bkl 2009 new

BEXTEX

Project description

Name : BEXIMCO KNITTING LIMITED (Dyeing section)

Type : KNIT DYEING.

Year of establishment: 1996 Location : Beximco industrial park,

Chokroborty, (5 km north from DEPZ).

Address : Corporate Headquarter: 17, Dhanmondi, R/A, Road no. 2,Dhaka-1205

Operational Headquarter & Factory : Beximco Knitting Limited, Beximco industrial park, Sarabo, Kashimpur, Gazipur.

Sponsors : World Bank, Marubeni.

Fig: Location of BEXIMCO KNITTING LTD.

DEPZ

DEPZBipile

Nobinagar

Chakraborti

Beximco Industrial Park

Abdullahpur

Savar Ashulia

College of Textile

Technology

National Assembly

Mir

pur

Roa

d

Farmgate

J. U.

Asad gate

Mirpur

Gabtoli

Tongi

Uttara

New Air port

Old Air portPrime Minister’s House

Dha

ka M

ymen

sing

Roa

d

Mohakhali

Sat Rasta

Physical Infrastructure : - Single storied building (only dye warehouse is double storied )

- Concrete structure (about 30 ft high)

Different dept : A) Production oriented department - Production Planning and control

-Knitting - Batch preparation -Dyeing -Finishing

- Lab& Quality assurance - Dye warehouse

- Maintenance- Utilty- Finished warehouse

B) Supporting department- personnel administration- procurement- marketing- IT- HRD- finance & accounting.

Remark:- Available data on physical infrastructure was not available.- Production per day ranges from 8-12 tons.

Manpower management

Chief executive officer (CEO)

Head of manufacturing Chief operating officer

DGM (Production)

Maintenance Manager Knitting Manager Dyeing Manager Finishing Manager Q.C Manager

Asst. Manager Deputy Manager Shift officer Shift officer

Shift officer Shift officer

Electrical Incharge Mechanical Incharge

ORGANOGRAM OF MANPOWERORGANOGRAM OF MANPOWER

MACHINE DESCRIPTION

Introduction: BKL is an integrated computerized company. It has total 18 dyeing machines among of them 10 machines are fully computerized. The machines are centrally controlled by Beacon Controller.

Specification :

Dyeing machineries:

Machine No. : 1, 2, 3, 7, 8

Machine Name : Eco-soft

Company Name : Thies, Germany

No. of Nozzle : 4

Capacity : 500-600 kg.

Diff. Pressure : 500-600 m.bar.

Rope speed : 200-250 m/min.

fig: Thies machine

Machine No. : 5

Machine Name : Mini-soft


No. of Nozzle : 1

Capacity : 75 kg.



Machine No. : 6

Machine Name : Eco-soft


No. of Nozzle : 2

Capacity : 350 kg.



Machine No. : 9

Machine Name : Luft-roto


No. of Nozzle : 2




Machine No. : 10

Machine Name : Luft-roto


No. of Nozzle : 3




Machine No. : 11

Machine Name : Local

Company Name : Beximco, Bangladesh

Capacity : 70 kg.

Pressure : 500-600 m.bar.


Machine No. : 12






Machine No. : 13



Capacity : 5-10 kg.


Rope speed : 100-150m/min.

Machine No. : 14




No. of Nozzle : 1



Machine No. : 15



No. of Nozzle : 2



Machine No. : 16, 17



No. of Nozzle : 3

Machine No. : 18


Company Name : Beximco, Bangla

Capacity : 8-15 kg.


DESCRIPTION OF FINISHING M/C:

HYDRO EXTRACTOR M/C: Manufacturer : Nazar corporation (Pakistan)

Extraction % : 65% Maximum.

Speed : 1400 rpm.

.

DEWATERING M/C:

Manufacturer: CALATOR BORAS (SWEDEN)

Controlling Parameters:

Padder pressure : 4-7 barPick up % : 85%GSM : 20-35%Speed at m/c : 8.5 m/min-60 m/min

DRYER

Controlling parameters:

GSM : 15-35%

Shrinkage : 12-15%

EQUIPMENT USED:

Following equipment are used for relax drying process:

a) Ruckh relax dryer (Germany):* Gas burner heated.

* 4 chamber, 1 burner/ 2 chamber.

b) Santex Relax Dryer (USA):* Steam heated.

* 2 Chamber.

