Industrial attachment of knit concern group

1. 1 | P a g e INDUSTRIAL TRAINING Course Code: Tex -4036 Course Code: Tex -4036 Course Code: Tex -4036 INDUSTRIAL TRAINING INDUSTRIAL TRAINING INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT KNIT CONCERN GROUP KNIT CONCERN GROUP KNIT CONCERN GROUP

2. 4 | P a g e CONTENTS CHAPTER CONTENT PAGENUMBER 3 5 6-19 20-25 26-34 35-37 38-45 46-51 Acknowledgements Introduction Project Description ManpowerManagement Grey Fabric Inspection Batch Section Knit DyeingLaboratory Dyeing Machine Descriptionand their mechanismof working FinishingSection SpecialFinishingSection Raw MaterialsUsed in Dyeing ProductionSequences and Operations Quality Testing,Control & AssuranceSystem MaintenanceSection UtilitySection Cost Analysis MarketingActivities Conclusion Chapter-1 Chapter-2 Chapter-3 Chapter-4 Chapter-5 Chapter-6 Chapter-7 Chapter-8 Chapter-9 52-65 66-68 69-72 Chapter-10 73-84 Chapter-11 85-94 Chapter-12 Chapter-13 Chapter-14 Chapter-15 95-101 102-108 109-112 113-115 116-118

3. 5 | P a g e INTRODUCTION The word “textile” originally applied only to woven fabrics, now generally applied to fibres, yarns, or products made of fibres, yarns, or fabrics. The term textile originates from the Latin verb texere, meaning “to weave”. It has, however, come to include fabrics produced by other methods. Thus, threads, cords, ropes, braids, lace, embroidery, nets, and fabrics made by weaving, knitting, bonding, felting, or tufting are textiles. Some definitions of the term textile would also include those products obtained by the papermaking principle that have many of the properties associated with conventional fabrics. In addition to clothing and home furnishings, textiles are used for such industrial products as filters to air conditioners, life rafts, conveyor belts, tents, automobiletires, swimmingpools,safety helmetsand mine ventilators. At KNIT CONCERN LTD., cutting-edge technologies merge seamlessly with human ingenuity and deep seat recommitment to ensure excellence in every stage and area of their activities. From fiber to fabric, KNIT CONCERN LTD is truly integrated undertaking. The KNIT CONCERN LTD. has the capability to offer a complete product range for the export textile markets. The goal of KNIT CONCERN LTD. is to become the preferred partner for sourcing high quality fabrics and clothing from Bangladesh With highly advanced technology and an emphasis on developing local human resources. KNIT CONCERN LTD has the potential to make an important contribution to the nation's growing ready- made garments exportsector.

4. 6 | P a g e PROJECT DESCRIPTION KNIT CONCERN LTD.

5. 7 | P a g e General Information About The Factory: General Information About The Factory: General Information About The Factory: Nameof the Company Type Knit ConcernLtd. 100 % ExportOrientedComposite knitwearIndustry knitwearIndustry 100 % ExportOrientedComposite 62,WaterWorks Road Godnail,Narayangonj-1400 Bangladesh 02 7631086, 02 7645641 02-7641087 62,WaterWorks Road Godnail,Narayangonj-1400 Bangladesh 02 7631086, 02 7645641 Factory Address: Contact No Fax E-mailAddress URL info@knitconcern.com http://www.knitconcern.com http://www.knitconcern.com info@knitconcern.com Personto be contact Mr. JahangirAlam (ManagingDirector) Mr. JahangirAlam (ManagingDirector) Year of Establishment Business 1990 100% exportorientedknit fabrics manufacture& readymadeknit garments exporter Knit Fabrics & Knit Garments Knitting: 35 tons/day Dyeing& Finishing:35 tons/day 350 100% exportorientedknit fabrics manufacture& readymadeknit garments exporter Knit Fabrics & Knit Garments Knitting: 35 tons/day Dyeing& Finishing:35 tons/day Products Productioncapacity No. Of employees No. Of workers 3000 Legal Form of Company Private Limited Company. Private Limited Company.

