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Industrial Attachment of Interstoff apparels limited

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Industrial Attachment of Interstoff apparels limited

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  1. Mill Training Report INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT INTERSTOFF APPARELS LIMITED Interstoff Apparels Ltd. 1

  2. Mill Training Report Interstoff Apparels Ltd. 2

  3. Mill Training Report PROJECTDESCRIPTION CHAPTER-01 Interstoff Apparels Ltd. 3

  4. Mill Training Report NAME : INTERSTOFF APPARELS LIMITED TYPE : 100% Export oriented composite knit dyeing industry YEAR OF ESTABLISHMENT : 2003 YEAR OF STARTING PRODUCTION : End of 2004 LOCATION : Chandora, Kaliakoir, Gazipur, Dhaka, Bangladesh. ADDRESS : Chandora, Kaliakoir, Gazipur, Dhaka, Bangladesh. SPONSOR : Bangladesh and UK joint venture PRODUCT MIX: Single jersey, Lycra single jersey. Lycra rib (1x1, 2 x 2 etc.), Stripe Rib. Lacoste (Single & Double), Fleece, Mesh, Interlock. Collar & Cuff. Polyester cotton blend fabric And also mélange (grey, ash). TOTAL WORKING DAYS: 355 days/year TOTAL WORKING HOURS: 24 hours/day PROJECT COST: The project cost of INTERSTOFF APPARELS LIMITED is nearly 250 corer taka. PRODUCTION CAPACITY: The production capacity of INTERSTOFF APPARELS LTD. are given below- Knitting : 2-3 ton/day Dyeing : 10-12 ton/day Finishing : 12-15 ton/day The production capacity of INTERSTOFF APPARELS LTD is an approximate idea, it may vary. Interstoff Apparels Ltd. 4

  5. Mill Training Report LOCATION N IAL : Interstoff Apparels Limited CTET: COLLEGE OF TEXTILE ENGINEERING & TECHNOLOGY W E MR S pallibiddut Kona Bari chando Gazipur chourasta IAL Abdullahpur CTET Sath Rasta The Project is located at. Pallibidut Chandora, Kaliakoir, Gazipur, Bangladesh. It is about 45kilometers from “COLLEGE OF TEXTILE ENGINEERING AND TECHNOLOGY.” Interstoff Apparels Ltd. 5

  6. Mill Training Report HISTORY OF THE PROJECT DEVELOPMENT: INTERSTOFF APPARELS LTD started their business by some knitting m/c in 2002. Then at the end of 2004 they started their fabric processing plant and after that gradually they expanded their garments section and print shop. DIFFERENT DEPARTMENT: KNITTING SECTION: a) knitting b) inspection DYEING SECTION: a) grey inspection b) batching section c) dye house d) finishing section e) lab and Q.C. f) Quality control (on line) PRINT SHOP: a) sample section b) production section GARMENTS SECTION: a) product development b) production merchandising c) sample section d) spreading and cutting section e) CAD & CAM section f) sewing section g) finishing section MAINTENACNE SECTION: a) electrical b) mechanical STORAGE SECTION SUPPORTING DEPARTMENT: a) personnel administration b) HR c) procurement d) marketing e) finance and accounting f) security department Interstoff Apparels Ltd. 6

  7. Mill Training Report TOTAL MANPOWER: In production section In administration section MAJOR CUSTOMERS: a) MARKS AND SPENCER b) TESCO c) CHAPS d) GARAGE e) COLOMBIA f) ESPRITE g) SAINS BURRY h) KAPPAHL PHYSICAL INFRASTRUCTURE: The mill is built in such a way that there is possibility for further expansion of the mill. The structure such as mill, office buildings, record rooms, guardrooms & dining room etc. are made of solid hard concrete & brick mtls. The whole area wall .The main set up for m/c’s are built of corrugated iron & iron sheet, transparent hard plastics with enough ventilation & scope for passing light & air. is surrounded by safety brick REMARKS: INTERSTOFF APPARELS LTD. is a profitable project and contributes the economy of our country. Interstoff Apparels Ltd. 7

  8. Mill Training Report MANPOWER MANAGEMENT CHAPTER-02 Interstoff Apparels Ltd. 8

  9. Mill Training Report MANAGEMENT SYSTEM: The company has skilled administration, management and marketing team guided by proficient, dexterous & experienced leaders of offer right solution for the consumers with the right eminence & with the shortest lead-time for the export market in Bangladesh. The best use of continuous development of human resources by providing them International standard equal opportunity comprehensive competence in all level of the organizational hierarchy. is the keys for achieving ORGANOGRAM OF MANPOWER ADMINISTRATION Board of director: Mr.Nazim Uddin Chairman 01 Mr Md shahriar Alam Managing director 02 Mr Shaikh Mohd. Ilias Director 03 Naimul Basher Chowdhury Director 04 Interstoff Apparels Ltd. 9

