Industrial attachment of cotton club bd ltd

1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF COTTON CLUB (BD) LTD.

2. PART-A INTRODUCTION Bangladesh is one of the leading readymade garments exporters of the world. Every year Bangladesh exports more than one third of the total garments requirement of the RMG market of the world. Every year Bangladesh earns more than 76% of its foreign currency from this sector .That is why the study of garments technology does deserve well practical practice. So our university provides 6 weeks industrial training in a RMG factory. As a student of garment technology I have completed this industrial training in COTTON CLUB (BD) LTD From garments making to decorating garments with embroidery is a truly Exclusive fashion house that deals with lots of stuff like fabric quality, garments quality, dyeing quality, washing quality. The Garments Division has the capability to offer a complete product range for the 100% export to EU & USA market. The vision of the Garment Division is to become the preferred partner for sourcing high quality value added garments from Bangladesh. With an urge to developing local human resource, the Garments Division has the potential to make an important contribution to the nation’s growing RMG export sector to make it more competitive

3. Chapter One Training Background This chapter begins with explaining the purpose of the report; followed by its scope and limitations. It ends by mentioning the students’ responsibilities in training program and institution partnership with the company. Background Training Program After successfully completing the B.Sc. in Textile Engineering course from Primeasia University, every student have to take part in 42 days Industrial Attachment Training Program. For this training program the students are divided into several groups and the groups of students are sent to the large and famous Textile Industries for practical training. Purpose The Industrial Attachment program fulfills part of the requirement in pursuing the degree of Bachelor of Applied Science (B.Sc in Textile Engineering) in Primeasia University. This report serves to summaries the activities and experiences gained with Cotton Club (BD) Ltd. Scope and Limitations During the industrial attachment training, we, a group of two students of Primeasia University & other University were involved in training through the whole factory. This report will only cover parts of the project, which were done by the students. The experience gained during the attachment had helped the students to fulfill the objectives of the attachment. However, due to unforeseen circumstances, the commencement of the attachment was delayed. This resulted in a shortage of time for the completion of the project. Therefore, this report will be limited to the stages of implementation prior to the date of reporting. Further work and research that done after the date of reporting is not described fully in this report. The emphasis of this report will be on the research done by the students, in addition to the experience that they gained during the attachment. Frequent references will be made with regards to these concepts. Students’ Responsibilities With the four years education in the institution students gain much theoretical knowledge. For the fulfillment of B.sc in Textile Engineering course the Industrial Attachment Training program plays a vital role. It gives the students a lot of practical knowledge and introduces with the factory environment. In this training program the students has much responsibilities. They have to learn about all the process going on in the factory, all the machineries used, faults and remedies in the different sections, administrations, utilities, costing of the products. Finally students have to make a report on whole training program. Institution Partnerships Cotton Club (BD) Ltd has an extensive network of relationships with selected departments in leading academic institutions in Bangladesh, and invests considerable resources to support them. They are important to Primeasia University because it shares with the academic community a concern to foster innovative research, and to develop the skills and experience of the people involved in its generation and transfer. Over the past 10 years CCL has built up a portfolio of programs to encourage collaboration with universities across a broad spectrum of mutually beneficial activities. Every year CCL hosts the students of PAU who work as internee to gain industrial experience for their academic qualifications. It is hoped that this relationship will be increased day by day.

4. Chapter Two Company Details This chapter will give a brief introduction on the history of Cotton Club (BD) Ltd., the attached company, Factory profile, No. of Employers and workers, their responsibilities, Organogram of different sections of the factory and Head office, types of production and marketing, etc.

5. History of Cotton Club Ltd Cotton Club Ltd established in the year 2006, the quality standards and is engaged in manufacturing of all kinds of knitted garments. Under the profound guidance of their mentor Haji Abdul Majid Mondol (Chairman of Mondol Group, established in 1991), their company has gained an immense success and has earned goodwill with twenty years of experience in the garments industries. The Chairman is guiding their team with his wide experience and skill. Their product is made using top quality yarn that is procured from reliable sources across world. They make use of world class in-house infrastructure and modern machines as well as simple hand tools that helps in producing high quality fabric in large volumes and varieties. They are dedicated to offer timely delivery of goods and services at affordable prices. Mission Cotton Club Ltd. mission is to enrich the quality of life of people through responsible application of knowledge, skills and technology. Cotton Club Ltd. is committed to the pursuit of excellence through world- class products, innovative processes and empowered employees to provide the highest level of satisfaction to its customers. Vision Cotton Club (BD) Ltd will endeavor to attain a position of leadership in each category of its businesses. Values Strong work force that ensures quality finished fabric. Major Competitor Cotton Club ltd company is a fully export oriented company so they have face both local and international competition locally. There are many company compete with the Cotton Club ltd company those are India, Pakistan, Koria, Thailand, China and in locally beximco, DBL Group, Anlima Group, Jalima Group, Square Textile, Robin Tex ,ACS Textile.etc.