MACHINE SETUP:

a) M/C set up for Ruckh relax dryer:

M/C parameter Set-up value

Temperature setting 1000c- 1200c for white shade

1200c-1300c for light shade

1300c-1400c for Dark shade

1500c-1700c for curing

Blower fan setting Auto

Exhaust fan setting Auto

M/C Speed 3-35 m/min. Depends on quality of fabric.

Over feed 0-40% depends on fabric construction.

Width of expreader setting 45-114 cm: Depends on the required width of

fabric.

Burner Gas pressure 10-15 m bar.

b) M/C set up for Santex Relax Dryer:

M/C parameter Set-up value

Temperature 1000c- 1100c for white shade

1100c-1200c for light shade

1200c-1300c for Dark shade

Blower fan setting Push button switch on

Exhaust fan setting Push button switch on

M/C Speed 1-12 m/min. Depends on quality of fabric.

Over feed 0-45% depends on fabric construction.

Checking parameters : 1. Shade Check

2. Width check

3. Weight check

4. Compaction check

SLITTER M/C:

Equipments used:

Airtex Slitter Machine (Sweden)

Speed : 20-25 m/min.

M/C parts :a) Rotary blade b) Ring

c) Guide Roller d) Plaiting

e) Sensor

Checking parameters:1) Cutting line check

2) Bow & slant check

3) Fault check :

STENTER M/C:

Equipment used:Krantz Stenter Machine (Germany)No of chamber : 7No of Burner : 14No of Padding through : 2No of exhaust fan : 7 fig: stenter machine

Machine Setup:

M/C parameters Set up value

Padder pressure 2 to 8 bar

Temperature setting 90- 1800 c

Blower fan setting lower to high

Exhaust fan setting Manual

Width of m/c chain setting 110 cm up to 260 cm

Over feed 0-60%

Burner gas pressure 30-50 m/ bar

Machine speed 6 to 60 m/ min

Light wt (100-140 GSM)

Medium wt (150-180 GSM)

Heavy wt (190-250)

20-30 m/min

14-18 m/min

10-15 m/min

Checking parameters : 1. Shade Check

2. Width check

3. Weight check

4. Compaction check

5. Fault check : Operator checks -

TUBULAR COMPACTOR :

Equipment used:

Ruckh Tubular Compactor m/

M/C set up:

M/C parameters Set up valueSteam pressure 4-6 bars

Air pressure 5 bar

Temperature 90-1000c

Cooling fan Motor Auto

Width control 48 to 114 cm

Speed setting 5- 35 m/min

Checking parameters: 1. Shade Check

2. Width check

3. Weight check

4. Compaction check

Open compactor:

Manufacturer: Feraro (Italy)

Fig: Open Compactor m/c

M/C set up:

M/C parameters Set up value

Steam pressure 4-6 bars

Air pressure 5 bar

Temperature 700-1000c

Width 36”-100”

Speed 5-25 m/min.

Checking parameters: 1. Shade Check

2. Width check

3. Weight check

4. Compaction check

RAW MATERIALS

INTRODUCTION: Raw material is a unique substance in any production oriented textile industry. It plays a vital role in case of continuous production & for high quality fabric.

Types of raw materialThe basic raw materials used are:

fabricdyestuffschemicals & auxiliaries.

Names & source Fabric:

Different types of fabric treated in BKL dyeing section are namely- Single Jersey- Single jersey with lycra attachment - Polo pique - Back pique- Rib Fabric - Lycra fleece - Jacquard- Cross -rib

Dyestuffs:

Chemicals:

Brand name Type SourceAnti creasing agent Techna,Italy

Bluton BVB1 Violet tone brightener CHT,GermanyCibacel DBC Sequestering agent Ciba,India.Cibafix ECO Fixing agent Ciba ,Switz.Cibafluid C Anticreasing agent Ciba ,Switz.SandocleanPCLF Detergent Clarient,GermanyPermacol FA Stabilizer Techna,ItalyNovostone CR Enzyme Techna,Italy

Redder tone brightener CHT,GermanyCyclanon E Fixing agent BASF,GermanyCyclanon ECO Reduction cleaning agent BASF,GermanyJinlev RLF349 Dispersing agent Geigy,TaiwanEulysin S pH buffer in PET dyeing BASF,GermanyFelosan NOF Detergent CHT,GermanyUvitex EBF Whitening agent Ciba ,Switz.Jinlev CL-225 Levelling agent for reactive dye Geigy,TaiwanOxalic caid Iron remover -Palegal FA-8 Levelling agent for disperse dye BASF,Germany