  10. Mill Training Report GM Fabric Manager Lab&QA Deputy Manager Knitting Store Officer Asst. Manager R&D DGM, Dyeing & Finishing Manager Planning Print Shop Fabric Development Executive Batch Asst. Manager Finishing Jr. Executive Sub con Fabric Deputy Manager Dyeing Incharge 03 Incharge 03 Interstoff Apparels Ltd. 10

  11. Mill Training Report ORGANIZATION OF DYEING SECTION: General Manager Deputy General Manager Manager Deputy Production Manager Asstt. Production Manager Sr. Production Officer Production Officer Supervisor Asstt. Supervisor Sr. Operator Operator Asstt. Operator Helper SHIFT CHANGE: changed at every 8 hours. Shift Change/ for worker of Security: A Shift – 6.00-2.00 Pm B Shift – 2.00 – 10.00 Pm C Shift – 10.00 – 6.00 Pm There are three shifts in the industry. So the shifts are General shift for staff A Shift – 08:00 – 20:00 B Shift – 20:00 – 08:00 Management personal work on general shift of duration 9.00am to 6.00pm and 6 days per week Interstoff Apparels Ltd. 11

  12. Mill Training Report RESPOSIBILITIES OF PRODUCTION OFFICER: 1. To check recipe according to lab dip 2. To check shade 3. To m/c plan 4. To check the dyeing process 5. To manage floor 6. To accelerate in arranging batch 7. To carry out the order of production manager JOB DESCRIPTION OF P.O & S.P.O: Job title: Production officer & Senior Production officer Report to: Production Manager PURPOSE: To control shift according to the plan made by the production manager Territory: Dyeing section (major) Batching and Finishing section (minor) Shift in charge: 1 Supervisor: 1 NATURE AND SCOPE Role within the organization: Responsible minimum time. for own shift production with good quality and Environment: Production officer has to work under huge stress. He has to work in acute heat under physical and mental pressure. Also he has to work in acute heat all the year round. TASKS: • Areas for development: Responsible for training the production people to get maximum and quality output from them. • Control: He has to control the production and the people according to the plan to get the optimum efficiency. Interstoff Apparels Ltd. 12

  13. Mill Training Report • Organizing: He watches over the process of dyeing and introduces required system it needed for quality produced during dyeing. • Re-viewing: Production officer review the activities of shift-in- and supervisors every month production manager order. charge according to the • Planning: Production officer has to plan in all sections for the smooth flow of production. He has to distribute the work of the worker for balancing their work. • Administration: He checks daily and monthly production report including reprocess of dyeing section as well as the daily production report. • Leadership: He made the worker to give their best by inspiring and motivating. He commit himself to the company and faster that same kind of commitment in his followers. He knows their strength, weakness, hope and goals. He demonstrates strength of character by their word and actions. • Management contact: The jobholder matter of consults with Production and manager distribution of the people. He also consults with quality assurance manager incase of quality falls as well as the Production quality for the individual buyers. in Production planning work MANAGEMENT SYSTEM: • Intercom telephone • Fax • Written letters & • Oral REMARKS: The management system of INTERSTOFF APPARELS LTD is so good, because the overall efficiency of GSM is nearly 90%. Management system can influence the productivity. Interstoff Apparels Ltd. 13

  14. Mill Training Report M/C DESCRIPTION CHAPTER-03 Interstoff Apparels Ltd. 14

  15. Mill Training Report LIST OF MACHINERY Dyeing section Dyeing Machine Sample Dyeing Machine Finishing section Slitter Dewatering Machine Stenter Dryer Tube compactor Open width compactor Sueding Machine 1. 2. 07 09 1. 2. 3. 4. 5. 6. 7. 01 02 02 01 01 01 02 8. 9. Inspection Machine Turning Machine 01 01 SPECIFICATION OF DIFFERENT MACHINERY: DYEING SECTION Dyeing m/cs with specification: M/c no 01: Type: Fabric dyeing m/c Brand: Thies Max. Temp: 98ºC Origin: Germany Capacity: 630 kg Liquor ratio: 1:6 M/c no 02: Type: Fabric dyeing m/c Brand: Thies Max. Temp: 135ºC Origin: Germany Capacity: 430 kg Liquor ratio: 1:6 M/c no 03: Type: Fabric dyeing m/c Brand: Thies Max. Temp: 135ºC Origin: Germany Capacity: 430 kg Liquor ratio: 1:6 Interstoff Apparels Ltd. 15

