1 / 83

Industrial attachment of landmark textile mills ltd.

Presentation about 'Industrial attachment of landmark textile mills ltd.'

sheshir
Download Presentation

Industrial attachment of landmark textile mills ltd.

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

E N D

Presentation Transcript

  1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Landmark Textile Mills Ltd.

  2. TABLE OF CONTENTS Chapter No. Topics Contents Page no. Chapter-I Project Description Name, Type, Year of establishment, Address, Sponsors, Product Mix, Annual Production Capacity, Project cost, History of the project development, Location, Different departments, Physical infrastructure, Remarks. Organ gram /Man power of administration, production & maintenance, Management system, Shift change, Responsibilities of production officers, Job description of production officer, Job description of Asst. dyeing master, Remarks. No. of machines, Origin, Brand name, Machine specification, Machinery Layout Plan, Remarks. Types, Price, Source, Remarks. Production flow chart, Dyeing parameters, Description of Production Process- Recipe, Dyeing curve & Finishing m/c settings, Daily production report, Monthly average production, Remarks. Quality Policy, Quality assurance procedure, Inspection area, Problems encountered in dyeing, List of equipment, Quality 5-8 Chapter-II Manpower Management 9-12 Chapter-III Machine Description 13-20 Chapter-IV Raw Materials 21-24 Chapter-V Production Planning Sequence & Operations 25-47 Chapter-VI Quality Assurance 48-55 2

  3. standard, Remarks. Chapter-VII Maintenance Maintenance of machinery, Routine, Manpower set up for maintenance, Maintenance procedure, Maintenance tools and their functions, Remarks. Utility facilities available, Capacity and other technical details, Source of utility, Cost of different utility, Remarks. Scope of inventory control, Frequency of inventory update, Inventory system of- Raw material, Spares, Finished goods & others, Remarks. No available data Consumer of the product, Country of export, Local market, Marketing strategy, Duties and responsibilities of marketing officer, Remarks. Introduction, Machine Description, Features of dyeing machines, Features of Acrylic yarn dyeing process, Process flowchart, Process description, Quality standards, Drawbacks, Buyers, Remarks. 56-62 Chapter-VIII Utility Services 63-67 Chapter-IX Store and Inventory Control 68-70 Chapter-X Chapter-XI Cost Analysis Marketing Activities 71-72 73-75 Chapter-XII Acrylic Yarn Dyeing 76-82 Chapter-XIII Conclusion 83-84 3

  4. CHAPTER – 1 PROJECT DESCRIPTION 4

  5. Name of the Company Project Name Type Year of Establishment Address Head Office : Landmark Fabrics Ltd. : Landmark Textile Mills Ltd. : Knit Composite Textile Industry. : 2000 : : House#488/a, Road#32, New DOHS Mohakhali, Dhaka-1206,Bangladesh. Ph: 88-02-8811679, 8814839 Fax: 88-02-8823999,8815868 E-mail: gbilmd@citechco.net : lmdfab@bttb.net.bd Factory : Boro Ashulia, Savar, Dhaka. Ph:88-02-9289365-7, Fax:88-02-9289364 E-mail:knitfty@dhaka.net : The industry is sponsored by Jamuna Bank Ltd. : 100% cotton 100% polyester(micro + coolmax) 100% viscose CVC (chief value cotton) P/C Gray mélange Nylon/Cotton Sponsors Product Mix Annual Production Capacity: Knit Dyeing – 3000 ton ; Yarn Dyeing – 1400 ton Project Cost : Initial investment is approximately 25 Crore Tk. History of Project Development :  The construction work of the factory was started at 1999, after acquiring 20 bighas of high land at Shadhurpara, Boro Ashulia, Savar, Dhaka. The construction work was completed at the beginning of 2000. At the very beginning, the project consisted only Knitting, Knit dyeing, Garments section and Utility supply section. In 2001, Acrylic yarn dyeing and sweater manufacturing unit was started. In 2002, production capacity of knit dyeing section was increased with the addition of new Jet dyeing m/c, Stenter m/c, Raising m/c. In 2004, Spray dyeing unit was started.     5

  6.  Effluent treatment plant was under construction. Future plans to establish Acrylic Yarn manufacturing unit, hospital, designing and packaging unit. Location : Ashulia Bazar Landmark Complex Tongi Abdulla hpur 6