6. 8 | P a g e LOCATION OF KCL Knit Concern Limited is located at Godnail , in Narayanganj about 18 km from the EPZ. GoogleMapsView of Knit ConcernGroup Satelite View of Knit ConcernGroup

7. 9 | P a g e VISIONOF KNITCONCERNLIMITED VISIONOF KNITCONCERNLIMITED VISIONOF KNITCONCERNLIMITED In the global marketing, ever-changing fashion world, knit Concern Ltd considers its prime mission to suit every new taste, whim and demand of Customersfrom around the worldand all strains of human culture. Customersfrom around the worldand all strains of human culture. Customersfrom around the worldand all strains of human culture. In the global marketing, ever-changing fashion world, knit Concern Ltd considers its prime mission to suit every new taste, whim and demand of considers its prime mission to suit every new taste, whim and demand of In the global marketing, ever-changing fashion world, knit Concern Ltd KCL acts on the basic premise that “fashion is an exploration into the images peopleseek to convey– about themselvesand the way they live.” peopleseek to convey– about themselvesand the way they live.” peopleseek to convey– about themselvesand the way they live.” KCL acts on the basic premise that “fashion is an exploration into the images KCL acts on the basic premise that “fashion is an exploration into the images So, in dealing with its target consumers, KCL mainly aims to know their perception about themselves and translates those into garments. Doing that, over the years, KCL designers have acquired an understandingof the consumers’needs. understandingof the consumers’needs. So, in dealing with its target consumers, KCL mainly aims to know their perception about themselves and translates those into garments. Doing that, over the years, KCL designers have acquired an over the years, KCL designers have acquired an So, in dealing with its target consumers, KCL mainly aims to know their perception about themselves and translates those into garments. Doing that, almost telepathic almost telepathic almost telepathic KCL has started manufacture and export garments since late 1990. Its mission is to produce the latest design; quality knit fabrics and apparels for internationalmarkets. internationalmarkets. internationalmarkets. KCL has started manufacture and export garments since late 1990. Its mission is to produce the latest design; quality knit fabrics and apparels for is to produce the latest design; quality knit fabrics and apparels for KCL has started manufacture and export garments since late 1990. Its mission KCL is one of the few elite private sector business groups, which contributed wealth as well as welfare to the struggling economy of Bangladesh.As time is essential to space so is taste to its products. The secret is love – which, paired with meticulous efficacy and a keen sensitivity to style, makes KCL an emerging brand destinedto light up the horizonof fashion. brand destinedto light up the horizonof fashion. brand destinedto light up the horizonof fashion. KCL is one of the few elite private sector business groups, which contributed wealth as well as welfare to the struggling economy of Bangladesh.As time is essential to space so is taste to its products. The secret is love – which, paired with meticulous efficacy and a keen sensitivity to style, makes KCL an emerging with meticulous efficacy and a keen sensitivity to style, makes KCL an emerging KCL is one of the few elite private sector business groups, which contributed wealth as well as welfare to the struggling economy of Bangladesh.As time is essential to space so is taste to its products. The secret is love – which, paired KCL has team of skilled and dedicated technocrats backed by adequate number of modern USA and European machinery and equipments to match internationalstandardof all kinds of knitwearproducts. internationalstandardof all kinds of knitwearproducts. KCL has team of skilled and dedicated technocrats backed by adequate number of modern USA and European machinery and equipments to match of modern USA and European machinery and equipments to match KCL has team of skilled and dedicated technocrats backed by adequate number

