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Industrial Attachment of Beximco knitting ltd.

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Industrial Attachment of Beximco knitting ltd.

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  1. BEXIMCO KNITTING LTD. 2013 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUTRY NAME: BEXTEX YRS SEU Page 1

  2. BEXIMCO KNITTING LTD. 2013 ACKNOWLEDGEMENT Industrial Attachment Course is an academic function of the Southeast University. Like all other years our teacher Prof. Syed Fakhrul Hasan, Chairman, Department of Textile Engineering, gave us an opportunity to choose preferable mills for Industrial Attachment Course. We, the three students of 04thbatch choose BEXIMCO Knitting Ltd. Joyfully with the supervision of our teacher Md. Fazley Elahi. During the attachment with BEXIMCO Knitting Limited we worked in all the departments related with the Wet Processing Section. We not only gave priority to the Wet Processing but also worked sincerely in the Knitting Section, Utilities, Maintenance and Effluent Treatment Plant. Beside these, we learned about Quality Control Section and Finished Fabric Inspection Section, warehouse & Store & Inventory, finishing specially dyeing. We owe a particular debt of gratitude to MD. Lat Mia, Asst. Manager, Dyeing Section, BKL. He gave away some of his valuable time regularly in helping us to achieve our intended goal.We also express our gratitude to all the executives of BKL knitting, batching, store & inventory control. Of course, we wish to pay our special thanks to the persons guided us, inspired us & cared us during these days-Md. Khairul Islam, Manager, Dyeing Section & Mr. Rafikul Islam Raju, GM, BKL. Lastly we express our gratitude to our supervising teacher, the name that should be mentioned first, Md. Fazley Elahi, Lecturer of the Dept. Textile Engineering, SEU, for his valuable direction & supervision. However, we have prepared our Industrial Attachment report overcoming all the difficulties & also the shortage of time. Here we would like to present the report. Date: ……../……../2010 (Rahat Bin Rahman) (Md. Yeasin Arafat) YRS SEU Page 2

  3. BEXIMCO KNITTING LTD. 2013 (Md. Abu Hurayra Chapter- 01 Project Description YRS SEU Page 3

  4. BEXIMCO KNITTING LTD. 2013 Company Information  Name : BEXIMCO KNITTING LIMITED (Dyeing section)  Type : KNIT DYEING.  Year of establishment  Location : : 1996 Beximco industrial park, Sarabo, Kashimpur, Gazipur. (5 km north from DEPZ).  Address: Corporate Headquarter: 17, Dhanmondi, R/A, Road no. 2, Dhaka- 1205 Operational Headquarter & Factory: Beximco Knitting Limited, Beximco Industrial park. Sarabo, Kashimpur, Gazipur.  Sponsors : World Bank, Marubeni. YRS SEU Page 4

  5. BEXIMCO KNITTING LTD. 2013 DEPZ Chakraborti Bipile Nobinagar DEPZ J. U. Beximco Industrial Park Dhaka Mymensing Road Savar Ashulia Tongi Gabtoli Abdullahpur Mirpur Uttara Mirpur Road New Air port Mohakhali Prime Minister’s House Old Air port National Assembly Asad gate Farmgate Sat Rasta Figure- Location of BEXTEX YRS SEU Page 5

  6. BEXIMCO KNITTING LTD. 2013 HISTORY OF BEXIMCO GROUP 1965-1973: Beximco was born. 1965 New Dacca Industries Ltd 1973 Beximco UK branch. 1976-1989: Beximco diversifies 1978 Beximco foods Ltd. 1979 Beximco pharmaceuticals ltd. 1982 Shinepukur Jute Spinners Ltd. 1985 Beximco apparels Ltd. 1987 Recognised as export house for contribution to country’s export. 1990-1995: Beximco expands 1990 Padma Textile Mills Ltd.(plant -1) 1992 Beximco Synthetics Ltd. 1996-1999: Beximco preparing for the new millennium. 1996 Beximco Textiles Ltd (Phase 1).  Beximco Knitting Ltd.  Beximco Denims Ltd . 1997: Padma Textiles Mills Ltd (Plant -2). 1998: Beximco Textiles Mills Ltd (Phase 2). Beximco Fashions Ltd . Physical Infrastructure  Single storied building (only dye warehouse is double storied )  Concrete structure (about 30 ft high) YRS SEU Page 6