  7. Different Departments : To ensure smooth running of various activities, some departments are available they are given bellow:  KNITTING SECTION: 1.Knitting 2.Inspection  KNIT DYEING SECTION: 1.Batch section 2.Store house for dyes & chemicals 3.Dye house 4.Dyeing & QC lab 5.Finishing  GARMENTS SECTION: 1.Merchandising 2.Sample 3.Production  MAINTENANCE: 1.Electrical 2.Mechanical  ACCOUNTS & COMMERCIAL SECTION  ADMIN SECTION Physical Infrastructure Buildings- 2 ten storied buildings, 1 five storied building, 3 two storied buildings and 1 dyeing shade. Buildings are made by concrete. Total Area of Industry : 30 Bighas. : Remarks: The company owns 30 bighas of high land property at Sadhurpara, Baro Ashulia, Savar, Dhaka; which is 40 km from the heart of the capital city. Charming sights along with natural beauty of rural areas with no hazards or air pollution attracts the foreign buyers during their visits. The company has the desire to achieve recognition of the project as the ‘Landmark Industrial Park’ and to set up within the park area industries and health care center in near future. Plans include for Acrylic Yarn manufacturing unit, Packaging unit, Designing unit and Hospital. 7

  8. CHAPTER – II MANPOWER MANAGEMENT 8

  9. Organ gram of Production Unit: . Landmark Fabrics LTD. BORO ASHULIA, SAVAR, DHAKA Administration Knitting Dyeing Finishing Lab Batch Maintenance General Manager Manager Asst. Dyeing Master Mechanical Engineer Asst. Admin. Officer Production Officer In-charge In- In- Electrical Engineer charge charge Mech. Fitter & Electrical Super visor Store In-charge Supervisor Supervisor Q.C. Chemist Super- visor Supervisor Store Keeper Operator Operator Operator Assistant Heeler Asst. Mechanic Office Boy Helper Helper Helper Helper Electrician Cleaner Cleaner Cleaner Asst. Electrician Management System:  Buyer sample is send to G.M.  Matching is done by lab in charge.  Sample is prepared by asst. dyeing master. 9

  10.  Sample is send to the buyer for approval.  Approved sample is returned and taken as std. 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. Responsibilities of Production Officer:        Over all supervision of production both dyeing & finishing. Batch preparation and pH check. Dyes and chemical requisition, issue and check. Write fabric loading and loading time from machine. Programme making, sample checking, color matching. Control the supervisors, operators, asst. operators and helpers of dyeing machine. And also other work when it is required by top level management. Job Description: Title: Asst. Dyeing Master Dept/section: Dyeing and Finishing. Report to: G.M. Job Summary:  After having the work order, prepares production plan.  To execute and follow up the plan along with quality conformation.  To face various difficulties of production and overcome them.  Inspecting the material for conformation to buyer requiremnt. Title: Asst. Production Officer Dept/section: Dyeing and Finishing 10

  11. Report to: Asst. Dyeing Master. Job Summary:  To execute the plan given by asst. dyeing master.  Organizing personnel under him.  Control the supervisors, operators, asst. operators and helpers of dyeing machine.  Checking of shade match. Remarks: The manpower management system of Landmark Textile Mills Ltd. is well arranged. Every officers & stuffs are responsible for their duty. But there are only three textile engineers in the industry (General manager, Asst. dyeing master and Production officer). It is not sufficient for smooth production. More technical people is required. 11

  12. CHAPTER – III MACHINE DESCRIPTION 12

  13. Dyeing machinery: In dyeing section of Landmark Fabrics Ltd, there are 7 Dyeing Machines, among them 2 m/c’s are for sample dyeing and 5 m/c’s are for bulk production. Besides these, a Salt Dozing m/c and an Air Turner m/c are available. Machine no.- 01 Name of the m/c Brand Name Manufacturing Country Year of Manufacturing M/C Specification M/C capacity No. of nozzle MaxmTemp Motor : Sample Jet Dyeing Machine : Thies. : Germany. : 2001 : : 20 kgs : 01 : 1350C : : 01 : 01 : 01 winch motor pump motor stirring motor Machine no.- 02 Name of the m/c Brand name Manufacturing country M/C specification M/C capacity No. of nozzle : Bangla Winch Dyeing M/C. : None : Bangladesh : : 25 kgs : 02 Machine no.- 03 Name of the m/c Brand name Manufacturing country Year of manufacturing M/C specification M/C capacity No. of nozzle Motor winch motor pump motor : Jet Dyeing M/C : Thies : Germany : 2001 : : 170 kgs : 01 : : 01 : 01 13

  14. stirring motor : 01 Machine no.- 04 Name of the m/c Brand name Manufacturing country Year of manufacturing M/C specification M/C capacity No.of nozzle Motor winch motor pump motor stirring motor : Jet Dyeing Machine . : Thies. : Germany. : 2001 : : 350 kgs : 02 : : 02 : 01 : 01 Machine no.- 05 & 06: Name of the m/c Brand name Manufacturing country Year of manufacturing M/C specification M/C capacity No.of nozzle Motor winch motor pump motor stirring motor : Jet Dyeing Machine . : Thies. : Germany. : 2001 : : 450 kgs : 03 : : 03 : 01 : 01 Machine no.-07: Name of the m/c Brand name Manufacturing country Year of manufacturing M/C specification M/C capacity No.of nozzle Motor winch motor pump motor stirring motor : Jet Dyeing Machine . : Thies. : Germany. : 2001 : : 1000 kgs : 04 : : 04 : 01 : 01 14

