimen is wrapped round a glass end of 5 to 8 mm dia
and tied loosely with a thread.
2. Then placed into a liquor.
3. Distilled water ( Slightly acidic of pH - 6n can be maintained by acetic acid) is
taken in the liquor with M:L is 1:3.
4. The specimen is put for 30 minutes (70 ± 2)°C
5. Then taken out unwrapped.
6. The specimen is then dried at temp ≤ 60°C
Report:
Change of shade & degree of staining is measured by the grey scale & staining scale
Fastness to Rubbing (Dry & Wet) Test:
Sample:
1. Dyed fabric – 15 cm × 5 cm
2. White Test Cloth – 5 cm × 5cm
Procedure:
1. White test cloth is put on to the grating and stag steel wire.
2. The sample is run twenty times manually for ten seconds and the rubbing fastness
of the sample cloth and degree of staining is accessed.
3. For rubbing fastness (Wet), the rubbing cloth is placed in the water and socked and
squeeze. The wet rubbing cloth is placed on to the assess the rubbing cloth and the
rubbing fastness of the sample cloth is accessed.
Report:
Change of shade of the sample is measured with grey scale and degree of staining of the
white test cloth is measured by staining scale.
There are also some tests are done in the lab. And the process is described below:
A. Measuring the Dimensional Stability (Shrinkage & Spirality):
Sample:
1. Two piece of 50 cm × 50 cm fabric is taken for test
Procedure:
1. At first the sample to be tested should be put in table for 4 hrs for conditioning
before starting test.
2. Then a rectangular bed is made and then 50 cm* 50cm line is taken in both side (
length & width).
3. Put sample in washing machine and run according to buyer’s choice.
4. Then drying is done by tumble dryer.
Shrinkage Test Calculation:
Shrinkage % = Before wash− After wash
Before Wash × 100
Spirality Test Calculation:
S = ( S1 + S2) / 2
Spirality = ( S / L ) * 100
Suppose,
S1 = The right side distance of the specimen from the stitch line after wash
S2 = The left side distance of the specimen from the stitch line after wash
L = Length before wash
B. Strength Test for Soda Ash:
Reagent:
1. HCl 0.1 N solution
2. Phenolphthalein indicator (0.1 %) in Ethanol
3. Methyl orange indicator (0.1 %) in Ethanol
Procedure:
1. Take 5 gm. Soda ash and dried it for 1 hr. at 105°.
2. Take 0.2 gm. Soda ash (from dried 5 gm.) and mix it with 50 ml distilled water.
3. Add 2 drops Phenolpthalein indicator and titrate by 0.1 N HCl to the
disappearance of red. Take the 1st reading
4. Add 2 drops methyl orange indicator and titrate by 0.1 N HCl. End point of
methyl orange indicator. Take the 2nd reading.
Result: (2 nd reading−1 st reading)∗ 0.1 ∗ 0.084∗ 100
Sample weight
Standard Result: 80 – 100
C. PH of a Dyed Fabric Test:
Test Specimen:
1. 2 gm of dyed fabric is taken
2. The fabric is cut into pieces of (0.5 cm × 0.5 cm )
Procedure:
1. The sample is taken into conical flax
2. 100 ml distilled water (slightly warm) is taken into the conical flax
3. The conical flax is put on the Magnetic Stirrer for 30 minutes
Report: The PH of the conical flax is measured by Digital PH meter
Response of Q.C. Officer:
Response to Q.C. Faults:
Faults Response
Yarn fault Inform yarn supplier
Knit fault Inform knitting department
Dyeing fault Inform dyeing manager
Response of Machine Fault:
Faults Response
Any electrical fault Inform electrical maintenance
Any mechanical fault Inform mechanical maintenance
Remarks: The Mashriquee Textiles Limited always about the quality of the product. The
quality of the product is always approved by the buyer. The follow the quality standard:
ISO – 9002:2000, SGS & Oekotex requirements. Mashriquee Textiles Limited is well
equipped for checking the quality of the product. They sent the quality report to the buyer
time to time/batch to batch.