  7. BEXIMCO KNITTING LTD. 2013 Different Department A) Production oriented department Production Planning and control Knitting Batch preparation Dyeing Finishing Lab& Quality assurance Dye warehouse Maintenance Utility Finished warehouse B) Supporting department - Personnel administration - Procurement - Marketing - IT - HRD - Finance & accounting. Remarks: - - Available data on physical infrastructure was not available. Production per day ranges from 8-12 tons. YRS SEU Page 7

  8. BEXIMCO KNITTING LTD. 2013 Chapter- 02 Manpower Management YRS SEU Page 8

  9. BEXIMCO KNITTING LTD. 2013 ORGANOGRAM OF MANPOWER Chief executive officer (CEO) Head of manufacturing Chief operating officer DGM (Production) Finishing Manager Q.C Manager Dyeing Manager Maintenance Manager Knitting Manager Asst. Manager Deputy Manager Shift officer Shift officer Shift officer Shift officer Electrical incharge Mechanical Incharge 2.1 Shift change: Per shift is 8hrs 1stshift 2ndshift 3rdshift General shift : : 2:00 PM - 10:00 PM : 10:00 PM - 6:00 AM 9:00 AM - 5:00 PM 6:00 AM - 2:00 PM : YRS SEU Page 9

  10. BEXIMCO KNITTING LTD. 2013 2.2 Responsibility of a production officer:       Overall supervision of dyeing, finishing production. Batch preparation & pH check. Dyes & chemical requisition issue & check. Write Fabrics loading &loading time from m/c. Program making, sample checking, colour measurement. Control the supervisor, operator, asst. operator and helper of dyeing m/c. And also any other work as & when required by the management.  2.3 Job description: Title Dept/Section Report to Job summary : : : : Production Officer Dyeing Sr. Production Officer To plan, execute & follows up the production activities& control the quality production with related activities. Title Dept/Section : Report to Job summary : : Sr. Production Officer Dyeing Asst manager (production) To plan, execute & follow up the production activities. : YRS SEU Page 10

  11. BEXIMCO KNITTING LTD. 2013 Chapter- 03 Machine Description YRS SEU Page 11

  12. BEXIMCO KNITTING LTD. 2013 3.1 Dyeing Machines: BKL is an integrated computerized company. It has total 19 dyeing machines among of them 10 machines are fully computerized. The machines are centrally controlled by Beacon Controller. 3.1.1 Dyeing Machine Specifications: Machine No. : 1, 2, 3, 7, 8 Machine Name : Eco-soft Company Name : Thies, Germany No. of Nozzle : 4 YRS SEU Page 12

  13. BEXIMCO KNITTING LTD. 2013 Capacity : 500-600 kg. Diff. Pressure : 500-600 m.bar. Rope speed : 200-250 m/min. Machine No. : 5 Machine Name : Mini-soft Company Name : Thies, Germany No. of Nozzle : 1 Capacity : 75 kg. Diff. Pressure : 500-600 m.bar. Rope speed : 200-250 m/min. YRS SEU Page 13

  14. BEXIMCO KNITTING LTD. 2013 Machine No. : 6 Machine Name : Eco-soft Company Name : Thies, Germany No. of Nozzle : 2 Capacity : 350 kg. Diff. Pressure : 500-600 m.bar. Rope speed : 200-250 m/min. Machine No. : 9 Machine Name : Luft-roto Company Name : Thies, Germany No. of Nozzle : 2 Capacity : 200-350 kg. Diff. Pressure : 500-600 m.bar. Rope speed : 200-250 m/min. Machine No. : 10 Machine Name : Luft-roto Company Name : Thies, Germany No. of Nozzle : 3 Capacity : 500-550 kg. Diff. Pressure : 500-600 m.bar. Rope speed : 200-250 m/min. Machine No. : 11 Machine Name : Local Company Name : Beximco, Bangladesh Capacity : 70 kg. Pressure : 500-600 m.bar. YRS SEU Page 14

  15. BEXIMCO KNITTING LTD. 2013 Rope speed : 200-250 m/min. Machine No. : 12 Machine Name : Local Company Name : Beximco, Bangladesh Capacity : 10-20 kg. Diff. Pressure : 500-600 m.bar. Rope speed : 200-250 m/min. YRS SEU Page 15