Dye Brand name Origin/source

Ciba Ciba , Switzerland

Kemafix Jaychem,IndiaLevafix Dystar , GermanyProcion Dystar, germany

Kemazol Jaychem,IndiaRemazol Dyestar , GermanySolazol Solarfine , TaiwanSolacion Solarfine , Taiwan

Disperse dyeTerasil Ciba , SwitzerlandDianix Dystar, germanyDispersol Dystar, germany

Antifoaming agent BASF,GermanyPermacol SQ Sequestering agent Techna,ItalyNa thiosulphate Peroxide killer -Uniperol O Washing agent for PET dyeing BASF,GermanyUvitex EVF PET brightener Ciba, Switz.Uvitex 2B Yellow tone brightener Ciba ,Switz.Mollan129 Soapinging agent Rota,dystarAcetic acid pH controller -Reduction HCS Reduction cleaning agent Geigy,TaiwanMollan130 Sequestering agent Rota,dystarBluton 2B Whitening agent Ciba,India

Final Inspection

Finished Store

Delivery to Garment industry

SEQUENCE OF OPERATION:

Kniting

Grey inspection

Batch preparation

Pretreatment White Processing

Polyester dyeing Cotton dyeing

Hydro extracting

Dewatering

Drying compacting

The BEXIMCO Knitting Limited is a self-sufficient modern company. Its knitting section is divided into two sections –

1. Flat knitting section & 2. Circular knitting section.

1. Flat Knitting Section:

.

Equipments used:

1.1 Production Equipment

The following equipments are used for production:

Name Fabric

type

Manu. Model Gauge Length No. of

m/c.

STOLL semi-

jacquard

Germany -------- 14 84 inch 2

MATSUYA Plain Japan M-100 14 100 cm 26

MATSUYA Plain Japan M-70 14 70 cm 22

KAUO

HENG

Semi-

jacquard

Taiwan KH-

313

14 54 inch 17

MATSUYA Semi-

jacquard

Japan 14 64 inch 2

Total machines = 69

2. Circular Knitting Section:

.

Equipments used:

2.1 Production Equipment

Gauge Model No. Origin No. of Cylinder Existing Set-up18 1995 CAMBER, UK 05 020 1995 CAMBER, UK 10 0824 1995 CAMBER, UK 14 1428 1995 CAMBER, UK 26 06

16 (RIB) 1995 CAMBER, UK 01 0118 (RIB) 1995 CAMBER, UK 01 0120 (RIB) 1995 CAMBER, UK 01 0

Total 58

Note: There are 7 (Seven) machines with lycra facilities.

Knitting Faults: Barre or stripe Press off Miss stitch/ drop stitch Needle mark Sinker mark Oil stain Crease mark/Edge mark Holes Excessive slubs Spirility Broken needle Pin hole Tight course Missing Yarn,etc.

Equipment used:

a)Inspection m/c( Calator Sweden)

b) Inspection Table.

M/C Set up (Inspection m/c):

Greiege body and Rib Inspection Greiege body and Rib Inspection

M/C set up Parameter range Set value

Roller speed 0-40 m/min 25-30 m/min

light Not applicable Artificial day light

Length measuring unit

Not applicable Attached with m/c.

Following faults are detected:

Faults:

H= Hole OS= Oil stain

DS= Drop stitch. WD=Wrong Design

NL = Needle line. S = Stripe

TT = Thick & Thin yarn. S = Slubs

SM = Sinker Mark. WP=Wrong Ply,etc.

Process sequence of Batch preparation receive batch card from Grey In-charge

Make the priority as per dyeing plan

Take one specific Batch card.

Read the Batch Card for own understanding

Check the availability of fabric

Take required quantity of body fabric from ware-house.

Make required no. of Rope maintaining equal length.

Take collar/cuff as per size, keep the total weight.

Batch preparation

Distribute the collar /cuff or Rib in each rope equally unsure equal length

Stitch the fabric

Write down the weight against roll no. in the back side of the Batch Card.

Write the total weight in Batch Card.

Put signature & date.

Fill up the production report form.

M/c for Batch preparation : Two types of m/cs

a) Turning m/c b) Plaiting m/c.

SINGEING :

Equipments used:

Machine: Sando Gas Singing m/c.

Manufactures: Sando Iron Works, Japan.

M/C Setup:

Setup parameters Range Set value

Speed(m/min) 0-120 55-60 for cotton.

70 for PC/CVC.

Potentiometer Setting (rpm) 0-150 80-90 for cotton fabric

60-70 for CVC/PC.

Burner in use 1 or 2 2

Burner operation mode. Auto/Manual Auto

Flame height (cm) 1-8 6 for white & light shade fabric.