8. 10 | P a g e HISTORYOF THE KNITCONCERNLIMITED HISTORYOF THE KNITCONCERNLIMITED HISTORYOF THE KNITCONCERNLIMITED Knit Concern Limited home base is Narayangonj- a city with the largest river port of Bangladesh. It launched its very humble journey in 1990 from a rented building at Nayamati. That potential embryo, by virtue of futuristic enterprising, dedication to quality, commitment to excellence, adoption of state-of-the-art technology, and keen focus on customers' satisfaction, it could very rapidly metamorphose into a large corporate entity, in its most modern sense,just by 1998. Its production has branched out into four full-fledged factories at three location- Godnail & Chasara at Narayangonj and Mirpur in Dhaka. Knit Concern Limited at present has a daily production capacity of over 20 ton of knitted fabric, 30 tons of dyedfabric and 60,000 pieces of garments. Knit Concern Limited became one of the few garments in Bangladesh that implemented ISO 9001:2000 Quality Management System. The government of Bangladesh also recognized its excellence by awarding the status of a Commercially Importance Person (CIP) to its Chief Executive, Mr. Joynal Abedin Mollah,the founder ManagingDirector of KCL, since 1995 withoutbreak. Mollah,the founder ManagingDirector of KCL, since 1995 withoutbreak. Mollah,the founder ManagingDirector of KCL, since 1995 withoutbreak. Knit Concern Limited home base is Narayangonj- a city with the largest river port of Bangladesh. It launched its very humble journey in 1990 from a rented building at Nayamati. That potential embryo, by virtue of futuristic enterprising, dedication to quality, commitment to excellence, adoption of state-of-the-art technology, and keen focus on customers' satisfaction, it could very rapidly metamorphose into a large corporate entity, in its most modern very rapidly metamorphose into a large corporate entity, in its most modern Knit Concern Limited home base is Narayangonj- a city with the largest river port of Bangladesh. It launched its very humble journey in 1990 from a rented building at Nayamati. That potential embryo, by virtue of futuristic enterprising, dedication to quality, commitment to excellence, adoption of state-of-the-art technology, and keen focus on customers' satisfaction, it could Its production has branched out into four full-fledged factories at three location- Godnail & Chasara at Narayangonj and Mirpur in Dhaka. Knit Concern Limited at present has a daily production capacity of over 20 ton of knitted fabric, 30 tons of dyedfabric and 60,000 pieces of garments. Knit Concern Limited became one of the few garments in Bangladesh that implemented ISO 9001:2000 Quality Management System. The government of Bangladesh also recognized its excellence by awarding the status of a Commercially Importance Person (CIP) to its Chief Executive, Mr. Joynal Abedin Commercially Importance Person (CIP) to its Chief Executive, Mr. Joynal Abedin Its production has branched out into four full-fledged factories at three location- Godnail & Chasara at Narayangonj and Mirpur in Dhaka. Knit Concern Limited at present has a daily production capacity of over 20 ton of knitted fabric, 30 tons of dyedfabric and 60,000 pieces of garments. Knit Concern Limited became one of the few garments in Bangladesh that implemented ISO 9001:2000 Quality Management System. The government of Bangladesh also recognized its excellence by awarding the status of a Project Cost: Project Cost: Project Cost: 1000 core Taka (Approximately). 1000 core Taka (Approximately). 1000 core Taka (Approximately). Project Area: Project Area: Project Area: approx. 82000 sq. ft. approx. 82000 sq. ft. approx. 82000 sq. ft.

9. 11 | P a g e Project Layout

10. 12 | P a g e Physical Infrastructure: Physical Infrastructure: Physical Infrastructure: Within only a decade, by hyper-growth has been transformed into a futuristic entrepreneurial saga. Its production has branched out into four full fledged factories at three locations – Godnail in Narayanganj and Mirpur in suburbanDhaka. and Mirpur in suburbanDhaka. and Mirpur in suburbanDhaka. Within only a decade, by hyper-growth has been transformed into a futuristic entrepreneurial saga. Its production has branched out into four full fledged factories at three locations – Godnail in Narayanganj out into four full fledged factories at three locations – Godnail in Narayanganj Within only a decade, by hyper-growth has been transformed into a futuristic entrepreneurial saga. Its production has branched KCL’s Godnail premise houses the parent organization and ultra-modern Unit- 1, with seven-storage building as the main one. A new 10- storage building is its subsidiary KC Apparels Ltd. Its other subsidiary, Crescent Star Ltd, is located at Mirpur. at Mirpur. at Mirpur. KCL’s Godnail premise houses the parent organization and ultra-modern Unit- 1, with seven-storage building as the main one. A new 10- storage building is its subsidiary KC Apparels Ltd. Its other subsidiary, Crescent Star Ltd, is located its subsidiary KC Apparels Ltd. Its other subsidiary, Crescent Star Ltd, is located KCL’s Godnail premise houses the parent organization and ultra-modern Unit- 1, with seven-storage building as the main one. A new 10- storage building is Product mix: Product mix: Product mix: - 100 % cotton - CVC (Chief Value Cotton) (60/40) - Grey melange * 5 % Viscose& 95% Cotton * 10 % Viscose& 90% Cotton * 15 % Viscose& 85 % Cotton - Ecro melange (2%) - Camel melange (1%, 2%) - PC (52/48, 60/40, 65/35, 80/20) -Sewingthread. -Sewingthread. -Sewingthread. - 100 % cotton - CVC (Chief Value Cotton) (60/40) - Grey melange * 5 % Viscose& 95% Cotton * 10 % Viscose& 90% Cotton * 15 % Viscose& 85 % Cotton - Ecro melange (2%) - Camel melange (1%, 2%) - PC (52/48, 60/40, 65/35, 80/20) - PC (52/48, 60/40, 65/35, 80/20) - 100 % cotton - CVC (Chief Value Cotton) (60/40) - Grey melange * 5 % Viscose& 95% Cotton * 10 % Viscose& 90% Cotton * 15 % Viscose& 85 % Cotton - Ecro melange (2%) - Camel melange (1%, 2%) Product Range: Product Range: Product Range: • Men • Men • Women • Kids • Men

