1 / 66

Industrial attachment of aman tex ltd.

Presentation about 'Industrial attachment of aman tex ltd.'

sheshir
Download Presentation

Industrial attachment of aman tex ltd.

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. INDUSTRIAL TRAINING Course Code: Tex -4036 Course Code: Tex -4036 Course Code: Tex -4036 INDUSTRIAL TRAINING INDUSTRIAL TRAINING INDUSTRIAL ATTACHMENT AMAN TEX LIMITED AMAN TEX LIMITED AMAN TEX LIMITED INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT 1 | P a g e

  2. ACKNOWLEDGEMENT A number of People have made significant contribution to the preparation of this report. Their insights, advice & suggestions helped us a lot. Firstly, I am very much thankful to our supervising teacher Rajib Saha for his encouragement & valuable suggestions for incessant improvement of the report. I would like to express my sincere gratitude & appreciation to Mr. Khalid Hossain Khan, Director (Production),for allowing me to perform my industrial attachment in the Aman Tex Lmtd. I am also very grateful to all managers & assistant managers for helping to get proper information about every section during industrial training. Finally I want to thank our teacher Professor Syed Fakhrul Hasan for his guidance, encouragement & keen interest in delivering thoughtful advice during the period of industrial training. 2 | P a g e

  3. INTRODUCTION By means of practical knowledge it’s not possible to apply the theoretical knowledge in the practical field. For any technical education, practical experience is almost equal important in association with the theoretical knowledge. The industrial attachment is the process, which builds understanding, skills and attitude of the performer, which improves his knowledge in boosting productivity and services. University education provides us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, skills about various processing stages. It also provides us sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their operation techniques etc. the above mentioned can not be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on. Industrial attachment makes us reliable to be accustomed with the industrial atmosphere and improve courage and inspiration to take self responsibility. Textile education can’t be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. I got an opportunity to complete two-months long industrial training at Aman Tex which is a 100% export-oriented composite Knit Dyeing Industry. It has well planned & equipped fabric dyeing-finishing and garments units in addition to facilitate knitting and knitwear manufacturing. 3 | P a g e

  4. PICTURE: AMAN TEX LIMITED 4 | P a g e

  5. 1. ABOUT AMANTEX: Aman Tex Limited is a young & dynamic Knit Garments industry. Though incorporated in the year 2004 as a private limited company it came came into existence in late December 2008. The mill being established in Boiragirchala, Sreepur, Gazipur, Bangladesh aspires to create a niche within a short period of time in highly competitive global market of Knit Garments. Promoted by a team of young & dynamic visionaries, Aman Tex is 100% export oriented Composite Knit Industries. It posses all the latest machineries from the from the European Countries with few from United States of America, Japan & Taiwan. The entire plant has been installed & erected by foreign & local engineers jointly under the same roof. The total plant is located in a eight storied building in an area of more than 500,000 square feet. Other than the plant area an additional area of 20,500 square feet covered by an ETP & Supply Water plant. The main Building accommodate all the department Knitting, Dyeing, Finishing & the Utilities required for this with all the relevant sections of those departments to cater the needs of a inimitable Garment manufacturing unit in totally meeting all the criteria of updated compliance. Certification: ISO: 9001-2008 (Quality management systems) ISO: 14001-2004 (Environmental management systems) WRAP (Worldwide Responsible Accredited Production ) Oeko-Tex@ Standard 100(Confidence in Textile) URS (United Registrar of System) 5 | P a g e

  6. COMPLIANCE: Strict compliance is observed in the case of female workers in terms of any harassment. Gender equality is also mention in the factory. Child labor never allowed or employed. The mill strictly follows no policy of discrimination appointment of workers. Working hours follow as ILO convention. CONTACT DETAILS FACTORY NAME : AMANTEX LIMITED CORPORATE OFFICE 2, Ishakha Avenue Sector-6 Uttara Dhaka, 1230 TEL : 88-02-7911691-3 88-02-8962297 FAX : 88-02-8921489 FACTORY: Boiragirchala, Sreepur Gazipur TEL : 06825-52790 FAX : 06825-52791 info@amangroupbd.com 6 | P a g e

  7. 1.1 LAYOUT FOR GOING TO THE AMAN TEX FROM DHAKA: Mauna Square DHAKA-MAYMANSHING HIGHWAY Mita Textile Crystal Sweter Factory Fakruddin Textile Mills Denimak Garments Chittagong Denim AMAN TEX & AMAN COTTON & FIBROUS LTD WEST SOUTH NORTH EAST 7 | P a g e