  16. BEXIMCO KNITTING LTD. 2013 Machine No. : 13 Machine Name : Local Company Name : Beximco, Bangladesh Capacity : 5-10 kg. Diff. Pressure : 500-600 m.bar. Rope speed : 100-150m/min. Machine No. : 14 Machine Name : Local Company Name : Beximco, Bangladesh Capacity : 120-150 kg. No. of Nozzle : 1 Diff. Pressure : 500-600 m.bar. Rope speed : 150-280 m/min. Machine No. : 15 Company Name : Thies, Germany Capacity : 150-200 kg. No. of Nozzle : 2 Diff. Pressure : 500-600 m.bar. Rope speed : 150-280 m/min. Machine No. : 16, 17 Company Name : Thies, Germany Capacity : 350-450 kg. No. of Nozzle : 3 Machine No. : 18,19 Machine Name : Local Company Name : Beximco, Bangladesh Capacity : 8-15 kg. YRS SEU Page 16

  17. BEXIMCO KNITTING LTD. 2013 3.2 Finishing Machines: 3.2.1 Finishing Machine Specifications: Hydro-extractor : : Manufacturer Function Nazar Corporation (Pakistan). To remove water from fabric by centrifugal extraction 1980 120 kg. Year Capacity : : Extraction % Speed Extraction Time : : : 65%. 1400 rpm. 5-7 min. . Dewatering M/C: Manufacturer: CALATOR BORAS (SWEDEN) Function: 1. 2. 3. Reduce water content. Apply chemicals. Open the fabric from the rope form. Controlling Parameters: Padder pressure Pick up % GSM Speed at m/c Stretch : : : : : 4-7 bar 85% 20-35% 8.5 m/min-60 m/min 8 to 12% minimum than the requirement of customers. Fig: De-watering m/c YRS SEU Page 17

  18. BEXIMCO KNITTING LTD. 2013 Chemical application: Softener: To soften the fabric. Recipe: Baso soft (Fatty acid condensation) Acetice acid pH : : : 4 g/L 0.25 g/L 7.5 Dryer: Drying: Drying is defined as a process where the liquid portion of the solution is evaporated from the fabric. Curing: Curing can be defined as a process following addition of a finish to textile fabrics in which materials are heated for a short time in elevated temperature to effect a chemical reaction. Controlling parameters: GSM Shrinkage : : 15-35% 12-15% YRS SEU Page 18

  19. BEXIMCO KNITTING LTD. 2013 Equipment Used: Following equipment are used for relax drying process: a) Ruckh relax dryer (Germany): * Gas burner heated. * Blower motor- 8 * Conveyor net- 2 * Over feed roller- 1 * 4 chamber, 1 burner/ 2 chamber * Maximum temperature- 150 °C * Capacity- 2.5 to 3.0 ton * Cyclon- 2 (for hot air remove) * Tube or open fabric can be dried. b) Santex Relax Dryer (SWITZERLAND): * Model- CH 9555 Tobel * Steam heated. * Blower motor- 2 * Conveyor net- 2 * Expander roller- 1 * Over feed roller- 1 * Variable speed- 10 to 15 m/min Machine Setup: Fig: Drying m/c a) M/C parameter Temperature setting M/C set up for Ruckh relax dryer: Set-up value 1000c- 1200c for white shade 1200c-1300c for light shade 1300c-1400c for Dark shade 1500c-1700c for curing Blower fan setting Auto Exhaust fan setting Auto M/C Speed 3-35 m/min. Depends on quality of fabric. Over feed 0-40% depends on fabric construction. YRS SEU Page 19

  20. BEXIMCO KNITTING LTD. 2013 Width of expreader setting 45-114 cm: Depends on the required width of fabric. b) M/C parameter Temperature M/C set up for Santex Relax Dryer: Set-up value 1000c- 1100c for white shade 1100c-1200c for light shade 1200c-1300c for Dark shade Blower fan setting Push button switch on Exhaust fan setting Push button switch on M/C Speed 1-12 m/min. Depends on quality of fabric. Over feed 0-45% depends on fabric construction. Recommended Temperature for Various Types of Fabric Rukh Dryer: Color/ Shade White Light Dark TC Single jersey, Pique, Fleece 180-220 c) Temperature °C 100-110 110-120 120-130 110-120 120-130 130-140 110-120 110-120 120-130 120-130 130-135 135-140 130-140 140-150 150-160 140-150 140-150 155-165 110-120 115-125 120-130 120-130 Fabric Type TC Single jersey, Pique, Fleece GSM 100-160 White Light Dark White Light Dark White Light Dark White Light Dark White Light Dark White Light Dark White CVC, Single jersey, Pique/ Fleece 100-160 CVC, Single jersey, Pique/ Fleece 180-220 CVC, Single jersey, Pique/ Fleece 230-260 CVC, Single jersey, Pique/ Fleece 270-350 100% Cotton, Single jersey, Pique, Fleece 100-160 100% Cotton, Single YRS SEU Page 20