6.5 for medium & dark shade fabric

Flame angle with the direction of fabric.

450 to 900 450 for blends

900 for cotton

Flame intensity Low/normal/

high

Low – not used

Medium – for white & light shade

High – for medium & dark shade fabric

Singeing Fault :

a)Singeing line :

b)Uneven singeing :

.

Mercerizing:

Equipment used: Dornier Mercerizing m/c (Germany).

Required parameters :

Parameters Value

Squeeze pressure 1.5-2 bar (by compressed air)

Temperature of washing 800-900c

PH after mercerizing 7-7.5

MERCERIZING PROCESS MERCERIZING PROCESS

Caustic solution temperature In mixing tank : 80-900c

In caustic stroage tank : 70-800c

In chiller : 140c

In Mercerizing bath : 160-200c

1st sigar diameter Set with fabric dia +3

2nd sigar diameter Set with fabric dia +5

Caustic strength 280 Be

SCOURING:

Single Stage Scouring-Bleaching:

Process steps : Take water in bath at required level.

Load fabric.

Circulate fabric & raise temp. at 60oc

Add Anti-creasing agent, Detergent, sequestering agent, stabilizer.

Add Caustic soda

Circulate fabric.

Add H2O2.

Continue circulation fabric 25 min. at 100oc

Decrease temp. at 800c

Rinse & Drain.

Add Detergent & H2O2 killer and raise temp 80oc

PRE-TREATMENT PRE-TREATMENT

Continue circulation for 10’ at 60oc

Rinse & Drain.

Hot wash for T/C TTC:

To remove waxes, fats.

Increase absorbency for T/C & TTC for dark shades.

Curve:

Recipe :1. Anti-creasing Agent : 1 g/L2. Detergent : 1.5 g/L

Steps : Take water in bath at required level. Load fabric. Circulate fabric & raise temp. at 60oc Add Anti-creasing agent, Detergent.

Circulate fabric and raise temp.

Enzyme Treatment:

If dead fibre or hairiness present in fabric then enzyme treatment is done.

Function: It attacks surface cellulose fibre and removes it from surface.

Precaution :

Excess enzyme is harmful for cellulose fabric.

Application of enzyme is done by two ways :

600c2

1

900c15

a) Pretreatment Enzyme treatment Dyeingb) Pretreatment Dyeing Enzyme treatment

Enzyme treatment carve :

REACTIVE DYEING

1.REACTIVE DYEING FOR SENSITIVE SHADE AT 60oC .

Dyeing curve:

90˚c

60˚c 60˚c

550c2+3

1

30

Drain 3 Drain

750c

10

REACTIVE DYEING FOR DARK SHADE AT 60oC:17. Unload fabric.

Dyeing curve:

60˚c 60˚c 80˚c 70˚c

Rinse

HOT BRAND REACTIVE DYEING :

DYEING AT 92oC :

Dyeing curve :

POLYESTER DYEING

Disperse dye:

Disperse dye is one kind of organic colouring substances which is free of ionizing group, less soluble in water & used on hydrophobic Textile material .

.Dyeing curve:

920c 60 Shade check

1

600c

10600c

2

3

20

Rinse

800c

4

5 10

5

600c

10

Rinse

Rinse

400c

800c

10

600c

Rinse

1

301300c

Rinse600c

Rinse600c

Rinse600c

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Rinse600c

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Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse

32

780c

Shade check

500

c

4

7 Rinse400c

800c Rinse

5+6

Recipe :1. Acid Buffer (Eulusin FAS) : 1.8 g/L2. Dispersing agent (Jinlev RLF349): 1.8 g/L3. Antcreasing agent (Ciba fluid C): 0.5 g/L4. Dianix Red : 0.106 %

Dianix Yellow : 0.07%Dianix Black: 0.78 %

5. Reduction clearing (Reduction HCS): 1-3 g/L6. Acetic Acid: 1g/l.6. Detergent (Albatex S): 0.5 g/L

Process steps for Polyester part:

STRIPPING:

Stripping is carried out to remove uneven of shade or to reduce dark shade. In BKL Stripping is done for 100% cotton, T/C, CVC & TTC.

I. FULL STRIPPING FOR 100% COTTON:

.

Curve: 100Cx60min

80C CR 60CX15

50C 80C 80CX10

3

1 2

Polyester striping

Process curve :

3c/min

Whitening:

Whitening Is A Chemical treatment, fabric white at a desried level by bleaching & OBA treatment.