Chapter-7
Maintenance
Maintenance is considered as important as other engineering functions. It makes
responsible for provision of a condition of machine, buildings and services that will
permit uninterrupted implementation of plans requiring their use.
7.1. Objectives & Maintenance of Machinery
Objectives of Maintenance:
1. To keep the factory-plants, equipment, machine tools etc. in an optimum working
conditions.
2. To ensure specified accuracy to products and time schedule of delivery to
customers.
3. To keep the down time of machines to the minimum thus to have control over
the production program.
4. To keep the production cycle with in the stipulated range.
5. To modify the machine tools to meet the augmented need for production.
6. To improve productivity of existing machine tools and to avoid sinking of
additional capital.
7. To reduce the maintenance costs as far as possible thereby leading to a reduction
in factory overheads.
8. To prolong the useful life of the factory, plant and machinery, while retaining their
acceptable level of accuracy of performance thus avoiding or prosponding
incurring of heavy capital expenditure involved in their replacement.
Maintenance of Machinery:
Preventive Maintenance:
Preventive maintenance is a predetermined routine actively to ensure on time
inspection/checking of facilities to uncover conditions that may lead to production break
downs or harmful description.
Breakdown Maintenance:
In this case repairs are made after the equipment is out of order & it can not perform
its normal functions.
Routine Maintenance:
Maintenance of different machines are prepared by expert engineer of maintenance
department. Normally in case of dyeing machine Maintenance after 30 days complete
checking of different important parts are done.
Economic Considerable of Maintenance:
1. It is very profitable activity & ensures maximum productivity at minimum costing.
2. It improves product quality.
3. It ensures less time to produce a specific product.
4. It improves machine accuracy.
5. It maintains a long life of the machine.
6. No chance of back order.
Maintenance
Preventive
Maintenance
Mechanical
Maintenance
Electrical
Maintenance
Breakdown
Maintenance
Mechanical
Maintenance
Electrical
Maintenance
Head of Maintenance
Technician
Assistant
Maintenance Flow Chart:
Manpower Set-Up For Maintenance:
1. A Shift 7 AM-3 PM
2. B Shift 3 PM-11 PM
3. General Shift 9 AM- 6 PM
7.2 Functions of Maintenance Personnel:
1. Inspection or Check-Ups:
1. External Inspections: Watching and detecting defects form abnormal sound,
vibration, heat, smoke etc. when machine is in operation.
2. Internal Inspections: Inspection of parts such as gears, bushes, bearings, tolerances
in the parts etc. when machine is under pre-planned shutdowns.
3. Inspections of Important Machines: Machines which can disrupt whole of the
production, are delicate and require much time for the repair. Attentions are given
for inspection of these machines and schedule for inspection, cleaning lubrication
are done rigidly.
4. Inspection of Ordinary Machines: Frequency of inspection of ordinary machines
is kept as low as they do not affect the production.
5. Lubrication: Mechanical components like gears, bearings, bushes and other friction
surfaces etc. give good performance for long periods when they are systematically
lubricated. Systematic lubrication means the application of right type of lubricants
at the right time, at right place and in right quantity. For lubrication, a lubrications
schedule should be prepared and that should be followed strictly. Here lubrication
is done whenever is needed.
6. Planning and Scheduling: Every preventive maintenance work should be pre-
planned in detail on the basis of the analysis done on the past records. A
scheduled programme thus prepared should be followed strictly. Thus programme
should be in detail specifying the point-requiring daily, weekly, monthly, half yearly
or yearly attention.
7. Records and Analysis: Good record keeping is essential for good maintenance, as
it helps in for casting maintenance. For this purpose following records are generally
maintained:
1. Operation manual
2. Maintenance and instruction manual
3. History Cards and History registers
4. Spares Procurement Registers
5. Inspection Registers
6. Log books
7. Defect Registers etc.
1. Training of Maintenance Personnel: For the success of maintenance a sound
training is essential for the maintenance personnel. Hence the technicians and
supervisors are trained to carry out maintenance, inspection and repaired in a
systematic way.