6. General Information of Factory: Board of Directors of Cotton Club (BD) Ltd.

7. Man Power Cotton Club (BD) Ltd. Staffs of all section’s

8. Cotton Club (BD) Ltd. Workers of all section: Total Manpower of Cotton Club (BD) Ltd. Cotton Clout (BD) Ltd. Staffs of all section’s 8

9. Cotton Clout (BD) Ltd. Workers of all section: Total Manpower of Cotton Clout (BD) Ltd Grand Total: 9

10. Organogram of all division: Organogram of Head Office: 10

11. ORGANOGRAM OF ADMIN AND PRODUCTION: 11

12. ORGANOGRAM OF GARMENTS DIVISION: 12

13. ORGANOGRAM OF DYEING DIVISION: 13

14. ORGANOGRAM OF KNITTING DIVISION: 14

15. Duties and Responsibilities of Different Working Personnel: 15

16. 16

17. 17

18. Machine Details in all sections: Knitting Machines: Dyeing Machines: 18

19. Sewing, Cutting and Finishing Machines: 19

20. Embroidery and Printing Machinery: Power/ Utility: Production Related Information: 20

21. Buyer and Exporting Country: Certificate Gain: Bank Details: 21

22. Sister Concerns of Mondol Group: Tropical Knit Composite Ltd. 22

23. PART-B CHAPTER-1 KNITTING SECTION This chapter begins with the fundamentals of knitting, then it goes with different types of fabrics produced in the Cotton Club and machines used for preparation of those and specification, manufacturing country and uses. Here different knitting terms, notation of fabric with cam arrangement are briefly discussed. This chapter ends with the faults of knitting and their remedie Definition of Knitting Technology: Weaving and knitting is different for the interlacing techniques of yarn. In weaving it needs warp and weft yarn for produce woven fabric but in knitting, fabrics are produced from a series of yarn in warp or weft directions. Knitting techniques can be defined as follow. The processes in which fabrics are produced by set of connect loops from a series of yarns in warp or weft direction is defined as knitting. Different knitting machines are use to perform this techniques. Types of Knitted Fabrics: Mainly two types of knitted fabrics are produced. They are as follow: Warp knitted fabrics: In a warp knitted structure, each loop in the horizontal direction is made from different thread and the number of thread used to produce such a fabric is at least equal to the numbers of loops in horizontal row. Weft knitted fabrics: A horizontal row of loops can be made using one thread runs in horizontal direction. The fabric structure is different from one from another. Weft knitted fabrics are widely use. 23

24. Knitted Fabrics Produced in Cotton Club (BD) Ltd.: The following types of fabrics are generally produced in Cotton Club. 1. Single Jersey a) Plain Single Jersey b) Single Jersey with Lycra c) Single Lacoste d) Double Lacoste e) Single Pique f) Double Pique g) Polo Pique h) French Terry i) Terry with Lycra j) Fleece k) Fleece with Lycra 2. Double Jersey a) Rib Fabric b) Interlock Fabric c) Collar and Cuff 24