  15. Salt Dozing Machine : Brand name Manufacturing country M/c capacity : Fong’s National Eng (Shenzhen Co.) : China : kgs Function of the m/c: It is an additional m/c only used for the large m/c(capacity-1000kgs).When large amount of salt are to be added, in that case salt are added by dosing system which are maintained by this m/c. Air Turner M/C: Brand name : Dong Nam Industrial Co. Manufacturing country : Korea Function of the m/c : To turn the fabric Finishing Machinery: In finishing section of Landmark Fabrics Ltd, the machines which are available are listed below: 1. Slitter m/c 2. Stenter m/c 3. Dewatering & Detwisting m/c 4. Gas Burnt Tensionless Dryer m/c 5. Tubular Compactor m/c Slitter M/C: Specification: Brand name Manufacturing Country Year of manufacturing M/c speed M/c width : BIANCO : Italy : 2001 : 60 meter/min : 80 inch Purpose of the m/c:   To open the fabric from tubular form to open width form Fabric is cut according to the needle drop Main parts: 15

  16.  Turntable  Rope Squeeze  De-twister  Pulley Drive  Beater  Centering Unit  Slitting Unit  Squeezing Utilities used:   Electricity(to drive the m/c only) Compressed air(to keep the tubular fabric to be cut in proper tension) Stenter m/c: Specification: Brand name Manufacturing country Year of manufacturing Production/day Maximum steam pressure Maximum air pressure : Mahlo + Bruckner : Germany : 2002 : 12,000 Kg/day : 2 bar : 10 bar Purpose of the m/c:    To make the fabric dry For heat setting in case of p/c & 100% polyester fabric Width control Main parts:  Heating Chamber(7)  Width Control Device  Selvedge Trimming Device  Selvedge Gumming Device  Blower(14)  Biasing Unit  Softener Applicator  Folding Device Heating system: Gas Burner Gripping system of fabric edges: pinning Utilities used:    Electricity Gas Steam Controlling points:     Fabric speed Fabric width Temperature Overfeed % 16

  17. Dewatering & Detwisting m/c: Specification: Brand name Manufacturing country Year of manufacturing : Santex group : Switzerland : 2001 Purpose of the m/c:  To remove excess water of fabric by squeezing after pretreatment and dyeing For the application of softener finish which make the fabric soft in hand feel Wet-on-wet application is possible Shrinkage is controlled by overfeed mechanism    Main parts:      De-twisting device(to deliver the fabric roll in untwisted form) Over feeding wheel(to control shrinkage) Stretcher(to control width) Squeeze roller(to remove water) Folding device(to delivery the fabric in folded form) Utilities used:   Electricity Compressed air(to form the tube fabric into balloon to ensure the delivered fabric to be crease free) Chemical used: 1. Softener (10g/l) 2. Acetic acid (1g/l) Controlling points: Over feed control Pressure of squeeze R/r Fabric speed Width control Gas Burnt Tensionless Dryer: Specification: Brand name : Santex Group 17

  18. Manufacturing country Year of manufacturing : Switzerland : 2001 Purpose of the m/c:   To dry the fabric uniformly in tensionless state To control the shrinkage Main parts:  Heating chamber(2)  Blower()  Teflon conveyor  Folding device  Exhaust fan  Mesh Heating system: Gas Burner Utilities used:    Gas Electricity Compressed air Controlling points: Speed control Temperature control Exhaust fan control  Motor control  Net vibration Heating chamber height Tubular compactor: Specification: Brand name Manufacturing country Year of manufacturing Prodn/day : Santex Group : Switzerland : 2001 : 12,000 Kg/day Purpose of the m/c:   Used for tubular fabric as final finishing Amount of shrinkage is given to the fabric in compaction zone as per buyer requirement Final finished width and GSM can be obtained as buyer requirement  Main parts:   Stretcher Steam heated roller 18

  19.   Blanket Teflon R/r Folding device Utilities used:    Electricity Steam Compressed air Raising M/c: This m/c is used only for raising finishing which imparts a hairy surface to the fabric. A layer of fabric fibres lifting from the body of the fabric is achieved by passing it over a no. of pile R/r and counter R/r. It is mostly applied on Terry fabric, Polar fabric etc. Specification: Brand name Manufacturing country Year of manufacturing Type of m/c No. of pile R/r No. of counter R/r Roller width Avg. speed of m/c : Yantu : Taiwan : 2001 : Gear type raising m/c : 12 : 12 : 2000 mm : 30 m/min Remark: Landmark Fabrics Ltd is a well-equipped industry. It contains machinery of well known brands like Thies, Bruckner, Bianco, Santex, etc. The availability of these m/c’s are helpful to increase the productivity of the industry. The arrangement of machines is very beautiful and there is enough space for movement of the workers. 19