Factors Influencing Whitening:

1. PH

2. Temp.3. Time

Whitening Process for 100% cotton:

Process curve:

500c

1

Rinse2

3

30

600c

5600c

6

10

1350c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

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Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse

5

10

4700c

900c

30

Cold rinse

Check shade

600c

4

1

Rinse6

3 5

30

600c

10

800c

8

10

2 7

1000c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

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Rinse600c

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Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse

c

5

10

Process steps:

Take water at required level. Load fabric. Raise temp. at 600c & circulate fabric. Add Detergent, Anti-creasing agent stabilizer. Add caustic & circulate fabric. Continue circulation & add Hydrogenperoxide Add Uvitex 2b & circulate fabric. Add Glauber salt & continue 5 min. Raise temp. at 1000c & continue 60 min. Decrease temp. at 800c. Rinse for 10 min. & Drain. Hot fill & raise temp at 800c and continue 10 min. & Drain. Drain. Mixed water fill, add acetic acid & raise temp at 600c & continue

10 min. Rinse & Drain.

T/C whitening process:

Process curve :

600c4

1

Rinse5

3 6

30

600c10

800c

1010

2 8

7 9

1100c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

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Rinse600c

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Rinse600c

Rinse600c

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Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse

900c

Rinse600c

Rinse600c

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Rinse600c

Rinse600c

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Rinse600c

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Rinse600c

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Rinse

700c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

Rinse600c

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Rinse600c

Rinse600c

Rinse600c

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Rinse600c

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Rinse600c

Rinse600c

Rinse600c

Rinse

FINISHING FINISHING

INTRODUCTION After dyeing, knit fabric is required to finish. During dyeing all knit fabric are dyed in

tubular form. According to buyer’s requirement knit fabric are finished in Open form or tubular form.

For Tubular form following m/c are required:

Hydro-extractor

De-watering

Dryer

TubularCompactor

For open form following m/c are required :

Hydro-extractor

De-watering

Dryer

Slitter

Stenter

Open compactor

For collar & cuff finishing following m/c are required :

Hydro-extractor

Softening Machine

Dryer

Chemicals used:

TC collars & cuffs:1. Softener (cationic & nonionic) 2. Additive 3. Stiffener 4. Acetic Acid to adjust pH

100% cotton fabric (soft): 1. Softener

2. Additive3. Acetic acid to adjust PH

100% cotton collar & cuffs (cross-linking):

1. Softener (cationic /nonionic) 2. Additive

3. Resin4. Catalyst.5. Acetic acid to maintain PH

CVC collar & cuffs:1. Softener (cationic & nonionic)2. Additive3. Stiffener 4. Acetice acid to maintain PH

CVC collar cuffs (soft):

1. Softener 2. Additive 3. Acetic acid to maintain PH

Water Repellent collar & cuffs:

1. Hydrophobic agent. 2. Softener 3. Additive 4. Acetic acid to adjust the PH

M/C set up:

M/C parameters Set up valuePadder pressure 2-7 bar

M/C speed As standard speed set by manufacturer.

\Equipments used: a) Nazer Inspection m/c, Pakistan.

b)Verivide Day Light box.

Following faults are detected & identified in final inspection for body :

a) Penalty points legend:H= HoleOS = Oil stainCS= Chemical stain.W= Water spots.Fy= Fly yarn.YC = Yarn contamination.WX= White speaks.IS = Insect spots.R= Rub mark.DS= Dye stain.D= Dirt stain.Rs= Rust stain.

Collar & cuff inspection.

FINAL INSPECTION FINAL INSPECTION

Following faults also detect and identify:

Faults Decision

1. Rub mark Reject

2. Cutting Reject

3. Hole Reject

4. Crumple Reprocess

5. Tipping bleed Reprocess

6. Uneven shade Reprocess

7. Neps Enzyme wash

8. Oil spot Reject

9. Role to role variation Reprocess

10. Yarn contamination Reject

11. Barre mark Reject

QUALITY ASSURANCE SYSTEM

Equipment used in Lab:

a) Rota Dyer:

Manufacturer: Qayyum Textile Ltd., Pakistan.

Capacity : 12 beaker per m/c

Purpose : Sample dyeing ,Measure wash fastness.

b) Ahiba Nuance dyeing m/c:

Manufacturer : Data color International

Capacity : 12 beaker per m/c

Purpose : Sample dyeing.

c) Ahiba Spectra dye:

Manufacturer : Data color International

LAB

Capacity : 24 beaker per m/c.