2. Storage of Spare Parts: Sometimes machine remains idle for want of spare parts
for considerable time and thus it affects considerable loss of production. Hence it
is essential to keep the spare parts so as to avoid loss of production.
7.3 Maintenance Tools/Equipment & Their Functions:
Sl. No. Maintenance Tools/Equipment Functions
01. Adjustable wrench Used for setting nut & bolts.
02. Pipe spanner For pipe fitting.
03. Spanner Fixed spanner for nut & bolts fitting.
04. Socket spanner Handle system for nut & bolt fitting.
05. Hammer To apply load where required.
06. Screw driver To release any screw.
07. Punch Used to fit any worn out shaft.
08. Lock opener To open the clip of bearing.
09. Hack saw To cut any metallic thing.
10. Outside calipers To measure outside dia.
11. Inside calipers To measure inside dia.
12. Slide calipers To measure very small dia.
13. Vernier scale To measure very small dia.
14. Chain ton To lift heavy load.
15. Welding machine To join metallic parts.
16. Tester To test electric circuit.
17. Pliers To grip anything & cut anything.
18. Avometer/Voltmeter To measure voltage.
19. Steel tape To measure length, width & height.
20. Chisel To cut any metal.
21. Gasket cutter For gasket cutting.
22. File To smooth the rough surface.
23. Grinding machine To make the smooth fabrics.
7.4 Maintenance Procedure: Normally maintenance is done here. During maintenance
procedure following points should be checked.
Maintenance of Knitting Machine/Flat Knitting Machine:
Sl. No. Items need to be Checked & Serviced
01. Check and tightening all motor terminals.
02. Check and clean pressure sensor and tightening terminals.
03. Clean the ventilation fans of panel board and circular fan on top of
machine.
04. Check and clean the interfacing and data cables.
05. Check and tightening the proximity switch terminals.
06. Inspection, cleaning and tightening all the terminals in the panel.
07. Check and tightening limit switch, safety door guard and the
emergency switch.
08. Functional test of the yarn detector.
Maintenance of Dyeing Machine (Mechanical):
Sl. No. Items need to be Checked & Serviced
01. Grease the winch bearing.
02. Complete cleaning of machine.
03. Cleaning of drain valves, replace scales if required.
04. Check air supply filters, regulators and auto drain seals.
05. Clean filters element and blow out.
06. Greasing of unloading roller bearings.
07. Checking oil level and bolts of unloading roller gearbox.
08. Checking of unloading roller coupling and packing.
09. Check and cleaning of main vessel level indicator.
10. Check the oil level of pump bearing and refill if required.
11. Check the function heat of heat and cool modulating valves.
12. Check all belts and belt tension.
13. Check all door seals.
Maintenance of Dyeing Machine (Electrical):
Sl. No. Items need to be Checked & Serviced
01. Check & clean fluff and dirt at all motor fan covers.
02. Check all motors terminals.
03. Check main panels (by using compressed air).
04. Check panel cooling fan & clean it filter.
05. Clean main pump inverter and its cooling fan.
06. Check all circuit breaker, magnetic contractors and relays.
07. Check current setting of all circuit breaker & motor over loads.
08. Visual checking of all power & control cables.
09. Check all pressure switches.
10. Check DC drive of neel motors.
11. Check calibration of main vessel.
12. Check calibration of all additional tank.
13. Check all pneumatic solenoids.
14. Check calibration of heating/cooling.
15. Check setting of tangle sensor.
16. Check setting & operation of lid safety switches.
17. Check all emergency switches.
18. Check all indicating lamps.
19. Check all on/off switches.
Maintenance of Slitting Machine:
Sl. No. Items need to be Checked & Serviced
01. Grease all bearing with stuburg NBU-12 energrease.
02. Complete cleaning of the machine.
03. Check all belt and belt tension.
04. Check gear box of plating and its oil.
05. Check chain and give oil if required.
06. Clean exhaust blower and duct.
07. All chamber blowers check and clean.
08. Chamber nozzle cleaning.
09. Check all door slits.
10. Check all pin bars and clean.
11. Check gas pressure, adjust if required.
Maintenance of Stenter Machine:
Sl. No. Items need to be Checked & Serviced
01. Check and tightening all motor terminals and clean the motor fan (30
days)
02. Check activity of wide and sensor and pneumatic regulator.
03. Check and clean pressure sensor and tightening terminals.
04. Clean the A/C ventilation fans of panel board.
05. Check the fan and the heat sink of the inverters in the panel board.
06. Check and tightening the edge sensors.
07. Check and tightening the photo sensor terminals.
08. Check and tightening the safety light barrier and tightening the
terminals.
