Professional Documents
Culture Documents
On
Department of Textile Engineering
Prepared By:
MD. ALAMIN KHAN
ID-101-196-041
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ACKNOWLEDGEMENT
DAFFODIL INTERNATIONAL UNIVERSITY has given us the opportunity to perform
the industrial attachment with Aboni Textile Limited (A concern of Babylon Group).
We would like to convey our deep gratitude to our departmental head Prof. Dr. Md.
MahbubulHaque for his throughout support without whose help it would not have possible
to complete the training successfully.
We are grateful toMd. Azharul Islam for supervising us to accomplish the attachment. May
we also take the opportunity to express my sincerest gratitude toAboni Textile Limited (A
concern of Babylon Group)management, and administration & personnel for their kind cooperation.
Above all, we would like to acknowledge our deep debt to all teachers of our university
especially of Fabric Manufacturing Technology department for their kind inspiration and
help, which remain as the backdrop of all our efforts.
Finally, we would like to acknowledge that we remain responsible for the inadequacies and
errors, which may remain in the report undoubtedly.
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INTRODUCTION :
CHAPTER-1
INTRODUCTION
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CHAPTER-2
COMPAN
Y
PROFILE
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Inside view
Outside view
Company Profile
Serial
no.
Subjects
description
6 | Page
1.
Name
2.
Type
3.
Legal Form of
Company
4.
Year of In corporation
6.
Location
7.
Certification &
awards
2001
Hemayetpur, Savar,Dhaka, Bangladesh.
B.S.C.I
ISO 9001:2000
OKO-TEX
8.
Production capacity
9.
Working Period
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Company Details
Primary Information
Company Name :
624
Membership Type :
Ordinary Member
Year of Registration :
2002-03-13
Contact Information
Managing Director
Addresses :
Factory
Address :
PLOT-169-171,UNION-TETULZHORA
HAMAYETPUR,SAVAR
Telephone :
88-02-8023495-6, 8013449
Fax :88-02-7713502
Office Address :
2-3/1,DARUSSALAM
ROAD,MIRPUR,DHAKA
Telephone :88-02-7713652
Fax :88-02-8015128
Email :
badylon@babylon-bd.com
Web :www.babylongroup.com
Factory Information
Factory Category :
Number of Machine :
KNITTING : 68
DYEING : 14
Production Capacity :
300 TON/MONTH
ABONI TEXTILE LTD is a sister concern group of Babylon Ltd. With a vision to
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transform the group into a self sufficient 21st century conglomerate, Babylon has
diversified its products and services gradually and expanded to 18 strategic business
units (SBU). All the units are controlled from the headquarter based in Dhaka which
ensures integrated and smooth operation. It also enables Babylon to offer competitive
price to its customers.
(SBU)are :
Babylon Garments Ltd.
Babylon Dresses Ltd.
Suravee Garments Ltd.
Aboni Fashions Ltd.
Babylon Casual Wear Ltd.
Aboni Knitwear Ltd.
Aboni Textiles Ltd.
Juniper Embroideries Ltd.
Babylon Trims Ltd.
Babylon Washing Ltd.
Babylon Printers Ltd.
TRENDZ (Local Retailing)
Babylon Buying Services Ltd.
Babylon Medical Services
Babylon Outfit Ltd.
Babylon Logistics Ltd.
Babylon Products (Softy)
Babylon Agriscience Ltd.
BOARD OF DIRECTORS :
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In charge of FINANCE
In charge of EXPORT & EMBROIDERY
Different Department:
Knitting
Dyeing (Knit).
Finishing
Garments.
Washing
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Supporting Department:
Personnel department
Marketing and Merchandising
Utility
Human resource Department
Accounting and financing
France
Sweden
H&M
Spain
ZARA
Italy
TRR.
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le
Ltd
CHAPTER-3
AKH group
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CHAPTER-4
HUMAN RESOURCE MANAGEMENT
A. Recruitment Policy:
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B. Selection:
During the selection of the workers following factors are
considered:
Good physical appearance/fitness
Age 18 years minimum must be supported by certificate from educational
institution or local govt. authorities and confirmed by medical officer.
Educational qualification as per job profile.
Skill ness (practical for operators).
Wages/salary negotiation.
Joining date.
C. Joining:
Selected workers/trainees submit the followings to personal
department on joining:
Prescribed application form duly filled.
D. Service Confirmation:
On completion of 3 months satisfactory job performance, company confirms
the employees' service permanently.
Trainees who fail to show satisfactory performance within this time his/her
apprenticeship period are generally extended for another one month. If he/she
cannot cope-up within this given period then his/her service is terminated.
E. Daily Working Hours and Over Times:
Eight hours a day from 8.00 am to 5.00 pm with one hour lunch break.
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Maximum two hours overtime per day (maximum 12 hours per week) with
one-hour Tiffin break in the afternoon/evening.
Friday is weekly holiday.
F. Medical:
Medical facilities are as follows:
Surgical gauze.
Cotton.
Surgical scissors.
Tourniquet.
Adhesive tape (plasters).
Antibacterial ointment sterile
(Savlon cream).
OTHER FACILITIES:
A. Salary & Wages:
Salary and wages are paid to the staff and workers as per gazette notification of
the government of Bangladesh.
Payment of salary and wages are made regularly on 1st of each month.
In the salary sheet basic salary, house rent, medical allowance and gross salary
are shown separately for each employee.
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B. Overtime:
(1) Overtime is calculated on the basis of double the basic salary calculation of
over time per hour is.
Basic salary x 2 26 (days) x 8 (hours)
(2) Payment of overtime is made of 1st date of each month.
C. Bonus:
Two festival bonus equivalents to two month basic salary are paid to each
employee, Who has completed one year of service.
D. Leave:
(1) Casual: All employees enjoy 10 days casual leave in a year with full salary/wages.
(2) Sick Leave: All staff & workers are entitle 7 days sick leave upon submission of
medical certificate.
(3) Maternity Leave: Female employees are entitled to enjoy 12 weeks (6 weeks
before & 6 weeks after delivery) maternity leave with 100% salary/wages.
(4) Earn Leave: For adult worker, 1 day leave for 22 days of work (but they have to
work minimum 1 year for the entitlement).