  8. 1.2 Different Section of Aman Tex: a) knitting Section:  Knitting  Inspection b) Dyeing section:  Batch section  Sample Section  Dyeing lab.  Dye Section  Quality control  Finishing Different Sections c) Garments section:  Merchandising  Sample  Cutting Section  Printing Section  Embroidery Section  Sewing Section  Finishing Section d) Maintenance section:  Electrical  Mechanical e) Store Section f) Administration Section g) Security Section h) Marketing Section i) PMC, Work Study & IE Department j) Human Resource & Development Section 8 | P a g e

  9. KNITTING SECTION 2.1 Machine List of Knitting Section in Aman Tex : Machine Name Circular Knitting(Single jersey) m/c Circular Knitting(Rib) m/c Engineering Stripe m/c V-bed Knitting m/c Grey Fabric Inspection m/c Machine Quantity 16 11 08 08 02 9 | P a g e

  10. 2.2 Specification of Circular Knitting Machine: Machine no-01 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 32 Gauge: 24 Capacity: 300 Kgs Machine no-02 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 32 Gauge: 24/28 Capacity: 280 Kgs Machine no-03 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24/28 Capacity: 280 Kgs Machine no-04 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 280 Kgs Machine no-05 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 280 Kgs 10 | P a g e

  11. Machine no-06 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 32 Gauge: 24 Capacity: 300 Kgs Machine no-07 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 280 Kgs Machine no-08 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 280 Kgs Machine no-09 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 280 Kgs Machine no-10 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 28 Capacity: 280 Kgs 11 | P a g e

  12. Machine no-11 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 36 Gauge: 24 Capacity: 300 Kgs Machine no-12 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 18/24 Capacity: 280 Kgs Machine no-13 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 18/24 Capacity: 280 Kgs Machine no-14 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 34 Gauge: 24 Capacity: 300 Kgs Machine no-15 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 280 Kgs 12 | P a g e

  13. Machine no-16 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 26 Gauge: 24 Capacity: 260 Kgs Machine no-17 M/c type: Three Thread Fleece Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 20 Capacity: 280 Kgs Machine no-18 M/c type: Three Thread Fleece Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 280 Kgs Machine no-19 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 36 Gauge: 18 Capacity: 300 Kgs Machine no-20 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 18/24 Capacity: 280 Kgs 13 | P a g e

  14. Machine no-21 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 34 Gauge: 24 Capacity: 300 Kgs Machine no-22 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 280 Kgs Machine no-23 M/c type: Single Jersey Brand name: Fukuhara Origin: Japan Cylinder Dia: 26 Gauge: 24 Capacity: 260 Kgs Machine no-24 M/c type: Three Thread Fleece Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 20 Capacity: 280 Kgs Machine no-25 M/c type: Three Thread Fleece Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 280 Kgs 14 | P a g e

  15. Machine no-26 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 18 Capacity: 280 Kgs Machine no-27 M/c type: Rib Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 18 Capacity: 280 Kgs Machine no-28 M/c type: Engineering Stripe/Auto Stripe (Single Jersey) Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 100 Kgs Machine no-29 M/c type: Engineering Stripe/Auto Stripe (Single Jersey) Brand name: Fukuhara Origin: Japan Cylinder Dia: 34 Gauge: 24 Capacity: 120 Kgs Machine no-30 M/c type: Engineering Stripe/Auto Stripe (Single Jersey) Brand name: Fukuhara Origin: Japan Cylinder Dia: 34 Gauge: 24 Capacity: 120 Kgs 15 | P a g e

  16. Machine no-31 M/c type: Engineering Stripe/Auto Stripe (Single Jersey) Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 100 Kgs Machine no-32 M/c type: Engineering Stripe/Auto Stripe (Single Jersey) Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 20 Capacity: 120 Kgs Machine no-33 M/c type: Engineering Stripe/Auto Stripe (Single Jersey) Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 120 Kgs Machine no-34 M/c type: Engineering Stripe/Auto Stripe (Single Jersey) Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 120 Kgs Machine no-35 M/c type: Engineering Stripe/Auto Stripe (Single Jersey) Brand name: Fukuhara Origin: Japan Cylinder Dia: 30 Gauge: 24 Capacity: 120 Kgs 16 | P a g e