25. Different Types Knitted Fabric: 25

26. Process Flow Chart of Knitting: Fabric manufacturing methods are divided into three types; they are as weaving, knitting and non-weaving. Yarns use to produce different types of fabric. Knitted fabrics are one of them. Knitting technology is one of the interesting methods for producing knitted fabrics. Knitted fabrics are produced as the following flow chart. Yarn in cone form ↓ Feeding the yarn cone in the creel ↓ Feeding the yarn in the feeder via trip tape positive arrangement and tension device ↓ Knitting ↓ Withdraw the rolled fabric and weighting ↓ Inspection ↓ Numbering Knitted fabrics have world wide popularity. Different designed knitted fabrics are produced by this above techniques. Classification of Knitting Machine: Knitting machines are use to produce knit fabric. Knitted fabrics are produced by the interlocking of one or more yarns through a series of loops by the use of hooked needle. Knitted fabrics are differing from one to another depending on their fabric design. Specific fabrics are produced from specific knitting machine. Knitting machines are classified as follows: A. Weft Knitting Machine 1. Flat Bar Knitting Machine a) Flat Bed b) V-Bed c) Single Bed d) Unidirectional 2. Straight Bar Knitting Machine a) Single Needle b) Double Needle 3. Circular Knitting machine a) Revolving Cylinder; Sinker Top or Open Top Single Jersey Knitting Machine b) Revolving Cylinder; Cylinder and Dial Double Jersey Knitting Machine 4. Circular Bearded Single a) Sinker Wheel Knitting Machine b) Loop Wheel Knitting Machine B. Warp Knitting Machine a) Rachel Knitting Machine b) Tricot Knitting Machine In modern times knit fabrics have a large verity. Verities type of knit fabrics is the demand of modern time. Such types of fabrics are produced in the knitting mill. 26

27. Profile of Knitting Machines of Cotton Club (BD) Ltd. Circular Machine (Single Jersey) Sl.No Machine Descriptio n 1 SINGLE JERSEY 2 SINGLE JERSEY 3 SINGLE JERSEY 4 SINGLE JERSEY 5 SINGLE JERSEY 6 SINGLE JERSEY 7 SINGLE JERSEY 8 SINGLE JERSEY 9 SINGLE JERSEY 10 SINGLE JERSEY 11 SINGLE JERSEY 12 SINGLE JERSEY 13 SINGLE JERSEY 14 SINGLE JERSEY 15 SINGLE JERSEY 16 SINGLE JERSEY 17 SINGLE JERSEY Sl.No Machin e Descrip tion 1 SINGLE JERSEY OPEN 2 SINGLE JERSEY OPEN 3 SINGLE JERSEY OPEN 4 SINGLE JERSEY OPEN 5 SINGLE JERSEY OPEN Gauge Attach Feeder Qty Brand Origin M/C Dia Truck No 18‖ 24 4 LYCRA 54 1 JIUNNLONG TAIWAN 19‖ 24 4 LYCRA 57 1 JIUNNLONG TAIWAN 20‖ 24 4 LYCRA 60 1 JIUNNLONG TAIWAN 21‖ 24 4 LYCRA 63 2 JIUNNLONG TAIWAN 22‖ 24 4 LYCRA 66 2 JIUNNLONG TAIWAN 23‖ 24 4 LYCRA 69 2 JIUNNLONG TAIWAN 24‖ 24 4 LYCRA 72 2 JIUNNLONG TAIWAN 25‖ 24 4 LYCRA 75 2 JIUNNLONG TAIWAN 27‖ 24 4 LYCRA 81 1 JIUNNLONG TAIWAN 28‖ 24 4 LYCRA 84 1 JIUNNLONG TAIWAN 30‖ 24 4 LYCRA 90 1 JIUNNLONG TAIWAN 32‖ 24 4 LYCRA 96 1 JIUNNLONG TAIWAN 34‖ 24 4 LYCRA 102 1 JIUNNLONG TAIWAN 36‖ 24 4 LYCRA 108 1 JIUNNLONG TAIWAN 38‖ 24 4 LYCRA 114 1 JIUNNLONG TAIWAN 40‖ 24 4 LYCRA 120 1 JIUNNLONG TAIWAN 42‖ 24 4 LYCRA 126 1 JIUNNLONG TAIWAN M/C Dia Gauge Attach Feeder Qty Brand Origin Truck No 24 4 LYCRA 90 1 TAYU CHINA 30‖ 24 4 LYCRA 92 1 TAYU CHINA 32‖ 24 4 LYCRA 102 1 TAYU CHINA 34‖ 24 4 LYCRA 108 1 TAYU CHINA 36‖ 24 4 LYCRA 114 1 TAYU CHINA 38‖ 27