  16. Mill Training Report M/c no 04: Type: Fabric dyeing m/c Brand: Thies Max. Temp: 98ºC Origin: Germany Capacity: 270 kg Liquor ratio: 1:6 M/c no 05: Type: Fabric dyeing m/c Brand: DILMENLER (DMS 11 HT JUMBO) Max. Temp: 140 c Max. Pressure: 2.5 bar Origin: TURKIYE Capacity: 900 kg Liquor ratio: 1:6 M/c no 06: Type: Fabric dyeing m/c Brand: DILMENLER (DMS 11 HT JUMBO) Max. Temp: 140 c Max. Pressure: 2.5 bar Origin: TURKIYE Capacity: 600 kg Liquor ratio: 1:6 M/c no 07: Type: Fabric dyeing m/c Brand: FONG’S Max. Temp: 98 c Origin: CHINA Capacity: 600 kg Liquor ratio: 1:6 Sample m/c 01: Type: Fabric dyeing m/c Brand: SUNTEX Max. Temp: 135ºC Origin: Switzerland Capacity: 30 kg Liquor ratio: 1:6 Sample m/c 02: Type: Fabric dyeing m/c Brand: SUNTEX Max. Temp: 135ºC Origin: Switzerland Capacity: 20 kg Liquor ratio: 1:6 Interstoff Apparels Ltd. 16

  17. Mill Training Report Sample m/c no 03: Type: Fabric dyeing m/c Brand: Thies Max. Temp: 98ºC Origin: Germany Capacity: 25 kg Liquor ratio: 1:6 Local Sample m/c no 04: Type: Fabric dyeing m/c Brand: Bangla Max. Temp: 98ºC Origin: Bangladesh Capacity: 20 kg Liquor ratio: 1:8 Local Sample m/c no 05: Type: Fabric dyeing m/c Brand: Bangla Max. Temp: 98ºC Origin: Bangladesh Capacity: 50 kg Liquor ratio: 1:8 Interstoff Apparels Ltd. 17

  18. Mill Training Report Chemical Store Chemical Mixing Area eeeeeeeeeeeeeeeejkughh S9 1 5 Office 2 6 3 4 7 S1 S8 S2 W1 Dewa tering m/c S 6 S7 LS5 LS 4 S3 S S Layout plan of dyeing floor E Interstoff Apparels Ltd. 18

  19. Mill Training Report Sample m/c 06: Type: Fabric dyeing m/c Brand: SUNTEX Max. Temp: 135ºC Origin: Switzerland Capacity: 10 kg Liquor ratio: 1:6 Local Sample m/c no 07: Type: Fabric dyeing m/c Brand: Bangla Max. Temp: 98ºC Origin: Bangladesh Capacity: 30 kg Liquor ratio: 1:8 Sample m/c 08: Type: Fabric dyeing m/c Brand: SUNTEX Max. Temp: 135ºC Origin: Switzerland Capacity: 50 kg Liquor ratio: 1:6 Sample m/c 09: Type: Fabric dyeing m/c Brand: SUNTEX Max. Temp: 135ºC Origin: Switzerland Capacity: 30 kg Liquor ratio: 1:6 Interstoff Apparels Ltd. 19

  20. Mill Training Report 4 3 6 7 2 5 1 1 S E N Layout plan of finishing floor Interstoff Apparels Ltd. 20

  21. Mill Training Report FINISHING SECTION 1. Name: Dewatering m/c Brand Name: AB CALATOR Company Name: AIRTEX CALATOR Origin: Sweden 2. Name: Dryer Brand Name: suntex group Origin: Switzerland 3. Name: Monti Tube Compactor Brand Name: Monti Origin: Italy 4. Name: Compactor (open) Brand Name: FERRORO Origin: Italy 5. Name: Slitter & Dewatering m/c. Brand Name: bianco Origin: Germany 6. Name: Stenter m/c (4 chamber) Brand Name: BRUCKNER Origin: Germany 7. Name: Stenter m/c (5 chamber) Brand Name: BRUCKNER Origin: Germany REMARKS: conventional and old specially the Theis machines and the Fongs machine are quite back dated, the dewatering machine as well as. Most of the machineries of INTERSTOFF APPARELS LTD is Interstoff Apparels Ltd. 21

  22. Mill Training Report RAWMATERIAL CHAPTER-04 Interstoff Apparels Ltd. 22

  23. Mill Training Report TYPES: Mainly raw materials of Interstoff Apparels Ltd. is 1. Gray fabric • • • 100% cotton PC,CVC Melange Again grey fabric of following construction are commonly are dyed Single jersey Single jersey with lycra Polo pique Single lacoste Fleece Interlock Rib Rib with lycra 1Χ1 rib 2Χ2 rib Different types of collar & cuff. ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ The knitting section of INTERSTOFF APPARELS LTD is not sufficient enough to supply all the fabric needed by fabric processing plant. It is capable to fulfill only one forth the fabric processing plant’s demand. Rest of the grey fabric needed is knitted in other industries through sub contract. 2. Chemicals Dyes Chemicals Auxiliaries ƒ ƒ ƒ Interstoff Apparels Ltd. 23