  17. Pictures of Knitting Machine of Aman Tex : Pictures of Knitting Machine of Aman Tex : Single Jersey Circular Knitting m/c Single Jersey Circular Knitting m/c Flat Knitting M/C Flat Knitting M/C Interlock Knitting/Rib M/C Interlock Knitting/Rib M/C Auto Stripe Knitting M/C Auto Stripe Knitting M/C 17 | P a g e

  18. 2.3 DIFFERENT PARTS OF KNITTING MACHINE Creel: Creel is used to place the cone. Feeder: Feeder is used to feed the yarn. Tensioning device: Tensioning device is used to give proper tension to the yarn. VDQ pulley: VDQ pulley is used to control the GSM by controlling the stitch length. Guide: Guide is used to guide the yarn. Sensor: Sensor is used to seen & the machine stops when any problem occurs. Spreader: Spreader is used to spread the knitted fabric before take up roller. Take up roller: Take up roller is used to take up the fabric Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machine to feed the yarn at specific finger. Rethom: These devise are used in Electrical Auto Striper Knitting machine 2.4 PROCESS FLOW CHART OF KNITTING: Yarn in cone form Feeding the yarn cone in the creel Feeding the yarn in the feeder via trip-tape positive feeding arrangement and Tension device. Knitting Withdraw the rolled fabric and weighting Inspection Numbering 18 | P a g e

  19. 2.5 RAW MATERIALS USE FOR KNITTING: Type of yarn Count 16s,20s, 22s, 24s, 26S, 28S, 30S, 34S, 40S Cotton Yarn Polyester Yarn 75D, 100D,150D Spandex yarn 20D,40D,70D 20S,22S,24S, 26S,30S,34S Grey Mellange (C-90% V-10%) 24S, 26S, 28S, 30S PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S CVC 2.6 CONSIDERABLE POINTS TO PRODUCE KNITTED FABRICS When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows-        Finished G.S.M. Type of Fabric or design of Fabric. Yarn count Types of yarn (combed or carded) Diameter of the fabric. Stitch length Color depth. 19 | P a g e

  20. 2.7 Yarn Count, Stitch length for different types fabric knitting: Fabric Type Plain Single Jersey GSM 115 135 150 160 Yarn Count 40/1 CB 30/1 CD 28/1 CB 26/1 CD Color Black Anthracite Black Ribbon red Stitch Length M/c dia x gauge Finished Width 2.54 30 x 28 2.68 36 x 24 2.75 36 x 24 2.7 30 x 24 33" Tube 72" Open 74" Open 62" Open Lycra Single Jersey H.F.L-190 F.F.L-250 190 32/1+20DL 30/1CB+40DL 32/1+20DL Wash Black Wash 2.85 2.98 2.85 30 x 28 30 x 28 30 x 28 64" Open 64" Open 64" Open 160/65 210/20 210/20 220 220 215/20 32/1CD 22/1CD 22/1CD 22/1CD 22/1CD 24/1CB Blue White White White White Light 2.7 2.72 2.75 2.75 2.75 2.64 30 x 24 28 x 24 25 x 24 24 x 24 25 x 24 32 x 24 43" Tube 76" Open 35.5" Tube 66" Open 66" Open 46" Tube Single Lacost Lycra S/Lacost 210 28/1+40DL Average 2.85 26 x 24 66" Open 160/65 160/65 160/65 160/65 30/1CD 30/1CD 32/1CD 32/1CD White White Blue White 2.65 2.65 2.58 2.52 30 x 24 28 x 24 30 x 24 30 x 24 43" Tube 41" Tube 43" Tube 43" Tube Double Lacost 175 200 200 200 200 200 220 34/1 CB 30/1 CB 30/1 CB 30/1 CB 32/1 CB 28/1 CB 28/1 CB Light 2.54 2.52 2.64 2.54 2.54 2.58 2.52 40 x 18 38 x 18 38 x 18 38 x 18 38 x 20 38 x 18 36 x 18 37" Tube 74" Open 37" Tube 68" Open 41" Tube 74" Open 68" Open Light Violet Medium Light Black White Red/Green 1x1 Rib 1x1 Lycra Rib 280 380 28/1CB+70DL 34/2CB+70DL Average Average 2.85 3.1 34 x 18 36 x 16 32" Tube 34" Tube 2x2 Rib 300 380 24/1 CB 20/1 CB Average Average 3.3 3.42 40 x 18 40 x 18 24" Tube 24" Tube 2x2 Lycra Rib 340 24/1CB+70DL Average 3.45 36 x 18 22" Tube Pique 220 20/1CD Average 2.78 26 x 24 37" Tube Fleece 260 280 270 300 30/1CD+75DP+26/2CB 34/1GM+75DP+20/2CB 32/1CD+12/1CD 32/1CD+12/1CD Medium Anthalatic Grey Dark Dark P-4,B-3,L-1.5 P-3.5,B-3.25,L-1.6 P-4.3,B-3.3,L-1.6 P-4.1,B-3.3,L-1.6 30 x 20 30 x 20 30 x 20 30 x 20 68" Open 68" Open 74" Open 74" Open B/B B/B Lycra Fleece 260 260 30/1CD+70DP+26/1CB+20DL 30/1CD+75DP+26/1CB+20DL Medium Dark P-4,B-3.1,L-1.5 P-4,B-3,L-1.5 30 x 20 30 x 20 68" Open 64" Open Engineering 165 26/1Dyed Wash 2.75 30 x 24 64" Open Stripe(S/j) 190 Wash 3 36 x 24 76" Open 200 Wash 2.85 30 x 24 64" Open 20 | P a g e