(5) Festival Leave: 10 days per calendar year.
MANAGEMENT SYSTEM:
Buyer sample is send to G.M or merchandising manager.
Marching is done under lab manager.
Sample is prepared by asst. dyeing manager.
Sample is send to the buyer for approval.
Approved sample is returned and taken as STD. sample for
bulk production.
Dyeing manager gives responsibilities to asst. dyeing manager.
Then shift in-charge with the supervisors start bulk production.
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On line and off line quality check is done by lab in-charge and
asst. dyeing manager.
After dyeing asst. manager (finishing) controls the finishing
process with the supervision of shift in-charge.
Finally G.M checks the result with dyeing manager and decision
is taken for delivery.
SHIFTING:
In Aboni Textiles Ltd the whole day production time is divided into 3 shif
Per shift Consists of 12hours.
Shift
A
B
c
Duration
8.00 AM-2.00PM
2.00PM-10.00PM
10.00PM-8.00AM
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Shift In charge:
To follow the workers movement.
Should discuss with the production Officer about what is
happening.
To maintain the production sequence.
To check the sample at certain time interval.
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CHAPTER-5
PRODUCTION PLANNING & CONTROL
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CHAPTER-6
KNITTING SECTION
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Knitting:.
Knitting is the method of creating fabric by transforming
continuous strands of yarn into a series of interlocking loops,
each row of such loops hanging from the one immediately
preceding it. The basic element of a knit fabric structure is the
loop intermeshed with the loops adjacent to it on both sides &
above and below it.
Knitted fabrics are two types. One is weft & another is warp.
ATL produces weft knit fabrics.
Classification of knitting:
Knitting
warp knitting
weft knitting
Circular/tubular knitting
Flat
knitting
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Single jersey
Double
jersey
Example:
1. Lacose
2. pk
3. Fleece
Interlock
4. Tery fleece
Rib
Purl
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Machine Quantity
Knitting(Single 30
Circular 19
Knitting(Rib+Interlock) m/c
V-bed Knitting m/c
18
03
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Pai lung
42,36
84f
18g,28g
2376,3168
21
TAIWAN
Rib
Circular Knitting M/C:
Brand name
Cylinder dia
Feeders
Needles
Origin
m/c type
Gauge(NPI)
RPM
FUKAHAMA
38
76
2148T
JAPAN
Single jersey
18G
23
Brand name
Cylinder dia
Feeders
Gauge(NPI)
Needles
RPM
JIUNN LUNG
32,42,38,36
96F,84F,114F,
24G,18G,24G,24G
2400T,2484T,2880T,2212T
21,18
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07
08
Origin
m/c type
TAIWAN
Single jersey, Rib
Brand name
Cylinder dia
Feeders
Needles
Origin
m/c type
Gauge(NPI)
RPM
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Machine parts :
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NEEDLE
Needle is the primary knitting element. It is a thin metal bar.
SINKER
Sinker is the second primary knitting element. It is a thin metal
plate.
KNITTING CAM
Cam is the device which converts rotary machine drive into a
suitable reciprocation action for the needle.
Knitting cams (raising) are three types. These are:
i.
Knit cam
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ii.
iii.
Tuck cam
Miss cam
KNIT CAM:
TUCK CAM
MISS CAM
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CAM BOX:
OILING POINT:
AIR PIPE:
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Brand
Model
Gauge
Origin
Dia
KAUO HENG
KH-313
14
TAIWAN
54
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06
18
Design analysis
Setting the
machine for the
specific design
Production
Quality control
Send to batch
section
Plain
Rib
Interlock
Appearanc
e
Unroving
Different on
face & back
Either end
Curling
Tendency to
curl
No tendency to curl
Thickness
& warmth
Thicker &
warmer than
plain woven
made from
same yarn
Same on
both sides
Only from
end
knitted last
No
tendency
to curl
Very much
thicker &
warmer
than plain
Structure
Properties
End-uses
Ladies
stockings, fine
cardigans,
dresses, base
fabric for
coating
Socks, cuffs,
waistbands, collars,
Underwear,
knitwear.
Underwear
, shirts,
Suits,
sportswear
,
Dresses.
Single Jersey
Pique
Interlock
Rib
Lacoste
Count
20S ,24S, 26S, 28S, 30S, 32S,
34S, 36S ,40S
Polyester
70D, 100D,150D
Spandex yarn
20D,40D, 70D
PC (65%Polyester & 35% 24S, 26S, 28S, 30S
cotton)
CVC(60% Polyester & 40% 24S, 26S, 28S, 30S
Cotton)
Count
GSM depends on yarn count
Gauge
If gauge decrease then stitch length increase.
Feeder
Production increase with increase of number of feeder.
Design
Cam setting
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Set of needle
Size of loop shape.
Size Of Defects
3 inches or less
Over 3 inch but not over 6 inch
Over 6 inch but not over 9 inch
Over 9 inch
Causes
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Star mark
Hole
Set-up
Needle mark
Barrie
Oil mark
Drop stitches
Yarn breakage.
Needles hook breakage.
Needle latch breakage.
Dirt in needle slot.
Needle line.
Improper cam setting.
Bad yarn.
Needle to loose or tight in trick.
Count variation in same lot.
Lot mistake.
Low tensioned yarn.
Old produced yarn.
Faulty yarn.
Excess oil or grease use in
the machine.
Poor quality lubricant.
Mixing of lubricant.
Leakage in oiling system.
Faulty needle.
Wrong setting of yarn feeder.
Improper yarn feeding.
Unlocking the wheel lock.
Raising the wheel to upper collection.
free
Slubs
Packy
Thicked yarn.
Black spot
Loop
Yarn contra
Lycra drop
Lycra out
Breakage of yarn.
Dusted yarn.
GSM variation
Count variation
Design variation
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Batching :
Batching is the process to get ready the fabrics for wet
processing like scouring, bleaching, dyeing, finishing, washing,
heat setting etc.
Where the greige fabric are visually Inspected & divided into
different batches. It is a part of dyeing process & it is done to
feed the dyeing machines for fabric dyeing.