28. Sl.No Gauge Attach Feeder Qty Brand Origin M/C Dia Truck No Machine Descriptio n SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY SINGLE JERSEY 1 19‖ 24 4 LYCRA 57 1 FUKAHARA JAPAN 2 20‖ 24 4 LYCRA 60 1 FUKAHARA JAPAN 3 23‖ 24 4 LYCRA 69 1 FUKAHARA JAPAN 4 24‖ 24 4 LYCRA 72 1 FUKAHARA JAPAN 5 25‖ 24 4 LYCRA 75 1 FUKAHARA JAPAN 6 26‖ 24 4 LYCRA 78 1 FUKAHARA JAPAN Circular Machine (Rib/Interlock) Sl.No Machine Description 1 RIB/INTERLOCK 2 RIB/INTERLOCK 3 RIB/INTERLOCK 4 RIB/INTERLOCK 5 RIB/INTERLOCK 6 RIB/INTERLOCK 7 RIB/INTERLOCK 8 RIB/INTERLOCK 9 RIB/INTERLOCK 10 RIB/INTERLOCK 11 RIB/INTERLOCK Gauge Attach Feeder Qty Brand Origin M/C Dia 24‖ 26‖ 28‖ 30‖ 32‖ 34‖ 36‖ 38‖ 40‖ 42‖ 44‖ Truck No 4 4 4 4 4 4 4 4 4 4 4 18/22 18/22 18/22 18/22 18/22 18/22 18/22 18/22 18/22 18/22 18/22 LYCRA LYCRA LYCRA LYCRA LYCRA LYCRA LYCRA LYCRA LYCRA LYCRA LYCRA 48 52 56 60 64 68 72 76 80 84 88 1 1 1 1 1 2 1 1 1 1 1 JIUNNLONG JIUNNLONG JIUNNLONG JIUNNLONG JIUNNLONG JIUNNLONG JIUNNLONG JIUNNLONG JIUNNLONG JIUNNLONG JIUNNLONG TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN 28

29. Different Parts of Knitting Machine & Functions of Machine Parts Knitting machines are mainly two types; they are circular knitting machine and flat bed knitting machine. This two types are hugely use in knitting machine. A knitting machine is composed of lots of parts. Every parts of a machine are important for run the machine smoothly. Every part has a specific function during operation. Different knitting machine parts and their functions are given below: 1. Creel: Creel is called the holder of cone. Cone is placed in a creel for feeding the yarn to the feeder. 2. Feeder: Yarn is feed through the feeder. No of feeder is depends on the design of the fabric. 3. VDQ Pulley: G.S.M of the knit fabric is controlled by VDQ pulley. VDQ pulley is used for controlling the stitch length of the fabric. 4. Guide: Guide is called the supporting element. Guide is used to guide the yarn. 5. Sensor: Sensor is an automatic controlling system. When a yarn pass through this sensor than if any yarn break down or any problem occur than it automatically stop by this sensoring system. 6. Cylinder: Cylinder is the main parts of a knitting machine. Adjustment of a cylinder is important. Cylinder carries needle, sinker, cam and many more. 7. Spreader: Spreader is used to spread the knitted fabric before take up roller. Knit fabrics may be tube or open type. Spreader is adjusted as need. 8. Fixation Feeder: This type of feeder is used in electrical auto striper knitting machine to feed the yarn at specific finger. 29

30. 9. Rethom: Rethom is used in electrical auto stripper knitting machine. 10. Needle: of knitted loops but all of them can be grouped in three main needle types: In Cotton Club (BD) Ltd., Latch Needles are used for construction of weft knitted fabrics. Main Parts of Latch Needle: a) Hook b) Latch c) Rivet d) Butt e) Stem 30

31. 11. Needle Bed: The needles are disposed in the slots of needle beds which can be flat or circular (dial and cylinder). A flat needle bed consists of a steel plate with grooves. In the grooves the latch needles are inserted in such a way that their butts protrude above the plate of the steel plate. In a cylinder needle bed the knitting needles are placed between the tricks inserted in cuts along the cylinder surface generated. 12. Cam: Cam is the second primary element. The cams are the mechanical devices which convert the rotary drive into a suitable reciprocating action for the needles or other elements. Types of Cam: Cams used in knitting machine are of three types: 31

32. Function of Knitting Cam: individual or seriatim movement in the tricks of latch needle weft knitting machines as the butts pass through the stationary cam system (revolving cylinder machines) upon machine design, are fixed, exchangeable or adjustable. 13. Sinker: the hook side between adjoining needles. Function of Sinkers: It may perform one or more of the following functions depending on the machine knitting action and consequent sinker shape and movement. a) Loop formation b) Holding-down c) Knocking-over 14. Air Gun: possible to attach the needle when machine running 32