  20. CHAPTER – IV RAW MATERIAL 20

  21. Raw material: Landmark Fabrics Ltd is a knit composite textile industry. In the industry the raw materials used for production are: 1.Grey Fabrics 2.Dyes 3.Chemicals 1. Grey Fabrics: Following types of grey fabrics are processed Single jersey Single jersey/lycra Interlock Rib 1X1rib/lycra Combined rib Lacoste Terry & French terry Polar Eyelet & mini-eyelet Mesh (warp knitted fabric) waffel Collar & cuff Pique Source 40% comes from the Knitting Department of Landmark Fabrics Ltd and other 60% comes from outward as sub-contract. Daily Fabric Production Capacity Item Quantity Single jersey, Pique Lacoste, Interlock Rib Collar & cuff 1000 kg/day 3500 kg/day 3500 kg/day 6000 pcs 2. Dyes: In Landmark Fabrics Ltd. the following types of dyes are used:  Reactive dyes (cold brand & hot brand)  Disperse dyes The commercial name of the dyes with their prices are collected from the dye stock report Sl. No . 1 Names of the dyes Price in Tk/kg Sl. No Names of the dyes Price in Tk/kg 800/- Kemazol black-B - 32 Drimarine Red CL-5B 2 Kemazol Turqu.BlueG2-HC - 33 Drimarine Blue CL-2RL 2250/- 21

  22. 3 Kemafix red 2B 750/- 34 Drimarine Navy CL-R 1100/- 4 Kemafix black GR 260/- 35 Drimarine Orange CL-3R 720/- 5 Kemafix yellow 4G 325/- 36 Drimarine Yellow CL-2R 825/- 6 Kemafix yellow FRL 390/- 37 Drimarine Yellow CL-3G 1000/- 7 Kemafix red-3BC 390/- 38 Drimarine Blue CL-BR 1100/- 8 Kemafix Blue F2R 430/- 39 Drimarine Turquise CL-B 750/- 9 Kemafix Orange 2RL 400/- 40 Dianix Black CCR 340/- 10 Kemafix N.Blue MER-150% 390/- 41 Dianix Navy CC 650/- 11 Kemafix Red HE-3B 385/- 42 Taicron Black SE-EXNT 300% 450/- 12 Kemactive Orange HER - 43 Taicron N.Blue SE- EXNT 300% 480/- 13 Kemactive Red HE-3B 385/- 44 Taicron Rabine SEBL-T 200% - 14 Solacion Red HE-3B 440/- 45 Taicron Scarlet EBT 200% - 15 Terasil Red WFS - 46 Taicron Yellow SE -4GT 200% 550/- 16 Terasil Yellow W6HG - 47 Taicron Orange E-BRT 200% 380/- 17 18 Terasil Red W4BS Terasil G.Yellow W3R - - 48 49 Taicron Red EE-BNT 200% Taicron Blue EBRT 200% 600/- 720/- 19 Terasil Blue 3RL - 50 Taicron T.Blue SE-2BT 200% 1100/- 20 Terasil Blue WBLS - 51 Taicron Blue SE-2BT 750/- 2I Remazol Brilliant Red 5B - 52 Taicron Black HWT 400/- 22 23 Foron D.Blue RD-2RE-300-6RN Foron D.rubin RD-GFL-200% - - 53 54 Taicron Scarlet-HWT Taicron Navy-HWT 650/- 650/- 24 Foron black RD-BRE-300-GRM - 55 Taicron Red-XFT 450/- 25 Foron brilliant orange ERL-200% - 56 Cibacron Yellow EN-2R 1700/- 26 Foron yellow RD-4GRL-300-6RN - 57 Cibacron Red FNR 1600/- 27 Foron yellow brown F2RL-300% - 58 Cibacron Blue FNR 2600/- 28 Foron blue SE-2R - 59 Cibacron Dk.Blue WR 1150/- 29 Foron turquise S-2B - 60 Cibacron Red EB-150% 1100/- 30 Foron scarlet RD-FRS-200% - 61 Best Acid Yellow BMR - 31 Foron black RD-3G-300% - 62 Best Milling red 2B - Sources Matex Dyestar Grasim Ahmed Enterprise 3.Chemicals: 22