The main function of batching section is to prepare the batch
for dyeing according to machine capacity, order and
emergency. This section receive the grey fabric from knitting
section and make batch according to order for particular shade.
Then this batch delivers to dyeing section for dyeing.
Objects of Batching:
To use maximum capacity of existing dyeing m/c.
To minimize the washing time or preparation time & m/c
stoppage time.
To keep the no. of batch as less as possible for same
shade.
To use a particular m/c for dyeing same shade.
Batch calculation:
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Batch=
quantity
Example:
Let, machine capacity 500Kg
Given Dia
Quantity
45
866
49
4688
51
2545
Calculation:
Total quantity = 866+4688+2545
=8099
No. of batch
= 8099500=17
For 45 Dia,
500
8099 866 = 54Kg
For 49 Dia,
500
8099 4688 = 290Kg
For 51 Dia,
500
8099 2545 = 158Kg
Operation Procedure:
1. Check production plan to set the priority
2. Select 7-8 batches/shift to prepare
3. Consult with previous shift stuff to get the required
information about the batches
4. Check batch card & job card specification(e.g.-Yarn
type, quality, weight etc) for fabric & collars/cuffs
respectively
5. Calculate number of batches, nozzles & rolls to be
prepared for each order & specify on the batch & job
card. One should be very careful while calculating &
entering such data on these cards.
6. Start batching operation & check the following
information7. Machine no
8. Number of nozzle to be prepared
9. Order no.
10.
Customer number
11.
GSM
12.
Width
13.
Lot no.
14.
Turning required or not
15.
Special instruction(if any)
16.Prepare the body fabric of specified weight. This
weight must be accurate & each nozzle of same batch
must weight equal to ensure even dyeing.
17.Calculate the number of collar/cuffs & attach the
collars& cuffs with the body fabric
18.Write down the weight of each roll on the back of
batch card
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Lab dip:
A lab dip is a swatch of fabric test dyed to hit a color standard.
Several lab dips may be submitted for feedback until the
standard is achieved and the lab dip is approved. Lab dips are
reviewed in a "light box".
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Lab dips are done to provide a visual aid on how a color will
look when it is dyed. Actual production sample will vary from
the lab dip that is provided.
It is not possible to lab dip enough fabric for a sample cap or
garment. When the goods are dyed in a real production run, the
conditions are dramatically different from the laboratory.
Production will not begin on fabric unless a lab dip is approved
or the customer waives the lab dip process. Once a lab dip is
approved, we will dye only to the lab dip approved.
OBJECTS OF LABDIP
To know about the shade % of fabric for sample dyeing.
To calculate revise recipe for sample dyeing.
To compare dyed sample with swatch by light box
spectroflash.
Finally approved lab dip(Grade: A B C)
Digital/Manual Pipatting
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Unload
Normal wash
Acid wash
Hot wash
Cold rinsing
Drying
03
04
05
06
07
08
M/C NAME
Manual twist
tester
Motorised crock
meter
TYPE
Yarn twist
testing
Rubbing
fastness
testing
Digital pilling
Pilling
tester
testing
Incubator
Colorfastne
ss to water
Indesit drayer
Tumble
dryer
Electrolux dryer dryer
Washcator
washing
Electrolux
Dimension
Washcator
al stability
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09
10
11
12
13
14
15
16
17
Electrolux
washing m/c
AHIBA top
speed 2
AHIBA nuance
washing
Sample
dyeing
Sample
dyeing
Rapid Eco dryer dryer
Spectrophotom Recipe
eter
making
Digital Ph
Ph & temp
meter
measuring
Digital pipette
Automatica
lly
pipetting
Vervide cac-60 Color
matching
cabinet
Manual wrap
Count
reel m/c
measurem
ent
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( Recipe % Liquor)
Salt
(gram
per liter).
1000
(cc).
(1000Stock solution %)
56 | P a g e
Spectrophotometric measurement:
Color fastness is usually assessed separately with respect to:
It is an alternative to the visual method of assessment by
Grey Scale. The color of the specimen which has been
subjected to the color fastness test and the color of an
original specimen are measured instrumentally by
spectrophotometric measurement.
The CIE LAB coordinates for lightness L*, chroma C* and
hue H* for both specimens are measured.
The total color difference value AE* which is the function
of AL *, AC*, AH * are calculated and converted to a Grey,
Scale by means of a series of equations or by the following
table
Functions of spectrophotometer:
Color difference
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Metamerism
Pass/fail operation
Fastness rating
Shade library
Cost comparison
Color match production
Reflectance curve.
Water dosing
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Dry sample
Hot wash
Soaping
Neutralization
Cold wash
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Drying
Yes
Bulk production
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Page 62
CAPACITY CHART:
MACHINE NUMBER
TOTAL CAPACIY
Page 63
HT-3
HT-2
HT-1
HT-4
DM-3
DM-4A
540KG
360KG
180KG
450KG
600KG
600KG
DM-4B
DM-4C
HT-5
DM-6
KOREAN
HT-B(sample dyeing machine)
600KG
600KG
750KG
900KG
150KG
50KG
25KG
25KG
15KG
30KG
Machine Quantity:
MACHINE TYPE
SCLAVOS
DILMENLER
KOREAN
LONGCASE
QUANTITY
04
07
01
01
SCLAVOS
03
540Kg
Page 64
2.8
140
Twin soft flow system
2005
Athence Greece
DILMENLER
06
900Kg
.5
98
Winch dyeing
2005
Turkey
BENEKS
02
25Kg
1.5
135
Winch dyeing
2010
Turkey
Page 65
Scouring:
Gray fabrics contain fats, waxes, and other impurities. The
absorbency of the fabric is adversely affected due the presence
of these impurities .this leads to improper dyeing, printing and
finishing in the subsequent process. These impurities are
removed from the fabric by a chemical treatment. This
chemical treatment is called scouring process.
Bleaching:
Bleaching is the process for removing natural nitrogenous coloring
matter, i.e. dust ,husk, broken seeds, protein, leaf , etc from the
fabric and make it white by oxidizing or chemical treatment .