09. Inspection, cleaning and tightening all the terminals in the panel.
10. Check and tightening limit switch, safety door guard and the
emergency switch.
Maintenance of Compactor Machine:
Sl. No. Items need to be Checked & Serviced
01. Check steam pressure and adjust it if required.
02. Complete cleaning of machine.
03. Check steam and pneumatic pipeline for any leakage and
service/repair if required.
04. Check the function of all pneumatic cylinders and service/repair if
required.
05. Check all pneumatic solenoids.
06. Check all talons for visible damage, foreign particles and check its
position.
07. Check all motors, gearbox, roller and its bearing for any defect and
grease the bearing.
08. Check all the belts for tension, visible damage and position on roller.
09. Check impellers of suction & exhaust blower for clogging with
foreign particles and clean.
10. Check all chain and sprockets for alignment, tension and lubrication.
11. Check the exit conveyor for smooth running and visible damage.
12. Check all belt and belt tension.
13. Check plaiter for smooth operation.
14. Check loading device.
15. Check steam trap.
Maintenance of Tumble Drier Machine:
Sl. No. Items need to be Checked & Serviced
01. Check filter net of the machine.
02. Clean hot air ducting of the machine.
03. Burner blower impeller cleaning.
04. Complete cleaning of the machine.
05. Greasing of all the bearing.
06. Conveyor net checking & repairing if required.
07. Inside chamber all fiber rail checking.
08. Exit conveyor checking properly & repair if required.
09. Plaiter checking.
Maintenance of Boiler Machine:
Sl. No. Items need to be Checked & Serviced
01. Check and clean fluff & dart at all machine.
02. Feed pump servicing.
03. Main boiler servicing.
04. Check all temperature & pressure gauge meter.
05. Check gas strainer.
06. Clean gauge glass & change if required.
07. Clean feed tank.
08. Clean fire tube.
09. Clean all safety valves.
10. Check all steam valves (ball value, glove value, pneumatic value etc.).
11. Check all gas regulator.
12. Auto blow down operation check.
7.5 Maintenance Schedule:
Sl. No. Parts Description Check Time
01. All pumps (bearing, coupling) 3 month
02. All belts (loose/tight) monthly
03. All bearing (grease/sound) monthly
04. All gear box (oil/sound) monthly
05. All valves leak monthly
06. Reel rubber monthly
07. Mechanical seal monthly
08. Steam trap monthly
09. Handle of lid monthly
10. LID opening stopper monthly
11. LID glass monthly
12. Safety valve ( main kier & heat
exchanger)
monthly
13. Pressure gauge weekly/ monthly
14. Water leveling scale monthly
7.6 Remarks: The maintenance department of Mashriquee Textile Limited is well
equipped. It has sufficient maintenance manpower including mechanical and electrical
engineers. They perform maintenance tasks of the machines during the holidays and
vacations. Otherwise, they perform breakdown maintenance, which as started earlier is very
rare in This industry. To increase the lifetime of the machineries and ensure the proper
running of the machines, the task of this is very important.
Chapter-8
Utility Services
Mashriquee Textiles Limited is not so big project but it of course having a vast project
of utility service. Here the total accounts of utility facilities are available. The utilities
are:
Gas
Electricity
Steam
Compressed Air
Effluent Treatment Plant
8.1 Gas: Gas is mainly used for steam produce. The gas is used from TITAS GAS
DISTRIBUTION CO. Generally 33 m3 gases are required to produce 1 ton steam and 180
m3 gases is required per hour for each generator.