  21. BEXIMCO KNITTING LTD. 2013 Light Dark White Light Dark White Light Dark 130-140 140-150 130-140 140-150 150-160 140-150 145-155 160-165 jersey, Pique, Fleece 180-220 100% Cotton, Single jersey, Pique, Fleece 230-260 100% Cotton, Single jersey, Pique, Fleece 270-350 Checking parameters: 1. Shade Check 2. Width check 3. Weight check 4. Compaction check 5. Fault check: Operator checks - a) b) Knitting faults Spinning faults c) Dyeing faults d) Other faults 6. Bow and Slant check for Ruckh Relax Dryer only. Slitter M/C: Slitting: Slitting is a process that is applied for cutting the tubular fabric through the intended break wales line on lengthwise direction prior to stenter processing. Equipment used : Airtex Slitter Machine (Sweden) Speed: 20-25 m/min. M/C parts: a) c) Rotary blade b) Guide Roller Ring Plaiting d) YRS SEU Page 21

  22. BEXIMCO KNITTING LTD. 2013 Checking parameters: 1) 2) 3) Cutting line check Bow & slant check Fault check Operator checks – a) b) Knitting faults Spinning faults c) d) Dyeing faults Other faults Stenter M/C: Fig: Slitter m/c Equipment used: Name No of chamber No of Burner No of Padding through No of exhaust fan Type Pick up% Total length Width control range Capacity : Krantz Stenter Machine (Germany) : 7 14 : 2 7 Pin stenter 80% 22 m 1 to 2.6 m 9-10 ton/24 hrs. : : : : : : : Parts of the Stenter: a) Chamber: Each chamber contain-  4 air duck nozzle  2 hot air fan  1 hot blower motor  2 burner b) Chemical mixing tank  2 chamber  2 motor Fig: Stenter m/c c) Chemical bath YRS SEU Page 22

  23. BEXIMCO KNITTING LTD. 2013  3 roller (1 free, 2 expander)  Padder 2 roller 1 motor d) Controller  To control spirality  2 motor  2 roller (1 blowing) e) Loading section  1 motor  2 expender roller  2 free roller  1 over feed roller  2 sensor f) Connecting device  To centre the fabric  Expender (to expand the fabric)  2 motor  5 roller g) J- box  To store the fabric h) Chain  2 chains  120 m length  Moves horizontally  2 feeding motor/ wheel  4 pin push i) End side Fig: Chain Guider  Cooling chamber  2 cooling fan  4 air duck nozzle j) Selvedge cutting device  To cut the selvedge of the fabric. k) Delivery section  Platting  4 free roller  1 over feed roller YRS SEU Page 23

  24. BEXIMCO KNITTING LTD. 2013 Function: 1. 2. 3. 4. 5. 6. 7. 8. Apply chemicals. To dart set the T/C fabric. Drying of fabric. To control width. Curing of fabric. Apply pigment dyeing. To control GSM. To control shrinkage. Machine Setup: M/C parameters Padder pressure Set up value 2 to 8 bar 90- 1800c Temperature setting Blower fan setting Lower to high Exhaust fan setting Manual Width of m/c chain setting 110 cm up to 260 cm Over feed 0-60% Burner gas pressure 30-50 m/ bar Machine speed 6 to 60 m/ min Light wt (100-140 GSM) Medium wt (150-180 GSM) Heavy wt (190-250) 20-30 m/min 14-18 m/min 10-15 m/min Checking parameters: 1. Shade Check 2. Width check 3. Weight check 4. Compaction check 5. Fault check Operator check: a) b) Knitting faults Spinning faults c) Dyeing faults YRS SEU Page 24