Purpose : Sample dyeing.

d) Incubator:

Purpose :

Pre-drying., Water fastness.

e) Taba Gs:

Purpose : To boil water.,Washing fastness.

f) Electrolux Washcator:

Manufacture : James H. Heal & Co. Ltd. Halifax.

Country : England.

Purpose : Washing & Hydro-extraction.

g) Tumble dryer :

Country : UK (Electra).

Purpose : Drying.

h) Pilling Tester:

Manufacturer: James H. Heal & Co. Ltd. Halifax.

Speed:30-60rpm.

i) Electronic Balance:

Manufacturer: ohaus corp. USA

Readability:0.001gm

Maxm Capacity:210gm

Some Fabrics used in BKL Lab:1. Single jersey.

2. Polo Pique.

3. Back Pique.

4. Normal Rib.

5. Interlock.

Chemicals & Auxiliaries Used:

For reactive Dyeing: For Cibacron Dyes:

L: R = 1: 8600C Dyeing:

For Levafix Dyes:L: R = 1: 8

600c Dyeing:

For Remazol Dyes:

L: R = 1: 8

600C Dyeing:

For Procion Dyes:

L: R = 1: 8

820C Dyeing:

L: R = 1: 8

920C Dyeing:

For Disperse Dyeing :

i) Temp. : 1300c

ii) Dispersing agent : 0.8-1 g/L

iii) Acetic acid : 0.5-1 cc/L

iv) PH : 4.5-5

Program Number in Ahiba Dyeing Machine:

Program no. Temperature Time

1 1000c 68

2 800c 90

3 400c 20

4 600c 50

5 500c 37

6 620c 60

7 900c 96

8 600c 40

9 800c 40

10 600c 45

11 600c 70

12 700c 30

13 950c 30

14 950c 10

15 950c 60

16 1300c 76

17 1100c 30

18 1000c 40

On line quality control WORKING AREA OF ON LINE QUALITY CONTROL:

a) On line circular knit:

.

b) On line flat knit:

c) Greige inspection:

.d) On line finishing:

Response to faults:

Following response are to be taken:

Faults Response

Greige inspection Inform yarn supplier & knitting department.

Knitting fault Inform knitting Department

Finishing fault Inform Finishing Department

Off line quality control Typical Quality control in BKL:

a) Shade Check.

b) Gram per square meter (GSM) test

c) Width on dia check.

d) Shrinkage test

e) Spirality test

f) Crocking/Rubbing Fastness test.

g) Pilling resistance test.

h) Wash fastness test.

i) Water fastness.

j) Color fastness to perspiration.

a) Shade check:

Shade check after finishing of fabric is done according to customer's recommended light source.

Equipment used: Verivide Light box.

Manufacturer: James H. Heal & Company, Halifax, England.

Light sources:

Artificial day light D65

TL 84

F (Filament)

UV (Ultra violet) light etc.

b) Gram per square Meter:

After finishing of fabric gram per square meter is check by GSM cutter.

Equipment used: GSM cutter.


c) Width or Dia Check :

After finishing of fabric width on dia of the fabric is check by measuring tape.

d) Shrinkage test:

After finishing of fabric shrinkage is tested.

Equipment used: Electrolux wascator

Manufacturer: James H. Heal & Co. Ltd. Halifax, England.

Test Method

BS 26330 3A 60 +/- 30c Prog – 13

BS 26330 4A 50 +/- 30c Prog – 14

BS 26330 5A 40 +/- 30c Prog – 15

\

Standard Shrinkage %:

Length (max): 5% after domestic washing

Width (max): 5% after domestic washing.

e) Spirality test:

After finishing of fabric spirilily is tested.

Equipment used: Electrolux wascator.

Manufacturer: James H Heal & Co. Ltd. Halifax, England.

Procedure:

1

Test Method

BS 26330 3A 60+/-30c Prog – 13

BS 26330 4A 50+ /-30c Prog – 14

BS 26330 5A 40+/-30c Prog – 15

Where,

L= Length of Sample.

D1, D2 = Distance of seam movement.

Calculation:

Spirility % = 100

Standard spirility % :

Maximum : 5% after domestic washing.

f) Rubbing / Crocking fastness:

After finishing of fabric rubbing fastness is measured.

Equipment used: Crock meter.

Manufacturer: James H. Heal & company, Hali fax, England.

Method: AATCC 8

g) Pilling resistance test:

LL

D1 D2

1st Side 2nd Side

After finishing of fabric pilling resistance test is carried out.

Equipment used: ICI pilling box


Method: BS 5811 or according to customer requirement.