  23. In Landmark Fabrics Ltd., the following chemicals are used. The names of the chemicals with their prices are collected from the dye stock report: Sl no. Names of the chemicals Price in Tk/kg Sl no. Names of the chemicals Pric e in Tk/ kg - 1 Caustic soda(Alkaline Medium) 26/- 33 TC Antistati kem NPSZ(Antistatic Electricity Agent) Powersoft-18(Silicon Softener) Nalco 450(Boiler Chemical) Protek SB-157(Boiler Chemical) Sindonerin MC(Silicon Softener) Oxalic acid(Sequestering Agent) Adasil SM(Silicon Softener) 2 3 4 Hydrozen per oxide(Bleaching Agent) Acetic acid (Acid Medium) Common salt(Exhausting Agent) 32/- 65/- 5/- 22 23 24 - - - 5 Soda ash(Alkaline Medium) 18/- 25 - 6 Rucostab LGE(Multi-Purpose Chemical as alkali, stabilizer,sequestering agent) Verlon LGA(Multi-Purpose Chemical as alkali, stabilizer,sequestering agent) Bittex-0X(O.B.A Agent for Cotton ) 120/- 26 46/- 7 - 27 274/- 8 250/- 28 Ludox AM-400(Silicon Softener) Adasil ME(Silicon Softener) Gissapol-115(Wetting Agent) Felloson NOF(Oil Remover) Biopolish AL(Acid Enzyme) Remapon-173(Anticreasing Agent) Powersoft-CD34E(Silicon Softener) Bickersoft CFL(Silicon Softener) Welsoft-40(Silicon Softener) Belfasin 615(Cationic Softener) Valzyme(Acid Enzyme) Setamol BL(Dispersimg Agent) Palagal FAH8(Leveling Agent) Glycerine(Solvent) - 9 10 11 12 13 Alvatex HOS(Stabilizer) Lanapex HTS(Stabilizer) Eulysin(Acid Buffer) Multisoap SR(Soaping Agent) Ludox SPL(Oil &mineral Iron remover) 120/- - 34.50 120/- - 29 30 31 32 33 178/- 160/- 163/- - 135/- 14 Mollan-130(Sequestering Agent) 140/- 34 - 15 Alvatex 66-C(Fixing Agent) 135/- 35 - 16 17 18 19 20 21 Glauber salt(Exhausting Agent) Alvasoft EG(Cationic Softener) Hydrose (Reducing Agent) Feran ice(Hydrophilic Softener) Tabanol FTR(Levelling Agent) Unitex EBF(O.B.A Agent for Polyester) 10.50 155/- 80/- - - - 36 37 38 39 40 41 - - 330/- 65/- 138/- - Sources BASF Hightech-Oxichem Global Colourchem Ltd. Matex Friends International Remarks: 23

  24. Landmark Fabrics Ltd is so careful about its raw materials. The raw materials are always collected from those suppliers who supply the dyes & chemicals of higher quality. CHAPTER-V PRODUCTION PLANNING, SEQUENCES & OPERATION 24

  25. Production Flowchart: Knitting Inspection Dyeing Tubular Open Width Dewatering Slitter(Drying) Gas Dryer Stenter(Heat Setting) Stenter Compactor Folding Folding 25

  26. Dyeing Parameters: a. pH: - - - During H2O2bleaching pH 9.2 – 12 During reactive dyeing pH 10.5 – 12.5 During disperse dyeing pH 4.5 – 6.0 b. Temperature: For cotton scouring 1050C For cotton cold wash 300– 400C For cotton hot wash 700-800C For cotton acid wash 450C For cotton dyeing - - - - - 980C (For hot brand) 600C (For cold brand) Polyester dyeing: 1350C OBA application 980C - - c. Time: Set Actual For scouring & bleaching 30 mins For reactive dyeing 60-90 mins For disperse dyeing 60-90 mins - - - - For scouring & bleaching 90 mins - For reactive dyeing 150 mins - For disperse dyeing d. M:L ratio: - For reactive dyeing M:L ration maintained between 1 : 6 to 1 : 8 Dyeing Recipe: 1. 100% Cotton Fabric Dyed in Deep Shade with Hot Brand Color– Gisapol 115 Felosun NOF Remapon 173 Alvatex HOS 26

  27. Caustic Soda H2O2 Gisapol 115 Acetic Acid Common Salt Soda 3.04% Kem Orange HER 0.046% Kem Navy Blue HER 3.76% Kem Red HE7B Multisoap SR Acetic Acid Alvatex 66C Acetic Acid Dyeing Curve: 105c x 30 min B A 80c 60c Drain A = 1) Gisapal 115 2) Felosun NOF 27

  28. 3) Remapon 173 4) Alvatex HOS 5) Caustic Soda B = Hydrogen Per Oxide 98c x 45c 5 min Gisapal115 Acetic Acid 5 min x Normal 80c Drain Temp Drain 98c x 60’ 30’D Soda 80 20’D 10’D c Salt Dye 10’ Drain 10’ 10’ 60c 40c 98c Multisoap SR x Acetic Acid 5 min Normal 80c Drain Temp Drain Alvatex 66c 50c 28