  25. BEXIMCO KNITTING LTD. 2013 Tubular Compactor: Equipment used : Ruckh Tubular Compactor m/c (Germany). Function: 1. 2. 3. 4. To control shrinkage. To control width. To control GSM. To smooth fabric. Fig: Tubular Compactor M/C set up: M/C parameters Steam pressure Air pressure Temperature Cooling fan Motor Width control Speed setting Set up value 4-6 bars 5 bar 90-1000c Auto 48 to 114 cm 5- 35 m/min Checking parameters: 1. Shade Check 2. Width check 3. Weight check 4. Compaction check 5. Fault check Operator checks - a) b) Knitting faults Spinning faults c) d) Dyeing faults Other faults 6. Edge line checking YRS SEU Page 25

  26. BEXIMCO KNITTING LTD. 2013 Open Compactor: Manufacturer: Feraro (Italy) Function: 1. 2. 3. 4. To control shrinkage. To control width To control GSM. To smooth the fabric. Fig: Open compactor M/C set up: M/C parameters Set up value Steam pressure 4-6 bars Air pressure 5 bar Temperature 700-1000c Width 36”-100” Speed 5-25 m/min. Checking parameters: 1. Shade Check 2. Width check 3. Weight check 4. Compaction check 5. Fault check Operator checks - a) b) Knitting faults Spinning faults c) d) Dyeing faults Other faults YRS SEU Page 26

  27. BEXIMCO KNITTING LTD. 2013 Beacon Controlling System In BKL Beacon Controller 2800 is used. It contains programs of pretreatment, washing, rinsing, unloading, dyeing. It shows graphs for every program. Where, Yellow line = Indicates theoretical required temperature. Red line = Indicates practical temperature. Blue line = Indicates theoretical chemical dosing to vessel from tank. Pink line = Indicates practical chemical dosing to vessel from tank. Green line = Liquor level in vessel. In BKL from m/c no. 1-10 is controlled by this Beacon Controller. Advantages: 1. One officer can control 10 m/cs at a time. 2. Production is high. 3. Show programs with graphs. Dye Kitchen: Dyeing m/c no. 1-10 require 4 tanks. Tanks no. 1, 2, 3 are present in dye kitchen and tank no. 4 is present with dye vessel. In dye kitchen operator measures dye & soda according to requirement. Then operator dissolves dye with water in tank no. 1. According to program dye passes to tank no. 4 and then to dye vessel. After required time operator dissolves soda with water in tank no.1 which pass to tank no. 4 and to dye vessel. Fig: Dye Kitchen House YRS SEU Page 27

  28. BEXIMCO KNITTING LTD. 2013 CHAPTER - 04 RAW MATERIALS YRS SEU Page 28

  29. BEXIMCO KNITTING LTD. 2013 4.1 Introduction: Raw material is a unique substance in any production oriented textile industry. It plays a vital role in case of continuous production & for high quality fabric. 4.2 Types of raw material The basic raw materials used are: fabric dyestuffs Chemicals & auxiliaries. Names & source  Fabric: Different types of fabric treated in BKL dyeing section are namely - Single Jersey - Single jersey with lycra attachment - Polo pique - Back pique - Rib Fabric - Lycra fleece - Jacquard - Cross –rib - STB Pique - Thermal - Fleece  Dyestuffs: Dye Reactive dye Brand name Bezactive Ciba Dychufix Origin/source Bezema , Switzerland Ciba , Switzerland Hubei Hwalle Ind.co. Jaychem,India Dystar , Germany Dystar, germany India Jaychem,India Dyestar , Germany Solarfine , Taiwan Solarfine , Taiwan dyestuff Kemafix Levafix Procion Jackazol Kemazol Remazol Solazol Solacion YRS SEU Page 29