Washing:
Page 66
Batch Weight*1000
Dia (Inch)*0.254*G.S.M*No Of Nozzle*Cycle
Time
Cycle Time=
Batch Weight*1000
Dia (Inch)*0.254*G.S.M*No Of Nozzle* Reel
Speed
Effect of Cycle Time:
When Cycle Time Increase Then increase Uneven Shade,
Running Mark
When Cycle Time decrease Then Color pick up low
Pretreatment
Page 67
II.
III.
IV.
V.
Enzyme
Dyeing
Washing
Softening
Fixing
07
08
09
10
11
12
13
14
15
16
17
Chemical Name
Brand Name
Detergent
Sequestering agent
Stabilizer
Anti-creasing agent
Caustic Soda
Bleaching
agent/Oxidizing
agent
Peroxide Killer
AceticAcid/Neutraliza
tion
Enzyme
Leveling agent
Glauber Salt
Soda Ash
Soaping/Washing
Agent
Softener
Fixing Agent
OBA
Reducing Agent
DFW,RWD
1090
SIF
CA
NaOH
H2O2 50%
VHK
CH3COOH,Green-acetic acid
Mataenzyme-E
DLR
Na2SO4
Na2CO3
DSP
NISB,OFS,CSIL,SCH
Optifix-EC, GG-100
G.CO3
Hydrose powder BASF
Dyes Brand
Matex
Remazol
Novacron
Page 68
Ciba
Chemical used:
Detergent-1.5gm/l
Oil spot remover-0.75 gm/l
Sequestering agent-1.0 gm/l
Anti crease-1.0 gm/l
Anti foam-0.2 gm/l
Causting-3.0 gm/l
Sif-0.6 gm/l
H2o2-6.0 gm/l
PROCESS:
Detergent, oil spot remover, sequestering agent, anti crease,
anti foam apply into the machine.
causting
d/t: 10min
Temp: 60c, steam up 70c
Aboni Textiles Limited (A concern of Babylon Group)
Page 69
h2o2
D/t: 10 min
Temp: 98c
Total r/t: 60 min.
after this time cooling the machine 70 and cut a sample for
check the scouring rate.
D/t: 10min
Temp: 80-90ccooling 70c
3. COLD WASH
D/t: 10min
Temp: 70c
DRAIN THE WATER AND TAKE NEW WATER
4. NEUTRALIZTION PROCESS:
Page 70
CHEMICAL USED:
o H2o2 killer (vhk)-0.6 gm/l
o acide (as)-0.5 gm/l
o detergent (dfw)-0.2 gm/l
PROCESS:
mixing the entire chemical in the blanket then dossing the
chemical into the machine.
D/t:2-3 min
R/t: 10 min
Temperature: 60c
*ph must be check.
5. COLD WASH
D/T: 10MIN
TEMP: 70C
6. ENGYME:
Page 71
7. COLD WASH
D/t: 10min
Temp: 70c
DRAIN THE WATER AND TAKE NEW WATER
8. DYEING PROCESS:
o
o
o
o
D/t:2-3 min
R/t: 10 min
Temperature:
Page 72
Dyes:---------------------Deep shade:
D/t: 20min
R/t: 10 min
Temperature: 40c (deep shade)
Light shade:
D/t: 30 min
R/t: 20 min
Temperature: 60c (light shade)
Soda:
D/t: 40min
Aboni Textiles Limited (A concern of Babylon Group)
Page 73
R/t: 20min
Temp: 40
Again sample check.if ok.
9 .COLD WASH:
APPLY NORMAL WSAH TO THE FABRIC.
TEMP: 70C
R/T: 10 MIN (LIGHT)
20 MIN (DEEP)
10. NEUTRALIZATION:
DETERGENT (DFW)-0.5 gm/L
ACIDE (AS)-1.0 gm/L
PROCESS: MIXING THE ENTIRE CHEMICAL IN THE BLANKET
THEN DOSSING THE CHEMICAL INTO THE MACHINE.
D/T:2-3 MIN
R/T:20 MIN
TEMPERATURE: 50C
Page 74
11. SOAPING:
SOAP (DSP)-0.5 gm/L
CLEAR-0.3 gm/L
CSC-0.5 gm/L
12. SOFTENER:
SOFTENER-0.5 gm/L
SEQUESTERING AGENT (1090)-0.10 gm/L
ACIDE-(CN)-0.10 gm/L
Page 75
White COB-0.23%
Sky BVB-0.161%
Page 76
PROCESS: Take required amount of water in the m/c and run the
machine 10 min .finally drain the water and take new water in the
machine.
1. NUTRALIZATION PROCESS:
Acid (As)-0.3%
Sequestering agent (FE+)-0.5 gm/L
6. ENZYME WASH:
ENZYME (Bio-f)-1.0gm/L
TEMPERATURE & TIME: 55C&40min
Page 77
Process: mixing the entire chemical in the blanket then dossing the
chemical into the machine.
D/t: 2-3 min
R/t: 10 min
temperature: 80c
Page 78
Test the scouring by absorbancy test.if ok thenProcess: mixing the entire chemical (rwd, osr, ca, fe, mx) in the
blanket then dossing the chemical into the machine.
D/t: 2-3 min
R/t: 5 min
Temperature: 50c
Caustic:
D/t: 10
R/t: 5
Temp: 60c
H2o2& sif:
Take cold water 100l and mixing the chemical.
D/t: 5 min
R/t: 10min
Aboni Textiles Limited (A concern of Babylon Group)
Page 79
Temp: 70c
Final temperature: 100c
R/t: 60 min
Then cooling the temp and cut the sample.
Page 80
r/t: 5-10
Process: mixing the entire chemical in the blanket then dossing the
chemical into the machine.
D/t: 2-3 min
R/t: 10 min
Temperature: 60c
*ph must be check
As-0.1
Engyme (ds)-0.5
Aboni Textiles Limited (A concern of Babylon Group)
Page 81
Dfw-0.3
Apply normal hot to the fabric with sequestering agent. (0.5 gm/l).
Temp: 70c
R/t: 10
Ph-4.5 & hardness check
Page 82
Process: mixing the entire chemical in the blanket then dossing the
chemical into the machine.