  24. Mill Training Report Dyes: List of dyes used in INTERSTOFF APPARELS LTD. Sl. No. 01 02 03 04 05 06 07 08 09 10 Name of the Dyes Ciba Yellow FN2R Ciba Red FNR Ciba Red FN2BL Ciba Blue FNR Ciba Br. Blue FNG Ciba Red FN3F Ciba Yellow F4G Ciba Scarlet F3G Ciba Yellow WR Ciba Red WB Ciba Navy WB Ciba Dk. Blue WR Ciba Red HF Ciba Orange HR Ciba Navy H2G Ciba Black WHF Drim Yellow HFR Drim Red HF2B Drim Blue HFRL Drim Yellow CL2R Drim Red CL5B Drim Navy CLB Drim Orange CL3R Drim Yellow CL3GL Drim Turquis CLB Drim Turquis K2B Remazol Yellow RR Remazol Red RR Remazol Blue RR Remazol Br Blue (RSPL) Remazol Blue BB Remazol T/Blue G Type Source Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Swiss Color Clariant Clariant Clariant Clariant Clariant Clariant Clariant Clariant Clariant Clariant Dyestar Dyestar Dyestar Dyestar Dyestar Dyestar Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Interstoff Apparels Ltd. 24

  25. Mill Training Report Remazol Yellow 3RS Remazol Red 3BS Dianx Yellow SEG Dianx Red CC Dianx Navy CC Sunfix Yellow EXF Sunfix Red EXF Sunfix Blue EXF Sunfix Blue BRF Sunfix Yellow S3RD Sunfix Red S3BD Remazol Yellow GR Remazol Red F3S Remazol Navy Blue RGB Remazol G. Yellow RNB Bezactive Red VBN Bezactive Yellow V2R Foron Red SWF Foron Navy SWF Dianix Blue ER Dianix Black CCR Kemifix Yellow FRL Kemifix Red 3BS Kemifix Red F6B Kemifix Yellow 4G Kemifix Blue F2R Kemifix Orange 2RL Impozyn Black VB Impozyn Red 3BF Impozyn Yellow E3R Impozyn Blue V3R Impozyn T. Blue VG Impozyn Br. Orange V3R Tera Yellow W4G Tera G. Yellow W3R Tera Navy WRS Tera Red W4BS Reactive Dye Reactive Dye Disperse Disperse Disperse Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Disperse Disperse Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Disperse Disperse Disperse Disperse Dyestar Dyestar Dychufix Dychufix Dychufix Sumitomo Sumitomo Sumitomo Sumitomo Sumitomo Sumitomo Dyestar Dyestar Dyestar Dyestar Bezema Bezema N/A N/A Dychufix Dychufix N/A N/A N/A N/A N/A N/A Impo color Impo color Impo color Impo color Impo color Impo color Swiss Color Swiss Color Swiss Color Swiss Color 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Interstoff Apparels Ltd. 25

  26. Mill Training Report Tera Blue WBLS Tera Black WNS Tera Black BFE Drimarin G. Yellow K2R Drimarin Blue CLBR Drimarin Blue K2RL Remazol Carbon RGB Remazol Black B Remazol Red RB Levafix Blue CA Levafix Rubine CA Levafix Amber CA Ciba Yellow HG Ciba Blue HRN Ciba Red HBL Ciba Orange EBR Solacion Yellow HEXL Solacion Red HEXL Bezactive Turquis VGC Bezactive Red S2B Disperse Disperse Disperse Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Reactive Dye Swiss Color Swiss Color Swiss Color Clariant Clariant Clariant Dyestar Dyestar Dyestar Dyestar Dyestar Dyestar Swiss Color Swiss Color Swiss Color Swiss Color N/A N/A Bezema Bezema 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 List of Chemicals Used Acid 1. 2. Acetic Acid Hydrochloric Acid Detergent Sandoclean PCLE Washing Agent Cibapon R Levelling Agent Drimazine E2R Sequestering Agent LanapexHTS Interstoff Apparels Ltd. 26

  27. Mill Training Report Salt 1. 2. Gluber Salt Common Salt Softener 1. 2. 3. SoftamineCL Sapamine CWS Dekol SN Fixing Agent Cyclonol ERL Reducing Agent Hydrose Bleaching Agent H2O2 Enzyme 1. 2. Bioace Tinozyme 44L Stabilize apex HPST Anticreasing Agent 1. Depsolube ACA PHController 1. Acid 2. Soda Ash 3. Caustic soda Per-oxide Killer Na Thiosuphite Interstoff Apparels Ltd. 27