8.2 Electricity: The main utility electricity is supplied from PDB and also by Generator
Equipment.
8.2.1 No. of Generator: 02
Specification:
Type: Diesel
Manufacturer: Cummins power generator
Manufactured Country: UK
Year of Construction: 2006
Model: C250-D5
Prime Power (kW): 182.0
Standby Power (kW): 200.0
Prime Power (kVA): 227
Standby Power (kVA): 250
Noise: 68dBA @ 7 mt
Run Time : 8.3 hrs @ 75% load
Warrenty (yrs): 1 year
Dimension (L/W/H): 3670/1100/2045
Dry Weight (KG): 4200
Phase: 3
Starting Method: Digital Auto
Fuel Type: Diesel
Fuel Capacity: 350 lt
Sockets: Hard wired, no sockets
8.2.2 No. of Stabilizer: 01
Specification:
Type: Automatic Voltage Stabilizer
Manufacturer: ENSYSCO
Manufactured Country: Bangladesh
Year of Construction: 2006
Phase: Three Phase
Input Voltage Range: 250 V~480 V
Output Voltage : 380 V/400 V/415 V/440 V/460 V
Frequency: 50 Hz
Control System: Combined or Individual Phase Control
Protection: Short Circuit, Surge, Spike etc.
Monitoring System: LCD/LED Display / Digital Display
Correction Accuracy: 11% / 13%
Correction Speed: 30 to 50 V/ Sec
Cooling System: Natural Air/ Air Forced/ Oil immersed
Waveform Distortion: Negligible
Transient Suppression: Up to 800 V Peak
Boiler
Feed Water Tank
Blower
Steam
Factory House
BurnerGas
Load Power Factor Effect: Nil
Environment Condition: 40~600 C
Duty Cycle: 95% Continuous
Humidity: Maximum 98%
Over Load Capacity: 100% for 15 sec
8.3 Steam: Pure steam with required temperature must be produced to meet the
continuous demand of steam in different sections. There are two Fire tube type boilers
used for steam generation, to meet the requirement of different sections. At first the boiler
takes NTA (Natural gas) from the gas line and suck air. Then through the air and gas
inside the boiler. For this reason the water is boiled water and produce steam. The steam
is supplied by the steam line in the different section.
8.3.1 No. of Boiler: 01
Specification:
Name: Gas Generator
Brand Name: Cochran Boiler
Model Name: ST-36
Manufacturer’s Name: Hamworthy Combustion Engineering
Year of Manufacture: 2008
Country Name: Scotland
Design Pressure: 10.34 Bar
Design Temperature: 212°C
Design Continuous Rating: 6000 kg/hr
Maximum Pressure: 17.2 Bar
Maximum Continuous Rating: 24000 kg/hr
Fuel Type: Natural Gas
8.4 Compressed Air : Compressor is mainly used to deliver compressed air to different
section as required. In Mashriquee Textiles Limited there are two compressors are used to
produce and deliver compressed air to different section.
No. of Compressor: 01
Specification:
Manufacturer: ATLAS Copco Airpower
Origin: Garmany
Type: GA55C
Pressure Maximum: 10 Bar, 145 psi, 1 MPa
P. Motor: 55 KW, 75 HP
N. Motor: 2975 r/min
Air Pressure: 8 Bar
Maximum Pressure: 10 Bar
Air Suck: 5.83 m3/min
8.5 Effluent Treatment Plant: The Effluent generated from the different section of a
textile industry must be treated before they are discharged to environment. Various
chemicals & Physical means are introduced for this purpose.
There are three Effluent Treatment Plants which are:
Physio – Chemical Treatment Plant
Chemical – Biological Treatment Plant
Biological Treatment Plant
The Effluent Treatment Plant in Mashriquee Textiles Limited is Chemical – Biological
combination process developed by India.
8.5.1 Objects Effluent Treatment Plant: This process is provided for treating the
Effluents of dyeing, printing, finishing, weaving & thus allow to discharge it as per norms
given by World Bank Dept. of Environment of Bangladesh. This process comprises of
collecting, pumping, clarification, filtering, setting, aeration, pH correction, discharging etc.