  30. BEXIMCO KNITTING LTD. 2013 Terasil Dianix Dispersol Boron Ciba , Switzerland Dystar, germany Dystar, germany Zenith chemicals,Taiwan Disperse dye Brand name Novolube Jet Bluton BVB1 Cibacel DBC Cibafix ECO Cibafluid C SandocleanPCLF Permacol FA Novostone CR Cotton white T Cyclanon E Cyclanon ECO Jinlev RLF349 Eulysin S Felosan NOF Uvitex EBF Jinlev CL-225 Oxalic caid Palegal FA-8 Respumit BU Permacol SQ Na thiosulphate Uniperol O Uvitex EVF Uvitex 2B Mollan129 Acetic acid Reduction HCS Mollan130 Bluton 2B Type Anti creasing agent Violet tone brightener Sequestering agent Fixing agent Anticreasing agent Detergent Stabilizer Enzyme Redder tone brightener Fixing agent Reduction cleaning agent Dispersing agent pH buffer in PET dyeing Detergent Whitening agent Leveling agent for reactive dye Iron remover Leveling agent for disperse dye Antifoaming agent Sequestering agent Peroxide killer Washing agent for PET dyeing PET brightener Yellow tone brightener Soapenging agent pH controller Reduction cleaning agent Sequestering agent Whitening agent Source Techna, Italy CHT, Germany Ciba, India. Ciba, Switz. Ciba, Switz. Clarient, Germany Techna, Italy Techna, Italy CHT, Germany BASF, Germany BASF, Germany Geigy, Taiwan BASF, Germany CHT, Germany Ciba , Switz. Geigy, Taiwan - BASF, Germany BASF, Germany Techna, Italy - BASF, Germany Ciba, Switz. Ciba, Switz. Rota, dystar - Geigy, Taiwan Rota, dystar Ciba, India Remarks - The list is for the time of our industrial attachment. It varies according to the availability of the material & their price. YRS SEU Page 30

  31. BEXIMCO KNITTING LTD. 2013 CHAPTER -05 PRODUCTION PLANNING & SEQUENCE OF OPERATION YRS SEU Page 31

  32. BEXIMCO KNITTING LTD. 2013 SEQUENCE OF OPERATION Knitting Grey inspection Batch preparation Pretreatment White Processing Polyester dyeing Cotton dyeing Hydro extracting Dewatering Drying Compacting Final Inspection Finished Store Delivery to Garment industry YRS SEU Page 32

  33. BEXIMCO KNITTING LTD. 2013 5.1 Introduction and Basic Procedure of Planning and Control: A planned work brings success. Without planning nothing is completed within the required time. So planning has its own importance which is intolerable. "Planning" gives a scheduled task and 'control' completes it successfully. But production planning and control is not an easy task. So BEXIMCO has a self-sufficient and high- performance department called "Production Planning & Control". Its Basic working procedure is as follows – 1. 2. Taking orders from marketing division. Analyzing the orders. 3. 4. 5. Planning for knitting the fabric. Planning for dyeing the fabric. Planning for finishing the fabric. It is only a basic procedure. It may change according to the type of order. Sometimes, order is places only for finishing the material or only for dyeing the white goods. Then some steps are omitted for planning procedure. 1. Taking orders from marketing division: BEXIMCO marking division supplies Fabric Orders to the BKL Planning and control division by a special format. 2. Analyzing the orders: This section analyzes the orders according to buyers, Order Quantity, type of orders (i.e. type of fabric, color to be dyed etc.), delivery date etc. Then it selects which M/C. to use, no of M/C. to use, time required for production etc. This section plans for required quantity of fabric to be knitted (Order quantity + 6% of Order Quantity), knitting balance, fabric need to be dyed. Dyeing balance, RFD (Ready for delivery), RFD balance, delivered fabric and delivery balance. 3. Planning for knitting: This section plans for knitting production. It selects machine for knit the fabric for specific type of fabric, type of yarn used, required GSM, width etc. It also gives delivery data for knitted fabric. It also places orders for buying of yarn from spinning mills by a specific schedule. 4. Planning for dyeing the fabric: Production planning for dyeing is called 'Batch Plan'. According to the batch no. And color, width, style and construction the batch plan is made. For easy understand this YRS SEU Page 33

  34. BEXIMCO KNITTING LTD. 2013 section gives some 'T.' cards. 'T' cards are serialized according to the priority of delivery. The batches and 'T' cards also serialized as to dye light shade at first and lastly the dark shades, since faulty shades can be converted to dark color later. 5. Planning for finishing the fabric: Finishing schedule is same us the dyeing. After dyeing the material goes to the finishing section with the batch plan. Finished data is written to the batch card and is informed to the planning section. However, this section always enforces to all the departments to finish all the works within the delivery time given by the buyers. This section delivers materials by truck, micro, air etc to the customer within the meantime. Thus it plays a very important role in the success of the company. YRS SEU Page 34