  28. Mill Training Report ANNUAL REQUIREMENTS: To determine annual requirements is very tuff. It mainly depends on the buyer order and subcontract order. When the buyer order is large then the consumption is high and vice-versa. The annual requirements of grey fabric depend on the buyer order and the requirements of dyes and chemicals depend on the colour depth. REMARKS: For smooth running of a factory uninterrupted supply of raw materials is very essential. As soon as I saw the raw material control of INTERSTOFF APPARELS LTD is good. Interstoff Apparels Ltd. 28

  29. Mill Training Report PRODUCTIONPLANNINGAND SEQUENCEOF OPERATION CHAPTER-05 Interstoff Apparels Ltd. 29

  30. Mill Training Report FLOW CHART OF DYEING SECTION: Grey fabric from knitting section ↓ Batching ↓ Dyeing ↓ Transfer to finishing FLOW CHART OF FINISHING SECTION: Finishing section Open fabric Tube fabric Dewatering machine Slitting machine Drying machine Stentering Tube Compacting machine Compacting machine Final inspection Final inspection Interstoff Apparels Ltd. 30

  31. Mill Training Report SEQUENCE OF OPERATION: Grey fabric inspection ↓ Batching ↓ Fabric turning ↓ Loading to the m/c ↓ Pre-treatment (Scouring & Bleaching) ↓ Dyeing ↓ Dewatering ↓ Drying ↓ Compacting & Calendaring ↓ Final inspection & packing PRODUCTION PARAMETERS: a. PH - During H2O2 bleaching PH9.2-12 - During reactive dyeing PH10.5-12.5 - During disperse dyeing PH4.5-6.0 b. Temperature: - For cotton scouring: - For cotton cold wash: 300-400C - For cotton hot wash: 700-800C - For cotton acid wash: 600C - For cotton dyeing: 980C 80-850C (For hot brand) 650C (For cold brand) 1300C - Polyester dying: c. Time: - For Scouring: 40-60 minutes - For Disperses dyeing 50-60 minutes. - For cotton dyeing 120-130 minutes Interstoff Apparels Ltd. 31

  32. Mill Training Report d. M: L ratio: - For pretreatment M:L ratio maintained 1:7 - For reactive dyeing M:L ratio maintained 1:6 BATCH SECTION Function or purpose of the batch: 1. To receive the grey fabric roll from knitting section or other source 2. To prepare the batch of fabric for dyeing according to the following parameter: ● Order sheet (Received from buyer) ● Dyeing shade (Color or white, Light or Dark) ● M/C capacity ● Fabric structure ●Yarn type, etc 3. To send the grey fabric to the dyeing floor by trolley with batch card. 4. To keep records for every previous dyeing. Proper batching criteria: ∗To use maximum capacity of existing dyeing m/c ∗To ensure every dyeing m/c running in full production. ∗To minimize the m/c washing time or preparation time. ∗To keep the no of batch as less as possible for same shade, etc. Batch management: Primary batch is done by the dyeing manager. Batch section in charge receives this primary batch plan from dyeing manager. Then the works is adjusting, according to m/c condition. Remarks: Proper batch can minimize the batch to batch shade variation. It can near or same dyeing condition for every batch of same shade. Thus it improves the dyeing quantity minimize dyeing cost a lot. Interstoff Apparels Ltd. 32

  33. Mill Training Report SCOURING-BLEACHING PROCESS : Scouring-Bleaching is carried out in the same both and at the same time simultaneously. Scouring-Bleaching Chemicals Used in a batch: Agent Brand Name SandocleanPCLN LanapexHTS LanapexHPST DepsolubleACA Soda ash H2O2 Acetic Acid G/L 1 0.4 0.4 2 5 3 0.6 Detergent Sequestering agent Stabilizer Anticreasing agent Alkali Bleaching agent Acid Procedure of Scouring-Bleaching : # At first required amount of water is taken in the m/c. # Then the fabric is loaded # Then Sequestering, Stabilizer is added at 500C. For s/j anticreasing is added. Runtime 6 minutes. # Then Temperature rise to 600C. # Then Caustic soda is added by dosing 6 minutes. Runtime 5 minutes. # Then rise temp. to 70c .Then H2O2 dosing by 8 minutes. # Then Keep 98 min # Drain. # A. Acid is transferred at 600C. Runtime 10 minute then Drain . Process curve: Fig: process curve of single stage cotton scouring & bleaching process. Interstoff Apparels Ltd. 33