  29. Acetic Acid x 15 min Drain 2. 100% Cotton Fabric Dyed in Light Shade with Hot Brand Color– Gisapol 115 Felosun NOF Remapon 173 Alvatex HOS Caustic Soda H2O2 Gisapol 115 Acetic Acid Mollan -130 Tabanol - FTR Glouber Salt Soda 0.136% Drimarine T. Blue CL - B 0.0162% Drimarine Yellow CL 2R 0.0066% Drimarine Blue CL – 2RL Multisoap SR Acetic Acid 29

  30. Note – Since Turquise Blue color is being used, Dye dosing will be done first. Then Glouber salt dosing will be done. If salt is added first oily substance is formed which creates mark in the dyed fabric. Dyeing Curve: 105c x 30 min B A 80c 60c Drain A = 1) Gisapal 115 2) Remapon 173 3) Alvatex HOS 4) Caustic Soda B = Hydrogen Per Oxide 45c 98c Gisapal115 x Acetic Acid 5 min Normal 80c Drain Temp Drain 85c x 40 min A= Mollan 130 15’ D B= Tabanol FTR Soda Ash 80c 15’ D 30’D A&B Dye G.Salt 20’ 30

  31. 15’ 20’ 60c Drain 40c 98c Multisoap SR x Acetic Acid 5 min Drain Normal 80c Temp Drain 3. 100% Cotton Fabric Dyed in Deep Shade with Cold Brand Color– Gisapol 115 Felosun NOF Remapon 173 Alvatex HOS Caustic Soda H2O2 Gisapol 115 Acetic Acid Common Salt Soda 10.4% Kem Black GR 1.38% Kem Red 3BS 1.39% Kem Yellow FRL 31

  32. Multisoap SR Acetic Acid Alvatex 66C Acetic Acid Dyeing Curve: 105c x 30 min B A 80c 60c Drain A = 1) Gisapal 115 2) Felosun NOF 3) Remapon 173 4) Alvatex HOS 5) Caustic Soda B = Hydrogen Per Oxide 98c x 45c 5 min Gisapal115 Acetic Acid 5 min x Normal 80c Drain Temp Drain 30’D 15’D 20’D 65c x 60 min Salt Dye Soda 32

  33. 10’ 10’ 20’ Drain 60c 40c 98c Multisoap SR x Acetic Acid 5 min Normal 80c Drain Temp Drain Alvatex 66c 50c Acetic Acid x 15 min Drain 4. 100% Cotton Fabric Dyed in Light Shade with Cold Brand Color– Gisapol 115 Felosun NOF Remapon 173 Alvatex HOS Caustic Soda H2O2 Gisapol 115 Acetic Acid Mollan -130 33

  34. Tabanol FTR Glouber Salt Soda 0.96% Kem Yellow FRL 0.156% Kem Red 3BS 0.0018% Kem Blue F2R Multisoap SR Acetic Acid Dyeing Curve: 105c x 30 min B A 80c 60c Drain A = 1) Gisapal 115 2) Remapon 173 3) Alvatex HOS 4) Caustic Soda B = Hydrogen Per Oxide 45c 98c Gisapal115 x Acetic Acid 5 min Normal 34

  35. 80c Drain Temp Drain 65 c x 45 min 10’ D 20’D 20’D 30’ D 1/4 Salt Dye 3/4 Salt Soda Ash A&B 60 c 10’ 20’ 10’ 20’ Drain A= Mollan -130 B= Tabanol -FTR 40c 98c Multisoap SR x Acetic Acid 5 min Drain Normal 80c Temp Drain 5. 100% Cotton Fabric With Optical Brightening Agent – 0.5% Gisapol 115 3.5% Caustic Soda Rucostab LGE H2O2 0.6% Bittox.ox (BYB) 35

  36. Acetic Acid Dyeing Curve: A= Gisapal 115 105c x 15 min B= Caustic Soda A B 80c Drain 105c x 70 min B 80c A 60c Drain A=Rucostab LGE B= Hydrogen Per Oxide 40c 98c OBA x Acetic Acid 10 min Normal 80c Drain Temp Drain 36

  37. 6. 100% PET Fabric Dyed in Deep Shade – 2% Soda Gisapol 115 Felosun NOF Hot Wash Acetic Acid Setamol BL Palagal FA8 Eulysin -S 5% Tai Black HWT 2% Dainix Black CCR 1% Tai Orange HWT 4% Hydrose 3% Caustic Soda 1% Setamol BL Hot Wash Dyeing Curve: A= Soda 90c B= Felosun NOF A,B&C x C= Gisapol 115 20 min 37