  21. 2.8 END PRODUCTS OF CIRCULAR KNITTING MACHINE: Single Jersey M/C: a) S/J Plain b) Single lacoste c) Double lacoste d) Single pique e) Double pique f) Terry Rib M/C: a) 1*1 Rib fabric b) 2*2 Rib fabric c) Honeycomb V-BED KNITTING M/C: a) Collar b) Cuff c) Emboss 2.9 PRODUCTION CALCULATION: A. Production/shift in kg at 100% efficiency    RPM No . of Feeder 3527 No . of Needle SL ( mm )   80 . Yarn count B. Production/shift in meter Course / min cm .  Course /   cm   RPM No . of Feeder 60  12 Efficiency  Course / 100 C. Fabric width in meter: Total no . cm of wales   Wales / 100 Needles Total no . of used in knitting   Wales / cm 100 21 | P a g e

  22. 2.10 PRODUCTION PARAMETER: 1. Machine Diameter 2. Machine rpm (revolution per minute) 3. No. of feeds or feeders in use 4. Machine Gauge 5. Count of yarn 6. Required time (M/C running time) 7. Machine running efficiency 22 | P a g e

  23. 2.11 FAULTS, CAUSES & THEIR REMEDIES IN KNITTING: 1. Hole Mark Causes:  Holes are the results of yarn breakage or yarn cracks.  During loop formation the yarn breaks in the rejoin of the needle hook.  If the yarn count is not correct on regarding structure, gauge, course and density.  Badly knot or splicing.  Yarn feeder badly set. Remedies:  Yarn strength must be sufficient to withstand the stretch as well as uniform.  Use proper count of yarn.  Correctly set of yarn feeder.  Knot should be given properly. 2. Needle Mark Causes:  When a needle breaks down then needle mark comes along the fabrics.  If a needle or needle hook is slightly bends then needle mark comes on the fabrics. Remedies:  Needle should be straight as well as from broken latch. 3. Sinker Mark Causes:  When sinker corrode due to abrasion then some times can not hold a new loop as a result sinker mark comes.  If sinker head bend then sinker mark comes. Remedies:  Sinker should be changed. 4. Star Causes:  Yarn tension variation during production.  Buckling of the needle latch.  Low G.S.M fabric production. Remedies:  Maintain same Yarn tension during production.  Use good conditioned needles. 5. Drop Stitches 23 | P a g e

  24. Causes:  Defective needle.  If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook.  Take-down mechanism too loose.  Insufficient yarn tension.  Badly set yarn feeder. Remedies:  Needle should be straight & well.  Proper feeding of yarn during loop formation.  Correct take up of the fabric & correct fabric tension.  Yarn tension should be properly. 6. Oil stain Causes:  When oil lick through the needle trick then it pass on the fabrics and make a line. Remedies:  Ensure that oil does not pass on the fabrics.  Well maintenance as well as proper oiling. 7. Rust stain Causes:  If any rust on the machine parts. Remedies:  If any rust on the machine parts then clean it.  Proper maintenance as well as proper oiling. 8. Pin hole Causes:  Due to break down or bend of the latch, pin hole may come in the fabric. Remedies:  Change the needle 24 | P a g e