  34. Mill Training Report DESCRIPTION OF THE PRODUCTION PROCESS: Description of the production process is different for different products. I describe here one light shade, one dark shade and another white colour. DYEING RECIPE DARK COLOR Shade name: curry Fabric type: S/J 165 Recipe for Pre-treatment: Sandoclean PCLF Lanpex-HTS Depsolube-ACA Lanapex-HPST Antimussol-HTS Caustic soda Hydrogen-per-oxide Recipe for soaping: Dekol SN T 100 Recipe for neutralization: Acetic acid Recipe for Bio-polish: Acetic acid Genecor BF 1600L Recipe for dyeing: Ladiquest 1097 Depsolube-ACA Drimagen-E2R Antimussol-HTS Rem. Yellow RR Kem. Yellow 4G Rem. Blue RR Gluber salt Soda-Ash Recipe for After-Treatment: Dekol SN Recipe for neutralization: Acetic acid Recipe for softener: Acetic acid Sapamine CWS 1 0.4 g/l 1.5 g/l 0.4 g/l 0.1 g/l 2.25g/l 3 g/l (Detergent) (Sequestering agent) (Anticrease agent) (Stabilizer) (Antifoaming agent) (Alkali) (Bleaching agent) g/l 0.2 g/l 0.06 g/l (Soaping agent) (Peroxide killer) 1 g/l (Acid) 0.3 g/l 1 (Acid) (Enzyme) g/l 1.5 0.5 0.5 0.1 3 0.78 g/l 0.052 g/l 60 20 g/l g/l g/l g/l g/l (Wetting agent) (Anticrease agent) (Leveling agent) (Antifoaming agent) (Dyestuff) (Dyestuff) (Dyestuff) (Salt) (Alkali) g/l g/l 0.75 g/l (Soaping agent) 100% (Acid) 0.25 g/l 1.5 (Acid) (Cationic softener) g/l Interstoff Apparels Ltd. 34

  35. Mill Training Report DYEING SEQUENCE FOR DARK SHADE: Pre treatment at 98ºC, 40′ Soaping at 90 ºC, 10′ Neutralization at 60 ºC, 10′, pH 5.5-5.8 Peroxide killer at 50 ºC, 10′ Bio polishing at 55 ºC, 45′, pH 4.5-5 Dyeing at 65 ºC (at first run time 10′, color dosing 20′, then run time 10′, salt dosing 10′ and run time 30′, then soda dosing 30′and run time 1 hr serially done) Neutralization at 50 ºC, 10′ Soaping at 90-98 ºC, 10′ Softener 30′ DYEING RECIPE MEDIUM COLOR Shade name: V SUNSET Fabric type: S/J 140GSM Recipe for Pre-treatment: Sandoclean PCLF Lanpex-HTS Depsolube-ACA Lanapex-HPST 1 0.4 g/l 1.5 g/l 0.4 g/l g/l (Detergent) (Sequestering agent) (Anticrease agent) (Stabilizer) Interstoff Apparels Ltd. 35

  36. Mill Training Report Antimussol-HTS Caustic soda Hydrogen-per-oxide 0.1 g/l 2.25 g/l 3 (Antifoam agent) (Alkali) (Bleaching agent) g/l Recipe for soaping: Dekol SN T 100 0.2 g/l 0.06 g/l (Soaping agent) (Peroxide killer) Recipe for neutralization: Acetic acid 1 g/l (Acid) Recipe for Bio-polish: Acetic acid Genecor BF 1600L 0.3 g/l 1 (Acid) (Enzyme) g/l Recipe for dyeing: Ladiquest 1097 Depsolube-ACA Drimagen-E2R Antimussol-HTS Rem. Blue RR Kem. Yellow FRL Kem red Gluber salt Soda-Ash 1.5 0.5 0.5 0.1 0.66 g/l 0.8 0.196g/l 60 20 g/l g/l g/l g/l (Wetting agent) (Anticrease agent) (Leveling agent) (Antifoaming agent) (Dyestuff) (Dyestuff) (Dyestuff) (Salt) (Alkali) g/l g/l g/l Recipe for After-Treatment: Dekol SN 0.75 g/l (Soaping agent) Recipe for neutralization: Acetic acid 100% (Acid) Recipe for softener: Acetic acid Sapamine CWS 0.25 g/l 1.5 (Acid) (Cationic softener) g/l Interstoff Apparels Ltd. 36

  37. Mill Training Report Interstoff Apparels Ltd. 37

  38. Mill Training Report Interstoff Apparels Ltd. 38

  39. Mill Training Report Figure 1: Dyeing curve of Dark Shade Interstoff Apparels Ltd. 39

  40. Mill Training Report DE= detergent; STA= stabiliger; AF= antifoaming agent; SE=Sequeristing agent Curve for neutralization soaping and fixing application: Process of Cotton whitening (white dyeing): Process Curve: 90 min 98 C Steam 80 C(Hot wash) 70 C 55 C(Acetic acid) Brightener dosing 60 min Check Enzyme Check dosing sample Caustic pH Bath Steam dosing Peroxide dosing(10 min) (5 min) drop 60 C Det (10 min) +AFA+ACA+Sequesterant Interstoff Apparels Ltd. 40