33. Knitting Action of Latch Needle Circular Knitting Machine: Knitting actions are: a) Rest position, b) Clearing position, c) Yarn receiving, d) Cast off or knock over stitch formation. e) Stitch Formation Considerable Points for Producing Knit Fabrics Knit fabrics are the fashion of new age. Various designed fabrics are produced in knitting machine. Knitting flow chart should follow during operation. During production processes following machine parameters are considered. rpm (revolution per minute) 33

34. Considerable points to produce knit fabrics: Generally knit fabric production runs according to the order of buyer. When a buyer orders for fabric, they mention some points related to production and end product quality. Before production of knitted fabrics, these factors are needed to consider. Those are as follow: a) Type of fabric or design of fabric: Knitted fabrics are various in design. When a buyer order for a product they give a sample or give the specification of the end product. Different designed fabrics are produced by changing the cam setting, needle setting and size of loop shape. b) Finished G.S.M: It is technical term that indicates the weight of the fabric per square meter. In knitting section grey fabrics are produced but the programmer should make his program for getting the finished G.S.M after dyeing. Some points are considered while setting grey G.S.M; they are enzyme level, color and suided or non suided. G.S.M of the fabric is controlled by the following way: bric can be changed. If pulley moves towards the positive directive then the G.S.M is decrease and in the reverse direction G.S.M will increase. This also depends on the machine type. c) Yarn Count: Yarn count differ on the finished G.S.M. Higher the yarn count higher the G.S.M of the fabric. Sometimes spandex or lycra is used with the cotton in that‘s case yarn count of cotton select with the combination of lycra. d) Type of yarn: Different types of yarn are used for knit production. Cotton yarns may be combed or carded. Also synthetic fiber like lycra is used with cotton for some special case. All depends on the buyer requirement. e) Diameter of fabric: Diameter of the fabric is another factor. Fabric may be open diameter or tube diameter. Anyhow grey dia. will be selected with response of finished dia. of the fabric. f) Stitch length and color depth: If the depth of color of the fabric is high then loop length should be higher because in case of fabric with higher loop length is less compact. In dark shade dye take up% is high so G.S.M is adjusted then. Similarly in case of light shade loop length should be relatively smaller. Stitch length varies depending on yarn count and shade of the fabric. If stitch length is not fixed with respond to finished G.S.M then knitting faults appear. GSM (Gram Square Meter): Measurement of GSM: GSM is a very important parameter for specified a certain quality of knitted fabric. The production of knitted fabric is calculated in weight. The GSM cutter is very popular and easy usable GSM testing instrument used in most knitted factory. But the construction of this cutter is very simple. It is circular disk of 100 square cm area with sharp blade attached to its edge. So 100 square cm of fabric can easily cut by it and weighted at the electric balance to get GSM reading. GSM=(CPI X WPI X SL(mm)/Ne) X 0.9158 Here, CPI = Course per Inch WPI = Wales per Inch SL =Stitch Length Ne =Count Stitch length: In the process sequence, yarn count is the first but in the order of overall importance. Stitch length has the most influence. GSM control means control the stitch length of the knitted fabric. 34

35. Larger stitch length/loop length produces lower GSM & smaller stitch length/loop length has higher GSM i.e., stitch length = Course length/ Total no of needle Machine Gauge: A term giving a notational indication of the no. of needles per unit length along a needle bed or needle bar of a knitting machine in current practice, a common unit length of one English inch (25.4mm) is used for all types of warp and weft knitting machine. Selection of machine gauge depends upon yarn diameter. Yarn diameter depends upon the following: Knitting Calculation: Production of a knitting machine: Production= (RPM x No. of Feeder x No. of Needle x SL x Effc. x 60 x 8) / (10 x 2.54 x 36 x 840 x 2.2046 x Count ) kg Formula for GSM Calculation: GSM = s x l x Tex /100 GSM= s x l x 590 / Ne Where S= Wales per cm x Course per cm= wpc x cpc l = loop length in mm 35