  25. 9. Grease stain Causes:  Improper greasing  Excess greasing Remedies:  Proper greasing as well as proper maintenance 10. Cloth fall- out Causes:  Cloth fall- out can occur after a drop stitch especially when an empty needle with an empty needle with closed latch runs into the yarn feeder and remove the yarn out of the hook of the following needles. Remedies:  Make sure all the latches of needle are closed with feeding yarn after a drop stitch. 11. Barre: A fault in weft knitted fabric appearing as light or dark course wise (width wise) Stripe. Causes:  This fault comes from yarn fault.  If different micro near value of fiber content in yarn.  Different lusture, dye affinity of fiber content in yarn.  During spinning different similar classes of fiber is mixed specially in carded yarn & these fibers have similar characteristics.  In draw fame different similar classes sliver is mixed and make one sliver. Remedies:  We can use this fabric in white color. 12. Fly dust: Causes:  In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production. Remedies:  Blowing air for cleaning and different parts after a certain period of time.  By cleaning the floor continuously.  By using ducting system for cleaning too much lint in the floor.  Over all ensure that lint does not attach to the fabric. 25 | P a g e

  26. 13. Yarn contamination Causes:  If yarn contains foreign fiber then it remains in the fabric even after finishing,  If lot, count mixing occurs. Remedies:  By avoiding lot, count mixing.  Fault less spinning. 14. Yarn Faults:  Neps.  Slubs.  Yarn count variations.  Thick/Thin place in yarn.  Hairiness. 26 | P a g e

  27. LABROTORY 3.1 LABORATORY MACHINERIES WITH ITS SPECIFICATION: 1. Brusting Strength Tester: No. of m/c-01 Name of the m/c : TruBurst Brand Name Origin : James H Helal : U.K 2. Pilling & Snagging Resistant Tester: No. of m/c-01 Brand Name : SDL ATLAS Origin : U.K 3. Data color M/c: No.of m/c-01 Brand Name : Ahiva-600 Origin : U.S.A 4. Test Name Name of the m/c : Rota Wash Origin : U.K No.of m/c : 02 Test Method :ISO105-C06, ISO105-D02 : Colorfastness to Washing, Dry cleaning. 5. Test Name Name of the m/c : Crock Master Brand Name : James H Helal Origin : U.K No.of m/c : 01 : Colorfastness to Rubbing 6 Test Name Name of the m/c : Eltrolux wascator. Brand : SDL ATLAS Origin : U.K No.of m/c : 02 Test Method : ISO 6330, ISO 26330 : Dimensional Stability, Spirality, Appearance after washing. 7. M/C Name: Datacolor AutoLab TF Gravimetric Lab dispenser No.of m/c-01 Brand Name : Ahiva-600 Origin : U.S.A 27 | P a g e

  28. 8. Lab Dip m/c: No.of m/c: 02 M/C NO- 01 Brand name : Ahiba Nuance Lab Dip Dyeing m/c Origin : U.S.A 3.2All Buyer Test Manual: 28 | P a g e

  29. Rubbing Fastness Tester M/C Rubbing Fastness Tester M/C Washing M/C Washing M/C Data Color M/C Data Color M/C TruBurst M/c 29 | P a g e

  30. Lab Dip M/C Pilling or Snagging M/C Pilling or Snagging M/C Wash Fastness Testing M/C Wash Fastness Testing M/C Washing M/C 30 | P a g e

  31. 3.3 SOME TEST PROCEDURE Color fastness to rubbing (wet & dry): Procedure: At first take a sample of size (14 × 5) cm at Wales & Course wise. Put the crocking cloth on to the finger & stag by finger clip & run 10 times in 10 seconds manually & assess the crocking cloth with gray scale. Place the crocking cloth on the water, it will sucked some water and then squeeze the crocking cloth. Then place the wet rubbing cloth on to the finger and stag with finger clip and run 10 times in 10 seconds manually. Then assess the crocking cloth by gray scale for wet rubbing. Wet and dry rubbing are checked according to buyer’s requirement. Color fastness to washing. (ISO/05-CO6): Procedure: 1. Size of specimen: Cut sample & multifibre at (10 × 2)cm then stitch. 2. Detergent: 4g/l ECE detergent (WOB) + 1g/l sodium per borate put in distilled water & cooled at 20°C & measured PH(where necessary). 3. Run the program in the following way: - Test no. Temp°C Liq.volume ml Time min. Steel balls Adjust pH C2S 60°C 50 30 25 10.5±1 4. Rinse the sample twice with cold water. 5. Dry at 60°C by hanging or by flat iron pressing but temperature should not less more than 150°C. Pilling test: Procedure: Cut the fabric 12.5 x 12.5cm & balance mark should be 10cm by using template. Then sewn the fabric so that it can be firmly fit in the tube a moulded polyurethane tubes. Then four tubes are placed in a box & start 60±2 rev/min for 5 hrs or according to buyer requirement. Here mainly used 3hrs(1100 cycle). Then assess the pilling by putting tested specimen on the viewing cabinet & compare with standard photographs. 31 | P a g e