11. 13 | P a g e Knit Dyeing Section: It has two section of knit dyeing floor – KCL (old floor) & KCA (new floor). Each containsaround 100 thousandssquareft area. Productioncapacity: approximately50 ton/day Yarn dyeing section: AREA: 100 thousandssq. fit. Floor: MULTI-STOREDFLOOR (25,000 sq.ft/floor). PRODUCTION: 25 Tons/day (Approximately). It has two lifts, two cranes of capacity=12 tons. There is a Bas Bar (have no wire) system to facilitate production. Different Departments: ProductionOriented Department:  Yarn store  Planning& Control  Batching  Chemicalstore  Windingsection  DyeingSection  FinishingSection  Dyeing lab section  Wet lab  QualityControl  Maintenance  Utility  Water treatment plant  Effluenttreatment plant

12. 14 | P a g e Supportingdepartment: - - - - - - - - - Prochurement Merchandising Marketing IT HRD Finance& accounting Medical PersonnelAdministration Security Other Facilities: Staffcanteen The canteenis capableto accommodateabout250 personsat a time. Mosque The mosqueis capableto accommodateabout500 personsat a time. Medical AvailableFacilities with a Air ConditionedAmbulance. Lighting: Sufficientlighting arrangementis there with proper lighting shadefixedalong with overheadchannel Cleanness: The factory premiseare kept clean, removingthe dirt & refuges,cleaners sweepthe floor at regular interval effectivearrangementare made to dispose off the wasteto the nearby dustbin. Water: Sufficient water is suppliedfrom in house deep-tube-wellto all production lines including toilet. Moreover,each floorprovided with tank for portable water.

13. 15 | P a g e Toilet: Sufficient numbers of toilets are available for male & female workers as per requirements. Soaps & towels are also supplied. Emergency ElectricitySupply: During the electricity failure, available generators can fulfill requirement of the whole complex. Salary& Wages: a. Salaryand wagesare paid to the staff and workers as per gazette notificationof the governmentof Bangladesh. b. Paymentof salaryand wages are made regularlyby 5th - 7th of each month. c. In the salarysheet basic salary, houserent, medical allowanceand gross salaryare shownseparatelyfor each employee.

14. 16 | P a g e ACHIEVEMENT Knit Concern now is having Oeko Sustainable Textile, i.e., Oeko-Tex Standard 100, which, as you know, entrusts it to produce apparels using organic cottons cultivated and traded conformingto eco-friendlystandardsall through. Knit Concern is also certified by CONTROL UNION.INDIA to manufacture garments using organic cotton yarn under the prestigious coverage of scope CERTIFICATE. On May 1, 2010, the Ministry of Labor, Government of Bangladesh, has honored Knit Concern with the May Day Award 2010 for the top order ranking as a labor-friendlyknit factory in the country. Besides numerous local and overseas top order business as well as CSR awards and recognitions, many of those - such as the 'Premium Quality Supplier' etc - being offered by its valued buyers and some business and financial publication houses highly noted in the country, the government also has awarded Knit Concern the national trophies several times for performing as the top and the best exporterof knit apparels. On its way towards success, Knit ConcernimplementedISO- 9001:2008 Quality ManagementSystem back in 2002. BGMEA BKMEA OEKO-TEX

15. 17 | P a g e CERTIFICATE OrganicCertificate ISO Certificate 1stMay Fair Certificate Oeko-Tex Certificate

16. 18 | P a g e List of Major Buyers: List of Major Buyers: Buyers Name H & M Buyers Name Sign Sign Okaidi Jules CAMAIEU KLiNGEL

17. 19 | P a g e Carrefour Sayan K & L A M S Phildar W E

18. 20 | P a g e HUMAN RESOURCE MANAGEMENT MANAGEMENT MANAGEMENT HUMAN RESOURCE HUMAN RESOURCE

19. 21 | P a g e Organogramof man power in Dyeing Section:

20. 22 | P a g e Managementsystem: → Buyer sample is send to G.M. → Matching is done by lab in charge. → Sample is prepared by asst. dyeing master. → Sample is send to the buyer for approval. → Approved sample is returned and taken as standard. Sample for bulk production. → Asst. dyeing master gives responsibilities to production officer. → Then production officer, with the supervisors start bulk production. → On line and off line quality check is done by lab in charge and asst. dyeing master. → After dyeing finishing in charge controls the finishing process with the supervision of production officer. → After finishing, the material is checked by asst. dyeing master. → Finally G.M. checks the result with asst. dyeing master and decision is taken for delivery. Shift Change: Two shifts (day and night): each of 12 hrs Day shift→8 a.m. to 8 p.m. Night shift→8 p.m. to 8 a.m. Responsibility of Production officers: • • • • • • • • • • To give dyeing program slip. To match production sample with target shade. To collect production sample lot sample matching next production, To observe dyed fabric during finishing running & also after finishing. To identity disputed fabrics & report to P.M/G.M. for necessary actions. To discuss with P.M about overall production if necessary. To sign the store requisition & delivery challan in the absence of P.M. Also to execute overall floor works. To maintain loading'/unloadingkhata. Anyotherassignmentgivenbyhigherauthority. Title ReportTo Job Summary: To plan, execute & follows up the production activities &. control the quality productionwithrelatedactivities. :Production Office : Sr. Production Officer.

21. 23 | P a g e Duties & Responsibilities of SPO:  Overall supervisionof dyeing,finishingproduction.  Batch preparation& pHI check.  Dyes& chemicalrequisitionissue& check.  Write Fabricsloading& unloadingtime fromm/c  Programmaking,samplechecking,colourmeasurement  Controlthe supervisors,operator,asst.operatorandhelperof  Dyeingm/c.  Andalsoanyotheroverworkas &whenrequiredbythemanagement. Title ReportTo Job Summary: To plan execute & follows up the production activities & control the quality productionwithrelatedactivities. : Sr. ProductionOfficer : Manager Duties & Responsibilities of GM:  Overall supervisionof dyeing,finishingproduction.  Checksthesensitiveparametersofdifferentmachineforsmoothdyeing  Checksthedifferentlogbooksofdifferentareas&reporttomanagement  Checksouttheplantocontrolthebestoutputfromsupervisors &workers.  To trainedup&motivethe subordinateshowto improvethequalityproduction.  Control the supervisor, operator, Asstt. Operator & helper of dyeing.  Maintenanceof machine& equipmentAny otherworks& whenrequiredbythe management.

22. 24 | P a g e ManpowerList (Dyeing Department) No. Section Person 01 GM 01 02 DM 01 03 DDM 01 04 SPO 01 05 P.O 08 06 Planning 02 07 Q.C / Q.I 86 08 Maintenance 71 09 Batch 75 10 Dyeing 149 11 Finishing 139 12 Store 26 13 Delivery 29 14 Washing 26 15 Accounts 03 16 Marketing 02 17 Store (Acc) 02 18 Ex.Of./'Time 04 19 Pion 04 Total 650

23. 25 | P a g e FLOW OF OPERATION Knitted fabric from Knitting Grey Fabric Inspection Section Batch Section Dyeing Laboratory Dyeing Floor Finishing Section Quality Checking Dispatch/ Delivery Section Supporting sections:  Planning  Chemical store  Utilities Sections – water, power, boiler, compressor, waste water management system.  Maintenance Section

24. 26 | P a g e GREY FABRIC INSPECTION INSPECTION INSPECTION GREY FABRIC GREY FABRIC

25. 27 | P a g e Grey Fabric Inspection Section: Fault name Causes Remedies Image # Yarn breakage or yarn cracks. # If the yarn count is not correct on regarding structure, gauge, course and density. # Badly knot or splicing. # Yarn feeder badly set. # If yarn tension too high #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 1. Hole Mark # When a needle breaks down. # If a needle or needle hook is slightly bends . # If needle does not catch yarn . # Needle should be straight as well as from broken latch. 2. Needle Mark # Yarn tension variation during production. # Buckling of the needle latch. # Low G.S.M fabric production # Maintain same Yarn tension during production. # Use good conditioned needles. 3.StarMark:

26. 28 | P a g e # 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. #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. 4.Drop Stitches # Use of irregular yarn having higher long term irregularities. # Using different count thread. # remove irregular yarn # use proper yarn count #we can use it for white fabric 5.Bariness # If needle latch is hard or curve. # if yarn tension is loose . # clean or change the needle. # set proper yarn tension 6.Loop

27. 29 | P a g e Cause by If lycra is missed or Lycra attach with the yarn Check the feeder and attatch laycra. 7.Lycra out # if needle latch is not work properly/jaum # Causes by thick yarn # Improper/large knot 8.Seat up (cloth fallout) Make sure all the latches of needle are closed with feeding yarn after a drop stitch. # Excessive oil flow in the needle # Leakage of oil line # Ensure that oil does not pass on the fabrics. # Well maintenance as well as proper oiling. 9.Oil mark