Revolutions for BS 5811 method:

a) 7000 cycle for low pilling

b) 9000 cycle for Medium pilling

c) 11000 cycle for High Pilling.

h) Wash fastness test:

After finish of fabric wash fastness is checked:

Equipment used :

a) AG machine.

Manufacturer : Quyyum textile Engineering, Pakistan

b) Ahiba Nuance.

Manufacturer : Data Color International, U.K.

Method : ISO 105-C06

Standard result:

i) Water fastness:

After finishing of fabric water fastness is checked.

Equipment used:

a) Perspirometer

Light shade Dark shade

Staining scale 4 3/4

b) Carbolite (Thermostat Oven)

Manufacturer:

James H. Heal & Company, Halifax, England.

Standard result:

Light shade Dark shade

Staining 4 ¾

j) Color fastness to perspiraion:

After finishing of fabric color fastness to perspiration is checked Equipment used:

a) Perspirometer

b) Carbolite

Manufacturer:

James H. Heal & Company, Halifax, England.

Method: AATCC 15.

MaintenanceMaintenance

Maintenance:

Types of maintenance:

Maintenance

Preventive Maintenance Corrective Maintenance

Mechanical Maintenance

Electrical Maintenance

Mechanical Maintenance

Electrical Maintenance

PM Tasks list

Maintenance : Mechanical

Machine : Thies Dyeing MachineSl. No.

Item need to be checked & Serviced

1. Crease the winch bearing (Grease Staburag NBU-12)

2. Complete cleaning of machine

3. Cleaning of drain valves, replace seals if required

4. Check air supply filters, regulators, and auto drain seals

5. Clean filters element and blow out

6. Greasing of Unloading Roller Bearings by BP Energrease LS-2

7. Checking of Oil level and bolts of Unloading Roller Gearbox.

8. Checking of unloading roller coupling and packing

9. Checking and cleaning (if required) of Main Vessel Level Indicator

10. Check the oil level of pump bearing and refill if required by BP Energol THB-100

11. Check the function of heat and cool modulating valves

12. Check all belts and belt tension

13. Check all door seals

Maintenance : Electrical

Machine : Thies Dyeing m/cSl. No. Items need to be checked & Serviced 1. Check & clean fluff and dirt at all motor fan covers2. Check all motor's terminals3. Check main panels (by using compressed air)4. Check panel cooling fan & clean it filter5. Clean main pump inverter and its cooling fan6. Check all on/off switches7. Check current setting of all circuit breaker & motor over loads.8. Visual checking of all power & control cables9. Check all emergency Switches10. Check DC drive of neel motors11. Check all pressure switches

12. Check calibration of main vessel & all additional tank13. Check all pneumatic solenoids14. Check calibration of heating/cooling. Modulating value.15. Check all indicating lamps

Maintenance tools & equipments :

1. Pliers2. Inside Calipers3. Outside Calipers4. Digital Multi Meter5. Heating Shoulder6. Hammer7. Philes8. etc.

Chapter 8

Utility services

Available facilities of utility:ElectricityGasWaterCompressed air

Steam.

Electricity : The main utility electricity is supplied from PDB and also by Generator.

Specification:Equipment used: Gas generator.No. of generator: 8 (1 self start able & other 7 are air+CH4

start able).Manufacturer : Wartsila-Frank.-Gas engine used.-16 cylinders per engine.-Overall efficiency : 80%.-Heat recovery possible from 4 engines.-Pressure of gas : 60-62 milibar.-Air pressure : 7 bar.-Electricity take up from PDB : 1.5MW/sec.

Total power is then distributed as per requirements of different section of Beximco industrial park.

Gas: Gas is mainly used for steam production.

The gas is used from TITAS.Generally 36 m3 gas is required to produce 1 ton steam.

Water: Continuous supply of water for BTL,BDL&BKL must be ensured by pump.Mainly two pumps are used for water pick up.

PUMP CAPACITY SETUPSubmersible pump-I 260 m3/hr Discharge value:100% openSubmersible pump-II 204 m3/hr Discharge value:100% open

Depth of pump: 140ft.Also pumps for chemical dosing & Centrifugal pump for yarn dyeing.

Steam: Pure steam with required temperature must be produced to meet the

continuous demand of steam in different sections.-Fire tube type boiler is used.

-No. of boiler: (4+1) twine boiler.1 boiler is operated by using burn gas.4 boiler is operated by Titas gas.