  32. Shrinkage & Spirality test: Buyer’s requirements: Template size: 50cm & 35cm, 25.5cm &18cm (use after quick wash). Shrinkage: length wise--- 5% Width wise----5% Spirality: Left -------- 5% Right -------- 5% Procedure: At first take two ply of fabric & put the template (50cm) on to the fabric. The template has 8 holes. Both length & width wise the template holes can measure 35cm at 3 places. Then we mark the 8 holes by permanent marker & also at the edges of the template. Then sewn the fabric & it is given to the washing m/c for run at 60°C for 60minutes with water. After that dry the sample & then measure the fabric Spin speed --- 500rpm Drum speed--500rpm Calculation: Shrinkage Test:  Lengthwise: After wash – Before wash ----------------------------------×100 Before wash = Width wise: After wash – Before wash = ----------------------------------×100 Before wash Spirality test:   Left side Right side 2 = × 100 % Length(wid th for H & M) 32 | P a g e

  33. Color fastness to water (ISO 105 EO1& EO2): 1. Sample size: Cut the specimen & multi-fiber at 10×2cm & sewn together. 2. Solution: Wet in distilled water at room temperature & it will suck water. 3. Place it in acrylic resin plates & put the weight on to the plates. 4. Keep it in oven & keep the temperature at 37± 2°C for 4hrs. 5. Open the specimen & dry it in the air hot exceeding 60°C. 6. Assess the staining & shade change with gray scale. Color fastness to perspiration Alkaline & Acid solution (Method: ISO 105 E04): 1) Procedure: Cut the specimen & multifibre at 10×2cm & sewn together. 2) Prepare solution: Alkaline Solution:  0.5g/l of 1-histadine mono hydrochloride monohydrate  5g/l of sodium chloride This solution is brought to pH -8 with 0.1 mole/l caustic solution. Acid solution:  0.5 g/l of 1-histadine monohydrochloride monohydrate  5g/l of sodium chloride.  2.2 g/l of sodium dihydrogen orthophosphate dehydrate. This solution is brought to pH-5.5 with 0.1 mole/l caustic solution. 3) M: L = 1: 50 4) Wet the specimen in flat dish containing acid & alkaline solution & keep for 30min. Then take the specimen & squeeze the excess solution by two glass rods. 5) Put the specimen in to the acrylic resin plates & put wt. on the plates. 6) Keep it in the woven at 37°C ± 2°C for 4hrs. 7) Open the specimen 6 multi fibre & dry separately in the air temperature not exceeding 60°C. 8) Access the staining & shade change with grey scale. 33 | P a g e

  34. PHTest: Procedure: Take 2gm sample fabrics and cut into small pieces. Then put it conical flax with 100cc water (M: L -1:50). Then shake it 15 min, then place it in a shaker m/c for 1 hour. Then check PHby PH meter. GSM TEST: Procedure: GSM is the most important factor. There is a GSM cutter. The sample cut by the GSM cutter is weighted in the electronic balance. The reading (in gm) from the balance is multiplied by 100 to get the value of GSM. 34 | P a g e

  35. Dyeing Section 4.1 Dyeing Machine Capacity : Sample No. of High temperature sample dyeing machine = 06 pcs Total machine capacity of sample m/c Total production capacity of sample m/c = 190 kgs = 150 kgs Production No. of High temperature dyeing machine Total Machine capacity on dyeing floor Total Production capacity on dyeing floor = 11 pcs = 6750 kgs = 16 metric tons/day 35 | P a g e

  36. 4.2 Dyeing Machine Specification: No.of Machine :11 Machine no-01 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 250 kg : One (01) : 0.35 Mpa : 0.55 Mpa : 2002 Machine no. -02 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 250 kg : One (01) : 0.35 Mpa : 0.55 Mpa : 2002 Machine no-03 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 500 kg : One (01) : 0.35 Mpa : 0.55 Mpa : 2002 36 | P a g e