  38. 80c Drain 135c x 60 min Temp Gradient: upto 100c  1c/min upto 135c  2c/min Dye Drain 45c A,B&C 40c 10’ A=Setamol BL B= Palagal FA8 C= Eulysin -S A= Soda 90c B= Hydrose A,B&C x C= Setamol BL 20 min 80c Drain 7. 100% PET Fabric With Optical Brightening Agent – 2% Soda 0.5% Felosun NOF Hot Wash Acetic Acid Palagal FA8 38

  39. Eulysin -S 0.6% Ultraphone BN 45c x Dyeing Curve: 90c Acetic Acid 10 min A&B x 20 min Normal Drain 80c Drain Temp A= Soda B= Felosun NOF 135c x 35 min Temp Gradient: 4.5c/ min OBA 45c A&B Drain 40c 20’ A= Palagal FA8 B= Eulysin -S 8. 100% Viscose Fabric With Optical Brightening Agent – 1% Multisoap SR 2% soda 2% H2O2 Alvatex HOS Multisoap SR 0.25% Bittox.ox (BYB) 39

  40. Acetic Acid Dyeing Curve: 98 c x 10 min 98c A,B,C&D Multisoap SR x 10 min 80c Drain 80c Drain A= Soda C= Alvatex HOS B= H2O2 D= Multisoap SR 40c 98c x Acetic Acid 10 min OBA Normal Temp Drain 80c Drain 9. 100% Viscose Fabric in Deep Shade with Cold Brand Color– 2% Soda 0.5% Felosun NOF 0.5% Gisapol 115 Hot Wash Acetic Acid Mollan -130 Tabanol FTR 40

  41. Glouber Salt Soda 7% Kem Black GR 0.83% Kem Red 3BS 0.53% Kem Yellow FRL Multisoap SR Acetic Acid Alvatex 66-C Acetic Acid Dyeing Curve: 98c 45c A,B&C x 20 min Acetic Acid 80c Drain Normal Drain A= Soda B= Felosun NOF C= Gisapol 115 Temp A= Mollan 130 B= Tabanol FTR 30’ D 30’D 30’ D 65c x 60 min A&B Dye G.Salt Soda Ash 15’ 20’ 20’ 60c Drain 40c 98c Multisoap SR x Acetic Acid 5 min 41

  42. Normal 80c Drain Temp Drain Alvatex 66c 50c Acetic Acid x 15 min Drain 10. C.V.C Fabric Dyed in Deep Shade– Setamol BL Palagal FA8 Eulysin -S 1.1% Terasil G. Yellow W3R 0.25% Megaperse Red RNA Gisapol 115 Felosun NOF Remapon 173 Alvatex HOS Caustic Soda H2O2 Gisapol 115 Acetic Acid Common Salt Soda 42

  43. 2.0% Kem Orange 2RL 0.11% Kem Red 3BS 0.1% Kem Yellow FRL Multisoap SR Acetic Acid Alvatex 66 - C Acetic Acid Note- 1. For Deep shade the sequence is : PET Dyeing  Scouring  Cotton Dyeing 2. For Light Shade the sequence is : Scouring  PET Dyeing Cotton Dyeing Dyeing Curve: 135c x 60 min Temp Gradient: upto 100c  1c/min upto 135c  2c/min Dye Drain 45c A,B&C 40c 10’ A=Setamol BL B= Palagal FA8 C= Eulysin -S 105c x 30 min B A 80c 60c Drain 43

  44. A = 1) Gisapal 115 2) Remapon 173 3) Alvatex HOS 4) Caustic Soda B = Hydrogen Per Oxide 45c 98c Gisapal115 x Acetic Acid 5 min Normal 80c Drain Temp Drain 65c x 60 min 30’D 15’D 20’D Salt Dye Soda 10’ 10’ 20’ Drain 60c 40c 98c Multisoap SR x Acetic Acid 5 min Normal 80c Drain Temp Drain Alvatex 66c 50c Acetic Acid x 15 min Drain 44

  45. Finishing: Dewatering M/C Setting  Fabric type Fabric Over feed% speed(m/min) 80 Single jersey(Viscose) 30 Single jersey(cotton/lycra) 80 22 Single jersey(cotton) 80 10-11 1X1 Rib 80 11 Interlock 80 14-15 Terry 80 5-9 Gas Burnt Tensionless Dryer M/C Setting  Fabric type Fabric speed (m/min) 6.5 Temperature Over feed% Single jersey(cotton) 140 15 Single jersey(cotton/lycra) 6.5 140 15 1x1 Rib 6 140 15 Interlock 5 140 15 Terry 5 140 15 Compactor Setting  Fabric Type Fabric speed (m/min) 25 Steam pressure (psi) 60 Compacting pressure (psi) 70 Temp c Overfeed% Single jersey (cotton) 120-150 5-7 Single 20 50 60 120-150 6-7 jersey(cotton/lycra) Single jersey (viscose) 25 60 70 120-150 8 45