8.5.2 Characteristics of waste water:
Unit Process Possible Pollutants Nature of Waste Water
Scouring NaOH, wax, grease, Na2CO3,
fragment of fabric
Strong alkaline, High BOD (30 %
of total)
Bleaching H2O2, NaOH, acid Alkaline (5% BOD)
Dyeing Various dyes, salts, alkali, acid,
auxiliaries
Strongly coloured (fairly BOD, 6
% of total)
Finishing Various softeners, Finishing
chemicals
Low BOD (2-4 % of total)
Mercerizing NaOH, Acid Strong alkaline (low BOD, less
than 1 %)
8.5.3 Chemical Used in ETP Plant:
Chemical Name Supplier
Ferrous Sulphate Globe Multi-Trade
Lime Powder S.K. Traders
Polymer Friends Chemitech
DAP Globe Multi-Trade
HCL Chowdhuary Traders
8.5.4 Functions of Different Ingredients used in ETP Plant:
Lime: Lime is used to change the color of effluent and to increase the
transparency of water
Ferrous Sulphate: Ferrous Sulphate is used for the agglomeration of the foreign
matters present in the effluent.
Poly Electrolyte: Poly Electrolyte helps to make the agglomeration materials be
gummy for easy deposition below the surface of water.
Hydrochloric Acid: Hydrochloric acid is used to sustain the required pH of the
treated.
8.5.5 Standard of Effluents for Discharge:
BOD 50 – 100 mg/l
COD 250 mg/l
Total Suspended Solid 250 – 300 mg/l
Total Dissolved Solid 2000 mg/l
PH 7-8
Color Colorless
Temperature < 40°C
8.5.6 Typical Output of the Plant:
Raw Effluent Treated: 15000 LPH
Raw Effluent Color: Black
Raw Effluent PH : 11
Treated Effluent Color: Light Greenish
Treated Effluent PH : 8.5
Treated Effluent Temperature: 38°C
Total Suspended Solids: 35 PPM
8.5.7 Flow Chart of Effluent Treatment:
Ecological Water
Raw Effluent
Equaliztion Tank
Flash Mixing Tank
Flocculation Tank
Tube Setter
Sand Filter
Carbon Filter
Output Water
Ecological Sludge
Sludge from all Tank
Sludge Sump
Sludge Thickener
Centrifugal Platform
Sludge Dryer Bed
Chapter-9
Store & Inventory Control
Introduction:
Inventory is planning and execution involves participation by most of the fundamental
segment of business sales, production, purchase, finance and accounting. Inventory is a
wider sense is defined as any idle resource of an enterprise however it is semi-finished
packing spares and other stocked in order to meet an expected demand or distribution.
9.1 Objectives of Inventory Control:
1. Financial activities:
1. To save amount of investment
2. To know the cash position
3. Property Protection:
1. Preventable waste
2. Insurable damage
3. Unauthorized use
4. Operating:
1. To obtain the best overall balance between production and inventory carrying cost.
2. To minimize losses
3. To avoid stock out and to keep inventory holding costs in costs in balance.
Scope of Inventory Control:
1. Raw materials:
1. Dyes store
2. Other chemicals
3. Grey fabrics
4. Finished fabric
5. Spare parts
6. General store:
1. Capital equipment
2. Accessories
3. Stationary
4. Maintenance part
Frequency of Inventory Update:
1. Monthly inventory control
2. Annual inventory control
9.2 Inventory Procedure:
1. Bin Card
2. Store Requisition
3. Store Ledger Account
4. Daily Inspection & Package Report
5. Monthly stock & Consumption Report
6. Received L/C & wise Delivery Report
Inventory Control System for Raw Materials:
Dye Store & Other Chemicals Store
1. Both of these are received by the store in charge
2. First he sends these to quality in-charge for inspection. If they are found to be
required quality then they are taken to store by the storekeeper.
3. Store in-charge supplies these when required and records the date, type of
material, quantity and section in which supplied, in his register book.