D/t: 2-3 min
R/t: 10 min
Temperature: 40c
Page 83
Soda-20 gm/l
Process: glubal salt apply to the m/c in 3 times equaly.each timeD/t: 10min
R/t: 30 min, temp-90c
Then salt sample check.if ok then
Cooling..60c
Soda:
D/t: 40min
R/t: 20min
Temp: 80(steam up 60 to 80c)
Again sample check.if ok
Page 84
R/t: 5-10
Neutralization:
Detergent (dfw)-0.3
Acide (as)-0.4
Process: mixing the entire chemical in the blanket then dossing the
chemical into the machine.
D/t: 2-3 min
R/t: 20 min
temperature: 50c
Soaping:
Soap (dsp)-0.5
Aboni Textiles Limited (A concern of Babylon Group)
Page 85
Clear-0.3
Csc-0.5(only for turquise)
Process: mixing the entire chemical in the blanket then dossing the
chemical into the machine.
D/t: 2-3 min
R/t: 15 min
Temperature: 50c
Softener-0.5
Sequestering agent (1090)-0.10
Acide-(cn)-0.10
Process: mixing the entire chemical in the blanket then dossing the
chemical into the machine.
D/t: 2-3 min
R/t: 15 min
Temperature: 50c
UNLOAD
Page 86
1. Loading :
3. NORMAL HOT:
Sequestering agent (FE+)-0.5 gm/L
TEMPERATURE & TIME: 90C&10min
Page 87
PROCESS: Take required amount of water in the m/c and run the
machine 10 min .finally drain the water and take new water in
the machine.
4. ENZYME WASH:
ENZYME (Bio-f)-1.0gm/L
TEMPERATURE & TIME: 55C&40min
5. COLD WASH:
TEMP: normal
R/T: 5(2 times)
DCP-2.0 gm/L
Sequestering agent (1090)-0.5 gm/L
ACID (As)-0.3 gm/L
BD-1.5 gm/L
DYES: --------------%
Page 88
PROCESS:
Leveling chemical dosing at 40c
Color dosing at 60c, D/T: 20min
R/T: 5, pH-4.0
Temperature up 60-100 at 2c/min
Temperature up 100-130 at 1c/min
Temperature down130-100 at 1c/min
Temperature down 100-60 at 2c/min
After that we need to check the sample .if ok then we move to
next step.
7. REDUCTION CLEARING:
DETERGENT (RWD)-2.0gm/L
CAUSTIC-3.0gm/L
HYDROSE-1.0 gm/L
PROCESS: this process is done for the removing extra dyes
which are staying the surface of the fabric specially cotton part.
8. NORMAL HOT:
Temp: 80c
R/t: 10
9. NUTRALIZATION PROCESS:
Acid (As)-0.3%
Sequestering agent (FE+)-0.5 gm/L
Temperature & time: cold&10min
Page 89
D/t:2-3 min
R/t: 10 min
Temperature: 60c (light shade)
40c (deep shade)
Dyes: ---------------------Deep shade:
D/t: 20min
R/t: 10 min
Temperature: 40c (deep shade)
Aboni Textiles Limited (A concern of Babylon Group)
Page 90
Light shade:
D/t: 30 min
R/t: 20 min
Temperature: 60c (light shade)
Soda:
D/t: 40min
R/t: 20min
Temp: 40
Again sample check.if ok
12 .cold wash:
Apply normal wsah to the fabric.
Aboni Textiles Limited (A concern of Babylon Group)
Page 91
Temp: 70c
R/t: 10 min (light)
20 min (deep)
13. Neutralization:
Detergent (dfw)-0.5 gm/l
Acide (as)-1.0 gm/l
Process: mixing the entire chemical in the blanket then dossing
the chemical into the machine.
D/t:2-3 min
R/t:20 min
Temperature: 50c
14. Soaping:
soap (dsp)-0.5 gm/l
clear-0.3 gm/l
csc-0.5 gm/l
Process: mixing the entire chemical in the blanket then dossing
the chemical into the machine.
D/t: 2-3 min
R/t: 15 min
Temperature: 50c
15. Softener:
o softener-0.5 gm/l
o sequestering agent (1090)-0.10 gm/l
o acide-(cn)-0.10 gm/l
Page 92
UNLOAD
DYEING PARAMETERS:
Initial Bath pH
6.5~7.0.
Before Enzyme, bath pH
4.5~4.7.
After Enzyme pH
5.5~6.0.
Scouring & Bleaching, bath pH
10.0~10.5.
After Scouring & Bleaching, pH
8.5~9.0.
After Adding Dyes, pH
6.2~6.35.
After Addition of Salt, pH
7.5~8.0.
After Addition of Soda, pH
10.5~11.0.
Before Softener, bath pH
7.2~7.8.
Page 93
Scouring, bath pH
10.0~11.5.
After Scouring, bath pH
8.5~9.0.
After Addition of Colors, bath pH
4.2~4.3.
During Reduction Clearing, bath pH
10.5~11.5.
Before Softener, bath pH
6.3~6.8.
1. Crease mark:
Causes:
Remedies:
Aboni Textiles Limited (A concern of Babylon Group)
Page 94
Page 95
Remedies:
Use standard dyes and chemicals.
Proper m/c speed.
Use of soft water
6. Dye spot:
Causes:
Improper Dissolving of dye particle in bath.
Improper Dissolving of caustic soda particle in bath.
Aboni Textiles Limited (A concern of Babylon Group)
Page 96
Remedies:
steel
7. Wrinkle mark:
Causes:
Poor opening of the fabric rope
Shock cooling of synthetic material
High temperature entanglement of the fabric
Remedies:
Page 97
Page 98
FINISHING SECTION:
Finishing is the general term for a multitude of processes and
treatments which a fabric may undergo after it has been made
(woven or knitted) and coloured (dyed or printed). It is the final
processing of the cloth and its purpose is to make the fabric
suitable for its intended end use.
Finishing
is the final
processing before the fabric is cut into apparel or made into
any articles of textiles.
In order to impart the required functional properties to the fiber
or fabric, it is customary to subject the material to different
types of physical and chemical treatments. For example, wash
and wear finish for a cotton fabric is necessary to make it
crease-free or wrinkle-free. In a similar way, mercerising,
singeing, flame retardant, water repellent, waterproof, antistatic and peach finishing achieve various fabric properties
desired by consumers.