  46. 1x1 Rib 25 60 70 120-150 3-4 Interlock 25 60 70 120-150 3-4 Terry 25 60 65 120-150 8 Stenter Setting  FABRIC TYPE FABRIC SPEED (m/min) 30-40 TEMPERATURE (0C) OVER FEED% Single jersey (Cotton) 160 Upto 30 Rib/Interlock (cotton) 25-30 160 Upto 30 Single jersey (Viscose) 26 170 Upto 60 Mini-eyelet(Polyester) 20-25 185 Upto 4 Mesh (Polyester) 20-25 185 Upto 4 Daily Production Report: The daily production report is recorded in the logbook and it contains following information Machine No. Date Batch No. Order No. Fabric Type Color Quantity Loading Time Unloading Time Runtime Shift Remark Monthly Average Production: The monthly average production of dyeing unit of Landmark Textile Mills Ltd. is 250 tons. Remarks: The production process, followed by the Dye-house of Landmark Textile Mills Ltd. is impressive. The processes are being carried out very quickly and accurately. Due 46

  47. to the excellence of process, machineries and lab trials very few cases of re-dyeing is performed. CHAPTER – VI QUALITY ASSURANCE SYSTEM 47

  48. Quality Policy: It is the policy of Landmark Textile Mills Ltd. to produce quality dyed knit fabrics that meet the customer’s expectations & needs. To implement this policy the top management of Landmark Textile Mills Ltd. is committed to provide adequate resources in terms of good raw materials and trained personnel & continually improve / upgrade its processes and systems. The quality control policy of Landmark Textile Mills Ltd. is stated below-  Leadership program from the top.  In-process quality control during manufacturing operation.  Evaluation programs in all areas of knitting, dyeing, cutting, sewing and finishing.  Maintain chain of responsibility.  Follow strict stuffing, auditing and reporting.  Use inspection machines in required points.  Maintain standard AQL.  Sufficient lighting and sanitation.  Final inspection prior to packaging.  Meeting the appropriate expectations of clients. Quality Assurance Procedure: Landmark Textile Mills Ltd. assures the quality of their products in the following three steps: 1. In laboratory. 2. In dyeing section 3. In finishing section The quality assurance procedures are described below: In laboratory:    Swatch card from buyer according to their requirement is received. Recipe prediction for sample dyeing using CCMS. Sample dyeing until matching with the swatch card. Acceptable color difference is less than 1. If matching is OK, then it is sent to the buyer for approval.  In dyeing section:  After approval form the buyer, sample dyeing is done in dyeing m/c, in dyeing shed & again matched with the approved sample. If result is OK, then balk production is commenced.  48

  49. During dyeing process, before the final acid wash, samples are taken and checked for accurate shade matching. After dyeing sample is collected & matching is done. Rubbing and wash fastness tests are carried out.   In finishing section:   Correctly dyed, after treated & matched fabrics are allowed for finishing. By usinga series of finishing machines correct width, softness & appearance are maintained according to requirements. Then sampling is done several times to test GSM, Shrinkage & fastness properties. Finally fabric is inspected & prepared for delivery.   Inspection area:  Shade match of fabric  G.S.M.  Fabric diameter  Spirality  Shrinkage (%)  Length wise  Width wise  Wash fastness  Rubbing fastness  Faults  Dyeing faults  Knitting faults  Finishing faults Knitting Faults   Hole  Slub  Needle mark  Stripe  Missing yarn  Contamination Dyeing Faults   Uneven shade  Running shade  Fastness property  Dye spots and marks Finishing Faults  49

  50.  GSM variation  Spirality  Shrinkage control  Marks PROBLEMs ENCOUNTERED IN DYEING: Uneven Dyeing   1. It can be caused due to rapid addition of dyes and chemicals. For this purpose the dosing of soda ash should be maintained properly. 2. Pressure difference. 3. Over loading in the m/c. 4. Yarn lot mixing. 5. Improper control of temperature. 6. Less amount of leveling agent. 7. Improper pretreatment. Uneven Shade in Rope to Rope   1. Improper rope length in each chamber. 2. Improper fabric flow speed in each nozzle. Off Shade  1. Improper M: L ratio. 2. Lower amount of auxiliaries. 3. Improper mixing of dyestuffs. Dye Spots   This is most common fault caused by operator not correctly mixing and thoroughly dissolving dyestuffs in the right amount of water. Batch to Batch Shade Variation   If any of parameters of dyeing are changed then it will produce problems in batch to batch consistency. In order to avoid this defect the following steps should be followed- 1. Maintain the same liquor ratio. 2.Check that the fabric has the same dye affinity. 3. Use the same standard program procedures for each batch. 4. Making sure that the operators add the right bach of chemicals at the same time & temperature in the process. 5. Check the water supply daily especially ph, hardness & Na2CO3content. 50

More Related