36. Some Knitted Fabric Stitch Notation, Cam Arrangement Fabric Name: Single Lacost 1. Stitch Notation: 1 = 1 Butt Needle 2 = 2 Butt Needle 3 = 3 Butt Needle 4 = 4 Butt Needle K= Knit stitch = Tuck stitch K = Knit cam T = Tuck cam Fig. Looping diagram 2. Cam arrangement & Needle arrangement: i) Using two track cams: ▲ ▲ ▲ T ▲ ▲ T ▲ ▲ ▲ 1 2 ii) Using three truck cams: ▲ ▲ ▲ T ▲ T ▲ ▲ ▲ ▲ ▲ ▲ T iii) ▲ 1 1 2 Using four truck cams: ▲ 2 3 ▲ ▲ ▲ T ▲ T ▲ ▲ ▲ T ▲ T ▲ 3 ▲ ▲ ▲ ▲ 4 ▲ ▲ ▲ Fig.- Cam arrangement Fig.- Needle arrangement Fabric Name: Double Lacost 1. Stitch Notation: 1=1 Butt Needle stitch 2=2 Butt Needle 3=3 Butt Needle 4=4 Butt Needle K = Knit cam T = Tuck cam Fig. Looping diagram 2. Cam arrangement & Needle arrangement: i) Using two track cams: ▲ ▲ ▲ ▲ T T 36

37. 1 ▲ T T ▲ ▲ ▲ 2 ii) Using three truck cams: ▲ ▲ ▲ ▲ T ▲ T T ▲ T T 1 2 T ▲ ▲ ▲ ▲ ▲ ▲ iii) Using four truck cams: ▲ ▲ ▲ ▲ T ▲ T T ▲ ▲ ▲ ▲ T ▲ T T T 1 ▲ ▲ ▲ 2 T ▲ ▲ ▲ 3 4 Fig.- Cam arrangement Fig.- Needle arrangement Fabric Name: Single Jersey 1. Stitch Notation: 1 = 1 Butt Needle 2 = 2 Butt Needle 3 = 3 Butt Needle 4 = 4 Butt Needle X= knit stitch K= knit cam Fig. Looping diagram 2. Cam arrangement & Needle arrangement: i) Using two track cams: ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 1 2 ii) Using three truck cams: ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 1 2 3 iii) Using four truck cams:s ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 1 2 3 4 Fig.- Cam arrangement Fig.- Needle arrangement 37

38. Feature of Flat Knitting Machine  Flat knitting machine has two stationary needle beds.  Latch needles are used.  Angular cam of a bi-directional cam system is used.  The cam system is attached to the underside of a carriage, which with its selected yarn carriers.  The carriage traverses in a reciprocating manner across the machine width.  There is a separate cam system for each needle bed.  The two cam systems are linked together by a bridge, which passes across from one needle bed to the other.  Normally machine gauge is 3 to 18 needles per inch and machine width up to 79 inches. Machine in Flat Knitting Section Company Name : Round Star International Co. Number of Machine : 21 Stopper : 15 Feeder : 06 Needle : 1906 Different Parts of Flat Knitting Machine: 1. Carriage 2. Beds 3. Take down Roller 38

39. 4. Programming Parts Flat/V-Bed Knitting Action V-BED LOOP IN REST POSITION BOTH LOOP CLEAR THE LATCH NEW YARN ARE RECEIVED BOTH LOOPS ARE CAST-OFF AS NEW STITCH Increasing Production in Knitting Floor Knit fabrics are produced from circular knitting machine or flat bed knitting machine. Circular knitting machines are two types, they are single jersey or double jersey knitting machine. This two type‘s machine has different cam arrangement settings, which is responsible for design production. Anyhow, production of knit fabrics depends on various factors. By developing the following factors we can increase the production of knit fabrics. 1. Machine Speed: Production per hour depends on the speed of the machine. Higher the machine rpm, faster the movement of needle which increase the production. But we should make sure that, this higher speed will not impose excess tension on yarn. Excess tension on yarn can increase the breakage of yarn which is not desired. 39

40. 2. Number of Feeder: If the number of feeder increases in the circumference of cylinder, then the number of courses will be increased in one revolution at a time. This is responsible for increasing the production. 3. Machine Gauge: Machine gauge also effect the production of knit fabric. Machine gauge vary depending on the type of machine and Manufacturers Company. Higher gauge machine gives higher production. 4. Automation System: By imposing automation in the machine, production can be increased. Following automation can be added for higher production. n system for smooth operation 5. By imposing other developments: Following development can increase the production. 6. Creel feeding system can increase the production. 7. Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage. 8. By using yarn feed control device. In modern time different advanced facilities added to the machine features, which will facilities the more production. Knit Fabric Faults, Causes and Ways of Remedies Knit fabric is produced from loop formation. So it needs to be careful during production. Different types of faults could be found in knit fabric, which could be the cause of fabric rejection. If we can find out the defects of fabric during production, than we can take steps to remove it from the next knitting production process. In practical; following knitting faults could be found in the knit fabric. Some knitting faults and their remedies are given bellow: Hole Mark Causes: Needle Mark Causes: needle marks come along the fabrics. Star Causes: 40