  37. Machine no-04 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 500 kg : One (01) : 0.35 Mpa : 0.55 Mpa : 2002 Machine no-05 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 500 kg : One (01) : 0.35 Mpa : 0.55 Mpa : 2002 Machine no-06 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 500 kg : One (01) : 0.35 Mpa : 0.55 Mpa : 2002 37 | P a g e

  38. Machine no-07 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 750 kg : Three (03) : 0.35 Mpa : 0.55 Mpa : 2002 Machine no-08 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 750 kg : Three (03) : 0.35 Mpa : 0.55 Mpa : 2002 Machine no-09 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 750 kg : Three (03) : 0.35 Mpa : 0.55 Mpa : 2002 38 | P a g e

  39. Machine no-10 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 750 kg : Two (02) : 0.35 Mpa : 0.55 Mpa : 2002 Machine no-11 Machine name Origin Capacity Number of nozzle Max. working Temperature : 140°C Working Pressure Test pressure Year of Construction : Thie’s (High temperature machine). : Germany : 1000 kg : Two (02) : 0.35 Mpa : 0.55 Mpa : 2002 39 | P a g e

  40. Sample Section Specification Of Sample Dyeing Machine: No. of Machine : 06 Machine no-01 Machine name Origin Capacity Max. Variable Temperature : 160°C Max. Operating Pressure Year of Construction : Thie’s (High temperature machine) : Germany : 60 kg : 400 Kpa : 2002 Machine no-02 Machine name Origin Capacity Max. Variable Temperature : 160°C Max. Operating Pressure Year of Construction : Thie’s (High temperature machine) : Germany : 30kg : 400 Kpa : 2002 Machine no-03 Machine name Origin Capacity Max. Variable Temperature : 160°C Max. Operating Pressure Year of Construction : Thie’s (High temperature machine) : Germany : 10kg : 400 Kpa : 2002 Machine no-04 Machine name Origin Capacity Max. Variable Temperature : 160°C Max. Operating Pressure Year of Construction : Thie’s (High temperature machine) : Germany : 10kg : 400 Kpa : 2002 40 | P a g e

  41. Machine no-05 Machine name Origin Capacity Max. Variable Temperature : 160°C Max. Operating Pressure Year of Construction : Thie’s (High temperature machine) : Germany : 10kg : 400 Kpa : 2002 Machine no-06 Machine name Origin Capacity Max. Variable Temperature : 160°C Max. Operating Pressure Year of Construction : Thie’s (High temperature machine) : Germany : 20kg : 400 Kpa : 2002 4.3 Raw materials for dyeing: Raw materials used in the dyeing section are: 1. Grey fabrics 2. Dyes 3. Chemicals. Grey fabrics: Following types of gray fabrics are dyed:  Single jersey  Single jersey with lycra  Polo pique  Back Pique  Single lacoste  Double Lacoste  Fleece  Rib  Rib with lycra  1Χ1 rib  2Χ2 rib  Different types of collar & cuff. 41 | P a g e

  42. 4.4 Flow Chart For Dyeing : Flow Chart For Dyeing: Grey fabric receive from knitting section Batching Select m/c no Fabric loading Select production program Pre treatment Select recipe for dyeing Recipe confirm by D.M / S.P.O Dyeing Post treatment Unload  42 | P a g e

  43. 4.5 Common dyeing faults with their remedies 1. Uneven dyeing: Causes: - Uneven pretreatment (uneven scouring & bleaching). - Improper color dosing. - Using dyes of high fixation property. - Uneven heat-setting in case of synthetic fibers. - Lack of control on dyeing m/c Remedies: - By ensuring even pretreatment. - By ensuring even heat-setting in case of synthetic fibers. - Proper dosing of dyes and chemicals. - Proper controlling of dyeing m/c 2. Batch to Batch Shade variation: Causes: - Fluctuation of Temperature. - Improper dosing time of dyes & chemicals. - Batch to batch weight variation of dyes and chemicals. - Dyes lot variation. - Improper reel speed, pump speed, liquor ratio. - Improper pretreatment. Remedies: - Use standard dyes and chemicals. - Maintain the same liquor ratio. - Follow the standard pretreatment procedure. - Maintain the same dyeing cycle. - Identical dyeing procedure should be followed for the same depth of the Shade. - Make sure that the operators add the right bulk chemicals at the same time and temperature in the process. - The pH, hardness and sodium carbonate content of supply water should check daily. 43 | P a g e