  41. Mill Training Report DYEING SEQUENCE FOR LIGHT & CRITICAL SHADE: Pre treatment at 98ºC, 40′ Soaping at 90 ºC, 10′ Neutralization at 60 ºC, 10′, pH 5.5-5.8 Peroxide killer at 50 ºC, 10′ Bio polish at 55 ºC, 45′, pH 4.5-5 Dyeing at 65 ºC (at first run time 10′, color dosing 20′, then run time 10′, salt dosing 10′ and run time 30′, then soda dosing 30′and run time 1 hr serially done) Neutralization at 50 ºC, 10′ Soaping at 90-98 ºC, 10′ Softener 30′ Interstoff Apparels Ltd. 41

  42. Mill Training Report FINISHING After dyeing knit fabric is required to finish. During eyeing all knit fabric are dyed in tubular form. According to buyer’s requirement knit fabric are finished in open form or tubular form. Flow chart of final process (S/J knit fabric) Dyed Fabric from Dyeing Department Shade check Open with Tubular form Dewatering Slitting Stentering/Dryer Drying Open compactor Tube compactor Final Inspection Final Inspaction Packing Packing Delivery Delivery Interstoff Apparels Ltd. 42

  43. Mill Training Report Flow chart of finishing process (Brushing or Sueding purposes) Dyed fabric from Dyeing Department Shade check Open with Tubular form Dewatering Slitting Stentering/Dryer Drying Sueding/Brushing Brushing Stentering/Dryer Tube compactor Open compactor Final Inspaction Packing Final Inspection Packing Delivery Delivery Interstoff Apparels Ltd. 43

  44. Mill Training Report Finishing section is divided into two section, they are: -Open line -Tube line The machines that are used in open line that are given bellow: 1.Slitting m/c 2. De-watering m/c 3. Stenter 4. Dryer 5.Open Compactor The machines that are used in tube line that are given bellow: 1. De-watering m/c 2. Dryer 3. Tube Compactor Other machines: 1.Back sewing m/c 2. Sueding m/c Tubular fabric: De-watering m/c: After finishing ready for de-watering . This is the process to remove the water from the fabric completely by squeezing . This is the main function of the de-watering machine . But here also control the some important factor of the fabric quality The basic function of the de-watering machine : ● To remove the water from the fabric . ● To control the width of the fabric . ● To control the length of the fabric . ● To control the spirality of the fabric . ● To control the grain line of the fabric . ● To control the over feeding system the dyeing process from the dyeing machine then the fabrics are Dryer: After de-watering then the fabric is passed through the dryer. The main function of the dryer to dry the fabric & full fill the other fabric properties according the to Buyer’s requirement. This dryer has four chambers. The speed of the dryer depends on the temperature of the machine & the GSM of the fabric. The vibration speed of the machine for heavy jersey / GSM high is 750 m/min & Single jersey / normal GSM is 500 m/min . The temperature of the machine depends on the machine speed. Higher the temperature of the machine; higher the the speed. Interstoff Apparels Ltd. 44

  45. Mill Training Report The basic function of the dryer are as follows : • To dry the fabric . • To control the over feed system . (Shrinkage control) • To control the vibration . (To increase the GSM) The temperature of different chambers according to the shade of the fabric are : Shade Light Medium Deep Chamber 1 120° C 120° C 170° C Chamber 2 115° C 130° C 160° C Chamber 3 110° C 140° C 150° C Chamber 4 105° C 150° C 140°C 1. Tube Compactor : The mechanism of the compactor machine classified in the four sections. In the first section, entry the fabric in to the machine by the tube form. The second section is Edge driver. The function of edge driver to increase & decrease the GSM & dia of the fabric . Here also passed the steam to soft the fabric & slightly shade match. The third section of the machine & it’s also called the compaction station. Here to control the GSM & callendaring the fabric. There is also a blade to smooth the fabric surface. In the section four the out put section of the machine. Here the fabric keep on to the up & down moveable table. The up & down movement of the table control with the photo detector (Sensor) . In case of deep shade the steam & roller pressure will be high & for light shade steaming & roller pressure will be low. Suppose, We input fabric GSM 220. Then we control the out put GSM maximum 225 & minimum 212. The main function of the compactor machine: • • • • • To control the GSM .(Increase & decrease) To control the dia . To control the shrinkage . (Increase & decrease) To smooth the fabric surface . To challender the fabric . Interstoff Apparels Ltd. 45