41. Sinker Mark Causes: sinker mark comes. Drop Stitches Causes: loose of take down mechanism. Oil Stain Cause: Rush Stain Cause: . Pin Hole Cause: Grease Stain Causes: Cloth Fall Out Cause: Cloth fall out can occur after a drop stitch especially when an empty needle with an empty needle with close latch runs into the yarn feeder and remove the yarn out of the hook of the following needles. Barre Causes: different micro near value of fiber content in yarn. fibers have similar characteristics. 41

42. n draw frame different similar classes sliver is mixed and make one sliver. Yarn Contamination Causes: Fly Dust Cause: In knitting section too much lint or short fiber is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attached to the fabric surface tightly during knit fabric manufacturing. Yarn Faults Causes: Different yarn faults also are cause for knitting faults. Now, if we want to remove these knitting faults we should be aware before yarn selection and during knitting of fabric. Knitting machine conditions should be perfect. Needle, Sinker, Feeder and other equipments, which is used, should be fault free. So, Management related person should be aware about the causes of knitting faults and try to reduce the knitting faults. 42

43. CHAPTER-2 DYEING SECTION This chapter deals with the dyeing floor of the Cotton Club (BD) Ltd. It begins with the machine specification of dyeing floor and then is followed by the name of the dyes and chemical used, uses of the different chemicals, dyeing procedure of different types of fabric with different types of dyestuff. In this chapter the main faults and remedies of dyeing are briefly explained. Batch Preparation: Objectives of Batching: – batch as less as possible for same shade. Batch Management: Primarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing manager. Some time planning is adjusted according to m/c condition or emergency. 43

44. Process sequence of Batch preparation : 44

45. Machines Used in Dyeing section: Turning machine : Manufacturer Dong Nam Industrial Co., Ltd., Korea Feature: 1. The Machine is used to reverse the knitted face to back and back to face. 2. The Machine has capacity blower pipe, fabric turning pipe, roller and folding parts. 3. Process of fabric turning. Air Turning Machine: Model : DNAT-400 Width : Roller 400 mm Machine Space : Over All = W1100 × L5600 × H1410 Set-Up = W2100 × L7600 ×H1510 Production Capacity : 7~10 Ton/22h/Day General Structure : Induction Pipe Parts Frame & Fan Parts Roller & Plaiting Part Spare Parts : Tool Box = 1set Electric Capacity : 11.75kw Fan Motor = 11kw × 1 Roller Motor = 0.75kw × 1 Air Consumption : 35mm-Lq PACK'CBM : 5.3 CBM G/R Weight : 1.4ts W/C Total 2 Case No.1 Body Parts 3.9 cbm, G/R 1.0ts (W1300 ×L1800 × H1660) No.2 Pipe Parst 1.4 cbm, G/R 0.4ts (W500 × L5200 × H530) Dyeing Machines: The dyeing section of Cotton Club (BD) Ltd. Has 14 Dyeing machine. Three of them are sample dyeing machine and the rest are for bulk production. Machine specification of the machines is given bellow. Sample Dyeing Machine: No. Of Machine : 3 Sets Name of Machine : ECL-S Medium batch yarn dyeing machine Manufacturer : Flying Yang, China Model : ECL-S-15 Nominal Capacity : 8-15Kg Total Power : 7.7 Kw 45

46. Dimension : 2450mm×1050mm×2060mm Machine Details: Factory Serial No. 1 Manufacturer : M/c Type : Dilmenler, Turkey DMS 25 Sample Dyeing Machine 25 Kg 1360C 1:6-1:8 25 Bar M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working Pressure Maxm Surface Temp. External Tank Capacity : : : : : : 1400C 15 Lt (Chemical) + 15 Lt (Dye) 15 L 2 Dilmenler, Turkey DMS 50 Sample Dyeing Machine 50 Kg 1360C 1:6-1:8 25 Bar Water Capacity : Factory Serial No. Manufacturer M/c Type : : : M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working Pressure Maxm Surface Temp. External Tank Capacity : : : : : : 1400C 35 Lt (Chemical) + 35 Lt (Dye) 35 Lt 3 Dilmenler, Turkey DMS 150Sample Dyeing Machine 150 Kg 1360C 1:6-1:8 25 Bar Water Capacity Factory Serial No. Manufacturer M/c Type : : : : M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working Pressure Maxm Surface Temp. External Tank Capacity : : : : : : 1400C 100 Lt (Chemical) + 100 Lt (Dye) 100 Lt 4 Dilmenler, Turkey DMS 600 HT Jumbo Dyeing Machine 600 Kg 1360C 1:6-1:8 25 Bar Water Capacity Factory Serial No. Manufacturer M/c Type : : : : M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working Pressure : : : : 46