The use of 100% synthetic textiles has increased considerably
since the development of textured yarns made of filaments,
and the growing production of knit goods. The use of open
weave has enabled production of lighter, breathable, fabrics to
ensure better wearing comfort.
Object of finishing:
Finishing is done to improve following things:Aboni Textiles Limited (A concern of Babylon Group)
Page 99
Page 100
Open fabric
Tube fabric
Dewatering machine
Dyed fabric
Stentering
Open
Compacting m/c
Drying Machine
Tube compacting machine
Final inspection
Page 101
Machine name
Brand
Origin
De-Watering
No. of
machine
01
0
1
0
2
0
3
0
4
0
5
0
6
Santex
Switzerlan
d
Slitting
01
Corino
Italy
stenter
01
Unitech
Italy
open compector
01
Lafar
Italy
tube compector
01
Santex
Switzerlan
d
dryer
02
- Santex
- Unitech
bag-sewing
01
local
Switzerlan
d
-Italy
Local
0
7
0
8
hydroextractor
01
Dilmenler
Turkey
Page 102
De-watering machine:
After dyeing process from the dyeing machine then the fabrics arc ready for dc-watering.
This is the process to remove the water from the fabric partially by squeezing. This is the
main function of the squeezing machine. But here also control the some important factor of
the fabric quality.
M/C Specification:
Brand Name
Company
Model
Origin
Electr. Voltage
working Speed
Year of Manufacture
Overfeed Range
Santex
Santex ag
Sth
Switzerland
400 v
40~ 60 m/min
2004
-5% to +10%
M/C Parts:
1)
2)
3)
4)
5)
Spreader
Hand wheel
Water tank
Over feed
Turn tube
spreader
6) Densing roller
Page 103
7) Air pressure
Open the tube fabric to remove the crease mark.
8) Padding roller
2 Set
a)
Front roller - After squeezer water contain 20%
b)
Back roller - After squeezer water contain 30%
9)security shield
Automatic system to ensure the
security of padder.
Padding roller pressure capacity-6bar
Maximum apply-4bar.
Normally applied-2 bar
Controlling point:
1. Speed: As much as possible (40-60 m/min). Higher the
GSM lower the speed.
2. Over feed: As required. Higher the GSM higher the over
feed.
3. Padder pressure: 2-2.5 bar as required. Higher the GSM
lower the padder pressure.
4. Width: Fabric width is adjusted as per required width.
SLITTING MACHINE:
Slitting machine is used for removing excess water from tube
fabric or open fabric .That is applied by cutting the tubular
fabric into open wide fabric.
Machine name
brand
Year
Model
Slitting machine
Corino
2004
177/04
Page 104
Maximum pressure
Maximum working speed
8 bar
80-85 m/min
M/C Parts:
Twist detector- detect the twist of fabric which is in rope
form.
Cutting knife/device - cutting the fabric according to
specific needle mark.
Ring use to help the cutting process.
Sensor Identify the specific wales line .makes sense for
it.
Guide roller after slitting ,plaiting of the fabric to
plaiting .
Plaiting - open fabric is make plait by plaiting.
Padder- to remove the required exact water.
Controlling point:
Maintain fabric expanding shape to keep minimum dia of (1*1)Rib,
(2*1)Rib,(2*2)Rib fabric, otherwise after slitting fabric dia increased.
Speed -The speed should be optimum (30-80 m/min).More
speed,less remove of water.
Pressure: The padder pressure should be according to
requirement. Although ATL normally used 2 to 2.5 bar at
front padder.
Hairiness remove Remove hairiness of fabric otherwise it
may causes uneven padder pressure.
DRYER:
Drying is defined as a process where the liquid portion is
evaporated from the fabric. After de-watering then the fabric
through the dryer.
Page 105
Santex AG
Santex AG
2001
Switzerland
Santashrink 2K/240, IRGF1
,GAS
CH-9555, Tobel
30 m/min
3 m/min
1850C
02
0% to -25%
02
Specification of UNITECH :
Brand Name
Company
Year of Manufacture
Origin
Type
Model
No. of Chamber
Burner
UNITECH dryer
UNITECH co Ltd
2005
Italy
DF-3K-260
Gold evo 3
03
03
M/C Parts:
Conveyor net
Chamber
Aboni Textiles Limited (A concern of Babylon Group)
Page 106
Burner
Exhaust air fan
Over feed roller
Filter net
Fan
Nozzle
Color
Temp()
01
02
Black
Average
color
White
polyester
03
04
150
140
Vibratio
n
400
400
Speed(m/m
in)
25-30
20-25
Overfeed(
%)
20-25
20-25
120
110-120
400
400
20-25
25-30
20-25
Color/GSM
White
Average color
Black
220
180
Temp()
140
160
170
150
160
Speed(m/min)
5.5
6.6-7
8-9
5.5-6
7-8
Color
Scouring
White
Pale/light
Deep/dark shade
Temp()
160
140
150
160
Overfeed(%)
20
20
20
20
Page 107
Stenter machine:
A machine or apparatus for stretching or stentering fabrics. The
purpose of the stenter machine is to bringing the length and
width to pre determine dimensions and also for heat setting
and it is used for applying finishing chemicals and also shade
variation is adjusted. The main function of the stenter is to
stretch the fabric width wise and to recover the uniform width.
M
c
s
a
o
t
h
r
e
ln
i
o
n
t
o
e
r
Functions
of Stenter
Machines:
Heat
setting is done by the stenter for lycra fabric, synthetic
and blended fabric.
Page 108
UNITECH
A5040158
Italy
2004
(7-150)m/min
(70-210)
06
(114-250)cm
3 bar
06
MATLo
Gas,Air,Electricity
M/C Parts:
Padders
Weft straighter(mATLo)
Burners
Aboni Textiles Limited (A concern of Babylon Group)
Page 109
Heat recovery
Attraction rollers
Circulating fans.