  46. Mill Training Report 5. Compactor (Farraro): The mechanism of the compactor machine classified in the four sections. The function (of straitener to pass the fabric forward and strectch the fabric as required length. The overfeed mechanism to increase & decrease the GSM & dia of the fabric. Here also passed the steam to soft the fabric & slightly shade match . This is the third section of the machine it’s also called the compaction station (blanket) . Here to control the GSM & challendering the fabric surface. The main function of the compactor machine : ● To control the GSM .(Increase & decrease) • To control the dia . • To control the shrinkage . (Increase & decrease) • To smooth the fabric surface . • To challender the fabric . Open width fabric 1. Slitting m/c: After finished the dyeing process from the dyeing machine then the fabrics are ready for slitting. The basic function of the de-watering machine: ● To slitting the fabrics. 2. De watering m/c: After finished the dyeing process from the dyeing machine then the fabrics are ready for de-watering . This is the process to remove the water from the fabric completely by squeezing . This is the main function of the de-watering machine . But here also control the some important factor of the fabric quality The basic function of the de-watering machine : • • • • • • To remove the water from the fabric . To control the width of the fabric . To control the length of the fabric . To control the spirality of the fabric . To control the grain line of the fabric . To control the over feeding system Interstoff Apparels Ltd. 46

  47. Mill Training Report 3. Stentering m/c: The main mechanism of the stentering machine ,under feed roller to feed the fabric ,over feed roller to increase and decrease GSM , spending roller to remove the crease mark ,mahalo to adjust the bowing angle ,Fabric wheel to stretch the fabric and contact with chain , The main function of the Stentering machine: • • • • • • • To control the shrinkage of the fabric To control the width of the fabric . To control the length of the fabric . To control the spirality of the fabric . To dry the fabric. To control the over feeding system To control the GSM .(Increase & decrease) 4. Open Compactor: The mechanism of the compactor machine classified in the four sections . The section wise mechanism in the first section to entry the fabric in to the machine by the open form . In the second section Edge driver . The function of edge driver to increase & decrease the GSM & dia of the fabric . Here also passed the steam to soft the fabric & slightly shade match . This is the third section of the machine it’s also called the compaction station . Here to control the GSM & challendering the fabric . Here also a blade to smooth the fabric surface . In the section four the out put section of the machine . Here the fabric keep on to the up & down moveable table . The up & down movement of the table control with the photo detector (Sensor) . In case of deep shade the steam & roller pressure high & light shade steaming & roller pressure low . Suppose ,We input fabric GSM 220 . Then we control the out put GSM maximum 225 & minimum 212 . The main function of the compactor machine : • • • • • To control the GSM .(Increase & decrease) To control the dia . To control the shrinkage . (Increase & decrease) To smooth the fabric surface . To challender the fabric . OTHERS MACHINE: 1. Sueding m/c: Basic Function: ● To increase softness ● To increase luster . Interstoff Apparels Ltd. 47

  48. Mill Training Report MONTHLY AVERAGE PRODUCTION: The monthly production of fabric processing plant of INTERSTOFF APPARELS LTD at the year of 2008 is listed below: January: February: 229 ton 271 kg March: 258 ton 240 kg April: 274 ton 258 kg May: 249 ton 822 kg June: 225 ton 278 kg July: 273 ton 565 kg August: 230 ton 801 kg September:197 ton 230 kg October: 238 ton 435 kg November:288 ton 360 kg December:267 ton 890 kg 249 ton 280 kg So, monthly average production is 229 ton 78 kg REMRKES: INTERSTOFF parameters like time, temperature, M:L ratio, pH etc. As they do some difficult shade, it takes more time for the production of the batch. Because of the generator failure, the production process is sometimes hampered. Considering these limitations the production production officer try their best to reduce the production time. APPARELS LIMITED strictly follow up the production officer and the senior Interstoff Apparels Ltd. 48

  49. Mill Training Report QUALITYASSURANCESYSTEM CHAPTER-06 Interstoff Apparels Ltd. 49

  50. Mill Training Report QUALITY ASSURANCE SYSTEM: Interstoff apparels ltd is more concern about quality. The quality assurance depernent assign to maintain consistently uniform quality on the material in process and various stages of manufacturing . OBJECTS OF QUALITY CONTROL: 1. Research. 2. Selection of raw materials. 3. Process control. 4. Process development. 5. Product testing. 6. Specification test QUALITY ASSURANCE PROCEDURE: Quality assurance procedure may be divided into two major parts: 1. Online quality control 2. Offline quality control Online Q.C: Online quality control comprises with the raw material quality control and the process control. Raw material control: As the quality product depends upon the raw material quality so we must ensure the best quality of raw material consideration. with an economical • The fabric must be without faults, with proper absorbency, whiteness as per requirement of the subsequent process. The chemicals should be with a known concentration with a higher degree of purity. All the m/c’s engaged should be higher a precisions. • • Process control: The method chosen for process must be provided with the necessary accurate parameters. Here the specific gravity, water level, pH, time, temperature at each stage is checked. Lab-dip preparation: In any dye house, a laboratory equipped with required machines and equipment is essential. It assists in product prediction, minimization of time consumption and waste reduction. It also in producing the product of required quality. Interstoff Apparels Ltd. 50

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