47. Factory Serial No. Manufacturer M/c Type : : : 5 Dilmenler, Turkey DMS 900 HT Jumbo Dyeing Machine 25 Kg 1360C 1:6 25 Bar M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working Pressure Maxm Surface Temp. External Tank Capacity : : : : : : 1400C 600 Lt (Chemical) + 600 Lt (Dye) 600 Lt 6 Dilmenler, Turkey DMS 1200 HT Jumbo Dyeing Machine 1200 Kg 1360C 1:6 25 Bar Water Capacity Factory Serial No. Manufacturer M/c Type : : : : M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working Pressure Maxm Surface Temp. External Tank Capacity : : : : : : 1400C 800 Lt (Chemical) +800 Lt (Dye) 800 Lt 7 Dilmenler, Turkey DMS 600 HT Jumbo Dyeing Machine 600 Kg 1360C 1:6 25 Bar 1400C 400 Lt (Chemical) + 400 Lt (Dye) 400 Lt 8 (A) Dilmenler, Turkey DMS 450 HT Jumbo Dyeing Machine 450 Kg 1360C 1:6 25 Bar Water Capacity Factory Serial No. Manufacturer M/c Type : : : : M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working Pressure Maxm Surface Temp. External Tank Capacity : : : : : : Water Capacity Factory Serial No. Manufacturer M/c Type : : : : M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working : : : : 47

48. Pressure Maxm Surface Temp. External Tank Capacity : : 1400C 300 Lt (Chemical) + 300 Lt (Dye) 300 Lt Water Capacity Factory Serial No. Manufacturer M/c Type : : : : 8 (B) Dilmenler, Turkey DMS 450 HT Jumbo Dyeing Machine 450 Kg 1360C 1:6 25 Bar 1400C 300 Lt (Chemical) + 300 Lt (Dye) 300 Lt M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working Pressure Maxm Surface Temp. External Tank Capacity : : : : : : Water Capacity Factory Serial No. Manufacturer M/c Type : : : : 9 (A) Dilmenler, Turkey DMS 300 HT Jumbo Dyeing Machine 300 Kg 1360C 1:6 25 Bar 1400C 200 Lt (Chemical) + 200 Lt (Dye) 200 Lt M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working Pressure Maxm Surface Temp. External Tank Capacity : : : : : : Water Capacity Factory Serial No. Manufacturer M/c Type : : : : 9 (B) Dilmenler, Turkey DMS 300 HT Jumbo Dyeing Machine 300 Kg 1360C 1:6 25 Bar 1400C 200 Lt (Chemical) + 200 Lt (Dye) 200 Lt M/c Capacity Maxm Working Temp. Liquid Ratio Maxm Working Pressure Maxm Surface Temp. External Tank Capacity : : : : : : Water Capacity : 48

49. Main Parts of The M/C: Main Tank: Main tank is the largest part of the dyeing machine. This is the main dye bath which contains the dye liquor & the fabric. The size of the tank depends on the capacity of the machine. Liquor & 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. 49

50. Reserve Tank/P.T: This tank is mainly used for storage of hot water that will be used for the dyeing of fabric. The temperature of water in the P.T. tank is maximum 800C. By using this hot water in the machine during dyeing there is a reduction of time for heating the water in the main tank which results in the reduction of total dyeing time. Dosing Tank/Additional Tank/Mixing Tank: The dyes, chemicals & auxiliaries used in dyeing are passed to the main tank from additional tank. There may one or two mixing tank. At first, the dye or chemicals are mixed in the additional tank then it is injected or dosed in the main tank depends on the requirements. Heat Exchanger: During the different stage of dyeing (also pre-treatment, after-treatment), there is a need of increasing or decreasing the temperature of dye liquor gradually. We cannot use liquor of required final temperature directly because there may be possibilities of thermal shocking of the fabric. So, the temperature should be increased or decreased in a controlled manner. This controlling is done by heat exchanger. Actually it is an indirect heater. During the circulation of dye bath liquor, the liquor passes through the heat exchanger. 50