Grey Fabric Store
1. Grey fabric is usually stored in another storeroom, which is spate from dyeing
shade.
2. Grey fabric is first sent to the QC department for quality assurance and then
taken to the storeroom.
3. Grey fabric is received by fabric store in-charge.
4. He supplies the fabric as per requirement and records the date, type of material,
quantity and section in which supplied, in his register book.
At present the grey fabrics store of Mashriquee Textiles Limited. containing the
following types of fabrics-
1. Single jersey.
2. 1×1 Rib.
3. 2×2 Rib.
4. 2×1 Rib.
5. Melange.
6. Pique.
7. Single jersey ( with Lycra attachment )
8. 1×1 Rib ( with Lycra attachment ) etc.
9. Single lacost
10. Double lacost
11. Fleece
12. Terry Fleece
13. Interlock
Stage of Grey Fabric Inventory Control:
1. After knitting production.
2. Grey inspection.
3. Warehouse.
4. Batch preparation.
5. Dye.
Inventory Control System for Finished fabric:
1. Finished fabric from the compactor or stenter goes to inspection team. Here
inspection is done by a four points systems.
2. Required GSM, width (diameter), shrinkage, spirality, wash fastness, rubbing fastness
etc are tested from the lab before packaging.
3. After finishing the fabric is kept in package before their transfer to the garments
department.
4. It is controlled by the finishing in-charge who keeps a list of total finished
product. He also keeps a list of delivery products.
5. He supplies the fabric as per requirement and records the date, type of material,
quantity and section in which supplied, in his register book.
Stages of Finished Fabric Inventory Control:
1. Finishing section.
2. After final inspection.
3. Warehouse.
Others: There is a central store at Mashriquee Textiles Limited. In that store the various
types of forms, papers, stationary & other necessary goods are kept.
Inventory Control System for Spare Parts:
1. Spare store officer keeps the spare parts in store and makes a list of spare parts.
2. If the spare parts are little in stock he gives requisition to maintenance manager.
3. Maintenance manager gives requisition to head office. Head office imports spare
parts or buys from local market as per requirement.
4. As new spare parts arrive to store officer, he receives and catalogues them.
5. He supplies the spare parts as per as requirement and records the date, type of
material, quantity and section in which supplied, in his register book
Remarks:
Mashriquee Textiles Limited. Has individual stores for raw materials, finished goods and
spare parts. The store of dyestuff and chemicals are not clean. There is no enough space
to store the finished goods. It requires increasing the store area.
Chapter 10
Marketing Activities
Introduction:
Mashriquee Textiles Limited is a 100% Export oriented industry no product can be
marketed at the local market. The goods produced at this factory are exported at different
countries of the world. Mashriquee Textiles Limited has a number renowed buyers.
Following are the most important buyers of Mqashriquee Textiles Limited:
# EFRA
# Comfit
# Al-hasan
# Mukul
# Network.
# Unique
# Gulf
# Ayesha
# Unigear
# S&P
# Southern
# Lazim
# Next
# Stead fast
Product Label:
There are following labels used by this mill:
1. Care Label: It contains washing in hot or cold water, chemical cleaning, drying
conditions etc.
2. Size Label: It contains size of garments.
3. Composition Label: It contains the fabric composition of different fiber type.
4. Decorative Label: Decorative is as buyer or consumer choice wise.
Package Size & Label Market:
Package size & label differs from buyer to buyer. The package size & label are prepared
according to the buyer requirements. Normalling the following package sizes are used:-
60 × 40 × 40 cm
58 × 33 × 44 / 43 / 42 cm
58 × 33 ×25 cm
58 × 33 × 13 / 16 / 18 cm
10.1 Local Market:
Mashriquee Textiles Limited is 100% export oriented mill. So there is no local market
involved in it. But the knitting section takes some sub-contact for knitting an amount of
fabrics from their given yarn.
Importing Countries: There are some countries which are importing goods from
Mahriquee Textiles Limited which are given given:-
1. United State of America
2. England
3. France
4. Germany
5. Italy
6. UK
Manpower of Marking: Marketing is the important department of any industry or
institution to describe the feature of the products to the buyer & to communicate with
the buyer. Almost ten marketing officers and ten others worker act under the Executing
Director.