  44. 3. Patchy dyeing effect: Causes: - Entanglement of fabric. - Faulty injection of alkali. - Improper addition of color. - Due to hardness of water. - Due to improper salt addition. - Dye migration during intermediate dyeing. - Uneven heat in the machine, etc Remedies: - By ensuring proper pretreatment. - Proper dosing of dyes and chemicals. - Heat should be same throughout the dye liquor. - Proper salt addition. 4. Roll to roll variation or Meter to Meter variation: Causes: - Poor migration property of dyes. - Improper dyes solubility. - Hardness of water. - Faulty m/c speed, etc Remedies: - Use standard dyes and chemicals. - Proper m/c speed. - Use of soft water 5. Crease mark: Causes: - Poor opening of the fabric rope - Shock cooling of synthetic material - If pump pressure & reel speed is not equal - Due to high speed m/c running Remedies: - maintaining proper reel sped & pump speed. - Lower rate rising and cooling the temperature - Reducing the m/c load - Higher liquor ratio 44 | P a g e

  45. 6. Dye spot: Causes: - Improper Dissolving of dye particle in bath. - Improper Dissolving of caustic soda particle in bath. Remedies: - By proper dissolving of dyes & chemicals - By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the large un-dissolved particles are removed 7. Wrinkle mark: Causes: - Poor opening of the fabric rope - Shock cooling of synthetic material - High temperature entanglement of the fabric Remedies: - Maintaining proper reel sped & pump speed. - Lower rate rising and cooling the temperature - Higher liquor ratio 8. Softener Mark: Causes: - Improper mixing of the Softener. - Improper running time of the fabric during application of softener. - Entanglement of the fabric during application of softener Remedies: - Maintaining proper reel sped & pump speed. - Proper Mixing of the softener before addition. - Prevent the entanglement of the fabric during application of softener 45 | P a g e

  46. Finishing Section 5.1 Machine List of Finishing Section: Machine Name Machine Quantity Slitting m/c 02 Hydro Extractor 02 Dryer 02 Stenter 02 Open Compactor 01 Tube Compactor 01 Single Drum Raising m/c 01 Double Drum Raising m/c 01 Sueding m/c 01 5.2 Flow chart for tube fabric finishing: Tube fabric Dewatering Dryer Compactor 5.3 Flow chart for open fabric finishing: Open fabric Slitting Stenter/Dryer(santex) Compactors Raising/Sueding Stenter/Dryer(santex) 46 | P a g e

  47. 5.4Function of Different Finishing M/C: Objectives of De-Watering M/C:  Remove excess Water  Application Of GSM  To control the crease mark of the fabric. Hydro Extractor M/C:  To extract excess water. Slitting M/C:  To open tube fabric according to specific needle mark. Dryer M/C:  To dry the fabric.  To control the overfeed system  To control the vibration which increase the GSM Compactor M/C:  Shrinkage control  Width control  Stenter M/C:  Heat setting  Width control, Finishing chemical application  Loop control  GSM control  Drying  Shrinkage control 47 | P a g e

  48. Printing Section 6.1 Different Types of Printing:  Pigment Printing  Rubber Printing  Flocking Printing  Glitter Printing  Emboss Printing  Screen Printing 6.2 Chemical Used: Thickener (PG): It is a main compound for making a paste. Binder: Hold color on to the fabric surface. Pigment: It is a coloring substance. 6.3Printing Process Sequence: 6.4 Pigment Printing: Recipe: Thickener-2% Binder-8% Fixer-2% Water-90% Sequence: Table Preparation Fabric Plaited on the table Pigment Printing paste apply with the help of screen Curing at 160’c (Belt speed 6.50 m/min) Delivery 48 | P a g e

  49. 6.5 Faults in Printing: Fatting: If the pigment printed fabric is fatted (on printed portion) after washing, then this fabric is rejected. So it is a major fault in printing. Cracking: If the rubber printed fabric is braking (on printing portion) after elastration Machine Used in Printing Section: Machine Name Brand Origin Machine Quantity Tunnel Dryer Sujou-Yuhui Chaina 01 IR dryer Sujou-Yuhui Chaina 04 Exposer Sujou-Yuhui Chaina 01 Heat press M/C Sujou-Yuhui Chaina 03 Screen Frame Binder Sujou-Yuhui Chaina 01 Mixture M/C Sujou-Yuhui Chaina 01 49 | P a g e

  50. Picture Gallery . 50 | P a g e

More Related