  35. BEXIMCO KNITTING LTD. 2013 CHAPTER- 06 KNITTING SECTION YRS SEU Page 35

  36. BEXIMCO KNITTING LTD. 2013 6. Introduction: The BEXIMCO Knitting Limited is a self-sufficient modern company. Its knitting section is divided into two sections – 1. Flat knitting section & 2. Circular knitting section. 6.1. Flat Knitting Section: Flat knitting section consists of Flat Knitting Machines. Its main production is Collar and Cuff. Different types of designed collar & cuff is produced here with relation to the body of the garments. 6.1.1 Production Equipment Table: The following equipment are used for production- Name Fabric type Manu. Model Gauge Length No. of m/c. STOLL semi-jacquard Germany -------- 14 84 inch 2 MATSUYA Plain Japan M-100 14 100 cm 26 MATSUYA Plain Japan M-70 14 70 cm 22 KAUO HENG Semi-jacquard Taiwan KH-313 14 54 inch 17 MATSUYA Semi-jacquard Japan 14 64 inch 2 Total machines = 69 Note: Collar & cuff prepared is mainly rib fabric. Tipping is also used in the collar & cuff. ‘Tipping’ is stripe design mainly knitted by Polyester yarn. YRS SEU Page 36

  37. BEXIMCO KNITTING LTD. 2013 Semi- Jacquard (KH-313) Plain flat bed knitting. m/c. (M-70) Semi- Jacquard MATSUYA Semi Jacquard YRS SEU Page 37

  38. BEXIMCO KNITTING LTD. 2013 6.2. Circular Knitting Section: Circular Knitting section consists of Circular Knitting Machines. Different types of body fabric are produced in this section. 6.2.1 Production Equipment BEXIMCO Knitting Limited (BKL) is capable to knit Weft Knitted fabrics only. Following types of machines are available with BEXIMCO Knitting Ltd. for Circular Knitting. Gauge 18 20 24 28 16 (RIB) 18 (RIB) 20 (RIB) Model No. 1995 1995 1995 1995 1995 1995 1995 Origin No. of Cylinder 05 10 14 26 01 01 01 58 Existing Set-up 0 08 14 06 01 01 0 CAMBER, UK CAMBER, UK CAMBER, UK CAMBER, UK CAMBER, UK CAMBER, UK CAMBER, UK Total Note: There are 7 (Seven) machines with lycra facilities. Single Jersey (Lycra facilities) Single Jersey Stripe YRS SEU Page 38

  39. BEXIMCO KNITTING LTD. 2013 Double Jersey Circular kng. m/c. Single Jersey Circular kng. m/c. 6.3 Knitting Faults:        Barre or stripe Miss stitch/ drop stitch Sinker mark Crease mark/Edge mark Excessive slubs Broken needle Tight course Press off   Holes   Missing Yarn etc.  Needle mark Oil stain  Spirility Pin hole  YRS SEU Page 39

  40. BEXIMCO KNITTING LTD. 2013 CHAPTER- 07 GRIEGE BODY & RIB INSPECTIONS YRS SEU Page 40

  41. BEXIMCO KNITTING LTD. 2013 7. Inspection: To detect and identify the knitting fault in fabric by visual assessment on Inspection m/c. 7.1 Collar & cuff inspection: Collar & cuff inspection is a process of identifying quality fault in knitted collar & cuff from flat knit m/c. Equipment used: a) Inspection m/c (Calator Sweden) b) Inspection Table. M/C Set up (Inspection m/c): M/C set up Parameter range Set value Roller speed 0-40 m/min 25-30 m/min light Not applicable Artificial day light Length unit measuring Not applicable Attached with m/c. 7.2 Faults: H = Hole OS = Oil stain DS = Drop stitch. WD = Wrong Design NL = Needle line. S = Stripe TT = Thick & Thin yarn. S = Slubs SM = Sinker Mark. WP = Wrong Ply,etc. 7.2.1 Four Point System: Size of defect Penalty 3 inches or less 1 points over 3 but not over 6 2 points Over 6 but nor over 9 3 points Over 9 inches 4 points YRS SEU Page 41

  42. BEXIMCO KNITTING LTD. 2013 Acceptance calculation: Total point per 100 square yards Actual points counted 36   100 = Actual Roll length Actual width = Points/100 square yards. Classification of Inspection Fabric : < 40 points = A 41-60 points = B 61-80 points = C 80 above = Reject. Acceptance: Generally any piece of fabric with 40 points or less faults per 100sq. yard is allowed to pass however for a roll, the average value should not exceed 18point per 100sq.yard.More than 40points faults per 100sq yard is recorded as “REJECT”. YRS SEU Page 42