-3 pass heating system.-Measuring meter for water supply.-4" depth greasol insulation so no heat at outside of drum.-Boiler capacity; 10ton.-Steam pressure; 8.2bar.-Steam flow = 7 ton(approximately)-Manufacturer: Thermax;India.-Model: TD-100-10-54/6AS/E.-Fuel: Natural gas.-Water pressure: 10.3bar.-Evaporation= 1000*3 kg/hr.

COMPREESOR

Parameters Set value Unloading pressure 7.5 barPressure difference 0.6 barOil pressure 1.2 barMotor running time 15 sec

-Total no. of compressor = 3+3 =6-Capacity: 774 lt air/compressor/sec.-Manu: Atlas capco.-Country: Belgium.

Oil free air is prepared by Electronikon.

Chiller:Manufacturer: Thermax.Country: India.

-To start a chiller electricity & steam is required.-Capacity :[(21083)+(500*1)] ton = 1130 ton water cooling.-Absorption type Chiller is used.

Source of Utility:Electrically : PDB & Generator.Steam : Boiler.Water : Pump.Compressed air : Compressor.Temperature control : Chiller.Gas : TITAS.

The effluent treatment plant:

Characteristics of raw effluents:Volume : 3600 cubic meter/dayPeak flow : 225 cub met/hrpH : 10-12.5BOD : 500-800 PPMCOD : 1300-2000 PPMTDS : 2000-5000 PPMS S : 100-400 PPMColour : Black/ Blue

Chemicals used & their colours:

Chemicals used AppearanceFerrous sulphate Granular solid, greenish colourLime White bulk formPolyacrylate White granular solidSulphuric acid Clear liquidAlum White bulk formNa-hypochlorite Clear liquidHydrochloric acid Clear liquid

Flow chart of effluent treatment:

Raw effluent

Skin chamber

Collection Sump

Pump station

Dissolved Air Floatation Tank

Clarifier fig: Aeration tank

Aeration tank

Setting tank

Clear water, pH check

Sand filter

Carbon filter

Drain

Sludge separation:Sludge of DAF

Sludge thickening plant

Sludge drying be

Typical output of the plant:

Raw effluent treated 15000 LPHRaw effluent colour BlackRaw effluent pH 11Treated effluent colour Light greenishTreated effluent pH 8.5Treated effluent temp. 38 CTo0tal suspended solids 35 PPM

STORE & INVENTORY CONTROL

☻Frequency of inventory control:- Monthly inventory control- Annual inventory control

Scope of inventory control- Raw materials

Dyes store Others chemicals store Grey fabrics

- Finished fabric- Spare parts- General store

Capital equipmentAccessoriesStationaryMaintenance parts.

Store capacity- Dyes 6-7tons

- Chemicals 33-35tons- Grey fabric 20-25 tons- Yarn storage 50 tons- RFD 50 tons- Set range of dyes 80-100kg/day

- Set range of Chemicals 2-2.5ton/day

COST ANALYSIS

Costing of the product: Costing of the product is done by the consideration of the following factors:

1.Amount of raw materials consumed.2.Direrct labour.3.Indirect labour.4.Factory cost.5.Office and administrative cost.6.Sales and distribution cost.7.Profit,etc.

Remarks: The costing of product is a secret matter of the industry. They are not interested to flash up the cost related data.So, we could not collect the price of the product and costing of the product.

MARKETING ACTIVITIES

Consumer of the products: Beximco knitting LTD. is a100% export oriented industry. . Name of the main buyers of the products of the industry are given below:

1.Ash city.2.B&C.3.Wall mart.4.Haddad.5.Pimkie.6.Zara.7.Charter House.8.H&M.

Package size and label:

Local Market: Beximco knitting LTD. is a100% export oriented industry. All the goods produced in this industry are exported into various foreign countries. So,goods are not supplied into local markets.Importing countries:The countries which are importing goods from Beximco knitting Ltd are given below:

1.USA.2.Canada.3.Germany.4.Europian countries.

CONCLUSION

LIMITATION OF THE REPORT:

►Because of the secrecy act, the data on costing and marketing activities has not been supplied and hence this report excludes these chapters. ►we had a very limited time. In spite of our willing to study more details it was not possible to do so. ►Some of the points in different chapters are not described as these were not available.

►These whole process is not possible to bind in such a small frame as this report, hence our effort spent on summarizing them.

LASTLY: The special in this report is that the information, data and description is very much subjective and practical. So, one can easily have an idea about the whole dyeing unit of BKL at a single look on it. The new comer can use this report for further details study or can know Beximco knitting Ltd. without much work. But what should be remembered the chemicals, some process steps may be modified within the period this paper goes to the reader.

bkl 2009 new

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