28. 30 | P a g e 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. # 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 10.Fly 11.Yarn contamination # If yarn contains foreign fiber then it remains in the fabric even after finishing, # If lot, count mixing occurs # By avoiding lot, count mixing. # Fault less spinning. # 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 Sinker should be changed 12.Sinker Mark

29. 31 | P a g e Inspection Machine Specification: - - - - - - - - - - - - UZU machine for garment Width: 69 & 100 inch No of m/c: large – 3 Power supply required: 200 volt Motor- 1 hp. Efficiency – 75% Brand Name :UZU Model: HC-TIM -1500 mm Country Of Origin : Thailand No of motor: 02 Motor: 210 HP Power : 220 V small – 6 50/60 Hz Checking Standard: Varies depending on buyers’ requirements. - For H&M – 4 point system is followed. - For others – 10 point system is followed. Inspected Fabric Storage Section: - - - Two storied storage sections with racks of multistoried rails. Total capacity – approx. 250 tons Storage fabrics are sorted and separated under following parameters---- 1. Buyer 2. Order no 3. Color 4. Count 5. Brand 6. Yarn lot 7. FabricDia & GSM.

30. 32 | P a g e Sample of frequently produced knit-fabrics: 1.SingleJersey 2.DoubleJersey (RIB) 3.DoubleJersey (Interlock)

31. 33 | P a g e 4.Terry Fleece 5.S/J Lycra Stripe 6.PiqueStripe

32. 34 | P a g e 7.Tricot

33. 35 | P a g e BATCH SECTION SECTION BATCH

34. 36 | P a g e Batching: Batching meansseparationof fabric accordingto specification,Dyeing machine capacity & availability,urgency of the order. Two types of Batching: 1. Solid 2. Assorted Batch containsbody of garmentsas well as collar-cuffsaccordingto the design. Total requiredquantity X Dia Quantity  Batch Quantity = Total quantity Total batch quantity + total parts  Batch Ratio = Batch Quantity M/C for Batch preparation Name Brand Name : PUJI Type No. of m/c :Turning m/c : REVERSING : 03 LoadingCapacity: In dyeing machine, 250 kgs of fabric can be one nozzle through dyeing machine. Normally, for the fabric with high G.S.M and large width, maximum load can be done. Nozzle: Each batch is divided into 1-4 stacks,which are termed as nozzle, generallyeach nozzle weight 250 kgs Rolls: Each nozzle is further divided into 1 to 5, which are termedas rolls. Usuallyeach roll weight about 22-27 kgs(orup)

35. 37 | P a g e Process flow chart of Batch preparation: Receive the order sheet from in-charge Make the batch card on the priority of shipment Take the Batch card which order have to deliver first Check the availability of the fabric Take require quantity of body fabric from the store Take collar/cuff as per size and keep the total weight Distribute the collar/cuff or Rib in each rope equally ensuring equal length. Turn off the fabric (if necessary) Stitch the fabric Write down weight against roll no. in the back side of the Batch card Write the total weight in the batch card Fill up the Production report form Deliver the Fabric to dyeing section

36. 38 | P a g e KNIT DYEING LABORATORY LABORATORY LABORATORY KNIT DYEING KNIT DYEING

37. 39 | P a g e Knit concern has a ‘Central Lab’ including three major sections – Knit-Dyeing lab, Yarn- Dyeing lab & Physical Lab. Main Responsibility:  Accepting the ‘Swatch’ from the buyer and analyze the color & Dyes.  Preparingthe Recipe accuratelymatchingthe requiredcolor.  Storing & maintainthe dyes to be used for dyeing.  Producing self-shades& storing it into the computer.  Record & analysisof chemicals & dyes quality.  Making plans for bulk dyeing.  Followingthe color coding system given by the distinctive buyer & also prepare own color bank.  Testing the dyed goods. Flow of work: Swatchfrom buyer/merchandiser (Contains:fabric construction-gsm-colorname-colorcode-style) Shadematching by lab works Shade submission (Samplematch A, B, C) Approved Rejected Recipe delivered for bulk-production