  43. BEXIMCO KNITTING LTD. 2013 CHAPTER- 08 BATCH PREPARATION YRS SEU Page 43

  44. BEXIMCO KNITTING LTD. 2013 Batch Preparation Sequence Process sequence of Batch preparation receive batch card from Grey In-charge  Make the priority as per dyeing plan  Take one specific Batch card.  Read the Batch Card for own understanding  Check the availability of fabric  Take required quantity of body fabric from ware-house.  Make required no. of Rope maintaining equal length.  Take collar/cuff as per size, keep the total weight.  Distribute the collar /cuff or Rib in each rope equally unsure equal length  Stitch the fabric  Write down the weight against roll no. in the back side of the Batch Card.  Write the total weight in Batch Card.  Put signature & date.  Fill up the production report form. M/c for Batch preparation: Two types of m/c’s : a) Turning m/c b) Plaiting m/c. YRS SEU Page 44

  45. BEXIMCO KNITTING LTD. 2013 CHAPTER- 09 SINGEING YRS SEU Page 45

  46. BEXIMCO KNITTING LTD. 2013 9. Singeing: Singeing is the process of burning of the fibre hairs projecting through the fabric surface. In a gas-singeing machine this burning is carried out by passing fabric against hot flames under specified conditions. Objects: To obtain a uniform & smooth fabric surface by removing hairiness.  To ensure uniform optical reflectance throughout the fabric surface in subsequent fabric wet process.  Equipment-used: Machine : Sando Gas Singing m/c. Manufactures : Sando Iron Works, Japan. Required Parameters: a) Steam: Steam is supplied to the steam box of the machine. Compressed air: The standard air supply pressure requirement is 4 kg/cm2. b) Water: The standard water supply pressure requirement is 1-1.2 kg/cm2. c) Natural gas: The standard gas supply pressure requirement is 3 kg/cm2. d) YRS SEU Page 46

  47. BEXIMCO KNITTING LTD. 2013 M/C Setup: Setup parameters Range Set value Speed(m/min) 0-120 55-60 for cotton. 70 for PC/CVC. Potentiometer Setting (rpm) 0-150 80-90 for cotton fabric 60-70 for CVC/PC. Burner in use 1 or 2 2 Burner operation mode. Auto/Manual Auto Flame height (cm) 1-8 6 for white & light shade fabric. 6.5 for medium & dark shade fabric 450to 900 450for blends 900for cotton Flame angle with the direction of fabric. Low – not used Medium – for white & light shade High – for medium & dark shade fabric Flame intensity Low/normal/ high Singeing Faults: a. Singeing line: Due to ununiform joint of bricks by cement, there become gaps between flame and thus singeing line is formed. b. Uneven singeing: One to uneven flame height uneven singeing is occurred. YRS SEU Page 47

  48. BEXIMCO KNITTING LTD. 2013 CHAPTER- 10 MERCERIZING PROCESS YRS SEU Page 48

  49. BEXIMCO KNITTING LTD. 2013 10. Mercerizing: Mercerizing is a physio-chemical process in which cotton fabric is treated with concentrated solution of caustic alkali & subsequently stretched & washed under specified conditions. Objects: To increase lusture of fabric.  To increase the strength of fabric.  To improve dimensional stability.  To increase dye absorbency.  Equipment used: Dornier mercerizing m/c (Germany). Required parameters: Parameters Value Squeeze pressure 1.5-2 bar (by compressed air) 800-900c Temperature of washing PH after mercerizing 7-7.5 In mixing tank : 80-900c In caustic stroage tank : 70-800c In chiller : 140c In Mercerizing bath : 160-200c Caustic solution temperature Set with fabric dia +3 1st sigar diameter Set with fabric dia +5 2nd sigar diameter 280Be Caustic strength YRS SEU Page 49

  50. BEXIMCO KNITTING LTD. 2013 Function of m/c parts: Sigar:  1. To stretch the tubular knit fabric. 2. To prevent shrinkage. 3. To retain dimensional stability of fabric. 4. To wash off mercerizing chemicals from the fabric by spraying water on it. Padder Pressure:  To squeeze and drive the fabric to a little extent otherwise there is a risk of forming edge line at two sides of fabric. Water valves:  Supply water to washing tank. Steam values:  Steam value supply steam to washing chamber. Mercerizing process faults: PHvariation  Crease  Water drop mark  Spot  Problem from sigar  Holes  Distortion of dimensional stability  YRS SEU Page 50

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