Clips
Pins
I.R
Nozzle
Chain arrangement
Blower
Exhaust air fan
Over feed roller
3.0 bar
2.5 bar
3.5 bar
GSM
Dia
Temp
Single
jersey
115150
2+ 110140
Over
Feed
4045%
2 3035
11001300
Page 110
Single
jersey
160220
2+ 120170
4045%
Lycra
Single
jersey
160200
4+ 130160
50%
Lycra
Single
jersey
200250
4+ 140160
50%
Pique
160200
3+ 130160
4045%
Lycra
Pique
190220
4+ 130160
50%
Fleece/Ter
ry
260300
4+ 140170
4045%
1x1 Rib
160220
2+ 130160
45%
190220
2+ 140160
45%
190220
3+ 130160
50%
2x2 Rib
Interlock
2.5
bar
2530
12001400
bar
2 2530
12001400
bar
2 2428
12001400
2530
12001400
bar
2 2025
12001400
bar
2 2025
13001400
bar
2 2428
13001400
bar
2 2025
12001400
bar
2 2025
12001400
1.52bar
COMPACTOR MACHINE:
Compactor is a textile finishing machine which is designed
specially for compacting 100% cotton knitted fabric like jersey,
pique, interlock, plush, rib and sinker etc. as well as cotton
blended fabric in rope form, changing the loft and dimensional
stability of the fabric and presenting it to plaited form. Fitted
with two felt compacting units which makes it to obtain top
quality fabric, with minimized shrinking nature and a soft fluffy
hand.
Aboni Textiles Limited (A concern of Babylon Group)
Page 111
GSM control
Control shrinkage
Twisting control
Increase smoothness of fabric
Heat setting is done of fabric
Shade match control.
Santex ag
year
2001
Manufacturing
country
Italy
Speed range
25-45 m/min
Temperature
110-150
Used utilities
model
STS(Santaspread)
Page 112
Maximum width
50
Minimum width
17
Applied for
Tube fabric
Brand name
Lafer
year
2004
Manufacturing
country
Italy
Speed range
8-45 m/min
Temperature
20-150
Used utilities
model
SPA
(50-100)m/min
Applied for
open fabric
M/C Parts:
Page 113
Teflon covers.
Tension roller
Sensor roller
Temperature roller
Cold roller
S/
L
0
1
0
2
0
3
Color
Temp()
Speed
35
Overfe
ed (%)
100
Finish
dia
70.5-71
Compacti
on (%)
5
Black
140-150
Average 140-150
color
White
140-150
35
100
70.5-71
35
100
70.5-71
S/
L
0
1
0
2
0
3
Fabric style
Overfeed(%)
Compaction(%)
S/j
12
6-7
(1*1)Rib
12
5-6
Single/double
lacoste
20-22
8-10
Page 114
Page 115
Quality Control:
Quality control is concerned with the evaluation of test data
and its application to control of the textile process, raw
materials, intermediate products and final products.
It is concerned not only with quality level and cost of
maintaining this quality level but also concerned with the
presentation of tangible values to measure quality and changes
in quality. In order to control quality one must know about the
consumers expectations.
Page 116
The every roll with every meter check (as per four (04) point
system)
Make a report.
List of Equipments:
1. Computer
Aboni Textiles Limited (A concern of Babylon Group)
Page 117
2.
3.
4.
5.
6.
7.
8.
9.
Light box
Electric Heater
Sample Dyeing M/C
Electrical Balance
PH meter
G S M Cutter
Washing M/ C
Shrinkage & spirality measurement instrument
Quality control
Page 118
On Line Test
Physical Tests
Chemical
Tests
On Line Test:
Fabric GSM control
Grey Fabric Inspection with 4 point system
Diameter and Width control
Shade Check;
Bias and Bowing;
Visual appearance (Enzyme performance);
Stripe.
Off Line Test:
Off line quality are divided into two groupsPhysical Tests and Chemical Tests.
Color
Color
Color
Color
Color
Color
Color
Color
Color
fastness
fastness
fastness
fastness
fastness
fastness
fastness
fastness
fastness
to
to
to
to
to
to
to
to
to
washing
rubbing/crocking
perspiration
water
sea water
light
saliva
saliva & perspiration
phenolic yellowing
Page 119
Page 120
YARN TEST:
1. twist
2. Yarn appearance
3. Yarn count
4. Tensile strength
5. Tensile strength
OTHER TEST:
1. General appearance
Yarn receiving
Sample Knitting
Batching
Dyeing (Check shade & Faults)
Dewatering
Page 121
Final inspection
Quality assurance:
Quality assurance is defined as all those possible planned and
systematic actions necessary to provide adequate confidence
than a product or service will satisfy given requirements for
quality. The Quality Assurance Department is assigned to
maintain consistently uniform quality of the material in process
and various stages of its manufacturing.
In laboratory
In dyeing section
Page 122
List of equipments:
Electronics Balance
Iron
Lab. Dyeing Machine
Rota Wash
Crock Meter
Spectro-photometer with software (Data Color)
Page 123
PH meter
Fabric Inspection:
The inspection of fabric is a procedure by which the defects of
fabric are identified and fabric is classified according to degree
or intensity of defects. The fabric inspection is done for both
gray and finished fabric.
Uneven shade
Oil spot
Neps
Crease mark
Machine Stoppage mark
Listing
Line mark
Pick missing
Double yarn
Dead cotton
Page 124
Bowing
Fly yarn contamination
Some test procedure are given below
G S M Test:
GSM is the most important factor. There is a G S M Cutter. The
Sample is cut then weighted in the electronic balance. The
reading is then (in gm) from the balance, multiplied by 100, to
get Value of G S M.
Page 125
Chemical:
ECE Detergent
4gm/l
Sodium per-borate
1gm/l
Time
30 mine
Temperature
60C
Steel balls
25
Solution of chemical
150 ml (From 1 litter ECE or
Sodium per-borate)
Required materials:
Sample size 40 x 10 cm
Multi-fiber at 40 x 10 cm
ECE detergent (WOB)-4g/L
Sodium Per-borate (Na2BO3.H2O2-1g/L)-1g/L
Distilled water
Normal cold water
Required instrument:
Rota wash
Scissor
Stitch machine
Process:
Aboni Textiles Limited (A concern of Babylon Group)
Page 126
Staining
sample to multi-fiber
Purpose:
Light fastness is the test design to evaluate the laundering
fastness test of dyeing, Pigment which re to be made in
comparison of result obtained on many test pieces treated
under light.