10.2 Marketing Strategy: Marketing strategy should be planned successfully & in a
well-organized manner to sale the products to the buyer. If the marketing strategy is not
so developed, it will be very hard to reach the goal. In case of garments marketing the
dealings with the buyer is a very important factor.
At Mashriquee Textiles Limited senior marketing officers, merchandiser & higher officials
deal with the buyer. There are some fixed buyers of the industry. The buyers give their
orders continuously all over the year. The marketing officers & the merchandisers
communicate with buying houses to collect the orders.
By the understanding of both side the rate & the order quantity are fixed.
A well-defined marketing strategy has the following characteristics:
1. Good quality
2. Low price or competitive price
3. Prompt service
4. Good commitment
5. Good business communication
Duties & Responsibilities of Marketing Officer:
Job summary:
1. Market search
2. Market development
3. Customer’s motivation
4. Production follow up
5. Technical assistance of customer
Dealing with the buyer & convince the buyer is the main duty of marketing officer. A
marketing officer also has some other duties. The main duties & responsibilities of a
marketing officer are given below:-
1. Executive director takes order from the buyer and gives order the marketing
officer’s troops to produce a cost sheet.
2. Marketing officers are known the amount and design of product.
3. Knitting section adjusts the amount of total yarn and knitting conditions and
dyeing sections adjust the amount of dyes and chemicals. They send a rough
calculation to the marketing section.
4. Finally, they adjust their cost sheet after consulting with the Executive Director
and copy several pieces of the cost sheet.
Basically the responsibilities & duties of marketing officers begins from getting order of
buyer & ends after sending goods to the buyer. So, he should be always smart, sincere to
work.
10.3 Merchandising: Garment merchandising is a complicated and detail oriented job. If
this task can be performed successfully & properly then it will bring both money and
reputation for the industry. But when a merchandising department of an industry fails it
will be a great threat for the existence of industry. For this reason the merchandising of
textile industry must be highly qualified, well trained and experienced.
In the Mashriquee Textiles Limited fully skilled and experienced personnel run the
merchandising section. After receiving an order, the merchandising with the help of
pattern master calculates the total consumption of fabric. Then according to the cost
detail sheet and the price mentioned by the buyer costing is done. After the price is
negotiated with the buyer order is placed to the suppliers of raw material and
accessories.
The manufacturing factory as per the requirement suppliers the fabric and a leger is
maintained regularly to access the production status. The accessories such as label, button,
zipper, sewing thread, packing materials are collected from outside (sometime mentioned
by the buyer) through back-to-back L/Cs. The merchandising department also looks for the
sources for procuring yarns to produce fabric.
Merchandising section monitors the production status regularly and ensures timely
delivery of the shipment.
Remarks: Marketing activities are very important tasks for a productive factory. A well-
planned marketing strategy can help an industry to meet its goal. In this mill, there
having highly qualified marketing officers. As a result, the mill is getting more order
from the buyers.
Chapter- 11
CONCLUSION
We have completed our industrial attachment successfully by the grace of Allah. Industrial
attachment sends us to the expected destiny of practical life. The completion of the two
months Industrial attachment at Mashriquee Textiles Limited. We have got the impression
that factory is one of the most modern export oriented knit composite complex in
Bangladesh. Though it was established only a few years ago, it has earned “very good
reputations” for its best performance over many other export oriented textile mills.
During our training period, talking with the clients of this mill we knew that the mill is
fulfilling the country’s best export oriented white finished fabric as well as very good
colored fabric due to its modern machinery & good management system.
Mill is settled with utility to give all convenient supports to the productions for twenty-
four hours. It had self-power generator system to satisfy total power consumptions of the
mill. We are enough fortunate that we have got an opportunity of having a training in this
mill. During the training period we are received co-operation and association from the
authority full & found all man, machines & materials on appreciable working condition.
All stuffs & officers were very sincere & devoted their duties to achieved their goal.