38. 40 | P a g e Shade matching system: Spectrophotometer: Spectrophotometers designed specifically for the measurement of coloured materials, are at centre of any modern colour formulation, colour production, or colour quality control system. Although these colour spectrophotometers are designed measure samples both accurately & repeatedly, they accomplish these measurements only within a range of applicable tolerances. Spectrophotometers are not perfect measuring devices, & how well they measure often depend on factors under control of system operator. The objective is how to spectrophotometers, so that their measurements are as accurate & repeatable as possible. These tips are intended for those attempting to get the best possible measurementperformancefrom their colourmeasuringspectrophotometer better operate and control colour The Datacolor high performance bench top spectrophotometers (Datacolor 650™, Datacolor 600™, Datacolor 400™) are the newest generation of bench top color measuring instruments, incorporating state-of-the-art technology in the instrument design. All are intended for use as a device for measuring, specifyingand evaluatingcolor in both laboratoryand productionsettings. CMOS integrated circuit [Spectrophotometer– Data color model600] This high-precision, close-tolerance, reference grade spectrophotometer has special capabilities to handle fluorescentmaterials. ❖ Automatedzoom lens and specularport ❖ Exceptionalinter-instrumentagreement ❖ AutomatedUV control ❖ Multipleviewingapertureswith automaticaperturerecognition ❖ Automaticgloss compensation

39. 41 | P a g e Pantone book: - Buyer’s Swatch: may be piece of fabric or C.I. number of any specified‘Pantonebook’. Thereare 4 types of pantone bookis available: 1. TP ----- textile paper 2. TC ----- textile cotton 3. TPX --- textile paper for bright 4. TCX --- textile cotton for bright The given swatch is measured by the ‘Spectrophotometer’, which is preparedby reach memoryof different dyestuffself-shades. Also the matchingmay be done by previousworkingrecord. - - - Some self-shade samples: • DyechufixYellow HS-3R : 0.01% 0.05% 0.1% 0.5% 1% 2% 3% 4% 5%

40. 42 | P a g e • AmronRed HR2D 0.01% 0.05% 0.1% 0.5% 1% 2% 3% 4% 5% • EV Blue SP. EBR 0.1% 0.5% 1% 2% 3% • ReactiveYellow4GL 0.1% 0.5% 1.0% 2% 3%

41. 43 | P a g e List of machine: Auto lab Dispenser& Solutionmaker 01 Ahiba Naunce-(Sample 01 Dyeingm/c) Sandolabsampled/m 04 Lab Extractor 01 Dryer 01 Data color SpectrophotometerSF 01 600 Plus CT Incubator( Oven) 01  Lay outof Knit-DyeingLab:

42. 44 | P a g e Lab Dyeing Machine: AHIBA NUANCE Data color lab dyeing machine Feature:    Easy to operate multi-step controller with alpha-numeric program names Advanced microprocessor technology controls the heating and cooling system Dyeing parameters are constantly monitored during every step of the dyeing process and displayed on the large graphical display Memory cards store an unlimited number of processes Increased power output ensures reproducible level dyeing Suitable for all substrate.    AUTOLAB DISPENSER

43. 45 | P a g e SPECIFICATION: Manufacturer:Data Color Origin: USA FUNCTION:  Preparationof stock solution  Auto dispensing of given recipe Lab dip: Lab dip is a process by which buyers supplied swatch is matched with the varying dyes percentage in the laboratory with The help of “DATA COLOR” or see the previous matching sample or give the recipe by the practical experience, Lab dip plays an important role in shade matching & and detaching the characteristics of the dyes and chemicals are to be used in the large scale of productionso this is an importanttask before bulk production. Key accessories for Lab:  Datacolor computer  Lab, receive file  Electronic Blench  Plastic/Glassbeakers  Steel stirrer  Scissors  Stainless reference & dyeing beakers  Dryer  Variablelight box  Electric Heater

44. 46 | P a g e DYEING MACHINE DESCRIPTION AND THEIR MECHANISM OF WORKING MECHANISM OF WORKING MECHANISM OF WORKING DYEING MACHINE DESCRIPTION AND THEIR DESCRIPTION AND THEIR DYEING MACHINE

45. 47 | P a g e DYEING FLOOR Knit concernDyeing floor consists of two separatefloors – KCL & KCA. The Dyeing Machinesare all Winchdyeing m/c of both atmospheric& high temperature types. No. of Machines: Type capacity no. of m/c Sample dyeingmachine – 10 kg 3 20 kg 4 30 kg 7 60 kg 3 100 kg 2 Bulk dyeing machine- 150 kg 5 200 kg 2 250 kg 300 kg 3 2 400 kg 4 500 kg 2 600 kg 2 750 kg 800 kg 3 3 1000 kg 2 1200 kg 1 1500 kg 2 2200 kg 1