Method: ISO
Apparatus:
1. Light fastness tester & blue scale
2. Scale
3. Scissor
Aboni Textiles Limited (A concern of Babylon Group)
Page 127
4. Hard paper
5. 4cm X 2cm
Process:
Standar
d
8
7
6
5
4
3
Rating
2
1
Not fast
Not fast
Fast
Fast
Average
Average
Average
Average
Result:
The test result of light fastness test is equivalent to the class of
standard 6.So we can say that the color fastness of dyed fabric
is aver
Shrinkage test:
M/C Name:
Washing m/c
Temperature
40 C
Time
(37-40) minutes
Water amount
20 litters
Page 128
Chemical:
ECE Detergent
requirement)
---------------------------------- 100
Before wash
= --------------------------------------- 100
Before wash
Page 129
Page 130
Maintenance:
Maintenance is a process by which equipment is looked after in
such a way that trouble free. Service and increased machine
life can be ensured and specific product quality required by the
customers is sustained. On time maintenance increase m/c
lifetime & ensures trouble free services. Maintenance of
machineries is very important for any type of industries and it
is must for a knit composite factory. All machines and machine
parts of knitting, dyeing and garments are maintained with
extreme care. Because production quality and quantity, both
depends on the maintenance with regularity.
Objective of Maintenance:
To keep the factory plants, equipments, machines. Tools in
an optimum working condition.
To ensure specified accuracy to product & time schedule of
delivery to customer.
To keep the machine down time to minimum thus to have
control over the production program.
To keep the production cycle within the stipulated range.
To modify the machine settings to meet the need for the
production.
Maintenance of Machinery:
Mainenance
Preventive Maintenance
Maintenance Maintenance
Maintenance
Preventive Maintenance
Preventive maintenance is a predetermined
routine actively to ensure on time inspection / checking of
facilities to uncover conditions that may lead to production break
downs or harmful description.
Routine Maintenance
Maintenance of different m/c is prepared by
expert engineer of maintenance department. Normally in case of
dyeing m/c maintenance after 30 days complete checking of
different important parts are done.
Mechanical
Electrical
1. Pliers
1. Voltmeter
2. Inside Calipers
2. Ammeter
3. Outside Calipers 3. Contact
4. Digital Millimeter
Cleaner
5. Heating Shoulder
6. Hammer
7. Pliles
8. Gauge
9. Vernier Calipers
Aboni Textiles Limited (A concern of Babylon Group)
Page 132
10.
Lather M/C
11.
Drill M/C
12.
Welding M/C
13.
Spanner Set
14.
Alen Key Set
15.
Steel Roll
16.
Measuring
Tape
17.
Crew Driver
18.
Cutting
oil
(WD-40)
Maintenance Procedure:
Normally preventive maintenance is done here.
maintenance procedure following points should be checked:
During
Machine:Squeezer Machine
Maintenance: Mechanical
Grease squeezer bearings.
Aboni Textiles Limited (A concern of Babylon Group)
Page 133
Machine:Compactor
Maintenance: Mechanical
Check, Grease if necessary
Nuts of width adjustment spindles for wear
Check all spindle bearings for free running
Free running of guide rollers, deflection rollers &
contact rollers
Pressure springs of chain tensioner
Perform visual inspection: Gear box oil level
Belts, pulleys
Machine: Stenter
Maintenance: Mechanical
Crease all bearing with stuburg NBU-12, energrease
1002
Complete cleaning of the machine
Check all belt and belt tension
Check all door sills
Check gear box of platting and its oil.
Check all pin bars & clean
Check chain and give oil if required .Clean exhaust
blower & duct
All chamber blowers check and clean
Chamber nozzle cleaning
Aboni Textiles Limited (A concern of Babylon Group)
Page 134
Machine: Boiler:
Maintenance: Mechanical
Remarks:
Maintenance of m/c is very essential to prolong the m/c
life and good maintenance is important consideration. In this
industry maintenance program is done by expert maintenance team.
So, very few times production is stopped due to m/c problem.
Page 135
Page 136
Electricity
Gas
Water
Compressed air
Steam
Electricity
It is impossible to continue the production without electricity. A
frequent supply of electricity is very much essential to ensure
smooth production. In ATL. the whole demanded electricity is
generated by Own Generator.
Page 137
ENVIRONMENTAL STANDARDS
All the solid waste and effluent generated by the factory are
treated and disposed off in an environmentally safe manner.
Our textile complex has its own water treatment facility or
Effluent Treatment Plant (ETP). The Environmental Protection
Agency (EPA) of Bangladesh certifies the compliance.
ATL commitment:
To continuously improve our waste management facilities.
Meet relative environmental safely standards.
Continual waste reduction, recycle and reuse.
Improve work environment and work safety.
ETP:
Page 138
1) Polyelectrolyte
2) Lime
2kg/1000L
(50-100) kg/1000L
3) FeSO4
50 kg/1000L
4) DAP +Urea
(8+2) kg/1000
Page 139
is
used
for
removing
color
of
waste
water.
4) Sodium Hypochlorite:
Function:
It is used to kill the harmful bacteria. It is used in the
biological oxidation tank.
6) FeSO4:
Function:
Used for coagulation and sludge separation from waste
water.
7) Lime:
Function:
To change the color of waste water.
8) Di-ammonium phosphate:
Function:
Using food of bacteria.
9) Urea:
Function:
Page 140
Page 141
Parameters
Discharge limits
BOD(20 C0.mg/L)
150 mg/L
COD(mg/L)
100 mg/L
TSS(mg/L)
2100 mg/L
TDS(mg/L)
10 mg/L
605-9
pH
Page 142
Parameters
Discharge limits
BOD(20 C0.mg/L)
150 mg/L
COD(mg/L)
100 mg/L
TSS(mg/L)
2100 mg/L
TDS(mg/L)
10 mg/L
605-9
pH
Remarks:
Page 143
CHAPTER-15
Page 144
Conclusion
Page 145
Reference:
To write this report I take some help from different source. To
developed this attachment I collect data from internet, different
journal, and book. Which photo I attach here thats I collect
from different web site.
Page 146