46. 48 | P a g e In KCL there are mainly two types of dyeing machine- - - • • Atmosphericmachine:these runs in atmosphericpressure. High temperature& High Pressure(HTHP) Lay out plan of Dyeing sections:

47. 49 | P a g e Fong’s Sampledyeingm/c Fong’s Sampledyeingm/c Fong’s Sampledyeingm/c Fong’s HTHP(Jumboflow) winchdyeingm/c Fong’s HTHP(Jumboflow) winchdyeingm/c Fong’s HTHP(Jumboflow) winchdyeingm/c MECHANISMOF DYEING MACHINE: MECHANISMOF DYEING MACHINE: MECHANISMOF DYEING MACHINE: Main Partsof DyeingMachine: 1. Main Vessel or Chamber 2. Winch roller or Reel 3. Heat Exchanger 4. Nozzle 5. Reserve Tank 6. Chemical dosingtank 7. Utility lines i.e. water line, drain line, steam inlet etc. 8. Controlling unit or Processor 9. Fabric Plaiter 10. Differenttypes of motors & Valves 10. Differenttypes of motors & Valves 10. Differenttypes of motors & Valves Main Partsof DyeingMachine: 1. Main Vessel or Chamber 2. Winch roller or Reel 3. Heat Exchanger 4. Nozzle 5. Reserve Tank 6. Chemical dosingtank 7. Utility lines i.e. water line, drain line, steam inlet etc. 8. Controlling unit or Processor 9. Fabric Plaiter 9. Fabric Plaiter Main Partsof DyeingMachine: 1. Main Vessel or Chamber 2. Winch roller or Reel 3. Heat Exchanger 4. Nozzle 5. Reserve Tank 6. Chemical dosingtank 7. Utility lines i.e. water line, drain line, steam inlet etc. 8. Controlling unit or Processor WorkingPrincipleof Winchdyeingmachine: WorkingPrincipleof Winchdyeingmachine: WorkingPrincipleof Winchdyeingmachine: Winch Dyeing machines are most suitable for knit fabric dyeing. Here fabric is dyed in tubular from where fabric runs in endless circular path. Inside the m/c the upper part of the fabric runs through a nozzle & the lower part is immersed into liquor, in the nozzle the liquor is sprayed onto the fabric. The fabric and liquor both circulated by a high pressurepump. pressurepump. pressurepump. Winch Dyeing machines are most suitable for knit fabric dyeing. Here fabric is dyed in tubular from where fabric runs in endless circular path. Inside the m/c the upper part of the fabric runs through a nozzle & the lower part is immersed into liquor, in the nozzle the liquor is sprayed onto the fabric. The fabric and liquor both circulated by a high the liquor is sprayed onto the fabric. The fabric and liquor both circulated by a high Winch Dyeing machines are most suitable for knit fabric dyeing. Here fabric is dyed in tubular from where fabric runs in endless circular path. Inside the m/c the upper part of the fabric runs through a nozzle & the lower part is immersed into liquor, in the nozzle

48. 50 | P a g e Fig: cross-sectionaldiagramshowingfabricpath& nozzlein the high pressurewinch d/m The main pump draws the liquor from the bottom of the vessel & passed this liquor through the heat exchanger to the top of vessel into the Nozzle. The winch roller or the reel also helps running the fabric smoothly. The liquor gets heated or cooled by exchangingtemperaturein the heat-exchanger. Fig: schematicdiagramof the circulationsystemof liquor in a dyeing machine

49. 51 | P a g e Advantages of Winch Dyeing : a. Constructionand operationof winch are very simple. b. The winch dyeing machinesare suitablefor types of wet processingoperations c. The winch dyeing machineis suitablefor practically all types of fabrics ,which can withstandcreasing in rope form processing. d. The tensionexerted on winch is less than jigger, the materialthus dyed is with fuller hand. e. The appearanceof the dyed goods is clean and smooth on winch dyeing machines. GeneralParametersof Dyeingmachines: • Capacity per nozzle: theoretically250 kg but practically not more than 200 kg should be used. • Nozzle pressure: 4-6 psi • Steam pressure: 7 bar (inlet of heat exchanger) • Cold water temp. • & pressure: 25 c & 3 bar • Maximumtemp.: 140 for high temp. M/c • Reel/Winch speed: 150-250 rpm • Main motor efficiency:80-85% 100 for atmospheric

50. 52 | P a g e FINISHINGSECTION FINISHINGSECTION FINISHINGSECTION